w •' VII PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING AND ALLIED JOINING AND CUTTING PROCESSES, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING One Word Select-Arc's New (Line and Reputati U-Si Qii^lily.r. 1 fk % Select-Arc, Inc. has earned teristics, consistent deposit electrodes' higher deposi- Discover for yourself the an outstanding reputation chemistry and excellent tion rates improve produc- many benefits of specifying in the industry as a manu- overall performance you tivity and reduce welding Select-Arc's new premium facturer of premium quality have come to expect from costs. stainless steel electrodes. Call tubular welding electrodes Select-Arc. us today at 1-800-341-3213 for carbon and low alloy SelectAlloy's smooth bead or you can visit our website steel welding. The chart below shows contour, easy peeling slag, at www.select-arc.com for that SelectAUoy flux cored minimal spatter, closely more information. Now Select-Arc has controlled weld deposit expanded its range of Typical Deposition Rates for compositions and metal exceptional products Various Stainless Steel Consumables soundness deliver addi- with the introduction tional savings. SELECT of a complete line of .0 45" Fll xCor .045" vletal ( lored Elect rode E ectrod The Select 400-Series austenitic, martensitic // metal cored electrodes and ferritic stainless / V sS r offer the same advan- steel electrodes. Both f s 600 Enterprise Drive the new SelectAUoy So 45" So IdWir e tages as SelectAUoy and ^ * Elect ode P.O. Box 259 and Select stainless are ideally suited for Fort Loramie,OH 45845-0259 steel wires deliver the difficult-to-weld appli- . 5/32" Covered Phone: (937) 295-5215 superior feedability, su- ^ Electrode cations, such as auto Fax: (888) 511-5217 perb welding charac- Current (amps) exhaust systems. www. select-arc .com For Info go to www.aws.org/ad-index OLYMPUS Your Vision, Our Future PHASED ARRAY FOR WELD INSPECTION Phased Array imaging provides many benefits for weld inspectors: fast, easy reproducible, and cost-effective. Olympus offers manual, semi-automated, and automated solutions for all your nondestructive weld inspection and code compliance needs. OmniScan MXU-M-2.2 Software • Single-axis encoded or time-based C-scan • Higher A-scan refresh rate • Simplified user interface • DAC/TCG, ASME, JIB, and DGS sizing curves • AWS and API code wizards • Weld Package option with RayTracing• and Weld Overlay features See us at Fabtech Show, booth 38043 For worldwide representation visit www.olympus-ims.com • [email protected] For Info go to www.aws.org/ad-index KISWEL WELDING PRObrr Our world class manufacturing plant in Florence, Kentucky is a showplace for producing the highest quality welding materials in North America. * Visit our website at: www.kiswelweldingproducts.com Mild Steel Covwed Electrodes Stainless Stee^ Mild Sleel Covered Electrodes & Low Alloy Flux Cored Wires Stainless Sleel Flux Cored Wires Mild Sleel & Low Alloy Stainless Steel TIG & MIG Wires TIG & MIG Wires 7950 Dixie Highway Florence KY 41042 USA General Office Phone 859 371 0070 Fax 859 371 5210 Email kiswel@kiswelusa com For Info go to www.aws.org/ad-index CON TENTS October 2009 • Volume 88 • Number 10 Features 26 26 Aluminum's Role in Welded Fabrications Since the end of the 19th century, aluminum has been a AWS Web site www.aws.org light-weight competitor to steel and its applications have grown to even greater heights today T. Anderson Departments Editorial 4 Washington Watchword 6 Press Time News 8 Brazing & Soldering Today News of the Industry 10 31 Evaluating Margins of Safety in Brazed Joints Letters to the Editor 14 Load-bearing capabilities of brazed joints are evaluated to Aluminum Q&A 18 determine margins of safety in the design criteria Technology 20 Y. Flom et al. New Products 22 39 Solving the Problems Inherent to Torch Brazing Aluminum Brazing & Soldering Today The inherent problems with flux, filler metal, and techniques when brazing aluminum are addressed Technology News 50 K. Allen Profiles 54 Brazing Q&A 56 43 Soldering Silver to Aluminum and Copper for Cryogenic Applications Coming Events 60 A new approach to soldering cryogenic evaporators may be a Welding Workbook 64 solution to microprocessor cooling Society News 65 L. A. Shapiro Tech Topics 68 48 Testing Sinter Braze Integrity Using Resonant Inspection Errata: A5.12 68 The resonant acoustic method of nondestructive testing proves reliable in determining the integrity of sinter brazed ASME Section IX Changes ....71 powder metal parts Guide to A WS Services 82 R. W. Bono New Literature 84 Personnel 88 Classifieds 92 Advertiser Index 94 Welding Research Supplement 193-s Transient High-Frequency Welding Simulations of Dual-Phase Steels Numerical and experimental simulations were used to improve the end joining of continuous-fed steel strip Welding Journal {\SSH 0043-2296) is published R. Baumer and Y. Adonyi monthly by the