February ' -I~"~Z J ~" /., v/ I~ C / WeldingAluminuM nd the Hew Ford GT Advantages of Electron Beam Welding PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGYAND APPLICATION OF WELDING : : ;:;::x: ;: :,, I i;; !' ,: : G: i I I Whatever your critical welding levels from 80-120 Ksi, Select-Arc can For more detailed requirement, Select-Arc has the right provide the low alloy electrode that is information on ~llllllllllllll~ SELECT-ARC low alloy, flux cored electrode for the ideally suited to handle your selecting the Select- I~IInlIIIIIIIMF job. That is because Select-Arc offers a individual application. Arc low alloy, flux complete line of electrodes specially cored electrode that is formulated for welding low alloy and Select-Arc low alloy, flux cored appropriate for your specific need, call high strength steels. With your choice electrode grades include: 800-341-5215 or contact: of slag systems (T-5, T-1 and all • Molybdenum position T-l) and available in strength • Nickel • Chromium - Molybdenum • Nickel - Chromium - Molybdenum • Manganese - Molybdenum • Weathering These exceptional tubular welding electrodes are manufactured under Select-Arc's quality system, which is approved to ISO 9001, ABS-Level II, CWB 600 Enterprise Drive and the military, and are backed P.O. Box 259 by the company's unparalleled Fort Loramie, OH 45845-0259 • commitment to customer service Phone: (937) 295-5215 and support. Fax: (937) 295-5217 www.select-arc.com Circle No. 32 on Reader Info-Card Hodgson Custom Rolling inc. services a wide variety of industries in the ENERGY 44"1D 6" Thick SECTORS of hydro, petro chemical, atomic, gas, oil, 96"Long wind, etc. in addition to those in heavy manufactudng~ steel, pulp & paper, mining, marine, forestry, etc. Hodgson's commitment to providing customers superior products and personalized professional service has earned itself a reputation for excellence, making the name HODGSON synonymous with ,'paramount quality and workmanship". America's largest plate rolling, forming, section rolling and fabricating companies. PLATE ROLLING & FLATTENING i i Hodgson Custom Rolling specializes in the rolling and flattening of heavy plate up to 7" thick and up to 12 feet wide. Cylinders and segments can be rolled to diameters ranging from 10" to over 20 feet. Products made include ASME pressure vessel sections. Crane Heist Drums, thick walled pipe, etc. PRESS BRAKE FORMING & HOT FORMING Hodgson Custom Rolling's brake department processes all types of steel sections and plate up to 14" thick. Developed shapes such as cones trapezoids, parabolas, reducers (round to round, square to round) etc. STRUCTURAL SECTION ROLLING Hodgson Custom Rolling has the expertise to roll curved structural sections into a wide range of shapes and sizes (angle, wide flange beam. I-beam. channel, bar, ~ tee section, pipe, tubing, rail. etc.). We specialize in Spiral Staircase Stringers, flanges, support beams, gear blanks, etc. FABRICATING Hodgson Custom Rolling combines expertise in rolling, forming, assembly and welding to produce various fabrications including kiln sections• rock drums, heavy weldments, ladles, pressure vessel parts, multiple Components for Heavy Equipment applications etc. ASME Cerhfied Hodgson SO 9001:2000 *~ CustomRolling Inc. 5580 Kalar Road Telephone: (905) 356-8132 U.S Address: Niagara Falls Toll-free: (800) 263-2547 M.P.O. Box 1526 Ontario, Canada Fax: (905) 356-6025 Niagara Falls, N.Y. Circle No. 28 on Reader Info-Card L2H 3L1 E-mail: [email protected] 14302 - 1526 Website: www.hodgsoncustomrolling.com Show the Welding World How to COMPETETHROUGH SMARTERWELDIHG Exhibit Your Products to a Devoted International Audience. Be a Part of the World's Largest Annual Welding Event. Tools, techniques, demonstrations, publications, education, conferences, seminars, teachers, trainers, students, shopmen, foremen, presidents, owners, and about everything else you'd .,,,o.,,o,,,,,,,. ao4 CHICAGO ° APRIL 6-8, 2004 ..~.;~ maimIn a -~- ,~i :J ":-, | - ,,. j • I! !, in Exhibit at the 2004 AWS Welding Show • McCormick Place Lakeside Center • Call 305-443-9353 ext. 295 TO Attend, Learn More at www.aws.org/expo Circle No. 8 on Reader Info-Card CONTENTS .o,o, .,o,uoe .,uo ,, AWS Web site http:llwww.aws.org Features Departments 24 Robotic Welding of Aluminum Space Frames Washington Watchword.......... 4 Speeds Introduction of Sports Car Ford's hottest new sports car races by on an all-welded Press-Time News ................ 6 aluminum space frame C. Occbialini Editorial ............................ 8 News of the Industry ............ 10 28 New Developments in Aluminum Shipbuilding High-speed aluminum craft for both military and Point of View .................... 16 commercial use take advantage of new high-strength aluminum alloys R. Messier T. Anderson New Products .................... 20 32 EBW of Aluminum Breaks Out of the Vacuum Aluminum Q&A .................. 42 Nonvacuum electron beam welding of aluminum reduces cycle time and improves productivity Brazing Q&A ...................... 44 K. Sehulze and D. E. Powers Soldering Q&A .................. 46 Coming Events .................. 48 40 Friction Welding of Aluminum Cuts Energy Costs by 99% Navy Joining Center ............ 52 Mazda puts into production friction welding as an alternative to conventional spot welding Welding Workbook .............. 54 R. Hancock Society News .................... 55 Guide to AWS Services ......... 70 New Literature .................. 72 Welding Research Supplement Red Hot .......................... 74 39-S An Investigation of Ductility-Dip Cracking in Classifieds ........................ 78 Nickel-Based Weld Metals m Part III High-resolution scanning electron microscopy and Advertiser Index ................ 80 electron backscattered diffraction are used to gain insight into elevated-temperature ductility in welded Ni-based alloys M. G. Collins et al. 50-S Liquation Cracking in Full-Penetration AI-Cu Welds Alloy 2219 was used as a tool to better understand the effect of weld-metal solute content on liquation cracking C. Huang and S. Kou 59-S Influence of Stress Ratio on Fatigue Crack Propagation Behavior of Stainless Steel Welds Crack closure measurements were used to help explain the relationship between crack growth rate and increased stress ratio C. S. Kusko et al. Single-Pass Laser Beam Welding of Clad WeldingJournal (ISSN 0043-2296)is published 65-S monthly by the AmericanWelding Society for Steel Plate $90.00 per year in the UnitedStates and posses- The possibility of making sound welds with satisfactory sions,$130 per year in foreigncountries: $6.00 per diluuon was investigated using laser beam welding with singleissue for AWS membersand $8.00 per sin- a stainless steel filler metal gle issuefor nonmembers.American Welding So- S. Missori et al. ciety is locatedat 550 NW LeJeuneRd., Miami, FL 33126-5671;telephone (305) 443-9353. Periodi- calspostage paid in Miami,Fla., and additional mail- ing offices.POSTMASTER= Send address changes to WeldingJournal, 550 NW LeJeuneRd., Miami, FL 33126-5671. Readersof WeldingJournalmaymake copies of ar- ticlesfor personal,archival, educational or research purposes,and whichare not for saleor resale.Per- missionis grantedto quotefrom articles, provided customary acknowledgment of authors and Cover picture provided by Ford Motor Co. sourcesis made.Starred (*) itemsexcluded from copyright. I WELDING JOURNAL mm tVASHINGTOI~ BY HUGH K. WEBSTER WATCHWORD] AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE 2003 Congress Produced Most Bills Ever understand their concerns and possible solutions. Regarding the assistant secretary position, the exact duties have not been iden- The first session of the 108th Congress, which ended in De- tified, but it is expected that this person will be a primary advo- cember, introduced almost 7000 pieces of legislation, the most cate for manufacturing within the federal government. ever by any Congress. Of these, only 159, or less than 3%, were actually enacted into law. Campaign Finance Ruling May Bring More Regulation Proposed Greenhouse Gas Emissions Guidelines The U.S. Supreme Court's recent decision upholding almost all of the provisions of the McCain-Feingold campaign reform The U.S. Department of Energy has released proposed guide- law is expected to bring more government regulation of federal lines for the voluntary reporting of greenhouse gas emissions and elections. Even though the margin of victory was 5-4, the case reduction efforts. These guidelines are related to the Depart- was a strong endorsement of the legal authority of Congress to ment of Energy's registry program and are con- regulate election financing. And while the sistent with the current Administration's volun- ban on so-called soft money is expected tary efforts to reduce U.S. greenhouse gas emis- to greatly increase the influence of politi- sions. The guidelines, which are subject to a 60- cal action committees, these entities can day comment period, are available on the De- Structural expenses also expect that their higher profile will partment of Energy's Web site, www.doe.gov. result in increased oversight and restric- such as taxes, tions from Congress. Manufacturing Competitiveness benefits, regulatory State Ergonomics Rules Costs Study Released compliance, litigation, Rejected External, nonproduction costs add approxi- mately 22% to unit labor costs of U.S. manufac- and energy add nearly After a bruising battle, a public ref- erendum in the state of Washington to turers (nearly $5 per