Welding and Materials-At A Glance06,07,2013

MATERIALS AND
WELDING For Engineers

AT A GLANCE

ART IN STEAM CO.
HRSG BOILER EXPERTS
WWW.ARTINSTEAM.COM MAY-JUNE 2013

The main purpose for preparing this free magazine is to summarize the most
famous and leading welding magazines .
We believe these article are proper for designers, engineers and inspectors in
oil, gas and power .
In the following issue we have articles from :
1-Practical welding-The official publication of fabricators and manufacturers
association
2-AMP The ASM journal of advanced material processing
3- Inspection trends-The AWS inspection and testing journal
4-The welding Journal-AWS welding and material journal
5-The Fabricator- The official publication of fabricators and manufacturers
association
There are also other several important magazine in materials and welding
such as :Connect-TWI magazine, Paton welding journal, Welding news ...
Which we try to have some articles from in the future.
Sincerely yours
Art In Steam co. Manager

An offcial publication of the Fabricators &
Manufacturers Association, International
www.practicalwelding.com
May/June 2013
THE REAL WORLD FOR WELDING PROFESSIONALS
GMAW guns:
The right one makes
all the difference
GMAW guns:
The right one makes
all the difference
MayJune13PWT.indd 1 4/25/13 3:23 PM
www.practicalwelding.com PRACTICAL WELDING TODAY May/June 2013 8
By Amanda Carlson, Associate Editor
A
s a former consultant and robotic welding shop owner,
Mark Satka, product engineer at Innovative Product
Ideas LLC, Neenah, Wis., has seen rsthand the cre-
ative ways welders clean away spatter around the welded sur-
face. Hes seen them use everything from scrap metal to chis-
els, screwdrivers, and homemade tools, and it always struck
him as odd that there wasnt a dedicated tool for the job.
Spatter is an unwelcome yet very common side effect of
many welding applications. To combat this, welders usually
take matters into their own hands.
None of the weld shops I visited as a consultant had a
specic tool for removing the postweld spatter. A lot of people
had their own homemade chisels or screwdrivers to remove
spatter, but there was nothing specically made for the spatter
removal process, Satka explained.
And with welders using whatever means necessary to re-
move the spatter, leaving the base material vulnerable to
scratches and surface marring, Satka believed there was a bet-
ter way. This realization is what led him down the path to
developing a tool designed specically for postweld and cut
surface cleaning that was durable enough to remove tough
spatter from the areas surrounding a weld, dross from thermal
cutting operations, or slag, but forgiving enough not to dam-
age the base material.
Its been a journey thats been 10 years in the undertak-
ing, but after much research and development that went into
designing the product and procuring the right blade mate-
rial, the Scrap-N-Burr
was nally unveiled last November at

FABTECH
in Las Vegas.
The concept is simple,
but the pathway to the
end product was anything
but, said Tim Houselog,
president of Innovative Prod-
uct Ideas, the manufacturer
of the tool. For the most part
it revolves around the propri-
etary high-strength steel used
for the blade.
It was important to de-
velop something that would
remove spatter without mar-
ring the parent material, while
at the same time ensuring
the blade would maintain its
dual working edges so welders
werent constantly tasked with
sharpening the blade with a
grinding wheel, Houselog
said.
The company has focused
much of its efforts for the last
four years on the blade cong-
uration, Satka added. Blades
are equipped with DuaLast
technology, which Houselog said stands for dual edge long

lasting. They are designed to be durable enough to withstand
the harsh conditions of spatter removal and edge deburring.
Blade size and conguration was another aspect that the
company worked on to accommodate as many applications
as possible
A lot of places say they wish they had a wider blade or a
narrower blade. One of the features weve included is the blade
widths are interchangeable, Satka explained.
Flat blades are available in 1-, 3-, and 4-in. sizes. The
company recently released blades specically designed for tube
applications. Six blades are available starting at
3
4 in. and in-
creasing in quarter-inch increments up to 2-in.-dia. tubing.
A -in. hole drilled into the side of the scraper accepts
any -in. shank accessory or wire brush. This is important for
welders who are using ux-core or rodany application in
which slag is left over. They can chip the slag off with the blade
and then use the wire brush over the top of it.
The -in. shank leaves it up to your imagination. People
sometimes come up with things to put in there that you would
Technology Spotlight
Get your scrape on
New hand tool dedicated for slag, spatter, and dross removal
New to the Scrape-N-Burr
family are the six blades dedicated for tube

cleaning applications.
Welders have a
choice of three at
blades in 1
1
2-, 3-,
and 4
1
2-in. sizes.
MayJune13PWT.indd 8 4/26/13 11:57 AM
www.practicalwelding.com May/June 2013 PRACTICAL WELDING TODAY 9
never think possible. If it works for them and what theyre do-
ing, thats all that counts, Houselog explained.
The handle has a cushioned grip for comfort and a striking
surface on the back so welders can use it as a chisel or hammer
during difcult cleanup applications. Depending on the blade
size, the tool weighs around 1 pound.
If the standard version of the tool does not suit a welders
needs, the company can design a specialty blade or handle to
accommodate the application.
We did a special run for Caterpillar for an application
where they were pushing through extremely large weldments.
We specially made them a tool with a 3-ft. handle instead of
the standard 11 in. We were able to turn around a version of
the product really quickly that would work great for them.
They love them, Houselog said.
Scrape-N-Burr, 866-895-1531, www.scrapenburr.com
Abicor Binzel www.abicorusa.com
Abirob A500 air-cooled torch heat
reduction
SITUATION: Flex-N-Gate is a leading Tier One manu-
facturer of high quality, stamped metal components and
complex assemblies, supplying over 84% of metal bumper
systems for trucks and SUVs in North America. This facility
was experiencing heat related issues and high consumable
usage (nozzles, diffusers, and contact tips). The excessive
heat was also causing distortion of swannecks and fre-
quent re-teaching of weld points in robot programs.
RESOLUTION: The Abirob A500 amp air-cooled torch
package was tested in a dual robot cell that was hav-
ing the most issues. This cell was chosen to do head to
head comparison against the current welding torch and
document results. The Abirob A500 amp thru arm torch
package was installed in less than 2 hours and the testing
began. A thermal imaging camera was used to look at the
heat difference between the ABICOR Binzel swanneck and
safety clutch versus the current brand.
Photos were taken immediately after a steady produc-
tion run. Weld settings are 18-21 volts, 200 amps, pulse
mode. As you can see from the photos the Abirob A500
product ran considerably cooler than the other torch, es-
pecially in the safety clutch that resulted in the swanneck
staying cooler and consumables lasting longer. The Abi-
rob welding package resulted in longer consumable life
and considerably less downtime related to the better heat
dissipation from the swanneck. Scott Abernathy of Flex-N-
Gates MasterGuard production liked the ease of instal-
lation and, Overall, a more robust system than what we
were previously using.
Converting to the ABICOR Binzel product has resulted
in less overall cost of consumable usage and less down-
time resulting in higher throughput of parts.
Advertorial
The dual-edge blade is tough enough to remove spatter and slag without
damaging the parent material.
MayJune13PWT.indd 9 4/26/13 11:55 AM
PRACTICAL WELDING TODAY May/June 2013 18
Cover Story
8
criteria for choosing
the right GMAW gun
Application requirements and
operator preference are key
A gun that matches your personal preferences
helps if you weld in difcult positions often.
www.practicalwelding.com 18 PRACTICAL WELDING TODAY May/June 2013
May/June 2013 PRACTICAL WELDING TODAY 19 www.practicalwelding.com
By Ross Fleischmann
E
ven the most experienced and tal-
ented welding operator requires
the right tools to do the job well.
To optimize weld quality, its important
to carefully select all the tools involved,
from the welding power source to the
accessories. For gas metal arc welding
(GMAW), the right gun can be criti-
cal in ensuring an effcient and properly
functioning system.
With so many guns available, it may
be confusing to know which is the best
option. A determining factor is whether
youll need the gun for one specifc ap-
plication with fairly consistent param-
eters or for a variety of projects. If you
plan to use the gun for more than one
welding application, you may want to
consider a model with a wide range of
abilities.
At the heart of your decision should
be comfort. Gun weight, heat dissipa-
tion, shape, hand positioning, and trig-
ger confguration all contribute to your
experience. Although you may purchase
welding guns based solely on cost and
basic application needs, your personal
preferences should also be taken into
consideration. These eight criteria will
help you in your journey to select the
GMAW gun that is right for you and
your welding operation.
1
Wire Size and Type
The welding wire type and size you use
will dictate certain features your GMAW
gun will need. Aluminum wire requires
a gun with a Tefon
liner, while solid

or cored mild and stainless steel wires
need a gun with a liner made from pia-
no wire a tempered, high-carbon steel
also known as music wire or spring steel.
Its also important to match the liner
diameter and gun tip with the wire di-
ameter. If a liner is not sized properly
for the wire, it can create resistance and
the wire wont feed smoothly and pos-
sibly create a birds nest. If the liner is
too large, the wire can snakemove in a
serpentine motioninside the liner and
feed erratically. As a rule, use the correct
liner size. With that said, you can get by
with a liner thats one size larger than
the diameter of wire being used. For ex-
ample, an 0.045-in.- dia. fux-cored wire
will perform just fne in an 0.052-in.-
dia. liner.
2
Amperage and Duty Cycle
The arc-on time for a job has a signif-
cant impact on the guns amperage and
duty cycle ratings. For applications that
require a lot of arc-on time, the gun
must be rated for higher duty cycle to
meet those requirements. For jobs with
A paddle-shaped gun handle, like the one shown, reduces stress on your hand.
www.practicalwelding.com
low arc-on time, youre making short
welds, or you spend time on setup or
cleaning between welds, a gun with a
lower rating may be appropriate.
Duty cycle defnes how long the ma-
chine can be used before work must be
stopped to let the gun cool down. Duty
cycle ratings are expressed as a percent-
age of a 10-minute period. If a gun is
rated at 60 percent duty cycle at 400
amps, it can be used to weld for up to
6 minutes at 400 amps before needing
a cool-off period of 4 minutes. Unlike
most power supplies in which a thermal
overload will shut them down, guns
have no protective fuses and can operate
beyond their duty cycle. When guns op-
erate at amperages other than the ones
stated, their corresponding duty cycle
goes up or down accordingly.
If you use the gun longer than its
duty cycle rating, it becomes overheated
and uncomfortable to use. Repeated
overheating can damage a gun. In some
cases, it may be more cost-effective and
convenient to choose a higher-amperage
gun to use for many applications instead
of having multiple guns to change out
throughout the day.
Guns are available in air-cooled and
water-cooled models. Most air-cooled
guns use a coaxial design. As amperage
rating increases for air-cooled guns, the
cables become larger and the guns be-
come heavier, making them more diff-
cult to maneuver.
Water-cooled guns have water lines
that run through the cable indepen-
dent from the liner. They have smaller
handles and smaller cables, so they are
lighter-weight. So in applications with
longer arc-on times at 400 amps or
more, a lighter water-cooled gun can
reduce fatigue and improve maneuver-
ability. Although a water-cooled gun
may cost more upfront, it can improve
productivity. Water-cooled guns also
keep consumables cooler, which extends
parts life. The downside is that they cost
more, can leak water, and have more
maintenance requirements.
3
Shielding Gas
Shielding gases can have an effect on
the duty cycle of a GMAW gun. For ex-
ample, an argon/oxygen or argon/CO
2

mixture used for spray-transfer weld-
ing will produce more heat than a gas-
shielded fux-cored wire process using
CO
2
. Consider choosing a gun with a
slightly higher rating if you weld with
argon blends. For example, if a proce-
dure calls for spray-transfer welding at
350 amps, select a 400-amp gun.
PRACTICAL WELDING TODAY May/June 2013 20
Dont be tempted to remove the strain relief steel springs to
improve maneuverability; doing so risks wire feeding problems.
4
Cable Length
Applications involving large weldments
may require long gun cables. When
choosing a gun, its best to select the
shortest gun cable necessary. As cables
get longer, there is more opportunity for
friction in the line, which can affect feed-
ability of the wire in push-style guns.
Wire size and type can help you de-
termine the best cable length. Wire that
is 0.035 in. and smaller is very diffcult
to push through gun cables longer than
12 ft. Larger wire, such as a 0.052- or
1
16-
in. dia., is easier to push through 15- or
20-ft. cable. If the required lead length
causes feeding problems, try mounting
the wire feeder on a boom or pole above
the work area.
For extraordinary circumstances
when using solid or cored wires and for
aluminum applications, consider using
a push/pull gun. These guns have two
sets of drive rollsone at the feeder and
one at the gun. The drive rolls work in
conjunction with one another to main-
tain consistent wire tension and ensure
smooth feeding performance at distanc-
es up to 35 ft.
5
Cable Strain Relief
If the bend radius of the cable becomes
strained at the handle, it can cause
kinked wire and poor feedability. Guns
with steel springs at the handle will im-
pose less strain on the lining, which can
be especially important in applications
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with tight spaces or overhead-mounted wire feeders. Although
you might be tempted to remove the spring to improve ma-
neuverability in small areas, doing so could create feedability
problems.
6
Conductor Tube
Most standard GMAW guns have a short conductor tube
commonly called a gooseneckbecause its closer to the work
and it gives you more control. Longer conductor tubes offer
larger radiuses and are available in different shapes to allow for
better access in special applications. In some cases, GMAW
equipment manufacturers can custom-design conductor tubes
that meet the confgurations for unique applications.
Longer conductor tubes are often used for duty cycle appli-
cations that are 450 amps or more because it keeps your hands
far away from the arcs heat. Flexible conductor tubes can be
used on jobs that have issues related to joint access.
PRACTICAL WELDING TODAY 23
7
Consumables
Many consumables are available that can
enhance the productivity of any gun. Be
sure to choose a contact tip based on the
amperage, duty cycle, and wire diameter
of your application. Contact tips are
available recessed, fush, or protruding
from the nozzle.
A protruding tip gives you better visi-
bility of the arc. Flush tips often are used
for lower-duty-cycle, lower-amperage
welding and pulsed GMAW. Recessed
tips offer a greater arc-to-work distance
and reduce spatter when using 100 per-
cent CO
2
. Spot nozzles have crowns cut
out of the nozzle to relieve gas pressure
for spot welding. Gasless fux-cored tip
assemblies effectively dont have a nozzle
because gasless fux-cored wire doesnt
require shielding gas.
8
Handle and Trigger
GMAW gun handles come in differ-
ent styles, so you need to determine
which one is most comfortable in the
position your application dictates. Some
gun handles have a round cross section,
much like a broomstick handle. Other
guns have a paddle-shaped cross section,
which gives you more leverage to ma-
neuver the gun cable. Many operators
report that a paddle-shaped handle also
reduces hand fatigue, particularly in ap-
plications where they need to twist the
gun cable to get correct alignment.
Before choosing a gun, consider your
preferred hand positioningdo you grip
the gun like a pistol with the index fnger
on the trigger, or do you hold it upside
down with your thumb on the trigger?
Make sure the gun you are considering
accommodates your preferred grip style.
More modern guns have longer trig-
gers that allow you to move along the
length of the handle for repositioning.
This ability to change hand position
helps reduce muscle fatigue and repeti-
tive-motion injury. To enhance comfort
further in applications with high arc-on
time, a dual-schedule trigger will lock in
the on position like a toggle until you
press it again. n
Ross Fleischmann is senior brand manager,
Victor Technologies
, 16052 Swingley Ridge

Road, Suite 300, St. Louis, MO 63017, 800-
426-1888, www.victortechnologies.com.
A
luminum vessels are steadily
making their way into the
U.S. Navy feet. While on-
the-water repairs to steel-hulled ships are
nothing new, working with aluminum
presents far greater challenges. While
dry docking these ships would address
these welding challenges, it is not always
feasible. With global reach, U.S. Navy
ships can be nearly anywhere on earth,
and dry docks rarely are nearby.
In addition, the dry docking process
wreaks havoc on the Navys intricate de-
ployment scheduling. As a war-fghting
machine, the Navy and its ships must
be at the ready and in position to move
at all times. The cost of dry docking is
much higher than keeping the ship in
the water when performing mainte-
nance and repair.
The Navy has been searching for new
weld-repair methods for its aluminum-
hulled ships beyond dry docking, which
currently is the only option. It may have
found one with a promising new tech-
nique: underwater aluminum gas metal
arc welding (GMAW) in a hyperbaric
chamber.
Phoenix Intl., Largo, Md., an under-
water services company that has held the
Navys Diving Services contract for the
past 15 years, is performing tests at Bay-
ou Vista, La., with a third-party auditor
validating the results.
Underwater Aluminum
Welding: A Tough Proposition
Aluminum is generally considered
much more diffcult to weld than steel.
For example, aluminums high thermal
conductivity and low melting point can
easily lead to burn-through and warp-
age problems if proper procedures are
not followed. Aluminums high thermal
conductivity means the material tends
to act as a heat sink, making fusion and
penetration more diffcult.
In terms of chemical composition,
aluminum has a high maximum solu-
bility for hydrogen atoms in the liquid
form and a low solubility at the solidi-
fcation point. This means that even a
small amount of hydrogen dissolved in
the liquid weld metal will tend to escape
as the aluminum solidifes, and porosity
is likely to occura great cause of con-
cern during the welding process.
All-aluminum U.S. Navy littoral
combat ships (LCS-2s) began enter-
ing service in 2009, creating an urgent
Case Study
Ditching the dry docks in favor of the chamber
Underwater aluminum GMAW in a hyperbaric chamber helps keep aluminum-hulled ships afoat
need to develop a dependable, certifed
underwater aluminum welding process.
Stick welding, or shielded metal arc
welding, does not work well on alumi-
num, so we had to develop a GMAW
procedure for performing underwater
dry-chamber aluminum welding re-
pairs, explained Justin Pollack, under-
water ship husbandry/underwater weld-
ing program manager for the Naval Sea
Systems Command and supervisor of
salvage and diving for the U.S. Navy.
Phoenix has been developing the
new process for more than two years.
Ultimately, the companys procedures
must pass three hyperbaric aluminum
weld tests: 5083 alloy welded to itself;
5083 alloy welded to a 6000-series al-
loy; and a 6000-series alloy welded to
another 6000 series.
While welding aluminum on dry
land poses a number of challenges,
welding in an undersea environment
vastly complicates the process. Early
on in development of the new proce-
dure, aluminum welds performed on
the surface passed X-ray tests, but when
the same process was performed in the
water, the welds experienced signifcant
porosity, Pollack said.
We realized that we have to control
the environment. The welders are work-
ing around water, so humidity is an is-
sue, and because they are working at
depth, pressure is increased.
Ken Elliott, welding manager for
Phoenix Intl., echoed the concerns
about pressure.
Underwater, a dry environment such
as a hyperbaric chamber has an elevated
pressure, and elevated pressure will fnd
any route back to ambient pressure, he
said. The habitat environment is trying
to escape. Even through the small space
between the wire conduit and the wire
itself, pressure tries to escape to the sur-
face, taking contaminants with it.
Given the pressure variation, impuri-
ties in the habitat atmosphere, including
moisture, can work their way into the
weld, contaminating the weld bead and
leading to porosity, which signifcantly
weakens the welding joint. Beyond
that, underwater welding in a hyperbaric
chamber presents its own set of challenges.
The hyperbaric chamber, also
known as a habitat, measures about 6
feet tall by 4 feet wide and 5 feet deep,
explained Nathan Martin, welder/diver
for Phoenix Intl.
Ditching the dry docks in favor of the chamber
Underwater aluminum GMAW in a hyperbaric chamber helps keep aluminum-hulled ships afoat
The Navy has been searching
for new weld-repair methods
for its aluminum-hulled
ships beyond dry docking. A
promising new technique
underwater aluminum gas
metal arc welding (GMAW)
in a hyperbaric chamber
has the potential to allow
welders to make necessary
repairs on-site.
We are welding in 23 ft. of water
with everything around us that a nor-
mal welder would have. In the chamber,
we have a greater sense of how clean to
keep the work area. We are covered in
hoses and leads and have to make sure
that we can make the necessary body
movements to weld comfortably, so we
practice those before we actually weld.
Commercial welder/diver Whitney
Ehrgott, Martins colleague at Phoenix
Intl., agreed, and also has learned to rely
on senses beyond sight to create proper
welds.
Our visibility diminishes when weld-
ing underwater, so we have to feel and
hear the process, and these heightened
senses help us to create better welds.
The Right Process,
Procedures, and Equipment
Make All the Difference
Phoenix Intl. used a Power Wave
S350
welding machine, a Power Feed
25M
wire feeder, and a SuperGlaze
5556
3
64-in.-diameter wire from Lincoln Elec-
tric, Cleveland. The power source and
wire feeder are located above the sur-
face of the water on land, connected to
a push/pull welding gun with a 50-ft.
gun cable located 24 ft. underwater in
a hyperbaric chamber. The process and
procedures have been carefully selected
for easy repeatability anywhere in the
world. Accordingly, the team selected
procedures that used 100 percent argon
as the inert shielding gas.
One project goal was to develop a
way to repair an aluminum ship in any
theater throughout the world. So we
wanted a welding process that would
work without using helium in the gas
mix. If we cant fnd the right gas mix, we
cant repair the ship, Elliott explained.
The standard Power Mode
advanced
process on the power source lends itself
to using 100 percent argon inert gas very
easily, according to Elliott, while pro-
viding consistent weld penetration with
reduced voltage input. The process uses
high-speed regulation of output power
to deliver fast response to changes in
the arc. The result is improved GMAW
performance, including low spatter, uni-
form and consistent bead-wetting, and
controlled penetration.
Getting power and wire to the weld-
ing gun, with a feeding distance in this
application of 50 ft. from the wire feed-
er, is another challenge.
Lincoln has provided true 100-ft.
separation between the power source
and wire feeder, and by using a 50-ft.
push/pull gun on top of that, we can get
huge separation from where we need to
plug in and get power to the actual arc,
Elliott said.
Also, we have not experienced wire
failure in terms of pushing or pulling it
through a 50-ft. gun cable. A 50-ft. gun
cable is essential in repairing the ships
in the water, and 50 ft. is the extreme
distance at which you can push/pull any
soft material like aluminum, Elliott
continued.
While welding aluminum on dry land can be tricky, welding in an undersea environment vastly complicates the process. Early on in development of
the new procedure, aluminum welds performed on the surface passed X-ray tests, but those made in water had signifcant porosity.
By Dirk Herzog
W
hen band saw
cutting I-beam,
square, and
round tubing, straight cuts are
crucial to preparing the part
properly for welding. Parts
with crooked cuts make weld-
ing difcult, to say the least,
and as a result, welders often
must use a ller or additional
welding wire to ll the gap left
by the uneven edge. In more
severe cases, the parts with
uneven cuts may have to be
recut or scrapped altogether,
which is both costly and time-
consuming.
If you are performing
structural cuts with a band
saw, consider these tips to help
ensure that edges are straight
and that welders can join parts
easily and efciently. Keep in
mind the importance of rou-
tine maintenance on the band
saw machine. If a machine has problems
with its feed system or its variable-speed
system, it will negatively affect the life of
the band saw blade.
Know the Sawing Parameters
The best way to ensure the cuts you
make will be straight is to set your saw-
ing parameters correctly. Set the ma-
chine to the correct blade speed and cut
rate for the material being cut. As a rule,
slow the blade for tough material and
increase speed for softer material.
Also, check to make sure the con-
veyor rollers that hold the material are
aligned properly. Rollers that are out of
alignment can lead to crooked cuts.
Set the Tension Properly
Use a gauge to measure and set the ten-
sion on the blade in the band saw ma-
chine. Most band saws work best with
the blade tension set to a minimum of
25,000 PSI or a maximum of 32,000
PSI. Anything less than 25,000 PSI leads
to poor beam strength, band fatigue, or
crooked cuts. Tensions set to
32,000 PSI or more can break
the band, crack the gullets, or
wear out the machine bearings.
Cut From the Back of
the Weld Seam
For applications that involve
cutting through a weld seam
on tubing, it is easier and
more efcient for the band
saw blade to enter the ma-
terial from the back of the
weld seam. Cutting directly
into the weld seam serves as a
shock point to the blade teeth
and often results in shorter
blade life or teeth strippage.
Secure the Bundles
When band sawing bundles
of material, it is best to strap
down the entire bundle or
tack weld the ends of the bun-
dle to prevent any pieces from
moving. If the individual
pieces vibrate or move during
the cutting process, there is a possibility
that the teeth will strip.
Use Proper Lubrication
The proper amount of cutting lubri-
cant, also known as coolant, will help
extend blade life. Band saws use a ood-
coolant or a mist system to lubricate the
blade. Not only does lubrication help
maximize blade life, it also helps mini-
mize the buildup of metal chips that
result when the material is cut. Coolant
should wash over the blade as it enters
Technology Overview
Band sawing
structurals
Cutting tips that lead to better welds
Photos courtesy of Simonds Intl., Fitchburg, Mass.
MayJune13PWT_B.indd 30 4/30/13 4:14 PM
and exits the cut. Although the coolant
is recirculated and used continuously
throughout the cutting process, be sure
to replace water that evaporates from the
mixed solution.
Breakin New Blades
Be sure to break in new band saw blades
before you ramp them up to full-speed
cutting. This practice will hone the teeth
and extend blade life. The best way to
break in new bimetal blades is by reduc-
ing the normal feed rate by half during
this initial period. The band speed isnt
what breaks teeth during blade break-
in; its the pressure an excessive feed rate
produces that is most damaging.
To break in your bimetal saw blade,
multiply the recommended blade speed
by 25 percent, and cut that number of
square inches. Be sure to run the blade
at 50 percent of the recommended blade
feed rate. Once you approach the end
of the break-in period, gradually bring
your band saw feed rate up to normal.
Use the Right Blade
The right band saw blade makes all the
difference when cutting structurals,
where the desired outcome is a clean,
straight cut that simplifes weld prep
applications. Be sure to choose a blade
that can withstand the stresses of struc-
tural cutting, produce a smooth fnish,
and ensure maximum blade life. Also,
optimal tooth geometry is key to creat-
ing faster cutting rates, which increase
productivity. n
Dirk Herzog is West Coast regional sales
manager at Simonds Intl., 135 Intervale Road,
P.O. Box 500, Fitchburg, MA 01420, 978-
424-0100, www.simondsinternational.com.
When sawing material bundles, tack weld the
ends or strap down the entire bundle to help
keep the pieces in place.
MayJune13PWT_B.indd 31 4/30/13 4:15 PM
Consumables Corner | Nino Mascalco
Do you have a consumables
question for Nino?
Send comments and technical
questions in writing to:
Amanda Carlson, Associate Editor
Practical Welding Today
833 Feather stone Road
Rockford, IL 61107-6302
Fax: 815-484-7788
E-mail: amandac@thefabricator.com
Our company is using 0.045-in.-dia.
mild steel solid wire for GMAW with
90 percent argon/10 percent CO
2
shielding gas. A majority of our base
metal is to 1 in. thick welded out
of position about 30 percent of the
time. We are considering a change
in our welding process to reduce
lead-times. Can you offer some in-
sight to help us choose the best
process?
There are numerous variables to consid-
er, which would take an in-depth study
to determine the best process based on
your production, both currently and
in the future. However, here are some
questions to ask when selecting a differ-
ent welding process or wire.
How much extra capacity do I
require or anticipate requiring? How
much can I handle without creating
material-ow bottlenecks?
What are my budgetary limits for
new machine purchases, training, and
welding qualications?
What equipment do I have cur-
rently? Is it multiprocess equipment?
What are the maximum operating con-
ditionsduty cycle, wire diameter, peak
power output, and process control?
What is the skill level of our work-
force?
Are there any environmental work
condition limitations?
What is the surface condition of
the steel before its welded?
If you dont foresee any of these fac-
tors being a major hindrance in chang-
ing your welding process, then youve
got several possible solutions to consider.
A larger-diameter solid wire, such as
0.052 in. or
1
16 in., will provide higher
deposition rates without incurring much
additional cost. As long as your equip-
ment has the capability to run at higher
welding currents and duty cycles, this
would be a relatively simple change.
Keep in mind the weld joints need to
be relatively free of contaminants, espe-
cially mill scale. With the shielding gas
you are using, welding in spray-transfer
mode will produce a good-quality weld
with high deposition efciency and low
fume generation.
If your machines have the ability to
run in pulse-welding mode, then you
can weld lightweight material with the
larger-diameter wire too, which helps
reduce wire changeover time. In pulse
mode, the ability to weld with lower
voltages and currents still produce a
high-quality weld with minimal spat-
ter and distortion. Pulse mode also im-
proves out-of-position welding speeds.
If speed is an important factor, you
might want to think about changing
to a metal-cored wire. Metal-cored arc
welding (MCAW) can produce higher
deposition rates at similar arc currents
compared to solid wire. This reduces the
overall heat input because youre able to
achieve faster travel speeds, which can
also minimize distortion.
Metal-cored wires are not designed
to weld out of position unless you have
pulsing capabilities. And just like with
solid wire, the weld joints need to be
relatively clean and free of mill scale.
The nal manual welding process
to consider is ux-cored arc welding
(FCAW), which can produce quality
welds with good deposition rates. How-
ever, because it is necessary to remove
slag, the deposition efciency is about
12 to 15 percent lower than GMAW or
MCAW. Additionally, the fume gener-
ated and weld cleanup time are signi-
cantly higher.
With that said, FCAW ller metals
are designed to handle moderately heavy
rust and mill scale without affecting
weld quality. If you currently dont have
the ability or time to shot-/sandblast or
grind weld joints before you weld, this
would be a better alternative. FCAW
wires also are available in two different
typesall-position and at/horizon-
tal positionneither of which require
pulse-welding capabilities.
Finally, depending on your produc-
tion quantity, you could also look into
robotic welding or automated sub-
merged arc welding (SAW). These proc-
esses may require some raw material
design changes for xturing and posi-
tioning, which can be rather costly.
Nino Mascalco is application engineering man-
ager at ESAB Welding & Cutting Products,
411 S. Ebenezer Road, Florence, SC 29501,
636-485-2253, www.esabna.com.
The thought process behind
changing a weld process
A larger-diameter
solid wire will provide
higher deposition rates
without incurring much
additional cost.
Arc Welding 101 | Paul Cameron
I am looking for some insight on
the best approach, best practices,
and industry standards for quoting
weldments. There seems to be a
great deal of information out there
about deposition rates and travel
speeds, but not a lot about the ad-
ditional variables like clamping, part
handling, cleaning, grinding, and
packaging. Any insight you can pro-
vide is greatly appreciated.
Matt W.
South Bend, Ind.
Before quoting any job, you need to de-
termine a couple of things, mainly your
arc-on time and cycle time. Following
are arc-on time guidelines I have devel-
oped for quoting purposes:
20 percent arc-on timeOccurs
in a typical manual workcell that as-
sembles, tacks, and welds parts.
40 percent arc-on timeOccurs in
a typical manual workcell that receives a
tacked assembly and nish-welds it.
in a manual workcell where the welder
rarely moves, doesnt add parts, and is
continuously welding. Also may occur
in a robotic workcell that welds many
short (less than 4 in.) welds with lots of
arm movement and touch sensing.
in a robotic or automated workcell
that completes continuous or multipass
welds and does little touch sensing.
When estimating inches of weld
to be laid, gure llet welds
1
4 in. and
shorter will be single-pass welds. Welds
bigger than that should be calculated as
three-pass welds, or weld length multi-
plied by 3.
These guidelines you establish for
yourself are important. Get them wrong
and youll never make money, and thats
why were hereto make money and
keep folks employed.
I once had an employer that calcu-
lated weld cost simply by knowing how
many inches of welds the weldment
would require. The estimates were very
accurate, but a system like that would
take years to develop and theirs did.
My advice is to apply these rules of
thumb and nd yourself a good weld
calculator program that you are com-
fortable with. Im not big on reinventing
the wheel.
Paul W. Cameron, CWI, is quality control
manager for Thomas & Betts, Hager City,
Wis., 507-269-7142 or weldinspector@
charter.net. He also is a member of Practical
Welding Todays Editorial Review Committee.
Do you have a welding
question for Paul?
Send comments and technical
questions in writing to:
Amanda Carlson, Associate Editor
Practical Welding Today
833 Feather stone Road
Rockford, IL 61107-6302
Fax: 815-484-7788
E-mail: amandac@thefabricator.com
Advice for quoting weldments
Surface Finishing Solutions
1-800-700-5919 www.csunitec.com
Rolei
BE5
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PTX Eco Smart
Shadow-free satin finish
up to a mirror polish
Linear grinder utilizes slip-on
abrasives, saving time and money
PIPE-MAX
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Polisher
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and pipe
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sheets, conduits, metal pipes
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CSU-201305-PWT 3rd_CS Unitec PWT 3rd Ad 4/24/13 2:15 PM Page 1
Testing Composites for Auto Applications
Voids in Electronic Parts Yield to Ultrasound
Developing a Microscale Fatigue Testing Technique
Composites Testing/Characterization
AN ASM INTERNATIONAL PUBLICATION
JUNE 2013 VOL 171, NO 6
www.asminternational.org
Russ Kappius, a mountain-bike enthusiast and research geo-
physicist/software developer, wanted a bicycle hub with more
speed and responsiveness. After working out a design for a novel,
oversized hub and high-performance drive assembly that would
transfer more power from pedal to chain to wheel, Kappius
patented the concept. In late 2011, Kappius discovered direct
metal laser sintering (DMLS), an industrial additive manufactur-
ing technology from EOS GmbH that met his companys rapid
turnaround needs and enabled it to produce parts to exacting
specifications and with additional design complexity.
The beauty of the lightweight-yet-durable hub comes from the
sleek carbon-fiber shell (handmade by his son), as well as the drive
assembly housed insideincluding a drive ring, toothed inner
ring, and pawls (or flippers), all made using DMLS. The techno-
logical advance in the system comes from two developments: the
oversized designits about twice the current standard diame-
terand many more points of engagement than standard designs.
These two features constitute the heart of the hubs intellectual property and allow a cyclist to translate the act of ped-
aling into increased drive force. www.eos.info/en.
Sprayable foam stops bleeding
Remedium Technologies Inc., College Park, Md., received a $500,000 Small Business Innovation Research grant
from the National Science Foundation to test sprayable foam for rapidly halting traumatic bleeding. In collaboration
with Massachusetts General Hospital and the University of Maryland, Remedium will complete preclinical trials to
evaluate the safety and efficacy of Hemogrip Foam in controlling noncompressible hemorrhaging, i.e., bleeding not ac-
cessible to direct pressure.
The technology is based on chitosana natural biopolymer found in the exoskeleton of shrimp, crabs, and other
crustaceans. Chitosan is unique as a natural material because it is biocompatible, antimicrobial, and highly durable
under a wide range of environmental conditions. When applied to wounds, Hemogrip creates a nanoscale 3-D mesh,
rapidly coagulating blood and staunching blood loss. It is dispensed from a handheld, lightweight canister that is easy
to use by surgeons, soldiers, and others. It can be removed quickly and easily without damaging tissue, and because it
is based on chitosanthe second most abundant biopolymer on earthit is
also inexpensive. http://remediumtechnologies.com.
Seahorse armor inspires robotics
Seahorse tails are exceptionally flexible due to their structure, made up of
bony, armored plates, which slide past each other. Researchers at the University
of San Diego are hoping to use a similar structure to create a flexible robotic
arm equipped with muscles made out of polymer, which could be used in med-
ical devices, underwater exploration, and unmanned bomb detection and det-
onation.
Researchers wanted to see if the plates in the seahorses tail act as an armor,
so they took segments and compressed them from different angles. They found
that the tail could be compressed by nearly 50% of its original width before per-
manent damage occurred because the connective tissue between the tails bony
plates and muscles bore most of the load from the displacement. Even when the
tail was compressed by as much as 60%, the spinal column was protected from
permanent damage. The next step is to use 3-D printing to create artificial bony
plates, which would be equipped with polymers that would act as muscles. The
protected, flexible arm would be able to grasp a variety of objects of different
shapes and sizes. www.ucsd.edu.
Taking 3-D printing for a spin
ADVANCED MATERIALS & PROCESSES JUNE 2013 4
i nterest
of material
Russ Kappius, developer of the Kappius hub, and his
son, Brady, professional mountain-bike racer, outside
their garage shop. Courtesy of Kappius Components.
A seahorse skeleton and its bony plates are shown
through a micro CT scan. Courtesy of McKittrick
Research Group/Jacobs School of Engineering,
UC San Diego.
Synthesized niobium oxide suits high-performance supercapacitors
Researchers at UCLA
synthesized a material
that shows high capability
for both the rapid storage
and release of energy. The
team defines the charac-
teristics of a synthesized
form of niobium oxide
with a great facility for
storing energy. The mate-
rial would be used in a su-
percapacitor, which combines the high storage capacity of lithium ion batteries with the
rapid energy-delivery ability of common capacitors. The team said the development could
lead to extremely rapid device charging, in applications from mobile electronics to indus-
trial equipment. For example, supercapacitors are now used in energy-capture systems that
help power loading cranes at ports, reducing the use of diesel fuels.
Researchers synthesized a type of niobium oxide that demonstrates substantial storage
capacity through intercalation pseudocapacitance, in which ions are deposited into the
bulk of the niobium oxide in the same way grains of sand are deposited between pebbles.
As a result, electrodes as thick as 40 can quickly store and deliver energy as fast as elec-
trodes more than 100 times thinner. For more information: Prof. Bruce Dunn, 310/825-
1519, bdunn@ucla.edu, www.ucla.edu.
Steel eliminates weight gap with aluminum car bodies
The latest research study by WorldAutoSteel, Detroit, suggests that in the near future,
steel auto body structures can be as lightweight as todays aluminum bodies, while meet-
ing all crash performance standards and at cost comparable to todays steel structures. The
studies also show how car makers can form and fabricate sophisticated steel designs and ac-
celerate their implementation in production vehicles.
Building on a weight reduction of 35% announced in 2011 in its initial FutureSteelVehi-
cle (FSV) design, the most recent studies boost lightweighting to 39%, compared to a base-
line vehicle using an internal combustion engine. The optimized FSV body weighs 176.8 kg,
putting steel on par with todays aluminum-intensive production designs. These lightweight,
advanced high-strength steel (AHSS) body structures, designed to carry heavier electrified
powertrains, fall in line with the lightest internal combustion engine aluminum vehicles, and
are on par with other concepts featuring alternative materials. www.worldautosteel.org.
Solar-powered airplane flies day and night
The sun-powered Solar Impulse aircraft will fly with more than 6000 parts made from 11
different products from Solvay, Brussels, Belgium, including high-strength, lightweight plas-
tics, battery components, lubricants, insulation, and solar panel film coatings. Solar Impulse
is the worlds first solar-powered airplane capa-
ble of flying day and night without fossil fuel.
The plane has a wingspan that accommo-
dates more than 10,000 solar panels covering
the wings surface. These cells capture the solar
energy that turns its propellers, allowing the
aircraft to fly. Solvays PVDF (Solef ) and
ECTFE (Halar) polymers are used for ultra-thin
single layer films, laminated films, and adhe-
sives that encapsulate the cells to reduce the
impact of stressors, deformations, temperature
variations, and solar radiation that occur when
news
industry
bri efs
The Steel Market Development
Institute, a business unit of the
American Iron and Steel
Institute, Washington, D.C., hosted
the 12th annual Great Designs in
Steel Seminar in May in Livonia,
Mich. It brought together
automotive and steel industry
leaders to discuss the latest
automotive steel usage trends. The
technical program featured more
than 35 presentations highlighting
steels role in the automotive
industry, including advanced high-
strength steel (AHSS) technologies
in new vehicle platforms,
advancements in the development
of third-generation AHSS, steel
designs to meet upcoming fuel and
emissions requirements, and
steels unique advantages as an
automotive material.
www.autosteel.org.
A study conducted by EDAG
Group, Germany, and
commissioned by the Aluminum in
Transportation Group of the U.S.
Aluminum Association, Arlington,
Va., shows that all-aluminum
vehicles can shed more than 40%
body mass, boosting fuel economy
by 18% when combined with
secondary mass savings and other
design changes. The study was
presented at the Society of
Automotive Engineers (SAE)
World Congress during a panel
discussion on advances in lower
weight materials. The research
used a full aluminum body and
closures to achieve almost 3 the
body mass reduction over the
Environmental Protection Agency
studys high strength steel vehicle,
while maintaining safety and
performance standards.
www.drivealuminum.org.
METALS POLYMERS CERAMICS
Illustration of niobium oxide synthesized by UCLA researchers.
Courtesy of UCLA/Nature Materials.
flying. Solvay materials also reduce overall aircraft weight.
www.solvay.com.
High impact polymer
strengthens sky and sea applications
U.S. Naval Research Laboratory Chemistry Division (Wash-
ington, D.C.) scientists developed a second generation, cost-ef-
fective polyetheretherketone (PEEK)-like phthalonitrile resin
that demonstrates superior high temperature and flammability
properties for use in numerous marine, aerospace, and domes-
tic applications. The resin can be used to make composite com-
ponents by established industrial methods such as resin transfer
molding (RTM), resin infusion molding (RIM), filament wind-
ing, prepreg consolidation, and potentially by automated com-
posite manufacturing techniques such as automated tape laying
and fiber placement.
Phthalonitrile-based polymers are a class of high tempera-
ture thermosets that remain strong at temperatures to 500C,
are nearly fireproof, and are easily processed into shaped fiber
reinforced composite components by low cost, nonautoclave
techniques. For more information: Daniel Parry, 202/767-2541,
daniel.parry@nrl.navy.mil, www.nrl.navy.mil/chemistry.
Titan Spine, Mequon Wis., has clinical data that supports the use of its
Endoskeleton titanium interbody cage for achieving rapid lumbar fusion
and improved patient outcomes. The study looked at 77 patients with a
mean age of 46 years who underwent an anterior lumbar interbody
fusion procedure using the Endoskeleton interbody device. A total of
138 spinal segment levels were treated. Radiographic analysis revealed
a 100% fusion rate between 6-12 months, with no appreciable
subsidence and an interobserver reliability rate of 95%.
www.titanspine.com.
Harper International, Buffalo, N.Y., is hosting the Carbon Fiber R&D
Workshop event July 2526. The goal is to connect peers in the carbon
fiber research space with an opportunity to network and share insights
on material and process technology innovations. Harpers Carbon Fiber
Microline research system will be on display, a flexible toolkit designed
to support research and development efforts, along with an advanced
UHT (ultrahigh temperature) furnace for carbon fiber production.
www.carbonfiberworkshop.com.
Yanfeng USA Automotive Trim Systems, Riverside, Mo.,
will construct a 258,000-sq-ft manufacturing plant in the
Kansas City area. The Michigan-based subsidiary of Yanfeng
Visteon of China, a General Motors supplier, plans to build
the $45 million manufacturing and sequencing facility and
expects to create 263 new jobs. The Riverside plant will
manufacture interior trim components, including door
panels, floor consoles, and instrument panels for General
Motors assembly plants in Kansas City, Kan., and
Wentzville, Mo. Construction is expected to begin in the next
month and the plant will be operational in early 2014.
www.yf-usa.com, www.thinkkc.com.
news
industry
bri efs
Staples Inc., Framingham, Mass.,
is the first major U.S. retailer to
sell 3-D printers. The Cube from
3D Systems Inc., Rock Hill, S.C.,
is available on Staples.com for
$1299.99 and will be sold in a few
stores by late June. It includes Wi-
Fi, Mac or Windows compatibility,
and 25 3-D templates. It can print
items up to 5.5 5.5 5.5 in.
using material cartridges in 16
different colors. Users can print
from a template or create a design
using Cubify Invent software, sold
separately. www.staples.com,
www.3DSystems.com.
Graphene Technologies, Novato,
Calif., was issued U.S. Patent
Number 8,420,042 for a process
for atom-by-atom synthesis of
graphene by the exothermic
chemical reduction of CO
2
.
According to company sources, the
process represents a dramatic
departure from current methods of
producing graphene, such as
chemical vapor deposition. By
combusting magnesium in the
presence of CO
2
, bulk volumes of
pristine, few-layer graphene
platelets are produced from
commonly available feedstock.
CO
2
is used to oxidize magnesium
at temperatures up to 7000F,
forming nanoscale magnesium
oxide and carbon.
www.graphenetechnologies.com.
New metamaterial boosts invisibility
Engineers at Stanford University, Calif., took another step toward designing a meta-
material that works across the entire visible spectrum. The new material exhibits a refrac-
tive index well below anything found in nature, such as air, whose refractive index hovers
just above 1. Interesting physical phenomena can occur if this index is near-zero or nega-
tive. Researchers designed a single metamaterial atom with characteristics that would allow
it to efficiently interact with both the electric and magnetic components of light. The team
began with a 2-D planar structure then folded it into a 3-D nanoscale object, preserving the
original properties. The metamaterial consists of nanocrescent-shaped atoms arranged in
a periodic array and it exhibits a negative refractive index over a wavelength range of
roughly 250 nm in multiple regions of the visible and near-infrared spectrum. A few tweaks
could make it useful across the entire visible spectrum. For more information: Ashwin Atre,
aatre@stanford.edu, www.stanford.edu.
Stainless steel fuel cell charges phones
Point Source Power Inc., Alameda, Calif.,
used technology developed at Lawrence
Berkeley National Laboratory (Calif.) to create
an inexpensive way to recharge cell phones in
the developing world. The new device is based
on a solid oxide fuel cell powered by burning
charcoal, wood, or cow dung. The fuel cell sits
in the fire and is attached to circuitry in a han-
dle that is charged as the cell heats to 800C.
The handle contains an LED bulb, which can
be detached and used for lighting or to charge
a phone. The fuel cell tolerates contaminants
like sulfur and carbon, which would kill simi-
lar devices, says CEO Craig Jacobson, who co-
invented the device called VOTO while
working as a materials scientist at Berkeley
Lab. Replacing most of the ceramics in the fuel cell with stainless steel allows it to withstand
welding and thermal shock and is less expensive to manufacture. VOTO will debut in Kenya
later this year. www.lbl.gov, www.pointsourcepower.com.
Nanowires grown on graphene have surprising structure
When engineers at University of Illinois, Urbana-Champaign, set out to grow compound
semiconductor nanowires on top of a sheet of graphene, they did not expect to discover a new
paradigm of epitaxy. The self-assembled wires have a core of one composition and an outer
layer of another, highly desirable for advanced electronics applications. Led by professor Xi-
uling Li, the research team used a method called van der Waals epitaxy to first grow
nanowires on a flat substrate of semiconductor materials, such as silicon.
The group has since grown nanowires made of indium gallium arsenide (InGaAs)
on a sheet of graphene, which is more flexible than silicon. It also conducts like a
metal, allowing for direct electrical contact to the nanowire. Researchers pump
gases containing gallium, indium, and arsenic into a chamber with a graphene sheet
and the nanowires self-assemble into a dense carpet. By using three elements, the
group made a unique finding: The InGaAs wires grown on graphene spontaneously
segregate into an indium arsenide (InAs) core with an InGaAs shell around the out-
side. By tuning the ratio of gallium to indium in the semiconductor mix, researchers
can tune the wires optical and conductive properties. For more information:
Xiuling Li, 217/265-6354, xiuling@illinois.edu, www.illinois.edu.
A dense array of InGaAs nanowires grown on graphene. Courtesy of Parsian Mohseni.
EMERGING TECHNOLOGY
Craig Jacobson, in the test labs of Point
Source Power. Courtesy of Julie
Chao/Berkeley Lab.
PROCESS TECHNOLOGY
news
industry
bri efs
Ikonics Corp., Duluth, Minn., is
working with Lockheed Martin
Corp., Bethesda, Md., to develop a
new method of machining ceramic
matrix composite (CMC) materials
using particle beam technology.
CMC is difficult to machine
because of its hardness and
nonuniformity. According to
company officials, Ikonics
technology eliminates edge
damage to the material caused by
remelt with lasers or delamination
with waterjet or mechanical
machining methods.
www.ikonics.com.
Materials science and engineering
professor Jiann-Yang Jim Hwang
and 2012 Ph.D. graduate Zhiwei
Peng will receive Michigan
Technological Universitys 2013
Bhakta Rath Research Award for
work involving the use of
microwaves in steelmaking. The
award is endowed by Michigan
Tech alumnus Bhakta Rath and his
wife, Shushama, and recognizes a
doctoral student and faculty
advisor for exceptional research.
The research entails theoretical
and experimental work on using
microwaves to heat materials,
particularly magnetic substances,
and also provides guidelines for
making large-scale microwave
furnaces for industrial use.
www.mtu.edu.
Robotic paint-stripping system wins Edison Award
A robotic paint-stripping system being de-
veloped by Carnegie Mellon Universitys Na-
tional Robotics Engineering Center (NREC),
Pittsburgh, and Concurrent Technologies Corp.
(CTC), Johnstown, Pa., was named a Gold win-
ner in the materials science category of the 2013
Edison Awards, announced April 25 in Chicago.
The Advanced Robotic Laser Coating Removal
System uses lasers mounted on mobile robotic
platforms to remove paint and coatings from
fighter and cargo aircraft. NREC and CTC are
developing the system for the U.S. Air Force.
NREC is building six autonomous mobile robots, each equipped with a high-power
laser coating remover developed by CTC. It uses a continuous wave laser to strip paint and
other coatings from aircraft rather than traditional abrasives or paint removers. The laser
can selectively remove coatings while a HEPA system collects debris as it is removed from
the aircraft. As part of a two-year project, the robots will be deployed in teams to remove
paint and other coatings from aircraft at Hill Air Force Base in Utah. For more information:
Byron Spice, 217/268-9068, bspice@cs.cmu.edu, www.cmu.edu.
Gas nitriding strengthens mini medical devices
An established automotive manufacturing technique holds promise for enhancing the
performance of micro and nanoscale medical devices. Masaru Rao, assistant professor at
Bourns College of Engineering, University of California, Riverside, received a $400,000
award from the National Science Foundation to explore the potential to strengthen minia-
turized titanium medical devices. Coating of machined parts to increase hardness is com-
monplace at the macroscale, but is constrained at the micro and nanoscale by challenges
such as maintaining coating uniformity and quality over complex structures.
To address these limitations, Rao will use gas nitriding, a technique widely employed
to increase the wear resistance of macroscale metal parts for automotive applications, such
as case-hardened engine camshafts. Machined part surfaces are strengthened by heating
in a nitrogen atmosphere, causing nitrogen to diffuse into the metal. Rao believes this tech-
nique holds significant potential for tiny medical devices because gas nitriding can be ap-
plied to devices after fabrication and also avoids limitations of coating-based processes.
The diminutive dimensions will make it easy to diffuse nitrogen throughout the entire
structure to allow through-thickness strengthening, says Rao. For more information:
Masaru Rao, 951/827-5870, mprao@engr.ucr.edu, www.ucr.edu.
Resin transfer molding suits composite leaf springs
Benteler-SGL of Austria and Henkel AG & Co., Dsseldorf, Germany, developed a
process for resin transfer molding (RTM) of glass-fiber-reinforced leaf springs, using a
polyurethane matrix resin. Compared to conventional steel leaf springs, com-
posite versions are up to 65% lighter.
Henkels Loctite MAX 2 is a polyurethane-based composite matrix resin that
cures significantly faster than epoxy products usually employed for the RTM
process. Due to its low viscosity, the resin more easily penetrates and impreg-
nates the fiber material, enabling very short injection times to be applied. Resin
injection processes such as RTM are widely used to make automotive compos-
ites because they make it possible to control the curing reaction more reliably,
either by adjusting the temperature or adding an accelerator. For more infor-
mation: Lisa Kretzberg, lisa.kretzberg@henkel.com, www.henkel.com.
Working together, Henkel and Benteler-SGL are mass-producing lightweight,
fiber-reinforced leaf springs based on polyurethane matrix resin.
This rendering shows how a team of
robots might be deployed to strip paint
from a C-130 cargo plane.
SURFACE ENGINEERING
news
industry
bri efs
Researchers at McMaster
University opened the
Biointerfaces Institute, Canadas
first facility for developing unique
new surfaces using high-speed
robots and other advanced
technology. Millions of
combinations of biological agents
and complex surfaces will be
tested in pursuit of rapid solutions
to stubborn health, safety, and
other problems. The accumulated
results will reside in a database to
assist researchers from both
inside and outside the university.
www.mcmaster.ca.
Fraunhofer Institute for Electron
Beam and Plasma Technology
FEP, Germany, introduced the
newest developments in vacuum
coating technology at the recent
international vacuum conference
SVC TechCon 2013 held in
Providence, R.I. The new and
highly efficient processes for
coating large areas, such as
arcPECVD (hollow cathode arc
PECVD), plasma-activated high-
rate evaporation using a dual
crucible, and the sputtering of
indium-free transparent
conductive coatings were
presented. All three technologies
are ready for industrial use.
www.fep.fraunhofer.de/en.
PPG Industries, Pittsburgh,
opened its new automotive OEM
coatings development and
application center in Tianjin, China.
The facility is the first of its kind
locally and will focus on
developing automotive coatings in
China. It is PPGs largest coatings
manufacturing facility and the
expansion significantly increases
the plants production capacity for
waterborne coatings. The center is
also equipped with advanced
machinery to simulate automatic
car painting processes.
www.ppg.com.
Pretreatment process boosts automotive aluminum use
Henkel Corp., Detroit, began using the Bonderite Flex Process on 2013 Ford F-150
trucks made in North America. The process enables a significant increase in aluminum
use by replacing traditional zinc phosphating with a zirconium oxide pretreatment. The
2013 F-150 features an all-aluminum hood. Once aluminum content on vehicles reaches
approximately 30%, the use of zinc phosphate becomes more difficult to control and leads
to an increase in sludge generation. In addition to enabling more aluminum use, zirconium
oxide provides better corrosion protection and reduces sludge waste by two-thirds.
www.henkel.com/automotive.
Cold spray coatings technology program
A cold spray coating technology program established at the University of Wisconsin,
Madison, is aimed at fundamental materials science research and industrial applications.
The program includes a commercial scale, high pressure CGT 4000-34 Kinetik system. In
the cold spray process, powder particles of the coating material are propelled at supersonic
velocities onto the surface of a part or substrate to form a dense coating. The particle tem-
perature is low and deposition occurs in solid state. The low temperature minimizes oxi-
dation, thermal decomposition, and other phase changes in the powder material during
deposition. Coatings can be synthesized with novel micro and nanostructures with en-
hanced properties. High deposition rates in the cold spray process make it attractive for ad-
ditive and near-net-shape manufacturing, as well as for low temperature dimensional
restoration and repair. Research and development activities include aluminum-alloy coat-
ings to address corrosion issues in Navy ships under an Office of Naval Research program,
energy and electronics sector applications, and hybrid coatings. For more information:
Kumar Sridharan, kumar@engr.wisc.edu, www.wisc.edu.
Clad pipe manufacturing facility opens in Ohio
Abakan Inc., Miami, performed a test run on its CermaClad high-intensity arc lamp
prior to the April opening of its first clad pipe manufacturing plant in Euclid, Ohio. The
plant is a 1-line CermaClad corrosion-resistant clad pipe manufacturing facility with
the capacity to produce up to $60 million of clad pipe for use in upstream oil and gas
production. The plant is the first production facility to use MesoCoats CermaClad high-
speed large-area fusion cladding technology to produce a high quality product 40 times
faster than weld overlay processes, and at significantly lower costs compared to other
alternatives.
MesoCoat Inc.s CEO, Andrew Sherman stated, Our new facility enables us to demon-
strate continuous, automated production of 12-meter pipe segments, and is a major mile-
stone towards offering cost effective asset protection in an effort to reduce the estimated
$2.2 trillion wasted worldwide as a result of preventable corrosion and wear.
www.abakaninc.com, http://mesocoat.com.
The clad pipe
manufacturing
facility uses
MesoCoats
CermaClad
high-speed
large-area fusion
cladding
technology.
T
he U.S. Air Force operates and maintains
approximately 24,000 turbine engines,
and many components in these engines
are limited by fatigue life. Current strategies for
estimating engine component lifetimes gener-
ally rely on extrapolating mean fatigue lifetime
behavior from extensive experimental data-
bases. Although these extrapolations may yield
overly conservative predictions
[1-3]
, such strate-
gies are critical for developing preventive main-
tenance schedules that ensure safety at an
affordable cost. Significant savings may be real-
ized by further developing and implementing
microstructurally based mechanistic models of
fatigue behavior
[2-4]
.
Fatigue behavior is weak link
Fatigue behavior is known to be a weak-link
process significantly influenced by local mi-
crostructural configurations
[5,6]
. Typically, lab-
oratory scale tests are used to determine a
materials fatigue capability because these tests
are relatively inexpensive and easily run to fail-
ure. Fractography is often performed after
specimen failure to determine which mi-
crostructural features are associated with fa-
tigue crack initiation and growth. These tests
provide lifetime-to-fatigue failure data under
specific loading conditions and microstructural
configurations.
Often, it is impossible to unambiguously
identify the mechanism of fatigue crack initia-
tion and cyclic damage accumulation through
post-mortem investigations, as many different
microstructural configurations can lead to
damage accumulation and subsequent crack
initiation
[6]
. Fatigue properties of titanium alloy
microstructures are of particular interest be-
cause of their use in critical aircraft and engine
aerospace components.
Aerospace titanium alloys usually consist of
two phases at service temperatures. The first
phase (beta) has a bcc structure and is more
ductile, with lower strength, than the second
phase (alpha). The alpha phase is an hcp struc-
ture with either lath-like or equiaxed grains, de-
pending on the thermomechanical processing
of the material. In laboratory scale fatigue tests
of alpha + beta titanium alloys, fatigue cracks
typically initiate via a facet formation on the
basal plane of primary alpha (
p
) grains
[6-10]
.
The microstructural neighborhood surround-
ing these grains also plays an important role in
the crack initiation process, and specific attrib-
utes of these neighborhoods were identified.
However, there are numerous paths for cyclic
strain to accumulate and various types of mi-
crostructural neighborhoods may lead to simi-
lar fatigue lifetimes
[6]
.
Traditionally, researchers use in situ testing
methods to characterize mechanisms of damage
accumulation due to cyclic loading, and these
studies have historically been limited to contin-
uum length scales. Advances in micromachining
and small-scale testing capabilities
[11,12]
enable in-
situ mechanical testing at the microstructural
scale
[13-16]
. Other advances facilitated quantitative
3D analysis of microstructures, including high-
fidelity crystallographic scale and orientation
information
[17-19]
. The current work describes
modifications of an in-situ monotonic mechani-
cal testing device
[20,21]
to enable in situ microscale
fatigue testing
[22]
, coupled with subsequent serial
sectioning methods to interrogate tested sam-
ples. The long term goal of this work is to develop
a fatigue damage metric capable of representing
and predicting fatigue damage accumulation
within specific microstructural neighborhoods
using a crystal plasticity finite element modeling
(CPFEM) approach.
Development of a
Microscale Fatigue Testing Technique
C.J. Szczepanski
P.A. Shade
M.A. Groeber
J.M. Larsen,
FASM*
U.S. Air Force
Research Laboratory,
AFRL/RX
Wright-Patterson
Air Force Base, Ohio
S.K. Jha
Universal Technology
Corp.
Dayton, Ohio
R. Wheeler
UES Inc.
Dayton, Ohio
A microscale
fatigue testing
technique for
characterizing
mechanical
response
and relating
this response to
microstructural
features
contained
within the
tested
volume
enables more
accurate
approaches to
predicting
mechanical
behavior in
larger fatigue
volumes.
*Member of ASM
International
Fig. 1 A schematic of
the microtesting rig
used for in-situ testing.
Adapted from
[20]
.
Piezoelectric
actuator
Alignment flexor
Attocube x/y/z
50 mm
piezoelectric
Sample positioning
stage
50
mm
Load cell
Silicon
grip
150 mm
Machining and testing
Microspecimens machined in targeted microstruc-
tural regions isolate specific types of microstructural
configurations within a specimen. Micro-electro dis-
charge machining (Micro-EDM) was used for coarse
machining of oversized specimen posts, and a focused
ion beam (FIB) microscope was used for the final ma-
chining of tensile specimen profiles. The gage sections
of these microspecimens were typically 20 m diame-
ter 50 m long, depending on the specific mi-
crostructure being tested.
The testing platform used in this investigation was
developed to accomplish monotonic loading in both
tension and compression
[20,21]
. The device, shown in
Fig. 1, uses a three-axis piezoelectric actuator to posi-
tion the grip over the sample head. Once the specimen
is seated within the grip, another piezoelectric trans-
ducer is activated to apply a displacement, which in-
duces a load in the specimen. Fatigue loading
experiments are conducted under pseudo-load control,
where a load cell is used to calibrate the applied piezo-
electric actuator voltage necessary to achieve a desired
load level. Blocks of 500 to 1000 fatigue cycles are ap-
plied by sinusoidally cycling the applied piezoelectric
actuator voltage. Following each block, the applied
voltage range is recalibrated for current load levels and
an image is acquired to document any accumulated
displacement within the specimen gage.
Ti-6Al-2Sn-4Zr-6Mo samples with a duplex mi-
crostructure were tested in situ using this microscale
fatigue testing technique
[22]
. Experiments were com-
pleted to identify the mechanisms of fatigue damage
accumulation, thereby linking specific microstructural
features to mechanical behavior. For this work, a spec-
imen was subjected to microscale fatigue testing at
stresses (
max
) ranging from 860 to 980 MPa. The spec-
imen was imaged at 20 kV using a backscattered elec-
tron (BSE) detector.
Test results
Tested specimens are shown in Fig. 2, with the re-
sulting mechanical response shown in Fig. 3. From Fig.
2(a), it is clear that individual
p
grains are accumulat-
ing localized fatigue damage in the form of slip bands,
highlighted by the yellow arrows in Fig. 2(c). As fatigue
cycling continues, slip lines continue to intensify, as
shown in Fig. 2(d). The test for this specimen was con-
ducted in the SEM and imaged using an accelerating
voltage of 20 kV and a backscattered electron (BSE) de-
tector. The data shown in Fig. 3 illustrate that the fa-
tigue performance of this specimen exceeds the fatigue
behavior of typical laboratory-scale fatigue specimens
tested at similar stress levels. These differences can be
attributed to specimen size scale effects and differences
in testing procedures
[22]
. However, it is clear that slip
lines are initiated and continue to intensify with addi-
tional fatigue cycling, which is consistent with the be-
havior of more traditional specimens. Improved
methods to perform dynamic system calibration are
currently being evaluated and implemented into the
testing methodology.
Microscale fatigue specimens are also amenable to
characterization via electron backscattered diffraction
(EBSD). EBSD data provide the identification of spe-
cific slip systems that were activated in individual
phase constituents. Figure 4 illustrates an example of a
microscale specimen tested in tension that was charac-
terized using this approach. It is clear from close ob-
Fig. 2 BSE micrograph of the test specimen: (a) Microscale fatigue specimen,
(b) onset of localized slip activity, and (c) and (d) continued slip intensification as
additional blocks of 10
7
cycles were applied at increasingly higher stresses. Slip
band development is highlighted by yellow arrows in (c).
Fig. 3 Microscale fatigue data of Ti-6Al-2Sn-4Zr-6Mo samples overlaid with
data from conventional laboratory scale specimens. The red squares and green
triangles represent data obtained from the in-situ microspecimen testing
technique. Adapted from
[22]
.
(a)
(b) (c) (d)
10 m
5 m
max
= 860 MPa
N = 10
7
cycles
max
= 920 MPa
N = 10
7
cycles
max
= 980 MPa
N = 10
7
cycles
10
4
10
5
10
6
10
7
10
8
10
9
10
10
Cycles to failure (N
f
)
Bulk yield strength
20 Hz Conventional
20 kHz Conventional
20 kHz Runout
100 Hz Microspecimen
1 Hz Microspecimen
1200
1100
1000
900
800
700
600
500
400
m
a
x
(
M
P
a
)
servation that most of the slip lines in this specimen
(identified in the figure by yellow dotted lines) are
aligned with the basal planes of the
p
grain. A Hikari
camera within an FEI/PhillipsXL-30FEG-SEM oper-
ating at 20 kV, 50 nA, with EDAX-TSL software using
a 0.1 m step size captured the image. There is no ap-
parent activation of localized slip elsewhere within
the fatigue specimen.
The small size of the microscale
specimens allows their microstruc-
ture to be fully analyzed using a
3D-EBSD serial sectioning proce-
dure
[17-19]
. This allows the explicit
3D microstructure to be input into
a CPFEM framework. Figure 5 is a
3D reconstruction of the physical
microscale tensile specimen shown
in Fig. 4. An FEI Nova 600 Dual
Beam FIB-SEM equipped with a
high speed Hikari EBSD camera
was used to conduct the serial sec-
tioning process.
An ion beam with an accelerat-
ing voltage of 30 kV and a current
of 9.5 nA was used to mill 100-nm-
thick slices in cross-section. The
cross-section faces were subsequently cleaned
using a 5-kV accelerating voltage to remove sur-
face damage
[23]
and improve the quality of the
EBSD patterns. EBSD data acquisition was con-
ducted with an electron beam at an accelerating
voltage of 30 kV, current of 5nA, and square grid
with 0.15 micron step size. The entire 3D-EBSD
data collection procedure was automated using
Fig. 4 EBSD
characterization of a
microscale
specimen
illustrating (a) the
orientation of slip
lines, (b) the prism
plane trace, and
(c) the basal plane
trace.
Fig. 5 3D reconstruction of a
microscale fatigue specimen,
where color represents
crystallographic orientation relative
to the tensile axis.
Slip lines Prism pl trace Basal pl trace
10 m 10 m 10 m
1010
0001 2110
custom scripts. A total of 400 slices were analyzed
and reconstructed using DREAM.3D software
[24]
.
Tools are being developed and refined to inter-
rogate these microstructural volumes and inte-
grate results with other experimental techniques
including digital image correlation. These results
are anticipated to permit calibration of the crystal
plasticity models to actual measured material
response, and therefore enable more accurate
prediction of mechanical response through
simulation.
For more information: Jaimie S. Tiley is senior materi-
als engineer, U.S. Air Force Research Laboratory, 2230
10
th
St., Dayton, OH 45433-7816, 937/255-5347,
jaimie.tiley@wpafb.af.mil, www.wpafb.af.mil.
References
1. U.S. Air Force. MIL-HDBK-1783B (w/change), De-
partment of Defense Handbook: Engine Structural In-
tegrity Program, 2004.
2. S.K. Jha, et al., Scripta Mater., Vol 48, p 163742.
3. S.K. Jha, M.J. Caton, and J.M. Larsen, Mater. Sci. Eng.
A, 468470:2332, 2007.
4. J.M. Larsen, et al., Int. J. Fatigue, Article in Press.
5. S.K. Jha and J.M. Larsen, 4th Intl. Conference on Very
High Cycle Fatigue, VHCF-4, Ann Arbor, Mich., p
38596, 2007.
6. C.J. Szczepanski, et al., Metall. Mater. Trans. A,
39:284151, 2008.
7. A.L. Pilchak, R.E.A. Williams, and J.C. Williams,
Metall. Mater. Trans. A, 41A:10624, 2010.
8. I. Bantounas, D. Dye, and T.C. Lindley, Acta Mater.,
57:358495, 2009.
9. F. Bridier, P. Villechaise, and J. Mendez, Acta Mater.,
56:395162, 2008.
10. S.K. Jha, et al., Int. J. Fatigue, 42:24857, 2012.
11. M.D. Uchic, Science, 305: 986-989, 2004.
12. M.D. Uchic and D.M. Dimiduk, Mater. Sci. Eng. A,
400401:268278, 2005.
13. M.D. Uchic, et al., Scripta Mater., Vol 54, p 759-
764.
14. J. Michler, et al., Appl. Phys. Lett., 90, 043123, 2007.
15. D. Kiener, et al., Acta Mater., 56:580-592, 2008.
16. J.Y. Kim and J.R. Greer, Acta Mater., 57:5245-5253,
2009.
17. M.D. Uchic, et al., Scripta Mater., Vol 55, p 23-28.
18. M.A. Groeber, et al., Mater. Charact., 57:259273,
2006.
19. N. Zaafarani, et al., Acta Mater., 54:1863-1876,
2006.
20. P.A. Shade, et al., Acta Mater., 57:45807, 2009.
21. R. Wheeler, P.A. Shade, and M.D. Uchic, JOM,
64:58-65, 2012.
22. C.J. Szczepanski, et al., Int. J. Fatigue, 2012.
23. A. Genc, et al., Microsc. Microanal., Vol 13 (suppl.
2), p 1520-1521.
24. DREAM.3D [http://dream3d.bluequartz.net/].
1964 1965 1966 1967 1968
Celebrating ASMs First 100 Years
in Supporting Materials Innovation
A
s we celebrate the 100-year anniversary of ASM International (1913-2013), we look at the many notable advancements in materials and
processes technology that occurred along the way. ASM has played a significant role in this by providing a forum for bringing together
engineers, scientists, and practitioners to exchange information on these advancements, and by disseminating information about them to
the engineering community in general. The society, which began in 1913 as the Steel Treaters Club, also went through several changes over
the years to its present ASM International. In each issue of AM&P in 2013, we are highlighting in 10-year increments significant advancements
in technology, as well as advancements in the society.

ASM Mobile Metallography Lab
ASMs mobile lab and first hands-on
metallography course were unveiled
at the New York Metal Show. By
1964, ASMs Metals Engineering
Institute was operating for six years,
presenting courses to more than
8000 students and issuing 6000
certificates.
Stainless
steel replacements
for vehicle
exhaust systems are
launched into the
U.S. automotive
market.
Materials Applications News for Design &
Manufacturing, a quarterly publication, is introduced
along with Metals/Materials Today, a monthly technical
news magazine replacing Metals Review.
Volume 2 of the
Metals Handbook is
published: Heat
Treating, Cleaning, and
Finishing is nearly 700
pages long, written by
45 author committees
and more than 700
contributors.
Metal Science Kit
The ASM Education
Committee devised a kit of
materials and an
instructional booklet that
would be most helpful to
the young man who is
interested in metals
and perhaps is
thinking of metallurgy
as a career. Costing
$30, kit contains 108
experiments and a
furnace to heat
specimens as large as
8.25 4 in.
Gateway Arch debuts
Eero Saarinen (1910-1961), the
famed Finnish-American architect,
won a contest in 1946 to design a
monument for the Jefferson National
Memorial in St. Louis. His arch
consists of hollow triangular legs
that gradually decrease in size as it
rises. Saarinen chose stainless steel
as the cladding material because he
wanted it to last for a thousand
years. The monument measures
630 ft tall 630 ft wide at the base.
Metals Abstract is launched, a new
journal resulting from the merger of
ASMs Review of Metal Literature
and IOMs Metallurgical Abstracts.
ASTM Committee E-28 on
Mechanical Testing is organized.
One of the first color
photos printed in Metal
Progress appears in an
article titled A Decade
of Improvements in
Generator Rotor
Forgings. It shows the
largest ingot ever
produced at the U.S.
Steel Homestead
Works. Vital statistics:
657,000 lb, 17 ft tall,
and more than 11 ft in
diameter.
ASM considers adding a
Center for Continuing
Education at Metals Park.
The Board of Trustees
has approved the concept
of further development of
Metals Park to be of
maximum benefit to the
ASM member, and to the
engineering and scientific
community.
1969 1970 1971 1972 1973

The 64-story U.S.
Steel Tower in
Pittsburgh debuts as
the companys
headquarters, as well
as a showpiece for
one of their
products, COR-TEN
steel. The weather-
resistant steel
develops a tightly-
adhering brown
oxide coating that
never needs
painting. However,
the metal had the
unwelcome effect of
staining nearby
sidewalks and
buildings with rust
that was difficult to
remove.
Neil Armstrong
becomes the first
man to walk on the
Moon on July 20,
1969. The Lunar
Excursion Module
is shown in the
background.
Three astronauts
traveled to the Moon
on the Columbia
Command Module
after blasting off
the Earth on a
Saturn 5 rocket.
Wrought iron
production ceases
The closing of the A.
M. Byers Company of
Ambridge, Pa., marks
the end of wrought
iron production in
North America. The
ASTM Committee A-2
on Wrought Iron,
organized in 1905,
disbands in 1970.
F. Kenneth Iverson takes over at Nuclear Corp.
to create the first steel mini-mill, making bars
starting with steel scrap melted in an electric arc
furnace. His plant in rural Darlington, S.C., hires
nonunion farmers, salesmen, and sharecroppers.
Iverson branches into sheet steel production, in
direct competition with Big Steel and one of their
most lucrative products. Nucor becomes the
second-largest
U.S. steel
manufacturer
while launching
an entire mini-
mill industry.
First electric arc steelmaking furnace in the
Western Hemisphere, and ASMs first National
Historic Landmark. Dedicated at Colt
Industries Crucible Specialty Metals Division,
Syracuse, N.Y. The furnace now stands at
Pittsburghs Station Square.
Harry Chandler becomes editor of
Metal Progress, a position he will hold
through 1985. Chandler
also authored how-to
books for ASM,
including the classic
Metallurgy for the
Non-Metallurgist. Prior
to joining ASM, he
served for nearly
five years in the
U.S. Marine
Corps, earned a
M.A. in journalism,
and worked for
several other
publications, including
Penton Publishings Steel.
The first class of
ASM Fellows, 200
strong, is installed
at ceremonies at
Metals Park. ASM
established the
honor of Fellow of
ASM to recognize
members for
distinguished
contributions to
materials science
and engineering.
The National Congress
on Technology for
Productivity was developed
for the 1971 Metal Show.
Twenty-three of the
nations leading technical
societies and associations
cooperated in the
preparation of close to 40
separate sessions.
Dr. Taylor Lyman
(1917-1973)
Lyman was the editor
and driving force behind
the Metals Handbook
series. Dr. Taylor Lyman
was a man of tremendous
intellectual proportion.
His encyclopedic mind
and his genius in the
organization of knowledge
have given the technical
world the Metals Handbook.
His towering knowledge of
metals was not limited to the
United States, but extended
to the Western Hemisphere
and the world itself, notes
ASM Director Allan Putnam
in tribute.
Singing the praises of brass
From an advertisement for The American Brass Company, Metal
Progress, March 1945
Remember your introduction to Brass? As a boy perhaps, in a
manual training classor possibly on the bench of your home
workshop. Wherever it was, you realized then that the yellow
metal was not only royal in appearance, but that it was a
workable metal, too.
It seems that Brass was especially made to be machined and
worked and formed into so many useful things that people
needthanks to copper-alloy metallurgy that has developed a
variety of Brasses with properties that manufacturers find so
indispensable: Brasses that can be worked hot or cold, that
can be forged, rolled, spun, stamped,
pressed, coined, upset or drawn; Leaded
Brasses that machine at top spindle
speedsductile Brasses that could be
formed or shaped with the pressure of your
fingersor hard spring Brasses that can
be stressed through millions of cycles
without danger of failure by fatigue.
pasti mes
Sara is weld-formed
from strips of
COR-TEN steel.
Selected items from the pages of ASM Internationals monthly magazine: Metal Progress was published from 1930 to
1986, after which Advanced Materials & Processes came into being.
Admiring the beauty
of steel
From an advertisement for COR-
TEN steel from U.S. Steel, Metal
Progress, September 1972
Her name is Sara. Five foot four,
154 pounds, and if exposed to the
weather is destined to grow more
beautiful with age. Sara is the work of
sculptor Charles Park, Hockessin,
Delaware, who weld-formed her from
strips of COR-TEN Steel. Sculptors
are using USS COR-TEN Steel for
its strength, low cost, natural beauty
and its built-in durability, the same
qualities that make it so attractive to
designers. Exposed to the weather,
USS COR-TEN Steel forms a dense
protective oxide film thats self-
maintaining. Its handsome russet color
grows progressively deeper and richer.
Surface scratches heal themselves.
COR-TEN Steel is strong too, it can be
obtained in minimum yield points as high
as 50,000 psi, in thicknesses through 4 in.,
and as high as 60,000 psi in thickness
through 1 in. It comes in practically all
shapes and sizes. And costs only 11
cents a pound.
A tribute to summer
From Letters to the Editor, Metal Progress,
February 1964
Water Wonderland
Scientific detachment
is always difficult. It sometimes
requires strong will to interpret
laboratory results and avoid
any predilection due to
personal bias. This is
particularly true in the
vacation season, when the
fish are biting and the lakes and rivers beckon. It becomes
exceedingly difficult when the data refuse to cooperate and
instead assume forms that translate into woods and waters.
For example, this photograph appears to be a picture of a
large Canadian goose carrying off a fine specimen of
Michigans largemouth bass. Technically speaking, however, it
pictures FeO inclusions in steel, rolled to a 46%
reduction at 2400F. Composition: 0.035 C,
0.01 Si, and 0.145 O, bal Fe. (200 , unetched)
F.E. Alberts, Ford Motor Co., Dearborn, Mich.
This March 1945
advertisement
extolls the virtues
of brass.
www.aws.org
April 2013 / Vol. 16 / No. 2
THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL
Inspecting Stainless
Tube and Pipe
Starting A Business
Inspecting Stainless
Tube and Pipe
Starting A Business
Tips for Working
Overseas
Tips for Working
Overseas
April cover_IT Spring 4/06 3/20/13 4:03 PM Page C1
News Bulletins
Inspection Trends / April 2013 8
NDE Methods to Enable Electron Beam Direct
Manufacturing in F-35 Aircraft Production
The Navy Metalworking Center, Johnstown, Pa., is
managing a project funded by the Industrial Base Innovation
Fund and Navy ManTech to advance electron beam direct
manufacturing (EBDM) that will be used in F-35 Joint Strike
Fighter production.
The project will assess the capability of traditional and
advanced nondestructive examination (NDE) processes for
detecting defect types and sizes likely present in these parts.
Also, it will quantify the effects of surface finish and heat-
treatment conditions on detection capability.
The integrated project team will investigate methods such as
traditional radiography, standard and phased array ultrasonic
inspection, and computed tomography. Developing NDE test
methods and acceptance standards are required for EBDM
technology to be approved for fabricating F-35 airframe
components.
In addition, utilizing the technology for manufacturing F-35
titanium components will lower overall manufacturing costs
considering EBDM facilitates fabricating components to a near-
net shape, requiring less raw material and machining.
Upon approval, the recommended NDE practices will be
implemented by Sciaky, Inc., and Lockheed Martin
Aeronautics Advanced Development Program on all
designated EBDM components for the F-35 program beginning
in 2015.
GE Oil & Gas Establishes Technology Center
in Iraq with Testing and Inspection Services
To help rebuild Iraqs energy infrastructure, GE Oil & Gas
recently established a new technology and service center near
Navy test pilot Lt. Christopher Tabert flies F-35B Joint
Strike Fighter aircraft BF-3 with inert AIM-9X Sidewinder
missiles over the Atlantic Test Range. (U.S. Navy photo
courtesy and copyright of Lockheed Martin by
photographer Michael D. Jackson.)
IT News Spring 2013_Layout 1 3/19/13 3:06 PM Page 8
Print and Product Showcase
Ultrasonic Gauge Offers Auto
Linear Compensation
The ST-130 ultrasonic thickness
gauge provides a measuring range of
1.0 to 300 mm, accuracy of 1%H+0.1
mm, a resolution of 0.01 mm, and a
working frequency of 5 MHz. The
gauge also offers auto calibration and
auto linear compensation. Featured are
data store, data recall, and data delete
functions, as well as a LCD backlight
display.
Sonostar
www.sonostar-ndt.com
86 20-23282095
Simulation Software Models
UT Inspections
CIVA ATHENA 2D couples
ultrasonic testing with finite element
modeling (FEM) to extend the
softwares ultrasonic testing (UT)
simulation possibilities. While doing a
simulation, the software takes into
account all physical phenomena, even
the most complex, within a user-
defined perimeter that is placed around
the defects. This interface remains
close to the usual CIVA interface and
does not require knowledge of FEM.
This provides a faster calculation time
and beam propagation, and its
interaction with flaws can also be
visualized.
EXTENDE, Inc.
www.extende.com
(518) 602-1368 (fax)
LEDs Enhance Pipe Inspection
Performance
The LED illumination for
QuickView pipe inspection cameras
enhances short- to mid-range zoom
inspection of storm and sewer pipes. It
is available as an option on new
systems or as an upgrade to existing
ones. The LED option offers better
April_Layout 1 3/19/13 2:34 PM Page 12
diffusion for viewing near targets, as
well as other benefits commonly
associated with LED lighting such as
extended life, instant start-up, variable
intensity, good color balance, and
reduced power consumption. It is
available for both standard and
Haloptic versions of QuickView.
Envirosight LLC
www.envirosight.com
(866) 936-8476
Fluorescent Light Provides
Twice the Output
The EPL-48-216 is a 20,000-lumen,
explosion-proof, fluorescent light fixture
with Class 1 and Class 2 Division 1 UL
listings. Equipped with four T5HO bulbs
within the same size and shape as a
standard four-foot, two-lamp model, the
EPL-48-216 offers twice the output of a
standard hazardous area light.
Larson Electronics
www.larsonelectronics.com
(800) 369-6671
Corrosion Testing System Fits
in Palm of Your Hand
The Pocket CORPAC corrosion
testing system, built on the platform of
the original model, is less than a quarter
of the size of its predecessor. Combining
the latest user-guided software with the
portable convenience made possible by
acoustic emission technology, the system
detects localized corrosion without
taking industrial structures out of
service, and effects can be seen or felt. It
increases operational safety with short,
periodic, in-service monitoring, while
simplifying asset maintenance on
industrial structures and materials.
Mistras Group, Inc.
www.mistrasgroup.com
(609) 716-4000
New Software Manages and
Analyzes Materials Testing
TrendTracker, a software package
for managing and analyzing test results
for Bluehill 3 materials testing
software, accelerates a labs data
analysis workflow. With the
TrendTracker Plugin, Bluehill results
across multiple samples are
automatically exported to a robust and
scalable database on Microsofts SQL
Server. The TrendTracker Viewer
provides an intuitive interface to
search, display, and analyze results
over time, and across multiple samples
and test frames to eliminate file
searching and copy/paste. Search
results can also be exported to file
formats that can be easily opened in
statistical packages. The database can
be installed on the customers SQL
server or on an Instron-distributed
Express edition.
Instron
www.instron.com
(800) 564-8378
Inspection Trends / Spring 2013 13
Fischers Feritscope
FMP30
is the ideal solution for fast,
precise measurement of ferrite
content of constructional steels,
welded claddings, austenitic
stainless steels and duplex steels.
Non-destructive measurement
in the range of 80% