» » » July 2005

-•.'•"

Bener Qua '_!. owing the Heat-Affected Zone RSW Power Supply Welding Standardization

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING AND ALLIED PROCESSES, INCLUDING JOINING, BRAZING, SOLDERING, CUTTING, AND THERMAL SPRAYING Creating a New Force in Hardsurface Welding...

Jeff Schnabel and Select-Arc. When Jeff Schnabel joined comprehensive group of most demanding the Select-Arc team of hardsurfacing electrodes, hardsurfacing electrode welding specialists, he specifically developed to requirements. envisioned adding a new improve your welding The many customers who dimension to the productivity, enhance have depended on Select- company's highly regarded performance and extend Arcs quality electrode flux cored and metal cored the life of components products, superior service and machinery. Jeff SELECT product lines. Today, the and most value-added can union of Jeff's extensive incorporated his years of now enjoy the significant hardsurfacing electrode hardsurfacing experience benefits of specifying ARC INC. • knowledge and Select-Arc's with Select-Arc's dedicated Select-Arc hardsurfacing exceptional manufacturing research professionals to electrodes. For more 600 Enterprise Drive expertise has revolution­ produce the innovative information on Select P.O. Box 259 ized the welding industry. Select Wear hardsurfacing Wear electrodes, call Fort Loramie, OH 45845-0259 electrode products. These Jeff at 1-800-341-5215 Phone: (937) 295-5215 new wires are designed to or visit our website at Fax: (937) 295-5217 With the introduction of a meet and exceed your www.select-arc.com. www.select-arc.com

Circle No. 27 on Reader Info-Card The essential standard for quality fabrication, Now available in Structural Bundles that save you money too. AWS Dl .1, Structural Welding New for 2004: • Contains the latest workmanship standards, inspection - Code—Steel procedures, acceptance criteria Save time and money, and Clarifies requirements that need an engineer's approval, Structural minimizing code-interpretation conflicts I Welding Code- maximize reliability and safety, Modifies allowable stress range formulae I Steel with the 2004 edition of AWS D1.1, - Enhances construction integrity safety by requiring additional Structural Welding Code—Steel. tests when FCAW and GMAW constant current power supplies Engineers, architects, and are used fabricators depend on this book • Reflects advances in technology by the addition of new steels to ensure the integrity of welded to pre-qualified base metal list steel structures. ANSI Approved. Adjusts welder qualification essential variables AVAILABLE AS A CD TOO! Adjusts dimensions and tolerances on prequalification o joint details Order today. Call us at 800.854.7179 or visit global.ihs.com to get your copy.

D1.1/D1.1M:2004, Structural Welding Code—Steel D1.1/D1.1M:2004 CD, Structural Welding Code—Steel Order Code: AWS D1.1/D1.1M, Nonmembers: $360, AWS Members: $270 Order Code: AWS D1.1 /D1.1M CD, Nonmembers: $380, AWS Members: $285 D1.1/D1.1 M:2004 COMBO, Structural Welding Code—Steel Order Code: AWS D1.17D1.1M COMBO, Nonmembers: $620, AWS Members: $465 Save $$$ with these AWS Structural Bundles

INDIVIDUAL INDIVIDUAL BUNDLE PRICE PRICING PRICING 15% OFF NONMEMBER MEMBER NONMEMBER Bundle A - Structural Steel/AISC Steel Building Structures AWSD1.1/D1.1M 2004 STRUCTURAL WELDING CODE—STEEL $360 $270 AWSA2.4 1998 STANDARD SYMBOLS FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 AWSA3.0 2001 STANDARD WELDING TERMS AND DEFINITIONS $128 S96 Bundle Total Order Code: AWS BUNDLE A $624 S468 $532 $399 Bundle B - D1 All Structural Welding Codes AWSD1.1/D1.1M 2004 STRUCTURAL WELDING CODE—STEEL $360 $270 AWS01.2/D1.2M 2003 STRUCTURAL WELDING CODE—ALUMINUM $132 $99 AWSD1.3 1998 STRUCTURAL WELDING CODE—SHEET STEEL $100 $75 AWSD1.4 1998 STRUCTURAL WELDING CODE—REINFORCING STEEL $84 $63 AASHTO/ AWSD1.5M/D1.5 2002 BRIDGE WELDING CODE $188 $141 AWSD1.6 1999 STRUCTURAL WELDING CODE—STAINLESS STEEL $132 $99 Bundle Total Order Code: AWS BUNDLE B $996 $747 $848 $636 Bundle C - AISC Conventional and Complex Steel Building Structures AWSD1.1/D1.1M 2004 STRUCTURAL WELDING CODE—STEEL $360 $270 AW$A2.4 1998 STANDARD SYMBOLS FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 Bundle Total Order Code: AWS BUNDLE C $496 $372 $424 $318 Bundle D - AISC Simple and Major Steel Bridges AA$HT0/ AWSD1.5M/D1.5 2002 BRIDGE WELDING CODE $188 $141 AW$ A2.4 1998 $TANDARD $YMB0L$ FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 Bundle Total Order Code: AWS BUNDLED $324 S243 $276 $207 Bundle E - Structural Aluminum AWSD1.2/D1.2M 2003 STRUCTURAL WELDING CODE—ALUMINUM $132 $99 AWSA2.4 1998 STANDARD SYMBOLS FOR WELDING, BRAZING, AND NONDESTRUCTIVE EXAMINATION $136 $102 AWSA3.0 2001 STANDARD WELDING TERMS AND DEFINITIONS $128 $96 Bundle Total Order Code: AWS BUNDLE E $396 $297 $336 $252

American Welding Society visit our Web site www.aws.org for membership information Sink your teeth into an unmatched assortment ...of forming, fabricating, tube & pipe, and welding technology. Compare 800 exhibits and more lhan 2,000 machines in action. Consult with thousands of technical experts who can help you work smarter and run a leaner, more competitive operation. Evaluate more than 300 new products to boost your productivity. Select from over 50 conference sessions lo maximize performance. At last, there's one show where you can easily evaluate options, upgrade critical skills and stay on top ofthe latest innovations. It really doesn't get any sweeter than thisl November 13-16, 2005 McCormick Place South INTERNATIONAL© J*»«M Chicago, Illinois USA WELDING SHOT North America's Largest Metal Forming Fabricating & Welding Event Register online today for free show admission! www.aws.org/expo

Circle No. 5 on Reader Info-Card CONTENTSJuly 2005 • Volume 84 • Number 7 AWS Web site http://www.aws.org SOLID /ELD FUSION SOLUTION Features Departments ONE ZONE ZONE Press Time News 4 22 Aluminum Weld HAZ Fundamentals A guide to understanding aluminum alloys helps avoid Editorial 6 problems with the heat-affected zone T. Anderson CyberNotes 7

26 Understanding Stainless Steel Heat-Affected News olfhe Industry 8 Zones Letters to the Editor 12 PARTIALLY OVER UN/ Know the grades of stainless steel that are subject to ANNEALED AGED potential problems with the HAZ Stainless Q&A 16 ZONE ZONE C. Meadows and J. D. Fritz New Products 18

32 Power Supply Designed for Small-Scale Welding Workbook 47 Resistance Spot Welding A unique power supply provides a testing bench for Coming Events 48 studies of different weld schedules and control methods for RSW Society News 51 L. J. Brown and J. Lin Tech Topics 62

37 Exploring Temper Bead Welding Standards Errata Temper bead welding is explained as a means of improving the properties of the deposited weld metal Guide to AWS Services 77 and the heat-affected zone W. J. Sperko Conferences 79

41 Hobart Marks 75 Years of Welder Education Navy Joining Center 80 Festivities mark the 75th anniversary of a well-respected learning center for welding Personnel 81 H. M. Woodward New Literature 82

44 Standardization in Welding Classifieds 84 Liquid The pursuit for consensus on globally relevant standards continues Advertiser Index 86 J.-P. Gourmelon

Welding Research Supplement

101-s Reliable Calculations of Heat and Fluid Flow during Conduction Mode Laser Welding through Optimization of Uncertain Parameters To improve the reliability of heat transfer and fluid flow prediction calculations, optimized values for process variables were factored into the model A. De and T. DebRoy

113-s Properties and Sulfide Stress Cracking Resistance Welding Journal (ISSN 0043-2296) is published of Coarse-Grained Heat-Affected Zones in monthly by the American Welding Society for V-Microalloyed X60 Steel Pipe S90.00 per year in the United States and posses­ Thermal simulations that induced coarse-grain sions, $130 per year in foreign countries: $6.00 per conditions in the HAZ aided a study on postweld heat single issue for AWS members and $8.00 per sin­ treatment schedules for high-strength steel pipe gle issue for nonmembers. American Welding So­ J. E. Ramirez et al. ciety is located at 550 NW LeJeune Rd., Miami. FL 33126-5671; telephone (305) 443-9353. Periodi­ cals postage paid in Miami, Fla., and additional mail­ ing offices. POSTMASTER: Send address changes to Welding Journal. 550 NW LeJeune Rd., Miami. FL 33126-5671.

Readers of Weldingjoumal may make copies of ar­ ticles for personal, archival, educational or research purposes, and which are not for sale or resale. Per­ mission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright. • ,

WELDING JOURNAL PRESS TIME NEWS WELRIMG

Mazda Develops Steel and Aluminum Joining Technology Publisher Andrew Cullison that Uses Friction Heat Editorial Editor/Editorial Director Andrew Cullison According to Mazda Motor Corp., Hiroshima, Japan, it has developed the world's Senior Editor Mary Ruth Johnsen first direct spot joining technology to join steel and aluminum. j\ssociate Editor Howard M. Woodward This new technology was first employed in 2003 in the development of the company's Assistant Editor Kristin Campbell RX-8 sports car, and used friction heat to join separate aluminum sheets. The technol­ Peer Review Coordinator Doreen Kubish ogy has evolved and will be used to join the trunk lid and bolt retainer for the company's updated MX-5 sports car. Publisher Emeritus Jeff Weber Welding two different metals such as steel and aluminum has been a difficult task — Graphics and Production but by optimizing the rotating tool shape and joining characteristics, and by using galva­ Managing Editor Zaida Chavez nized steel on one side, joining steel and aluminum has been made possible. The process Production Assistant Brenda Flores is similar to that of joining two pieces of aluminum when a joining gun holds the parts from both sides with a welding tool. The joining tool is then made to spin while force is Advertising applied, which in turn generates frictional heat that subsequently joins the aluminum National Sales Director Rob Saltzstein materials to the steel sheet metal. Galvanized steel helps prevent the galvanic corrosion Advertising Sales Representative Lea Ganigan Badwy that results from the contact of two different types of metal. Advertising Production Frank Wilson Mazda has applied for more than 20 patents related to this technology. Subscriptions Leidy Brigman Hyundai Opens Its First U.S. Manufacturing Facility [email protected]

Hyundai Motor Manufacturing Alabama, LLC (HMMA), recently celebrated its American Welding Society grand opening. The $1.1 billion plant in Montgomery, Ala., has been under construc­ 550 NW LeJeune Rd., Miami, FL 33126 tion since 2002. It is the company's first U.S. manufacturing facility. (305) 443-9353 or (800) 443-9353 The 2-million sq-ft manufacturing plant resides on 1744 acres of land. It includes a stamping facility, paint shop, vehicle assembly shop, a two-mile test track, and an engine Publications, Expositions, Marketing Committee shop. It can produce 300,000 vehicles per year at full capacity. R. D. Smith, Chair All material flow from the stamping shop into the welding shop is 100% automated. The Lincoln Electric Co. After arriving by electro-monorails from the stamping shop, more than 250 robots in D. L. Doench, Vice Chair the welding shop move the material, weld, and seal, converting stamped steel into vehi­ Hobart Brothers Co. cles by complete automation. Automation minimizes damage to the steel. J. D. Weber. Secretary The plant employs more than 2000 team members. Sixty-four suppliers have located American Welding Society businesses throughout North America to support this new plant. Altogether, these sup­ R. L. Arn. WELDtech International pliers are expected to create 5500 additional jobs with a combined capital investment of T. A. Barry, Miller Electric Mfg. Co. $500 million. M. Balmforth. Sandia National Labs R. Durda. The Nordam Group J. R. Franklin. Sellstrom Mfg. Co. Northrop Grumman to Build New Huntsville Campus R. G. Pali, J. P. Nissen Co. L. Pierce. Cee Kay Supply Northrop Grumman Corp. will construct a new five-building complex in Cummings J. F. Saenger. Jr.. Edison Welding Institute Research Park, Huntsville, Ala. It has selected developer Colonial Properties Trust for S. Smith, Weld Aid Products the $80 million project to be located off Interstate 565. S. Liu. Ex Off.. Colorado School of Mines D. C. Klingman, Ex Off, The Lincoln Electric Co. The company employs about 1200 people in the Huntsville area in more than 20 fa­ D. J. Kotecki. Ex Off. The Lincoln Electric Co. cilities. Most current operations will be consolidated in the new headquarters facility, D. J. Landon. Ex Off. VermeerMfg. Co. which will house offices, laboratories, and research and development centers. E. D. Levert, Sr., Ex Off, Lockheed Martin The team managing the Kinetic Energy Interceptors missile-defense portion ofthe E. C. Lipphardt. Ex Off.. Consultant program is in Huntsville. Other Huntsville activities include developing and fielding ad­ R. W. Shook Ex Off, American Welding Society vanced tactical command posts under the Command Post Platform program; serving as D. W. Wilson. Wilson Industries the prime contractor for Forward Area Air Defense; and producing the Longbow mis­ sile and Viper Strike munition.

Drew Industries Acquires Venture Welding

Drew Industries, Inc., White Plains, N.Y., recently announced its Lippert Compo­ nents, Inc., subsidiary has completed the acquisition of certain assets and the business Copyright © 2005 by American Welding Society in both printed and elec­ tronic formats. The Society is not responsible for any statement made or of Venture Welding, Elkhart, Ind., for approximately $19 million. opinion expressed herein. Data and information developed by the authors Venture Welding, a manufacturer of chassis and chassis parts for manufactured homes, of specific articles are for informational purposes only and are not in­ tended for use without independent, substantiating investigation on the modular homes, and office units, had annualized sales prior to the acquisition of ap­ part of potenlial users. proximately $18 million. Drew said the acquisition also included several patents. The patents will permit Lip- pert to manufacture chassis using a cold camber process, as well as the hot cambering BPA process currently being used. INTERNATIONAL Lippert also acquired two of Venture's four factories and will consolidate production of certain of Venture's products into its existing factories.

JULY 2005 7" i,i

• Tl^f

Jac Products Welding Protection

In today's fast paced environment, time is valuable. Searching for safety products can rob you of that valuable time which is why Jackson Products is committed to providing our customers with high-quality safety systems. From auto-darkening welding helmets to face shields, hardhats, glasses and more, Jackson's full line of safety products will keep you up to speed. As a trusted source for over 80 years, we are driven to providing 100% customer satisfaction. Shift into high performance protection and take our top-of-the-line NexGen Auto-Darkening welding helmet for a test drive; 14 days, risk free. Visit www.jacksonproducts.com for details on how you can experience the NexGen today.

Jackson Products Circle No. 23 on Reader Info-Card 1-800-253-7281 www.jacksonproducts.com EDITORIAL American Welding Society Founded in 1919 to Advance the Science, Technology and Application of Welding

Officers President Damian J. Kotecki What Stage Are You In? The Lincoln Electric Co. Vice President Gerald D. Uttrachi As July turns into August, my daughter will celebrate her wedding day. She is not WA Technology, LLC just my only daughter, but also my only child. Recently, I have been spending much of Vice President Gene E. Lawson my quiet time reminiscing and recalling our years together. ESAB Welding & Cutting Products As I reflect back, I can clearly identify the changing stages in her life. There were the times of her climbing into my lap to learn her numbers on a handheld calculator, grow­ Vice President Victor Y. Matthews ing into those parent-trying years of teenage driving, and now an adult changing her last The Lincoln Electric Co. name and beginning the foundation for her own family. Treasurer Earl C. Lipphardt I believe that these growth stages are typical of life and are analogous to the stages Consultant of maturity we have with our membership in AWS. As new members, we are anxious to learn more about the basics of the organization. Most likely we are helped by a senior Executive Director Ray W Shook member of our local Section who serves as a mentor. After a period of time, we become American Welding Society more involved in AWS and are interested in working on a committee or a special proj­ ect to employ our knowledge and talents. Gaining more experience, we then grow into additional stages of AWS membership. Directors AWS is a volunteer-driven organization. Simply stated, the organization exists only T. R. Alberts (Dist. 4), New River Community College because of the work and services provided by its many active volunteers. B. P. Albrecht (At Large), Miller Electric Mfg. Co. I recently had the opportunity to review the collective inputs of the attendees of the six Leadership Symposiums. One of the group activities of the program is to identify 0. Al-Erhayem (At Large), JOM and offer potential solutions to common problems faced by Section leaders. In the team A. J. Badeaux, Sr. (Dist. 3), Charles Cty. Career & Tech. Center environment of the symposiums, the groups come together and provide great insights K. S. Baucher (Dist. 22). Technicon Engineering Services, Inc. into the issues facing AWS Sections. J. C. Bruskotter (Dist. 9), Bruskotter Consulting Services The number one problem identified each year by symposium attendees is the need for additional volunteer participation in Section activities, especially in the various lead­ C. F. Burg (Dist. l6),Ames Laboratory IPRT ership roles. Many of our Sections struggle to locate new volunteers to plan a meeting N. M. Carlson (Dist. 20). Idaho National Laboratory or special event, or who are willing start the process of becoming a Section officer. Only H. R. Castner (At Large), Edison Welding Institute by the active participation of us, the AWS volunteers, can our Sections remain viable and meaningful sources of information, technology exchange, and as networks of friends N. A. Chapman (Dist. 6), Entergy Nuclear Northeast and colleagues. S. C. Chappie (At Large), Consultant The numerous AWS committees are additional opportunities for personal growth in N. C. Cole (At Large), NCC Engineering membership participation and technical knowledge. These committees include techni­ J. D. Compton (Dist. 21), College ofthe Canyons cal, educational, certification, and other subject-specific volunteer groups that come to­ gether to enhance the science and technology of welding. As with the Sections, these L. P. Connor (Dist. 5), Consultant committees require volunteers from the membership to step forward and participate at J. E. Greer (Past President), Moraine Valley C C. various levels of the organization. There are opportunities for involvement on topic- M. V Harris (Dist. 15), Reynolds Welding Supply specific subcommittees, through the more expansive role of technical committees, and R. A. Harris (Dist. 10), Penton Publishing Co. continuing to the more global subjects discussed at the Standing Committee level of activity. W. E. Honey (Dist. 8), Anchor Research Corp. Speaking from my personal experience, there is great satisfaction in participating in D. C. Howard (Dist. 7), Concurrent Technologies Corp. AWS. I have had the good fortune to become active in many committees and subcom­ J. L. Hunter (Dist. 13), Mitsubishi Motor Mfg. of America, Inc. mittees of the Society and have found these opportunities to be very rewarding, both J. L. Mendoza (Dist. 18), City Public Service personally and with regard to my career. Similar to my life as a dad, I can reflect back and define various stages of maturity in my AWS membership. S. P. Moran (Dist. 12), Miller Electric Mfg. Co. So I ask you, at what stage in AWS membership are you? Whether as a neophyte or IM. Mustaleski (Past President), BWXT Y-12, LLC sage veteran, there is a place for you in working with the nearest AWS Section or com­ R. L Norris (Dist. 1), Merriam Graves Corp. mittee. Take the time to volunteer and participate. IC. Parker (Dist. 14), Miller Electric Mfg. Co. 0. P. Reich (Dist. 17), Terns State Technical College al Waco W. A. Rice (At Large), OKI Bering, Inc. E. Siradakis (Dist. \Y),Ahgas Great Lakes K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv. P. F. Zammit (Dist. 19). Brooklyn Iron Works. Inc.

Lee G. Kvidahl Chair, A WS Membership Committee

JULY 2005 CYBERNOTES A COLLECTION OF INDUSTRY NEWS FROM THE INTERNET

Interactive Job Board for Institut fur Normung. British Standards New Site Showcases Institution. Canadian Standards Robotics Industry Launched Association. European Committee for Robotics Systems Standardization. Japanese Standards Association, and the International Organization for Standardization. Subscriptions are available from ASTM Customer Service at (610) 832-9585 or mailto:service(Q asnn.org. A one-year sub­ scription for an individual workstation, one user, single PC access only, costs $995. For a one-year subscription, multi-user access at a single site, the cost is $1750. Options allow users to search using the following fields: Motion Controls Robotics, Inc. This • Standards developing organization Fremont, Ohio, based company recently Robotic Industries Association (RIA). • Specification title changed its name from Motion Controls This trade group for the robotics industry • Standard designation Plus, Inc., and launched a new corporate recently added an interactive career center • Grade, class, type, symbol, steel name Web site. The company provides automa­ to its Web site. Job seekers can post • Steel number or UNS number tion solutions for a variety of applications, resumes, search job listings, and save their • Product form (18 forms) including material handling, material job search criteria so that they are auto­ • Alloy group (8 groups) removal, sanding, deflashing, arc welding, matically notified by e-mail of new listings • Chemical composition (search 36 ele­ and vision-guided systems. The site offers a that match their specifications. Employers ments by minimum, maximum, mini­ company history and information regard­ can enter job descriptions, check the status mum/maximum range, nominal compo­ ing products, service, parts replacement, of postings, edit information, renew or dis­ sition, or search for alloys containing any and applications. It also includes several continue postings, and make payments amount of a specific element) case studies that describe how robotics online. With a paid job listing, employers • Mechanical properties such as tensile or were used to solve specific problems. In can search the database of resumes and yield strength, elongation, reduction of addition, customers can register to access contact candidates. There is an automatic area, impact strength, and hardness. the customer resource center. notification system when new resumes Results from each search can be sorted match an employer's criteria. Along with and selected according to user preferences. www.motioncontrolsrobotics.com each job posting, employers can provide Results can also be copied into programs information about their company and a such as Microsoft Excel® to save informa­ link to their Web site. tion electronically. Web Site to Help Engineers with Industrial Automation www.roboticsonline.com www.astm.org

Site Highlights Flux Cored Design Line ! Online Steel Database Wire Available

CMP Media LLC - Electronics Group. The company's EE Times recently launched the Industrial Control DesignLine Web site, which is targeted at design engineers and engineering man­ agers involved in the development of net­ Cor-Met, Inc. This Web site offers working systems, factory equipment, robot­ product information regarding the compa­ ic systems, motor control systems, and ASTM International. Users who sub­ ny's lines of covered electrodes and flux other devices used in industrial automa­ scribe tt) ASTM's new Passport to Steel cored wires for the forging, alloy fabricat­ tion. Visitors can sign up for a weekly e- online steel database can find information ing, high-temperature, corrosion, and abra­ mail newsletter, check out the site's techni­ about more than 20,000 alloys and stan­ sion industries. The site also highlights the cal library, participate in an online forum, dards from standards development organi­ company's welding equipment and servic­ read a variety of how-to articles and a blog zations around the world. The database, es. Visitors can request Material Safety by site editor Terry Costlow. The site also developed in partnership with CASTI Data Sheets and other literature, and read includes product information and industry Publishing, Inc., incorporates steel data about new products. from ASTM, Association Frangaise de news items. Normalisation, American Petroleum Institute, SAE International, Deutsches www.cor-met.com www.industrialcontroldesignline.com

WELDING JOURNAL NEWS OF THE INDUSTRY ESAB Equipment Chosen for Wind Tower Manufacturing Plant in Tennessee

ica's first automated wind tower production facility. Aerisyn, a Wisconsin based alternative energy company, is currently modifying an existing manufacturing plant in Chat­ tanooga, Tenn. The plant is expected to be in full production in August. ESAB assisted with the plant layout and material flow de­ sign. This will be the first installation in North America of the company's automated assembly. In addition, Aerisyn will utilize several other of the com­ pany's systems, including two large cutting machines, position­ ing equipment, specialized welding manipulators, as well as submerged arc filler metals, and a variety of handheld welding and shop equipment. The key to making wind towers is the ability to produce di- mensionally accurate parts with precise weld preparation bevel­ ing on all sides. Two of the company's cutting machines pro­ duced at the Florence, S.C, plant will handle the task — the The company's Avenger cutting machines, along with other sys­ Avenger 1, a 14-ft-wide plasma contour bevel machine, and the tems, will be put to use in North America's first automated wind Avenger 3, a 30-ft-wide model equipped with dual oxyfuel bevel tower production facility in Chattanooga. Tenn. heads. Aerisyn is investing more than $7 million in equipment and ESAB Welding and Cutting Products, Florence, S.C, has capital improvements to the Alstom Building in Chattanooga. been selected by Aerisyn, LLC, to supply all the cutting, assem­ It is estimated that it will be able to produce up to 200 of the bly, welding, and material-handling equipment for North Amer­ 200-300-ft-tall towers in the first year of production.

Lincoln Electric Company of Canada WEPAN Award Winners Honored Celebrates its 75th Anniversary with The Women in Engineering Programs & Advocates Network Launch of Mobile Demonstration Unit (WEPAN) recently honored five individuals, companies, and pro­ grams for their work in the support of women in engineering. • Barbara Bogue, Affiliate Associate Professor of Engineering Science and Mechanics and former Director of the Women in Engineering Program at The Pennsylvania State University, re­ ceived the 2005 Founders Award. This award recognizes Bogue's dedicated service to the advancement of WEPAN and her con­ tribution to an engineering infrastructure conducive to the suc­ cess of women in the engineering profession. • Clemson University's Women in Science and Engineering Program was the recipient of the Women in Engineering Initia­ tive Award that recognizes a program or project that serves as a model for other institutions. • Hewlett-Packard won the 2005 Breakthrough Award for "cre­ ating a work environment that enhances the career success of women engineers of all ethnicities." This award signifies the abil­ ity of an employer to "break through" the artificial barriers that prevent women engineers of all ethnicities from attaining their full potential. • Sheryl Sorby, Ph.D., chair of engineering fundamentals and associate dean of engineering at Michigan Technological Univer­ sity, received the 2005 Betty Vetter Research Award that recog­ The Lincoln Electric Company of Canada, which is celebrating its nizes achievement in research related to women in engineering. 75th anniversary, recently launched a mobile demonstration unit • Worcester Polytechnic University's Diversity and Women's (MDU). Embarking on a cross-Canada tour, the MDU comes fully Programs received the Engineers Week Award for its contribu­ equipped with some ofthe company's newest welding technology. tions to Introduce a Girl to Engineering Day. This is a national program aimed at encouraging young girls in their pursuit of sci-

JULY 2005 ence, math, and engineering. The awards were presented at the 2005 WEPAN NAM EPA (National Association for Minority Engineering Program Ad­ ministrators) Annual Conference held in Las Vegas, Nev.. April 10-13.

Tenaris Acquires Romanian Steelmaking Facility

Tenaris S.A., Luxembourg, has completed the acquisition of a 97% shareholding in Donasid S.A., a Romanian steel producer, for approximately $48 million. The company is also assuming approximately $22 million in long-term debt held by Donasid with AVAS, the Romanian state privatization agency, and expects to spend an additional approx­ imately $32 million in investments to adapt the steel shop to pro­ duce round steel bars and other improvements. Donasid's assets include a steel shop located at Calarasi on the river Danube in the south of Romania. The steel shop, which has an annual capacity of 470,000 tons, includes an electric arc Ferris State University welding students (from left) Jason Ball, Ken­ furnace and continuous casting facilities, and uses steel scrap as neth Camling, Jeffrey Lemke, and Brandon Reinhold are recipients its principal raw material. ofthe William A. Beegle Memorial Scholarship. (Adam Blaskowski is not pictured.) Ferris State University Welding Students Receive Scholarships gle, a past faculty member in the Welding Technology and Weld­ Five students in the Welding Engineering Technology Depart­ ing Engineering Technology programs at Ferris State from 1975 ment at Ferris State University, Big Rapids, Mich., have been to 1995. Beegle was an active member ofthe American Welding awarded the William A. Beegle Memorial Scholarship. Society and the originator of the AWS Student Chapter at Ferris The scholarship recipients were Jason Ball, Adam Blaskowski, State. Kenneth Camling, Jeffrey Lemke, and Brandon Reinhold. The scholarships were funded by Beegle's wife, Carol, and The scholarships are in remembrance of William "Bill" Bee- donations from private welding industry individuals. Water

Take Your Welding Skills Underwater. Tram In 5 Months For A High-Paying And Exciting Career As An Underwater Welder. 1 Dive In, Get Wet... And See Sparks Fly In Your New Career!

I*©, Classes y" • Now % Forming ^ m S*-

[DIVERS;AGADEMYtl / INTERNATIONAL" apj£38?DIVEi Commercial Deep Sea Dive Training Since 1977 www.diversacademy.com

Circle No. 18 on Reader Info-Card WELDING JOURNAL World Trade Center 9/11 Investigation oped world with high-wage structures have to compete with metal and alloy parts made by conventional and established routes using Could Result in New Generation of low-wage earners in the developing countries. Also, there are Building Safety and Fire Prevention Codes new companies in the low-wage countries that are adopting the MIM technology. The International Code Council (ICC) will use its code de­ North America comprises the bulk ofthe market with a share velopment process to address building safety and fire prevention of 44.5% in 2004. Its share is likely to drop to 42% as it grows at code issues raised in the National Institute of Standards and Tech­ an AAGR of 7.1% through the forecast period. nology (NIST) findings from its World Trade Center investiga­ The MIM market in Japan stood at $112 million in 2004. This tion. is the fastest growing market with an AAGR of 10.6% through As a result of the Worid Trade Center attacks and proposed 2009. code changes to address terrorism-related issues in the built en­ For more information, contact the company at (203) 853-4266, vironment, the ICC formed an Ad Hoc Committee on Terrorism ext. 309 or e.-ma.i\publisher(Sbccresearch.com. Resistant Buildings. The committee, which is made up of code officials, engineers, architects, and other building professionals, will look at the NIST report and its forthcoming recommenda­ tions, and other research. The ICC updates its codes every three years through a gov­ Industry Notes ernmental consensus process. FANUC Robotics America and Robotic Production Technol­ ogy (RPT), Auburn Hills, Mich., jointly announced the sign­ Global Metal Injection Molding Market to ing of a new five-year agreement where RPT is reappointed as Reach $571 Million by 2009 FANUC Robotics' distributor/market channel for all water-jet and nonmetallic routing applications in the Americas. According to a soon-to-be-released report from Business Communications Co., Inc., RGB-306 Metal Injection Molding. Airgas, Inc., Radnor, Pa., has completed acquiring the assets the global metal injection molding market was estimated at $382 and operations of Vancouver Welding Supply, Inc., based in million in 2004. This market is projected to grow at an average Vancouver, Wash., and Cumberland Welding & Supply Co., annual growth rate (AAGR) of 8.4%, reaching $571 million by Inc., in Cumberland, Md. 2009. The metal injection molding (MIM) companies in the devel­ Rath Manufacturing, Inc., of Janesville, Wis., and Gibson Tube,

MANUFACTURERS OF CORED WELDING WIRE AND STICK ELECTRODES We have been told that we are the best-kept secret in the welding industry. In an effort to correct this situation we advise that: WE MAKE Stainless Cast Iron Cobalt AISI Nickel 410NiMo FC 33% Ni 1 4130 ENiCrFe-2 502 FC 55% Ni 6 4140 ENiCrFe-3 505 FC 99% Ni 12 4340 EniCrCoMo-1 E2553 FC 21 ERNiCrMo-3 E2209 FC 2101 ERNiCr-3 E630 FC 904L FC THE ABOVE ARE JUST A FEW OF THE CORED WIRES THAT WE MAKE. FOR MORE INFORMATION CALL: COR-MET, INC. • 12500 EAST GRAND RIVER • BRIGHTON, Ml 48116 PH: 800-848-2719 FAX: 810-227-9266 www.cor-met.com Circle No. 14 on Reader Info-Card JM JULY 2005 Inc., of North Branch, N.J., are merging. A new tubing com­ ering the company's respiratory protection and gas-detection pany is being formed, and it will be known as RathGibson. products around the world. These three operating centers, lo­ cated in Germany, Pittsburgh, and Singapore, will be known Century Aluminum Co., Monterey, Calif., recently announced as operating "Hubs" within the company. that Nordural ehf., a wholly owned subsidiary, has signed an agreement with a Icelandic gcothermal power producer. Hi- Motion Controls Plus, Inc., Fremont, Ohio, has changed its taveita Sudurnesja hf., and the municipality of Reykjanesbaer, name to Motion Controls Robotics. Iceland, to explore the feasibility of constructing a new alu­ minum smelter in Helguvik, Iceland, or at another mutually Esmark, Chicago, 111., has completed the purchase of Piqua, agreeable site. The agreement gives Nordural exclusive rights Ohio-based Miami Valley Steel Services, Inc., a flat-rolled steel to the project. First production of primary aluminum would and value-added specialist that sells approximately 200,000 be targeted for 2010-2015. tons of steel per year, for $81 million in cash. Nachi Robotic Systems, Inc., (NRS) is moving the U.S. train­ Maverick Tube Corp., St. Louis, Mo., has begun work on a $12 ing center to a newly constructed building, adjacent to NRS million project to expand the capacity of its Precision Tube headquarters in Novi, Mich. The facility will provide 20% more coiled tubing facility by more than 50%. The previously an­ training lab floor space. The company is also acquiring floor nounced expansion is taking place at the company's Precision space in the same location for a 50% expansion of its U.S. man­ Tube Houston, Tex., facility and is expected to be completed ufacturing. In addition, Nachi-Fujikoshi (NF) is doubling its in the first quarter of 2006. robot manufacturing floor space in Toyama, Japan. This facil­ ity is an investment of approximately $10 million and is situ­ ated within the main NF Toyama campus. Both facilities be­ Alberici Constructors, St. Louis, Mo., has been awarded the came fully operational in June. national AGC/Willis 2003 and 2004 Construction Safety Ex­ cellence Award in the ''Heavy Construction, Over One Mil­ Automated Concepts, Inc., has built and moved into a new lion Work Hours" category. Award recipients are chosen for 65,000-sq-ft facility in Council Bluffs, Iowa, that provides more their commitment and approach to safety and health issues, as than 60% more space in which to design, manufacture, and well as statistical results measured throughout the year. program complete turnkey robotic applications. Chart Industries, Inc., Garfield Heights, Ohio, has completed Draeger Safety, Inc., Pittsburgh, Pa., has been named one of the acquisition of Changzhou CEM Cyro Equipment Co. Ltd., three Draeger corporate central distribution points for deliv­ a wholly owned subsidiary of CEM International (Asia).

Available in grades E308L, E309L, E316L& E317L I/U4SHINGT0N XILLOK CO. EAST COAST WEST COAST 7010-G Realms Rd 8535 Utica Ave Charlotte. NC 28216 Rancho Cucamonga, CA 91730 (888)522-8296 Tel (800)830-3094 Tel (704)598-6673 Fan (909)291-4=86Fai Se Habla Espanol

Circle No. 28 on Reader Info-Card WELDING JOURNAL LETTERS TO THE EDITOR

Reader Comments on Austenitic processes employing coated electrodes and should be reserved for cases where those Stainless Steel Article flaxes that produce slag. Coated electrodes patterns or colors provide useful addi­ and fluxes were not used or covered in the tional information. The following letter was sent in reference to work reported in the Welding Journal arti­ Third, I found the table listings for the ArthurH, Tuthill's article "Corrosion Test­ cle, but do pose special problems as Mr. stick melt point data to be curious and un­ ing of Austenitic Stainless Steel Weldments, " Ebert points out. clear. If the test sequence, as described in which appeared in the May 2005 issue of My own experience is that it is relatively the article, includes using calibrated tem­ the Welding Journal. The author's response easy to remove about 90% ofthe slag from perature increments of 50°F, how does the follows. welds made with coated electrodes, and ex­ stick melt point temperature get reported tremely difficult to remove that last 5% left as a temperature different than the cali­ I wish to compliment Mr. Tuthill for on either side ofthe weld bead. As Mr. Ebert brated temperature and to a precision of his May 2005 Welding Journal article that points out, slag remaining on either side of 0.1°F? Did the author plot the data and summarized the corrosion mechanisms as­ the weld bead and on the ID of pipe welds then extract the table data from the lin­ sociated with austenitic stainless steel can lead to "underslag" coirosion in many ear correlation line? I would guess so, but weldments. It was a good idea for the aqueous environments. These problems that is the point of my comment. The Welding Journal to address such welding- with coated electrodes are a good reason to reader should not need to have to guess related subjects. prefer gas tungsten arc (GTAW) and gas at how the data was achieved. Naturally, Mr. Tuthill did not provide metal arc welds (GMAW) for stainless steel For technical articles, clarity in the data a detailed review ofthe chemicals that cor­ pipe and vessel fabrications. For large ves­ presentation is important in allowing the rode the SS under different temperature sels where multipass welds are required, reader to, hopefully, come to the same and pressure conditions. This must be ad­ shielded metal arc welding (SMAW) is conclusions as the authors. The concerns dressed by the equipment operators and, sometimes used for completion after the root listed above detracted from what other­ with one exception, cannot be influenced pass has been made using GMAW or wise would have been a useful and inter­ by the welding activities. GTAW. esting article. The one exception deals with welding processes that employ coated electrodes Tom Doody, AWS Member and fluxes that produce some slag. When AWS Member Reacts to Article using such processes, most coatings and about Temperature-Indicating Regarding the first and second points, I fluxes contain some halogens such as flu­ Methods agree with the commenter that the graphs orides to chemically break down the high are veiy hard to see with the colors selected. melting temperature oxides and thereby The following letter was sent in reference to The commenter is also coirect that the "data reduce the risk of inadequate fusion. Robert K. Wiswesser's article "Temperature- points " are the actual temperatures that were Some of these halogens will be retained Indicating Methods Are Tested, " which ap­ established on the heated test specimen. in the slag, and they can be leached out peared in The American Welder section of The third point refers to the manner in when exposed to an aqueous environment the May 2005 Welding Journal. The au­ which the temperature-indicating crayons' and form a strong acid. This highlights the thor's response follows. melting point was determined. We placed a need to remove all slag after welding. cut section of the crayon on the specimen There is no problem doing this on the I was disappointed in the data clarity as the heat was increased through each data OD of a pipe weld. However, it must be in the article "Temperature-Indicating point temperature. In some cases, the crayon realized that some slag will form on the Methods Arc Tested" in several different melted slightly below, and in other cases, underside of a root pass and that it is often ways. slightly above the data point temperature. impossible to remove it on the pipe ID First, the four figures in the article We recorded that temperature when the and some other inaccessible locations. showed graphs with one axis labeled as crayon started melting. The use of backing rings or strips does not ''calibrated temperature" while the other We were very surprised to obsei-ve that help since some slag will form in the space axis was labeled "data points." Nowhere the crayons melted within ± PF of the label between the ring and the pipe. I recall one in the article or graphs were the "data temperature. project where a small amount of slag ate points" listed or explained. Yes, it is "ob­ One typographical error appeared in the through >«in. of stainless steel during a vious" that they correspond to the indi­ printed article. The "Emissivity of Gun 2" four-hour-long exposure to high-temper­ cated temperature of the measurement as referenced below the tables should be ature water. method. It is my contention that the graph 0.95. We must be sure that the welding does axis for each plot should have been labeled not contribute to any corrosive attack. precisely that, i.e. "indicated tempera­ ture." (By the way, whatever happened to Based upon the above, it is advisable to Dear Readers: thoroughly remove all slag and not to em­ the convention of using the independent variable on the x-axis?) ploy any slag-producing welding process The Welding Journal encourages for SS root passes and for welds that are Second, the graph color selection made an exchange of ideas through not accessible from the back side, when­ it almost impossible to distinguish one of letters to the editor. Please send ever there is the possibility that the weld­ the data sets. Just because graphing pro­ your letters to the Welding Journal ments will be exposed to an aqueous grams permit a user to apply different Dept., 550 NW LeJeune Rd., environment. background colors and patterns does not Miami, FL 33126. You can also Harry W Ebert. PE mean that they should be used, particu­ reach us by FAX at (305) 443-7404 larly when it results in a loss of readabil­ Fellow of the American Welding Society or by sending an e-mail to Kristin ity. There is nothing wrong with using a Campbell at [email protected]. / wish to thank Mr. Ebert for his com­ standard white background for graphs. ments on problems arising from welding Use of background patterns or colors

JULY 2005 Take Up The Torch Week September 12-16,2005

TO TAKE UP THE TORCH TODAY-Visit www.takeupthetorch.org Become an Industry Partner and link your website to ours. Mentor those starting out—Sign up for the Speakers' Bureau in your area. Students— Explore the benefits of a career in welding, by visiting the site and requesting a FREE poster, video and career information package. For more information, visit www.takeupthetorch.org, call 800-443-9353, ext. 308 or email: [email protected] Circle No. 11 on Reader Info-Card AWS Foundation is proud to announce its 2005-2006 National Scholarship Recipients

Paul Boulware Adam Rolfes Steven C. Woods James R. Cuhel The Ohio State University The Ohio State University The Ohio State University Ferris State University Welding Engineering Welding Engineering Welding Engineering Welding Engineering Technology Howard £ Adkins Airgas - Jerry Baker Airgas - Terry Jarvis Arsham Amirikian Engineering Memorial Scholarship Scholarship Memorial Scholarship Scholarship "It is an honor to receive the "I am honored to be the recipient "I am honored to be the recipient of "I am greatly honored to be the Howard £ Adkins Memorial ot the Airgas-Jerry Baker Scholarship. the 2005-2006 Airgas-Terry Jarvis recipient of the Arsham Amirikian Scholarship. I greatly appreciate the I would like to thank the American Memorial Scholarship. I would like to Engineering Scholarship. This A WS Foundation's support ot welding Welding Society and the Airgas-Jerry thank the American Welding Society scholarship is a great aid in helping education, and hope to use this Baker Scholarship Committee for and Airgas for their support of welding me continue my education in welding scholarship to help make positive selecting me for the national engineering students. This scholarship engineering technology, lam also strides in the welding industry." scholarship. Your generosity is greatly will allow me to focus my efforts on thankful for the A WS Foundation for appreciated." furthering welding technology. Lastly, their dedicated support for higher thanks to my parents tor their support education." and motivation."

Timothy Schanken Adam Uziel KurtVerhoff Justin Nielson Pennsylvania College The Ohio State University The Ohio State University LeTourneau University of Technology Welding Engineering Welding Engineering Welding & Mechanical Welding & Fabrication William A. and Ann M. Brothers Donald F. Hastings Scholarship Engineering Engineering Technology Scholarship "I'm truly honored to be the Donald and Shirley Hastings Edward J. Brady Memorial "I'm honored to be nationally recipient of the Donald F. Hastings Scholarship Scholarship. This scholarship will Scholarship recognized as a recipient of the William "The financial support provided by A. and Ann M. Brothers Scholarship. I provide support and be a source of "Receiving the Edward J. Brady the Donald and Shirley Hastings deeply appreciate the efforts of the motivation as /pursue my degree in Memorial Scholarship is an Scholarship has greatly assisted my AWS Foundation to encourage the welding engineering. I would also like incredible honor and I would like to pursuit of a career in welding pursuit ot careers in welding to thank the AWS Foundation for thank the A WS Foundation and all ot engineering. I look forward to the engineering. This financial support will this opportunity and the national the people involved in selecting me opportunity of making contributions to assist mea good part ot the way to recognition." lor this prestigious award. I look the field of welding engineering and finishing my welding engineering torward to using the award to turther am grateful of the AWS Foundation's degree next year. My sincere thanks to advance my education in the field of assistance in providing me this all that made this possible." welding engineering." opportunity. Thank you for supporting my education." Circle No. 6 on Reader Info-Card Benjamin Newcomb Troy A. Genow Ryan Nichols Raymond W. Angus Ferris State University Ferris State University Ferris State University Ferris State University Velding Engineering Technology Welding Engineering Technology Welding Engineering Technology Welding Engineering Technology William B. Howell Memorial ITW Welding Companies ITW Welding Companies John C. Lincoln Memorial Scholarship Scholarship Scholarship Scholarship '"As a recipient of the William B. Howell "It is truly an honor and a privilege to "I am honored to be selected as a "It is an honor and a privilege to be Memorial Scholarship, my thanks go out receive the ITW Welding Companies recipient of the ITW Scholarship. With awarded the John C. Lincoln Memorial o the A WS Foundation. I am indebted to Scholarship. I am grateful for the AWS the encouragement of the instructors Scholarship. I would like to thank the vy wife Jenny, Scott Griskavich and the and their dedication towards helping the from Southeast Community College at selection committee and the team at Badger Welding Supplies, and welding industry and its future welders. Milford, Nebraska, I have decided to benefactor for selecting me as the Kevan Kokkonen of Miller Electric for Thank you very much for investing in my further my education in welding recipient and with their investment in encouraging me to further my education future as a welding engineer. I would engineering. This scholarship will help me, I know I will become a valuable n welding engineering. I look forward to also like to recognize my family, my me pursue that educational goal. individual to the welding community. continuing my involvement with the girlfriend Shannon, and the Ferris State Thank you." Thank you again for your support in AWS...however possible." Welding Engineering professors..." my education and career."

Caleb Roepke Joel Troyer Joshua W. Sleigh Linda Nicole Dutruch LeTourneau University LeTourneau University LeTourneau University University of Mobile Welding Engineering Materials Joining and Welding Engineering Technology Business Administration Matsuo Bridge Company Ltd. of Mechanical Engineering Jerry Robinson - Inweld James A. Turner, Jr. Memorial Japan Scholarship Praxair International Scholarship Scholarship Scholarship "It is an honor and a blessing to "Thank you for honoring me with the "What a blessing it is to receive the "I would like to once again thank the receive this award. I would like to Praxair International Scholarship. I am Jerry Robinson-lnweld Scholarship to American Welding Society for awarding 'hank the AWS Foundation and Matsuo very grateful to the AWS Foundation pursue my dream of becoming a me with the James A Turner, Jr. Memorial Bridge Company Ltd. of Japan for and Praxair for their contribution for welding engineer and to seek higher Scholarship. I am very honored to have selecting me for this opportunity. I am the furthering of education in the field quality production in industries." received such a prestigious award on the excited about the internship and of welding engineering. I look forward national level..! will continue to won\ learning about welding engineering in to becoming a welding engineer and with Welding Engineering Supply the international field. Thank you for contributing to the field. Thank you to Company.Jhank you for your continued your help in achieving my goals." everyone who was responsible for this support in my education. I have been investment in my future." very fortunate to be involved with the welding industry. ..The American Welding Society is indeed a great asset to young people of today."

Each year, the American Welding Society Foundation provides scholarship funds to help hundreds of students who otherwise would be unable to afford a welding education. We are the only industry foundation with the specific mission of helping to fund the education of welding students. In so doing, we create the careers that sustain and grow our industry.

We get these funds from your contributions. The more you contribute, the more students we can help educate.

To make a scholarship contribution or set up your own National Scholarship, contact Wendy Sue Reeve at the AWS Foundation. Call 800-443-9353, x293 or email [email protected]. Thank you for your continuing support. k Foundation, Inc. Building Welding's Future through Education STAINLESS Q&A BY DAMIAN J. KOTECKI

Q: I'm trying to consistently pass quali­ fication tests on 3/16-in. (4.8-mm) 409 stainless steel, including a transverse face bend required by my customer. The sur­ faces of the bend specimens are first ground down to eliminate any notches at the bead edges. The bend radius is 3/4 in. (19 mm), so that should be easy. We are using one-side submerged arc welding (SAW). With 309L filler metal, we pass every time. But with 409Cb filler metal, we fail about half of the bend samples. The bend samples that fail are fracturing in the weld after very little bending. But Fig. I — Bend specimens of 409 submerged arc welded with ER409Cb. the sample right next to a failed one, from the same plate, is likely to pass. What's wrong?

A: Type 409 is a very lean ferritic stainless Figure 1 shows two samples of welds nar, parallel to the main crack or to one steel that is borderline for formation of you made with ER409Cb, one bent and of two other planes in the grain. The some martensite in the heat-affected zone one broken. Even at the low magnifica­ cracking appears to be cleavage along cer­ (HAZ). ER309L works well for such a tion of the macros, it is easy to see the tain crystallographic planes. I believe the joint because the diluted weld metal will grain growth that has occurred in the cracking is due to the action of diffusible be stable austenite with quite a bit of fer­ mostly ferritic microstructure of the weld hydrogen under the slow strain conditions rite. The austenite retains any hydrogen, metal and HAZ. A nearly continuous of bending. largely preventing it from causing any em­ grain boundary along the centerline of Normally, one doesn't think of ferrite brittlement in the HAZ, and the weld each sample is visible. Such centerline as being susceptible to diffusible hydro­ metal itself is immune to hydrogen dam­ grain boundaries are a plane of weakness gen damage, but it has been known to hap­ age. The austenite is also not sensitive to and have been known to be prone to cen­ pen in very coarse-grained ferritic stain­ grain size effects. The only thing that can terline cracking during solidification, but less steels. You should be able to estab­ cause problems with ER309L filler metal that is not what has happened to either lish that diffusible hydrogen is the cause is excessive dilution, which can result in a sample. Note that the fracture path in the of the failures by removing the diffusible fusion zone with considerable martensite. broken sample is not along the weld hydrogen before bending. I suggest that, and then the fusion zone would likely frac­ centerline. after welding, you cool the sample to room ture in a bend test. But that does not seem At higher magnification, as can be seen temperature (to make sure that austenite to be the problem in your case. in Fig. 2, it is clear that both welds con­ has transformed to martensite), then age However, there are several potential tain some grain boundary martensite, in­ the samples at 250°C (482°F) for f 6 h, or problems with the ER409Cb weld metal. dicating partial transformation to austen­ at 100°C (212°F) for 48 h, to remove dif­ These include grain growth, martensite ite during cooling from solidification. But fusible hydrogen before bending. If you formation in the HAZ and fusion zone, the grain boundary martensite is not the can now consistently pass the bend test, and diffusible hydrogen causing loss of crack path. that will identify diffusible hydrogen as ductility or cold cracking. Table 1 lists the Note that the main crack path is across the cause of the failures. composition of the three current versions ferrite grains, and that there are second­ Of course, you would not want to have of Type 409 in ASTM A240, along with ary cracks in the ferrite beside the main to age the finished product at elevated that of the ER409Cb from AWS A5.9. crack path. The secondary cracks are pla­ temperature before putting it into serv-

Table 1 — 409 Plate and ER409Cb Compositions

Composition1, wt-%

Type UNS C Mn P S Si Cr Ni N Ti Nb Number (Cb) 409 S40910 0.030 1.00 0.040 0.020 1.00 10.5 to 11.7 0.50 0.030 6x (C+N) to 0.50 0.17 409 S40920 0.030 1.00 0.040 0.020 1.00 10.5 to 11.7 0.50 0.030 8x (C+N) min.; 0.15 to 0.50 0.10 409 S40930 0.030 1.00 0.040 0.020 1.00 10.5 to 11.7 0.50 0.030 Ti + Nb = [0.08 + 8x (C+N)] to 0.75; Ti = 0.05 min. ER409Cb S40940 0.08 0.8 1.0 0.04 0.03 10.5 to 13.5 0.6 10C to 0.75

I. A single value is a maximum unless otherwise indicated.

• JULY 2005 lessen the hydrogen available from the moisture in the flux. That may be enough to eliminate the failures without any aging. •

DAMIAN J. KOTECKI is Technical Director for Stainless and High-Alloy Product Development for The Lincoln Electric Co., Cleveland, Ohio. He is president of the American Welding Society, and a vice president of the International Institute of Welding (IIW). He is a member of the A5D Subcommittee on Stainless Steel Filler Fig. 2 — Fusion zone photomicrographs of 409 stainless steel submerged arc welded with Metals; Dl Committee on Structural Welding, ER409Cb. Left — Successful bend specimen. Right —failed bend specimen. DIK Subcommittee on Stainless Steel Welding; and a member and past chair of the Welding Research Council Subcommittee on Welding ice, but a week or two at room tempera­ If diffusible hydrogen is the problem, Stain/ess Steels and Nickel-Base Alloys. ture will accomplish the same hydrogen you can very likely lessen or eliminate its Questions may be sent to Dr. Damian Kotecki removal. And, if the weldments are in­ effect by eliminating the sources of the clo Welding Journal, 550 NW LeJeune Rd., diffusible hydrogen. A very significant tended for service in an engine exhaust Miami, FL 33126; or send e-mail to system, the high temperatures ofthe serv­ possibility is that your flux has picked up Damian [email protected]. ice will accomplish the same hydrogen moisture. Baking the flux at 345° to 425°C removal. (650° to 800°F) before welding should

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

COLLEGE OF OCEANEERING A Division of National Polytechnic College of Engineering and Oceaneering FOR MORE INFO U0043^IUE WWWJiATPOLY.EDU An affiliate of the National University System

Circle No. 12 on Reader Info-Card

WELDING JOURNAL NEW PRODUCTS FOR MORE INFORMATION. CIRCLE NUMBER ON READER INFORMATION CARD.

Inverter Power Supply Delivers Welding Control for Microjoining Applications

The IPB-5000A 5-kHz inverter welding power supply, when paired with the ITB- 780-6A transformer, outputs a maximum current of 6000 A. It operates in constant current, voltage or power feedback modes, and can also weld in combination of cur­ rent and voltage. The IPB's full-color angles. XYZ Optics maps the full lens screen and simple user interface allow easy contour to the human eye. Lenses are programming of up to 127 weld schedules. milled from solid plastic blanks, ensuring A wide range of weld monitoring tools are razor-sharp vision at all angles. They are built into the unit for added process con­ available with clear or high-intensity yel­ trol. The unit has an envelope function that low lens. Each pair comes with a Micro- allows dynamic limits to be set around a monitored waveform to ensure the same re­ clear™ storage bag, which can be used to sistance rate occurs at the same rate for every weld. A precheck function determines help clean the lenses. resistance before the weld and can abort if it is out of limits. Torch Wear 103 Miyachi Unitek Corp. 100 2374 Edison Blvd.. Twinsburg, OH 44087 1820 S. Myrtle Ave., Monrovia, CA 91016 Cutting Package Features Drag or Standoff Cutting Power Supply Dust Covers Constructed of Black Nylon Canvas tfWQ

are two products in the Super Sawzall® reciprocating saw family with a 13-A Mil­ waukee-built motor. They offer orbital cutting action with a variable speed trig­ ger 0-3000 SPM. They also have a VA-in. cutting stroke. The Super Sawzall has a 360-deg rotating handle that locks at 45- The company's Dust Covers, con­ deg increments and can continuously ro­ structed of durable, heavyweight black tate in either direction without having to nylon canvas, are for its CUTMASTER"' go back to the starting position. The Or­ and PakMaster® power supplies. They bital Super Sawzall, along with the Rotat­ The Jesse James PowerCut® 650 are water resistant and feature a large ing Super Sawzall reciprocating saw, have plasma arc cutting machine offers cutting outer pocket for storing manuals or spare larger heavy-duty Quik-Lok™ blade performance in a lightweight, durable consumables. An adjustable draw cord en­ clamps with gripping ribs for fast, easy package. Designed to manually cut % in. sures a tight fit while reinforced and fin­ blade changes. and sever Min., its adjustable output al­ ished seams help keep them strong and lows the user to tailor the current to the sealed. They are available in three sizes Milwaukee Electric Tool Corp. 102 material being cut. Features like drag or — small, medium, and large. 13135 W. Lisbon Rd.. Brookfield. WI 53005 standoff cutting, high-frequency starting, and template following ease operation. Safety Glasses Available Output is 30 A at 60% duty cycle, 40 A at Thermal Dynamics Corp. 101 40% duty cycle. The cutting package 16052 Swingley Ridge Rd., Ste. 300, Chesterfield. MO 63017 with Clear or High-Intensity comes complete, fully assembled, and Yellow Lenses ready to cut, including the console, 25-ft Saws Offer Orbital Cutting PT-31XLPC torch, torch spare parts kit, Action Intended to be worn by themselves or air filter/regulator, input power cord with as primary eye protection under welding plug, and a 25-ft work cable with clamp. The Super Sawzall reciprocating saw or grinding helmets, the company's safety Model 6523-21 and the Orbital Super glasses employ Oakley's patented XYZ ESAB Welding and Cutting Products 104 Sawzall reciprocating saw Model 6536-21 Optics® to maintain visual clarity at all 411 S. Ebenezer Rd.. PO Box 100545. Florence. SC 29501-0545

JULY 2005 Power Connectors Include rectangular sanding pad allows for sand­ Positive Latch, Wire Strain ing into corners of drawers and cabinets. The rubber overmold of the tool reduces Relief vibration and cold air transmission to the user, and allows for a more comfortable feel while sanding. It is available in three different models.

Dynabrade, Inc. 106 8989 Sheridan Dr., Clarence. NV 14031-1490

Borescopes Contain New Objective Lens borescopes. They feature a high-quality, patented endoGRINS lens system that The company has upgraded its Slim lowers the dispersion of light, producing and Hardy models of Hawkeye a clear, sharp image. A new objective lens

The high-frequency attenuation deliv­ ered by the ACARA filtered electrical power connectors prevents radio-frequency emission. The ACARA male filtered con­ nector provides EMC performance to be­ yond 10 GHz. The integral feed-through capacitor construction incorporates low se­ ries inductance. The ACARA female power connector's plastic housing is polarized to the male filter, preventing the installer from reversing polarity. The positive latch pre­ vents accidental unmating, but allows im­ mediate power disconnect for emergency service or repair. The wire strain relief elim­ inates creep of the wire insulation jacket, which can expose bare conductors and re­ sult in electrical shock. The connectors arc available in 65-, 100-, 150-, and 250-A rat­ ings and in capacities from 100 to 2100 Debt ain't pretty. nano-Farad. Put a fresh face on your finances with Hands-On Home Loans Anderson Power Products® 105 13 Pratts Junction Rd., PO Box 579. Sterling. MA 01564-0579 • Get quick Cash

Orbital Finishing Sander • Home Improvement/Construction Loans Comes in Three Models • Refinance and consolidate debt/credit cards • Lowest rates available

Get funds for home improvement, tuition or personal use. We have thousands of different programs including many zero down payment options. *** Amazing purchase programs*** Call for a free consultation today. (888) 430-8695

The Dynabug® II air-powered orbital finishing sander is lightweight in design, weighing 1.6 lb, and handles vertical sand­ fr HANDS-ON ing applications. The tool utilizes a 10,000 Wl ^H HOME LOANS IJ^IJ^IJ^IJ^IJ^HI rpm air motor. It features a %-in.-diame­ ter orbit for blending and finishing. The Specializing in the trade field for over 10 years!

Circle No. 26 on Reader Info-Card WELDING JOURNAL produces a wider field of view and gives a fuller image in the 0- and 90-deg DOVs. Other features include an improved scratch-resistant mirror technology in the 90-deg mirror adaptor, and improved multilayered, broadband antireflection coatings on the objective lenses deliver­ ing truer color reproduction.

Gradient Lens Corp. 107 207 Tremont St., Rochester, NY 14608 Cordless Drill/Driver Equipped with Torque advantage of unused vertical space by en­ Settings abling item diverges and merges to and from vertically stacked conveyors. It sorts The BSZ 14.4 cordless drill/driver can items of varying weights and dimensions. drill, tap, and drive screws in a wide vari­ It offers a wide range of widths, and is ety of applications. It is equipped with 20 smooth gear change mechanism to extend compatible with virtually any belted con­ torque settings, plus a drill setting with tool life. It can drill up to !^-in. holes in veyor system. It features a durable steel forward and reverse modes. It also has a mild steel and up to lMc-in. holes in soft frame, standard flanged bearing cartridge two-speed gearbox, a keyless 14-in. chuck. wood. The tool weighs 4.6 lb with battery units for all pivoting and rotating mem­ and an ergonomic, rubber-coated T- and comes with a built-in case that holds bers, and 1045 turned-ground and pol­ handle. The 14.4-V motor offers increased two bits. ished high-strength steel shafting. It fea­ power — up to 487 in.-lb of torque. The tures EPA-compliant industrial-duty elec­ onboard Variospeed electronics allow in­ Metabo Corp. 108 tric motors and industry-leading gear re­ 1231 Wilson Dr.. West Chester. PA 19380 finite no-load speeds up to 1400 rpm. Its ducers. The units come standard with quick-charge battery is part of a new air- safety guards, side guards for its articulat­ cooled charging system that cools the bat­ Unit Sorts Items of Varying ing conveyors, and prewired photoelec­ tery and charger during the charging Weights, Dimensions tric sensors. process, and offers 30-min charging with up to 2000 charges per battery. The tool The LogiSort™ belted vertical unit FKI Logistex® North America 109 utilizes three-level planetary gears and a sorts up to 30 items per minute and takes 4612 Navistar Dr., Frederick, MD 21703

[;xSwjffwJh large and small) and Educational Institutions xx nsyji'drzu ngiflf edgeedge-of of thethe materialsmaterials joiningjoining industry!industry! TAINING COMPANY MEMBERSHIP Join an elite group of over AWS WELDING SHOW 425 AWS Sustaining Company • Exclusive usage of the AWS Sustaining For more information Members and enjoy: Company logo on your company's on AWS Corporate • Your choice of one of these money- letterhead and on promotional materials saving benefits: for a competitive edge Membership, call 1. AWS Standards Library ($7,500 value) • An attractive AWS Sustaining Company (800) 443-9353, ext. 253 2. Discount Promotional Package - save wall plaque on Welding journal advertising • Free hyperlink from AWS's 40,000-visitors-a- or 260. E-mail: and booth space at the FABTECH month website to your company's website INTERNATIONAL & AWS WELDING SHOW • Complimentary VIP passes to the FABTECH [email protected] {save thousands) INTERNATIONAL & AWS WELDING SHOW for an application. 3. 10 additional AWS Individual • An additional 5% discount off the already- Memberships ($920 value) reduced member price of any AWS conference Plus... or seminar registration • 10 AWS Individual Memberships • Up to 62% off Yellow Freight shipping American Welding Society ($920 value); each Individual Membership charges, outbound or inbound, short or 550 N.W. LeJeune Rd. includes a FREE subscription to the Welding long haul Miami, Florida 33126 Journal, up to an 87% discount on an Visit our website at www.aws.org AWS publication, Members'-only discounts AND MUCH MORE... and much more Also available AWS Supporting • Free company publicity - give your Company Membership, Your organization company a global presence in the AWS Welding Distributor needs solutions. Welding Journal, on the AWS Website, Membership and AWS Educational AWS means answers. and at the FABTECH INTERNATIONAL & Institution Membership Circle No. 8 on Reader Info-Card Welding Machine/Generator with the highest level of UV/IR protec­ power source provides an output of 280 Works on Steel, Cast Iron tion up to shade 16. It is available in the A/31 V at 35% duty cycle or 250 A/30 V company's VMX Viper™. at 60% duty cycle. It weighs 40 lb. It of­ fers a maximum of 280 A and enough ArcOne 111 power to run 3/<,-in. hydrogen electrodes. 85 Independence Dr.. launl,.n, MA 02780 The input power voltage selection has been expanded and users can select be­ SMAW/GTAW Power tween high and low voltage inputs to ac­ commodate domestic and international Source Provides Increased requirements. Optional 4-pack inverter Welding Outputs racks are available for multiple user ap­ plications. It features Adaptive Hot Start ™ for shielded metal arc starts, and Lift -Arc ™ starts, for gas tungsten arc start­ ing without the use of a high frequency. The Weldanpower® 125 offers DC Miller Electric Mfg. Co. 112 shielded metal arc welding power with 125 PO Box 100. Lithonia. GA 30058 DC A for a variety of projects and 5500 surge W of AC generator power. It allows MM Beveler Designed to the user to work on steel, stainless steel, 1 |» CST 280 „ cast iron, or hardfacing projects. It pro­ * Produce Oxide-Free, vides 120 or 240 V AC generator power — Clean Edges for lights, tools, pumps, or emergency power. The unit is powered by a With the TKF 1100 beveler, a user can Robin/Subaru® 9-hp EX 27 engine, which remove a 0.35-in. beveled edge of high- carries a 3-year warranty from Robin/Sub­ >• Ifl"' IT grade steel or 0.43-in. of steel in a single aru, and features a cast iron cylinder liner cutting stroke on sheets up to 0.98 in. for long service life. A chain-driven over­ thick. This model is designed to produce head cam engine is designed for easy starts consistently oxide-free and clean K, V, and low noise. A tubular roll cage pro­ X, or Y edges, even in stainless steel. The vides added protection and many lift han­ The CST™ 280 shielded metal arc dle points. The Weldanpower 125 features welding and gas tungsten arc welding — continued on page 83 a 3-year Lincoln warranty on parts and labor.

The Lincoln Electric Co. 110 22801 St. Clair Ave., Cleveland, OH 44117-1199 UNDERWATER Welding Filter Offers Large Viewing Area W"Tu; JUST 16 WEEKS!)

ADDITIONAL TRAINING: • Diver Medical Technician • Underwater Welding • Underwater Burning • NDT Level I & II • Chamber Operations • Emergency Dive The Industrial Xtreme autodarkening Accident Management welding filter has a 40% larger viewing area than previous models. It has an ex­ ternal command center for shade selec­ 1-888-974-2232 ^JKMJ* tion, sensitivity, and grinding. It also fea­ DMT Training Group Diver Medic Training QUH ^r - • • — • - • recognlied by ADC International in accordance Mpmhpr tures three LCDs to reduce angle de­ Jacksonville, Florida with HSEs Diving at Work Regulations. mofiuci pendency. It is water and dust resistant www.commercialdivingacademy.com Circle No. 13 on Reader Info-Card WELDING JOURNAL Aluminum Weld HAZ Fundamentals A guide to help you understand how alloying elements impact the heat-affected zone of arc welded aluminum

BY TONY ANDERSON

o appreciate the effect of arc weld­ Manganese (Mn) 3xxx. The addition ing on the heat-affected zone of manganese to aluminum increases Table 1 -— The Aluminum Alloy Series Used T(HAZ) of various aluminum alloys, strength to an extent through solution for Wrought Alloys it is necessary to evaluate the various strengthening. It improves strain harden­ types of aluminum alloys, how they obtain ing and does not significantly reduce duc­ Series Primary Alloying Element tility or corrosion resistance. These are their strength, and the potential for lxxx Aluminums 99.00% changes in strength after welding. moderate strength, non-heat-treatable 2xxx Copper materials that retain strength at elevated 3xxx Manganese The Types of Aluminum temperatures. However, they are rarely 4xxx Silicon Alloys used for major structural applications. 5xxx Magnesium The most common applications for the 6xxx Magnesium and Silicon When we consider the seven alu­ 3xxx series alloys are cooking utensils, 7xxx Zinc minum alloy series used for wrought radiators, air-conditioning condensers, alloys (Table 1), we can see that the main evaporators, heat exchangers, beverage extrude. Some common applications for alloying elements used for producing containers, residential siding, and han­ the 5xxx series alloys are truck and train each series are immediately identifiable. dling and storage equipment. bodies, buildings, armored vehicles, ship Further examination of each of these ele­ Silicon (Si) 4xxx. The addition of sili­ and boat building, chemical tankers, pres­ ments' effects on aluminum is possible. con to aluminum reduces melting tem­ sure vessels, and cryogenic tanks. The principal effects of alloying ele­ perature and improves fluidity. Silicon Magnesium and Silicon (Mg2Si) 6xxx. ments in aluminum are as follows: alone in aluminum produces a non-heat- The addition of magnesium and silicon to Pure Aluminum lxxx. Although the treatable alloy; however, in combination aluminum produces the compound magne- lxxx series alloys are almost pure alu­ with magnesium, it produces a precipita­ sium-silicide (Mg2Si). The formation of minum, they do respond to strain harden­ tion hardening heat-treatable alloy. this compound provides the 6xxx series the ing, especially if they contain appreciable Consequently, there are both heat- ability to be heat treated. The 6xxx series amounts of impurities such as iron and treatable and non-heat-treatable alloys alloys extrude easily and economically. For silicon. However, even in the strain- within the 4xxx series. The most common this reason, they are most often found in an hardened condition, the lxxx series alloys application for silicon additions to alu­ extensive selection of extruded shapes. have very low strength when compared to minum is the manufacturing of aluminum These alloys form an important comple­ the other series of aluminum alloys. The castings. The most common applications mentary system with the 5xxx series alloys. most common applications for the lxxx for the 4xxx series alloys are welding wires The 5xxx series alloy used in the form of series alloys are aluminum foil, electrical for fusion welding, and brazing of alu­ plate and the 6xxx series used in an extrud­ buss bars, metalizing wire, and some minum. ed form are often joined to the plate. Some chemical tanks and piping systems. These Magnesium (Mg) 5xxx. The addition common applications for the 6xxx series alloys are not heat treatable. of magnesium to aluminum increases alloys are handrails, drive shafts, automo­ Copper (Cu) 2xxx. The aluminum- mechanical properties through solid solu­ tive frame sections, bicycle frames, tubular copper alloys typically contain between 2 tion strengthening. Additionally, it lawn furniture, scaffolding, and stiffeners, and 6% copper, with small additions of improves their strain hardening ability. and braces used on trucks, boats, and many other structural fabrications. other elements. The copper provides These alloys are the highest strength non­ substantial increases in strength and heat-treatable aluminum alloys, and they Zinc (Zn) 7xxx. The addition of zinc to facilitates precipitation hardening. These are optimal and extensively used for aluminum (in conjunction with some alloys include some of the highest structural applications. The 5xxx series other elements, primarily magnesium strength heat-treatable aluminum alloys. alloys are produced mainly as sheet and and/or copper) produces heat-treatable The most common applications for the plate and only occasionally as extrusions. aluminum alloys of the highest strength. 2xxx series alloys are aerospace, military These alloys strain harden quickly; there­ The zinc substantially increases strength vehicles, and rocket fins. fore, they are difficult and expensive to and permits precipitation hardening.

TONY ANDERSON (tanderson@ esab.com,) is Corporate Technical Training Manager for ESAB North America, Florence, S.C, and past Technical Director of AlcoTec Wire Corp., Traverse City, Mich.

JULY 2005 EAT AFFECTED ZONE HEAT TREATABLE ALLOYS HEAT AFFECTED ZONE (HAZ)

WELD FUSION ZONE ZONE CD E NON HEAT TREATABLE HEAT TREATABLE A-WELD METAL 1200lA| A-WELD ZONE AS CAST STRUCTURE OF BASE & FILLER METAL 1100 1000 B-FUSION ZONE B-FUSION ZONE 900 WHERE PARTIAL MELTING C- SOLID SOLUTION ZONE OF BASE METAL OCCURS 800 WHERE ALLOY ELEMENTS 700 ARE SOLUTIONED & COOLED C-ANNEAL ZONE TO RETAIN SOLID SOLUTION WHERE BASE METAL IS 600 PARTIALLY OVER UNAFFECTED FULLY RECRYSTALLIZED - 500 D- PARTIALLY ANNEALED FULL SOFT ANNEALED AGED ZONE 400 OVERAGED ZONE D - PARTIAL ANNEAL ZONE WHERE HEAT HAS CAUSED ZONE ZONE WHERE BASE ALLOY IS 300 PRECIPITATION AND/OR RECOVERED AND PARTIALLY 200 COALESCENCE OF PARTICLES NOTE: MECHANICAL AND/OR CORROSION PROPERTIES SOFTENED 100 OF SOLUABLE CONSTITUENTS ARE SIGNIFICANTLY AFFECTED BY THE TOTAL E-UNAFFECTED RT E-UNAFFECTED HEAT INPUT.

Fig. 1 — The areas of the heat-affected zone for non-heat- Fig. 2 — An illustration ofthe HAZ in heat-treatable alloys. treatable and heat-treatable alloys.

Some of these alloys can be susceptible to er amounts of cold working represent Table 2 — Typical Tensile Strength Properties stress corrosion cracking and for this rea­ three-quarter-hard, half-hard, and quar­ of Groove Welds in Non-Heat-Treatable Alloys son are not usually fusion welded, while ter-hard conditions, respectively. others within this series are often fusion Base Alloy Base Alloy As-Welded welded with excellent results. Some of the Precipitation Hardening & Temper Tensile Strength Tensile common applications of the 7xxx series (ksi) Strength alloys are aerospace, armored vehicles, Precipitation heat treatment precedes (ksi) baseball bats, and bicycle frames. solution heat treating. Solution heat treating is achieved by heating a material 1060-H18 19 10 to a suitable temperature, holding at that 5052-H32 33 27 How Aluminum Alloys 5052-H39 42 27 temperature for a long enough time to Obtain Their Strength 5086-H34 47 38 allow constituents to enter into solid solu­ 5086-H38 53 38 tion, then cooling rapidly to hold the con­ 5083-H116 46 43 As mentioned previously, aluminum stituents in solution. Usually, precipita­ alloys consist of both heat-treatable and 3003-H34 35 16 tion hardening, or what is also termed 41 24 non-heat-treatable types. The addition of 3004-H38 artificial aging, follows. This is achieved alloying elements to aluminum is the by reheating the alloy to a lower temper­ principal method used to produce a selec­ ature and holding it at that temperature tion of different materials used in a wide for a prescribed period. The result is to assortment of applications. The principal heating and cooling during the welding produce a metallurgical structure within reason for adding the major alloying ele­ operation, arc welding on materials that the material that provides superior ments is to facilitate an improvement in have been strengthened by work harden­ mechanical properties. If, during heat the alloys' physical and/or mechanical ing or precipitation hardening will change characteristics. Typically, the purpose for treatment, the material is held at temper­ their properties. The properties of the adding primary alloying elements to alu­ ature for too long or the temperature HAZ may be extremely different than minum is to provide improvement in used is too high, the material will become that of the original base alloy and the work hardening and/or precipitation overaged, resulting in a decrease in ten­ unaffected area of the base material — hardening characteristics. sile strength. It is important to recognize Figs. 1, 2. that the precipitation hardening process Work Hardening is both time and temperature controlled. Non-Heat-Treatable Alloys

Work hardening — used extensively to The Effect of Arc Welding What is important from a HAZ per­ produce the strain-hardened tempers in on the Heat-Affected Zone spective is that annealing can restore alu­ the non-heat-treatable aluminum alloys minum alloys strengthened by strain — is an important process that increases In order to make a welded joint in an hardening to a full soft, ductile condition. the strength of materials that heat treat­ aluminum structure using arc welding, Annealing eliminates strain hardening, as ment cannot strengthen. This process melting of the base metal must occur. well as the microstructure that is devel­ involves a change of shape brought about During the melting operation, heat trans­ oped because of cooled working. The by the input of mechanical energy. As fers through conduction into the base heating of the HAZ, which takes place deformation proceeds, the material metal adjacent the weld. Typically, the during the arc welding operation, is suffi­ becomes stronger, but harder and less completed weldment is divided into three cient to anneal the base metal within the ductile. For example, the strain-hardened distinct areas: the weld metal, the heat- HAZ area. For this reason, the minimum temper of HI8, full-hard material, is affected zone adjacent the weld, and the tensile strength requirements for as- obtainable with a cold work equal to base material beyond the HAZ that the welded, non-heat-treatable alloys are about a 75% reduction in area. The HI6, welding operation has not affected. based on the annealed strength of the HI4, and H12 tempers obtained with less­ Because the HAZ experiences cycles of base alloy. Typical tensile strengths of

WELDING JOURNAL Table 3 — Typ cal Tensile Strength Properties On-Site of Groove Welds in Heat-Treatable Alloys Base Alloy Base Alloy As-Welded & Temper Tensile Strength Tensile Ferrite Content (ksi) Strength (ksi) Measurement 6063-T6 31 19 6061-T6 45 27 6061-T4 35 27 2219-T81 66 35 Fischer's Feritscope® MP30 is the ideal solution 2014-T6 70 34 for fast, precise measurement of ferrite content 7005-T53 57 43 of constructional steels, welded claddings, austenitic stainless steels and duplex steels

• Non-destructive measurement in the range non-heat-treatable alloys in their tem­ of 0-80% Fe or 0-120 WRC number pered condition and as-welded are shown • Battery or AC Powered in Table 2. • Large easy-to-read LCD display Heat-Treatable Alloys • Plug-in type smart probe • Statistical evaluation In the case of the heat-treatable alloys, • RS232 interface the HAZ will not be fully annealed. Typically, the HAZ is not maintained at an • Multiple application memories adequate temperature for a sufficient period to fully anneal the HAZ. This does www.Fischer-Technology.com not suggest that experiences in a reduction 1-800-243-8417 in strength in the HAZ will not occur. The effect on the HAZ of a heat-treatable 750 Marshall Phelps Road • Windsor, CT 06095 alloy that is welded in the solution heat- Phone: 860-683-0781 • Fax: 860-688-8496 treated and artificially aged condition is typically one of partially annealed and Circle No. 20 on Reader Info-Card overaged. This condition is affected by the heat input during the welding operation. The general rule is, the higher the heat input, the lower the as-welded strength. Typical tensile strengths of some of the WELDHUGGER heat-treatable alloys in their temper con­ COVER GAS DISTRIBUTION SYSTEMS dition and as-welded are shown in Table 3. Summary

Depending on the particular aluminum alloy type and its temper, there are often significant differences between the tensile strength of the HAZ and that of the unaf­ fected area of the welded component. The reduction in tensile strength of the HAZ under controlled conditions, particularly with the non-heat-treatable alloys, can be somewhat predictable. The reduction in HAZ tensile strength in the heat-treatable alloys is more susceptible to welding con­ ditions and can be reduced below the required minimum requirement if exces­ sive heating occurs during the welding operation.*

Change of Address? Moving?

Make sure delivery of your Welding Journal is not interrupted. Contact the ITJELC HUGGER Membership Department with your Toll Free: (877) WELDHGR (877) 935-3447 Fax: (480) 940-9366 new address information — (800) 443- Visit our website at: www.weldhugger.com 9353, ext. 217; [email protected]. Circle No. 29 on Reader Info-Card

JULY 2005 A POORLY SUPERVISED WELDER COULD COST YOUR COMPANY TEN TIMES MORE PER WELD THAN NECESSARY.

$37 3,650

300 S35<

WE CAN HELP CHANGE THAT. E NEW! the skills necessary to prevent your welders from costing your company too AWS Certified Welding much money on each and every job. Supervisor Training Seminar The new AWS Certified Welding Supervisor program targets productivity and & Certification Exam how to maximize it. It will enhance your supervisors' skills, providing added Pittsburgh, PA— value to your welding processes. October 17-22,2005 The program lets them gain the essential knowledge that will... Long Beach, CA— November 7-12,2005 improve productivity improve throughput improve weld quality improve safety If you're interested in reducing welding costs and increasing profitability, contact AWS.

For more information on the AWS Certified Welding Supervisor program, visit our website at American Welding Society www.aws.org/certification/cws Founded in 1919 to advance the science, technology or call 1 -800-443-9353 ext 470. Circlcirclee No NO. 2•> on o Readen Rear Info-Card and application of welding and allied processes including joining, brazing, soldering, cutting and thermal spray. Understanding Stainless Steel Heat-Affected

BY C. MEADOWS AND J. D. FRITZ

The HAZ properties are discussed as a function of microstructure

The structural changes that structure. This family includes occur in the heat-affected zone Inside Surface common grades such as 409, 430, (HAZ) of stainless steel weld­ 436, 444, and the more highly al­ ments can potentially degrade loyed grades such as Sea-Cure® strength, toughness, and corro­ (UNS S4466) and AL 29-4C® sion resistance. Therefore, it is (UNS S44735). important to understand which The duplex stainless steels have grades of stainless steel are sus­ a microstructure that consists of ceptible and the kinds of degra­ a combination of ferrite and dation that can occur. The poten­ austenite. Most commercial du­ tial problems associated with plex grades have a structure that stainless steel HAZs include ex­ consists of approximately 50% cessive grain growth, chromium austenite and 50% ferrite. In this carbide precipitation, precipita­ family, the most widely used tion of intermetallic compounds, grade is 2205 duplex stainless and improper phase balance. steel (UNS S32205). Stainless steels can be divided Other families of stainless steel into families characterized by the include the "martensitic" grades crystal structure of predominant such as 410, 420, and 440, and the phase or phases that are present "precipitation hardened" grades Cross section of a 409 ferritic stainless steel weld show- in the microstructure. The nature Figl- such as 15-5PH, 17-4PH, and 17- ing grain growth in the HAZ. of the HAZ and the possible 7PH. These steels can be hard­ problems that can occur in the ened by heat treatment, which HAZ often depend on the stain­ adds another dimension to the less steel family. steel, as well as more highly alloyed grades welding of these grades. In most The "austenitic" family of stainless such as 904L and 6%Mo grades like 254 cases, welding of these grades would re­ steels has an austenitic or face-centered SMO® (UNS S31254). quire postweld heat treatment to restore cubic crystal structure. The grades in this The "ferritic" family is the second most toughness and achieve matching mechan­ family are by far the most widely used of widely used group of stainless steels. ical properties in the weld and base metal. any ofthe stainless steels. The austenitic These grades have a crystal structure that Because of the need for postweld heat family includes the commodity grades is primarily composed of the ferrite phase, treatment, these grades are not discussed such as 304/304L and 316/316L stainless which has a body-centered cubic crystal in this paper.

C. MEADOWS (chuck.meadows(a outokumpu.com) is with Avesta Welding, Houston, Tex. J. D. FRITZ ([email protected] is with TMR Stainless, Pittsburgh, Pa.

JULY 2005 XX J . U* '

Weld

XX&-*X yX-i-. • vrv, S CKT X FmmMmm. \*y Fig. 2 — Surface of a sensitized 304 stainless steel showing inter­ Fig. 3 — Cross section of a 316 stainless steel weld showing granular attack characterized by deep grooves at grain boundaries chromium carbide precipitation at grains slightly removed from and grain dropping. the weld bead.

steel is held for sufficient time in the tem­ bide precipitation. For example, sensiti­ Potential Problems with perature range of 800°-1500°F. This can zation seldom occurs during welding of Stainless Steel HAZs be a factor because some region of the thin sheet material, which requires low HAZ will be in this temperature range heat input. Excessive Grain Growth during the welding process. Chromium Low-carbon grades or L-grades limit carbides by themselves do not lower the the carbon content to 0.03% maximum. With all steels, it is desirable to avoid corrosion resistance. However, the Cr- This reduced carbon level provides suffi­ excessive grain growth because the depleted region immediately adjacent the cient time for welding without the onset strength and toughness of the steel will carbides will reduce the corrosion resist­ of sensitization. Common grades that use decrease as the grain size increases. Grain ance. By definition, this condition is this approach include 304L and 316L. growth in the weld HAZ is usually not a termed "sensitization," and when sensiti­ An alternate approach is to use a sta­ problem with most stainless steels. How­ zation is caused by the heat input from bilized grade such as Type 347 or 321. Sta­ ever, grain growth can be an issue with welding, it is termed "weld decay." bilized grades use additions of Ti or Nb ferritic stainless steels. The ferritic struc­ to provide resistance to sensitization. At ture is much more prone to rapid grain Sensitization occurs when Cr and C temperatures above 1450°F, Nb and Ti growth than the austenitic and duplex atoms diffuse to the grain boundaries have a stronger affinity for carbon than structures. This, combined with the fact where Cr carbides (C2iC6) precipitate and that the ferritic grades by their nature have grow. As the carbides grow, a narrow re­ chromium. This results in the formation a relatively low toughness, make the fer­ gion in the vicinity ofthe grain boundaries of Ti and Nb carbides, which removes ritic grades vulnerable to embrittlement becomes depleted in Cr. As shown in Fig. available carbon, thus minimizing in the HAZ. 2, this condition can cause a susceptibil­ chromium carbide precipitation at lower ity to intergranular attack (IGA). temperatures. Figure 1 shows the kind of grain growth During welding, there will be a volume If sensitization does occur, the carbides that routinely occurs in the HAZ of fer­ of metal within the HAZ that is exposed can be dissolved and the corrosion prop­ ritic stainless steels. The grains in the to the sensitizing temperature range. If erties restored by a solution anneal heat HAZ show substantial growth compared the time of this temperature excursion is treatment. A typical anneal cycle for 300 to the grains in the base metal. As the long enough, sensitization will occur. As series stainless steel is 1900°F followed by grains increase in size, the toughness de­ shown in Fig. 3, the sensitized zones asso­ a rapid cool. Although this approach is creases and the ductile-to-brittle transi­ ciated with austenitic stainless steel welds very effective, it is not practical to heat- tion temperature increases. Because of tend to be slightly removed from the ac­ treat large components such as tanks, ves­ this, it is important to verily the strength tual weld. sels, and piping systems. and toughness of ferritic weldments. The kinetics of sensitization are a func­ Ferritic Stainless Steels. Sensitization Reducing the heat input can minimize tion of time, temperature, and carbon con­ in ferritic stainless steel is slightly differ­ excessive grain growth. Another option is tent of the stainless steel. Figure 4 shows ent than that in austenitic stainless. The to choose a stabilized grade containing Ti the time-temperature regions that pro­ difference is due to the lower solubility of and/or Nb additions, for example, Type duce sensitization for 304 stainless steel N in the ferrite structure, which results in 439 (Ti stabilized) instead of 430. The re­ with varying levels of carbon. Note that at the precipitation of chromium nitrides sulting Ti and Nb carbides and/or nitrides 0.062% carbon, the 304 grade will suffer (Cr N) in addition to the chromium car­ in the microstructure tend to pin grain 2 sensitization within a matter of minutes bides (Cr^Cg). Both of these precipitates boundaries slowing grain growth during at 1200° to 1400°F, while a carbon content can cause sensitization and a loss of cor­ welding. of 0.03% would require about an hour be­ rosion resistance in ferritic stainless steels. fore the onset of sensitization. Sensitization of ferritic stainless steels oc­ Chromium Carbide Precipitation Sensitization in the HAZ of austenitic curs when the alloy is cooled from a tem­ stainless steels can be controlled by vari­ perature above the carbide and nitride sol­ Austenitic Stainless Steels. In these ous means. Reduced heat input will result ubility temperatures (about 1700°F). stainless steels, chromium carbides can in less time in the sensitized temperature Hence, a much higher temperature excur­ precipitate on the grain boundaries if the range and will lower the likelihood of car­ sion is required to sensitize the ferritic

WELDING JOURNAL , 0.062 0.080,' V V X

J L JOsec. Jmm, 10 mm 1 h. 10h. TOOh. 1,000 h. 10,000 h.

Time-temperature-sensi!ization curves JW Base vletaf

Fig. 4— Time-temperature-sensitization curves for 304 stainless Fig. 5 — Cross section of a sensitized Type 409 weld showing in­ steel with varying levels of carbon. Note that the time required to tergranular attack on the weld and in the HAZ immediately ad­ sensitize the steel increases as the carbon content decreases — jacent the weld. Ref.1.

1100 254 2012 1000 SMO 1832 904L 1100 900 1652 70°C Type 316 800 1472 700 1292 600 B17LMN 1112 500 932 20°C 400 752 300 572 10 100 1000 10000 39? 200 ExDosuro Time. Hours 0.1 10 100 1,000 10,000 Time (minutes) Fig. 6 — Isothermal precipitation kinetics for sigma and chi for­ Fig. 7 — Iso-critical pitting temperature curves for AE-6XN® mation in 254 SMO®, 904L, and 317LMN compared to the (UNS N08367) showing the decreased pitting resistance due to chromium carbide precipitation kinetics of Type 316 stainless sigma precipitation — Ref. 3. steel — Ref. 2.

grades compared to the austenitic grades. zation of ferritic stainless steels is usually With stainless steels, intermetallic com­ Diffusion is more rapid in the ferritic avoided by selecting an adequately stabi­ pounds are formed from alloying elements grades compared to the austenitic grades. lized grade. Many of the commercial fer­ such as chromium and molybdenum, Hence, unstabilized ferritic grades cannot ritic grades such as 409,439, and 444 man­ which removes these elements from their be cooled fast enough using typical indus­ date sufficient Ti and/or Nb content to role of providing corrosion resistance. trial processes to avoid carbide and nitride allow normal welding operations. With There are several intermetallic com­ precipitation. Also, with standard produc­ unstabilized grades such as Type 430, a pounds possible in stainless steel, but the tion processing, it is not cost effective to postweld heat treatment can be used to most common are sigma phase and to a reduce the C and N to levels that will pre­ restore corrosion resistance. This heat lesser extent chi phase. Both of these in­ vent carbide and nitride formation. Be­ treatment consists of holding the steel in termetallic compounds form over the cause of this, most commercial ferritic a temperature range of about same temperature range (1050° to grades rely on a combination of reduced 1000°-1200°F for a long enough time for 1900°F). It is common to refer to all in­ C and N contents and additions of Ti Cr to diffuse back into the Cr-depleted re­ termetallic compounds that form in this and/or Nb to prevent sensitization. gions restoring the corrosion properties. temperature range as sigma phase even Figure 5 shows IGA of a sensitized fer­ Duplex Stainless Steels. The duplex though sigma may be only one of several ritic stainless steel weld. Note that the at­ stainless steels and most of the more intermetallic compounds that are present. tack occurs in the weld and in the HAZ highly alloyed austenitic stainless steels The formation of sigma reduces the immediately adjacent the weld. This is be­ such as 904L and the 6%Mo grades have corrosion resistance of stainless steel. cause these are regions that reach the re­ carbon contents below 0.03%. These Even worse is that the presence of sigma quired 1700°F temperature to initiate sen­ grades are essentially low-carbon grades embrittles the stainless steel. Sigma for­ sitization. This is different than the and sensitization during welding is typi­ mation can occur in austenitic, ferritic, austenitic grades where sensitization oc­ cally not a concern. and duplex stainless steels, and occurs curs in the temperature range of more readily in grades that have higher levels of Cr and Mo. 800°-1500°F. Intermetallic Compounds Reduced heat input during welding The kinetics of the sigma and chi trans­ cannot be used to avoid sensitization with An intermetallic compound is a phase formations depends on the alloy compo­ ferritic grades of stainless steel. Sensiti­ that is formed from two or more metals. sition. Higher chromium and molybde-

JULY 2005 1100 1000 Titanium Tfitride. 900 ;' Carbide and Nitrate 800- (Ti,Nb,Cr> \,(a 700 600 500 400 300 200 —I 1— 0.1 10 100 Time (minutes)

Fig. 8 — Isothermal precipitation kinetics for intermetallic phases Fig. 9 — Impact embrittlement behavior of a 29%Cr-4%Mo fer­ in 26%Cr-l to 4%Mo ferritic stainless steels. Note the longer ritic stainless steel measured at 25° and 100°C (77° and 212°F) times required to precipitate alpha prime — Ref. 2. with Charpy V-notch specimens. Curves indicate where speci­ mens demonstrated a 50% brittle fracture sutface — Ref. 4.

1.100

1,000 2507 -* ." ' /

500

W ^^. Mt>m Pi mt Cl«— Tougtae*» 400

300 J* 20O fcjO^ 2205 r* 2304 2507 :>« • >T^> V.

Fig. 10 — Isothermal precipitation kinetics for sigma and chi for­ Fig. 11 — Sigma precipitation (dark round particles) In the HAZ mation in various duplex stainless steels — Ref. 2. of a 25% Cr-4% Mo-7% Ni duplex stainless steel. Weld inteiface is at the 12 o'clock position just outside the field of view — Ref. 5. num contents favor higher rates of forma­ example, with the 6%Mo grade, 254 occurs in the range of 500° to 1000°F and tion and potentially larger volume frac­ SMO®, sigma will form in less than a is often termed "885 embrittlement." The tions. Nitrogen additions in austenitic and minute at 1450° to 1650°F. Because of this time-temperature-precipitation diagram duplex steels retard the transformation rapid precipitation, heat input during in Fig. 8 shows the regions of sigma and reactions. Because of this, the tendency welding must be minimized to prevent alpha prime formation in 26%Cr-4%Mo to form these detrimental phases can vary sigma formation in the HAZ. ferritic stainless steels. Because of the long substantially from alloy to alloy as well as The impact of sigma formation on the times required to form the alpha prime within a specific grade. If intermetallic corrosion resistance of a 6%Mo austenitic phase, 885 embrittlement is generally not compounds are present, they can be dis­ stainless steel is shown in Fig. 7. The crit­ a problem during welding. solved and the corrosion and toughness ical temperature required to produce pit­ As with the austenitic grades, inter­ properties restored by a solution anneal ting can decrease substantially when metallic precipitates reduce the toughness heat treatment. sigma is precipitated. and corrosion resistance of ferritic stain­ Intermetallic Precipitation in Aus­ Intermetallic Precipitation in Ferritic less steels. Figure 9 shows the influence tenitic Stainless Steels. Figure 6 shows Stainless Steels. Sigma and chi phases can of time and temperature on brittle frac­ the time-temperature-precipitation dia­ precipitate in the HAZ of ferritic stain­ ture in a 29%Cr-4%Mo ferritic stainless gram for sigma formation in some com­ less steels, particularly in the higher Mo- steel. mon austenitic stainless steels. For the bearing grades. In addition to sigma and Intermetallic Precipitation In Duplex more highly alloyed grades, the precipita­ chi formation, ferritic stainless steels are Stainless Steels. The time-temperature- tion kinetics can be quite rapid in the also susceptible to alpha prime formation, precipitation curves for the formation of 1450° to 1650°F temperature range. For which can embrittle the alloy. Alpha prime intermetallic compounds in various du-

WELDING JOURNAL Table 1 — The Effects of Sigma Formation on 2205 Duplex Stainless Steel

CVN Impact Energy Critical Pitting Temp (ft-lb at -40°F) CC) Condition Longitudinal Transverse Mill Annealed 185 127 35 1950°F + water quench 196 123 Plus 5 minutes at 1550°F 42 25 20 Plus 10 minutes at 1550T 32 16 15 Plus 15 minutes at 1550°F 26 12 Plus 20 minutes at 1550°F 21 9 15

and the structure will be enriched in the guidance on cleaning heat tint from stain­ ferrite phase. less steel see Refs. 7, 8. When welding a duplex stainless steel Fig. 12 — Cross section of a weld used to join a thin sheet of 2205 duplex stainless there is a balance between too much heat Conclusions steel to a thick carbon steel plate. Note the input, which can result in sigma forma­ lack of ferrite phase in the HAZ due to the tion, and too little heat input, which can Depending on the stainless steel fam­ rapid cooling. result in a high volume fraction of ferrite. ily and the weld procedure, a loss of cor­ Actually it is not the low heat input but rosion resistance, strength, and toughness the very rapid cooling rates that occur with can occur in the HAZ. An understanding low heat inputs that enriches the structure of the various types of degradation mech­ plex grades is shown Fig. 10. The more in ferrite. anisms and which stainless steels are sus­ highly alloyed grades such as 2507 and The nitrogen in a duplex stainless steel ceptible is helpful in avoiding problems. 2205 can suffer sigma formation after a is a strong austenite former and it causes Proper selection of stainless steel base ma­ relatively short time in the temperature austenite to form quickly, at a high tem­ terial and weld procedures will ensure range of 1450° to 1700°F. Depending on perature. With the high nitrogen levels in minimal loss of properties in the HAZ of the heat input and cooling rate, sigma for­ today's duplex stainless steels, it is possi­ stainless steels.* mation will occur in the HAZs of duplex ble to do most routine welding and still stainless steel welds — Fig. 11. When achieve adequate austenite levels in the sigma formation occurs, the corrosion HAZ. As shown in Fig. 12, welds that have References properties and the toughness are de­ very high cooling rates are prone to exces­ graded. The magnitude of the loss of prop­ sive ferrite levels in the HAZ. Problem 1. Welding of Stainless Steels and Other erties is summarized in Table 1 where ther­ applications include tube-to-tube sheet Joining Methods, A Designers' Handbook mal excursions into the sigma range pro­ welding, thin sheet linings on plate struc­ Series, No. 9 002. 1988. Nickel Institute, duce loss of impact properties and reduce tures, and resistance welds. When weld­ p. 6. critical pitting temperature. To avoid the ing these types of applications, it is possi­ 2. High Performance Stainless Steels, loss of properties, duplex stainless steel ble to increase the austenite volume frac­ Reference Book Series No 11 021. 2000. welding procedures must be designed to tion by preheating the base metal to Nickel Institute, pp. 17-20. minimize time at temperature. 200°-300°F before welding. When using 3. Grubb, J. F. 1996. High-temperature preheat, care must be taken to maintain aging of a 6% Mo superaustenitic stain­ less steel, Proceedings — International Improper Phase Balance the temperature ofthe metal below 500°F or alpha prime precipitation can occur. Conference: Stainless Steels 96, Dusseldorf, The properties of duplex stainless Germany, p. 367. steels depend on maintaining a proper Heat Tint 4. Aggen, G., Deverell, H. E., and volume fraction of austenite and ferrite. Nichol, T. T. 1979. Microstructure Versus Most commercial grades have a target of The presence of heat tint on the weld Properties of 29-4 Ferrite Stainless Steel, 50% austenite and 50% ferrite. A volume and HAZ of any stainless steel will lower STP 672, American Society for Testing fraction of ferrite of more than about 70% the corrosion resistance (Ref. 5). Heat tint and Materials, p. 334. can lead to a loss of toughness. Similarly, on stainless steels is primarily composed 5. Gunn, R. N. 1997. Intermetallic For­ if the HAZ becomes too enriched in the of chromium oxide, and when it forms, it mation in Superduplex Stainless Steel Heat- austenite phase, there could be a reduced depletes the underlying metal surface of Affected Zones, Duplex Stainless Steel - resistance to stress corrosion cracking. chromium. When left intact, heat tint will 97, 5th World Conference, Paper D97- Because of this, it is generally recom­ make the surface more susceptible to pit­ 029, p. 336. mended to maintain 30 to 70% volume ting and crevice corrosion. Heat tint and 6. Tuthill, A. H, and Avery, A. H. 1992. fraction of the austenite. the underlying chromium-deleted layer Heat tints on stainless steels can cause cor­ At temperatures above approximately should be removed using either a chemi­ rosion problems. Material Performance 2550°F, duplex stainless steels have a cal cleaning method or a combination of 38(2): 72. structure that is completely ferrite. Upon mechanical cleaning such as brushing, 7. Tuthill, A. H, and Avery, R. E. 1992. cooling, a transformation temperature is grinding, or blasting followed by chemi­ Specifying Stainless Steel Surface Treat­ reached where some of the ferrite trans­ cal cleaning. Chemical cleaning typically ment, NiDI Technical Series No. 10 068. forms to austenite. If the cooling rate is consists of either immersion in a nitric/hy­ 8. Cleaning and Descaling Stainless too rapid, there is not sufficient time for drofluoric acid pickling bath or applying Steels, A Designers' Handbook Series, the austenite transformation to proceed. a pickle paste to the affected surface. For No. 9001. 1988. Nickel Institute.

I JULY 2005 AWS Radiographic Interpreter.

We're proud to announce the AWS Radiographic Interpreter certification program. Designed for NDE professionals and current AWS Certified Welding Inspectors, this training and certification program assures employers and practitioners alike that the principles of radiographic interpretation are reliably applied to the examination of welds.

If your job responsibilities include reading and interpretation of weld radiographs, this program is for you. You'll learn proper film exposure, correct selection of penetrameters, characterization of indications and use of acceptance criteria as expressed in the AWS, API and ASME codes.

For more information on the course, qualification requirements, certification exams and test locations, please visit our website at www.aws.org/certification/RI I or call 1 -800-443-9353 ext 273. MM Bi

Am JU\DJDDJiAP>JJLi mSSiiPiiSiSJi TfuJmJU'j 'Xunwdf di UyrijJJCiiiiujj EAinn Uslmi'XrL-MjXlu, WJv Uiiiuu iluui}-d, LA - July Jii-23, 2UD5 Dallas,Taxa3- SajiL2D-L)yi. J,2UU5

American Welding Society

Founded in 1919 to advance the science, technology and application of welding and allied processes including Circle No. 3 on Reader Info-Card joining, brazing, soldering, cutting and thermal spray. Power Supply Designed for Small- Scale Resistance Spot Welding

The power supply provides more flexibility, a smaller size, and is portable for different application sites

BY L. J. BROWN AND J. LIN

Resistance spot welding (RSW) is one ent control schemes. The operation of the required during the high-frequency of the welding processes that involves the proposed power supply has been simulat­ switching. An output inductor is used to joining of two or more metal parts togeth­ ed, and the simulation results agreed with filter the output current. er in a localized area by applying heat and the experiments very well. Based on the The control electronics section pressure (Ref. 2). For applications such as experimental data, the weld quality and includes the driver circuits for the medical devices and electronic compo­ the stability of three different control MOSFETs, the sensing circuits for volt­ nents, the welded parts are thinner and modes have been analyzed, and the age and current, and other electronics cir­ smaller compared to common RSW results indicated that the constant power cuit for the control purpose. applications. Therefore, the authors refer control achieved the best weld quality. The microcontroller is the central con­ to this process as "Small Scale" RSW trol unit of the system, which includes (SSRSW) (Refs. 1, 5). System Description both the hardware and software. Based Studies of the SSRSW have shown on the given reference and feedback sig­ that 20% of the welding quality issues are Figure 1 shows the system diagram of nals, the microcontroller implements the welding schedule or power supply related a SSRSW system, which consists of a control schemes and provides the PWM (Refs. 3-5). Therefore, the study of dif­ micro welding machine, a DC power sup­ signal to drive the MOSFETs in the ferent weld schedules and control ply, and a 12-V battery. power section. An 8-bit microcontroller, schemes will contribute to weld quality The designed power supply consists of PIC16F73 from Microchip, Inc., was improvement. This article presents the the following three major sections: the selected as the CPU of the system. design and development of a novel power power section, the control electronics, supply, which can provide a testing bench and the microcontroller. Figure 2 illus­ Control Schemes for these studies, and at the end imple­ trates the system block diagram. ment the final results of the studies. The power section is a DC/DC con­ The following four control modes are This power supply uses pulse width verter, which converts the input power set in this power supply: modulation technique, with low cost from the 12-V battery to an appropriate 1) Voltage control mode; MOSFETs, to convert the power of a 12- output voltage to feed the welding 2) Current control mode; V battery to the weld current up to 800 A. machine. Power MOSFETs are used as 3) Power control mode; and Microprocessor/controller technology is the switching components, which switch 4) Generic control mode. used in the novel design, which provides at a frequency of 20 kHz. Filter capacitors The voltage control mode is to control the flexibility for the application of differ­ are used to assist the ripple current the output voltage as constant; the cur-

L. J. BROWN and J. LIN ([email protected]) are with the University of Western Ontario, London, Ont., Canada. Based on a paper presented at the A WS Welding Show and Annual Convention held April 25-28, 2005, In Dallas, Tex.

JULY 2005 DC Power Battery Supply (12V) Power Section Control Electronics Reference Microcontroller^ | PWM \*-\ PI \*—Q* (HW&SW) Fig. 1 — SSRSW system diagram.

Fig. 2 — System block diagram.

Miscellaneous PI D Power - Loss resistance i » PWM fc+( Controller • Supply - \ fc lo /W Peref ' L - ^~^AAr-rr Peo Vo llDynamic resistance f^—1 1 ' y) Voltage Cur rent Sens or a | V Sensor -&,« ] r Current a Sensor T ~^rr, • » fj Current r\. V Reference lE3

Fig. 3 — The novel generic control scheme. Fig. 4 — Simulation model for constant current control.

rent and power applied at the welding the equivalent power is defined as the That's why it is also called a dynamic machine tips change along with the load square root of the output power, and the resistance. resistance. In the current control mode, generic control scheme is the same as the In reality, the dynamic resistance is a the load current is kept as constant. The power control. complicated function of different vari­ voltage needs to be adjusted according to ables like current, voltage, and tempera­ load resistance, and the power changes System Simulation ture. To simplify the study, the following accordingly. In the power control mode, assumptions are made: the voltage is adjusted to keep the power The operation of the DC power supply 1) The welding process takes 20 ms; and constant. Consequently, the current is studied through simulation. Figure 4 2) A single resistance curve can be used changes as well. shows the simulation model for the regardless of power supplied. A generic control scheme is discussed, closed-loop constant current control According to these assumptions, the which covers all three control modes mode of the SSRSW system. dynamic resistance is described as a func­ above. Figure 3 presents the block dia­ The load-dynamic resistance is the key tion of time. Figure 5 gives an example gram of the generic control scheme. component in this model. The load is the waveform of this function taken from A variable called equivalent power welding machine, and its impedance con­ Ref. 7. Based on the experimental data (Pe) is defined as Pe = V" x I(i-a), where sists of the following components: from the prototype, an analytical expres­ a is a control index, which has the range 1) Resistance of the electrodes; sion for the dynamic resistance is between 0 and 1. The reference (Peref) 2) Bulk resistance of the workpieces; obtained as Equation 1 and feedback (Peo) are all based on this 3) Contact resistance between the elec­ definition. The PI controller takes the trode and workpiece; error signal (e) and calculates the duty 4) Contact resistance between pieces; Kelder = (1-1433' -0.8867)-(i<0-«(f-l)) ratio (D) of the PWM applied to the and + (0.7937('+54253) + 0.03)- 0.025 power supply. 5) Resistance of the cables. • (u(t -1)-u(t-20)) (1) The generic control scheme can rep­ An equivalent RL component should resent all three control schemes dis­ be an adequate representation for the cussed above by using a different control load. However, to simplify the simulation, where Rweider is the dynamic resistance in index a. When a = 0, the equivalent components 1 and 5 are considered in the mfl, t is the time in ms, and u(t) is the unit power (Pe) equals to the current (I), miscellaneous loss resistance, and the step function. therefore the generic control scheme is cable inductance is lumped in with the Figure 6 shows the simulated load equivalent to the current control. When battery inductance. Therefore, in the sim­ voltage and current, battery current, and a = 1, the equivalent power is the voltage, ulation model, the load only represents capacitor voltage during switching. The and the generic control scheme repre­ the components 2, 3, and 4, which will be simulation results are verified by the later sents the voltage control. When a = 0.5, changing during the welding process. experimental results.

WELDING JOURNAL Fig. 5 — Typical waveform ofthe dynamic resistance. Fig. 6 — Simulation results. Upper: blue — load current, red — battery current; bottom: blue — capacitor voltage, red — load voltage.

Table 1 — Variables for Testing Repeatability

Control Mode Repeatability Variable Open-loop voltage control Tip voltage Constant current control Welding current Constant power control Tip power Sensors'^ board is inserted into sion of the samples, and the more consis­ the computer and tent the weld quality. The repeatability of Connector panel Software Personal communicates the system is used to check that the Computer between the PC and change in consistency of the weld nuggets the connector panel. is due to the mode of the power system Fig. 7 — Block diagram of experimental setup. The software does the and not a result of the implementation of job of signal process­ the control modes. Experimental Results ing. A Tektronix TDS 2014 oscilloscope is The measured nugget sizes under the used to monitor some critical signals dur­ three control modes are presented in Fig. ing the welding process. 9. Note that the open loop or voltage con­ Experimental Setup trol has least repeatability and, hence, Experimental Results requires loose set points. The experimental setup includes a The variance of nugget size is SSRSW machine, the developed DC Parameters obtained from the lobe expressed as the following: power supply, current and voltage sen­ tests were implemented in welding tests sors, a data acquisition system, and a per­ for the three control modes. The welding sonal computer (PC). Figure 7 shows the test results provide the data for further °3=-E(A--D)J (2) block diagram of the setup. analysis and comparison of the three con­ '»=! The SSRSW machine is a Model 80 trol modes. Series from Unitek Peco. The welding Figure 8A-C shows the output wave­ where D, js the diameter of the nugget force can be adjusted by selecting a trig­ forms under different control modes. The sample (', D is the average of the nugget ger point within a range of 2 to 20 lb. experimental results show that the novel diameters, and a2, is the variance of the When the force reaches the trigger point, power supply can provide sufficient d a trigger signal is sent to the DC power power and control the welding process nugget size. supply, which controls the welding cur­ successfully. The variances of nugget size under the rent flowing through the electrodes and three control modes have been calculated the workpieces. A voltage sensor and a and the results are illustrated in Fig. 10. It current meter are used to measure the Experimental Data Analysis is obvious that the variance for the power electrodes' output tip voltage and welding Based on the experimental data from control is the smallest, and then the cur­ current, which are transmitted to the PC the welding tests, further statistic analysis rent control mode, followed by the volt­ through the data acquisition system. has been performed. The effects of the age control mode. The analysis results The data acquisition system is a three control modes are compared indicate that the power control mode Single-Board Simulator from DSpace, according to the statistic analysis results. achieves the best welding quality for the Inc., which includes a connector panel, The variance of the nugget size is used material of workpieces used in the study. PPC controller board, and the software. to evaluate the general effect of the con­ The variables used to measure repeata­ The connector panel samples the meas­ trol mode on the welding quality. The bility for the three control modes are listed ured signals, and the PPC controller smaller the variance, the less the disper­ in Table 1. For the open-loop mode, the control variable is the duty cycle, which is

JULY 2005 Vo (») to (A) 1800 B

16 00 1.4 - 400 1400 1.2 Vo " 200 1200 • 1 OOO \x lo V 1000 \ lo 0.8 . too 800 p / -Po 0 5 *~~1 x ° 600 600 6 04 f *-**^ 400 <*C0 J 0.2 -200 200 I V

0 500 1000 1500 2000 2500 3000 3500 4000 0 S00 1000 1500 2000 2500 3000 3500 4000

Sample points (sampling rate at 80 kHz) Sample points (sampling rate at 80 kHz)

c VO (v) 10(A). Po (Vi Nugget size comparison for different control modes

Vo 1.5 1500 constant power control 1 1000 Po voltage / control 0 5 SCO r^7 "\ constant current 9 10 11 12 13 14 15 16 17 control 1 500 1000 1500 2000 2500 3000 3500 4C 00 weld Sample points (sampling rate at 80 kHz)

Fig.8- A — Output waveforms under open-loop voltage con- Fig. 9 — Nugget diameters under different control modes. trol; B constant current control; and C — constant power control modes.

Variance comparison for three control modes — analysis from nugget size— 0.06 1.6

1.4 0.05 Vo(v) 1.2 E 0.04 1 y/ 0.8 ""^^a***-

0.6 reI 0.03 re 0.4

0.2 0.02 i 0.01 •0.2( 500 1000 1500 2000 2500 3000 3500 4000

voltage control power control current control 0 Sample points (sampling rate at 80 kHz)

Fig. 10 — Comparison of variances of nugget size for three con­ Fig. 11 — Tip voltage waveforms under voltage control mode. trol modes. not an appropriate variable for testing repeatability variable at time moment t is is the average of the repeatability variable repeatability of the controller implementa­ defined as: at time moment t. tion. However, control of the duty cycle, Figure 14 shows the variances of theoretically, is a form of voltage control. repeatability variables as functions of Hence, we have used tip voltage to meas­ time for three control modes. ure repeatability for this mode. Figures 11 2 ° x=-± XI. (3) The variance of the repeatability vari­ through 13 show the measured waveforms C(t) able over the whole welding process is of the repeatability variables from the defined as: repeated experiments under the three con­ trol modes, respectively. Af 2 1 In order to compare the three control where o (t) is the variance of the repeata­ ac=— XCTc00 (4) modes, the normalized values are used in bility variable at time moment t, n is the the definition of the variance of the number of samples, C,(f) is the repeata­ repeatability variable. The variance of the bility variable at time moment t, and C(t) Figure 15 shows the variances of

WELDING JOURNAL 700 800 Po (W) 600 600 500 400 400 lo (A) / 300 X 200 200 • : 0 100 1 L 0 { r -200 •100 0 1000 2000 3000 4000 0 500 1000 1500 2000 2500 3000 3500 4000 Sample points (sampling rate at 80 kHz) Sample points (sampling rate at 80 kHz)

Fig. 12 — Weld current waveforms under current control mode. Fig. 13 — Output power waveforms under power control mode.

0.4 variance of controlled variable over the welding process

- variance for voltage control 0.035 0.3 variance for current control variance for power control 0.03 0.025 - 0.2 0.02 0.015 0.01 0.005 0

1000 1500 2000 2500 3000 Sample points (sampling rate at 80 kHz)

Fig. 14 — Variances of the repeatability variables for three con­ Fig. 15 — Comparison ofthe variances of repeatability variables trol modes. over the whole welding process.

repeatability variables over the whole trol, current control, and power control tor-discharge power supplies. Journal of welding process under the three control modes can be seen as three special points Electronic Materials 30(8): 1012-1020. modes. From small to large variances, the in the generic power control mode. The 5. Chang, B. H., Li, M. V, and Zhou, control modes are the current control, the V-shaped nature of our existing results Y. 2001. A comparative study of small- power control, and the open-loop voltage suggests that a for the generic control has scale and 'large-scale' resistance spot­ control. The analysis results indicate that not yet been determined. • welding. Science and Technology of among the three control modes under Welding and Joining 6(5): 273-280. study, the current control mode is the References 6. Fundamentals of Small Parts most stable. Resistance Welding, UNITEK PECO The figure also shows that the vari­ 1. Steimier, D. W. 1998. "Downsizing" Company. ances of all three-control modes are get­ in the world of resistance welding. 1. Tan, Wen. 2004. Small-scale resist­ ting larger at the end of a welding period, Welding Journal 11: 39-47. ance spot welding of thin nickel sheets. and it indicates that the preset welding 2. Welding Handbook, eighth edition, Ph.D. thesis, Doctor of Philosophy in length 20 ms may be too long for the test­ 1991. Miami, Fla.: American Welding Mechanical Engineering, Waterloo, Ont., ed materials. Society. Canada. 3. Zhou, Y., Gorman, P., Tan, W., and Conclusion Ely, K. J. 2000. Weldability of thin sheet metals during small-scale resistance spot A low cost, highly flexible welding welding using an alternating-current power supply has been built. This power power supply. Journal of Electronic CLICK FOR supply is ideal for testing new control Materials 29(9): 1090-1099. parameters. It has been determined that 4. Zhou, Y., Dong, S. J., and Ely, K. J. CODE SECRETS constant power control mode produces 2001. Weldability of thin sheet metal dur­ more consistent sized nuggets. The imple­ ing small-scale resistance spot welding www.aws.org/catalogs mented three control modes, voltage con­ using high-frequency inverter and capaci­

JULY 2005 Exploring Temper Beat Welding

Bead #3 Bead #2 Bead #1

•|IJq»JlC«l •• Coatse Grain Subcritical Tempering/Stress-relief limil about 900°F I I Fine Grain IB Intercritical El Subcritical Tempered (PWHT) Ferrite + Carbide

Fig. 1 — Heat-affected zone transition points for various parts ofthe Fig. 2 — The effect of overlap of subsequent beads on the extent of HAZ as related to the iron-carbon equilibrium diagram. the HAZ of the previously deposited bead. The dotted lines show the previous weld bead locations. Note that the middle bead overlaps the right-hand bead by about 50% of the bead width, and that the re­ maining HAZ of the first bead is much smaller than the remaining HAZ of the middle bead. The left-hand bead overlaps the middle bead by about 10%o, resulting in very little effect on the HAZ of the middle bead.

For many years, metallurgists have rec­ croalloyed steels, particularly those con­ With this welding ognized that welding can have both posi­ taining vanadium, will lose toughness if tive and negative effects on the properties postweld heat treated. of the base metals being joined, as well as To optimize the properties of welds in technique, tight control on previously deposited weld metal. His­ modern steels where postweld heat treat­ torically, one way of ameliorating some of ment is not performed, or to optimize the deleterious effects was postweld heat properties of steels where postweld heat over subsequent weld treatment of welds. Postweld heat treat­ treatment might be desirable but is not ment was sometimes known as stress re­ practical, special welding techniques are lieving because it lowered residual stress used. Foremost among these is temper beads is used to control in welds from yield-point order of magni­ bead welding. tude to about one-third of yield. For high- The 2004 edition of the ASME Boiler carbon steels or low-alloy steels, postweld and Pressure Vessel Code, Section IX: heat treatment also tempered hard mi­ Welding and Brazing Qualifications, the properties of crostructures containing martensite, im­ added requirements for qualification proving resistance to cracking by improv­ when using temper bead welding. It de­ ing the toughness of the weld metal or fines temper bead welding as the follow­ previously deposited heat-affected zone (HAZ). ing: "A weld bead placed at a specific lo­ Modern steels have changed much of cation in or at the surface of a weld for the this. Postweld heat treatment is no longer purpose of affecting the metallurgical beads and the heat- a universal good as it was when steel prop­ properties of the heat-affected zone or erties were controlled by solution previously deposited weld metal." strengthening mechanisms. In fact, many The purpose of depositing a temper affected zone high-performance steels are designed to bead, then, is to affect the properties of be used in the as-welded condition. Mi­ the HAZ or the weld metal beneath that

WALTER J. SPERKO, P.E. ([email protected]) is President of Sperko Engineering Services, BY WALTER J. SPERKO Inc., Greensboro, N.C.

WELDING JOURNAL Fig. 3 — Effect ofthe second layer of weld metal on the weld metal Fig. 4 — Surface temper reinforcing bead placement. The distance and HAZ ofthe first layer. The dashed oval shows the location ofthe from the toe of the completed weld (right vertical line) to the toe of first bead. Note the untempered HAZ at the arrow. The technique for the surface temper reinforcing bead (left vertical line) needs to be suf­ tempering of this zone is shown in Fig. 4. ficiently small that the HAZ ofthe reinforcing bead tempers all ofthe unaffected HAZ in the base metal, but not so small that it creates its own untempered region. Surface temper reinforcing beads may re­ main in place or may be removed by grinding. bead that is being placed at a specific lo­ made with lower heat input cool more rap­ HAZ of the first bead is gone, as shown cation. What the definition implies, but idly than those made with high heat input. in the figure; if it only overlaps a little as does not say, is that the temper bead im­ Welds made on cooler base metals cool the third bead overlaps the second, little proves the properties of the HAZ or the more rapidly than welds made on hotter of the HAZ of the second bead will be af­ weld metal located under the temper base metals. fected. bead. To understand how this happens and Other areas of the HAZ are also af­ Obviously, the successive beads can­ how to optimize the effect, a little metal­ fected during welding. The portion of the not completely overlap the earlier beads lurgy is necessary. HAZ that sees temperatures above because that would result in a lump of Figure 1 shows a segment of the iron- 1900°F experiences grain growth forming weld metal that would not be very useful; carbon equilibrium phase diagram and the the coarse grain region — Fig. 1. The tempering occurs when successive weld locations on the diagram that mark tran­ longer this region stays above the grain beads overlap previous weld beads by 30 sition points in the HAZ. Keeping it sim­ growth temperature, the more grain to 70%, the optimum being 50%. This is ple, any portion of the HAZ that is heated growth there is. The larger these grains most easily done by having the welder run above the lower transformation tempera­ become, the more the toughness of that a stringer bead or a small weave with the ture (Aj) is subject to changes in mi­ region deteriorates. electrode pointed at the toe of the previ­ crostructure and mechanical properties What factors affect the amount of ously deposited weld bead. It is also im­ upon cooling. Those changes can vary grain coarsening that occurs? The same portant to make the beads consistent in from minimal for a low-carbon steel that ones that affect the cooling rate: Rapid width and thickness to ensure uniformity cools slowly to extreme hardening and em­ cooling results in a smaller HAZ and less of tempering by the next bead and next brittlement for a mid-carbon steel con­ loss of toughness in the HAZ. Slow cool­ layer of weld metal. taining a few percent chromium, molyb­ ing results in more loss of toughness. Once the first layer of weld metal has denum, or just a little vanadium. been deposited over an area, the second The factors that determine exactly layer is deposited. The energy from each what microstructures exist in the HAZ Optimizing Temper Bead bead of the second layer not only affects after a weld bead is deposited depend Welding Parameters neighboring beads just like in the first mostly on two factors. layer, but that energy penetrates into the 1. The chemical composition of the Going back to the definition, a temper weld layer below the second layer where base metal. This is usually expressed using bead is a weld bead placed at a specific lo­ it further tempers that weld metal and a carbon equivalent (CE) formula such as cation for the purpose of affecting the some of the HAZ beneath the layer — see that published by the International Insti­ metallurgical properties of the HAZ or Fig. 3. Note how the second layer HAZ tute of Welding (IIW): CE = C + Mn/6 previously deposited weld metal. Once overlaps the coarse-grain regions of the + (Cr + Mo + V)/5 + (Ni + Cu)/15. The one deposits the first bead, the properties first layer completely as well as a large higher the CE, the more hardenable the of that bead and its associated HAZ can portion of the fine-grain regions. Multi­ steel is, and the easier it is to damage dur­ be changed by weld beads that are de­ ple thinner layers provide more uniform ing welding. (Note that temper bead tech­ posited next to that bead; the energy flow­ tempering than a couple of thick layers. niques normally only apply to carbon and ing from the weld pool raises the temper­ In the old days, the effectiveness of the alloy steels. Temper bead welding is not ature ofthe previously deposited weld and second layer on tempering the first layer done to austenitic stainless steel, alu­ HAZ to "temper" it. was enhanced by grinding off part of the minum, copper, nickel, or titanium alloys.) As shown in Fig. 2, a portion of the first layer — the so-called "half-bead tech­ 2. The cooling rate. Faster cooling rates weld metal and HAZ of the first bead is nique." The difficulty with this technique cause harder and more brittle microstruc­ remelted by the heat from the second was accurately controlling removal of the tures in higher CE materials.Thicker ma­ bead. If the second bead overlaps the first first layer weld metal. One could not eas­ terials cool faster than thin ones. Welds bead a lot, much of the weld metal and ily tell if enough or too much of the first

JULY 2005 Table 1 -- Exampl e of Calculating Heat I lput Ratios between Weld Layers

Layer PQR Heat Ratio WPS Heat WPS Heat WPS Heat WPS Heat Number Input* Input 1 Input 2 Input 3 Input 4

1 30 25 30 40 60 2 45 1.5 37.5 45 60 90 3 55 1.22 45 > 55 73.3 110

*A11 heat inputs shown are in kJ/in., but could be expressed as bead size or deposit length per unit length of electrode.

layer was removed. Later research showed — the amount of energy consumed is the used on the test coupon, the ratio of heat that one could optimize the effectiveness same at both extremes for all practical input between layers must remain constant of the second layer by only grinding purposes. If that energy is spread out over as shown in Table 1. enough to clean and slightly smooth the a given length as a weld bead, and that For production welding, if the welder first layer, then depositing the second length is divided into measurement units, selected a heat input for layer 1 (the layer layer using heat input that was about 30 the energy per unit length will be constant. against the base metal) of 60 kJ/in., the to 70% greater than the heat input used For example, if it took 120 kJ of energy to nominal heat input for the next layer is re­ on the first layer. This resulted in opti­ melt a %-in. (3.2-mm) electrode from a 14 quired to be 90 kJ/in. For P-1 metals, sec­ mum overlap of the second layer HAZs in. length to a 2-in. stub, and that energy tion IX sets a tolerance of ±20%, so the over those of the first layer without the was spread out over a 4 in. length, the heat input for the second layer can be from labor, aggravation, and uncertainty of equivalent heat input would be 30 kilo- 72 to 108 kJ/in. grinding off a lot of otherwise perfectly joules per inch of weld length. If that en­ One might ask if this is technically good weld metal. For shielded metal arc ergy were spread out over a 3 in. length, sound. Doesn't increasing the heat input welding (SMAW), increasing the elec­ the heat input would be 40 kilojoules per against the base metal increase the size of trode size by one size while keeping the inch of weld length. One does not need to the HAZ? Yes, that does, but by increas­ same welding technique generally accom­ calculate the energy that it takes to melt ing the heat input in the next layer pro­ plishes this. the electrode when using this method; one portionally, that layer's HAZ is also in­ Once the second weld layer has been only needs to measure the length of weld creased proportionally. Imagine making deposited, controlling subsequent weld beads deposited for each unit length of the weld beads in Fig. 3 twice as large as layers remains critical to control the HAZ electrode consumed. Heat inputs quali­ they are on the figure; the HAZ of each properties until at least Ks in. (5 mm) of fied using this method are valid for only bead increases proportionally, and the fig­ weld metal has been deposited over the the size electrode used, although by meas­ ure does not look any different with beads base metal. uring both deposit length per unit length twice as large — except that it is larger. electrode and the heat input using the A WPS that specifies that "the heat Measuring Heat Input formula for various electrode sizes, one input for the second layer shall be between can easily develop correlations between 72 and 108 kJ/in." is inadequate unless the Heat input can be measured three ways. different electrode sizes. welder has been trained how to calculate First is the classic heat input formula The third method of measuring heat the heat input based on the amps, volts, input is by the size of the weld bead. A and travel speed that he or she will be larger bead will contain more energy and using. This means that the welder would Volts x Amps x 60 Heat input = automatically have a higher heat input per have to have a calculator and a stop watch, Travel speed unit length than a smaller bead. Weld bead and understand the math. In the author's size should be measured as width x thick­ opinion, heat input should be controlled In this formula, heat input is measured in ness for each bead, and the product in the WPS by appropriate nomographs Joules/inch (J/in.) or Joules/mm (J/mm) recorded as the bead area. or by tables showing the amperage and depending on whether the travel speed is To measure the heat input, one simply corresponding travel speeds for a given measured in inches per minute or mil­ records the heat input by any of the three heat input. For example, a heat input limeters per minute. Because the numbers methods for each pass on the first layer, showing 72 to 108 kj/in. at 28 V is detailed are large, this product is usually divided then selects a representative value to in Table 2. by 1000 and expressed in kilojoules per record on the procedure qualification By this table, if the welder chooses to unit length (i.e, kJ/in. or kJ/mm). record (PQR) for that layer. This process weld at 225 A, he or she has to be within The second way to measure heat input is repeated for subsequent layers until the the range of 3.5 to 5.2 in./min travel speed. is by the length of weld deposit per unit test coupon is welded out. All WPSs that specify heat input controls length of electrode consumed. This should provide the heat input parameters method is particularly easy to use with in such a manner that the welder and the SMAW because it does not require the Specifying Heat Input in QC inspector do not have to calculate any­ welder to measure the amperage, voltage, the WPS thing — they just look it up and use the or travel speed when making production required parameters. This includes speci­ welds. The basis for this method is simply When writing the welding procedure fying heat input by deposit length per unit that it takes a certain amount of energy specification (WPS), the heat input for each length of electrode (which would simply (Joules) to melt a given length of elec­ weld layer recorded on the PQR becomes be a minimum and maximum deposit trode. It does not matter whether the am­ the basis for the heat input limits specified length per unit length of electrode) or a perage used was at the high end of the on the WPS. While it is not necessary to use bead width range assuming some typical electrode's operating range or the low end the same heat input in production as was weld bead thickness.

WELDING JOURNAL Table 2 — Travel Speed Range for Various Amperages at 72 and 108 Min. at 28 V may have to add an additional layer of weld metal to the completed weld — and Amps Minimum TVavel Speed'3' Maximum Travel Speed(b' then grind it off. This results in temper­ (in./min) (in., min) ing of the remaining untempered weld metal and HAZ. One does, however, have 150 2.4 3.5 175 2.7 -.1 to be careful when approaching the edge 200 3.1 4." of the weld not to let this extra tempering 225 3.5 5.2 layer get too close to the toe of the weld. 250 3.9 5.8 If it does, it will create a new untempered 275 4.3 6.3 HAZ. The trick in optimizing the proper­ 300 4.7 _.(i ties at the toe of the weld is to place the (a) Based on 108 kj/in. heat input. tempering bead a short distance from the (b) Bsed on 72 kJ/in. heat input. toe, typically % to %, in. This allows the heat from the tempering bead to pene­ ness limits, the heat input may not be less trate the weld metal and the HAZ at the Heat Input for Fill Layers than 20% below the heat input qualified. weld toe, tempering both. Often, just tem­ Fill layers are those that complete the pering the weld toe is adequate to achieve the required properties, avoiding the extra weld joint after the layers affecting the Optimizing Properties HAZ have been deposited. Because these work of overlaying the entire weld surface layers are weld metal being deposited over at the Toe of a and then grinding it off — see Fig. 4. • weld metal, the welding engineer can Completed Weld choose appropriate filler metals to ensure that the weld metal has appropriate prop­ After completing a weld using the tem­ erties. If the basis for temper bead quali­ per bead technique, there is still one re­ ARE YOU UP fication is impact testing, the normal sup­ gion where no tempering of the HAZ has plementary essential variable QW-409.1 occurred. That is at the toe of the weld as TO STANDARD? applies. In this case, the heat input may shown in Fig. 3. In addition, there is weld not exceed that qualified for the fill lay­ metal that is also not tempered. If neces­ www.aws.org/catalogs ers. If the basis for qualification is hard­ sary to obtain the desired properties, one

THE ANSWER FOR INDEPENDENT WEIDING SHOPS! AWS AFFILIATE COMPANY MEMBERSHIP MEMBER BENEFITS: Quick access to welding information through a Exclusive usage of the AWS Affiliate Company personal library of AWS Pocket Handbooks: Member logo on your business card and • Priceless exposure of your shop with free 1. Everyday Pocket Handbook for promotional material for a competitive edge. publicity on AWS's 40,000-visitors-a-month website. Arc Welding Steel Wall certificate to show your company's affiliation 2. Everyday Pocket Handbook for Visual • $50 OFF a job posting on AWS JobFind with the world's premier welding association. www.aws.org/jobfind, your connection to hundreds Inspection and Weld Discontinuities - of welders, inspectors and other job seekers! Causes and Remedies Window decal to display on your shop's storefront. 3. Everyday Pocket Handbook for Gas Metal • An AWS Individual Membership ($80 value), which Arc and Flux-Cored Arc Welding Free passes to the FABTECH INTERNATIONAL & includes need-to-know technical information AWS WELDING SHOW for you and your shop's best through a FREE monthly subscription to the A 62% discount on freight shipments with employees. Welding Journal. WJ covers the latest trends, Yellow Transportation, Inc. Unmatched networking opportunities at local events, news and products guaranteed to make Practical information through The American Section Meetings, the annual FABTECH your job easier. Welder, a special section of the Welding Journal INTERNATIONAL & AWS WELDING SHOW, geared toward front-line welders. as well as at AWS-sponsored educational events.

Professional development via discounts on world- To join, or for more information call: (800) 443-0353, ext. 480 renowned and industry-wide AWS Certification or (305) 443-9353, ext. 480 Visit us on-line at www.aws.org programs, conferences and workshops.

Real-world business solutions for welding and fabricating shops Technical information through a 25% Members'- only discount on 300+ industry-specific AWS Publications and technical standards. Circle No. 7 on Reader Info-Card V 'j$*mX Educati

««UHI»TeCHHOLOGY

pioneering Ohio institution looks fonfward to a busy future

BY HOWARD M. WOODWARD

roy, Ohioans, and visitors nationwide convened May 14 to celebrate the 75th anniversary of the founding of what has Tevolved into the Hobart Institute of Welding Technology (HIWT) (see lead photo), and the rededication of the Unity of Man fountain (Fig. 1) gracing the main entrance to the facility. With such an impressive legacy to celebrate, HIWT Chairman and President Andre A. Odermatt joined with numerous local and national dignitaries, including HIWT past president and cur­ rent AWS Executive Director Ray Shook, for the event — Fig. 2.

Presentation of the AWS Plaque

Shook said it was his privilege to have worked for Hobart Brothers for 23 years and to serve as the school's president for two years. Shook noted, "The rededication of the Unity of Mart fountain is the ideal venue to highlight the unity that exists be­ tween HIWT and AWS. The cornerstone of this unity," Shook added, "is the AWS Certified Welding Inspector (CWI) pro­ gram." Shook noted HIWT has ten CWIs on staff and is the first non-AWS location to administer the CWI exam without an AWS proctor. The Institute is also an AWS Authorized Testing Facil­ ity (ATF), which means HIWT can offer welder certifications to AWS specifications. Shook concluded by presenting President Odermatt with a plaque engraved as follows:

American Welding Society Congratulates Hobart Institute of Welding Technology on 75 Years of Excellence in Welding Training and Education Fig. 1 — The 20-ft-high Image of Man fountain, originally com­ May 14, 2005 missioned to commemorate the 50th anniversary of Hobart Broth­ ers Co., was completely renovated In time for its rededication dur­ ing the celebration of Hobart Institute of Welding Technology's 75th In the Beginning anniversaiy.

William Hobart, Sr., recognized in 1930 a need to teach peo­ porated as a nonprofit corporation named Hobart Trade School. ple about the welding processes if welding was to become an ac­ cepted way to join metals. Beginning with four welding booths in The War Years a corner of the factory to train customers, the school soon ex­ panded to 15 booths. In 1937, the school was moved to a self- Later, during the WW II years, the school went to two-shift contained area within the factory featuring 30 welding booths. operation to train large classes of women students enrolled to Training was offered to anyone able to pay the $10 tuition for a learn defense production welding. After the war, the school was full week of instruction. On May 3, 1940, the school was incor- kept at operating capacity with male students who took advan-

HOWARD M. WOODWARD ([email protected] is Associate Editor of the Welding Journal.

WELDING JOURNAL Fig. 2 — The presenters at the Hobart 75th anniversary program included (from left to right) A WS Executive Director Ray Shook, Ohio Senator Tom Roberts, U.S. Representative John Boehner (R-OH), Peter C Hobart, William H. Hobart, HIWT Chairman and President Andre Odermatt, Ohio Representative Diana Fessler, Troy Mayor Michael Beamish, and Rev. Dr. James Wilson. (Photo by Josh Kovar, BK Photo,Troy, Ohio.) tage of the training benefits afforded by the G.I. Bill of Rights. Men accounted for about 90% of the students. At that time, the complete training program lasted only 16 weeks, and the school was selling its 516-page welder training manual for $2. In early 1941, the school moved to a new, modern, all-welded steel building housing 52 arc welding booths and 12 gas welding stations. in PRDTECtlOH fflMH BEYDtiO THIS f BUT DURIffi The 1950s and'60s SDBKOPBOCi HOWS. The 1950s saw the introduction of shorter one- and two-week- long courses, and in 1958, a modern 80,000-sq-ft facility was built on Trade Square East in Troy, under the direction of Howard Cary and Ray Dunlavy. The early 1960s prompted a need to provide technical infor­ mation and training in addition to the skills training. Technical workshops and seminars were started at the school. Also, gas metal arc welding was becoming more widely used in industry, necessitating that this course be added to the pro­ gram in 1963. A $5 deposit was required to enroll. In 1964, Hobart initiated what has since become one of the Fig. 3 — Not the average welder training facility, Hobart Institute nation's largest libraries dedicated to welding. Located on the of Welding Technology has light-colored walls, gleaming floors, and second floor, the John H. Blankenbuehler Library currently of­ spacious, well-ventilated work areas. fers more than 4000 references, texts, publications, and stan­ dards, both foreign and domestic. The facility is open, by ap­ pointment, to the public.

The Unity of Man Fountain Dedicated as a symbol ofthe Beauty — Strength — Flexibility Hobart's landmark Unity of Man fountain, created by the late available from good craftsmanship in the art of welding famed sculptor George Tsutakawa, was installed in 1967 to com­ memorate Hobart Brothers Co.'s 50th anniversary. Nearly 20 ft high, the 2700-lb tower spews plumes of water in all directions from 45 jets concealed by five silicon bronze spheres (welded The Roaring Seventies with the gas tungsten arc process). On February 4, 1971, the Hobart Trade School was renamed David Niland, professor of architecture at the University of Hobart School of Welding Technology, and became the first weld­ Cincinnati, designed the raised concrete stage, reflecting pool, ing school approved by the Ohio State Board of Schools and Col­ and gardens. Over time, the fountain's concrete stage, plumbing, lege Registration. In the summer of 1991, under the direction of pumps, and electrical wiring had deteriorated beyond repair. In then-President Ray Shook, the school took its present name, Ho­ 2004, after two years' of herculean efforts, the fountain's infra­ bart Institute of Welding Technology. structure was replaced and the fountain reassembled to full op­ erating condition, justifying its rededication at the 75th anniver­ Three shifts were taught around the clock with enrollment at sary ceremonies. The Unity of Man commemorative plaque, in­ an all-time high in 1976. As a result, ground was broken in 1978 troduced by Peter Cahill Hobart, vice president international, to expand the facility by 50,000 sq ft for new air-conditioned class­ Hobart Brothers Co., reads: rooms and state-of-the-art workstations — Fig. 3.

JULY 2005 The World of Welding

Hobart's quarterly publication, The World of Welding, began with the Spring 1990 issue. Following a several-year hiatus, the magazine was revived, redesigned, and expanded in content under the editorship of Martha (Marty) Baker — Fig. 4. Finally, 1990 was notable for the introduction of the Pipe Layout for Fitters and Welders course. Today, HIWT's complete welding program lasts 9 months. Students work with purchased-to-order, precleancd metals in well-ventilated booths equipped with the latest power sources.

The Hobarts Look to the Future

Peter C. Hobart said at the ceremonies, "Welding has always played an essential role in man's endeavors, from the basic tool of industry for developing countries to the strategic technologi­ cal role in war and peace for America and all nations." William H. Hobart, retired chairman ofthe board and CEO Fig. 4 — Marty Baker (right), manager, Internet and library ser\'- of Hobart Brothers Co., stated, "The philosophy of the institute ices, and editor, The World of Welding, and Teny Brown, HIWT is to help individuals to develop marketable welding skills through admissions representative, guided tours ofthe Hobart facilities. quality training at minimum cost. According to the U.S. Dept. of Labor, there is a shortage of trained welders and this labor sup­ More Recent Events ply shortage is projected to increase in the next 20 years. The challenge is to attract more young people to become welders, In 1990, the HIWT offered two associate degree options and Hobart Institute is well positioned to meet this challenge through cooperation with Sinclair Community College in nearby and to continue to help young people to create earning power Dayton, Ohio. for themselves and to fill the needs of the welding industry."*

Organized by: ASM International (ASM) American Ceramic Society (ACerS) MS rw Association for Iron & Steel Technology (AIST) Materials Science & Technology The American Welding Society (AWS) 2005 Conference and Exhibition The Minerals, Metals & Materials Society (TMS) September 25-28, 2005 Held in conjunction with: David L. Lawrence Convention Center • Pittsburgh, Pa. ASM Heat Treating Society Conference & Exposition

The only event spanning the entire spectrum of materials science & engineering technologies. Where Theory Meets Application Where Scientists Meet Engineers Where Technology Meets the Future

fc^. wfiw.matscitech.org

Circle No. 25 on Reader Info-Card

WELDING JOURNAL Standardization in Welding Are today's standards different from those of the past and can they ever be globally relevant?

BY JEAN-PAUL GOURMELON

f you look for a defini­ This definition of standardization is al­ the general scheme could be identical but ready 20 years old and does not corre­ the details widely different. tion of standardization spond with today's reality. Obviously, the Then, strong, fast development of Eu­ in a dictionary from basic rule remains but, in addition to an ropean standardization occurred, directly I agreement on technical content, a stan­ governed by establishment of the Com­ early in the 20th century, dard is also a marketing and economic mon Market, the European Economic you would not find one. At tool. The current ISO definition for stan­ Community, and, eventually, the Euro­ dard is "a document, established by con­ pean Union. Changes were made to na­ most, you will find "stan­ sensus and approved by a recognized tional standards, sometimes painfully, and dard" defined as "principle body, that provides, for common and re­ the consensus was not always the rule, but peated use, rules, guidelines, or charac­ progress came from discussions. used as a rule." The con­ teristics for activities or their results, aimed at the achievement of the optimum hat was one step. The next was the cept of standard, as we un­ degree of order in a given context." derstand it now, appeared World Trade Organization Agree­ Looking back, we see that the first pub­ Tment that underlined the impor­ around 1920 with the defi­ lished international standards were tance of international standards. The doc­ mainly about products, tests, or measur­ ument, which was signed on April 15, nition "formula defining a ing systems. 1994, in Marrakech, includes in its Annex type of thing, a product, a ixty years ago, the necessity ap­ Al an "agreement on technical barriers technical process in order peared for speaking about the same to trade." Its content makes strong refer­ Sthings with the same language, deal­ ences to international standards and en­ to simplify and rationalize ing with the same characteristics of prod­ closes a code of good practice for the ucts. The aim was that a part coming from preparation, adoption, and application of its production." As for one country should match another part standards. "standardization," it was coming from another country and all That new context was clearly explained points were well defined in standards such in a paper, "Welding Standards Together," more recently defined as as those concerning mechanical fasteners. published in the ISO Bulletin, May 1997, "a set of technical rules re­ Year after year, other types of interna­ by David Shackleton and Glenn Ziegen­ tional standards were written, containing fuss, respectively, chairman and standard­ sulting from an agreement more general specifications, but, from the ization officer in the IIW Select Commit­ between producers and view of today's definitions, they could be tee "Standardization." users, and leading to spec­ considered more as guidelines than as requirements. Use of Standards in Contracts ify, unify, and simplify for Concurrently, national standards were a better output in all fields developed, corresponding to national t appeared that standards should be practices, knowledge, and regulations. able to be referred to in contracts. Thus, of human activity." The result was that, for the same activity, Ithe y need to contain clear, precise re-

JEAN-PAUL GOURMELON ([email protected]) is an Honorary General Civil Engineer in France.

This is a condensed version ofthe Thomas Medal Lecture presented April 27 at the AWS Welding Show and Convention, Dallas, Tex.

JULY 2005 quirements so as to avoid any ambiguity in and justified on the basis of clearly iden­ its usefulness, another to agree on all cor­ the relation between contractors. tified market needs...." relative technical details. In some cases that implies a major The ISO/TMB policy and principles' change. A good example can be given with Involving the User statement on global relevance of stan­ welding quality management. dards specifies that "given existing and le­ In 1988, an ISO/DIS was circulated in hat does that mean? It means on gitimate marked differences, an Interna­ order to revise the 1978 version of ISO the one hand that standards tional Standard may pass through an evo­ 3834, Welding — Quality Assurance Re­ Wshould not be written only for the lutionary process, with the ultimate ob­ quirements for Welded Structures. That was pleasure of some experts, and on the other jective being to publish, at a later point, a short standard (a little bit more than two hand that they shall take into account the an International Standard that presents pages) and, when reading it we notice needs of all actors in the market. one unique international solution in all of some interesting points, but the specifica­ They should be written in close coop­ its provisions." tions remained at a general level and eration with all participants in relevant This solution was used in the field of could not be directly applied. That was, in fields, sometimes with other technical welding consumables where comparison fact, not so easy, welding being a tech­ committees, and not only in close circles between International and European nique that can be used in various fields of technical experts, even if they are the Standards was the occasion of hard dis­ with various levels of requirements. best in their fields. cussions. To begin with, there were essen­ In an annex, reference was made to the Participation of users is one of the tial differences concerning the reference ISO 9000 standards developed by ISO/TC major points in this standardization mechanical characteristics and the impact 176, but no link was underlined between process. They should be able to give their resistance values and temperatures. Then, the two standards. Almost at the same points of view from the early stage of writ­ standards such as ISO 2560, Welding Con­ time, under regulation pressure, the need ing. If that is not the case, the standard sumables — Covered Electrodes for Man­ appeared to develop a standard with spe­ could be, perhaps, the best technically ual Arc Welding of Nonalloy and Fine- cific requirements on the European level speaking but the worst economically. Grain Steels — Classification, and ISO and EN 729 was written. That standard, Coming back to the World Trade Or­ 14343, Welding Consumables — Wire Elec­ Quality Requirements for Welding — Fu­ ganization Agreement and its annex, it trodes, Wires, and Rods for Arc Welding of sion Welding of Metallic Materials, con­ would be too long to detail all provisions Stainless and Heat-Resisting Steels — Clas­ tained four parts: Part 1, "Guidelines for made in those documents, but their analy­ sification, were developed as "cohabita­ selection and use," and three others deal­ sis could be titled: "Use and misuse of tion standards" containing options with ing with comprehensive, standard, or ele­ technical rules and standards." As the the displayed objective to reach a unique mentary quality requirements. Greek fabulist Aesop said about the classification within five to ten years. Unlike the ISO/DIS mentioned previ­ tongue, it can be "the best thing as well as However, this solution shall not be used ously, the specifications were precise and the worst." without proper judgment and be consid­ could theoretically be applied directly but, ered as an easy way out. in fact, in some fields of application it was • The best: If they are tools in order to fa­ Welding is not a field where essential not so easy, the problem of requirement di­ cilitate exchanges and improve knowl­ differences in markets around the world versity being the same, and this standard edge between countries. should be addressed permanently, that is, being obviously under the influence of pres­ factors that are not expected to change sure vessel techniques and practices. Addi­ • The worst: If they are weapons in order over time, such as embedded technologi­ tionally, a link was clearly made with ISO to protect a market or if they represent cal infrastructures, climatic, geographical, 9000 standards and some countries or con­ one country's opinion or one partner's or anthropological differences. tractors intended to use it for the purpose (producer, user, authority) point of However, ISO/TMB policy draws at­ of certification. A few years after being is­ view. tention to the fact that committees can sued at the European level, this standard only ensure the global relevance ofthe In­ was adopted as a revision of ISO 3834. There is only one way to reach the best ternational Standards they produce if they With the revision of ISO 9000, this and avoid the worst: to work together, to are aware of all the factors that may af­ standard needed to be updated. This is examine arguments of every interested fect a particular standard's relevance. One currently under way and a fifth part will party, whatever they are, and try to find a of them is the way in which standards are be added: "Normative references for the common agreement, probably not the best applied; the same requirement may give requirements of ISO 3834-2, ISO 3834-3, for everybody but surely not the worst for different results depending on the coun­ and ISO 3834-4," so as to make its imple­ anybody. try — the cultural factor. mentation easier around the world. We can try to get a quick overview of This need for contractual references, The Case for Global Relevance the current corpus of standards in the field illustrated by this example, is applied at of welding. Could they be used tomorrow, the European level with stringent condi­ ight that be a good definition for meaning used worldwide? In other words, tions, national standards being replaced "global relevance"? do they have any chance to be "globally by European standards in order to dis­ M relevant"? mantle technical-economic barriers to The official ISO definition is "the re­ trade. Such conditions are not yet applied quired characteristic of an International Types of Standards to ISO standards, but it is clear that stan­ Standard that can be used/implemented dards are now considered economic tools as broadly as possible by affected indus­ e can distinguish three cate­ more than technical ones. That was tries and other stakeholders around the gories of standards: proved when business plans for standard­ world." w ization were introduced, in which the ISO This seems to be easy for a general • Product standards; Technical Management Board (TMB) standard such as ISO 9000, but when you • Process standards; specified, "Business plans are intended to deal with technical items needing precise • Quality management and test standards. ensure that the work program of ISO details, this would be more difficult. It is Product standards are mainly the field technical committees are derived from one thing to agree with the work item and of producers, who need to ensure the qual-

WELDING JOURNAL ity of their products, imagine new ones, Participation of users is ing— Part 1, Steels, despite the common and anticipate the needs of the market, will and interest to write a globally rele­ but above all to give the necessary char­ one of the major points in vant standard. This will take time, but we acteristics for their applications to the can't say that there is no more hope. users, as well for design as for fabrication. this standardization Last, but not least, are the nondestruc­ The first step is "cohabitation standards" tive testing standards. We previously said and, even if a general agreement is incon­ process. that it was a field for experts, which is true. ceivable on all products, there is great We can't ask anyone to know every detail, hope to solve pending problems for the e.g., about ultrasonic testing and its re­ majority of them. cent developments. However, NDT is a rocess standards are very specific; basic instrument for quality and users or they are the process manufacturers' An analysis of published standards re­ clients shall be able to specify how to use Pfield, and I am not an expert. But I lated to quality management shows that them, even without any technical knowl­ can imagine that a process is not used in the backbone of the system is ISO 3834, edge; that is the challenge. only one country or region. It is in manu­ which was mentioned earlier. As an ap­ Here again, the set of standards deal­ facturers' own interest to develop their plication to welding of ISO 9000, which is ing with NDT was conceived as a toolbox. production as broadly as possible, which the most globally relevant standard, it is The only need for the users is to know is the definition of global relevance. The globally relevant in itself; it provides op­ what type and size of imperfections are main question is to make it compatible tions to users and the last remaining prob­ allowed for its construction or equipment; with regional characteristics such as power lem of normative references will be solved this can be defined in application codes frequency or voltage. with the new part five. or by calculation. On the other hand, there Quality management and test stan­ sing ISO 3834 implies a good is no need for users to know what type of dards are the most numerous and proba­ knowledge and use of standards nondestructive method is to be used, but bly the most important. Even if some are Udealing with each particular point they shall be able to find somewhere their the experts' fields, such as standards for in the quality process. Going into detail, we scope and limits. nondestructive testing, others shall not be find two types of standards: those covering the private domain of welding engineers. all welding processes and materials and They shall be conceived like a "toolbox" those dedicated to a specific welding Who Are the Users? for the users and, as such, require their process. One ofthe latter is ISO 14555, Arc participation. They shall be open and pro­ Stud Welding of Metallic Materials. Under e spoke from the beginning vide the necessary set of options for dif­ revision, it is now at ISO/DIS stage. The about the "users," mysterious ferent applications. new text was fully rearranged so as to fol­ Wpersons who are at the end of low the general scheme of ISO 3834 and of­ the chain, take decisions, and have to use fers all necessary options for applications. standards. Who are they? There are many, Among the others, those dealing with so diverse are the practices depending on specification and qualification of welding the applications and countries. They Laser Alternative processes recently underwent a major might be consulting engineers, manufac­ change. Existing standards are to be re­ turers, constructors, and fabricators well placed by the new series ISO 15607 to ISO aware of the welding technique; they 15614. Those are a real toolbox covering might be architects, private clients know­ all welding processes and materials and ing nothing about welding; they might be offering several types of qualification standardizers writing application stan­ (tested welding consumables, previous dards who need the right references to be a Fraction of the Cost welding experience, standard welding pro­ referred to. How could so many different people find their way? The global rele­ • New/Used Equipment cedure, preproduction welding test, or welding procedure test). As it is true that vance should also take into account such diversity. A solution to improve the dis­ • Tools Service you can't require the same quality level semination of welding standards could be • Technical Support for an offshore platform, a pressure ves­ to write an informative document explain­ ABI Link-it sel, a bridge, a two-story building, or a bike ing their organization, their flowcharts, a Link Welder shed, you can find there the right proce­ kind of instruction guide: "How to use Loopers dure able to reconcile two apparently con­ welding standards." This could take the Auto& flicting objectives: safety and economy. If shape of an ISO technical report. Manual well used, that series is in a position to Fusion cover any situation anywhere, that is to be Finally, the challenge for welding stan­ Stud globally relevant as a whole. dards is • To be highly technical; Welders et's speak now about personnel qualification — probably the trick­ • To cover all fields of application; Liest question. Depending on the • To offer several economic solutions; country, it may imply several aspects: tech­ • To be varied, but precise; nical, economic, social, or regulatory. This • To be understandable by any concerned is a typical field in which a welding stan­ person. dard shall not be written by welding ex­ We can't ensure that all those items are Aelectronic Bonding, Inc. perts alone. For the time being, it appears fulfilled but, looking to the work done 1655 Elmwood Avenue that a consensus is being reached on the over the last ten years, we can say that we Cranston, Rl 02910 draft of the new standard ISO 14371, are on the right track. Welding standards 401-461-4140 • 888-494-BOND Welding Coordination — Tasks and Re­ are not standards from yesterday that gave Fax 401-461-5250 sponsibilities. On the other hand, the prob­ the "state of art"; they are definitely stan­ Abiusa.net • [email protected] lem is still pending on ISO 9606-1, Quali­ dards for tomorrow, bases for contracts fication Testing of Welders — Fusion Weld­ as broad as possible. • Circle No. 1 on Reader Info-Card

JULY 2005 WELDING WORKBOOK Datasheet 268 Solid-State Inverters

An inverter is a circuit that uses solid-state devices called metal oxide semiconductor field effect transistors (MOSFETs), or in­ tegrated gate bipolar transistors (IGBTs), to convert direct cur­ TRC SWITCH CONDITIONING —7 rent (DC) into high-frequency alternating current (AC), usually CIRCUITS / in the range of 20 to 100 kHz. Conventional welding power \ / sources use transformers operating from a line frequency of 50 V or 60 Hz. 1

Since transformer size is inversely proportional to line or ap­ LU plied frequency, reductions of up to 75% in power source size o i_ DD _ 5 and weight are possible using inverter circuits. Inverter power 0 O A sources are smaller and more compact than conventional weld­ o-=to 3 " > > ing power sources. They offer a faster response time and less o n Q electrical loss. 1 The primary contributors to weight or mass in any power ' ' source are the magnetic components, which consist of the main transformer and the filter inductor. Manufacturers have made various efforts to reduce the size and weight of power sources such as by substituting aluminum windings for copper. Inverter circuits control the output power using the principle Fig. 1 — Simplified diagram of an inverter circuit used to demon­ of time-ratio control (TRC), also referred to as pulse-width mod­ strate the principle of time-ratio control (pulse width ulation. The solid-state devices (semiconductors) in an inverter modulation). act as switches; they are either switched on and conducting, or switched off and blocking. Time-ratio control is the regulation of the on and off times of the switches to control the output. Fig­ ure 1 illustrates a simplifield TRC circuit that controls the out­ put to a load such as a welding arc. Another method of inverter control, frequency-modulation TRC, varies the frequency. Both frequency modulation and pulse- width modulation are used in commercially available welding inverters. INPUT °"TPUT BRIDGE BRItJGE Figure 2 shows a block diagram of an inverter used for direct- RECTIFIER INVERTER TRANSFORMER RECTIFIER current welding. A full-wave rectifier converts incoming three- phase or single-phase 50- or 60-Hz power to direct current. This l*OR3*— UuuJ direct current is applied to the inverter, which converts it into PRIMARY- high-frequency square-wave alternating current using semiconductor switches. In another variation used for welding, the inverter produces sine waves in a resonant technology with frequency-modulation control. The switching of the semiconduc­ INVERTER CONTROL tors takes place between 1 and 50 kHz, depending on the com­ CIRCUIT ponent used and method of control. This high-frequency voltage allows the use of a smaller step- down transformer. After being transformed, the alternating cur­ Fig. 2 — Inverter diagram showing power source sections and rent is rectified to direct currrent for welding. Solid-state con­ voltage waveforms with pulse-width modulation control. trols enable the operator to select either constant-current or con­ stant-voltage output, and with appropriate options these sources can also provide pulsed outputs. cuit switching determine the response time and switching fre­ The capabilities of the semiconductors and the particular cir- quency. Faster output response times are generally associated with the higher switching and control frequencies, resulting in Table 1 — Types of Inverter Switching Devices and Frequency Ranges more stable arcs and superior arc performance. However, other Applied to the TVansformer variables, such as the length of the weld cables, must be consid­ ered because they may affect the performance of the power Switching Device Frequency Range source. Table 1 compares inverter switching devices and the fre­ SCR devices 1-10 kHz quency applied to the transformer. Transistor devices 10-100 kHz Inverter technology can be used to enhance the performance of AC welding power sources and can also be applied to DC constant-current power sources used for plasma arc cutting.

Excerpted from the Welding Handbook, Vol. 2, ninth edition.

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

IIW 58th Annual Assembly and Int'l Conference. July 10-16, EMO Hannover: The World of Machine Tools & Metalworking. Prague, Czech Republic. Contact Int'l Institute of Welding at Sept. 14-21, Fairgrounds, Hannover, Germany. Contacts: www.iiw2005.cz. www.emo-hannover.de; Hannover Fairs USA, Angela Dessables, at [email protected]. 4th Int'l Surface Engineering Congress and Exhibition, and 19th Int'l Conference on Surface Modification Technologies. Aug. • Materials Science & Technology Conference and Exhibition. 1-3, Radisson Riverfront Hotel, St. Paul, Minn. Contact ASM Sept. 25-28, David Lawrence Convention Center, Pittsburgh, Pa. Int'l at www.asminternational.org/swface. Held in conjunction with the ASM Heat Treating Society Con­ ference. Contact www.matscitech.org. EPRI Int'l Conference on Maintenance. Aug. 8-10. Jersey City, N.J. To focus on both nuclear and fossil maintenance issues. Spon­ Metalform Mexico 2005. Sept. 28-30. Monterrey, Mexico. Con­ sored by Electric Power Research Institute (EPRI). Contact tact Graylin Presbury [email protected]. http://inter.viewcentral.com/reg/epri/2453. 5th Int'l Forum on Aluminum Ships. Oct. 11-13, Zenkyoren Bldg. Tokyo, Japan. All business conducted in English. Contact Standards Engineering Society Annual Conference. Aug. 15, 16, The Society of Naval Architects of Japan, [email protected]. Omni Charlotte Hotel, Charlotte, N.C. Contact H. Glenn Ziegen­ fuss [email protected] or visit www.ses-standards.org. Expo FABTEC-Canacintra. Oct. 12-14, World Trade Center, Mexico City, Mexico. Contact Grupo MFV Mexico, Schweissen & Schneiden 2005, 16th Int'l Welding Fair. Sept. www.gnipomfv.com; [email protected]. 12-17, Essen, Germany. Joining, cutting and surfacing, with Qual­ ity Testing Int'l, and Structural Bonding Int'l. Sponsored by Messe 15th Korea Machinery Fair (KOMAF 2005). Oct. 26-30, Korea Essen and DVS (German Welding Society). For complete infor­ Int'l Exhibition Center, Koyang, Korea. For complete informa­ mation, visit www.schweissenuschneiden.de. tion, visit www.komaf.org.

3rd China Int'l Coking Technology and Coke Market Congress. ICALEO® 2005, 24th Int'l Congress on Applications of Lasers Sept. 14, 15, Crowne Plaza Park View, Wuzhou, Beijing. China. and Electro-Optics. Oct. 31-Nov. 3, Hyatt Regency, Miami, Fla. Contact www.coke-china.com. Contact the Laser Institute of America at www.laserinstitute.org.

24M INURNAIIONAL CONGRESS ON APPLICATIONS OF LASERS & I r^ IHUAMLI Zlft )CTOBER ?i - NOVEMBER ? • HYAJT REGENCY MIAMI • MIAMI, FLORIDA USA

Conference General Chair: Andreas Osiendorf Laser Zentrum Hannover e.V., Hannover, Germany CElEbRATE ICALEO®!

CElEbRATE 2005 - ThE WoRld YEAR of Physics!

CElEbRATE AlbERT BNSTBN - whosE GEMUS GAVE RiSE TO OUR MulTibilliON MARkETplACE! FEATUMNQ: ••••••••••••••••••« • Laser Materials Processing Conference • Laser Microfabrication Conference • Poster Presentation Gallery • Laser Solutions Short Courses • Business Development Session • Networking with Industry Leaders • Laser Industry Vendor Table Top Display & Reception

DowNloAd TIHE AdvANCE PROGRAM JN PDF foRMAT AT WWWJCAIEO.ORG • REGISTER TodAy!

Circle No. 22 on Reader Info-Card

JULY 2005 Assn. for Manufacturing Excellence National Conference. Oct. 31-Nov. 4,Westin Copley Place Hotel, Boston, Mass. Cost is $2120, $1995 for AME members. Contact AME (847) 520-3282. TRIANGLE ext. 226; www.ame.org. T

Interkama Asia. Nov. 28-Dec. 1, Shanghai, China. Sponsored by Deutsche Messe AG. Contact www.interkama-asia.com.

2005 World Steel Bridge Symposium and Workshops. Nov. 29-Dec. 2, Orlando, Fla. Sponsored by National Steel Bridge Al­ liance and Federal Highway Administration. Contact www.ns- Test Weld Test baweb.org. Plates Pipe Coupons

FabForm 2005. Dec. 6-8, Exhibition Center, Nuremberg, Ger­ West Hanover, MA 02339 many. Encompasses key sectors of sheet metal forming and fab­ (781)878-1500 • (781)878-1374 • Fax(781)878-2547 ricating technologies. Contact www.fabform.de. www.trieng.com Circle No. 30 on Reader Info-Card weld Xf .the industry standard..

ME IX AWSD1.1 PQR '287/2^

• [Kf . ^m m HHl^k. ^Ml^k.

HEAVY D UTY TUNGSTEN GRINDER Industry standard QA/QC software for FOR 3/16" - .040" automatic creation and management of SiiFETY: Unclosed diamond wheel grinding area Welding Procedures and Welder Qualifications WELD QUALITV: 20 Ra finish improves tungsten life, starting & arc stability PRODUCTIVITY: Longitudinal diamond grind your tungsten under 30 seconds www. weld .com VALUE: Diamond flat, grind & cut your tungsten economically DIAMOND GROUND PRODUCTS ' Have your documents finished in minutes 2550 Azurite Circle, Newburv Park, California 91320 Phone (805) 498-3837 • FAX (805) 498-9347 Call (888) 673-9777 today! Email: [email protected] • Website: www.diamondground.com Circle No. 16 on Reader Info-Card Circle No. 17 on Reader Info-Card

WELDING dOURNAL AWS 2005 Schedule Denver, Colo. Oct. 2-7 Oct. 8 CWI/CWE Prep Courses and Exams (API 1104 Clinic also offered) Detroit, Mich. Sept. 25-30 Oct. 1 Exam applications must be submitted six weeks before the exam (API 1104 Clinic also offered) date. For exam information and an application, contact the AWS Houston, Tex. Aug. 14-19 Aug. 20 Certification Dept., (800) 443-9353, ext. 273. For exam prep (API 1104 Clinic also offered) course information, contact the AWS Education Dept., (800) 443- Long Beach, Calif. Nov. 6-11 Nov. 12 9353, ext. 229. (API 1104 Clinic also offered) Louisville, Ky. Nov. 13-18 Nov. 19 City Exam Prep CWI/CWE (API 1104 Clinic also offered) Course Exam Memphis, Tenn. Aug. 7-12 Aug. 13 (API 1104 Clinic also offered) Albuquerque, N.Mex. July 31-Aug. 5 Aug. 6 Miami, Fla. EXAM ONLY Aug. 18 (API 1104 Clinic also offered) Miami, Fla. EXAM ONLY Sept. 15 Miami, Fla. EXAM ONLY Oct. 20 Anchorage, Alaska EXAM ONLY Sept. 24 Miami, Fla. Dec. 4-9 Dec. 10 Atlanta, Ga. Oct. 23-28 Oct. 29 (API 1104 Clinic also offered) (API 1104 Clinic also offered) Milwaukee, Wis. Baltimore, Md. Oct. 30-Nov. 4 Nov. 5 Sept. 25-30 Oct. (API 1104 Clinic also offered) (API 1104 Clinic also offered) Minneapolis, Minn. Sept. 18-23 Beaumont, Tex. Nov. 6-11 Nov. 12 Sept. 24 (API 1104 Clinic (API 1104 Clinic also offered) dso offered) Sept. 11-16 Sept. 17 Charlotte, N.C. Aug. 21-26 Aug. 27 New Orleans, La. (API 1104 Clinic also offered) (API 1104 Clinic also offered) Chicago, 111. Oct. 23-28 Oct. 29 Orlando. Fla. Dec. 5-10 No Test 9-Year Recertification Course (API 1104 Clinic also offered) Phoenix, Ariz. Oct. 2-7 Oct. 8 Columbus, Ohio Aug. 8-12 Aug. 13 (API 1104 Clinic also offered) (MBBPVI) Pittsburgh, Pa. Oct. 16-21 Oct. 22 Columbus, Ohio Dec. 5-9 Dec. 10 " (API 1104 Clinic also offered) (MBBPVI) Portland, Ore. Nov. 6-11 Nov. 12 Corpus Christi, Tex. EXAM ONLY Dec. 17 (API 1104 Clinic also offered) Dallas, Tex. Sept. 25-30 Oct. 1 Reno. Nev. Oct. 30-Nov. 4 Nov. 5 Dallas, Tex. Nov. 14-19 No Test (API 1104 Clinic also offered) 9-Year Recertification Course Rochester, N.Y. EXAM ONLY Aug. 20 St. Louis, Mo. EXAM ONLY Dec. 3 Salt Lake City, Utah Aug. 7-12 Aug. 13 (API 1104 Clinic also offered) Has the lack of a CWI become San Antonio, Tex. Oct. 16-21 Oct. 22 (API 1104 Clinic also offered) San Diego, Calif. Aug. 22-27 No Test an obstacle to your success? 9-Year Recertification Course The Hobart Institute of Welding Technology can provide the San Diego, Calif. Sept. 18-23 Sept. 24 professional training you need to pass the Certified Welding (API 1ID4 Clinic also offered) Inspector and Educator exams. While m; San Juan, P.R. Dec. 4-9 Dec. 10 nearly all of our students pass with x *> (API 1104 Clinic also offered) flying colors, those who don't the Seattle, Wash. Sept. 18-23 Sept. 24 first time can return within six (API 1104 Clinic also offered) Sioux Falls, S.Dak. Nov. 13-18 Nov. 19 months free of charge.* (API 1104 Clinic also offered) We're that confident! Syracuse, N.Y. Sept. 11-16 Sept. 17 (API 1104 Clinic also offered) Visual Inspection [OBART INSTITUTE Tulsa. Okla. Oct. 16-21 Oct. 22 Sep. 13-15 'Nov. 8-10 loFWILDINC TEC11NOLOGY £f (API 1104 Clinic also offered) 1930 - 2(K)5 York, Pa. July 31-Aug. 5 Aug. 6 Arc Welding Inspection & Quality Control (API 1104 Clinic also offered) Sep. 26-30 • Nov. 14-18

Prep for AWS Welding Inspector/Educator Exam Jul. 25-Aug. 5 • Oct 10-21 • Dec 5-16 INTERNATIONAL COURSES The Mexico training and testing location is DALUS, S.A. de These and other comprehensive Technical Training C.V, Monterrey, N.L. Contact: Lorena Garza at [email protected]. DALUS is an AWS-accredited training and courses are offered throughout the year- testing facility. It employs the S.E.N.S.E. (Schools Excelling Through Skill Standards Education) programs. Call Today! 1-800-332-9448 Monterrey, Mex. July 11-15 July 16 or visit us at www.welding.orgfor more information. *Some Monterrey, Mex. Nov. 7-11 Nov. 12 restrictions apply; please contact us for details. C 2005 Hobart Institute of Welding Technology, Troy, OH, St. of Ohio Reg. No. 70-12-0064HT

Circle No. 21 on Reader Info-Card • JULY 2005 •

BY HOWARD Af. WOODWARD Welding Industry's High Achievers Celebrated at Dallas Show COMFORT A. ADAMS currently the director of welding and ap­ joint-tracking tech­ LECTURE AWARD plied sensing/control research program niques. His research Fukuhisa Matsuda in the Center for Manufacturing, and has been docu­ ukuhisa Matsuda received his an associate professor and the director mented in 90 papers Ph.D. in 1965 from Osaka Uni­ of graduate studies in the department and peer-reviewed Fversity. In 1967, he joined the uni­ of Electrical and Computer Engineer­ journals. Zhang has versity's faculty as an associate profes­ ing. Zhang's research interest lies in sen­ been an AWS mem­ sor in the Welding Engineering Depart­ sors, control systems, and arc welding ber since 1992. He is ment and the Japan Welding Research processes. He holds five U.S. patents for a senior member of Institute (JWRI). In 1976, he was pro­ his double-sided arc welding, metal IEEE and SME. and moted to professor. He served the uni­ transfer control, three-dimensional a member of ASME. YuMing Zhang versity and JWRI as a professor until weld pool surface measurement, and — continued on page 52 his retirement in 1996. He currently holds the title Professor Emeritus. From 1959 to 1967, he was with National Re­ search Institute for Metals (NRIM). His AWS Standards Writers on the Job research subjects included electron beam welding, welding of nonferrous metals, and solidification and hot crack­ ing. From 1965 to 1966, he was a re­ search fellow under Prof. Warren F. Sav­ age at Rensselaer Polytechnic Institute. As a professor at Osaka University and JWRI, his research included electron- and laser-beam weldability, weldability of aluminum alloys and refractory met­ als, toughness of the heat-affected zones of high-strength and pressure-vessel steels, and the SCC properties of steels in nuclear power plants. From 1996 to 2001, as general director, Tarasaki R&D Center, Japan Power Engineering and Inspector Corporation (JAPEIC), he The D8 Committee on Automotive Welding held its spring meeting April 12 in Romulus, conducted national welding technology Mich. Shown are (fivm left) Secretary Harold Ellison, Chair lohn Bohr, Bill Quails, Bill research projects for nuclear power Brafford, Jim Dolfi, Jim Osborne, Dave Kelly, Bernie Bastian, Glen Armstrong, Ted plants. Matsuda has authored more Coon, and Mtirall Tuniuluru. than 400 technical papers. On two oc­ casions he received the Excellent Paper Prize from the Japan Welding Society. He received the J. Chabelka Medal from Slovakia WRI, Honorable D.Sc. from the University of Kosice, Slovakia, was named Honorable Professor by Tianjin University, China, among other institute and Japanese-government recognitions.

ADAMS MEMORIAL MEMBERSHIP AWARD YuMing Zhang YuMing Zhang received his Ph.D. degree in mechanical engineering/weld­ Fhe A2 Committeee on Definitions and Symbols held its May meeting in Miami, Fla. ing from Harbin Institute of Technol­ Shown at AWS Headquarters are (from left) J. P. Christein, Dick Holdren, Jeiry Wairen, ogy, China. Since 1991, he has been with David Beneteau, Larry Barley, Pat Newhouse, Peter Howe, Lou Siy, Rich McGuire, the University of Kentucky, where he is Secretary Cynthia Jenney, and Chuck Ford.

WELDING JOURNAL on the local commu­ ROBERT J. CONKLING nity and education MEMORIAL AWARD overall. The commu­ This award is named in memory of nity projects with Robert J. Conkling. He encouraged civic and business young people to enter the welding in­ leaders have estab­ dustiy and contributed generously of his lished the Center's time and talents to the development of presence in its service the AWS Welding Show and Conven­ areas. Kee is a mem­ tion. This award is sponsored by the the ber of the State of American Welding Society, and pre­ Kee Sullivan Brace Tennessee Technol­ sented to the schools that trained the ogy Center Welding two first-place winners in the National — continued from page 51 Curriculum Committee, Carroll County SkillsUSA Welding Competition. Zhang received the Donald Julius Technical Center Advisory Committee, 2004 SkillsUSA Championships Groen Prize from the Institute of Me­ SkillsUSA/AWS Tennessee Welding Gold Medalists Schools chanical Engineers, U.K., the A. F. Contest Committee, and is a SkillsUSA First Place — High School Davis Silver Medal Award from AWS, Professional Member. Since 2003, he Flatrock HighSchool and the 15th IFAC Triennial World Con­ has served as a vice chair for the AWS Flatrock, Mich. gress Best Poster Paper prize from the West Tennessee Section, and has re­ First Place — Postsecondary International Federation of Automatic ceived recognition from the Section and Southeast Community College-Milford Control. He holds the James R. Boyd District 8 for his outstanding contribu­ Milford, Neb. Professorship in Electrical Engineering tions to education. at the University of Kentucky. A. F. DAVIS SILVER MEDAL AWARD James H. Sullivan Maintenance & Surfacing HOWARD E. ADKINS James Sullivan began his welding ca­ "Maintenance Welding on the MEMORIAL INSTRUCTOR reer with the Santa Rosa County School Trans-Alaska Pipeline" MEMBERSHIP AWARD District in 1995 as the welding program William A. Bruce Jimmy Kee instructor for Locklin Technical Center, William A. Bruce is lead engineer in Jimmy Kee teaches at Tennessee Milton, Fla. Prior to his joining the the Materials Section at Edison Weld­ Technology Center (TTC) at McKenzie, technical center, he attended Faulkner ing Institute (EWI) in Columbus, Ohio. Tenn. He began his welding career after State College, an Alabama Gulf Coast He holds a B.S. degree in welding engi­ graduating from high school, continu­ Community College, where he earned neering, is a Registered Professional ing in the apprenticeship program (boil- his certification in criminal justice. Prior Engineer, and an IIW International ermaker) with the Tennessee Valley Au­ to joining the Locklin Technical Center, Welding Engineer. Before joining EWI thority (TVA). In 1971, he received his its welding program was declining in in 1988, he was a senior engineer at Pan­ Combination Welder diploma for program assistance and class size. handle Eastern Pipeline Co. He has GTAW and SMAW from Vocational Under Sullivan's supervision, and with been involved in pipeline welding re­ Technical School — McKenzie. He con­ various school and community projects, search continuously since his gradua­ tinued his education at Memphis State the welding program has become suc­ tion from The Ohio State University in University. From 1976 to 1996, he was cessful for both high school and adult 1981. During his tenure at EWI, he with TVA/DuPont New Johnsonville, students. He is committed to both pro­ served a four-month assignment at The where he conducted AWS and ASME fessions as an educator and welder. Welding Institute in Cambridge, U.K. welder certifications and oversaw weld­ Sullivan is an active AWS member. Bruce's areas of interest include re­ ing operations. He joined TTC in 1997, He has served the AWS Mobile Section pair welding, inspection techniques, and where he has brought business and in­ as its Student Affairs Coordinator. He failure analysis. He has carried out nu­ dustry support to the Center. Through has been recognized as the District 9 merous projects pertaining to safety and competitions and exhibitions, students Welding Educator in 2000, and Section integrity aspects of repair, and modifi­ and potential employers have had the Welding Educator in 2001 and 2002. cation of in-service pipelines by weld­ opportunity to share ideas and futuris­ Since 1997, he has been involved with ing. He also pioneered the use of lasers tic tools and trades specific to welding. SkillsUSA as an Advisor and Region for mapping corrosion damage on ex­ His activities have had a positive impact Coordinator. posed pipelines. Bruce is an AWS rep-

Nominations Sought for 2006 Prof. Masubuchi Award

ominations are sought for the or younger, and may live anywhere in interests and accomplishments, educa­ 2006 Prof. Koichi Masubuchi the world. The candidate need not be tional background, professional experi­ N Award, sponsored by the Dept. an American Welding Society member. ence, publications, honors, and awards. of Ocean Engineering at Massachusetts The nomination package should be The award was established to recog­ Institute of Technology. prepared by someone familiar with the nize Prof. Masubuchi for his contributions It is presented each year to one per­ research background of the candidate. to the advancement of the science and son who has made significant contribu­ It should include a resume and three to technology of welding, especially marine tions to the advancement of the science five letters of recommendation from re­ and outer space structures. and technology of materials joining searchers familiar with the candidate. December 1, 2005, is the deadline. through research and development. The resume should include a summary Submit your nomination to Prof. John The candidate must be 40 years old statement of the candidate's research DuPont [email protected].*

JULY 2005 Norris and Carlson Announce 2004-05 District Director Awards

Russ Norris, District 1 director, has nominated the following to re­ ceive the District Director Award. Tom Ferri, Boston Glenn Myrick, Boston Beckett Kusko DuPont Warren Ballard, Boston Doug Desrochers, Central Mass./R.I. resentative on the American Petroleum Structure Design Ray Henderson II, Green & White Mts. Institute API 1104 Committee, and "Fhe Influence of Microstructure on Fa­ Geoff Putnam, Green & White Mts. chairs the API Maintenance Welding tigue Crack Propagation Behavior of Tom Cormier, Maine Subcommittee. Bruce is also a member Stainless Steel Welds" Jeff Fields, Maine of the AWS D10 Committee on Piping Chad S. Kusko David Hartley, Maine and Tubing. In 1995, He received from Chad S. Kusko received his M.B.A. Joel Stanley II, Maine AWS the Airco Award for his "...inno­ and Ph.D. in materials science and en­ SkillsUSA welding test team, Maine vation in the application of welding and gineering from Lehigh University in cutting techniques." In 2002, he re­ 2002. His research theses included a Nancy M. Carlson, District 20 di­ ceived a PRCI Distinguished Re­ fundamental investigation of marten­ rector, has nominated the following searcher Award from Pipeline Research site formation adjacent to the weld in­ to receive the District Director Council International. He received the terface of austenitic/ferritic dissimilar Award. W. H. Hobart Memorial Award from metal welds, and fatigue crack propaga­ Pierrette Gorman, Albuquerque AWS in 2004. tion behavior of stainless steel welds. Danny O. MacCallum, Albuquerque He joined Lutron Electronics in 2002, Mike Thomas, Albuquerque Alan S. Beckett where he is a senior operations project John Cantlin, Colorado Alan S. Beckett earned a B.S. degree engineer. Kusko served as a research as­ James Corbin, Colorado in welding engineering from Le­ sistant at Lehigh from 1997 to 2002. In Farren Elwood, Colorado Tourneau University, Longview, Tex. He 1999, he received an AWS Navy Joining Tom Kienbaum, Colorado currently serves as the Welding Program Center Fellowship. He has served as a Denis Clark, Idaho/Montana Steward for the Alyeska Pipeline Ser­ consultant to industry research projects Bob Shook, Idaho/Montana vice Co. In this position, he is responsi­ and has taught metallurgical courses. Bill Komlos, Utah ble for welding and materials used in Russel Rux, Wyoming maintenance and construction on the John N. DuPont 800-mile Trans-Alaska Pipeline (TAPS) John N. DuPont earned Ph.D. in ma­ The District Director Award pro­ that transports crude oil from the North terials science and engineering from vides a means for District Directors Slope of Alaska to the marine terminal Lehigh University. He served as a re­ to recognized individuals who have in Valdez, Alaska, as well as the 148- contributed their time and efforts to mile natural gas transmission pipeline search scientist and associate director of the Energy Liaison Program at the affairs of their local Section that supplies fuel to operate Pump Sta­ and/or District. • tions 1-4. Lehigh University until 1999. He joined — continued on page 54

New Standards and Bundles of Standards Announced

WS D16.4M/D16.4:2005, Specifi­ material and workmanship standards five bundles are detailed and priced on cation for the Qualification of Ro­ for manufacturers, fabricators, repair page 5 of the AWS 2005 Product Cata­ Abotic Arc Welding Personnel, has organizations, purchasers, and owners log. The catalog is viewable and down­ been released and is available for pur­ and operators of rotating equipment loadable at www.aws.org/catalogs. chase from Global Engineering Docu­ fabricated or repaired by welding. In­ For example, Bundle A — AISC ments online at www.global.ihs.com, or cluded are sections defining process Steel Building Structures, includes AWS call (800) 854-7179. qualifications, operator qualifications, Dl.l, Structural Welding Code — Steel, The document contains 20 pages, 2 quality control, inspection require­ AWS A2.4, Standard Symbols for Weld­ annexes, three figures, and four tables. ments, and repair requirements. It has ing, Brazing,and Nondestructive Exami­ Price is $28, $21 for AWS members. 282 pages, 18 tables, and 42 charts and nation, and AWS A3.0, Standard Weld­ The standard is the basis for the AWS figures. Price is $60, $45 for AWS mem­ ing Terms and Definitions. These three Certification of Robotic Arc Welding bers. The specification may be pur­ documents individually cost $624 list/ Personnel (CRAW) program. It pro­ chased from Global Engineering Docu­ $468 for AWS members. Purchased as vides requirements for the qualification ments online at www.global.ihs.com, or Bundle A, the three documents cost of robotic arc welding support person­ call (800) 854-7179. $532 list/$399 for AWS members. nel at three levels: CRAW-LI, CRAW- AWS offers its most popular Struc­ The other four bundles offered in the O, and CRAW-T The revisions align ed­ tural Welding Codes collected in "bun­ catalog are titled: Bundle B — Dl All; ucation and experience requirements dles," in five combinations, at prices sig­ Bundle C — AISC Conventional and more realistically with those in industry. nificantly lower than purchasing the Complex Steel Building Structures; AWS D14.6/D14.6M:2005, Specifica­ documents individually. Plus, AWS Bundle D — AISC Simple and Major tion for Welding of Rotating Elements of members received an additional 25% Steel Bridges; and Bundle E — Struc­ Equipment. This standard establishes discount off the bundle list price. The tural Aluminum. •

WFI niNn .milRWAI Hennessy joined

a AZCO, Inc., Appleton, Wis., in 1992. As inte­ grated quality coordi­ nator, his responsibili­ ties include writing, de­ veloping, and qualify­ ing AWS, ASME, and — continued from page 53 Advisory Board. He has served as a con­ API welding proce­ the Materials Science and Engineering sultant to industry and government re­ dures; welder training Department as assistant professor in search laboratories; and has developed and testing; acquiring 1999, and was promoted to associate and taught industrial short courses in new multiprocess welding and cutting professor in 2002. the areas of welding, failure analysis, equipment; implementing total quality DuPont's research interests cover metallurgy for the nonmetallurgist, and management inspection policies; and processing-microstructure-property re­ heat treating. new welding processes for increasing lations in solidification and joining of production without sacrificing quality. materials, laser engineered net shaping, Arnold R. Marder Prior to joining AZCO, Inc., Hennessy and alloy development. He has pub­ Arnold R. Marder received his Ph.D. worked on power-generation projects lished more than 140 technical articles, in metallurgy and materials science throughout the upper Midwest. He is a edited four books, and has been granted from Lehigh University in 1968. Cur­ journeyman Steamfitter with U.A. one patent. He has organized four in­ rently, he is professor in the Depart­ Local #597, Chicago, 111., for more than ternational conferences. He is currently ment of Materials Science and Engi­ 27 years. He is a project planner and the principal or coprincipal investigator neering, and associate director of the procedure writer of construction codes on nine research programs that support Energy Research Center at Lehigh Uni­ and standards, including AWS, ASME, a research group including two postdoc­ versity. Earlier, he worked for the Cur­ and API. Hennessy is also approved by toral students, two Ph.D. students, and tiss-Wright Corp., and was employed by the state of Wisconsin to administer six M.S. students. the Homer Research Laboratories of structural welding procedures and DuPont was an ASM scholar in 1990, the Bethlehem Steel Corp. for more welder performances tests, and than 20 years. Marder's present re­ and received an AWS National Fellow­ presently sits on the board of directors search interests include processing- ship Award in 1995. He received the of the Wisconsin Chapter of the Na­ structure-property relationships of ma­ AWS Charles H. Jennings Memorial tional Certified Welding Bureau. terials, including coatings and alloys for WILLIAM H. HOBART Award in 1996 and 2000, and the AWS ambient and high-temperature environ­ MEMORIAL AWARD William Spraragen Memorial Award in ments regarding erosion, oxidation, and "Microstructure-Property 1999 and 2000. He received the A.F. sulfidation. He also works on the physi­ Relationships in HAZ of New Davis Silver Medal Award from AWS in cal metallurgy of steel for weld overlay 13%Cr Martensitic Stainless Steels" 2001, 2002, and 2004, and the Warren F. coating of superalloys and iron alum- Odd M. Akselsen Savage Memorial Award in 2004. In nide intermetallics, as well as weldabil­ Since 1981, Odd M. Akselsen has 1999, he was awarded the AWS Prof. ity studies of Cr-Mo steels. been with SINTEF, working with mate­ Koichi Masubuchi Award. In 2000, he rials subjected to welding and joining. Marder has published more than 200 received a Young Investigator Award He received his Ph.D. in physical met­ technical papers, edited three books, from the Office of Naval Research for allurgy in welding in 1988. He was ap­ and has been granted 20 U.S. and for­ work on laser beam welding and surface pointed group leader of the welding eign patents. Among his honors, he won treatment of superaustenitic stainless metallurgy research group in 1985, and first-place in an AWS Professional steels in advanced double-hull combat­ was named research manager in 1994. Poster Competition. In 1996, he re­ ant ships, and a CAREER award from From 1999 to 2004, he served as re­ ceived the Charles H. Jennings Memo­ the National Science Foundation for re­ search manager for the Department of rial Award, and in 1998 the William search on Laser Engineered Net Shap­ Corrosion and Joining. Today, he is a Spraragen Memorial Award. He re­ ing. In 2000, DuPont received the Na­ senior scientist working with welding ceived the A. F. Davis Silver Medal tional Science Foundation Presidential and weldability of low-alloy and stain­ Award in Structure Design in 2001 and Early Career Award for Scientists and less steels. During the past ten years, he 2002. In 1990, he was elected a Fellow Engineers (PECASE) from President has been involved in the qualification of of ASM International, Lehigh Valley Clinton. In 2002, he received the AWS supermartensitic 13%Cr stainless steels Chapter. Adams Memorial Membership Award, for subsea pipelines. He is also involved and in 2003 was awarded the Lehigh in joining of specialty materials such as University College of Engineering DALTON E. HAMILTON MEMORIAL shape memory alloys and intermetallics, Teaching Excellence Award. DuPont is CWI OF THE YEAR AWARD and metal coatings to improve wear re­ currently a Principal Peer Reviewer for James P. Hennessy sistance. Akselsen has authored more the Welding Journal and is a reviewer for James P. Hennessy has been a weld­ than 170 publications, including articles the Journal of Materials Engineering and ing consultant and quality control field in international journals, international Performance. He is on the AWS Re­ inspection specialist with more than 33 conference proceedings, and technical search and Development Committee, years of industrial equipment and heavy reports. In 1993, he won the AWS Ar­ Welding Handbook Committee, Con­ steel construction experience. This in­ sham Amirikian Memorial Maritime ference Committee, Technical Papers cludes plant maintenance work in the Welding Award. Committee, and the Edison Welding In­ paper, petrochemical, and commercial Gisle Rorvik stitute Navy Joining Center Technical electric power industries. In 1984, Gisle R0rvik received his B.Sc. in metallurgy and materials tech- JULY 2005 with steel weldability, the Comfort A. Adams Lecture Award. inclusion engineering During the 2004 ASM International in steels, joining of in­ Conference on Joining of Advanced and termetallics, powder Specialty Materials, he was honored metallurgy, and shape with a special session in his name. He is memory alloys. He a Fellow of both ASM International and has published more the American Welding Society. than 30 conference and journal papers. INTERNATIONAL MERITORIOUS Pekkari CERTIFICATE AWARD DeFreitas Edwards HONORARY Bertil Pekkari nology. R0rvik worked as an engineer MEMBERSHIP AWARD Bertil Pekkari holds a M.Sc. degree and research scientist in SINTEF Ma­ Louis DeFreitas and a university degree in economics. terials Technology — Steel and Weld­ Louis DeFreitas received his M.A. He started his professional career in ing Group for 14 years. Since 1998, he degree in education administration 1964 as a development engineer for has been with the Norwegian Oil Com­ from San Francisco State University. electrical drives and battery chargers at pany Statoil ASA as a staff engineer and, He received his teacher training from ESAB in Laxa, Sweden. Later, he was most recently, as an advisor in metallic the University of California at Berke­ involved in the development of welding materials. His main fields of expertise ley, and holds a Standard Designated equipment when ESAB sold off its in­ include structural and stainless steels, Subjects Teaching Credential in weld­ dustrial equipment business. Since then, physical and welding metallurgy, metal­ ing, and a Community College Supervi­ he has worked in many positions at lography, fractography, and failure sor's Credential from the state of Cali­ ESAB, including research and develop­ analysis. He has authored or coauthored fornia. He has been in the welding in­ ment manager, production manager, more than 50 international scientific dustry for more than 50 years, working plant manager, and business area direc­ publications. In 1993, he received the as a welding engineer in the military, job tor for Welding and Cutting Automa­ AWS Arsham Amirikian Memorial shops, and the aircraft and electronics tion. He was the group vice president Maritime Welding Award. In 1997, he industries. DeFreitas has served more and technical director for 17 years, hav­ won a first-prize award for Artistic Mi­ than 30 years as a professor and chair ing responsibility for research and de­ croscopy — Color Only Class, in the In­ of the Welding Technology Department velopment, and quality and environ­ ternational Metallographic Contest pre­ at the College of San Mateo in Califor­ mental affairs. He was instrumental in sented by The International Metallo­ nia. For the past nine years, he has been introducing new technologies and busi­ graphic Society and ASM International. the director of the Arc Gas Training In­ nesses such as welding robotics, invert­ stitute in San Jose, Calif. DeFreitas is a ers, friction stir welding, laser process­ Per Egil Kvaale member of the American Welding So­ ing, knowledge-based systems, and Per Egil Kvaale studied physical met­ ciety, and served as chairman of the working environment strategies. He re­ allurgy at the Norwegian University of Santa Clara Valley Section 1994-1995. tired in 2004 after 40 years of service. Science and Technology, Trondheim, Presently he runs his own consulting Norway. Following graduation in 1974, Glen R. Edwards company BePe Konsult. He serves as he worked at the Norwegian Steel Mill's Glen R. Edwards holds a Ph.D. in chairman of the Swedish Welding Com­ laboratory until 1980. From 1980 to 1985 materials science and engineering from mission, chairman of the Swedish Weld­ he worked at SINTEF, researching Stanford University. Early in his career, ing Research Council, nonexecutive di­ welding of steels for offshore construc­ he worked for ACF Industries and Los rector at The Welding Institute, and as tion. In 1985, Kvalle joined the Norwe­ Alamos National Laboratory, then president ofthe International Institute gian Oil Co. Statoil ASA where he has served with the Naval Postgraduate of Welding. Pekkari is also an elected held various positions, including head School in Monterey, Calif. He joined member of the Royal Swedish Academy of the material department and chief the faculty of Colorado School of Mines of Engineering Sciences. engineer. Today, he is a special advisor (CSM) in 1976. Edwards served as pro­ for materials technology. His main ac­ fessor of metallurgical and materials en­ Shinsuke Tsutsumi tivities at Statoil have been the qualifi­ gineering for CSM until 2003. From Shinsuke Tsutsumi is a senior re­ cation of pipeline materials and weld­ 1984 to 2003, he was director of the searcher in the standards department at ing. He is a pioneer in the field of su­ CSM Center for Welding, Joining, and the Japanese Standards Assn. in Tokyo. permartensitic 13%Cr stainless steels. Coatings Research. He has advised He received his master's degree in met­ more than 50 students, and contribut­ allurgical engineering from Yokohama Casper van der Eijk ing more than 200 papers to the techni­ National University in 1975. That year Casper van der Eijk received his M.S. cal literature. In 2003, CSM awarded he joined Kobe Steel, Ltd., where he in materials science and technology him its honorary designation, Univer­ worked as a research engineer in the from Delft University of Technology in sity Emeritus Professor, for his distin­ Welding division. He served as manager the Netherlands in 1994. His thesis con­ guished service to the institution. Ed­ in the QA section for welding consum­ cerned the production of intermetallic wards has served on numerous national ables from 1991 to 2001. He has been a alloys using powder metallurgy technol­ committees of professional societies and member of the IIW Subcommission II- ogy. After completing his military serv­ has been a key reviewer for major re­ E and ISO/TC44/SC3. He proposed at ice in 1995, he emigrated to Norway. In search journals. He currently serves as an ISO meeting a "cohabitation idea" 1999, he completed his Ph.D. in physi­ U.S. Delegate for Commission IX ofthe for two systems to "live together" for cal metallurgy at the Norwegian Uni­ International Institute of Welding. The ISO welding consumables. In 1999, ISO versity of Science and Technology. His American Welding Society has awarded accepted his idea and has prepared the dissertation was the weldability of Ti- him the Warren F. Savage Memorial cohabitation drafts of ISO standards for deoxidized steels. He has been em­ Award, R. D. Thomas Memorial Award, welding consumables. Tsutsumi served ployed as a research scientist at SINTEF Adams Memorial Membership Award, as chair of the Subcommittee on ISO in Norway since 1999. He is working William Irrgang Memorial Award, and Standardization, Technical Committee,

WELDING JOURNAL John C. Lippold John Lippold received his Ph.D. de­ gree in materials engineering from Rensselaer Polytechnic Institute. He worked for seven years on the technical staff at Sandia National Laboratories, specializing in weldability of stainless steels and high alloys. From 1985 to 1995, Lippold was employed by Edison Welding Institute where he served as Kvidahl Ramirez Lippold materials department leader and man­ ager of research. In 1995, he joined the Welding Consumables Div., the Japan Matthew G. Collins faculty of the welding engineering pro­ Welding Engineering Society, 1998- Matthew Collins is a staff mechani­ gram at The Ohio State University. In 2004. This Subcommittee has prepared cal/welding engineer for Conoco 2004, he began a one-year term as In­ many cohabitation drafts of ISO stan­ Phillips Alaska, Inc., with 14 years of ex­ terim Chair of Industrial, Welding, and dards for welding consumables for arc perience in the oil and gas industry. Systems Engineering at the university. welding of steels. In 2003, Tsutsumi was Much of his work experience has been Over the past 25 years, Lippold has been awarded the IIW Thomas Medal for on the North Slope of Alaska working involved in research of welding metal­ contributions to the IIW/ISO interna­ at the Prudhoe Bay, Kuparuk, and lurgy and properties of engineering ma­ tional standards activities. He received Alpine oil field assets as a facility engi­ terials. His research has involved both the 2004 FY Award for the promotion neer, corrosion engineer, and a me­ fundamental and applied topics with a of industrial standardization from the chanical/piping/welding engineer. He high degree of industrial relevance. Lip­ Ministry of Economy, Trade, and Indus­ is the ConocoPhillips Alaska, Inc., tech­ pold has published more than 150 tech­ try of Japan. nical authority for piping, valves, weld­ nical papers and reports, and delivered ing, hot-tapping, and in-service welding more than 300 technical presentations. WILLIAM IRRGANG standards and specifications. Collins He is recognized internationally in the MEMORIAL AWARD earned a M.S. degree in welding engi­ field of stainless steel and high-alloy Lee G. Kvidahl neering, with a major in welding metal­ welding metallurgy, and weldability Lee Kvidahl, an AWS past president lurgy, from The Ohio State University, testing. Lippold has earned several (1993-1994), is a graduate of Stevens working under the advisement of Dr. AWS-sponsored awards including the Institute of Technology. He is the sec­ John C. Lippold. His graduate thesis is Charles H. Jennings Memorial Award tor manager of welding engineering for titled An Investigation of Ductility-Dip (1977, 1980), William Spraragen Northrop Grumman Ship Systems, re­ Cracking in Nickel-Based Filler Materi­ Memorial Award (1979, 1992), Warren sponsible for all welding engineering ac­ als. He is a registered Professional Me­ F. Savage Memorial Award (1993, tivities at the Pascagoula and Gulfport, chanical Engineer in the states of Alaska 1999), McKay-Helm Award (1994), Lin­ Miss., and the New Orleans and Tallu- and Ohio. He also is a licensed me­ coln Gold Medal (1983), A. F. Davis Sil­ lah, La., sites. He has served as the AWS chanical administrator in the state of ver Medal (2000), Irrgang Award Pascagoula Section chair, and District Alaska. Currently, he holds a National (2002), and Plummer Memorial Educa­ 9 director. He has chaired several AWS Board Owner/User Inspector Certifica­ tional Lecture Award (2002). He has standing committees, including Execu­ tion, and API-510, API-570, and API- received the Buehler Technical Paper tive, Compensation, National Nominat­ 653 Certifications. Further, he holds Merit Award (1985, 1989) from the In­ ing, Honorary-Meritorious Awards, and certifications as an AWS CWE, CWI, ternational Metallographic Society. In Role and Missions. He has served on the and an IIW Welding Engineer diploma. 1997, he presented the Comfort A. AWS Technical Activities, Technical Pa­ He is a member of AWS, ASME, and Adams Memorial Lecture at the AWS pers, and Counselors Committees. ASM International. Collins has pub­ Annual Convention in Los Angeles. In Presently, he chairs the AWS Member­ lished five technical papers on ductility 1994, Lippold was elected a Fellow of ship Committee, and is a member of the dip cracking in nickel-based filler met­ ASM International, and in 1996 was in­ D3 Committee on Welding in Marine als and will soon publish two papers on ducted as a Fellow of the American Construction, and the A5 Committee root pass welding of duplex stainless Welding Society. on Filler Metals and Allied Materials. steel pipeline girth welds using the SMA Kvidahl served as vice chair of the AWS process without the use of backing gas. MCKAY-HELM AWARD Foundation 1992-2004. He chairs the "Yttrium Hydrogen Trapping to National Shipbuilding Research Pro­ Antonio Jose Ramirez Manage Hydrogen in HSLA gram Welding Technology Panel. He Antonio Jose Ramirez received his Steel Welds" also is the chair of the Navy Joining Cen­ Chad A. Lensing ter Steering Committee and is a mem­ Ph.D. degree in materials science from Chad A. Lensing received his Ph.D. ber of its Technical Advisory Board. He the University of Sao Paulo, Brazil, and in metallurgy and metallurgical engi­ is a member of the American Bureau of a mechanical engineering degree from neering from the Colorado School of Shipping Special Committee on Mate­ the National University of Colombia, in rials and Welding, and is a member of materials characterization and electron Mines in 2001. Following graduation, ASM International and SNAME. microscopy. He was a research associ­ he joined BP America. Currently he is ate at The Ohio State University. Cur­ with its Integrity Management Team in rently, he is manager and a researcher Houston, Tex., as a specialist in corro­ CHARLES H. JENNINGS in the industrial research program at the sion, materials, and welding. Previously, MEMORIAL AWARD Brazilian Synchrotron Light Labora­ he served as a member of the Offshore "An Investigation of Ductility-Dip tory, Sao Paulo. He is an Invited Pro­ Systems Team, and a member of the Cracking in Nickel-based Weld Metals fessor at University of Campinas and Topsides Construction division. — Part III" University of Sao Paulo.

JULY 2005 ^y

Lensing Park Maroef Olson Kozeschnik Grubbs

Yeong-Do Park since 1972. He served as director of the for Global Divers and Contractors, Inc., Yeong-Do Park received his Ph.D. in Center for Welding (1981-1985), and Sulphur, La., from 1984 to 1999. From metallurgical and materials engineering dean of research and vice president of 1979 to 1984, he was president and from the Colorado School of Mines research and development (1986-1989). owner of D&W Underwater Welding (CSM) in 2003. Yeong-Do is currently He is a LANL University Affiliate. He Service, Inc., Baton Rouge, La., and senior research engineer, Materials Re­ has published numerous papers, holds held managerial positions in various ma­ search Team in the Advanced Technol­ several patents, and has authored, coau­ rine and underwater operations at ogy Center of Hyundai Motor Co. in thored, or edited numerous books. He Chicago Bridge and Iron from 1955 to Korea. From 2003 to 2005, he served on has advised 34 Ph.D., and 62 M.Sc, stu­ 1979. the CSM research faculty and as a guest dents. Olson is a Fellow of AWS and Grubbs chaired the Chapter Com­ researcher at National Institute of Stan­ ASM International. He is a Foreign mittee on Underwater Welding and Cut­ dards and Technology. While earning Member of the National Academy of ting for the AWS Welding Handbook, 8th his advanced degrees, he was a CSM Science of Ukraine. He has received edition, vol. 3; served on the D3 Com­ graduate research assistant. His work AWS technical paper awards, ANSI mittee on Welding in Marine Construc­ focused on the management of hydro­ paper awards, the ASM Bradley tion, founded and chaired the D3B gen in high-strength steel welds, and Stoughton Award (1976), 1999 TTCP Committee on Welding in Marine Con­ measurement of diffusible hydrogen Achievement Award (DOD), and the struction; founded and chaired the D3B content using the Seebeck effect, and 2001 Arata Medal (IIW). He is an in­ Subcommittee on Underwater Welding electronic measurements for evaluating ternational lecturer and has been an and Cutting; served on the executive metallurgical and microstructural phase American Council Delegate to IIW. committee on Safety and Health; was a stability. He has received the Korea member of the American Council of the Maritime University's Excellent Grade PROF. KOICHI MASUBUCHI IIW; and was technical representative Scholarships, 1990-1996, and the AWS AWARD for the AWS District 9 Acadiana Sec­ William Spraragen Memorial Award in Ernst Kozeschnik tion. Grubbs was a member of the IIW 2003. Ernst Kozeschnik studied physics at Commission VIII on Hygiene and the Graz University of Technology, Aus­ Safety; the Select Committee on Under­ Iman Soerjadrama Maroef tria, and received his Doctor of Techni­ water Welding; and Commission II, Arc Iman Soerjadrama Maroef joined cal Sciences degree in 1997. Under an Welding. He chaired Work Group D, the Welding Cluster at the Netherlands Erwin Schrodinger fellowship, he car­ Commission VIII, Safety in Underwa­ Institute of Metals Research (NIMR) ried out a one-year research project at ter Welding and Cutting, and was a del­ in 2003. His research involves metallur­ Oak Ridge National Laboratory. From egate in the American Council to the gical studies for metals joined with arc 1999 to 2000, he was a research assis­ Select Commission on Underwater welding, with primary focus on the weld­ tant at the Institute for Materials Sci­ Welding. For the U.S. National Re­ ing of dissimilar metals. Maroef re­ ence, Welding and Forming (IWS) at search Council, he was a member of the ceived his Ph.D. in metallurgical and Graz University of Technology, Austria. Materials Advisory Group of the Com­ materials engineering from the Col­ From 2000 to 2004, he was the opera­ mittee on Marine Structures, Technical orado School of Mines (CSM). Prior to tive project leader at the Materials Cen­ Advisory Committee to the Ship Struc­ joining the NIMR, he continued his in­ ter Leoben (MCL) in Austria. He has ture Committee on Project SR-1283, volvement at CSM in various aspects of been an assistant professor at IWS, and Performance of Underwater Weld­ metallurgy, including welding, steel pro­ since 2004 has served as a key researcher ments, and served on the Panel on Un­ cessing, electrochemistry, and failure at MCL. Kozeschnik has more than 40 dersea Facilities. He was a consultant analysis. publications on weld phenomena sub­ for the Marine Board Panels on Under­ jects, is a key reader for Metallurgical water Electrical Safe Practices, and David L. Olson and Materials Transactions, has organ­ Certification of Offshore Structures. David L. Olson is the John Henry ized international conferences on nu­ Mr. Grubbs was a consultant for the Moore Distinguished Professor of Phys­ merical analysis of weldability, is a coau­ U.S. Department of the Interior, Min­ ical Metallurgy, and a professor of met­ thor of the book, Mathematical Model­ eral Management Service, Technology allurgical engineering, at the Colorado ing of Weld Phenomena 7, and has given Assessment and Research Branch. He School of Mines (CSM). He is a licensed numerous talks addressing thermody­ chaired the Executive Committee for Professional Engineer in the state of namics and superalloys. the Joint Industry Underwater Welding Colorado. He received a Ph.D. in ma­ Development Program. He authored terials science from Cornell University SAMUEL WYLIE MILLER more than 40 technical papers on un­ in 1970. He did postdoctoral studies at MEMORIAL MEDAL AWARD derwater welding, including 15 interna­ The Ohio State University (1970-72), Conway E. "Whitey" Grubbs tional presentations. He is listed in with sabbatical studies taken at Norwe­ (Posthumous recognition) Who's Who in Science and Engineering gian Institute of Technology (1979). Conway E. "Whitey" Grubbs served (1998 and 2002) for his contributions to Olson has been a CSM faculty member as director of underwater welding R&D the science of underwater welding.

WELDING JOURNAL aluminum structure welding. Levert was also chairman of the VICA Chapter at Max Hayes Vocational High School in Cleveland, Ohio.

PRIVATE SECTOR INSTRUCTOR MEMBERSHIP AWARD Jay J. Jones Jay Jones received his associate de­ gree in applied arts and science for weld­ Castner Levert Jones ing technology from Eastfield College, Mesquite, Tex., and his state teaching Grubbs received two AWS Meritorious James R. "Rusty" Franklin certificate and B.S. degree in Education Certificate Awards for his outstanding Rusty Franklin has served the weld­ from Texas A&M University. Since achievements in the science of welding ing industry for almost 30 years. He has 2001, Jones has been with Thermadyne in 1987, and the other for serving as a B.S. degree in accounting from Cen­ Industries, Inc. Currently, he is senior founder and chair (1975-1988) of the tral State University, Edmond, Okla. trainer for Thermadyne Victor Equip­ D3B Subcommittee on Underwater He is currently vice president of Sell­ ment Co. Prior to joining Thermadyne, Welding. He was granted three U.S. strom Mfg. Co., a manufacturer of he was an adjunct welding instructor for patents. Grubbs patented a method for welding helmets and other personal pro­ 18 years for the Dallas County Commu­ underwater welding using pressurized tective equipment. He was formerly ex­ nity College District; a welding shop welding electrode transfer capsule and ecutive vice president and coowner of foreman with Smith's Welding Works, dry welding electrode in situ storage; an­ Sooner Supplies, Inc., a large independ­ Garland, Tex.; a welding technician with other patent covered a viewing scope for ent welding supply distributor in Okla­ Texas Instruments; and a full-time high turbid environments and use in under­ homa. Franklin has been active in AWS school welding instructor for five years water welding; and the third patent con­ for many years. He has served on its in the Garland Independent School Dis­ cerned a unique method of underwater board of directors for two three-year trict. At Thermadyne, he is involved with welding using a viewing scope. terms, was a member of the Executive oxyfuel processes, developing programs Committee for three years, a member and audits for end users, and demon­ NATIONAL MERITORIOUS AWARD of the Roles and Missions for three strating welding applications to assist Harvey R. Castner years, vice chair of the Manufacturers end users with production. He also de­ Harvey R. Castner received his Committee, first chair of WEMCO, and velops and presents product training to M.B.A. from Kent State University. He a member of WEMCO's Executive manufacturers' and distributors' sales has more than 30 years of experience in Committee for six years, a member of personnel. Other subjects he teaches in­ the welding field with extensive experi­ various AWS councils and committees clude arc welding, plasma cutting, arc ence in manufacturing, problem solv­ and served on several AWS Presidential gouging, and slice torch techniques. ing, and engineering management. In Task Groups. Jones has authored instructor guides for 1994, Castner joined, and currently di­ oxyfuel welding and cutting, shielded rects, the Government Programs Office PLUMMER MEMORIAL metal arc welding, gas metal arc weld­ at Edison Welding Institute (EWI), in­ EDUCATION LECTURE AWARD ing, gas tungsten arc welding, and flux cluding the Navy Joining Center (NJC). Ernest D. Levert, Sr. cored arc welding. He was a technical He is responsible for overall direction Ernest Levert received his degree in contributor to the oxyfuel portion of and management of welding-related welding engineering from The Ohio Welding Principles and Application, first R&D programs that develop and imple­ State University. He is employed as a and fifth editions, by Larry Jeffus. He ment welding technology to improve the senior staff manufacturing engineer for has authored publications and articles quality and cost-effectiveness of manu­ Lockheed Martin Missiles and Fire for various industry magazines, and was facturing and repair operations of the Control in Dallas, Tex. He has led ef­ a contributing author to the oxyfuel sec­ U.S. Navy, Dept. of Defense, and other forts on the Patriot Advance Capability tions of the 2004 AWS Welding Hand­ government agencies. Prior to joining (PAC-3) Missile, Line-of-Sight Missile book, 9th edition. He has delivered nu­ EWI, Castner was vice president of en­ (LOSAT). Joint Strike Fighter (JSF- merous technical presentations and gineering at Hartman Materials Han­ F22), International Space Station, Army training sessions nationwide to employ­ dling Systems, Inc. He also served as Tactical Missile System (ATACMS), and ees of shipyards, railroads, airlines, util­ manager of manufacturing automation the Multiple-Launch Rocket System ity contractors, the Alaska pipeline, technology at the Allis Chalmers Corp.'s (MLRS) Advanced Missile Programs. Advanced Technologies Center. Cast­ trade schools, and colleges. He has re­ Previously, Levert worked for General ceived special meritorious recognitions ner received the James F. Lincoln Gold Dynamics, Convair Div., in San Diego, Medal Award and the Arsham from the Garland Independent School Calif., as a welding engineer supporting District, Eastfield College, the Texas Amirikian Memorial Maritime Welding the Atlas space vehicle. Tomahawk Parks and Wildlife Chairman's Award Award. He is a registered professional cruise missile, and ground-launched for Public Services, and awards from engineer in the state of Ohio, an AWS cruise missile programs. He has worked AWS District 17. He has held all ofthe Life member, and an AWS director at more than 35 years in welding, support­ officer positions in the AWS North large. He is a member of various AWS ing the aerospace and defense indus­ committees including the Welding tries. Levert has presented several pa­ Texas Section. Handbook Committee, SHI Safety and pers on aerospace applications of weld­ Health Subcommittee on Fumes and ing with emphasis on the electron beam ROBOTIC AND AUTOMATIC ARC Gases, Conference Committee, and process. He is a registered professional WELDING AWARD chairs the Product Development Com­ engineer in the state of Texas. He has Chester L. Woodman, Jr. mittee. earned certifications in high-pressure Chester Woodman received his pipe welding, pressure hull welding, and MBA from Pepperdine University in 1957. He joined Ingersoll-Rand Co.

JULY 2005 Microbeam Analysis So­ ciety. He has received the McKay-Helm Award, Charles H. Jen­ nings Memorial Award, and Warren F. Savage Memorial Award. He also received the Burton Medal from Microscopy dm Society of America, K.F. Robino Woodman DuPont Michael Mizia J. Heinrich Award from the Microbeam Analysis where he worked for 18 years in various John N. DuPont Society, and the ASM Grossman positions. He started in engineering, fol­ Dr. DuPont's biography appears under Award. In 1998, he received an R&D lowed by manufacturing management the A. F. Davis Silver Medal Award. 100 Award. Michael has published before entering sales. When he left the more than 100 papers about materials company in 1974, he was national sales Charles V. Robino science and the application of materi­ manager for the Pump and Condenser Charles Robino received his Ph.D. als characterization techniques. Group. From 1974 to 1978, he worked in materials science and engineering for Ecolaire, Inc., first as president of from Lehigh University. From 1988 to Ronald E. Mizia the Green Fan Co. in Beacon, N.Y., and 2002, he was a principal member of the Ronald Mizia received his M.S. de­ later as president of the Allen-Sherman- technical staff at Sandia National Lab­ gree in metallurgical engineering from Hoff Co. in Malvern, Pa. For the next oratories, and was promoted to distin­ Michigan Technological University in ten years, Woodman was with Hobart guished member of the technical staff 1976. He is a senior consulting engineer Brothers Co., where he served as vice in 2002. His research includes fabrica­ at the Idaho National Laboratory. He president ofthe Welding Equipment di­ tion and service weldability, solidifica­ has more than 30 years of experience in vision, vice president of the Advanced tion, and phase transformations. He metallurgical and corrosion engineer­ Welding Systems division, and as group also performs materials selection, weld ing in the areas of nickel-based alloy de­ vice president of the Welding Products reliability, and weld processing studies velopment, corrosion testing of metal­ Group with global responsibilities for relating to Department of Energy pro­ lic and nonmetallic materials, welding all welding businesses. In 1979, Hobart grams in the defense and energy sectors. engineering materials for nuclear fuel brought the Yaskawa Robots to the U.S. Robino has authored or coauthored reprocessing and waste storage, and ma­ welding markets. Over the next nine more than 140 papers in the areas of terials for new reactor concepts. Mizia's years, Hobart installed more than 1200 welding, solidification, kinetics, and recent work concerns the development arc welding and cutting robots in North heat treatment. He has extensive expe­ of a patented gadolinium-containing America and more than 2000 systems in rience in the welding behavior of steels, nickel-based alloy as a fixed neutron ab­ Europe through its majority-owned refractory metals, stainless steels, and sorber. Mizia has another patent pend­ company, Torsteknik in Torsas, Sweden, nickel alloys. In 1997, he was awarded ing in the area of neutron-absorbing, where Woodman was chairman of the the AWS Koichi Masubuchi/Shinsho corrosion-resistant metallic coatings. board until 1990. From 1988 to 1990, he Corporation Award. In 1998 and 1999, His recent publications describe work was president of Berkeley-Davis Co. he received the William Spraragen in the development of the Ni-Cr-Mo- Woodman, from 1990 to 2001, was gen­ Memorial Award. He received the Gd alloys, underground corrosion, elec­ eral manager of the Automation divi­ McKay-Helm Award, the ISS/AISI trochemical noise monitoring of corro­ sion of The Lincoln Electric Co. He is Meritorious Award, and took the first- sion in nuclear waste tanks, and inno­ a long-time member of AWS. He served place poster award in the AWS Profes­ vative corrosion-measurement tech­ on the D16 Committee on Robotic and sional division. He was a corecipient of niques. He is on the editorial review Automatic Welding, and contributed the A. F. Davis Silver Medal in 2001. He board for the Journal of Failure Analy­ technical assistance to the AWS Weld­ is a member of AWS and ASM Interna­ sis and Prevention, and is the vice chair ing Handbook. He was a keynote tional. for the NACE Int'l Nuclear Systems speaker at the AWS Arc Welding Robot Corrosion Technical Exchange Group. Conference, and has served on the Joseph R. Michael Manufacturers Committee. Woodman Joseph Michael received his Ph.D. David B. Williams is a member of several technical soci­ degree at Lehigh University. He is a David Williams is the Harold Cham­ eties and associations and was the 1999 member of the technical staff in the Ma­ bers Senior Professor of Materials Sci­ recipient of the Fanuc Robotics Presi­ terials Characterization Department of ence and Engineering and vice provost dent's Circle of Achievement Award. Sandia National Laboratories. His pri­ for Research at Lehigh University. He mary interest is in the application of ad­ obtained his Ph.D. and Sc.D. from Cam­ SAFETY AND HEALTH AWARD vanced characterization techniques to bridge University. From 1974 to 1976, Harvey R. Castner the study of materials. His recent re­ he was a science research council fellow Mr. Castner's biography appears under search involved the application of elec­ in the Department of Metallurgy and the National Meritorious Award. tron backscatter diffraction and focused Materials Science at Cambridge. In ion beam techniques to materials sci­ 1976, Williams moved to Lehigh as an ence. Prior to joining Sandia, Michael assistant professor, becoming associate WARREN F. SAVAGE was a senior research engineer at the professor in 1979, and professor in 1983. MEMORIAL AWARD Bethlehem Steel Homer Research Lab­ He directed the Electron Optical Lab­ "Physical and Welding Metallurgy of oratory where he worked with the phys­ oratory at Lehigh from 1980 to 1998, Gd-Enriched Austenitic Alloys for Spent ical metallurgy of new HSLA steels with and chaired the Department of Materi­ Nuclear Fuel Applications — Part II: improved properties. Michael has als Science and Engineering from 1992 Nickel-Based A Hoys " served as president and director of the to 2000. Williams has coauthored and

WELDING JOURNAL 'fc i\^f fl 1; I i 1 Williams Elmer Palmer f Babu Wei Zhang edited 11 textbooks and conference pro­ Todd A. Palmer thermal cycles, phase stability and dif­ ceedings, and has published 200 journal Todd Palmer received his Ph.D. in fusion in complex alloys. In 1995, he pi­ papers, and 190 abstracts and confer­ materials science and engineering from oneered the development of online ence proceedings in the general areas The Pennsylvania State University, computational models for welding. of analytical and transmission electron where he studied under Prof. DebRoy. Babu has authored more than 100 pub­ microscopy and the application of these Since 2000, he has worked at Lawrence lications. He has received the Lidstone techniques to studies of precipitation Livermore National Laboratory where Medal Award from The Welding Insti­ and segregation. Williams has given 250 he started as a postdoctoral technical tute in 2003. invited presentations at universities, associate, and currently is a metallurgist conferences, and research laboratories in the Materials Science and Technol­ Wei Zhang in 25 countries. He is a Fellow of TMS, ogy division in the Chemistry and Ma­ Wei Zhang received his Ph.D. in ma­ ASM International, and the Royal Mi­ terials Science Directorate. Presently, terials science and engineering from the croscopical Society (U.K.), editor of he is vice chair of the C7B Subcommit­ Pennsylvania State University in 2004. Acta Materialia, and a past president of tee on Electron Beam Welding and Cut­ After graduation, he joined the Edison the International Union of Microbeam ting, and is a member of the Welding Welding Institute where he is currently Analysis Societies. Journal Peer Review Panel, the editorial an applications engineer. Zhang's re­ board of the journal, Science and Tech­ search interests include the computa­ WILLIAM SPRARAGEN nology' of Welding and Joining, and is a tional modeling of transport phenom­ MEMORIAL AWARD Key Reader for Metallurgical and Mate­ ena, welding metallurgy, welding stress "Direct Observations of Austenite, rials Transactions. He received the Ge­ and distortion. He has synthesized the Bainite, and Martensite Formation offrey Belton Award from The Iron and numerical tools from several disciplines during Arc Welding of 1045 Steel Using Steel Society in 2000, and won the ASM to study a wide range of welding Time-Resolved X-Ray Diffraction " International Graduate Student Paper processes and welded materials. Zhang John W. Elmer Competition in 1999. From 1995 to received an AWS Graduate Fellowship John Elmer received his Sc.D. in 1998, he held an AWS Graduate Re­ to support his doctoral research studies metallurgy from Massachusetts Insti­ search Fellowship. He is the author or at Pennsylvania State. He coauthored tute of Technology in 1988. From 1982 coauthor of more than 25 articles and a paper winning the Kenneth Easterling to 1984, he worked as a welding metal­ reports. His current research interests Best Paper Award. lurgist at Lawrence Livermore National involve the characterization of phase Laboratories (LLNL) for a variety of transformations in structural materials Tarasankar DebRoy defense-related programs. He returned using synchrotron based in situ x-ray dif­ Tarasankar DebRoy is professor of to LLNL in 1989, where he is currently fraction techniques, high-energy-den­ materials science and engineering at the deputy program element leader for sity electron beam and laser beam weld­ Pennsylvania State University. He re­ Stockpile Metallurgy and Joining, in the ing and joining processes, and electron ceived his Ph.D. from the Indian Insti­ Materials Science and Technology divi­ beam welding diagnostics. tute of Science in Bangalor, India. He sion, and serves as adjunct professor at did his postdoctoral work at the Imper­ the Pennsylvania State University. He Sudarsanam Suresh Babu ial college of Science and Technology, is a Fellow ofthe American Welding So­ Sudarsanam Suresh Babu obtained London, U.K., and Massachusetts Insti­ ciety and ASM International. He has re­ his Ph.D. in materials science and met­ tute of Technology. His research focuses ceived the Prof. Masubuchi-Shinsho allurgy at the University of Cambridge, on the application of numerical heat Corporation Award, William Spraragen U.K. From 1992 to 1993, he worked as transfer, fluid flow, and mass transfer to Award, A. F. Davis Silver Medal. War­ a research associate at Tohoku Univer­ understand welding processes and the ren Savage Memorial Award, and the sity, Japan. Babu joined Oak Ridge Na­ geometry, chemical composition, and Samuel Wiley Miller Award. He serves tional Laboratory (ORNL) in 1993 as a structure of welds. He has authored or as a member of numerous professional postdoctoral research scholar, then coauthored 215 papers on welding and committees for AWS and ASM Interna­ joined its research staff in 1997. He is modeling of various other materials pro­ tional, has published more than 90 arti­ currently a senior research and devel­ cessing operations. DebRoy has re­ cles and reports, and has been granted opment staff member at ORNL. Babu's ceived the Kenneth Easterling Award eight U.S. patents for his work in the expertise lies in the areas of phase trans­ for the International Institute of Weld­ field of welding. Elmer is renowned for formations, welding metallurgy of steels ing and Technical University of Graz, his understanding of solidification and and nickel-based superalloys, as well as and the Adams Memorial Membership the kinetics of phase transformations computational weld modeling. He is in­ Award, McKay-Helm Award, Charles during welding, high-energy-density volved in the application of state-of-the- H. Jennings Memorial Award, Warren beam material interactions, and the ap­ art characterization tools, including F. Savage Memorial Award, Comfort A. plication of synchrotron radiation for atom probe tomography, in-situ syn­ Adams Lecture Award, William Sprara­ real-time observations of phase trans­ chrotron, and neutron diffraction for gen Memorial Award, and the Honorary formations during welding. understanding interaction between weld Membership Award. He is also the re-

M JULY 2005 proceedings and has received numer­ was involved with the Resistance ous awards, including Dr. Rene Wasser­ Welder Manufacturers' Association, ul­ man Award, ASME's G.E. Widera Lit­ timately serving as its president in 1991. erature Award, and SAE's Henry Ford He also served on the advisory board at II Distinguished Award for Excellence Ferris State University for its welding in Automotive Engineering. He serves engineering technology program. as associate editor for ASME Transac­ tion Journal of Off shore Mechanics and Arctic Engineering, and the Journal of GEORGE E. WILLIS AWARD rt 11 i k Science and Technology of Welding and Kohuske Horikawa Hofman Horikawa Joining. He is also a Principal Reviewer Kohuske Horikawa received his cipient of the Wilson Research Award for peer-reviewed papers published in Ph.D. in engineering from the Univer­ from the Penn State College of Earth Welding Journal. Since 1994, he has sity of Tokyo in 1967 after which, he and Mineral Sciences, and Penn State's served as a U.S. Delegate to Interna­ joined the university as an assistant pro­ Faculty Scholar Medal for Outstanding tional Institute of Welding Commis­ fessor. In 1978, he joined the Welding Achievement in Engineering. DebRoy sions X on Fracture Avoidance of Research Institute, Osaka University, is a principal peer reviewer for the Weld­ Welded Structures, and has served since as associate professor. In 1987, he ing Journal, and is an editor of Science 2003 as chairman of Subcommission XE served as a full professor until his re­ and Technology of Welding and Joining, on Defect Assessment. tirement in 2002, when he was given the published by the Institute of Materials, title Professor Emeritus. During his ca­ U.K. He is a Fellow of ASM Interna­ reer, he conducted fundamental re­ tional, and AWS. ELIHU THOMSON RESISTANCE search and practical coordination for WELDING AWARD design, fabrication, and rehabilitation R. D. THOMAS Robert S. Hofman of heavy welded steel constructions, MEMORIAL AWARD Robert Hofman attended Grand quality management in welded con­ Pingsha Dong Rapids Community College, Michigan struction, and international standardi­ Pingsha Dong received his Ph.D. in State University, and Aquinas College zation of welding and allied processes. computational mechanics from the Uni­ where he majored in business adminis­ He has held the position of Head of versity of Michigan at Ann Arbor. He tration. In 1958, he joined Kirkhof Man­ Japanese Delegation to ISO/TC44, ISO is currently with Battelle Memorial In­ ufacturing where he worked in various Official Representative to CEN/TC121, stitute. As technical director, Center for production positions, progressing to chairman of Asian Welding Standard­ Welded Structures Research, his inter­ sales engineer. For five years he was a ization Forum, IIW vice chairman of Se­ ests include design and analysis meth­ sales manager for the Transformer di­ lect Committee Standardization, and ods for welded structures, advanced vision. In 1980, he became vice presi­ IIW vice chairman of Commission XV computational procedures for weld­ dent and cofounder of RoMan Manu­ Horikawa is a Life Member and a Fel­ ing/joining process simulations, fa­ facturing, Inc., a producer of resistance low of ASCE, and a 30-year member of tigue/fracture behavior of welded struc­ welding power sources. Hofman has AWS. He is the recipient of the Tanaka tures, and residual stress and distortion served as chair of the AWS Western Prize, JSCE, for "Repair Welding under mitigation techniques. Dong has pub­ Michigan Section, and served as Dis­ Service Conditions," and the IIW Gur- lished more than 180 papers in various trict 11 director (1977-1980), and an rera Medal for "Welding Coordination peer-reviewed journals and conference AWS director-at-large (1980-1983). He for Akashi Bridge."•

his successful efforts to coauthor and Fellows and Counselors Announced publish the AASHTO/AWS D1.5, Bridge Welding Code. at AWS Welding Show Kvidahl was recognized for his dis­ tinguished service in the shipbuilding ix AWS Fellows and six AWS and welding of superalloys. industry. Counselors were appointed at the Menon was recognized for his work Levert was cited for his significant S Dallas AWS Welding Show. on flux cored wires, and developing the conributions to major welding pro­ Appointed to AWS Fellow status first all-position nickel-based flux cored grams, including Atlas and Centaur were Harvey R. Castner, William H. wires in industry. space boosters and Space Shuttle and King, Ravi Menon, Suck-Joo Na, Ray­ Suck-Joo Na was honored for his International Space Station. mond George Thompson, and Thomas contributions to fusion welding, and Nally was recognized for his out­ Zacharia. defining the complex phenomena oc­ standing communications, advertising, Appointed to AWS Counselor status curring in the GMAW processes. trade show, and public relations skills. were Warren G. Alexander, Lee G. Kvi­ Thompson was named for his re­ Porter was honored for her work at dahl, Ernest D. Levert, Sr., Glenn M. search in the theory of weld HAZ mi­ Edison Welding Institute and involve­ Nally, Nancy C. Porter, and Amos O. crostructure evolution, microfissuring ment with welding engineering students, Winsand. and grain boundary migration. fundraising, and job placement assis­ Castner was cited for his develop­ Zacharia was honored for his re­ tance to further the Image of Welding. ment of fluxes for the GTAW process, search in weld pool modeling and en­ Winsand was cited for his numerous and an analytical approach to determin­ hancements to resistance spot welds for achievements, innovative ideas to im­ ing crack-resistant weld compositions. the automobile industry. prove the performance of multispot re­ King was noted for his extensive Alexander was cited for his work in sistance welding used for automotive work in the aerospace welding industry bridge fabrication quality standards and bodies.*

WELDING JOURNAL Tech Topics

TECHNICAL COMMITTEE MEETINGS INTERPRETATION OPPORTUNITIES

WS technical committee meet­ AWS D1.1, Structural Ship and Boatbuilding ings are open to the public. If you want to attend a meeting, con­ Welding Code — Steel The D3A Committee seeks volun­ A teers to help revise D3.7, Guide for tact the staff secretary of the commit­ tee as listed below at AWS, 550 NW Subject: OEM's Engineer Aluminum Hull Welding, and D3.5, LeJeune Rd., Miami, FL 33126; tele­ Code Edition: D 1.1:2002 Guide for Steel Hull Welding. Topics phone (800/305) 443-9353. Code Provision: Section 1.3.1 include design, cutting, qualifica­ tion, construction practices, inspec­ July 12,13, B2F Subcommittee on AWS Log: Dl.1-02-101 (INQ-48) tion, and welding processes and Plastic Welding Qualifications. Reno, equipment. Contact Brian Nev. Standards preparation meeting. Inquiry: Is it permissible for the McGrath, (800) 443-9353, ext. 311, Staff Contact: R. Hancock, ext. 226. Original Equipment Manufacturer bmegrath @aws. org. Aug. 11, Technical Activities Com­ (OEM) to designate a technically mittee. Columbus, Ohio. General qualified competent and capable Iron Castings meeting. Staff Contact: P. Howe, ext. Engineer from his organization as The Dll Committee seeks volun­ 309. "the Engineer" to make engineer­ teers to help revise D 11.2-89, Guide Aug. 30, D15 Committee on Rail­ ing evaluations based on design for Welding Iron Castings. Experts in road Welding. St. Louis, Mo. Standards analysis, and to accept previous the welding of iron castings as well preparation meeting. Staff Contact: R. WPS Qualifications and previous as users of iron castings are urged to Hancock, ext. 226. Performance Qualifications (in ac­ participate in this important work. Aug. 30, D15A Subcommittee on cordance with paragraphs 4.1.1.2 Contact John Gayler, (800) 443- Freight Cars and Their Materials. St. and 4.1.2.1)? 9353, ext. 472; [email protected]. Louis, Mo. Standards preparation meeting. Staff Contact: R. Hancock, Response: Yes. Inspection ext. 226 The Bl Committee on Methods of Inspection seeks volunteers to help Standards for Public Review revise AWS Bl.10:1999, Guide for AWS was approved as an accredited the Nondestructive Examination of standards-preparing organization by the Welds, and AWS Bl. 11:2000, Guide American National Standards Institute for the Visual Examination of Welds. (ANSI) in 1979. AWS rules, as approved Errata in D15.1 Meetings will be held using the by ANSI, require that all standards be Internet, teleconferences, and e- AWS D15.1:2001, Railroad open to public review for comment dur­ mail. A face-to-face meeting may be Welding Specification — Cars ing the approval process. This column held during the next AWS Welding and Locomotives also advises of ANSI approval of docu­ Show, Nov. 13-16, 2005, in Chicago. ments. The following standards are sub­ Contact Brian McGrath, (800) 443- P. 23, Table C2, under column ti­ mitted for public review. Draft copies 9353, ext. 311, [email protected]. • may be obtained from Rosalinda tled "Base Metal Thickness of ...", O'Neill, 550 NW LeJeune Rd., Miami, last entry, change "3/4 " T" to "3/4 FL 33126; (800/305) 443-9353, ext. 451,

JULY 2005 Stanley Takes the Gold in U.S. Open Weld Trials

oel Stanley II, 22, was judged the weld projects to learn w here he official winner of the U.S. Open lost points, and how to improve J Weld Trials held at the AWS Weld­ his performance. Stanley's ing Show in Dallas, Tex., in April. welding instructor. David There, he competed against six U.S. Hartley, who accompanied him welders plus contenders from Australia, to Finland, said, "Joel really Canada, Ireland, the Netherlands, knows how welding works, how Thailand, and the U.K. amperage and voltage affect A student at Northern Penobscot the weld pool and how to apply Tech Region III and Eastern Maine that knowledge." Community College, he spent an entire At Helsinki. Stanley com­ year practicing on weekends, and nights peted well against 24 of the after working full-time as a welder at world's best welders. His work Fastco Corp. in Lincoln, Maine. took fifth place after the en­ As he left Lincoln for Dallas, he said, tries of Korea, Australia, Thai­ "I think it's going to be a tough compe­ land, and Chinese Taipei. The tition, but I am looking forward to it. I competition was so close the feel pretty laid-back and confident top three contestants each re­ about competing." ceived a gold medal. He discovered that the Dallas con­ Experienced and evel test was tough. It required using de­ headed, Stanley flatly states it tailed welding blueprints to build four is virtually impossible to be constructs of steel, stainless steel, alu­ perfect in welding all the time, minum, and a pressure vessel of mixed and even the best welder can metals that contest judges tested with misjudge tolerances or have a X rays. weld crack. The Dallas win earned him a $40,000 As for his future, Stanley Joel Stanley is shown after his April win in Dallas scholarship presented by Miller Elec­ said, "I plan to use the Miller and before the Helsinki WorldSkills welding trials. tric Co., plus the opportunity to com­ $40,000 scholarship, but I pete in the WorldSkills welding compe­ haven't decided what course to Many of my friends recommend that I tition held the last week of May in follow yet. I prefer hands-on work, but look into Ferris State University since Helsinki, Finland. haven't ruled out an engineering career it has a good hands-on program, and Stanley used those few weeks be­ either. I will take the time to look at the The Ohio State University for its engi­ tween contests to scrutinize his Dallas schools to see what they have to offer. neering degrees."*

WEMCO Presents Its 2005 Five Sections Image of Welding Awards Cited by AWS Board of Directors he AWS Welding Equipment for the AWS Section Award. Manufacturers Committee WEMCO is a standing committee of n April 28, 2005, after due T the American Welding Society. Execu­ consideration of the recom­ (WEMCO) named seven profes­ tives from welding industry suppliers O mendations by Districts sionals to receive its third annual Image formed the committee as a forum to Council, the AWS Board of of Welding Award at the Dallas AWS promote their understanding of the Directors approved the disband- Welding Show. welding equipment market through cus­ ment of the AWS Puerto Rico Tom Morrissett was cited for the In­ tomized plans and programs. Enhanc­ Section, District 5, and the AWS dividual Award. ing the image of welding as a skill cru­ Southwest Idaho Section, District William Adams, Clovis Community cial to industry has been identified as a 20. College, Clovis, N.Mex., accepted the top-priority program. The name of the AWS Eastern Educator Award. Nominations for the 2006 Image of Idaho/Montana Section, District 20, Mahany Welding Supply, Rochester, Welding Awards are being accepted was changed to Idaho/Montana, and N.Y., received the Distributor Award. now. For information, contact Maggie the name of the AWS Maryland LeTourneau University, Longview, Alvarez-Miranda, AWS public relations Section. District 3, was changed to Tex., and Ferris State University, Big manager, at [email protected]. Baltimore. Rapids, Mich., tied for the Educational For complete information on The AWS Richmond Section, Facility Award. District 4, was placed on Inactive Dana Corp., Toledo, Ohio, took the WEMCO membership and benefits, Status.* Large Business Award honors. visit the committee's Web site at Detroit Section received recognition www.aws.org/wemco. •

WELDING JOURNAL New AWS Supporters

New Sustaining Companies Educational Institutions Machinery Movers, Riggers & Machinery Erectors. Local Union 136 Daily's 4 G. Welders Amarillo College 1820 Beach St., Broadview, IL 60155 6541 125th Ave. NE 1201 I Ave. Kirkland, WA 98033 Amarillo, TX 79111 Northeast Process Systems, Inc. Representative: Charles Lee Daily 7 Tolman Ave. Gateway Regional High School Gloucester, MA 01930 My father, Chuck Daily, first started 12 Littleville Rd. welder training in 1939. He has taught Huntington, MA 01050 Pelco Structural, LLC his two sons, two grandsons, two great- 1501 Industrial Blvd. grandsons, and many others how to Oak Ridge High School Claremore, OK 74017 weld and inspect each weld to a quali­ 127 Providence Rd. fied procedure and job specifications. Oak Ridge, TN 37830 R D Welding Services The company is pleased to be welding 301 Buckingham W partners, advisors, and consultants Oklahoma Dept. of Career Tech Milford, CT 06460 supporting the AWS Student Chapters, 1500 W 7th Ave. T. Rowe Pipe AWS scholarship programs, and work­ Stillwater, OK 74074 ing with AWS District 19, the Puget PO Box 41 Burbank, OK 74633 Sound Section, local welding schools, Prosser School of Technology instructors, students, and industry. 4202 Charlestown Rd. Tin Man Welding Services New Albany, IN 47150 5569 Oak St. Ft. Worth, TX 76140 Lake Murray Steel Inspection, Inc. Tulsa Technology Center PO Box 508 3420 S. Memorial Dr. Villareal Welding Prosperity, SC 29127 Tulsa, OK 74145 114 W. Flynn Representative: Richard C. Bannister Harlingen, TX 78550 Instituto Mexicano del Petroleo Lake Murray Steel Inspection, Inc., is a full-service quality assurance in­ Eje Central Lazaro Cardenas No. 152 New Supporting Companies Mexico, D.F. 07730, Mexico spection agency. We are capable of A. Murray Construction, LLC providing all of your construction and 4548 Cantina Dr. maintenance inspection needs. Do New Affiliate Companies Tyler, TX 75708 your welders or inspectors need train­ ing? Our staff is qualified to meet your Aaron's Technical Services certification needs for personnel and Automation International, Inc. 4101 S Longfellow Ave., Ste. E 1020 Bahls St. fabrication facilities. We provide con­ Tucson, AZ 85714 sulting and inspection services in- Danville, IL 61832 house or at your site. Accurate Steel and Pipe Fabricators JT Steel, Inc. 106 W 1st St., PO Box 217 Kennard, NE 68034 9550 S. Hawley Park Rd. Manitowoc Crane Group West Jordan, UT 84088 1565 Buchanan Trail East Bozankaya, LLC Shady Grove, PA 17256 81210 Siena Ave. Representative: Gary Martens Sacramento, CA 95828 The Manitowoc Crane Group com­ Dynamic Creations Membership panies compose one of the world's 4641 Emory broadest and most comprehensive Counts El Paso, TX 79907 families of lifting products, including Manitowoc Cranes, Potain, Grove, and National Crane. The Manitowoc Equipos Inoxidables del Norte, SA de CV, Member As of Crane Group is a wholly owned sub­ Piedras Negras #330 Grades 6/1/05 sidiary of The Manitowoc Co., which Parque Industrial Lagunero also includes a food service segment Gomez Palacio, Durango, 35070, Mexico Sustaining companies 420 and a marine division. Supporting companies 210 House of Weiss, LLC Educational institutions 347 587 Wallingford Rd., Unit 48 Affiliate companies 305 Welding Distributor Company Durham, CT 06422 Welding distributor companies 51 Total corporate members 1333 CCH Equipment Co. Industrial Construction & Welding, Inc. 14902 Preston Rd., Ste. 404-323 PO Box 227 Individual members 43,499 Dallas, TX 75254 Lithia, FL 33547 Student + transitional members 4,757 Total members 48,256 JULY 2005 Member-Get-A-Member Campaign RECRUIT NEW MEMBERS... WIN GREAT PRIZES A simple way to give back to your profession, strengthen AWS and win great prizes is by participating in the 2005-2006 Member-Get-A-Member Campaign. By recruiting new members to AWS, you're adding to the resources necessary to expand your benefits as an AWS Member. Plus, you become part of an exclusive group of AWS Members who get involved. Year round, you'll have the opportunity to recruit new members and be eligible to win special contests and prizes. Referrals are our most successful member recruitment tool. Our Members know first-hand how useful AWS Membership is. Who better than you to encourage someone to join AWS?

AMIS MEMBER BENEFITS CHECKLIST: • Annual subscription to the Welding Journal. < Networking opportunities through local Section • A 25% discount on hundreds of first-rate AWS meetings, the AWS Welding Show and an on­ technical publications and 140+ industry codes. line bulletin board on the AWS website at • Deep discounts on 120+ technical training . events every year. Members'-only discounts on auto insurance, • Access to widely recognized AWS Certification car rentals, credit cards and more. programs. ' Connection to career opportunities through • New Members can save nearly 90% off an AWS AWS JobFind - at www.awsjobfind.com publication. Choose from four of our most < The American Welder section of the WJ geared popular titles (see reverse). toward front-line welders. fe J • AWS Membership Certificate and Card. < And much more! GET INVOLVED TODAY, AND WIN! PRIZE CATEGORIES SPECIAL PRIZES President's Honor Roll: Participants will also be eligible to win prizes in LUCK OF THE DRAW Recruit 1-5 new Individual Members specialized categories. Prizes will be awarded at the For every new member you sponsor, your name is and receive a welding ball cap. close ofthe campaign (June 2006). entered into a quarterly drawing. The more new- members you sponsor, the greater your chances of President's Club: Sponsor of the Year: winning. Prizes will be awarded in November 2005. Recmit 6-10 new Individual Members The individual who sponsors the greatest number of new as well as in February and June 2006. and receive an American Welder™ polo shirt. Individual Members during the campaign will receive a Prizes Include: plaque, a trip to the 2006 FABTECH International and The AWS • American Welder™ T-shirt President's Roundtable: Welding Show, and recognition at the AWS Awards Luncheon at • one-page, black/white ad in the Welding foil ntal Recruit 11-19 new Individual Members the Show • Complimentary AWS Membership renewal and receive an American Welder™ polo shirt, American • American Welder™ polo shirt Welder™ T-shirt and a welding ball cap. Student Sponsor Prize: • American Welder™ baseball cap AWS Members who sponsor two or more Student Members President's Guild: will receive a welding ball cap. SUPER SECTION CHALLENGE Recruit 20 or more new Individual Members and receive an The AWS Member who sponsors the most Student Members The AWS Section in each District that achieves the highest net .American Welder™ watch, a one-year free AWS percentage increase in new Individual Members before the Membership, the "Shelton Ritter Member Proposer Award" will receive a free, one-year AWS Membership and an American Welder™ polo shirt. June 2006 deadline will receive special recognition in the Certificate and membership in the Winner's Circle. Weltlingjoiinml. Winner's Circle: International Sponsor Prize: The AWS Sections with the highest numerical increase and All members who recruit 20 or more new Individual Any member residing outside the United States, greatest net percentage increase in new Individual Members Members will receive annual recognition in the Welding Canada and Mexico who sponsors the most new will each receive the Neitzel Membership Award. Journal and will be honored at the AWS Welding Show. Individual Members will receive a complimentary AWS Membership renewal. American Welding Society 550 N.W. LeJeune Rd. • Miami, FL 33126 *The 2005-2006 MGM Campaign rims from June I. 2005 lo May 31.2606. Mm are auartletl al llx close ofthe campaign. Visit our website http://www.avvs.org SPECIAL OFFER FOR NEW AWS INDIVIDUAL MEMBERS - TWO YEARS FOR $135 (a $25 savings) + PLUS... Get a popular welding publication for only $25 ($192 value) AWS MEMBERSHIP APPLICATION BOOK/CD-ROM SELECTION 4 Easy Ways to Join or Renew: (Pay Only $25... up to a $192 value) ' Mail this form, along with your payment, to AWS NOTE: Only New Individual Members are eligible for this selection. Be sure to add $25 to your total payment. S Call the Membership Department at (800) 443-9353, ext. 480 ONLY ONE SELECTION PLEASE. • Fax this completed form to (305) 443-5647 B Join or renew on our website • •C^J Jefferson's Welding Encyclopedia (CD-ROM only) 3 Mr. • Ms. y\ Mrs. 2 Dr. Please print • Duplicate this page as needed J Design and Planning Manual for Last Name Cost-Effective Welding J Welding Metallurgy First Name, M.I. J Welding Handbook (9th Ed., Vol. 2)

Title _Birthdate -I New Member J Renewal Were you ever an AWS Member? J YES D NO If "YES," give year and Member # A free local Section Membership is included with all AWS Memberships Primary Phone ( ) Secondary Phone ( ) Section Affiliation Preference (if known): FAX( ) E-Mail Type of Business (Check ONE only) Did you learn of the Society through an AWS Member? 3 Yes 3 No A _J Contract construction If "yes." Member's name: Member's # (if known): B _l Chemicals & allied products C wl Petroleum & coal industries D J Primary metal industries ADDRESS NOTE: This address will be used for all Society mail. E -I Fabricated metal products F J Machinery except elect, (incl. gas welding) Company (if applicable) G y Electrical equip., supplies, electrodes H J Transportation equip. — air. aerospace I -I Transportation equip. — automotive Address J J Transportation equip. — boats, ships K J Transportation equip. — railroad L J Utilities Address Con't. M U Welding distributors & retail trade N • Misc. repair services (incl. welding shops) City State/Province _Zip/Postal Code. .Country 0 y Educational Services (univ., libraries, schools) P —I Engineering & architectural services (incl. PROFILE DATA NOTE: This data will be used to develop programs and services to _ assns.) serve you better. Q -I Misc. business services (incl. commercial labs) R J Government (federal, state, local) 0 Who pays your dues?: J Company j Self-paid @ Sex: j Male J Female S • Other Job Classification (Check ONE only) ® Education level: J High school diploma J Associate's J Bachelor's J Master's J Doctoral 01 J President, owner, partner, officer 02 _l Manager, director, superintendent (or PAYMENT INFORMATION (Required) _ assistant) 03 y Sales 04 J Purchasing ONE-YEAR AWS INDIVIDUAL MEMBERSHIP ^$8(K 05 y Engineer — welding 20 y Engineer — design TWO-WAR AWS INDIVIDUAL MEMBERSHIPt $M^ $135 21 J Engineer— manufacturing 06 -I Engineer — other Nov Member? Yes No 10 _J Architect designer 12 J Metallurgist If yes, add one-time initiation fee ofSI2 S 13 -J Research & development 22 _) Quality control Add $25 for book selection ($192 value), and save up to 87%tt S .(Optional) 07 y Inspector, tester 08 y Supervisor, foreman (Note: applies to new Individual Members only - Book selections on upper-right corner) 14 _1 Technician 09 _J Welder, welding or cutting operator TOTAL PAYMENT $ II Q Consultant 15—1 Educator AWS STUDENT MEMBERSHIPm NOTE: Dues include $18.70 for Welding Journal 17 3 Librarian 16 J Student J Domestic (Canada & Mexico incl.) $15 subscription and $4.00 for the AWS Foundation. 18 LJ Customer Service $4.00 of membership dues goes to support the AWS 19 Ll Other J International Sill Foundation Technical Interests (Check all that apply) TOTAL PAYMENT $ A J Ferrous metals Payment can be made (in U.S. dollars) by check or money order (international or foreign). B 3 Aluminum payable to the American Welding Society, or by charge card. c 3 Nonferrous metals except aluminum Advanced materials/lntermetallics • Check • Money Order 3 Bill Me D Ll Ceramics E y High energy beam processes CJ American Express J Diners Club _l Carte Blanche -J MasterCard _1 Visa -I Discover Q Other F J Arc welding G J Brazing and soldering H • Resistance welding I I I I • Thermal spray Your Account Number J J Expiration Date (mm/yy) K 3 Cutting NDT Signature of Applicant: — Application Date: L 3 Safety and health M 3 Bending and shearing Office Use Only N Ll Roll forming Check # Account # o U3 Stamping and punching Source Code WJ Date Amount p J Aerospace J Automotive ffro-year Individual Membership Special Offer applies only to new fl!8 Individual Mantes Q American Welding Society R -I Machinery "Discount Publication Offer applies only to new .WS Individual Member. Select one of ihe four S J Marine P.O. Box 440367 listed publications for an additional S.'i: Multi-Year Discount: Firs: par is 580. each additional year is T • Piping and tubing Miami, FL 33144-0367 (75. No limit on years (nol a\ailable lo Student Members). ttrStudent Member Any individual who U Pressure vessels and tanks V. u Sheet metal Telephone (800) 443-9353 attends a recognized college, university, technical, vocational school or high school is eligible Domestic FAX (305) 443-5647 WQ Structures Members are those students residing in North Amend (incl. Canada (s Mexico). This membership Other Visit our website: www.aws.org x y includes ihe Velding Journal magazine. Student Memberships do nol include a discounted publication. Y y Automation Airmail Postage Option: International Mantels may receive their magazines via .Airmail by adding 199 z y Robotics Computerization of Welding Member Services Revised 4/10/05 21 J SECTION NEWS DISTRICT 1 Director: Russ Norris Phone: (603) 433-0855

BOSTON APRIL 18 Activity: Stuart Olsen, materials man­ ager, and Jim Laverdiere, president, led the Section members on a tour of the KleenLine Engineered Conveyor Sys­ tems facility in Newburyport, Mass. The plant fabricates custom stainless steel conveying products for the food and Shown during the Boston Section's tour pharmaceutical industries. of KleenLine Engineered Conveyor Sys­ AWS President Jim Greer (left) presents tems are (from left) lim Laverdiere, pres­ John Ament with a certificate of appreci­ ident; Stuart Olsen, materials manager; ation at the Lancaster Section program DISTRICT 2 and Section Chair Gaiy Hylan. in April. Director: Kenneth R. Stockton Phone: (732) 787-0805 DISTRICT 3 Director: Alan J. Badeaux, Sr. Phone:(301)934-9061

LANCASTER APRIL 5 Activity: The meeting wasJfield at Sym­ posium Restaurant in Lancaster, Pa. In attendance were AWS President Jim Greer and District 3 Director Alan Shown at the Reading Section's sponsored welding competition held last March are the Badeaux. Greer presented Chairman contestants, judges, and instructors. John Ament with a certificate of appre­ ciation for serving as Section chair.

READING MARCH 19 Activity: The Section hosted its annual Vo-Tech welding competition at Berks County Vocational and Technological Career Center in Reading, Pa.

APRIL 21 Activity: The Reading Section hosted an awards-presentation banquet to honor the participants in its March welding competition. The event was held at Berks County Career and Tech­ nology Center West in Reading, Pa.

Attendees posed for a photograph during the Reading Section's awards-presentation banquet held in April.

WELDING JOURNAL Bill Rhodes (left), Southeast Virginia Sec­ tion chair, accepts an appreciation award Shown at the York-Central Pa. car show are (from left) Chair George Bottenfield, John from Ted Alberts, District 4 director. Lengel, and Tim Anderson.

Shown (from left) are George Bottenfield, Shown at the Southwest Virginia Section Students' Night program are welding instruc­ Mike Bunnell, and Lany Smith during tors (from left) Sandra Johnston, James Stump, Chris Oveifelt, Charlie Oveifelt, Bruce the York-Central Pa. car show in April. Hunt, Doug Thompson, and Jamie Huffman. YORK-CENTRAL PA. and York County School of Technology Student Chapter APRIL 16 Activity: The York-Central Pennsylva­ nia Section and its Student Chapter par­ ticipated in a car show featuring hot rods, classics, antique, custom-mades, trucks, motorcycles, stock, and muscle cars. The event was held at the school grounds featuring more than 180 vehi­ cles on display. The ESAB trailer pre­ sented welding and plasma arc demon­ strations. The Section's booth was manned by Mike Bunnell and George Shown are the students who participated in the Southwest Virginia welding competition. Bottenfield. DISTRICT 4 Director: Ted Alberts Phone: (540) 674-3600, ext. 4314 SOUTHWEST VIRGINIA APRIL 13 Activity: The Section hosted its Stu­ dents' Night program for 86 attendees. District 4 Director Ted Alberts pre­ sented Mike Bryant (Dabney S. Lan­ caster CC.) the Section Educator Award, and the Section Appreciation Award to Chairman Bill Rhodes. Weld­ Shown at the Southwest Virginia Section's Students' Night awards-presentation pro­ ing instructors in attendance included gram are (from left) Chair Bill Rhodes, Matthew Vanderkooy, David Williams, Layne Harmon, and Ted Alberts, District 4 director.

JULY 2005 Sandra Johnston (Patrick Henry H.S.), James Stump (Guiles Tech Center), Chris Overfelt (Arnold R. Burton Tech Center), Charlie Overfelt (Wm. Flem­ ing H.S.), Bruce Hunt (Botetourt Tech Education Center), Doug Thompson (Floyd County H.S.), and Jamie Huff­ man (Jackson River Tech Center).

South Carolina Section speakers (from DISTRICT 5 left) Marvin Tallent and Richard Director: Leonard P. Connor Grumbine are shown with Gale Mole, Phone: (954) 981-3977 Section chair, at the April program. PALM BEACH Mike Bryant (left) accepts the Section Ed­ JANUARY 19 ucator Award from Ted Alberts, District Speaker: Vergie Y. Bain, compliance 4 director, at the Southwest Virginia Sec­ specialist tion program in April. Affiliation: U.S. Dept. of Labor, OSHA Topic: OSHA regulations for oxyacety­ lene welding and cutting Activity: Len Connor, District 5 direc­ tor, attended this program, held at the Olive Garden Restaurant in Boynton Beach, Fla.

SOUTH CAROLINA APRIL 28 Len Connor (left), District 5 director, is Speaker Jim Omdotff (left) is shown with Speakers: Marvin Tallent, QC/QA shown with speaker Vergie Bain, and Tom Matecki, Niagara Frontier Section manager, Palmetto Bridge Construc­ Frank Rose, Palm Beach Section chair. chair, at the April program. tors; and Richard Grumbine, ASNT Level II inspector, Soil Consultants, Inc. Topics: Tallent discussed weld quality and workmanship; Grumbine presented a talk on nondestructive testing. Activity: The program was held at the Palmetto Bridge Constructors facility. DISTRICT 6 Director: Neal A. Chapman Phone:(315)349-6960 NIAGARA FRONTIER APRIL 21 Speaker: Jim Orndorff, CWI, CWE Affiliation: Quality Inspection Services Topic: Discontinuities in weld and base Niagara Frontier Section board members take a break for a group shot. metal Activity: The program was held at Qual­ ity Inspection Services in Buffalo, N.Y. DISTRICT 7 Director: Don Howard Phone: (814)269-2895

JOHNSTOWN/ALTOONA NOVEMBER 10,2004 Speaker: Fred Raco, president Affiliation: RNDT, Inc. Topic: Nondestructive testing methods

DECEMBER 9, 2004 Shown are the attendees at the December Johnstown/Altoona Division program. Speaker: Bart Sickles, Division chair

WELDING JOURNAL Shown at the Northwestern Pennsylvania Section program are (from left) Chair Speaker Brad Shaw (farleft) is shown with a few of the welding students present at the Chet Wesley, speaker Richard Harris, and March meeting of the Johnstown/Altoona Division. Secretary Lee Smith. DISTRICT 11 Director: Eftihios Siradakis Phone:(989)894-4101

DETROIT MAY 6 Activity: The Section hosted its annual Ladies' Night event at Cobo Center in downtown Detroit. The event was at­ tended by 420 members and guests. Spe­ cial guests at the program were Jeff Weber, AWS associate executive direc­ tor, and his wife, Linda. Honored at the Western Area Career & Tech Center Student Chapter meeting in May are (from left) Joe Bianchin,Carl Cosentino,Brian Birdsall, Brandon Wiei; Chapter Advisor Tony Reis, and Dave Kelly. Max Davis missed getting into the photo. DISTRICT 12 Director: Sean P. Moran Affiliation: Concurrent Technologies Honored were Joe Bianchin, Carl Phone: (920) 954-3828 Topic: Explosion welding and testing Cosentino, Brian Birdsall, Brandon Activity: District 7 Director Don Wier, Dave Kelly, and Max Davis. LAKESHORE Howard discussed national AWS activi­ APRIL 14 ties for the Johnstown/Altoona Division Activity: The Section members toured members. the Burger Boat facility in Manitowoc, DISTRICT 8 Wis., to study its yacht-building tech­ Director: Wallace E. Honey FEBRUARY 9 niques. Following the tour, the meeting Phone: (256) 332-3366 Speaker: Robert Wertz, senior project was held at Lighthouse Inn where John engineer Brodtke received his Silver Membership Affiliation: Concurrent Technologies Award for 25 years of membership in Topic: Fuel cell testing and evaluation DISTRICT 9 the Society. The award was presented Activity: This Johnstown/Altoona Divi­ by John Zielona, Section chairman. sion program attracted 48 attendees. Director: John Bruskotter Phone: (504) 394-0812 MARCH 9 MILWAUKEE Speaker: Paul Brad Shaw, senior proj­ APRIL 21 ect engineer DISTRICT 10 Speaker: William Bong Affiliation: Maglev, Inc. Affiliation: Arcmatic Integrated Sys­ Topic: The Pennsylvania high-speed Director: Richard A. Harris tems Maglev transportation project Phone: (440) 338-5921 Topic: Improved electroslag welding Activity: This Johnstown/Altoona Divi­ Activity: William Bong, Bob Shuster, sion event was held in Johnstown, Pa. NORTHWESTERN PA. and James Priestly demonstrated the APRIL 12 narrow gap improved electroslag weld­ Speaker: Richard Harris, contributing ing system to join two heavy plates in Western Area Career & Tech editor less than nine minutes that would have Center Student Chapter Affiliation: Penton Publishing Co. taken hours to weld by hand. The din­ MAY 4 Topic: The value of reading welding ner was held at Thunder Bay Grille in Activity: Six students from the AWS Stu­ trade magazines Pewaukee, Wis. Sean P. Moran, incom­ dent Chapter were inducted into the Activity: The program was held at Tri ing District 12 director, was introduced National Technical Honor Society. State Welding Lab in Erie. Pa. to the attendees.

JM JULY 2005 DISTRICT 13 Director: Jesse L. Hunter Phone: (309) 359-3063 DISTRICT 14 Director: Tully C. Parker Phone: (618)667-7744

INDIANA APRIL 18 Activity: The Section held its awards- presentation and officer elections pro­ gram at Jonathon Byrd's Cafeteria near Indianapolis.

LEXINGTON APRIL 12 Activity: The Section rallied to assist Herbert Harrison who lost everything Shown at the Indiana Section program in April are (front, from left) J. R. Hollers, Gene when his home burned down. Jim Lami- Poe, and Gaiy Dugger. Top, from left, are Mike Anderson, Steven Meckstroth, and Bob rande, Section chair, presented Harri­ Richwine. son with a $500 check.

ST. LOUIS FEBRUARY 17 Speaker: Gailyn Cornell, a trainer for the retail division Affiliation: The Lincoln Electric Co. Topic: Welder training Activity: The Section held its annual Students' Night program to award its scholarships and recognize the out­ standing student members.

MARCH 31 The proud instructors and their award-winning students posed at the St. Louis program Activity: The St. Louis Section toured in February. the Seyer Industries plant to study the building of parts and products used for maintenance of military helicopters, planes, and ships. Chris Seyer, presi­ dent, conducted the tour for 37 mem­ bers and guests.

Gailyn Cornell discussed welder training Shown at Busch Stadium during the St. Louis Section's Past Chairmen's outing are at the St. Louis Section Students' Night (from left) Chuck Gulash, Don Kimbrell, Mark Anderson, Larry Ingram, Jerry Simp­ program in February. son, Kevin Corgan, Norm Helton, and District 14 Director Tully Parker.

WELDING JOURNAL Shown at the Nebraska Section presentation ceremony at Westside High School are (from left) Mike Fraser, secretary; Steve Nell, vice chair; John Bombac, welding instruc­ tor; Karl Fogleman. awards chair; John Crook, school principal; Monty Rogers, Section Chris Seyer (left) accepts an appreciation chair; and Gregg Ratliff welding instructor. gift from Brian Muenchau, St. Louis Sec­ tion publicity chair, following the Section's March tour of Seyer Industries.

Winners on the Oklahoma City Section's Aqua Canyon course were (from left) Dan Andrews, Dean Evans. Rick Lawson, and John Francis.

John Crook (left), Westside High School principal, accepts a $2500 donation from Monty Rogers, Nebraska Section chair­ man.

MAY 7 Activity: The St. Louis Section hosted its annual Past Chairmen's Night pro­ gram at Busch Stadium in St. Louis, Mo., to watch the Cardinals play against the Padres. Past chairs in attendance were Chuck Gulash, Don Kimbrell, Mark Anderson, Larry Ingram, Jerry Simpson, Kevin Corgan, Norm Helton, Winners on the Oklahoma City Section's Cimarron course were (from left) Dave and District 14 Director Tully Parker. Quentero, Randy Wilkerson, Cary Reeves, and Tim Kerce. MID PLAINS ets, pliers, safety glasses, wire tips, weld­ APRIL 27 ing wire, gloves, and other valuable Activity: The Section toured the Bald­ welding-related items worth $2500. = DISTRICT 15 win Filter Plant in Gothenburg, Neb. John Crook, school principal, accepted Director: Mace V. Harris David Haynes, plant operations man­ the donation from Section Chair Monty Phone: (952)925-1222 ager, conducted the tour. Rogers.

NEBRASKA DISTRICT 16 APRIL DISTRICT 17 Director: Charles F. Burg Activity: The Section presented West- Director: Oren P. Reich Phone: (515)233-1333 side High School welding hoods, jack- Phone: (254) 867-2203

JULY 2005 EAST TEXAS APRIL 29 Speaker: Jeff Ding, welding engineer Affiliation: NASA Topic: Welding development at Mar­ shall Space Flight Center Activity: The Section held its election of officers for the 2005-2006 term in Berry Auditorium at LeTourneau Uni­ versity, Longview, Tex.

OKLAHOMA CITY MAY 16 Activity: The Section hosted its annual Shown at the Lake Charles Section crab boil outing are (from left) R. W. "Tac"Ed­ golf tournament fundraiser event at wards, Drew Fontenot, James Bobo, District 18 Director John Mendoza, David Savoy, Cimarron National Golf Course in Ronnie Hebert, Andy Davis, Kermit Babaz, and Jimmy Veillon. Guthrie, Okla. One hundred fifty en­ tered the event. The big winners in­ cluded Dan Andrews, Dean Evans, Rick Lawson, John Francis, Dave Quentero, Randy Wilkerson, Cary Reeves, and Tim Kerce. V / TULSA Xy JANUARY 25 Speaker: Bob Ball, manager of eco­ 5 •' nomic research Affiliation: Tulsa Metro Chamber of Commerce \\i Topic: The economic outlook for Tulsa's Oren Reich, District 17 director, presents Jane Morgan accepts an appreciation cer­ heavy manufacturing in 2005 an appreciation award to Jan Todd at the tificate from District 17 Director Oren Activity: The meeting was held at Tulsa Tulsa program in Febniaiy. Reich during the Tulsa Section program Technology Center, Lemely Campus. in Febniaiy.

FEBRUARY 12 Activity: The Tulsa Section hosted its annual Ladies' Night Out with Sweet­ hearts dinner, followed by bingo. Dis­ HI AMERICAN 1 trict 17 Director Oren Reich presented WELDING appreciation awards to Jan Todd and • IETY 1 Jane Morgan for their contributions to w the Section's activities.

MARCH 22 Activity: The Tulsa Section toured the jS^^^tT Airgas Mid South, Inc., facility in Tulsa, 1 ~ \ Okla., to study the operations per­ formed at this manufacturing and dis­ tribution center. Vice Chair Mark Ron Theiss (left) accepts a speaker plaque Davidson presented the Manufacturer's from Morris Weeks, Sabine Section vice Appreciation Award to Mike Duvall, chair, in April. president. Mark Davidson (left), Tulsa Section vice chair, presents an appreciation award to David Savoy, Ronnie Hebert, Andy Mike Duvall during the Section's tour of Davis, Kermit Babaz, and Jimmy Veil­ the Airgas facility in March. DISTRICT 18 lon. Director: John L. Mendoza Phone: (210)353-3679 SABINE MAY 17 APRIL 19 Speakers: James Phillips and Randy Speaker: Ron Theiss, nondestructive Veillon LAKE CHARLES evaluation program coordinator Affiliation: Car-Ber Testing Services APRIL 20 Affiliation: North Harris College in Topic: Hydrostatic testing Activity: The Section hosted its annual Houston, Tex. Activity: The incoming officers were in­ crawfish boil and awards night program. Topic: Radiographic film interpretation troduced: Grady Hatton, chairman; On hand for the event were R. W. "Tac" of welds Glynn Savage and James Amy, vice Edwards, Drew Fontenot, James Bobo, Activity: The program was held at Team chairs; Mark Clark, secretary; and Ruel District 18 Director John Mendoza, Cooperheat in Beaumont, Tex. Riggs, treasurer.

WELDING JOURNAL Topic: Distortion control when welding aluminum hull submarine sections Activity: The incoming Section officers were introduced: Chris Sundberg, chairman; Ken Johnson, vice chair; Terri Tovey, secretary; Tim Jackson, treasurer; and Steve Pollard, technical representative.

DISTRICT 20 Director: Nancy M. Carlson Phone: (208) 526-6302 Shown at the District 18 conference are (from left) A WS representative Vicki Pinsky, Raul Robles, Morris Weeks, James Amy, Drew Fontenot, Dennis Eck, John Mendoza, Jr., Al Marin, and Ruel Riggs. ALBUQUERQUE CALENDAR Contact: Mike Thomas, (505) 239-6295 [email protected] October meeting: A research scien­ tist from Los Alamos National Labora­ tories will give a presentation on flux core welding. November meeting: An OSHA rep­ resentative will present updates on com­ pliance in the workplace. December meeting: The holiday so­ cial will be held at Sandia Casino.

IDAHO/MONTANA JANUARY Shown are most ofthe 35 delegates and guests who attended the District 18 conference Activity: The Section toured RAVE in San Antonio, Tex. TDC (Rocky Mountain Agile Virtual Enterprise Technical Development Center) in Butte, Mont. RAVE provides hands-on technical education and man­ ufacturing prototyping. It houses a ro­ botic GMA welding machine, a GTAW system donated by Edwards AFB, and a Hass CNC lathe and a vertical mini

DISTRICT 21 Director: Jack D. Compton Phone: (661)362-3218

Shown working the AWS Foundation's Speakers James Phillips (left) and Randy booth during the Welding Show are (from Veillon (far right) receive the Sabine Sec­ left) Nora Mendoza, John Mendoza, Jr.. DISTRICT 22 tion's Texas plaque from Morris Weeks, Director: Kent S. Baucher and Mayra Medina. vice chair. Phone: (559) 276-9311

SAN ANTONIO FRESNO APRIL 19 DISTRICT 19 MARCH 17 Activity: Members of the Section Director: Phil Zammit Activity: The Section toured Pelco, Inc., manned the AWS Foundation Booth Phone: (509) 468-2310 ext. 120 in Covis, Calif., to study its manufacture during the AWS Welding Show in Dal­ of security camera systems led by las, Tex. Mayra Medina joined District PUGET SOUND Neadley Foster, director, and Brandon 18 Director John L. Mendoza"s wife. APRIL 7 Greene, security officer. CWI Brad Nora, and son, John Mendoza, Jr., help­ Speaker: Steve Pollard, engineer and Bosworth, secretary, presented the ing the Foundation to raise funds for welding manager Chairman Appreciation Certificate to welding scholarships. Affiliation: Machinist's Inc. Tim Youngberg.

JULY 2005 The incoming Puget Sound Section officers are (from left) Steve Pollard, Terri Tovey, Fresno Section Secretary Brad Bosworth Chris Sundberg, Ken Johnson, and Tim Jackson. (left) presents the Chairman Apprecia­ tion Award to Tim Youngberg.

!••••••" if 1 CHKP tlyipllp \>* •"11*' 1 W_ *

My Br • II L I 1 J§U l c • ~: • -: • Some ofthe Idaho/Montana Section members are shown during their tour ofthe RA VE 1 1 facility in Butte, Mont. Brandon Greene (left) isIII shown' with Tim Youngberg, Fresno Section chair, at the March 17program.

lb - jjf ^fflfBHw^^p™" Mi • m dfcv?,*' ' fi

1 911 V J| K- m y 1 mi 1 i 1 H Fresno Section members pose for a photo with Pelco director Neadly Foster (center- front).

WELDING JOURNAL Member-Get-a-Member Campaign

isted are the participants in the G. Navas, Washington, D.C. — 3 J. Fox, Northwest Ohio — 17 2004-2005 Campaign. See page 65 T Neubauer. Sangamon Valley — 3 D. Marks, Lehigh Valley — 17 Lfor campaign rules and prize list. N. Rampersad. International — 3 P. Bedel, Indiana — 16 Call Membership Dept. (800) 443-9353, T Baldwin, Arrowhead — 2 D. Newman, Ozark — 16 ext. 480, for more information. M. Batchelor, Boston — 2 J. Carey, Boston — 15 A. Baughman, Stark Central — 2 J. Daugherty, Louisville — 14 Winner's Circle A. Burton, Chicago — 2 J. Davis, Maryland — 14 (A WS Members who have sponsored 20 J. Campbell, Milwaukee — 2 B. Lavallee, Northern New York — 14 or more new Individual Members, per year, J. Cantlin, Southern Colorado — 2 A. Badeaux, Washington, D.C. — 13 since June 1, 1999.) J. Carney, Western Michigan — 2 D. Kowalski, Pittsburgh — 13 J. Compton, San Fernando Valley4 K. Carter, Tri-River — 2 H. Jackson, L.A./lnland Empire — 13 E. Ezell, Mobile2 C. Daily, Puget Sound — 2 D. Schnalzer, Lehigh Valley — 13 J. Merzthal, Peru2 M. Darnell, San Antonio — 2 A. Stute, Madison-Beloit — 13 B. Mikeska, Houston1 M. Davidson, Tulsa — 2 D. Combs, Santa Clara Valley— 12 R. Peaslee, Detroit1 J. Emmerson, Connecticut — 2 V Covey, Central Texas — 12 W Shreve, Fox Valley1 K. Erickson, Florida West Coast — 2 S. Robeson, Cumberland Valley— 12 G. Taylor, Pascagoula2 G. Fudala, Philadelphia — 2 N. Carlson, E. Idaho/Montana — 11 S. McGill, Northeast Tennessee1 G. Garner, St. Louis — 2 R. Collins, New York — 11 T Weaver, Johnstown/Altoona1 P. Harper, Baton Rouge — 2 L. Davis, New Orleans — 11 G. Woomer, Johnstown/Altoona1 B. Jaskulski, Western Michigan — 2 C. Kipp, Lehigh Valley — 11 R. Wray, Nebraska1 D. Kensrue, Long Beach/Orange Cty — 2 B. Yarrison, York-Central Pa. — 11 Superscript denotes number of times the J. Krall, Dayton — 2 T Moore, New Orleans — 10 Member achieved Winner's Circle status. P. Layola, International — 2 R. Thomas, Sr., Holston Valley — 10 Status will be awarded at the close of each R. Nielsen, Utah — 2 A. Demarco, New Orleans — 9 membership campaign year. R. Olson, Siouxland. — 2 W Harris, Pascagoula — 9 H. Riviere, South Florida — 2 G. Putnam, Green & White Mts. — 9 President's Guild R. Robles, Corpus Christi — 2 R. Tupta, Milwaukee — 9 (A WS Members sponsoring 20 or more D. Russell, Chattanooga — 2 M. Koehler, Milwaukee — 8 new Individual Members between June 1, S. Salamon, New Jersey — 2 G. Seese, Pittsburgh — 8 2004, and May 31, 2005.) W Scarince, Northwest — 2 C. Wesley, Northwestern Pa. — 8 M. Karagoulis, Detroit — 43 G. Schroeter, Puget Sound — 2 T Alberts, Southwest Virginia — 7 J. Compton, San Fernando Valley — 28 O. Templet, Baton Rouge — 2 R. Chase, L.A./lnland Empire — 7 E. Ezell, Mobile — 22 J. Crosby, Atlanta — 7 Student Sponsors R. Palovcsik, St. Louis — 7 President's Roundtable (A WS Members sponsoring 3 or more new J. Swoyer, Lehigh Valley — 7 (A WS Members sponsoring 11-19 new In­ A WS Student Members between June 1, J. Carney, Western Michigan — 6 dividual Members between June 1, 2004, 2004, and May 31, 2005.) R. Grays, Kern — 6 and May 31, 2005.) C. Daily, Puget Sound — 83 M. Hill, Lexington — 6 G. Taylor, Pascagoula — 16 G. Euliano, Northwestern Pa. — 60 W Kielhorn, East Texas — 6 D. Herr, York-Central Penn. — 12 M. Pointer, Sierra Neveda — 46 T Shirk, Tidewater — 6 W. Shreve, Fox Valley — 12 R. Norris, Maine — 44 M. Tait, L.A./lnland Empire — 6 R. Olson, Siouxland — 43 J. Boyer, Lancaster — 5 President's Club K. Langdon, Johnny Appleseed — 29 C. Bridwell, Ozark — 5 (A WS Members sponsoring 6-10 new In­ D. Harrison, Cleveland — 28 R. Ledford, Birmingham — 5 dividual Members between June 1, 2004, H. Hughes, Mahoning Valley — 27 R. Rux, Wyoming — 5 and May 31, 2005.) D. Atteridge, Inland Empire — 25 D. Vranich, N. Florida — 5 J. Bobo, Atlanta — 9 D. Ketler, Willamette Valley — 24 G. Bish, Atlanta — 4 J. McCarty, St. Louis — 9 D. Scott. Peoria — 24 P. Carney, Lehigh Valley — 4 R. Culbert, Inland Empire — 8 A. Baughman. Stark Central — 22 R. Hilty, Pittsburgh — 4 W Campbell, Mid-Ohio — 22 J. Knapp, Tulsa — 4 President's Honor Roll J. Pelster, Southeast Nebraska — 22 R. Robles, Corpus Christi — 4 (A WS Members sponsoring 1-5 new In­ T Buchanan, Mid-Ohio — 21 B. Taves, Puget Sound — 4 dividual Members between June 1, 2004, P. Childers, Oklahoma City — 21 R. Theiss, Houston — 4 and May 31, 2005. Only those sponsor­ J. Sullivan, Mobile — 21 S. Ulrich, St. Louis — 4 ing 2 or more Members are listed.) F Wernet, Lehigh Valley — 21 M. Collins, Charlotte — 3 O. Baker, Olympic — 5 A. Reis, Pittsburgh — 20 S. Colton, San Diego — 3 J. Jaeger, Kansas — 5 T. Geisler, Pittsburgh — 19 S. Gore, Charlotte — 3 M. Tryon, Utah — 5 D. Hatfield, Tulsa — 19 T Gordon, Sabine — 3 B. Breeden, Santa Clara Valley — 4 S. Siviski, Maine — 19 J. Hope, Puget Sound — 3 G. Euliano, Northwestern Penn. — 4 R. Boyer, Nevada — 18 J. Hurry, Washington D.C. — 3 D. Guthrie, Tulsa — 4 W Galvery, Long Beach/Orange Cty — 18 T Kienbaum, Colorado — 3 C. Reeves, Oklahoma City — 4 D. Roskiewich, Philadelphia — 18 J. Morash, Boston — 3 T Shirk, Tidewater — 4 A. Vidick, Wyoming — 18 R. Olesky, Pittsburgh — 3 H. Shore, Tulsa — 4 D. Zabel, Southeast Nebraska — 18 R. Richwine, Indiana — 3 D. Wright, Kansas City — 4 M. Anderson, Indiana — 17 J. Sullivan, Holston Valley — 3* B. Franklin, Mobile — 3 T. Baldwin, Arrowhead — 17 E. Levert, North Texas — 3 C. Donnell. Northwest Ohio — 17 JULY 2005 CERTIFICATION OPERATIONS Deputy Executive Director Guide to AWS Services Jeffrey R. [email protected] (264) 550 NW LeJeune Rd., Miami, FL 33126 Department Information (273) Phone (800) 443-9353; (888) WELDING; FAX (305) 443-7559 Internet: www.aws.org Director, Operations Phone extensions appear in parentheses. Terry Perez., [email protected] (470) Director, Int'l Business Accreditation and Welder Certification Walter Herrera.. [email protected] (475) AWS PRESIDENT PUBLICATION SERVICES Damian J. Kotecki Department Information (275) Information on personnel certification and ac­ [email protected] creditation services. The Lincoln Electric Co. Managing Director 22801 St. Clair Ave. Cleveland, OH 44117-1199 Andrew Cullison.. cullisonia aws.org (249) AWS AWARDS, FELLOWS, and COUNSELORS Welding Journal Managing Director ADMINISTRATION Publisher/Editor Wendy S. Reeve., [email protected] (293) Andrew Cullison.. cullisonfaaws.org (249) Executive Director Coordinates AWS awards and AWS Fellow Ray W. Shook., [email protected].. .(210) and Counselor nominees. National Sales Director CFO/Deputy Executive Director Rob Saltzstein..saltymaws.org (243) Frank R. Tarafa.. [email protected] .(252) Welding Handbook TECHNICAL SERVICES Deputy Executive Director Welding Handbook Editor Department Information (340) Jeffrey R. Hufsey .. [email protected] .(264) Annette O'Brien., [email protected] (303) Managin" Director Andrew"R. Davis., [email protected] (466) Associate Executive Director Publishes the Society's monthly magazine, International Standards Activities, American Coun­ Cassie R. Burrell.. [email protected] .(253) Welding Journal, which provides information on cil ofthe International Institute of Welding (IIW) the state of the welding industry, its technol­ Associate Executive Director ogy, and Society activities. Publishes Inspection Director, National Standards Activities Jeff Weber.. [email protected] .(246) Trends, the Welding Handbook, and books on Peter [email protected] (309) general welding subjects. Machinery and Equipment Welding, Robotic Executive Assistant for Board Services and Automatic Welding, Computerization of Gricelda Manalich.. [email protected] .(294) Welding Information. MARKETING Corporate Director Manager. Safety and Health COMPENSATION + BENEFITS Bob Bishopric, [email protected] (213) Stephen P. Hedrick.. [email protected] (305) Director Metric Practice, Personnel and Facilities Qual­ Luisa Hernandez., [email protected] (266) Senior Manager, Marketing ification, Safety and Health, Joining of Plastics Linda [email protected] ....(298) and Composites. DATABASE ADMINISTRATION Marketing Communications Technical Publications Corporate Director Senior Manager Senior Manager, Jim Lankford.. [email protected] (214) George Leposky [email protected] ....(416) Rosalinda O'Neill., [email protected] ....(451) AWS publishes more than 200 technical standards Manager, Public Relations and publications widely used in the welding industry. INT'L INSTITUTE OF WELDING Magda Mvarez-tJ\\[email protected]. (308) Senior Coordinator Technical Committee Secretaries Sissibeth [email protected] (319) Plans and coordinates marketing of AWS prod­ Harold P. Ellison., [email protected] (299) ucts and services. Welding in Sanitary Applications, Automotive Provides liaison activities involving other pro­ Welding, Resistance Welding, High-Energy fessional societies and standards organizations, Beam Welding. Aircraft and Aerospace, Oxy­ nationally and internationally. MEMBER SERVICES fuel Gas Welding and Cutting. Department Information . ..(480) John L. [email protected] (472) GOVERNMENT LIAISON SERVICES Associate Executive Director Structural Welding, Welding Iron Castings. Hugh K. Webster [email protected] Cassie R. Burrell.. [email protected] ....(253) Webster, Chamberlain & Bean Rakesh Gupta., [email protected] (301) Washington, D.C. Director Filler Metals and Allied Materials, International (202) 466-2976; FAX (202) 835-0243 Rhenda A. Mayo... [email protected] (260) Filler Metals, Instrumentation for Welding.

Identifies funding sources for welding educa­ Serves as a liaison between Section members and Ross Hancock., [email protected] ....(226) tion, research, and development. Monitors leg­ AWS headquarters. Informs members about Welding Qualification, Friction Welding, Rail­ islative and regulatory issues of importance to AWS benefits and activities. road Welding, Joining of Metals and Alloys. the industry. Cynthia Jenney .. [email protected] ....(304) EDUCATION SERVICES Definitions and Symbols, Brazing and Soldering, BRAZING and SOLDERING Managing Director Brazing Filler Metals and Fluxes, Technical Editing. MANUFACTURERS' COMMITTEE Richard J. DePue... [email protected] ....(237) Jeff Weber., [email protected] (246) Brian McGrath . [email protected] (311) Educational Product Development Methods of Inspection, Mechanical Testing of Director Welds, Thermal Spray, Arc Welding and Cut­ WEMCO — Welding Equipment Christopher Pollock.. [email protected](219) ting, Welding in Marine Construction, Piping Manufacturers' Committee, and and Tubing, Titanium and Zirconium Filler WIN — Welding Industry Network Responsible for tracking the effectiveness of Metals, Filler Metals for Naval Vessels. Mary Ellen Mills., [email protected] (444) programs and development of new products and services. Coordinates in-plant seminars and Note: Official interpretations of AWS standards workshops. Administers the S.E.N.S.E. pro­ may be obtained only by sending a request in writ­ CONVENTION and EXPOSITIONS gram. Assists Government Liaison Committee ing to Ihe Managing Director, Technical Services. Exhibiting Information (242, 295) with advocacy efforts. Works with Education Oral opinions on A WS standards may be ren­ Committees to disseminate information on ca­ dered. However, such opinions represent only the Associate Executive Director/Sales Director reers, national education, and training trends, personal opinions ofthe particular individuals Jeff Weber., [email protected] (246) and schools that offer welding training, certifi­ iving them. These individuals do not speak on cates or degrees. f ehalf of A WS, nor do these oral opinions con­ Director of Convention & Expositions stitute official or unofficial opinions or interpre­ John Ospina.. [email protected] (462) Conferences and Seminars tations of A WS. In addition, oral opinions are in­ Director formal and should not be used as a substitute for Organizes the annual AWS Welding Show and Giselle I. Hufsey.. [email protected] (278) an official interpretation. Convention. Regulates space assignments, reg­ istration materials, and other Expo activities. Responsible for conferences, exhibitions, and seminars on topics ranging from the ba­ WEB SITE ADMINISTRATION sics to the leading edge of technology. Orga­ Director nizes CWI, SCWI, and 9-Year Renewal certifi­ Keith Thompson., [email protected].. ..(414) cation-driven seminars.

WELDING JOURNAL TeleWeld Nominees for National Office FAX: (305) 443-5951

Publications Sales/Orders Only Sustaining Members, Members, a Student Member, must be frequently Honorary Members, Life Members, or available to the national office, and Global Engineering Documents Retired Members who have been mem­ should be of executive status in business (800) 854-7179 or (303) 397-7956 bers for a period of at least three years or industry with experience in financial online at www.global.ihs.com shall be eligible for election as a direc­ affairs. tor or national officer. Director-at-Large: To be eligible for Journal Reprints It is the duty of the National Nominat­ election as a director-at-large, an indi­ Order quality custom reprints from ing Committee to nominate candidates for vidual shall previously have held office Claudia Stachowiak, FosteReprints national office. The committee shall hold as chairman of a Section; as chairman or telephone (866) 879-9144, ext. 121 an open meeting, preferably at the Annual vice chairman of a standing, technical or e-mail at [email protected] Meeting, at which members may appear to special committee of the Society; or as present and discuss the eligibility of all District director. candidates. Interested parties are to send a let­ To be considered a candidate for posi­ ter stating which particular office they AWS Foundation, Inc. tions of president, vice president, treas­ are seeking, including a statement of The AWS Foundation is a not-for-profit urer, or director-at-large, the following qualifications, their willingness and abil­ corporation established to provide support qualifications and conditions apply: ity to serve if nominated and elected, for educational and scientific endeavors President: To be eligible to hold the and 20 copies of their biographical of the American Welding Society. office of president, an individual must sketch. Information on gift-giving programs is have served as a vice president for at This material should be sent to available upon request. least one year. Thomas M. Mustaleski, Chairman, Na­ Vice President: To be eligible to hold tional Nominating Committee, Ameri­ Chairman, Board of Trustees the office of vice president, an individ­ can Welding Society, 550 NW LeJeune Ronald C. Pierce ual must have served at least one year Rd.. Miami, FL 33126. Executive Director as a director, other than executive direc­ The next meeting of the National Ray W. Shook tor and secretary. Nominating Committee is scheduled for Treasurer: To be eligible to hold the October 2006. The term of office for Managing Director office of treasurer, an individual must candidates nominated at this meeting Wendy S. Reeve be a member of the Society, other than will commence January 1, 2008.* 550 NW LeJeune Rd.. Miami. FL 33126 (305) 445-6628; (800) 443-9353, ext. 293 e-mail: [email protected] Honorary Meritorious Awards general information: (800) 443-9353, ext. 689 The Honorary-Meritorious Awards Committee makes recommendations for the nomi­ nees presented for Honorary Membership, National Meritorious Certificate. William Irrgang Memorial, and the George E. Willis Awards. These awards are presented during the AWS Exposition and Convention held each spring. The deadline for submissions is July 1 prior to the year of awards presentations. Send candidate materials to Wendy Sue Reeve, Secretary, AWS Mission Statement Honorary-Meritorious Awards Committee, 550 NW LeJeune Rd., Miami, FL33126. A descrip­ tion of the awards follow. The mission oj the American Welding Society is to advance the science, National Meritorious Certificate International Meritorious Certificate technology, and application of welding Award: This award is given in recognition Award: This award is given in recognition and allied processes, including of the candidate's counsel, loyalty, and de­ of the candidate's significant contributions joining, brazing, soldering, votion to the affairs of the Society, assis­ to the worldwide welding industry. This cutting, and thermal spraying. tance in promoting cordial relations with award should reflect "Service to the Inter­ industry and other organizations, and for national Welding Community" in the the contribution of time and effort on be­ broadest terms. The awardee is not re­ It is the intent of the American half of the Society. quired to be a member of the American Welding Society. Multiple awards can be Welding Society to build AWS to the highest quality standards possible. William Irrgang Memorial Award: This given per year as the situation dictates. The award is administered by the American award consists of a certificate to be pre­ The Society welcomes your suggestions. Welding Society and sponsored by The Lin­ sented at the awards luncheon or at an­ Please contact any staff member, or coln Electric Co. to honor the late William other time as appropriate in conjunction AWS President Damian J. Kotecki Irrgang. It is awarded each year to the indi­ with the AWS President's travel itinerary, as listed on the previous page. vidual who has done the most to enhance and, if appropriate, a one-year member­ the American Welding Society's goal of ad­ ship in the American Welding Society. vancing the science and technology of weld­ ing over the past five-year period.

George E. Willis Award: This award is Honorary Membership Award: An administered by the American Welding Honorary Member shall be a person of ac­ Society and sponsored by The Lincoln knowledged eminence in the welding pro­ Electric Co. to honor George E. Willis. It fession, or who is accredited with excep­ is awarded each year to an individual for tional accomplishments in the develop­ promoting the advancement of welding in­ ment of the welding art, upon whom the ternationally by fostering cooperative par­ American Welding Society sees fit to con­ ticipation in areas such as technology fer an honorary distinction. An Honorary transfer, standards rationalization, and Member shall have full rights of member­ promotion of industrial goodwill. ship.*

JULY 2005 CONFERENCES

10th AWS/AA Aluminum Welding Friction Stir Welding Conference Conference & Exhibition November 16 October 24-26 FABTECH International & Orlando, Fla. The AWS Welding Show Grosvenor Resort in the Walt Disney World Resort Chicago, III.

Welding the High-Performance The most interesting new welding process in years — friction Stainless Conference stir welding — will be the subject of this one-day conference. The November 14,15 speakers will be ready to answer many of the questions that are FABTECH International & on the minds of welding engineers. Presentations will be deliv­ The AWS Welding Show ered on the various types of equipment available, the tooling used Chicago, lit. to make the welds, case studies, and cost. Considerable time will also be spent on the use of this process in various industries, in­ This two-day conference will focus both on conventional stain­ cluding aerospace and automotive. There will also be a great deal less steels as well as the new high-performance grades such as of coverage on the use of friction stir welding for aluminum. Also duplex stainless, the superaustenitics, the superferritics, and the highlighted will be some of the progress being made on such ma­ supermartensitic stainless steels. Dr. Ralph Davison will present terials as titanium and steel. an overview of the high-performance stainless steels, while Don­ ald Tillack will provide helpful guidelines for the welding of the Radiographic Interpreters conventional grades. Other topics on the program will include the welding of dissimilar metals and the use of ferrite numbers. AWS announces a new program to train and certify AWS Ra­ A presentation on the use of the hosts of shielding gases for stain­ diographic Interpreters. If your job responsibilities include read­ less steels will be given by Kevin Lyttle. ing and interpreting weld radiographs, this program is for you. Seminars and exams are scheduled throughout the rest of the For more information please contact the AWS Conferences and Semi­ year in various U.S. cities. Call the AWS Certification Depart­ nars Business Unit at (800) 443-9353, ext. 223. You can also visit the ment, 800-443-9353, ext. 273, or visit www.aws.org/certificationlRI Conference Department at 1v1v1v.fliv5.org for upcoming conferences and for more information. registration information.

Power Supply Welding Heads 200 Amp Capability 1/16" to 3" Diameter 12" Touch Screen Common Rotor Driver Easily Programmable Full Metal Jacket Series Memory Card Slim Line Series for 1/4" S3 Welding Capability* Tangent to 1" Diameter Inboard Thermal Printer High Duty Cycle Universal Power Input Gas Cooled Operates Other Manufac­ Compatible with Other Manufacturers Power turers Weld Heads Supplies Real Time Weld Graphing Pressure Controller* Purge Fittings* Automatically Controls 1-1/2" to 6" Diameter Internal Weld Pressure Size Ranges Compensates for Varia­ Quick Connect and tions in Supply Pressure Release and Flow High Purity Compatible Compensates for Changing Eliminates Complicated Weld Joint Conditions and Expensive Purge Operates as a Stand Alone Connections System or Links to EXEL's Gives Convenient Inputs EPS-2000 Power Supply and Outputs Fault Alarming Provides Turbulent Recommends Proper Flow Cleaning Flow and Pressure for a Weld Union for Weld Site Pressure Calibration

* Features Patent Pending E*EI- Orbital Systems, Inc. (310) 449-0054 Circle No. 31 on Reader Info-Card WELDING JOURNAL NAVY JOINING ^SHE^W CENTER A MANTECH CENTER OF EXCELLENCE OPERATED BY EWI NJC Explores New Techniques for Virginia Class Sub Construction

he Navy Joining Center (NJC) is Two NJC Tcurrently leading a project to develop Fellowships novel design-for-manu- Awarded at facturing methods (DFM) and welding au­ AWS Welding Show tomation to support product-centered struc­ tural fabrication at Gen­ The Navy Joining Center each eral Dynamics Electric year supports two graduate fellow­ Boat (GDEB). The ships as part of its commitment to fur­ project team is combin­ ther technical education and the ad­ ing the welding process vancement of materials-joining tech­ and automation expert­ Fig. 1 — The Virginia Class submarine. (Photo by Chris Oxley, nology. These fellowships are ise of Edison Welding Northrop Grumman Corp.) Institute (EWI) and the awarded through the American manufacturing systems Welding Society Foundation to sup­ be limited unless consideration is given to port graduate students whose re­ design expertise ofthe Institute for Man­ the sequence in which individual pieces ufacturing and Sustainment Technology search topics address materials- or subassemblies are introduced and in­ joining topics of interest to the Navy. (iMAST) to assist GDEB in planning a cluded in the final welded structure. To­ new state-of-the-art fabrication facility ward that end, the project team is select­ The two NJC graduate fellowships that will feature product-centered manu­ ing automation methods and developing for the 2005-2006 academic year facturing. new fixturing technology. Fixtures are were announced at the AWS Welding Early in development activity, the proj­ being designed to accommodate the ac­ Show held in Dallas, Tex., in April. ect team identified a family of tank com­ cess and positioning requirements dic­ The NJC Fellowships for the up­ ponents in the Virginia Class submarine tated by optimized welding procedures coming academic year have been (Fig. 1) as a candidate for DFM princi­ and automated welding systems. awarded to Timothy Anderson, ples. The result was a flexible fixture de­ A Welding Procedure Estimator™ was Lehigh University, and Morgan Gal­ sign for the feed water, bilge water, and developed in Phase I of the project to ac­ lagher, The Ohio State University. lube oil tanks. curately predict welding fabrication time. Anderson is pursuing master's and As a direct result of the success of that This tool is being optimized to assist in doctorate degrees in material science project, a second-phase effort has been making production work assignments and and engineering with studies in "Alloy initiated to identify an additional family to enable GDEB to easily compare the Development of a Robust Filler of tank components from the Virginia economic benefits of multiple welding Metal for the Superaustenitic Stain­ Class submarine. The new family of tanks processes, and to compare the pros and less Steel AL-6XN®." selected for fixturing is the auxiliary tanks cons of semiautomatic vs. automated de­ Gallagher is pursuing his Ph.D. in and their associated wing tanks. These ployment of a single welding process. welding engineering with studies in tanks are more complex than the tanks ad­ The key to exploiting product- 'An Investigation of Hot Cracking in dressed earlier in the project. centered manufacturing is to improve pro­ Hastelloy® Alloy C-22®." State-of-the-art welding automation ductivity across production operations. technologies will be evaluated for GDEB GDEB has achieved significant advance­ For more information on the re­ production welding operations. Addition­ ments in cutting, forming, marking, and quirements for receiving graduate fel­ ally, the most appropriate welding process surface-preparation processes. Without lowships, contact the AWS Founda­ and portable automation solutions will be developing the requisite infrastructure to tion at (800) 443-9353, ext. 689. determined and functional requirements support product-centered manufacturing, will be established for a comprehensive the potential of these enhanced capabili­ flexible fixture design. ties will not be fully realized. The primary purpose of any welding The first year's efforts have shown suc­ fixture is to 1) assist in the accurate posi­ cesses and will continue in the next year The Navy Joining Center tioning of components for production to apply flexible fixture approaches em­ 1250 Arthur E. Adams Dr. welding and, 2) provide minimal interfer­ ploying DFM principles for the fabrica­ rue Columbus, OH 43221 ence to the welder (or automated device) tion of foundation tanks in the Virginia Operated by Phone: (614) 688-5010 as the welds are deposited. Class submarine. For more information, FAX: (614) 688-5001 contact Nancy Porter. Navy Joining e-mail: [email protected] Even with an optimum fixture, the abil­ www: httpj/www.ewlorg ity to produce a final component meeting Center, (614) 688-5194. e-mail EUJi Contact: Larry Brown all of the dimensional requirements will nancy _porter@ewi. org.

JULY 2005 PERSONNEL

Northrop Grumman marketing communications and hardware Appoints Four Vice product management. The Gas and Weld­ ing-North sales team was restructured Presidents under senior vice president Jack Brull. Scott Latta was promoted to lead the Mid­ west region, and Scott Snyder joined the company to head the Eastern region. Named as regional zone managers were Shane Dillman (Wisconsin), Ken Ishman (Michigan), Don Speight (Chicago area), Mike Shawcross and Heath Wells (central Illinois and Mis­ souri), Joel Lewandowski (NE Ohio and to their promotions. Mahler served as pro­ western Pennsylvania), Hal Mager gram director responsible for completion (Cincinnati area, Kentucky, West Vir­ of the USS Ronald Reagan, and Shawcross ginia, and northern Tennessee), and Jim Robert L. Gunter Matthew J. Mulherin served as CVN 21 propulsion plant Simpson (central Indiana and Ohio). In program director. the Gas and Welding-South division, Northrop Grumman, Newport News, under Vice President Dave Carter, Paul Va., has named Robert L. Gunter, sector Smith has been named manager, Georgia vice president of operations; Matthew J. Linde Gas Announces region, replacing Bob Slagle, who was re­ Mulherin, sector vice president of pro­ Management Changes cently promoted to manager, regional op­ grams; Ken Mahler, vice president for air­ erations south. craft carrier overhauls; and Mike Shaw- Linde Gas, Cleveland, Ohio, has cross, vice president of the CVN 21 pro­ named Howard Hubert to succeed Cliff gram. Prior to this appointment, Gunter Caldwell who was recently promoted to MG Systems and Welding was vice president for aircraft carrier pro­ global specialty gas manager for Lin- Hires Sales Manager grams and vice president of engineering. deAG. Chris Ebeling has been named Mulherin most recently served as vice marketing director for gas and welding; MG Systems and Welding, Menomonee president for the CVN 21 program. Prior and David Browning appointed manager, — continued on page 83

HIRE JOB SEEKERS WHO STAND OUT i£U www.awsjobfind.com BETTER CANDIDATES, DETTED RESULTS AWS JobFind works better than other job sites because it special­ izes in the materials joining industry. Hire those hard-to-find Certified Welding Inspectors (CWIs), Welders, Engineers, Welding Managers, Consultants and more at www.awsjobfind.com You'll find more than 2,000 resumes of top job seekers in the industry!

THE TOOLS TO 00 MORE AWS JobFind provides companies with the tools to post, edit and manage their job listings easily and effectively, any day or time, have immediate access to an entire resume database of qualified candidates, look for candidates who match their employment needs: full-time, part-time or contract employees, receive and respond to resumes, cover letters, etc. via e-mail.

Circle No. 9 on Reader Info-Card WELDING JOURNAL NEW LITERATURE FOR MORE INFORMATION. CIRCLE NUMBER ON READER INFORMATION CARD.

Industrial Plastic Products modules, micro, guided, twin-rod, clamp­ Displayed ing devices, and NCT noncontact trans­ fer units. Also detailed are right-angle 1 flow controls as accessories. D | Bosch Rexroth Corp. 117 5150 Prairie Stone Pkwy.. Hoffman Estates. IL 60192 PUSTICS POWDEfl MET1 ! INDUSTRIAL & LABORATORY SUPPLIES fw Welding Course Catalog 1-800-362-1000 Anwwass

• ^ffli «-

tions, conference proceedings, and videos detailing every aspect of powder metal­ lurgy and particulate materials. General DfTED topics include ferrous powder metallurgy, PUJTWCO*«um!C. aluminum and light alloys, cemented car­ bides, metal and ceramic injection mold­ A colorful 88-page catalog illustrates ing, tungsten and refractory metals, me­ and describes the company's wide assort­ chanical alloying, sintering, nanotechnol- ment of products for industrial use. Shown ogy, and metallography. are plastic bins, containers, tubing, gloves, Metal Powder Industries Federation 116 The 44-page course catalog details the stretch film wraps, aprons, rainwear, cov­ 105 College Rd. E. Princeton. NJ 08540-6692 eralls, shoe covers, and Tyvek® clothing school's history, types of training, train­ products. Other items include siphons and ing methods, facilities, and detailed course rotary hand pumps, poly and steel drums Pneumatic Cylinders and contents, and schedules. Complete infor­ up to 55-gal, vials, and bags-on-rolls. Actuators Pictured mation is presented on costs, financial aid, loans, and grants. Included are descrip­ Consolidated Plastics Co., Inc. 115 The 700-page SC-Masterl catalog of­ tions of new seminars on laser welding and 8181 Darrow Rd., TXvinsburg. OH 44087 fers technical and ordering details re­ processing, and robotic arc welding. In­ garding industrial pneumatic cylinders formation is presented on opportunities Powder Metallurgy and actuators. Among the 23 product for in-plant training at the customer's site, Publications Detailed lines listed are TaskMaster® aluminum and other specialized training services. profile, PowerMaster® NFPA steel tie A 20-page catalog describes dozens of rod, Easy-2-Combine modular handling Hobart Institute of textbooks, manuals, standards, publica- system, grippers, rotary actuators and Welding Technology 118 400 trade Square East. Troy, OH 45373 Surface Prep Supplies for Contractors Showcased

COR-MET A brochure details the company's sup­ plies, equipment, service, and solutions SPECIALTY CORED WIRE for a wide range of surface preparation AND COATED ELECTRODES applications. Shown are air blast, abra­ sives, mass finishing, and coated and (810) 227-3251 FAX: (810) 227-9266 bonded abrasives. Other topics covered include service and training, air tools, dust www.cor-met.com collector cartridges, parts processing labs, industrial safety products, and wheel blast equipment and parts.

M4J International Surface Preparation 119 603 Park Point Dr.. Ste. 200. Golden. CO 80401

Circle No. 15 on Reader Info-Card JULY 2005 PERSONNEL NEW PRODUCTS

:d from page SI — continued from page 21

MEMBER MILESTONE

John L. Mendoza Elected to SkillsUSA Board

John L. Mendoza has been elected to the board of direc­ tors for the SkillsUSA Texas College/Postsecondary Division. The body is responsible for setting policy for SkillsUSA activi­ ties in the state of Texas. Mendoza is currently the AWS District 18 director. He is an AWS Certified Welding Inspector and a Certified Welding Educator.

John Mendoza

Falls, Wis., has manufacturing systems unit. Prior to join­ appointed John ing the company, Chambers held positions Hansen, south-cen­ with General Conveyor and Mathews Con­ tral territory regional veyor. Swietlinski, who now reports to sales manager, re­ Chambers, previously worked for General cutting direction can be changed quickly. sponsible for Texas, Conveyor, Comptrol, and Chronos/Howe It is equipped with a quick-release tool New Mexico, Okla­ Richardson. changer, and sheet thickness adjustment homa, Arkansas, and is accomplished without the use of addi­ Louisiana west of the tional tools. The required beveled edge Mississippi River. Airgas Names Senior VP height is selected on a dial, and the bevel Hansen has 23 years angle of 30. 37.5, or 45 deg is changed by John Hansen using different guide bracket options. The of experience work­ Airgas, Inc., Rad­ ing with capital motor offers 1600-W output and is nor, Pa., has named equipped with a two-stage planetary gear equipment and machine tools in marketing Michael Rohde to set for consistent power distribution while and sales positions. the new position of allowing the overall design to remain senior vice presi­ compact. dent, distributions Battelle Honors Scientist operations. Previ­ TRUMPF, Inc. 113 for Welding Breakthrough ously, Rohde served 111 Hyde Rd.. Farmington. CT 06032 as regional company Battelle Memorial Institute researcher president of Airgas Curtain Equipped with South for the past Pingsha Dong was awarded the Aerospace Michael Rohde Carbon Scrim 2004 Laurels Award from Aviation Week five years. and Space Technology for his breakthrough method of predicting the fatigue life of Electro-Safe, a heavy-duty transpar­ welded structures. Dong's Verity™ mesh- OBITUARY ent vinyl curtain, is equipped with carbon insensitive structural stress method, ex­ scrim, which grounds out all electrical perts say, could save billions of dollars in David J. Crawford charges, bringing the curtain down to zero aerospace, automotive, and other engi­ voltage. The 12-mil curtain is also fire re­ neering fields by allowing companies to sistant, making it recommended for oxy­ reduce expensive testing practices and ov- David J. Craw­ gen-rich and dust-free atmospheres. The erengincering of designs. ford, 53, died April antistatic curtain is resistant to abrasion, 15. Mr. Crawford cleaning processes, and corrosion. It is was involved in all useful for areas in which danger from ex­ aspects of distribu­ plosives is present. FKI Logistex Appoints Two tion and finance at Canadian Representatives Atlas Welding Ac­ Wilson Industries, Inc. 114 cessories, Inc., with 123 Explorer St.. Pomona. CA 91768 FKI Logistex, St. locations in Michi­ Louis, Mo., has ap­ gan and New York. pointed Glen Cham­ David J. Crawjord He was active in bers as regional di­ AWS District 11, rector, and Paul Swi- and Detroit Section etlinski as business events, and participated in the prepara­ HOTTEST WELDING development man­ tions for the AWS Welding Shows. Among BOOKS ON THE WEB ager, for the Cana­ his favorite activities were playing golf and dian operations of its basketball, and sports coaching. He is sur­ North American vived by his wife and three daughters. www.aws.org/catalogs Glen Chambers

WELDING JOURNAL CLASSIFIEDS

CAREER OPPORTUNITIES

ATTENTION HARDFACING SALES SALES POSITION

If you possess a thorough understanding of Seeking individual tor sales position with welding equipment welding processes manufacturer. Position is for Texas and Louisiana territory. It is pre­ ferred candidate reside in the Houston or western Louisiana region. If you have a successful track record in Industrial Sales Experience calling on distribution and end users a plus. A knowledge of welding processes a must. We offer a competitive salary and com­ Postle Industries may have an opening for you mission plan, company car, 401K, medical and dental insurance and more. Salary commensurate with experience.

Send resume with salary requirements/history to Abicor Binzel, Call 800-321-2978 Human Resources 650 Research Drive, Frederick, MD 21703 or Ask for John Postle email [email protected] EOE-Drug Free Work Environment

STAFF ENGINEER/COMMITTEE ADMINISTRATOR NDT TECHNICIAN INTERNATIONAL STANDARDS DEVELOPMENT - MIAMI, FL Must be qualified at Level 2, Radiographic inspections, Ultrasonic testing, Magnetic Principal duties include management of ISO technical com­ Interested parties should send a Particle testing. An AWS CWI certification mittees that develop International Standards for the welding resume and salary range along with would be a plus. All certifications must be industry worldwide, U.S. Technical Advisory Groups (TAGs) a cover letter outlining interest to traceable to a recognized industrial stan­ to ISO committees that develop U.S. positions on draft ISO dard, i.e., SNT-TC-1A and/or ANSI/ASNT. standards, and AWS Technical Committees that develop American Welding Society MT, RT, UT certification required. U.S. national welding standards. Involves approximately 550 N.W. LeJeune Rd. High familiarity of QC standards and pro­ 20% travel, some international. Miami. FL 33126 cedures is essential. A good working Requires a University degree, preferably in engineering or Attn.: Andrew Davis knowledge of welding and heavy metal fab­ Technical Services rication is essential. Ability to communi­ equivalent (experience in welding or manufacturing desir­ [email protected] able), standards development experience, especially ISO cate (written and verbal) required. procedures (either as a committee member or from a stan­ AWS -An Equal Opportunity Employer Kurt Geiger, PHR dards development organization), excellent verbal and writ­ Visit our Website at www.aws.org 215-875-2661 ten English skills. Must be computer literate, proficient in MS Kvaerner Philadelphia Shipyard Windows/PC environment and have good e-mail and inter­ Human Resources net skills (for web-based standards development). EXPERIENCED MIG WELDERS NEEDED REGIONAL MANAGER -CENTRAL/EASTERN US Westech/WOTCO, a 100% employee-owned fabrication co. located in Casper, Wyoming, has Come grow with us. immediate openings for day and night shifts. We Steiner Industries is a leading manufacturer of welding & industrial safety and protective have been in business since 1938 and at our products. Due to our growth and planned expansion, we are seeking a dynamic and present location since 1952. WOTCO builds experienced sales professional to manage regional sales through our existing network of LARGE off-road mining equipment that ships manufacturer's representatives in the welding and industrial distribution channels. worldwide. Must be able to weld with MIG using The Regional Sales Manager will be responsible for managing existing distribution, GMAW with .045 weld wire & FCAW with 3/32 & developing new business opportunities & planning for the growth in his or her region. 1/16. We offer great wages with an excellent ben­ Essential qualifications include: welding industry experience, exceptional written interper­ efit package THAT includes Employee Stock Own­ sonal, presentation & communication skills, and the desire to make things happen! Competitive compensation package including salary with bonus, travel allowance, health ership Plan, paid vacation, paid holidays, insurance, paid vacation and holidays and profit sharing plan. education support, IRA program, insurance coverage (health, dental & life insurance). Our STEINER INDUSTRIES 5801 North Tripp Avenue address is 415 1 st Street, Mills, WY or call toll Chicago IL, 60646 free 888-235-6475 x124 or e-mail [email protected] e-mail your resume to: [email protected] - pre-employment drug testing EOE. Please visit Learn more about Steiner at www.steinerindustries.com ^EK our website at www.wstch.com.

JULY 2005 EQUIPMENT FOR SALE OR RENT

JUST IN!! (6) "Late 2003" Panasonic Robotic TIG Welding Cells - Some with Cold Wire Feed & 7th Axis Pana-Dice Positioners. Exceptional Condition!! We Buy & Sell Surplus Call for Details. Welding Rod & Wire "BRAND-NEW 2005" IN OUR STOCK!! PANDJIRIS POSITIONERS!! All types, sizes & Quantities PRESTON-EASTIN & WEBB TURNING ROLLS!! JETLINE SEAMERS!! Well over 150 Positioners Total, Up to 60 Tons!! Head/Tailstocks. Turntables up to 100 tons. Manipulators up to 14' x 14', Travel Cars, Longitudinal Seamers from 6 in. to 26 ft, Turning rolls up to 400 Tons, Circular Weld Systems. Welding Lathes, Motoman and Panasonic Welding Robots. Call us first! "WE KNOW WELDING" TALK TO US!! * * * * COME VISIT US!! 800-523-2791 PA: 610-825-1250 www.weldplus.com FAX: 610-825-1553 E-mail: [email protected] 800-288-9414 WELD PLUS Jack, Pete, Paul or Dennis FOR SALE - FOR RENT Fax: 513-467-3585 Welding Positioners Headstock Tailstock Tank Turning Rolls Manipulators, Subarc Used-Robots Welding Machines 800-218-9620 ^j& 713-943-8032 We buy and sell www.mitrowskiwelding.com 1-877-487-3376 RED-D-ARC sales @ mitrowskiwelding.com We buy and sell Welderentals Welding Positioners & Turning Rolls WELDING RODS & WIRE New and Used ••ALL TYPES •• ALL SIZES •• www. red-d-arc. com ALL QUANTITIES All Types of Welding and Positioning Large selection in stock for Equipment for Rental and Lease immediate delivery.

1-800-245-3660 www.allfabcorp.com \Service Centers Across North America . Excess Welding Alloys, Inc. Call. Fax or Email for a free catalog. A division of Weld Wire Company Inc. 800-523-1266 FAX 610-265-7806 Email: [email protected] www.weldwire.net REPRINTS REPRINTS All-Fab Com Web: www-a"fa',corP-com Phone:269-673-6572 Fax: 269-673-1644 To order custom reprints ATTENTION! of articles in Welding Equipment Sales Personnel. We pay you for finding us good used Welding Journal, Turning Rolls welding systems, seamers, positioners, call FosteReprints at manipulators, turning rolls, etc. We will buy your customers' trade-ins. (219) 879-8366 or Positioners WELD PLUS, INC. (800) 382-0808 or. & Manipulators 1-800-288-9414 Request for quotes can be faxed to (219) 874-2849. New and Used You can e-mail robots4we Id ing FosteReprints at Joe Fuller LLC sales @fostereprints. com @ www.joefuller.com .com or email [email protected] Toll free: 1-800-762-6862 Phone: 979-277-8343 Fax: 281-290-6184

WELDING JOURNAL CERTIFICATION & SERVICES TRAINING

The AWS Certification

ADVERTISER INDEX

Aelectronic Bonding, Inc www.abiusa.net 46 Fischer Technology, Inc www.Fischer-Technology.com 24 AWS Certification Dept www.aws.org 25, 31 HANDS-ON Home Loans 888-430-8695 19 AWS Conference Dept www.aws.org 124s Hobart Inst. of Welding Technology www.welding.org 50 AWS Convention and Exhibitions ....www.aws.org 1 ICALEO www.icaleo.org 48 AWS Foundation www.aws.org 14 Jackson Products www.jacksonproducts.com 5 AWS Member Services www.aws.org 20, 40, 81 Lincoln Electric Co www.lincolneIectric.com OBC AWS Technical Services wwH.aws.org 2 Materials Science & Technology www.matscitech.org 43 Centerline Ltd www.cntrline.com RI Select Arc, Inc www.select-arc.com IFC College of Oceaneering www.coo.edu 17 Triangle Engineering, Inc www.trieng.com 49 Commercial Diving Academy www.commercialdivingacademv.com ..21 Washington Alloy Co www.welding-aIloys.com 11 Cor-Met www.cor-met.com 10, 82 Weld Hugger, L.L.C www.weldhugger.com 24 C-Spec www.weldoffice.com 49 WEMCO www.aws.org 13 Diamond Ground Products, Inc www.diamondground.com 49 Divers Academy International www.diversacademy.com 9 IFC = Inside Front Cover Edison Welding Institute www.ewi.org 80 IBC = Inside Back Cover ESAB Welding & Cutting Products ..www.esabna.com IBC OBC = Outside Back Cover Exel Orbital Svstems, Inc www.exelorbital.com 79 RI = Reader Information Card

JULY 2005 SUPPLEMENT TO THE WELDING JOURNAL, JULY 2005 Sponsored by the American Welding Society and the Welding Research Council

Reliable Calculations of Heat and Fluid Flow during Conduction Mode Laser Welding through Optimization of Uncertain Parameters

A deterministic approach is proposed to improve reliability of heat transfer and fluid flow calculations

BY A. DE AND T. DebROY

ABSTRACT. During conduction mode Introduction ufacturing or design applications. An im­ laser beam welding, the quality of numer­ portant difficulty is the uncertainty in­ ical simulation of heat transfer and fluid Since the temperature and velocity volved in specifying some ofthe necessary flow in the weld pool is significantly af­ fields in the weld pool are difficult to mea­ input variables such as absorptivity, effec­ fected by the uncertainty in the values of sure experimentally (Refs. 1-7), these im­ tive thermal conductivity, and effective absorptivity, effective thermal conductiv­ portant variables are often estimated by viscosity. Although the time-tested physi­ ity, and effective viscosity that cannot be numerically solving the equations of con­ cal laws such as the equations of conser­ easily prescribed from fundamental prin­ servation of mass, momentum, and en­ vation of mass, momentum, and energy ciples. Traditionally, values of these para­ ergy. In recent years, the numerically com­ provide a reliable phenomenological meters are either prescribed based on ex­ puted temperature fields have been framework for calculations, the reliability perience or adjusted by trial and error. utilized to estimate weld pool dimensions of the numerical process models greatly This paper proposes a deterministic ap­ (Refs. 4-7) and understand weld metal depends on the accuracy of several input proach to improve reliability of heat trans­ phase composition (Refs. 8-11), grain parameters. fer and fluid flow calculations. The ap­ structure (Refs. 10, 11), inclusion struc­ Many input parameters necessary for proach involves evaluation of the ture (Refs. 12-14), and weld metal com­ the numerical simulation of heat transfer optimized values of absorptivity, effective position changes owing to both vaporiza­ and fluid flow in conduction-mode linear thermal conductivity, and effective viscos­ tion of alloying elements (Refs. 15, 16) and laser beam welding can be readily speci­ ity during conduction mode laser beam dissolution of gases (Refs. 17, 18). fied. These include welding speed, beam welding from a limited volume of experi­ The transport phenomena-based nu­ power, beam diameter, and thermophysi­ mental data utilizing an iterative multi- merical models have been continually up­ cal properties of the material being variable optimization scheme and a nu­ dated to include more detailed and realis­ welded (Refs. 19,24). However, the values merical heat transfer and fluid flow model. tic descriptions of component physical of absorptivity, effective thermal conduc­ The optimization technique minimizes the processes for simple(Refs. 19-22) as well tivity and effective viscosity cannot be error between the predicted and the mea­ as for complex weld joint geometries (Ref. specified from fundamental principles sured weld dimensions by considering the 23). In recent years, these models have be­ (Refs. 2,24-30). For example, absorptivity sensitivity of weld dimensions with respect come relatively easy to use because of ad­ to absorptivity, effective thermal conduc­ depends on the chemical composition of vances in computational hardware and tivity, and effective viscosity. Five sets of the substrate, the surface finish, laser software. However, these powerful nu­ measured weld pool dimensions corre­ mode, and the prevailing temperature dis­ merical heat transfer and fluid flow mod­ sponding to five different welding condi­ tribution on the weld pool. As a result, the els have not found widespread use in man- tions were utilized for the optimization. absorption coefficient cannot be esti­ However, the procedure could identify the mated theoretically with high reliability. optimized values of the three uncertain However, an accurate value of absorptiv­ parameters even with only three sets of ity is critical for the dependable estimation measured weld pool dimensions. KEY WORDS of the rate of heat absorption. Similarly, appropriate values of effective thermal Laser conductivity and effective viscosity are A. DE ([email protected]) is with the Me­ Laser Beam Welding needed for the reliable modeling of the chanical Engineering Department, IIT Heat Transfer high rates of transport of heat, mass, and Bombay, Mumbai, India. T. DebROY (de- Fluid Flow momentum in weld pools with strong fluc­ [email protected]) is with the Department of Conduction Mode tuating velocities (Ref. 25). Enhanced val­ Material Science and Engineering, The ues of liquid thermal conductivity and vis­ Pennsylvania State University, University cosity have been frequently used to take Park, Pa. into account the effects of the fluctuating

WELDING JOURNAL BT ^0 i • i 'i i • i • i • i • i so 44- 44- V I 38- 38- / - \ \ 32- 1.10 \ 1.00 32- \ \ 26 * " 26 \ \ 1-15 / n* . •^ 1.25\ \ 20- : \ \ 1.05/ - 14- 0.80 \ \ " 14- 0.60\ V / 0.90 vJ \ 1n2 0 \ \ \ ' 8- 8- / ) ii/ ; 2- 2- Vv ,,(/ I'M I ' I ' I ' I ' I ' I ' I 1 3 5 7 9 11 13 15 17 1 3 5 7*9 11 13 15 17 k k*

Fig. 1 — Influence ofk* and u* on (i) p* and (ii) w'nwith assumed absorptivity (r]> of 0.30. Welding parameters: P = 3200 W. v = 3.33 mm/s (NHI = 21.90).

flow model several times for each measure­ Table 1 -- Measured Weld Dimensions Welding Parameters (Ref. 24) and Heat Input Index ment considering small changes in the ab­ sorptivity, effective thermal conductivity, Data Laser Weld Spot N,„ Weld Weld and effective viscosity (Refs. 29, 30). Set Power Velocity Radius Penetration Width The approach determines the values of Index (W) (mm.s-1) (mm) (mm) (mm) absorptivity, effective viscosity and ther­ 1 3500 8.33 1.3 9.67 1.00 4.00 mal conductivity in an iterative manner 2 5000 8.33 1.3 14.97 1.25 5.25 starting from a set of their initial guessed 3 3200 3.33 1.4 21.90 1.75 4.00 values. In order to include the effects of 4 4800 3.33 1.4 32.90 2.50 6.00 laser power, spot diameter, and welding 5 5000 3.33 1.3 34.53 2.25 6.75 speed into one convenient variable during optimization, a nondimensional heat input variable, NHI, is defined as Table 2 — Chemical Composition (wt-%) of properties (Refs. 1,2,24-30) and their val­ High-Speed Steel Used for Welding ues depend on welding conditions, partic­ Experiments131 ularly the heat input. Nm = *l- PCpS(TL-Ta) + PL The values of effective viscosity and (1) C Cr W Mo V Co Mn thermal conductivity have been determined in this work as a function of heat input from where P is the laser power (W), rb the spot 0.92 3.88 6.08 4.9 1.73 0 0.26 a limited volume of measured weld pool di­ radius (m), v the welding velocity (ms-1), Si S Ni P Cu Al Fe mensions for conduction mode linear laser CPS the specific heat of the solid metal 0.23 0.001 0.24 0.024 0.20 0.019 Bal. beam welding (Ref. 24) utilizing an opti­ (Jkg-i-K-1), p the density (kg-m-3), L the mization algorithm and a numerical heat latent heat of fusion (Jkg-1) and T and T, (a) for data set index 1, 2, and 5 (Ref. 24). L transfer and fluid flow model. In contrast are the liquidus and ambient tempera­ with the effective viscosity or the effective tures (K), respectively. In Equation 1, the components of velocities in the weld pool. thermal conductivity, the laser beam ab­ numerator represents the available laser In some cases, the two-equation k-e tur­ sorption coefficient is a materials property. power per unit volume and the denomina­ bulence model has also been used in esti­ Although it varies with temperature, the ex­ tor depicts the enthalpy required to heat a mating the effective viscosity and effective tent of the variation is normally much unit volume of metal from ambient tem­ thermal conductivity in the weld pool smaller than those of the effective thermal perature to liquidus temperature. The nu­ (Refs. 26-28). However, the two-equation conductivity or the effective viscosity. It has merator in Equation 1 when multiplied by k-£ turbulence model contains several em­ been taken as a constant in this work for the absorptivity, r\, provides the absorbed pirical constants that were originally esti­ simplicity. The optimization algorithm min­ heat per unit volume. The optimization mated from parabolic fluid flow data in imizes the error between the predicted and approach identifies a single value of ab­ large systems. As a result, its applicability the experimentally observed penetrations sorptivity and a linear trend of effective for the recirculating flow in small scale sys­ and the weld widths by considering the sen­ thermal conductivity and effective viscos­ tems has not been adequately tested. sitivity of the computed weld pool dimen­ ity with NJJJ from a limited volume of mea­ Since the effective thermal conductivity sions with respect to the absorptivity, effec­ surements. and viscosity depend on the turbulent ki­ tive thermal conductivity, and effective The work presented in this manuscript netic energy and other properties of con­ viscosity. The sensitivity terms are calcu­ represents a significant improvement over vection, these parameters are system lated by running the heat transfer and fluid the previous (Refs. 31-35) reverse model-

JULY2005 Fig. 2 — Influence ofk* and u* on O(f) with assumed absorptivity (r\) of Fig. 3 —Influence ofk* and u* on Off) with assumed absorptivity (r\) of 0.30. Welding parameters: P = 3200 W, v = 3.33 mm/s (NHI = 21.90). 0.30. Welding parameters: P = 5000 W,v = 8.33 mm/s (NH, = 14.97). ing work in welding reported in the litera­ Table 4 — Data Used for Calculations of ture. First, unlike the previous efforts, a Table 3 — Chemical Composition (wt-%) of High-Speed Steel Used for Welding Temperature and Velocity Fields-" well-tested, three-dimensional numerical Experiments11" heat transfer and fluid flow model is used Physical Property Value to compute the weld pool geometry. This C Cr W Mo V Co Mn is significant, because previous research Liquidus temperature, TL (K) 1700.0 has shown the importance of convective 0.21 0.21 <0.05 0.05 <0.02 <0.05 1.52 Solidus temperature, Ts (K) 1480.0 heat transfer in the weld pool. Second, the Si S Ni P Cu Al Fe Ambient temperature, T, (K) 293.0 Density of liquid metal, p (kg/m') 8.1 x 103 model input and the computed weld pool 0.36 0.006 0.14 <0.005 0.14 0.01 Bal. geometry are related by a rigorous phe­ Thermal conductivity of solid, 25.08 (a) for data set index 3 and 4 (Ref. 24). ks (W m-i K-i) nomenological framework of the conser­ Thermal conductivity of liquid, 25.08 vation of mass, momentum, and energy kL(Wm-iK-i) used in the optimization algorithm. The steels are given in Tables 4 and 5. The flow Specific heat of solid, 711.0 optimized values of absorptivity, effective of liquid metal in the weld pool in a three- CpS(Jkg-iK-i) thermal conductivity, and effective viscos­ dimensional cartesian coordinate system Specific heat of liquid, 711.0 ity were tested by comparing the com­ is represented by the following momen­ CPL(Jkg-iK-i) puted weld dimensions with the corre­ Temperature coefficient of -0.5 x 1(H tum conservation equation (Refs. 4, 21, surface tension. dy/dT (N nr1 Kr1) sponding experimentally determined 22, 36): 6 values (Ref. 4). Coefficient of thermal 1.5 xlO- expansion, p (K-') 3 The effect of volume of data on the 3«: d\u,uj) Viscosity of molten iron 6.7 x 10- outcome of the optimization was exam­ - + P- + s, at 1823 K, Hfi(kg.m-is-i) dx. dxt y dx, ined. First, the optimization was done (2) (a) for data set index 1. 2. and 5 (Ref. 24). using five sets of measured weld pool di­ mensions. Second, the optimization was where p is the density, t is the time, X; is the also carried out with only three measured distance along the i = 1,2 and 3 directions, data sets of weld pool dimensions. The op­ Uj is the velocity component along the j di­ avoid division by zero, C (=1.6 x 104) is a timized values of the uncertain variables rection, p. is the effective viscosity, and S, constant that takes into account mushy th were almost identical in both cases. is the source term for the j momentum zone morphology and Sb: represents both equation and is given as (Refs. 21, 22) the electromagnetic and buoyancy source Heat Transfer and Fluid Flow terms. The third term on the right-hand Simulation du.- side (RHS) represents the frictional dissi­ S,=- X + X pation in the mushy zone according to the dx Table 1 depicts five sets of measure­ 1 J Carman-Kozeny equation for flow ments of weld dimensions and the corre­ through a porous media (-Refs. 37, 38). sponding welding parameters that have 1-ft rrdUj _, The pressure field was obtained by solving been used in the present investigation. C itj-pU—L + Sbj the following continuity equation simulta­ The chemical compositions of the steels neously with the momentum equation fL +B dX: used are presented in Tables 2 and 3. The (3) steel compositions conform to two differ­ X'i) ent grades of high-speed steel (Ref. 24). where p is the pressure, fL is the liquid The thermophysical properties of these fraction, B is a constant introduced to dx, (4)

WELDING JOURNAL HI niiiniiisi

40.0- 40.0- i Initial guess : set 1 Initial guess : set 1 i \ Initial guess : set 2 Initial guess : set 2 •i 10.0- • i Initial guess : set 3 10.0- Initial guess : set 3 ; \ Initial guess : set 4 Initial guess : set 4 5.0- • \ 5.0- '. > 0(f) (i) O(f) (ii) 1.0- 1.0-

0.1 i • i • i • i • i ' i ' i • i 0.1 T T T 1 3 5 7 9 11 13 15 1 21 41 61 81 101 Number of iterations Number of iterations

40.0- 44.0 Initial guess : set 1 Initial guess : set 2 10.0- Initial guess : set 3 Initial guess : set 4 5.0- O(f) (in) 1.0-

1 i ' i ' i ' i ' i ' i ' 0.1 i 6 10 14 18 22 26 30 34 38 21 41 61 81 101 Non-dimensional heat input, N Number of iterations

Fig. 4 — Progress of calculation with four sets of intitial guessed values Fig. 5 — Estimated optimum values ofk* and \i* for all values ofNHI. (Op­ using li) LM method, (ii) CGPR method, and (iii) CGFR method. The ini­ timum value oft] = 0.25 for all values ofN^/) tial guessed values are presented in Table 6.

The total enthalpy H is represented by a energy equation (Refs. 4, 21): the value of the effective thermal conduc­ sum of sensible heat h and latent heat con­ tivity is not known. Since the weld is sym­ tent AH, i.e., H = h + AH where h = =C metrical about the weld centerline only p dh 3(M,-/I) _cf k dh dT, Cp is the specific heat, T is the tem­ half of the workpiece is considered. The dt dx. 3.v, Cp dx. perature, AH = fLL, L is the latent heat of weld top surface is assumed to be flat. The fusion and the liquid fraction f is assumed velocity boundary condition is given as L dAH diuiW) dh to vary linearly with temperature in the -p——pX- '—pil•jr (Ref. 4) mushy zone -(Ref. 4). ot dx, dx, dAH du dy dT T>T -pU JL L dx. dT dx fl T

JULY 2005 miMiiiiiiiii M

- ••'—i—i—i—' —!—,.. ,.. , , ' 1 ' I ' if) 0 : p„, 2.5- - _Q - ra D : Wm i_ - ru 2.0- > 1.5- - c 0.2 m/s QJ o i i i i i i i i i i i I i i i i' •a 1.0- G B a c o 1 2 3 cu Distance, mm Q. 0.5- - QJ Fig. 7 — Experimentally determined and computed weld pool geometry. The length ofthe black airow shows the magnitude ofthe velocities and the Q 1 0.0- 1 ' 1 1 • 1 ' 1 • i i i i solid lines show the isotherms. Welding parameters: P = 5000 W,r\= 0.25, 6 10 14 18 22 26 30 34 38 and v = 8.33 mm/s (NH, = 34.53). Non-dimensional heat input, N HI

Fig. 6 — Computed values ofp"n and w'using the optimized set ofk* and u* for all values ofNH[. spectively, y is the surface tension, and T of their application are described here. f corresponds to the given set of three un­ is the temperature. The w velocity is zero, The optimization of the absorptivity, ef­ known parameters in nondimensional since the liquid metal is not transported fective thermal conductivity and effective forms as across the weld pool top surface. The heat viscosity begins with the construction of an {/}-{/i Af,}' flux at the top surface is given as objective function that depicts the differ­ ence between the computed and the mea­ sured values of weld dimensions. {»• , dT dP d\y+y\ "Hf£< (12) k— = ^-exp Levenberg-Marquart (LM) Method where k ,p. , k ,/j., and r\ are thermal con­ dz 7trb s n eff V ductivity of solid material at room tem­ In the LM method, the search for the {T4-T?)-h {T-T ) perature, viscosity of molten iron at 1823 c a (8) optimized values follows the direction of K, effective thermal conductivity, effective the objective function gradient with step viscosity of liquid metal, and absorptivity, size modification by an adjustable damp­ where rh is the laser beam radius, d is the respectively. Assuming that O(f) is contin­ beam distribution factor, P is the laser ing parameter after each iteration. In the uous and has a minimum value, the LM beam power, r\ is the absorptivity, o is the CG method, the direction of optimization method tries to obtain the optimum values is a conjunction of objective function gra­ Stefan-Boltzmann constant, h is the heat of f^, f2, and f3 by minimizing O(f) with re­ c dient direction and the previous iteration transfer coefficient, and Ta is the ambient spect to them. In other words, Equation 11 temperature. The first term on the RHS is direction (Refs. 39-42). The objective is differentiated with respect to f f and function, O(f) is defined as h 2 the heat input from the heat source, de­ f3, and each derivative is made equal to fined by a Gaussian heat distribution. The zero as second and third terms represent the heat . obs •in i HI loss by radiation and convection, respec­ o(f)= I „obs 90(/)l tively. The boundary conditions are de­ Pr, m = \ 3/,- i=l,3 fined as zero flux across the symmetric ,ob.i surface (i.e. at y = 0) as (Refs. 4, 21) M + X Xi 111 = 1 i (,;-#+iK-im = \ ) V, /=1.3 M r - i M r * i du dw dh = 0 0, v = 0, 0, and a7 dn (13) (9,10) where fj represents k", p* or, r\. The vari­ c c where RJ and w& are the penetration and ables p m and w m in Equation 13 are ob­ At all other surfaces, temperatures are the width of the weld pool computed by tained from the numerical heat transfer taken as ambient temperature and the ve­ the numerical heat transfer and fluid flow and fluid flow calculations for a certain set 0 s locities are set to zero. model, respectively, p ^ and w<* are the off], f2, and f3, i.e. k*, p.*, and r\. The par­ corresponding measurements at similar tial derivatives in Equation 13 are referred Optimization Procedure welding conditions and p,; and w£ are as sensitivity of the computed weld width nondimensional and indicate the extent of and penetration with respect to the un­ Both the Levenberg-Marquardt (LM) over or underprediction of penetration known parameters. The values of the sen­ and the conjugate gradient (CG) methods and weld width, respectively. In Equation sitivity terms are numerically calculated. have been described in the literature 11, the subscript m refers to a specific weld For example, the sensitivity of p^with re­ (Refs. 39-42) and only the special features in a series of M number of total welds and spect to f i is calculated as

WELDING JOURNAL ni 40.00 Initial guess : set 1 i initial guess . sex I i Initial guess : set 2 i - - Initial guess : set 2 10.00- 10.00- Initial guess : set 3 • i Initial guess : set 3 5.00-j • \ 5.00- Initial guess : set 4 • \ '. \ Initial guess : set 4 O(f) O(f) - (i) (ii)

1.00 7 1.00-

\v _ 0.10- 0.10- 0.05-= 1 ' 1 i • i ' i ' i ' i i i 0.05 -np—i 1 1—i—r—i 1 1—r 3 5 7 9 11 13 15 21 41 61 81 101 Number of iterations Number of iterations

indicates the direc­ tions of search at the 40.00 - end of kth iteration Initial guess : set 1 corresponding to the *r./i+*,./2,/3, Initial guess : set 2 unknowns fj, f , and ft,, '"pother known parameters 2 10.00- Initial guess : set 3 and Bk is the size of the search step. Both d!< 5.00- Initial guess : set 4 * ffl'fl'f}' k "' pother known parameters and B are calculated for every iteration or O(f) (Ni) #i (14) step. The variable 6k where Sft is very small compared with fj. tends to adjust the ex­ 1.00- The solution of Equation 13 is achieved tent of increment in when both p^and w*,becomes close to one. unknown parameters In other words, the calculated values of p^ between successive it­ and W£ should be close to the correspond­ erations and logically ing measured values of p<*s and w<*s for all should assume a value 0.10 M welds. Since fj, f2, and f3 do not explic­ that will facilitate the itly appear in Equation 13, this equation condition of objective 0.05 needs to be rearranged so that it can serve function minimum. as a basis for an iterative scheme to evalu­ Thus, Bk is calculated 21 41 61 81 101 ate the optimum values of fj, f2, and f3. by minimizing the Number of iterations The procedure is explained in Appendix 1. residual objective The final form of equations to be solved is function 0(fi)k+1 Fig. 8—Progress of calculation with four sets of initial guessed values using (I) LM, (Ii) CGPR. and (iii) CGFR methods with three sets of measure­ ments (NHt = 14.97. 32.90 and 34.53). The initial guessed values are pre­ sented in Table 6. -M (15) where, dO(fif+l obtained either by Equation 20a using = {^HA/;*}for, = 1.3 = 0;/T >0 Poiok-Ribier's (CGPR) modification or dfik and {fj<+1} refers to the three unknown in­ (18) by Equation 20b using Fletcher-Reeve's k crements after (k+l)th iteration. Equa­ The directions of search, d , d|, and d^, at modification (CGFR) lh tion 15 provides the solution of the three the end of k iteration arc calculated as a unknown increments, {Aft} correspond­ linear conjugation of the corresponding th ing to the three unknown parameters. directions of search at the end of (k-l) r iteration and the respective residual gra­ Conjugate Gradient (CG) Method dient of the objective function, O(f), after sW^ kth iteration as fbr* = l,2,...andyu =0 In the conjugate gradient technique, (20a) dv = V0(/ *)+7*dit-1 the unknown parameters are iteratively 1 3 k k searched in the following sequence (Refs. : d-> Vo(//)- „kjk- i{vo{f, j\{vo(f, )-vo(X)} 40-42): Y "2 I k k ,* _ i'=t fjt+i = vo(f3 )+r dt fX=fi«-,3V* for £-1,3 (I7) (19) where ft+1 represents the values of the where -f- is a conjugation coefficient at the th for k = 1.2.... and y° =0 three unknowns after (k+l)th iteration. end of k iteration. The coefficient f* is (20b)

JULY 2005 iiiiy

Table 5 — Data Used for Calculations of Table 6 — Sets of Initial Guesses for the Unknown parameters, C, and C, Temperature and Velocity Fields'"1 Set 1 Set 2 Set 3 Set 4 Optimized values Physical Property Value C, = 0.5 C. = 1.0 C, = 1.5 C, = 2.0 Liquidus temperature, TL (K) 1800.0 Cj = 0.5 C,= l.d C, = 1.5 C4= 2.0 C4= 1.115 Solidus temperature, Ts (K) 1760.0 r| = 0.1 n = it: n = 0.3 n = o.4 il = 0.250 Ambient temperature, T, (K) 293.0 Density of liquid metal, p (kg/m3) 7.2 x 10' Thermal conductivity of solid, 25.08 ks (W m-i K-i) sponding measured values. for data set No. 2 in Table 1. These appar­ Thermal conductivity of liquid, 25.08 The effects of k' and p" on the com­ ently contrasting results are achieved for kL (Wm-'K-i) puted weld pool dimensions can be ex­ welds with different heat input indexes Specific heat of solid, 754.0 plained as follows: (NHi) of 21.90 and 14.97 for data set Nos. CPS (J kg-' K-i) Specific heat of liquid, 754.0 The dimensionless weld penetration, 3 and 2, respectively. The results in Figs. 2 p , increases with k* since high values of and 3 are consistent with the fact that k* CPL(Jkg-iK-i) m Temperature coefficient of -0.5 x 10-3 thermal conductivity facilitate rapid heat and p" are not materials properties and surface tension, dy/dT (N m-' K~i) transport in the downward direction. their optimum values depend on NHI. To Coefficient of thermal 1.5 x 10-6 However, the higher thermal conductivity account for the same in the procedure of expansion, p (K-') 1 also reduces the surface temperature gra­ optimization of k* and p* in a simplified Viscosity of molten iron 6.7 x 10-- dient and the radial convective heat trans­ manner, the following linear relationships at 1823 K, p (kg.irHs-') n port and, consequently, decreases. Higher are assumed for simplicity: (a) for data set index 3 and 4 (Ref. 24). values of p* lowers radial convection and the convective heat flow resulting in both •C C N lower weld width and slightly higher peak I+ 2 HI temperature. The higher peak tempera­ -- C} + C4 N, (21) Further details of these two ap­ ture enhances downward heat conduction proaches are given in Appendix 2. In the and increases penetration. Furthermore, where C, and C3 are the minimum values CG methods, the direction of search is im­ as k* is progressively increased, conduc­ of the effective conductivity and effective portant, since the solution may diverge if tion becomes the dominant mechanism of viscosity, respectively, and C2, and C4 are the direction of search loses sight of the heat transfer and changes in p'! do not sig­ constants. Since k* and p* equal 1 at low optimal solution. In the LM method, a nificantly alter either the peak tempera­ values of NHI, the values of both C( and C3 manual damping factor is used that con­ ture or the convective heat transfer rate. are taken to be one. Thus, the optimiza­ tinually tracks the search step (or incre­ Thus, the weld pool dimensions do not tion routine is used to estimate the values ment) so that the optimal solution cannot change significantly with p* at high values of C2 and C4 for each NHI. move away from the last computed mini­ of k* as observed in Fig. 1A and B. Results in Figs. 2 and 3 also indicate mum value of the objective function. It is quite apparent that in addition to that several combinations of k* and p* may There are two main limitations in find­ the variation in k* or p*, any change in the result in low values of O(f) for a given NJJJ. ing property data by the coupled heat and value of absorptivity will further influence In order to seek optimum values for k* and fluid flow and optimization procedure de­ the results presented in Fig. 1A and B. Al­ p* for a particular NHI, an additional con­ scribed in this manuscript. They are 1) the though it has been reported that r\ de­ straint is useful to achieve a physically re­ accuracy of measured depth and width pends on laser power (Ref. 43), the ab­ alistic solution. Since k* and p* are related and 2) how strongly the depth and the sorptivity is a material property, and its by the turbulent Prandtl number, PrT, its width vary with the uncertain parameter exact value depends on factors such as the value (= 0.9) provides a useful constraint. (sensitivity). surface temperature. An increase in the In other words, out of many possible solu­ value of absorptivity implies an enhance­ tions, the specific combination of k* and Results and Discussion ment in the heat absorption rate that leads p* nearest to the line corresponding to PrT to higher peak temperature, greater tem­ = 0.9 will be chosen as the final solution. The sensitivity of the computed weld perature gradient and larger computed PrT is defined as pool dimensions with respect to the effec­ weld pool dimensions for a specific set of tive thermal conductivity, effective viscos­ k* and p*. In contrast, a decrease in the ity, and absorptivity were determined by value of absorptivity leads to smaller val­ MTC.PL several heat transfer and fluid flow calcu­ ues of computed weld pool dimensions for kT (22) lations. Figures IA and B depict a number a specific set ofk* and p':. Such a behavior of isocontours of the dimensionless pene­ was also demonstrated in the case of a where prff = p, + pT, kc„ = kL+ kT and pT, tration, p^, and the dimensionless width, GTA weld pool (Ref. 29). To keep the kT are the turbulent viscosity and thermal \<, as a function of k* and p* for data set problem tractable, a single optimized conductivity, respectively, and pL and kL No. 3 in Table 1. It is observed from Fig. value of absorptivity (t|) for all the weld­ are the viscosity and thermal conductivity IA that the dimensionless penetration, p^, ing conditions considered in the present of the liquid, respectively. Finally, Equa­ increases with k* or p*. However, the di­ work is assumed. tion 12 is modified as mensionless width, w,;,, decreases with k* Figure 2 shows that high values of k* or p.* as shown in Fig. IB. For k* values and p'!: are necessary to achieve good above 7.0, both pmand wn,become fairly in­ agreement between the computed and the {/H./1/2/3MQQ'-} (23) sensitive to p*. Furthermore, both p*m and experimental weld pool geometry, i.e., low w^approached a value of unity at high val­ values of objective function for data set A set of initial values of C , C and n, is ues of k* and U*. When both p and w' are 2 4 " r^m ni No. 3 in Table 1. In contrast, Fig. 3 indi­ necessary to start the optimization calcu­ 1, pg, equals p<*f and wj, equals w»i;,s and the cates that low values of both k* and p* are lations by all three methods indicated in calculated results agree with the corre- necessary to reduce the objective function Appendixes 1 and 2. It is apparent from

WELDING JOURNAL En Iiiiiiiiiiiii T Figs, 1 through 3 that the expression form the optimization with a number of the minimum values of O(f) only when the (30(f)/3fi=i 3 does not conform to a con­ initial values so as to arrive at a best pos­ 2nd set of initial values (Table 6) is used — tinuous, convex, or concave-type function sible optimum solution. Furthermore, the Figs. 8ii and 8iii. The minimum value of and the solution of Equation 13 involves optimization in the present work was com­ O(f) could be reached within ten itera­ multiple local minima in the objective putationally intensive, since the number of tions using the LM routine and around 80 function. To address this difficulty, the op­ numerical heat transfer and fluid flow cal­ iterations in both CGPR and CGFR timization calculations have been per­ culations for each optimization iteration methods. The values of C2, C4, and n were formed with a number of initial values in was equal to the number of variables mul­ found to be 0.252, 1.115", and 0.253, re­ the ranges of 0.10 to 3.0, 0.10 to 3.0, and tiplied by the number of welds for sensi­ spectively, corresponding to the minimum 0.10 to 0.50 for C2, C4, and n, respectively. tivity calculation plus the number of welds value of O(f) following CG methods. Fol­ Table 6 presents four such representative for error verification. However, an appro­ lowing the LM method, the optimized val­ sets of initial values for which the progress priate choice ofthe initial values could sig­ ues of C2, C4, and n were found to be of the optimization calculations are pre­ nificantly reduce the volume of the com­ 0.265,1.138, and 0.228, respectively, when sented in Figures 4(i) to (iii). All measured putational work. Based on the results of only three sets of experimental data were weld pool dimensions indicated in Table 1 optimization, Equation (21) can be rewrit­ used in the optimization process. The op­ were used for the optimization. These fig­ ten as timized values of these parameters did not ures show that the minimum attainable k* = 1.0 +0.252 NHI change significantly when all five sets of value of O(f) is affected by the choice of experimental data were used for opti­ the initial values in both LM and CG p.* = 1.0+ 1.115 NHI (24) mization. methods. In the LM method, the mini­ The effectiveness of the optimization The values of k* and p* estimated in mum value of 0(f) was obtained when the process is evident from the fact that all the present work are within the range of 1st and 2nd set of initial values (Table 6) three optimization methods resulted in enhancement factors reported in the liter­ were used (Fig. 4i) while the 3rd and 4th nearly similar sets of the optimum values ature. For example, values in the range of set of initial values resulted in values of of C2, C4, and T|. 30 to 100 for both k* and p* were esti­ O(f) as 0.219 and 0.837, respectively. In Figure 5 shows that both k* and p* in­ mated through trial and error to achieve both the CGPR and CGFR methods, a crease significantly with NHI consistent good agreement between the computed minimum value of O(f) = 0.129 was with Equation 24. This behavior is ex­ and the measured weld dimensions (Ref. achieved when the 2nd set of initial values pected since higher heat input leads to 27). When the k-e turbulence model with (Table 6) were used (Figs. 4ii and 4iii). The more rapid transport of momentum and a spatially variable effective viscosity was value of O(f) could not be reduced below heat. The computed values of p^ and wm used, a maximum value of 16 for p* was re­ 0.129 with various other sets of initial using the optimized values of k* and p* ported for a stationary GTA weld pool guesses using all three optimization pro­ are plotted in Fig. 6 for all values of NH] (Ref. 26). Although the value of r\ and the cedures. The final optimum solutions of A fairly satisfactory agreement is obtained relationships between NHI and k*, and p* C2, C4 and n corresponding to O(f) = between the computed and measured are valid for the specific conditions of 0.129 were the same regardless of the ini­ weld dimensions. The slight discrepancy welding considered here, a similar ap­ tial guessed values of C2, C4 and r|. For ex­ between the computed and the experi­ proach can be adopted for other welding ample, a set of initial values of C2, C4 and mental values can be attributed, at least in conditions (Refs. 29, 30). Since q, k* and q equal to 1.0, 1.0, and 0.3, respectively, part, to the experimental errors. p* are linked with p„,and w,;, through the yielded nearly similar values of O(f) and Typical computed temperature and ve­ equations of conservation of mass, mo­ the optimized solution of C2, C4 and n locity fields are shown in Fig. 7. The results mentum and energy rather than through a were the same as those obtained with the show that the liquid metal is transported straightforward polynomial function, local 2nd set of initial values (Table 6). Al­ from the middle of the pool outward due minima should be avoided by repeating though a reduction in the value of O(f) to a negative temperature coefficient of the procedure with several sets of initial from 0.166 in the LM method to 0.129 in surface tension. The features of the com­ values. The intensive computational work the CG method appears to be small, it puted temperature and velocity fields are needed to determine the uncertain para­ should be noted that O(f) depicts the typical ofthe Marangoni convection dom­ meters results in enhanced reliability of square of the summation of the actual er­ inated laser melted pools and have been the numerical modeling of heat transfer rors representing the discrepancy between discussed in the literature (Refs. 16,19,20. and fluid flow in the weld pool. PS, and p*s- and wg and w^. This discrep­ 24, 26, 27). ancy can be important even for small val­ A test for the effectiveness of the pro­ Summary and Conclusions ues of 0(f) and achieving the smallest pos­ posed deterministic model is to check if sible value of O(f) is important. the values of the uncertain parameters can Reliability of numerical heat transfer A closed-form relationship between be evaluated from a relatively small vol­ and fluid flow calculations in the weld pool the dependent variables such as the weld ume of experimental data. For this pur­ can be significantly enhanced by deter­ dimensions and the unknown parameters pose, the values of C?, C4, and r\ were de­ mining the optimized values of effective does not exist. As a result, the lowest value termined from the experimental data for thermal conductivity, effective viscosity, of O(f) depends on the initial guessed val­ three welds with NHI = 14.97, 32.90, and and absorptivity from a limited volume of ues of the unknown parameters. At the 34.53 in Table 1. Figures 8(i) through (iii) measured weld dimensions. Three ver­ start of the iterations, the initial few gra­ show the variation of the objective func­ sions of gradient-based optimization tech­ dients of the objective function with re­ tion with number of iterations for four sets niques could produce low values of an ob­ spect to the unknown parameters affect of initial guesses presented in Table 6 jective function and determine the three the results of the subsequent iterations using all three optimization methods. It is aforementioned parameters. Although and, ultimately, the optimum value of observed that the LM method can provide the values of these parameters were inde­ O(f). One way to resolve the difficulty re­ an approximate minimum value of O(f) pendent of the optimization process, the sulting from the absence of a closed-form ©0.089 when the 1st and 2nd set of initial volume ofthe calculations needed and the relation between the objective function values (Table 6) are used — Fig. 8i. Both manner in which the optimized values and the unknown parameters is to per­ CGPR and CGFR routines could reach were obtained depended on both the opti-

JULY 2005 mization method selected and the initial arc welded HSLA-100 steel. Metall. Mater. unknown welding parameters from convective guessed values of the parameters. The val­ Trans. B. 30B: 483-493. heat transfer calculation and multivariate opti­ ues of effective thermal conductivity and 12. Hong, T, Pitscheneder. W. and De­ mization./ Phys. D:Appl. Phys. 37(1): 140-150. bRoy, T. 1998. Quantitative modeling of inclu­ 30. De, A., and DebRoy, T. 2004. A smart effective viscosity were found to be much sion growth in the weld pool by considering model to estimate effective thermal conductiv­ higher than their corresponding molecu­ their motion and temperature gyrations. Sci. ity and viscosity in weld pool. Journal of Applied lar values and also depended on heat Technol. Weld. Joining. 3(1): 33-41. Physics. 95(9): 5230-5240. input. Correlations are proposed to deter­ 13. Hong, X, and DebRoy, T. 2003. Non- 31. Hsu, Y. E, Rubinsky, B. and Mahin, K. mine these parameters from welding con­ isothermal growth and dissolution of inclusions 1986. An inverse finite element method for the ditions. The use ofthe optimized values of in liquid steels. Metal. Mater. Trans. B. 34B: analysis of stationary arc welding process. / absorptivity, effective thermal conductiv­ 267-269. Heat Transfer, Trans. ASME. 108(4): 734-741. ity and effective viscosity, determined 14. Hong, X, and DebRoy. X 2001. Effects 32. Beck, J. V. 1991. Inverse problems in of time, temperature and steel composition on heat transfer with application to solidification from a limited volume of experimental the growth and dissolution of inclusions in liq­ and welding. Proc. 5th Int. Conf. on Modeling of data and the proposed model, resulted in uid steels. Ironmaking and Steelmaking. 28(6): Casting, Welding and Advanced Solidification good agreement between the computed 450-454. Processes, eds. M. Rappaz et al, pp. 503-514. and the experimentally determined fusion 15. He, X., Fuerschbach. P., and DebRoy, T. The Minerals, Metals and Materials Society, zone geometry without the need to adjust 2004. Composition change of stainless steel Warrendale. Pa. these parameters by trial and error. during micro-joining with short laser pulse. J. 33. Rappaz, M., Desbiolles, J. L., Drezet, J. Appl. Phys. (In press). M., Gandin, C. A., Jacot, A., and Thevoz, P. 16. Zhao, H., and DebRoy, T. 2001. Weld 1995. Proc. 7th Int. Conf. on Modeling of Cast­ Acknowledgments metal composition change during conduction ing, Welding and Advanced Solidification The work was supported by a grant model laser welding of 5182 aluminum alloy. Processes, eds. M. Cross et al., pp. 449-457, The from the U.S. Department of Energy, Of­ Metall. Mater. Trans. B. 32B: 163-172. Minerals, Metals and Materials Society, War­ fice of Basic Energy Sciences, Division of 17. Palmer, T. A., and DebRoy, T. 2000. Nu­ rendale, Pa. Materials Sciences, under grant number merical modelling of enhanced nitrogen disso­ 34. Fonda. R. W and Lambrakos, S. G. DE-FGO2-01ER45900. The authors ap­ lution during GTA welding. Metall. Mater. 2002. Analysis of friction stir welds using an in­ preciate critical comments on the work Trans. B. 31B(6): 1371-1385. verse problem approach. Sci. Technol. Weld. JoininglCi): 177-181. from Mr. S. Mishra, Ms. Xiuli He and Mr. 18. Mundra, K, Blackburn, J. M., and De­ bRoy, X 1997. Absorption and transport of hy­ 35. Karkhin, V A., Plochikhine, V V, and A. Kumar. drogen during GMA welding of mild steels. Sci. Bergmann. H. W 2002. Solution of inverse heat Technol. Weld. Joining. 2(4): 174-184. conduction problem for determining heat References 19. He, X., Fuerschbach, P. W, and DebRoy, input, weld shape, and grain structure during T. 2003. Heat transfer and fluid flow during laser welding. Set Technol. Weld. Joining 7(4): 1. David, S. A., and DebRoy, T. 1992. Cur­ laser spot welding of 304 stainless steel. J. Phys. 224-231. rent issues and problems in welding science. D:Appl. Phys. 36(12): 1388-1398. 36. Patankar, S. V. 1992. Numerical Heat Science 257: 497-502. 20. Zhao, H. and DebRoy, X 2003. Macro- Transfer and Fluid Flow. New York, McGraw- 2. DebRoy, T„ and David, S. A. 1995. Phys­ porosity free aluminum alloy weldments Hill. ical processes in fusion welding. Rev. Mod. Phys. through numerical simulation of keyhole mode 37. Voller, V R., and Prakash, C. 1987. A 67(1): 85-112. laser welding. J. Appl. Phys. 93(12): fixed grid numerical modeling methodology for 3. Zhao, H., White, D. R.. and DebRoy, T. 10089-10096. convection-diffusion mushy region phase 1999. Current issues and problems in laser 21. Zhang, W, Roy, G. G, Elmer, J. W,. and change problems. Int. J. Heat Mass Transf. 30: welding of aluminum alloys. Int. Mater. Rev. 44: DebRoy, T. 2003. Modeling of heat transfer and 1709-1719. 238-266. fluid flow during gas tungsten arc spot welding 38. Brent. A. D., Voller. V. R.. and Reid, K. 4. Mundra, K, DebRoy, T„ and Kelkar, K. of low carbon steel. / Appl. Phys. 93(5): J. 1988. The enthalpy porosity technique for M. 1996. Numerical prediction of fluid flow and 3022-3033. modeling convection-diffusion phase change: heat transfer in welding with a moving heat 22. Kumar, A., and DebRoy, T. 2003. Calcu­ application to the melting of a pure metal. Nu- source. Numer. Heat Transfer A 29: 115-129. lation of three-dimensional electromagnetic merical Heat Transfer 13: 297-318. 5. Elmer, J. W., Palmer T. A., Zhang W., force field during arc welding. / Appl. Phys. 39. Beck. J. V, and Arnold, K. J. 1977. Pa­ Wood, B., and DebRoy, T. 2003. Kinetic mod­ 94(2): 1267-1277. rameter Estimation in Engineering and Science. eling of phase transformations occurring in the 23. Kim, C. H., Zhang, W. and DebRoy, T. New York, N.Y., Wilev International. HAZ of C-Mn steel welds based on direct ob­ 2003. Modeling of temperature field and solid­ 40. Beck. J. V, Blackwell, B., and Clair, C. servations. Acta Materialia. 51(12): 3333-3349. ified surface profile during gas metal arc fillet R., lr. 1985. Inverse Heat Conduction—/// Posed 6. Kou, S., and Wang, Y. H. 1986. Three di­ welding./ Appl. Phys. 94(4): 2667-2679. Problems. New York, N.Y., Wiley International. mensional convection in laser melted pools. 24. Pitscheneder, W 2001. Contribution to 41. Alifanov, O. M. 1994. Inverse heal Trans­ Metallurgical Transactions A. 17A(12): the understanding and optimization of laser fer Problems. Berlin, Springer-Verlag. 2265-2270. surface alloying. PhD Dissertation. University 42. Ozisik, M. N., and Orlande, H. R. B. 7. Pitscheneder, W.. DebRoy, T., Mundra. of Leoben, Austria. 2000. Inverse Heat Transfer. 35, New York, N.Y., K, and Ebner, R. 1996. Role of sulfur and pro­ 25. DebRoy, T, Mazumdar, A. K, and Taylor & Francis Inc. cessing variables on the temporal evolution of Spalding, D. B. 1978. Numerical prediction of 43. Fuerschbach, P. W 1996. Measurement weld pool geometry during multi-kilowatt laser recirculating flows with free convection en­ and prediction of energy transfer efficiency in welding of steels. Welding Journal 75(3): 71-s to countered in gas-stirred reactors. Applied Math­ laser beam welding. Welding Journal 75( 1): 24-s 80-s. ematical Modelling. 2: 146-150. to 34-s. 8. Cool, T, and Bhadeshia, H. K D. H. 1997. 26. Hong, K, Weckmann, D. C, Strong, A. Austenite formation in 9CrlMo type power B., and Zheng, W 2002. Modelling turbulent Appendix 1 plant steels. Sci. Technol. Weld. Joining. 2(1): thermofluid flow in stationary gas tungsten arc 36-42. welded pools. Sci. Technol. Weld. Joining. 7(3): 9. Mishra, S., and DebRoy, T. 2004. Grain 125-136. In order to explain the basic concept of topology in T1-6A1-4V welds — Monte Carlo 27. Choo, R. X C, and Szekely, J. 1994. The the LM method, a simplified system in­ simulation and experiments. Journal of Physics possible role of turbulence in GTA weld pool volving three unknown parameters, f1; f2, D: Applied Physics. 37: 2191-2196. behavior. Welding Journal 73(2): 25-s to 31-s. and ft„ and one dependent variable, p*m 10. Mishra, S., and DebRoy, T. 2004. Mea­ 28. Jonsson, P. G„ Szekely, J., Choo, R. I C, measured under five welding conditions is surements and Monte Carlo simulation of grain and Quinn, T. P. 1994. Mathematical models of structure in the heat-affected zone of T1-6A1- considered first. Equation 13 can be writ­ transport phenomena associated with arc weld­ ten for fj, ft, and f, as: 4V welds. Acta Materialia. 52(5): 1183-1192. ing processes: a survey. Modelling Simul. Mater. 11. Yang, Z. and DebRoy, T. 1999. Model­ Sci. Eng. 2(5): 995-1016. ing of macro- and microstructures of gas metal 29. De, A., and DebRoy, T. 2004. Probing

WELDING JOURNAL EF iiiisii

5 a set off], ft, f3 and other known parame­ and Al 1 are further simplified as: ty*„ k+l I \Pm-1 = 0; ters. So, (p„) that is the value of pn*,after m = \ (k + l)i" iteration is unknown since Afj,

5 Aft,and Aft are unknown. Next, substitut­ d[Pm} ing right hand side of Equation A4 in the [Pm A/i* + k+ 3/1 I (X-t place of (pm) '. Equations A6, A7, and A8 m=\ are rewritten as: 5 3 5 W ^ 3 P„ Xm = 0 A2A + = 0 I ^T"' 3/I I >dfl i t\k X'"l k JJI=I m = \ (A1,A2,A3) df A/(-l 3/3 The values of the three unknowns, ft, f2, d(P'») ,Jt , d{P'») ,A- and f cannot be directly obtained from A AA/3 3 dfi -x + (A12) the above equations since they do not ap­ 3/3 pear explicitly in these equations. The \k = 0 ( I * \k symbols fh f2, and f3 resemble k*, p*, and Pm*) +A^^ + I *\k d\Pml q (absorptivity), respectively. So, the de­ \Pm + pendent variable p^is expanded using the Taylor's series expansion to explicitly con­ d[Pm) k 9(Pm) ,. 3(Pm 3Pm tain values of increments and, f j, ft. and fj. '- AfX———X "A/, + Considering two successive iterations of a/2 9/3 I 3/2 3/2 m=\ p m and taking only the first order terms a/i (A9) L A/3-I 3/ (/>:,)' X -A/i* + 3/, (A13) « \k 3 UV d(p"m -Af* + -< [Pm) +A^Af < 3/2 dh (A4) y / „ \k <>(Pm where Af}, Aft and Aft are three unknown ii y>(pm) +A -A/i* + increments corresponding to f,, ft, and f3 4tf-l ix 3/jyt 3/2Xm + as 5 a/3 5 Xi d(jPm) \k = 0 -A/,* + fjt+1 rk I I 3/2 3/3 ;JJ = I ' 4/i* + J\ = /t X (pm*) k+\ a/, fl+*fl 3(Pm) ,. fi k l „ \* ' A/3* -1 o(p*m) k a(/;*,) 3/3 X^/XX (A5) A/2 +- a/, 3/3 -m +l (A14) and ff , fk+t, and f|+i correspond to the 3f2 th Equations A12, A13, and A14 are next re­ values of three unknowns after (k+ l) it­ (A10) arranged as eration. Except Aft, Aft, and Aft, all other terms on the right hand side of Equation / , u au,,,) A4 are considered to bc known. To solve d[Pm) a(p;„) for A% Aft, and Aft, Equations Al, A2 and I ~~3/i 3/T X A3 are first rewritten replacing p" by B»=] k+1 (Pn',) as ^-A^+M^-l 3(Pm) d[p*m) 5 °f2 m A/2* = 0; S i. I ~V\ 3/T I w -Tit I m=l m = l (/>,;) +XXAIU y d(Pm) d{Pm) ... u-+i *\ (3/' A/3* Pm ~ 1 3/2 d(Pm) k d[p*„) a/, 3/3 A/2' A/3* 3/2 3/3 5 M l,-\{dP*»f a/3 N - )xt (All) m=\ (A15) (A6, A7, A8) Neglecting higher order differentials e.g 1 However, pm equals to pg/p **, and al­ i though p;i» is a known measured value, p^ _a_ is to be computed using the numerical 3/, 3/t heat transfer and fluid flow calculation for etc., Equations A9, A10

JULY 2005 5 3(Pw) dfa) X A/i* and 5 ,» = ! ~~% a/T~ •}• si­ M- s'

3(Pm) 3(^) 3P» 3 w„ rA/2* + 3/2 3/2 * ^W 3/l 3/i =1 3/«/i

3 w 5 d\Pm) ( m) 3(PW) a(p;;,) ^('»<)\/ * X 3/2 3/2 ~~3^ 3/T wX 3/2 W

3(P,„) f, ,»* ) 31'Vm If, ,* 5 3(Pm) P„, -ll + - 3/3 "ll"',,,] - "I Pm) "] i^-f^r-3/3 i 3/3 ,„ = ! 3/2 (A25) (A16) A/,* A/ * Equations A5 and A21 do not change 3(Pm) 3(p«) A/*} = 2 A/,* + since the number of unknown parameters I A/3* m = l 3/3 3/5 remains three. Furthermore, the sensitiv­ ity terms such as (A20,A21) 3(p«) 3(p^ X + Thus, Equations Al, A2, and A3 are mod­ 3(/>m) a(u>;;,) a/3 a/2 ified to equation A18 where the three un­ 3/; 3/ (for ; = 1 to 3) in known incremental terms Aff, Aft, and Aft Equation A18 often tend to be very small 5 are explicitly defined in terms of the as the values of the unknown parameters 3(Pm) d[Pm) known quantities. The solution of Afj, Aft, X W'X + f 1, f2 and f3 move close to the optimum. As ~~#> 3/T and Aft are used next to obtain ff ', ft+i, a result, the matrix [S] tends to become and ft+i (expression A5) that are em­ c k+1 singular. To avoid numerical instability, ployed to compute (p ) using the nu­ Equation A18 is further modified follow­ 3(pm) merical heat transfer and fluid flow model. k+ ing the LM method as -x 3/f((-)'-i ) Next, 0(f) ' is calculated as (A17) ([S] + A/){A/*} = -{5*} (A26) Equations A15, A16, and A17 can be ex­ 0(/)* Pm - I pressed in matrix form as (A22) where X is a scalar damping coefficient, [S]{Aft}=-{S*} (A18) usually about 0.001, and I is a diagonal ma­ where Values of f 1, f2, and f3 are assumed to reach trix given by (Ref. 42) optimum when the calculated value of 0(f)k+l is smaller than a predefined small 0 0 Su s12 S|3~ Su number. For the two dependent variables s S S 0 S220 ra= 2t 22 23 p„*, and w„*,, Equation A19 is modified as s ^32 533 J 0 0 S33 31 (A27) 5 d(p*„) 9(Pm) 5 d(p* ) 3(p m The product A.I in Equation A26 ensures Su Sn %~ ,„=! 3/, a/, „tr, a/, a/2 that the left-hand term in Equation A26 [S] = S2] S22 ^23 will remain nonzero even if the determi­ s 3(p,*,) y>{p"m) 5 3(p„) 3(p,'i,) Ssi S32 5 nant of the matrix [S] is zero. The value of 33_ (A23) „t, If, sXh Xf2 X~ X is usually increased or decreased by a where factor of ten as the value of the objective 5 3(p,*,) S(P™) 5 a(p,;) s(p,;) k ^ Xm) Xm) function in subsequent iterations in­ ,,,=i 3/2 3/2 m=] 3/2 a/3 creases or decreases. This, in effect, en­ 3/i 3.0 sures the reduction or enhancement in s 3(p*) 3(p^) s d[p*„) d[p*,) for i,j = 1 to 3 step size as the solution respectively tends m = \ d w ,„=i 3/3 a/, „,=l a/3 3/2 [ m) Xn) to diverge or converge. The algorithm of I 3/i dfj the complete procedure using the LM 5 3(p,*,) 3(p„) method can be presented as follows: (A24) lh ,,,=1 3/3 9/3 Step 1. Guess initial values (e.g., k ) of Equation A20 will be modified as unknown variables set, {ft} fori=l,3from (A19) Equation 12. Step 2. Choose initial value of damping factor (X). Step 3. Compute the value of the ob­ jective function, O(ft) from Equation 11. Step 4. Solve for the set of unknown in-

WELDING JOURNAL IIIIIIII IIIIIEillilllll! •&'••> yyy'<-' . ,ii* crements {Aft} for i = 1, 3 from Equation Considering two dependent variables, Equations 20a and 20b can respectively be A26. and p"m , Wm , rewritten as +1 Step 5. Compute {ft } for i = 1,3 from k k k k k oif - p d ,f* - p d ,/,* - /?* 0(f<), set ?i = 10 X; o[f - p d ,/2* - p d .f - p d II reject {ft+!}; go back to step 4. -w^--'dff k k Step 8. If 0(ft+') < O(ft), set X = 0.1 X. -I Wm (/,* - W 4 - p 4 -fi - p 4) -'] (A32) Step 9. Exit if O(ft+0 - O(ft) " e, and m = \ +1 {ft }-{ft} " e2; or go back to step 4. e, k k k +1 [< [ft - n 4 -fi - p 4 •//' - P 4) -1] Pm -')%- + (»'-«-') and e2 are two small, predefined numbers. 3/," v ' 3/, (A30) 3 5 3p,"„ 3p, Appendix 2 Substituting Equation A30 in Equation >;-i) A29 and using Taylor's expansion, Equa­ II 3/,* 3//' Considering the objective function de­ tion A29 can be substantially rearranged ,'=lm=l k fined in Equation 11 with two dependent to give |3 as (Refs. 41, 42) 1 variables, p^ and wn*, ,and three unknown I 3/,* a/*" parameters, f1? f2, and f3, Equation 17 can 3p», 3 be written as dp'm ,k . d IliK-lA + k,-!) ' 2 '3/,* '3/,4' k + \ K k.k X3/, ^ 3/2* f •fXP d] [p*m 1 t (A33) 1 ck + \ k.k + dPm.dk for k = 1,2 and, y = 0. Apart from the cal­ •fXP*d: 3 5 3/* k+i k culation of conjugate coefficient, -f, both fi -fXp 4 (A28) X CGPR and CGFR methods are the same. +l +1 k k where ft , ft , df, d , and fS confirm to ,„=1 Xdk+^nLdk 2 their definitions presented previously. In w 3/,* ' 3/* k+l k+1 [ m -1 Equation 18, as 0(f,-) contains (p^,) 3 k , »'m ,k and (wn*) +i obtained from numerical heat + -.cki-d-, 3 transfer and fluid flow code using values of I 3/3 +I k+1 k+l p*. ff , f , and f**\ and 0(f;) depends on 7 k+ +1 k+1 f i, ft+i, and ft, . Thus, replacing (fj) in 3Pm 3H-,"„ Equation 18 by ff+1, f^+1, and f|+i, and sub­ stituting the right-hand side of Equation 5 A28 in place of them, Equation 18 can be oPm l P"',„ jk . rewritten as X d2 + 3/2* a/2* ) m=l k k .iXp d!,f2 3p,*„ a«r,, jk do d3 k k k k.k 3/3* 3/3* , p d _,fXP d 3/ = 0; /r > 0 a/3* (A31) (A29) -urt herm ore, fo lowing Equ ation 13,

Call For Papers

The 6th European Conference on Welding, Joining, and Cutting Santiago de Compostela, Spain, June 28-30, 2006

The 6th European Conference on Welding, Joining, and Cutting, sponsored by the European Federation for Joining, Welding, and Cutting (EWF), in association with the Spanish Association of Welding and Joining Technologies (CESOL), and the Metallurgical Research Association of the Northwest (AIMEN), has issued a call for papers and posters.

Papers are sought on a wide variety of topics including welding, joining, surfacing, cutting and related processes and equipment, such as laser beam and plasma arc welding, brazing and soldering, adhesive bonding, friction stir welding, resistance welding, welding con­ sumables. Visit www.cesol.es/EUROJOIN6/I6JTS.php for a complete list of recommended topics, detailed author's submittal infor­ mation, and description of the prizes to be presented in four categories.

The deadline for submission of titles and 300-500-word abstracts is September 30, 2005. The deadline for submission of completed conference papers or posters is February 28, 2006. Manuscripts and oral presentations may be presented in English or Spanish. Documents must be submitted in electronic MS Word format with figures provided in TIFF, JPEG, or GIF formats.

Send your intention to participate, including title and abstract of the work to be presented, to CESOL. Gabino Jimeno 5B, 28026 Madrid, Spain; FAX: +34 91 500 53 77; [email protected], by September 30, 2005.

JULY 2005 IIIHIIIIIM'I"?''!-?' f?IllIllSilS!IllliIlill] Properties and Sulfide Stress Cracking Resistance of Coarse-Grained Heat-Affected Zones in V-Microalloyed X60 Steel Pipe

The effect of weld cooling rates and postweld heat treatment on microhardness, microstructure, tensile properties, and sulfide stress cracking resistance was studied BY J. E. RAMIREZ, S. MISHAEL, AND R. SHOCKLEY

ABSTRACT. Evaluation of heat-affected zones with a maximum hardness of 264 enced during welding. The four general zone (HAZ) properties after postweld HV did not crack during exposure to sour regions and their corresponding tempera­ heat treatment (PWHT) is important not testing according to procedure specified in ture ranges are as follows: only for selection of suitable chemical standard NACE TM0177 (Method A). •Coarse-grained HAZ (CGHAZ) - composition of microalloyed steel pipes, 1100°C to melting point but also for development of welding pro­ Introduction •Fine-grained HAZ (FGHAZ) — cedures, including PWHT, for sour ser­ Ac^ 100°C vice. In this study, coarse-grained heat- During welding, the HAZ of base met­ • Intercritical HAZ (ICHAZ) — Ac,-Ac3 affected zones (CGHAZ) were induced in als is subjected to thermal cycles, which • Subcritical HAZ (SC-HAZ) — Below Aci V-microalloyed X60 steel pipe specimens produces a change in both its microstruc­ In multipass welds in C-Mn steels, each using a Gleeble weld thermal simulation. ture and mechanical properties. In addi­ of the HAZ regions can experience multi­ Cooling rates from 5 to 80°C/s were used tion to chemical composition, rate of cool­ ple temperature excursions that can fur­ to represent a broad range of welding con­ ing through the temperature range within ther alter the microstructure in the HAZ. ditions. The CGHAZ specimens were which transformation of austenite occurs For convenience, these regions can be cat­ subjected to PWHT at temperatures from to martensite, bainite, ferrite plus pearlite, egorized into six basic types as compared 635 to 670°C (1175 to 1238°F) for 3 to 15 or mixtures of these microstructural con­ to four in single-pass welding. The two hours. Microhardness and microstructure stituents, has a marked influence on the extra basic regions are as follows: inter- ofthe CGHAZ were evaluated in the sim­ hardness achieved for a particular compo­ critically reheated CGHAZ (IC- ulated "as-welded" and PWHT condition sition. The cooling time At8.5 through the CGHAZ) and subcritically reheated as functions of weld cooling rate and range 800° to 500°C, as descriptive of a CGHAZ (SC-CGHAZ). The mechanical PWHT schedule. The tensile properties given weld, has been widely adopted in properties vary across the different sub- and sulfide stress cracking resistance the welding community as an important zones. Among the HAZ subzones, the (SSC) of CGHAZ with selected hardness index. The temperature of 800°C, in most CGHAZ, which experiences the most se­ level were determined as well. The maxi­ steels, approximately represents the A3 vere thermal cycle, usually possesses the mum hardness of the CGHAZ increases transformation temperature and the y/a maximum hardness. As such, this region is from 233 to 392 HV-10, and its mi­ transformation takes place through the usually given the most attention regarding crostructure changes from ferrite with 800° to 500°C temperature range. alloy design and welding procedure, in­ aligned second phases to martensite by in­ For single-pass welds in C-Mn and low- cluding PWHT. creasing the cooling rate from 5 to 80°C/s. carbon microalloyed steels, four mi­ Postweld heat treatment is commonly None of the PWHT schedules used in crostructural regions can be distinguished applied to welded steel construction for this study induced hardening of the in the HAZ as indicated in Fig. 1. The mi­ three main reasons. First, it may be CGHAZ of the microalloyed steel. How­ crostructure in each region of the HAZ is deemed necessary to improve the me­ ever, the rate of softening may have been related to the temperature cycle experi- chanical properties, in particular the retarded because of VC secondary hard­ toughness, across the welds (Ref. 1). Sec­ ening. For a holding time between 3 and ond, heat treatment is applied to reduce 15 hours, the softening effect induced by the high level of residual stresses that are the PWHT can be described by the Lar­ induced along and across weldments (Ref. son-Miller tempering parameter. The ap­ KEYWORDS 1, 2). Third. PWHT is used to decrease the parent activation energy for tempering in hardness across the weldment to avoid the Heat-Affected Zone (HAZ) the different softening regimes observed risk to stress corrosion cracking (SCC) Postweld Heat Treatment (PWHT) during PWHT was determined. The be­ (Ref. 1), for example, hardness level below Coarse-Grained Heat-Affected havior ofthe CGHAZ during tensile test­ 22 HRC in sour service. According to the Zones (CGHAZ) ing depends on the degree of overmatch­ provisions established in the NACE mate­ Sulfide Stress Cracking Resistance ing between the CGHAZ and the base rial recommendations for sour service (SSC) material. Coarse-grained heat-affected (MR0175) (Ref. 3), a maximum hardness V-Microalloyed X60 Steel Pipe of 22 HRC (248 HVN) is recommended to Larson-Miller Tempering /. E. RAMIREZ is with Edison Welding Institute. avoid the risk to sulfide stress cracking. Parameter S. MISHAEL and R. SHOCKLEY are with The changes in strength, hardness, and Chevron Texaco Energy Technology Company. toughness during PWHT are the net re-

WELDING JOURNAL • [Hffiiliii H illlltlllHiKii •' !I

1

^^L ailidiriod wok) mSal Liquid

LU ji\ ^^ solid-liquid rrarssiiiofi zone a: MOO =1 ij \ CGHA2 : ^s. Lrquid+AustenilB

< ICHAZ BOO< UJ CL \T SCHAZ 600- : \^unaileeied ease ^^ maieiiil Ferrite+FegC §^^#^5^pi&^ai^5 400-

8M-J ~\ iwm^^^iSSJ^^^^^^^ 0-15 VO Pi Wl % C heai alfecled lone

Fig. 1 —A schematic illustration ofthe various single-pass HAZ regions with reference to the iron-carbon equilibrium diagram. (An Fe-0.15 wt-% carbon sleel is shown.)

Table 1 • Chemical Composition, Weight Percent, of the V-Microalloyed Seamless X60 Steel Pipe

Element C Si Mn P S Al Cu Cr Fig. 2 —A — General view of V-Nb microalloyed % 0.13 0.24 1.31 0.009 0.004 0.038 0.09 0.13 X60 steel pipe section; B — through-thickness lo­ Element Ni Mo V Ti Nb N B Ca cation of samples for Gleeble simulation and % 0.1 0.2 0.052 0.002 0.001 0.011 0.0001 0.0004 testing.

Ceq: 0.44 V + Ti + Nb: 0.055

method to investigate fundamental phe­ Table 2 — PWHT Schedules Imposed on the CGHAZ Specimens nomena that take place in the HAZ of a welded joint using a large number of spec­ PWHT Specimens Nominal Description Actual PWHT imens. It is used to simulate the weld ther­ mal cycle under laboratory conditions in 1 12,16,20,24 635°C for 15 h 636.4 ± 4.3°C for 15.27 h order to obtain information about mi­ 2 13, 17, 21, 25 635°C for 12 h 634 ±3.3°C for 12.03 h 3 14,18, 22, 26 635°C for 6 h 634.8 ± 2.5°C for 6.06 h crostructural and property changes in the 4 15, 19, 23, 27 635°C for 3 h 636.3 ± 4.2°C for 3.16 h HAZ. Although, in principle, these 5 28, 38,48, 58 650°C for 15 h 652 ± 1.9°C for 15.25 h changes can be observed and measured 6 29, 39, 49, 59 650°C for 12 h 651.1 ± 2.8°C for 12.1 h from real welds, in practice it is more con­ 7 30, 40, 50, 60 650°C for 6 h 653.7 + 2.2°C for 6.14 h venient to work with test pieces represen­ 8 31,41,51,61 650°C for 3 h 652.2 ±2.8°C for 3.14 h tative of one, not a range, of microstruc­ 9 33,42,52, 62 670°C for 15 h 673.7 ± 4.4°C for 15.25 h tures and grain sizes. LO 34,43,53, 63 670°C for 12 h 675 ±4.5°C for 12.14 h 11 35, 44,54, 64 670°C for 6 h 672.6 ± 1.7°C for 6.14 h In this experimental work, the effect of 120) 36, 45,55, 65 670°C for 3 h 680 ± 5°C for 3.26 h weld cooling rates representing a broad BW 32, 47, 57, 67 670°C for 3 h 674.3 ± 1.4°C for 3.16 h range of welding conditions and PWHT 14 68, 69, 70, 71, 72, 73 635°C for 6 h 634.6 ± 1.5°C for 6 h schedules, different holding temperatures and holding times, on the microstructure (a) PWHT 12 was repeated. and hardness of Gleeble-simulated CGHAZ of a V-microalloyed X60 steel suits of various metallurgical reactions. increases following PWHT due to V/Nb pipe were evaluated. Additionally, tensile The relative magnitude of these changes carbonitride precipitation. Because the properties and resistance to SSC of is, of course, dependent on the steel com­ solution temperature of vanadium car­ CGHAZ with selected hardness levels position and microstructure. Steels con­ bonitrides is lower than that of niobium were determined as well. taining V or Nb derive some of their carbonitrides, and because niobium is strength from finely distributed carbides more likely than vanadium to precipitate Experimental Procedures or carbonitrides of these elements. Vana­ in the austenite during cooling, it would be dium and niobium carbonitrides are dis­ expected that vanadium steels would be Materials solved in austenite at high peak tempera­ more susceptible than niobium steel to tures during the weld thermal cycle. PWHT hardening (Ref. 2, 4, 5). There­ The material specimens were ma­ Particles that do not reprecipitate upon fore, it is important to determine the ef­ chined from a 12.75-in. OD x 64-mm (2.5- cooling can precipitate during subsequent fect of PWHT on the HAZ of microal­ in.) wall thickness V-microalloyed seam­ subcritical thermal cycles or during loyed steels in a case by case approach. less X60 steel pipe. Figure 2A and B show PWHT. Therefore, the hardness of the Gleeble weld thermal simulation is an a general view of the V-microalloyed X60 HAZ in V/Nb bearing steels sometimes inexpensive, simple, and rapid test steel pipe section used for the experimen-

JULY2005 *y -;'!-,ip.nniH! iifiisniiiiiifiisiiiiiii

7 March 2003 730 PWHT 3: 63*1.8 "C for 6.06 hours 630 / / V •90

3 4G3 / \ t \^ 1 / \ 200

x 180 / ^- ' "1 0 2 fi 12 14 11 IS 10 T

Fig. 3 — Thermal cycle representing one ofthe PWHT schedules.

tal work, and the relative through-thick­ Microstructure and Microhardness ness location of the test specimens, re­ Evaluation spectively. The chemical composition re­ ported in the mill test report (MTR) of the After HAZ simulation or PWHT, the V-microalloyed seamless X60 steel pipe is samples were cross sectioned, mounted, shown in Table 1. polished, and etched for microstructural evaluation and microhardness testing. Gleeble Weld Thermal Cycle Simulation Five microhardness readings were ob­ tained from the cross section of each Fig. 4 — A — Round-bar specimen for proof- Single CGHAZ thermal cycles were sample. ring testing in sour environment; B — general simulated on 10- x 10- x 55-mm speci­ view of the proof-ring setup. mens. The thermal cycles were measured Tensile Testing of Simulated CGHAZ using fine k-type thermocouples. The as shown in Fig. 4A. thermocouples were percussion welded to Tensile tests were conducted in se­ The specimens were stressed to 90% (54 the samples. After the thermocouples lected CGHAZ samples in the simulated ksi) of the specified minimum yield strength were attached, the specimens were "as-welded" and in the PWHT condition. (60 ksi) of the steel pipe using a proof ring clamped between water-cooled jaws of a The CGHAZ tensile samples that were setup. Figure 4B shows a general view of the Gleeble machine, which, in addition to tensile tested have an average hardness of setup of the proof ring. The proof rings were serving as grips to hold the samples, pro­ 300 HV-10 in the simulated "as-welded" calibrated. The stress level was determined vide a means for introducing the current condition and an average hardness of 250 by measuring the deflection of the proof to the specimen during heating and ensur­ HV-10 after being PWHT at 635°C for 6 rings. Immediately after applying the stress, ing a rapid cooling when the current flow hours. For the tensile specimens, single the specimens were exposed to a test solu­ is interrupted. Coarse-grained heat- CGHAZ thermal cycles were simulated tion of 5.0 wt% NaCI and 0.5 wt% glacial affected zones thermal cycles with a peak on 10- x 10- x 110-mm specimens. Tensile acetic acid in deionized water for 30 days. temperature of 1320°C (2408°F) and cool­ subsize specimens with a gauge of 0.25 in. The solution was deaerated and purged ing rates ranging from 5 to 80°C/s through (6.35 mm) in diameter x 1 in. (25.4 mm) in with HiS gas in accordance with NACE the temperature range of 800° to 500°C length were used. TM0177 (Method A). The pH ofthe solu­ were imposed on the V-microalloyed X60 tion at the beginning was adjusted to 2.7. No steel pipe specimens using the Gleeble SSC Testing of a Simulated CGHAZ pH adjustment was made during the test. simulator. The pH of the solution at the end of the test Specimens representing a CGHAZ in was measured as between 3 and 4, which is Postweld Heat Treatment the PWHT condition were tested in a sour within the specification of TM0177 environment according to the procedure (Method A). Following HAZ simulation, CGHAZ specified in NACE TM0177 (Method A) After 30 days, both specimens were re­ samples with a nominal "as-welded" hard­ (Ref. 6). The simulated "as-welded" moved from the test cells. The external ness of 280, 300, 325. and 350 HVN-10 CGHAZ samples exhibited an average surface of the samples was evaluated for were subjected to the specified PWHT cy­ hardness of 300 HV-10. The average and presence of cracks using a binocular mi­ cles listed in Table 2. During PWHT, the maximum hardness of the samples after croscope at magnification of up to 30X. heating and cooling rates above 427°C being subjected to a PWHT at 635°C for 6 hours was 250 and 264 HV-10, respec­ (800°F) were maintained under and close Experimental Results and tively. The specimens for SSC were pre­ Discussions to 400°F/h and 500°F/h, respectively. The pared by imposing CGHAZ thermal cy­ furnace used to run the PWHT allowed a cles on 11- x 11- x 110-mm samples. After Effect of Cooling Rate on CGHAZ close temperature control (± 5°C or less) PWHT, round cross-section test speci­ Hardness and Microstructure during the PWHT cycles. Figure 3 shows a mens were manufactured from the square thermal cycle representing one of the bars. The specimens had a gage diameter The resulting CGHAZ microhardness PWHT schedules used during this study. of 0.250 in. and a gauge length of 1.0 in., was measured first by making indentations

WELDING JOURNAL Ul

Cross-Sectioned Specimens ...o

O) C ^^"^^ o •• 350 -

5X «w -| 300 - .0 o" X| 0 / ° J»-«^* aX | 250- g1 cy < —•— Side of H/>Z Samples •-0- Cross-Sectioned Specimens

0 20 40 60 80 100 40 60 Cooling Rate (°C/s) Cooling Rate CZIs)

Fig. 5 —Average HAZ hardness as fimction of cooling rate (data obtained Fig. 6 — HAZ hardness as a function of cooling rate (data obtained from from different specimen preparations). the cross-section of the HAZ specimens after complete metallographic preparation)

on the four sides of the Gleeble speci­ Table 3 — Average and Maximum CGHAZ Hardness as Function of Cooling Rate mens. After that, each sample was cross sectioned, mounted, polished, and etched. Specimen Cooling from 800° to 500°C Average Maximum Yurioka Method Five microhardness readings were ob­ °C/s 2*8-5 (s) Hardness Hardness Prediction tained from the cross section of each (HVN-10 kgf) (HVN-lOkgf) sample. It was observed that the hardness data 10 5.1 58.94 230 233 229 obtained from the cross section of the 1 10.5 28.56 271 277 246 37 15.6 19.23 286 294 262 specimens present a lower level of scatter­ II 15.7 19.13 280 292 262 ing than the data obtained from the side of 6 19.7 15.20 298 304 275 the samples. This is the result of a better 46 19.7 15.24 310 316 275 and smoother surface condition of the 7 25.1 11.94 305 318 290 samples that were cross sectioned, 56 30.3 9.9 331 339 303 mounted, polished, and etched. Addition­ 2 30.5 9.84 325 333 3(15 ally, the average hardness obtained from 8 38.1 7.88 336 350 320 the cross sections is higher than the aver­ 3 48.8 6.14 353 363 338 9 52.6 5.70 367 373 343 age hardness obtained from the side of the 4 80.2 3.74 385 392 368 specimens as shown in Fig. 5. This can be explained based on the roughness of the samples. For a given hardness, as the roughness of the samples increases, the size of the indentation will increase. This

Table 4 — Average HAZ Hardness and HAZ Hardness Range Obtained with Selected Cooling Rates

HAZ Cooling from Sample Hardness Range, Average HAZ Hardness, Target HAZ Hardness, 800° to500°C HVN-10 kgf HVN-10 kgf HVN-10 kgf

°C/s SZt 8.5 (s)

15.7 19.1 11 272-292 280 280 37 277-294 286 280

19.7 15.2 6 292-304 298 300 46 304-315 310 31 ll I

30.5 9.8 2 318-333 325 525 56 312-339 332 325

48.1 6.1 3 343-363 353 350 66 343-360 354 350

None None Base Metal 206-206.5 206

JULY 2005 iimmiiiiiimu iiitii-ii in IIIIIIII

Fig. 7— "As-welded" microstmcture of the CGHAZ in the V-Nb microalloyed X60 steel pipe that resulted at different cooling rates. A — 10°C/s; B — 20°C/s; C — 50°Cls;D — 80°C/s.

• 280 HVN "As-Welded" 0 300 HVN "As-Welded" • 325 HVN "As-Welded" » 350 HVN "As-Welded" w1 PWHT at 650 "C ,,\

"A\ \ a 3oo S- \\ K \\ "\- V\ \•-. \J xi -~~.7~r. § "-^-^^S ^—-t 1 1 r 10 12 6 8 10 12 PWHT Holding Time On) PWHT Holding Time (h)

Fig. 8 — Microhardness of simulated HAZ as function of original CGHAZ Fig. 9 — Microhardness of simulated HAZ as function of original CGHAZ hardness and PWHT holding time at 635°C. hardness and PWHT holding time at 650°C.

will result in a lower apparent hardness of in Fig. 6. It was observed that the maxi­ Response of Gleeble-Simulated CGHAZ the material. The average and maximum mum hardness of the CGHAZ increases to PWHT CGHAZ hardnesses as functions of the from 233 to 392 HVN-10 as the cooling cooling rate from the data obtained from rates through the temperature range of In order to evaluate the response of the cross section of the samples are listed 800° to 500°C increases from 5° to 80°C/s. Gleeble simulated CGHAZ to PWHT, in Table 3. The change of hardness as function of HAZ cooling rates of 15.7, 19.7, 30.5, and One of the most popular empirical cooling rate is the result of the expected 48.8°C/s were used to induce nominal equations that has been developed to pre­ change of the CGHAZ microstructure as CGHAZ hardness of 280, 300, 325, and a function of the cooling rate. The mi­ dict maximum HAZ hardness as function 350 HVN-10, respectively. The average of composition and cooling rates through crostructure of CGHAZ was observed to and HAZ hardness ranges obtained in the the transformation temperature range is change from mainly a mixture of grain the Yurioka method (Ref. 7). The maxi­ boundary ferrite and ferrite with aligned CGHAZ with these cooling rates are mum HAZ hardness predicted by the Yu­ second phases with a small fraction of listed in Table 4. The hardness of the base rioka method is included in Table 3. It was upper and lower bainite resulting from metal is included in Table 4 as a reference. noted that the measured maximum cooling rates in the range of 5 ° to 30°C/s CGHAZ hardness is generally greater to a microstructure with an increasing CGHAZ Hardness than the predicted maximum hardness. fraction of martensite and decreasing Therefore, the predictions of the Yurioka fraction of Ferrite, resulting from cooling The microhardness of the CGHAZ as method are unconservative for the specific rates in the range of 40° to 80°C/s. Figure a function of original hardness, PWHT V-microalloyed steel used in this study. 7A-D shows representative microstruc­ temperature, and holding time are shown A correlation between CGHAZ cool­ tures observed in the CGHAZ of the V- in Figs. 8-10. The average and maximum ing rate and CGHAZ microhardness, microalloyed seamless X60 steel pipe at hardness of each one of the tested samples HVN-10, obtained from the cross section different cooling rates through the are also listed in listed in Table 5. temperature range of 800° to 500°C. of the samples was determined as shown None of the PWHT schedules used in

WELDING JOURNAL iimEi'smiimiiK! Cinil3ll!!!IM>-

10 12 19.0 195 20.0 PWHT Holding Time (h) Larson-Miller Tempering Parameter

Fig. 10 — Microhardness of simulated HAZ as function of original Fig. 11 — Change ofthe CGHAZ hardness, tempering effect, as function CGHAZ hardness and PWHT holding time at 67CPC. ofthe as-welded hardness and the Larson-Miller tempering parameter

Tempering Results vs Okumura Method Sample 325HV Tempered at 650C for 3,6,12, and 15 Hours

310

, 300

260 250

19.2 19.3 19.4 19D 19.5 20 £ Tampering Parameter Larson-Miller Tempering Parameter j • Actual Results • Ofcumura * Martensite Softening Only

Fig. 12 — Hardness ofthe CGHAZ as function ofthe as-welded hardness Fig. 13 — Comparison of predicted CGHAZ hardness with actual CGHAZ and the Larson-Miller tempering parameter. hardness ofthe V-microalloyed X60 steel pipe after PWHT.

this study induced any apparent hardening steel type tested. Figs. 8-10, it is observed that most of the on the CGHAZ of the V-microalloyed As shown in Figs. 8-10, the change of decrease in hardness happens relatively X60 steel pipe tested. Age hardening may hardness as a function of time at a given early in the PWHT, holding times equal or occur during PWHT and a net increase in holding temperature indicates a higher less than 3 hours. At low tempering para­ hardness will be seen only if precipitation softening rate, slope, for holding times meter values, the tempering effect of a hardening is great enough to offset the mi­ shorter than 3 hours than the softening given PWHT increases with an increase in crostructural softening that occurs simul­ rate observed for holding times between 3 the as-welded hardness of the CGHAZ. taneously during aging. In a PWHT to 15 hours. This may result from different This behavior may be related to tempering process, recovery of ferrite, decrease in hardening and softening mechanisms in­ of an increasing martensite/bainite vol­ dislocation density, coarsening and spher­ teracting and being operative at short and ume fraction present in the CGHAZ as oidization of cementite, and the mi­ long holding times, as discussed in the the "as-welded" hardness increases. Addi­ crostructural changes in other con­ following sections. tionally, a harder "as-welded" CGHAZ stituents such as martensite and bainite Figure 11 shows the change of hard­ resulting from faster cooling rate is ex­ may also take place, contributing to soft­ ness in the CGHAZ in the V-microalloyed pected to have a higher dislocation density ening of the material. The net hardness X60 steel pipe as a function of the Larson- and a higher thermodynamic driving force changes in the CGHAZ during PWHT re­ Miller tempering parameter. The temper­ for tempering. sult from the contribution of all the soft­ ing effect or change of hardness in the On the other hand, the PWHTs with ening and hardening mechanisms and CGHAZ during PWHT depends not only holding times between 3 and 15 hours re­ their interplay. The relative magnitude of in temperature and time, but also on the sulted in roughly similar slopes of hard­ such changes is, of course, dependent on original hardness of the CGHAZ. The ness change per unit of tempering para­ the steel composition and microstructure. tempering effect of a given PWHT in­ meter change, e.g., nearly parallel lines, and any effects of PWHT on hardness, and creases with an increase in the as-welded independent of the original CGHAZ other properties, will be specific to the hardness of the CGHAZ. However, in hardness, as seen in Fig. 11. It is generally

JULY 2005 ISllllllllllUllllll t;?;*'!Mn;umn

B

^ , ; '••*;-.,

C

50 |im C30-T2-3H

C50-T2-3H Fig. 14 — Representative microstructures ofthe CGHAZ after PWHT. A — 15°C/s , PWHT at 635°Cfor 3 hours; B — 15"C/s, PWHT at 670°C for 15 hours; C — 30"C/s, PWHT at 650° C for 3 hours; D — 30°C/s, PWHT at 670°Cfor 15 hours; E — 50°Cls, PWHT at 650°C for 3 hours; F — 50°C/s, PWHT at 670°C for 15 hours.

expected that faster cooling rates would times between 3 and 15 hours, the inter­ pering parameter of each PWHT is listed result in higher vanadium supersaturation action of time and temperature in reduc­ in Table 6. The Larson-Miller tempering of the CGHAZ. Therefore, CGHAZ in­ ing the hardness of the CGHAZ during parameter was originally devised as an in­ duced with faster cooling rates should ex­ PWHT can be described by the Larson- dicator of the tempering behavior via a sin­ hibit stronger secondary hardening. How­ Miller tempering parameter, P, given by gle reaction (Refs. 8, 9). Therefore, in the ever, no obvious secondary hardening was the following equation: present case, there is clearly an indication observed in any ofthe CGHAZ evaluated. that the tempering behavior of the Had hardness changes during tempering P = T(C+logt) x lO-3 (1) CGHAZ in the V-microalloyed seamless been dominated by secondary hardening where T is the absolute temperature of X60 steel pipe at the holding temperatures from vanadium carbide precipitates, a PWHT in degree Kelvin, t is the PWHT used in this study and for holding times be­ nonlinear curve would be expected. time in hours, and C is a constant equal ap­ tween 3 and 15 hours is controlled by a sin­ As shown in Figs. 11 and 12, for PWHT proximately to 20. The Larson-Miller tem­ gle metallurgical reaction. This may indi-

WELDING JOURNAL iitriiniiiniiiii!

Table 5 — Change of CGHAZ Hardness (HVN-10 kgf) as Function of PWHT Temperature and Holding Time

Holding Holding Temperature Time (h) 635°C 650°C 670°C Nominal Hardness in the "As-Welded" Condition: 280

Average Maximum Average Maximum Average Maximum Hardness Hardness Hardness Hardness Hardness Hardness 0 280.2 292.0 280.2 292.0 280.2 292.0 3 235.0 244.0 232.4 239.0 215.6 222.0 6 237.2 241.0 224.6 227.0 220.7 227.5 12 223.2 229.0 215.6 218.0 213.8 218.0 15 222.3 230.0 206.8 215.0 204.4 210.0

Nominal Hardness in the "As-Welded" Condition: 300

Average Maximum Average Maximum Average Maximum Hardness Hardness Hardness Hardness Hardness Hardness 0 298.0 304 298.0 304.0 298.0 304.0 3 241.8 248.0 234.6 240.0 218.6 228.0 6 250.0 264.0 229.5 237.0 218.4 225.0 12 234.8 245.0 223.8 229.0 216.7 222.0 15 221.8 225.0 223.8 233.0 213.2 218.0

Nominal Hardness in the "As-Welded" Condition: 325

Average Maximum Average Maximum Average Maximum Hardness Hardness Hardness Hardness Hardness Hardness 0 325.0 333.0 325.0 333.0 325.0 333.0 3 249.0 256.0 249.6 253.0 231.6 235.0 6 252.8 258.0 233.9 238.0 230.9 236.0 12 246.6 253.0 235.6 238.0 216.3 219.0 15 245.6 249.0 227.8 234.0 213.7 218.5

Nominal Hardness in the "As-Welded" Condition: 350

Average Maximum Average Maximum Average Maximum Hardness Hardness Hardness Hardness Hardness Hardness 0 353.4 363.0 353.4 363.0 353.4 363.0 3 262.4 272.0 256.4 261.0 241.6 243.0 6 255.6 262.0 241.6 248.0 233.4 238.0 12 244.8 253.0 23N.II 241.0 226.0 229.0 15 247.7 252.0 234.2 239.0 220.1 226.0

cate that at long holding times, the soften­ Okumura method. Results show actual tardation of softening of the CGHAZ due ing mechanism becomes independent of CGHAZ hardness being significantly to minor precipitation reaction. starting hardness and microstructure. In below the predicted value; however, the Figure 12 shows the hardness of the this condition, tempering of the CGHAZ difference narrows as tempering parame­ CGHAZ in the V-microalloyed X60 steel may be approaching a purely carbide ter increases. These results indicate that pipe as function of the Larson-Miller tem­ coarsening dominated mechanism as ob­ for the specific X60 material tested in this pering parameter. As indicated in Fig. 12, served in the last stages of tempering of a study, the Okumura equation significantly PWHT with a characteristic Larson- martensitic microstructure. over predicts hardness at a given temper­ Miller tempering parameter of about Different methods have been developed ing parameter. The slope of the predicted 18.47, 18.96, and 19.16 is needed to de­ to predict the effect of PWHT on HAZ value curve which includes the combined crease the hardness of the CGHAZ in the hardness. One of these methods is the Oku­ effect of martensite softening and precip­ V-microalloyed X60 steel pipe from an as- mura method, which has been developed to itation hardening is much steeper than the welded hardness of 300, 325, and 350 combine martensite softening with harden­ actual data. Additionally, the actual HVN-10, respectively, to a hardness of ing caused by V, Nb, and Mo all as a func­ CGHAZ hardness data follows a similar about 248 HVN10. The maximum hard­ tion of tempering parameter, martensite trend that the prediction for tempering ness of 248 HVN-10 (22 RC) recom­ fraction, and composition (Refs. 5,10). controlled by martensite softening only. mended by NACE to avoid risk to SSC is A comparison between the prediction This also confirms the absence of sec­ included in Fig. 12 as a reference. These of the Okumura methods and observed ondary hardening as major reaction dur­ results have significant implications for CGHAZ hardness is shown in Fig. 13. In ing the tempering process of the CGHAZ the required control over welding proce­ this case, the effect of PWHT at 650°C for of the V-microalloyed steel pipe. How­ dure variables. These tempering condi­ 3, 6, 12, and 15 hours on the CGHAZ ever, the actual data presents a slope that tions require much longer holding times hardness of samples with simulated "as- is steeper than pure martensite softening, during PWHT than the holding time nor­ welded" hardness of 325HV is compared but not as steep as that predicted by the mally required in different industry codes, to the hardness values predicted by the Okumura equation.which may indicate re­ which are a function of thickness only.

JULY 2005 • 280HV "as-welded" O 300 HV "as-welded' 1 T 325 HV "as-welded m=-2530 V 350 HV "as-welded1

1 -

« £ X • 32. ij - • • 9 • _J •

•1 •

106 103 110 5 106 108 110 Temperature"' (x10 ic') Temperature"' (x10s lO

Fig. 15 — Tempering ofthe CGHAZ during PWHT for 3 hours, log of soft­ Fig. 16 — Tempering ofthe CGHAZ during PWHT for 3 to 15 hours, log ening rale (dH/dl) as function ofthe inverse temperature (1/T). of softening rate (dH/dl) as function ofthe inverse temperature (I IT).

CGHAZ Microstructure aries were more pronounced after PWHT, Therefore, the apparent activation en­ compared to the "as-welded" condition. ergy of tempering observed in the Figure 14A-F shows microstructures From the optical examination, this CGHAZ was also determined in the pre­ representative of the CGHAZ induced at seemed to be accompanied by carbide for­ sent work. The logarithmic form of equa­ different cooling rates and after being sub­ mation at colony and possibly prior tion 2 is log (dH/dt) = log A - m 1/T jected to different PWHT. Metallographic austenite grain boundaries. This effect has (3) where (dH/dt) is the softening rate and examinations showed a small dependence been noted in weld metals (Ref. 13) and, m = Q / 2.3R. of microstructure on PWHT time, al­ indeed, high angle boundaries are known The apparent activation energy for though a stronger effect of temperature to be preferred sites for carbide formation tempering of the CGHAZ during short was observed, in which the degree of dis­ both because of a higher carbon diffusion holding times, less than 3 hours, and dur­ persion of the carbides was temperature rate along such boundaries and because ing long holding times, 3 to 15 hours, was dependent. the high vacancy level more readily ac­ evaluated by plotting log (dH/dt) as func­ < Insert Fig. 14A-F, Figure 14-a.tif, Fig­ commodates the volume difference be­ tion of 1/T in the form of an Arhennitis ure 14-b.tif, Figure 14-c.tif, Figure 14-d.tif, tween cementite and the ferrite matrix. plot (Figs. 15, 16). The determined values Figure 14-e.tif, and Figure 14-f.tif> Additional fine scale microstructural of the apparent activation energy are As previously described, the mi­ variations during PWHT, such as marten­ listed in Table 7. crostructure of the CGHAZ can be re­ site decomposition, annealing of disloca­ As expected, the apparent activation garded as composed mainly of ferrite with tions, and V/Nb carbide precipitation that energy for tempering of the CGHAZ dur­ aligned second phases and an increasing are embodied in the variation in the HAZ ing short holding times depends on the fraction of bainitc/martensite constituents hardness data, are beyond the resolution original microstructure and associated as the cooling rate is increased. Based on capabilities of optical microscopy. hardness ofthe CGHAZ. The average ap­ optical microscopic observation, the parent activation energy for tempering of strongest effect of varying heat treatment Metallurgical Reactions Controlling CGHAZs that consist of mainly ferrite temperature was on the morphology of Tempering of CGHAZ with aligned second phases was deter­ the ferrite with aligned second phases. mined to be equal to 16,376 cal/mol. On With increasing temperature, the packets The fact that time and temperature the other hand, for CGHAZs with a of second phases spheroidizc, eventually have corresponding effects on tempering mainly martensitic microstructure, the ap­ forming a small number of globular pre­ of steels as shown in Figs. 8-12 has been parent activation energy for tempering cipitates to minimize the interfacial en­ known for a long time. The observed time- was determined to be equal to 9853 ergy. The elongated constituent would be temperature relation is based on the well cal/mol. Tempering at temperatures be­ expected to have a high interfacial energy known theory of rate processes, which tween 635° and 67()°C and holding times because of the higher surface area to vol­ states that the rate at which certain less than 3 hours are expected to induce ume ratio. It seems that during heat treat­ processes progress is related to tempera­ different thermally activated metallurgi­ ment, carbon diffusion enables the second ture by activation or Arhennius-type laws. cal reactions. These reactions include re­ phase to dissolve and form smaller pack­ Therefore, their temperature dependence covery of dislocations in the ferrite lath ets, as observed by other workers on both can be described in the form boundaries, recrystallization of ferrite base metal (Ref. 11) and weld metal (Ref. grains, transformation of low-carbon 12). At the same time, the low angle r = Ae -Q/KT (2) martensite to ferrite by losing both its car­ boundaries between the ferrite laths be­ where r = rate, A = constant, c = natural bon and tetragonality, precipitation of ce­ came less pronounced. logarithm base, Q = apparent activation mentite, and coarsening of the second As PWHT temperature was increased, energy for process, R = gas constant (2 phases. Therefore, it is difficult to associ­ the intragranular microstructure became cal/mol/°K), and T = absolute ate the apparent activation energy with a less defined. The grain and colony bound­ temperature, °K. specific physical phenomenon or reaction.

WELDING JOURNAL! On the other hand, it was observed that (Refs. 16,17). Therefore, it seems that the the apparent activation energy for tem­ transfer of carbon atoms from cementite pering of the CGHAZ during holding to ferrite is the main controlling mecha­ times between 3 and 15 hours was inde­ nism of tempering of the CGHAZ during pendent of the original microstructure the late stages of tempering. However, and associated hardness of the CGHAZ. further experimental work is needed to The average apparent activation energy support this statement. for tempering of CGHAZ during long holding times was determined to be equal Tensile Properties and SSC to 11,636 cal/mol. This makes sense taking Resistance of CGHAZ into account that after 3 hours of temper­ ing, the microstructure is expected to be Tensile Properties an aggregate of ferrite containing a large Fig. 17—Failure location of tensile test samples. number of spheroidal carbide and second- The results of the tensile tests are re­ phase particles independent of the origi­ ported in Table 8. All the samples seem to nal microstructure. The coarsening of ce­ have failed in the base metal very close to mentite and second-phase particles is con­ the interface with the simulated HAZ as sidered to be the primary metallurgical shown in Fig. 17. Therefore, the results are reaction controlling the softening of the not representative of the intrinsic me­ CGHAZ during late stages of tempering. chanical properties of the simulated The growth rate of carbide particles in CGHAZ. The fracture of all samples has iron-carbon alloys is diffusion-controlled a "cup-cone" feature characteristic of duc­ (Ref. 14). The activation energy for the tile failure. The lower tensile properties of transfer of carbon atoms from cementite the samples in the as-simulated condition to alpha iron is 9700 cal/mol (Ref. 15). The may be due to the normal variance of activation energy for the diffusion of car­ properties of the base metal from sample Fig. 18 — CGHAZ specimen after SSC testing. bon atoms in alpha iron is 20,100 cal/mol to sample and due to the clearly over­ matching condition of the HAZ as com­ pared to the base metal. A highly over­ matched condition would induce localized Table 6 — Larson-Miller Tempering Parameter, P, of different CGHAZ PWHT deformation in the base metal, which PWHT PWHT Description causes the point of instability to be con­ trolled by the properties of the base metal. I 636.4 ± 4.3°C for 15.27 h 19.26 On the other hand, a lower overmatched 2 634 ±3.3°C for 12.03 h 19.12 condition of the PWHT samples will cause 3 634.8 ± 2.5°C for 6.06 h 18.87 a more homogeneous distribution of the 4 636.3 ±4.2°C for 3.16 h 18.64 plastic deformation and the point of sta­ 5 652 ± 1.9°Cfor 15.25 h 19.59 bility being controlled by the strain hard­ 6 651.1 ± 2.8°C for 12.1 h 19.48 ening behavior of both the HAZ and the 7 653.7 ± 2.2°C for 6.14 h 19.26 base metal. Sample 75 failed at or near a 8 652.2 ±2.8°C for 3.14 h 18.96 gauge mark, which may have resulted in a 9 673.7 ± 4.4°C for 15.25 h 20.05 stress concentrator and the observed low 10 675 ± 4.5°C for 12.14 h 19.99 percent elongation. 11 672.6 ± 1.7°C for 6.14 h 19.66 120>) 680 ± 5°C for 3.26 h — SSC Resistance 13W 674.3 ± 1.4°C for 3.16 h 19.42 14 634.6 ± 1.5°Cfor6h 18.86 The PWHT CGHAZ specimens with an average and maximum hardness of 250 («) PWHT 12 was repeated. and 264 HV-10, respectively, did not rup­ ture in the H2S environment after 30 days

Table 7 — Apparent Activation Energy for Tempering of the CGHAZ Regime (Holding time) Original Characteristics of the CGHAZ Activation Energy, cal/mol (Hardness-Microstructure) 1 (Less than 3 hours) 280 HVN-Ferrite with aligned second phases 16,979 30(1 HVN-Ferrite with aligned second phases 15.773 325 HVN-Mainly martensite with small fraction 9,853 of ferrite with aligned second phases 350 HVN-Martensite 9,853

2 (3 to 15 hours) All 11,636

JULY 2005 Table 8 — Tensile Test Results of Simulated "As-Welded" and PWHT CGHAZ in V-Microalloyed X60 Steel Pipe

Specimen Nominal Hardness, UTS 0.2 Yield Strength Elongation Reduction of Area HV-10 MP ksi MPa ksi (%) (%)

74 300 603.4 87.5 466.2 67.6 30 76.3

75 300 615.9 89.3 482.8 70.0 14.9(a) 76.4

68 (PWHT) 250 628.3 91.1 520.7 75.5 26.1 76.2

69 (PWHT) 250 626.9 90.9 534.5 77.5 26.4 76.6

<•'> Sample failed at or very near a gauge mark. of testing. The specimens had a smooth, were not adequate to calculate and predict 6. NACE Standard TM0177, Laboratory black, shiny appearance —Fig. 18. No as-welded hardness and hardness after Testing of Metals for Resistance to Sulfide Stress cracks were visible on the external surface PWHT for the CGHAZ of the V-microal­ Cracking in H2S Environment. Houston, Tex. of the gauge length at magnifications up to loyed steel pipe evaluated. 7. Yurioka, N., Okumura, M., Kasuya, T, 30X. 9. The apparent activation energy for and Cotton. H. J. U. 1987. Prediction of HAZ tempering of the CGHAZ during short hardness of transformable steels. Metal Con­ Conclusions holding times depends on the original mi­ struction 119:217R-223R. crostructure and associated hardness of 8. Larson, F. R.. and Miller, J. 1952. A time- 1. The maximum hardness in the the CGHAZ. The apparent activation en­ temperature relationship for rupture and creep CGHAZ of the V-microalloyed X60 steel ergy for tempering of CGHAZ that con­ stresses. ASME 74: 765-775. pipe increases from 233 to 392 HV-10 by sists of ferrite with aligned second phases 9. Holloman, J. H., and Jaffee, L. D. 1945. increasing the CGHAZ cooling rate was equal to 16,376 cal/mol. The apparent Time and temperature relations in tempering through the 800° to 500°C temperature activation energy for tempering for steel. Trans. AIME 162: 223-249. range from 5° to 80°C/s. CGHAZ with a martensitic microstruc­ 10. Okumura. M., Yurioka, N., Kasuya, T, 2. The microstructure of CGHAZ ture was equal to 9853 cal/mol. and Cotton, H. J. 1987. Prediction of HAZ changes from a mixture of grain boundary 10. The apparent activation energy for hardness after PWHT. Proceedings of Interna­ ferrite and ferrite with aligned second tempering of the CGHAZ during holding tional Conference on Stress Relieving Heat phases resulting at cooling rates from 5° times between 3 and 15 hours was inde­ Treatments of Welded Steel Constructions, (7): to 30°C/s to a microstructure with an in­ pendent of the original microstructure 61-68. Sofia. Bulgaria. creasing fraction of martensite at cooling and associated hardness of the CGHAZ. 11. Cochrane, R. C. 1971. Some effects of rates from 40° to 80°C/s. The average apparent activation energy carbide particles size on the Charpy impact be­ 3. CGHAZ cooling rates of 15.7, 19.7, for tempering of CGHAZ during long havior of normalized and stress relieved C-Mn 30.5, and 48.8°C/s induced an average holding times was 11,636 cal/mol. steels. The Iron and Steel Institute, 3: 101-106. CGHAZ hardness of 280, 300, 325, and 11. The tensile test results were depen­ 12. Billy, J., Johansson, T, Loberg, B., and 350 HVN-10, respectively. dent on the degree of overmatching be­ Easterling, K. E. 1980. Stress Relief heat treat­ 4. None of the PWHT schedules used tween the CGHAZ and the base metal. ment of submerged-arc welded microalloyed in this study induced any apparent hard­ 12. The PWHT V-microalloyed X60 steels. Metal Technology 7(2): 67-78. ening on the CGHAZ of the V-microal­ steel CGHAZ with an average and maxi­ 13. Farrar, R. A., Taylor, L. G., and Harri­ loyed X60 steel pipe tested. mum hardness of 250 and 264 HV-10, son, E. M. 1979. Effect of stress relieving on 5. The softening rate ofthe CGHAZ or respectively, were resistant to SSC. fracture properties of submerged-arc welds of tempering effect of PWHT decreases C-Mn Steels. Metals Technology 6(10): after 3 hours at a given PWHT tempera­ References 380-389. ture used in this study. 14. Vedula, K. M„ and Heckel, R. W. 1970. 6. The tempering effect of PWHT on 1. Spaeder, lr., C. E., and Doty, W. D. 1995. Spheroidization of binary Fe-C alloys over a the CGHAZ for holding times between 3 ASME post-weld heat treating practices: An in­ range of temperatures. Met. Trans 1(1): 9. and 15 hours is described by the Larson- terpretive report. WRC Bulletin, 407. 15. Wert, C. A. 1950. Solid Solubility of Ce­ Miller tempering parameter. Therefore, 2. Stout, R. D. December 1985. Postweld mentite in alpha iron, trans. AIME 188(10): the tempering behavior of the CGHAZ is heat treatment of pressure vessel steels. WRC 1242-1244. controlled mainly by a single metallurgical Bulletin, 302 February. 16. Wert, C. A. 1950. Diffusion coefficient reaction. 3. NACE Standard MRO 175, Metals for Sul­ of C in a-Iron. Phys. Rev. 79(4): 601. 7. Coarse-grained heat-affected zones fide Stress Cracking and Stress Corrosion 17. Wert, C. A., and Zencr. C. 1949. Inter­ in the V-microalloyed X60 steel pipe with Cracking Resistance in Sour Oilfield Environ­ stitial atomic diffusion coefficients. Phys. Rev. an as-welded hardness of 300,325, and 350 ment. Houston, Tex. 76(8): 1169. HV-10 need to be subjected to a PWHT 4. Shiga. C, Gotoh. A., Kojima, T, Fukada, with a characteristic Larson-Miller tem­ Y., Ikeuti, K., and Matuda, F. 1996. State of the pering parameter of about 18.47, 18.96, art review on the effect of PWHT on properties and 19.16, respectively, to decrease the of steel weld metal. Welding in the World 37(4): hardness to 248 HVN10. This can have 163-176. significant impacts on welding procedure 5. Xu. P., Somers, B. R.. and Pense, A. W. qualification requirements. 1994. Vanadium and columbium additions in 8. The Yurioka and Okumura methods pressure vessel steels. WRC Bulletin, 395.

WELDING JOURNAL What if you could find better pay and more job security in welding?

FIND OUT HOW TO BECOME AN AWS CWI OR CWE. ENROLL TODAY AND SAVE OVER $900 ON YOUR BOOKS.

AWS Certification can mean better pay, more job secu­ rity, and the proof that your skills and knowledge label you as one ofthe industry's elite.

We offer five and a half days of intensive seminars that help prepare you to pass the AWS certification tests. Our experienced instructors help you learn the materi­ al you need to know fast, and show you how to use and understand the latest standards. AWS seminars are an excellent value. You save time and money too, because we supply many of the books you need (a $900 value). There are clinics for D1.1 Code, AP11104 Code, Welding Inspection Technology, and Visual Inspection, followed by the certification exam at the end of the week. By grouping the preparation with the test, you can attend AWS seminars with less time off from the job and less travel expense.

When it comes to preparing for an exam that proves you're one of the best, then take it from the people who know it best—AWS.

^ American Welding Society r To became an AWS member, call 800-443-9353, ext. 480, or visit our website at www.aws.org

FIND THE AWS SEMINAR NEAREST YOU. FOR MORE INFORMATION, CALL 800-443-9353, EXT. 449

LOCATION SEMINAR EXAM DATES DATES

ALBUQUERQUE, NM 7/31-8/5 8/6/2005 SYRACUSE, NY 9J 9/17/2005 TULSA, OK 10/16-21 10/22/2005 YORK, PA 7/31-8/5 8/6/2005 MINNEAPOLIS, MN 9J 9/24/2005 SAN ANTONIO, TX 10/16-21 10/22/2005 MEMPHIS, TN 8/7-12 8/13/2005 SEATTLE, WA 9J CHICAGO, IL 10/23-28 10/29/2005 SALT LAKE CITY, UT 8/7-12 8/13/2005 SAN DIEGO, CA 9J 9/24/2005 ATLANTA, GA 10/23-28 10/29/2005

COLUMBUS, OH (AT NBBPUI)- 8/8-12 8/13/2005 ANCHORAGE, AK (EXAM ONLY) RENO, NV 10/30-11/4 11/5/2005

MIAMI, FL (EXAM ONtv) 8/18/2005 DALLAS, TX 9J 10/1/2005 BALTIMORE, MD 10/30-11/4 11/5/2005 HOUSTON, TX 8/14-19 8/20/2005 DETROIT, Ml 9J LONG BEACH, CA 11/6-11 11/12/2005 HOUSTON, TX 8/14-19 8/20/2005 MILWAUKEE, Wl 9/ 10/1/2005 BEAUMONT, TX 11/6-11 11/12/2005 ROCHESTER, NY (EXAM ONtv) 8/20/2005 DENVER, CO 11 PORTLAND, OR 11/6-11 11/12/2005 CHARLOTTE, NC 8/21-26 8/27/2005 PHOENIX, AAZZ 11 10/8/2005 LOUISVILLE, KY 11/13-18 11/19/2005

MIAMI, FL (EXAM ONLY} 9/15/2005 MIAMI, FL (EXAM ONLY) 10/20/2005 SIOUX FALLS, SD 11/13-18 11/19/2005 NEW ORLEANS, LA 9/11-16 9/17/2005 PITTSBURGH, PA 10/22/2005 ST. LOUIS, MO (EXAM o 12/3/2005 Circle No. 4 on Reader Info-Card Use these convenient, postage- Please send literature on items circled at right: 1 35 69 103 137 171 205 239 273 2 36 70 104 138 172 206 240 274 3 37 71 105 139 173 207 241 275 paid inquiry cards to request July 2005 Card void after January 1,2006 4 38 72 106 140 174 208 242 276 tree information about the 5 39 73 107 141 175 209 243 277 Name Title 6 40 74 108 142 176 210 244 278 products or services 7 41 75 109 143 177 211 245 279 Dompanu 8 42 76 110 144 178 212 246 280 advertised in this issue of 9 43 77 111 145 179 213 247 281 Address 10 44 78 112 146 180 214 248 282 Welding dournal. 11 45 79 113 147 181 215 249 283 RHy Stats Zip 12 46 80 114 148 182 216 250 284 13 47 81 115 149 183 217 251 285 For information about specific 14 48 82 116 150 184 218 252 286 15 49 83 117 151 185 219 253 287 advertisements: Circle the 16 50 84 118 152 186 220 254 288 17 51 85 119 153 187 221 255 289 key number on the card that 18 52 86 120 154 188 222 256 290 Please circle an entry lor each category; 19 53 87 121 155 189 223 257 291 matches the number on the 20 54 36 122 156 190 224 258 292 21 55 89 123 157 191 225 259 293 bottom of the ad. 1. TYPE OF BUSINESS 6. Sales V. ANNUAL DOLLAR VOLUME 22 56 90 124 158 192 226 260 294 1. Construction 7. Purchasing 1. Under $1 Million 2. Primary Metal Products 8. Education 2. $1 Million to 5 Million 3. Fabricated Metal Products 9. Other 3. Over $5 Million 25 59 93 127 161 195 229 263 297 4. Transportation 26 60 94 128 162 196 230 264 298 III. PURCHASING AUTHORITY VI. THIS INQUIRY IS FOR 5. Petrochemical 27 61 95 129 163 197 231 265 299 1. Recommend 1. Immediate Purchase 6. Misc. Repair Services 28 62 96 130 164 198 232 266 300 2. Future Project 7. Educational Services 2. Specify 29 63 97 131 165 199 233 267 301 8. Utilities 3. Approve 3. General Information 30 64 93 132 166 200 234 268 302 9. Other 31 65 99 133 167 201 235 269 303 IV. NUMBER OF EMPLOYEES 32 66 100 134 168 202 236 270 304 II. JOB FUNCTION/TITLE 1. Under 33 67 101 135 169 203 237 271 1. Corp. Management 2. 50 to 99 34 68 102 136 170 204 238 272 2. Plant Mgmt. 3. 100 to 499 3. Engineer 4. 500 to 999 4. Welding or Cutting Oper. 5. 1000 to 2499 Please mail: 5. Quality Control 6. 2500 to more J 305- List of AWS publications • 306- Information on AWS Membership

ELD QUALITY

www.cntrline.com THE COMPLETE JOINING COMPANY

1-800-268-8330 • www.cntrline.com

Centerline (Windsor) Ltd., Windsor, ON N9J3T9 • Detroit, Ml 48232-1187

NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES

BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. 11992 MIAMI, FL !• iaster processing, POSTAGE WILL BE PAID BY ADDRESSEE please FAX this card to (630) 739-9700. Type or print the WELWMG information and copy C/O CREATIVE DATA before faxing. 519 E BRIARCLIFF RD This fax number is for BOLINGBROOK IL 60440-9882 the service bureau lv, not AWS. l.ll,,ll....l..l.l..lll,..I.M..I.M...I.II.I..I NO POSTAGE paid inquiry cards to request NECESSARY free information about the IF MAILED IN THE products or services UNITED STATES advertised in this issue of Welding Journal.

BUSINESS REPLY MAIL For information about specific FIRST CLASS PERMIT NO. 11992 MIAMI, FL advertisements: Circle the POSTAGE WILL BE PAID BY ADDRESSEE key number on the card that matches the number on the WELPJNG bottom of the ad. C/O CREATIVE DATA 519 E BRIARCLIFFRD BOLINGBROOK IL 60440-9882

I.IUI....IMI.I.,III„.I.I..I..I.I..I...I.I1.I..I

\X2 WELD QUALITY

I www.cntrline.com THE COMPLETE JOINING COMPANY

1-800-268-8330 • www.cntrline.com

Centerline (Windsor) Ltd., Windsor, ON N9J 3T9 • Detroit, Ml 48232-1187

Please send literature on items circled at right: 1 35 69 103 137 171 205 239 273 2 36 70 104 136 172 206 240 274 July 2005 Card void after January 1, 2006 3 37 71 105 139 173 207 241 275 4 38 72 106 140 174 208 242 276 Name Title 5 39 73 107 141 175 209 243 277 6 40 74 108 142 176 210 244 278 Company 7 41 75 •09 143 177 211 245 279 8 42 76 110 144 178 212 246 280 Address 9 43 77 111 145 179 213 247 281 10 44 78 112 145 •80 214 248 282 Citv Zip 11 45 79 113 147 •81 215 249 283 12 46 80 114 '48 182 216 250 284 13 47 81 115 149 183 217 251 285 Phone- Fax' 14 48 82 116 150 184 218 252 286 15 49 83 117 151 185 219 253 287 E-mail 34 118 152 186 220 254 288 17 51 85 119 153 187 221 255 289 Please circle an entry for each category: 18 52 86 120 154 188 222 256 290 19 53 87 121 155 189 223 257 291 20 54 36 122 156 190 224 258 292 I. TYPE OF BUSINESS 6. Sales V. ANNUAL DOLLAR VOLUME 21 55 89 123 157 191 225 259 293 NOTE: 1. Construction 7. Purchasing 1. Under $1 Million ?? 56 90 124 156 192 226 260 294 2. Primary Metal Products 8. Education 2. S1 Million to 5 Million 23 57 91 125 159 193 227 261 295 To speed the processing 3. Fabricated Metal Products 9. Other 3. Over $5 Million 24 58 92 126 160 194 228 262 296 4. Transportation ?S 59 93 127 161 195 229 263 297 of your inquiry, please 5. Petrochemical III. PURCHASING AUTHORITY VI. THIS INQUIRY IS FOR 26 60 94 126 162 •96 230 264 298 6. Misc. Repair Services 1. Recommend 1. Immediate Purchase 27 61 95 129 163 197 231 265 299 provide ALL the information 7. Educational Services 2. Specify 2. Future Project 28 62 96 1 30 164 198 232 266 300 requested on the card. 8. Utilities 3. Approve 3. General Information 29 63 97 131 165 199 233 267 301 9. Other "Mi 64 98 132 166 200 234 268 302 This will make it easier IV. NUMBER OF EMPLOYEES 31 65 99 133 167 301 235 269 303 II. JOB FUNCTION/TITLE 1. Under 3? 66 100 134 168 202 236 270 304 for the companies to follow 1. Corp. Management 2. 50 to 99 33 67 101 135 ' 69 203 237 271 2. Plant Mgmt. 3. 100 to 499 M 68 102 136 170 204 238 272 up on your request as soon 3. Engineer 4. 500 to 999 4. Welding or Cutting Oper. 5. 1000 to 2499 Please mail: as possible. 5. Quality Control 6. 2500 to more -1305- List of AWS publications • 306- Information on AWS Membership They trusted ESAB to restore what was lost. You can trust us to restore your productivity.

'yt*

\* \w

'*>**

Mi y ii a*? -L- $~-£2&&m £^-€ ^

Repairing the USS Cole after she was assaulted in 2000 was a matter of pride. Doing the job right was a necessity. Maybe that's why one of the nation's premier shipbuilders turned to ESAB for the plasma cutting tools, flux core and submerged arc welding systems, and filler metals needed for the task. For over 100 years, ESAB has been the trusted welding and cutting supplier for companies worldwide. And on signature projects across the country and throughout the world, they turn to us for products that perform day after day, job after job. They've counted on the durability of ESAB filler metals and equipment to stand up to any test and keep their projects moving, all backed by our 100% Satisfaction Guarantee. Whether it's bringing back the Cole or bringing our expertise to your welding and cutting projects, we do the job right. Ask for ESAB by name, and put us to work for you.

Great things happen when you put us to work. Your Partner in ESAB Welding & Cutting 1.800.ESAB.123 www.esabna.com

WELDING I CUTTING I FILLER METALS U.S. Navy imagery used in illustration without endorsement expressed or implied. Circle No. 19 on Reader Info-Card ujunR/AiecojRl

V Premium Cored Wire Electrode. MORE of What You Need in a Gas-Shielded Flux-Cored Wire.

ULTRA PERFORMANCE thanks to low spatter, easy operation and great operator appeal.

ULTRA DEPENDABILITY thanks to optimized mechanical properties and exceptional chemistry control.

ULTRA PROTECTION thanks to Lincoln's new ProTech foil bag packaging . Why Buy Anything Else?

[LINCOLN 1< 1 ELECTRIC THE WELDING EXPERTS

The Lincoln Electric Company Cleveland, Ohio U.S.A. 216-481-8100 www.lincolnelectric.com

Circle No. 24 on Reader Info-Card