American Welding Society for $120.00 per year in the United States and posses- 202-s Near Weld Interface Compositional Variations in sions, $160 per year in foreign countries: $7.50 per single issue for domestic AWS members and Low-Alloy Steel Weldments $10.00 per single issue for nonmembers and This work models concentration gradients adjacent to the weld in- $14.00 single issue for international. American terface based on mass transport processes during solidification and Welding Society is located at 550 NW LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. cooling of the weld Periodicals postage paid in Miami, Fla., and addi- D. B. Knorr and J. J. McGee tional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671. Canada Post: Publications Mail Agreement #40612608 Canada Returns to be On the cover: Three metal calibration cup assemblies designed and sent to Bleuchip International, P.O. Box 25542, assembled at the NASA Goddard Space Flight Center, Greenbelt, Md., London, ON N6C 6B2 that will be used in the Sample Analysis at Mars (SAM) experiment on the Mars Science Laboratory (MSL) rover. Each cup is about 3 in. Readers of Welding Journal my make copies of articles for personal, archival, educational or re- long and comprised of Ti-6Al-4V, Ni 200, Inconel 693, and Cu search purposes, and which are not for sale or re- components joined together using vacuum brazing and electron beam sale. Permission is granted to quote from articles, welding. More than 300 vacuum brazed joints were required to build provided customary acknowledgment of authors and sources is made. Starred (*) items excluded the SAM instrument. (Photo courtesy of Goddard Space Flight from copyright. Center.) WELDING JOURNAL American WeWIng Society EDITORIAL Founded in 1919 to Advance the Science, Technology and Application of Welding Officers A Letter to Those Who Support President Victor Y. Matthews The Lincoln Electric Co. the Welding Profession Vice President John C. Bruskotter Bruskotter Consulting Services, LLC As the new chair of the American Welding Society Foundation, I'll share some of the initiatives we have under way. Our major focus is addressing the shortage of skilled Vice President John L. Mendoza welders and our Welder Workforce Development fund-raising efforts. CPS Energy Market research conducted with funds from the National Science Foundation and updated in 2009 with help from the U.S. Department of Labor shows that despite the Vice President William A. Rice Jr. current economic downturn the anticipated skilled welder shortage will exceed 200,000 OKI Bering persons in the near future. The AWS Foundation has a two-pronged approach to help with the skilled welder Treasurer Earl C. Lipphardt shortage. First, we manage our traditional scholarship programs to assist students in Consultant gaining a welding education. Since its inception in 1991, we have awarded more than Executive Director Ray W. Shook 3000 scholarships in an amount of more than $3.8 million. The other effort, the AWS American Welding Society Welder Workforce Development Program, has generated a great deal of enthusiasm and excitement. Its focus is addressing the industry shortage of welders by helping with recruitment, training for specific industry needs, assisting with curriculum development Directors where needed, and working with training institutions to accomplish the training. We have B. P. Albrecht (At Large), Miller Electric Mfg. Co. established the Solutions Opportunity Squad (SOS) to implement the coordination of these efforts and others that arise. These initial initiatives have created an enormous J. R. Bray (Dist. IS), Affiliated Machinery, Inc. amount of interest and involvement by our many industry partners. H. R. Castner (At Large), Edison Welding Institute Our major funding support to date has been welding equipment and filler metals D. B. DeCorte (At Large), RoMan Mfg. Inc. manufacturers, distributors, and individuals. Although we have received some donations G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services from fabricators and construction companies who employ welders — and these are much appreciated — we feel there is an opportunity to speak with more of them as well as oth- D. A. Flood (Dist. 22), Tri Tool, Inc. ers who understand our business and know the efforts we have under way will strength- M. V. Harris (Dist. 15), Valley National Gases en the welding profession. R. A. Harris (Dist. 10), Consultant During these tough economic times we are reaching out to a broader base of sup- porters so we may continue our efforts. We have a significant need for qualified skilled D. C. Howard (Dist. 7), Concurrent Technologies Corp. welders to build the massive wind towers, nuclear power plants, and alternative fuel fa- J. Jones (Dist. 17), Thermadyne cilities like ethanol production, as well as to rebuild our bridges and other transportation W. A. Komlos (Dist. 2d),ArcTech LLC products, etc.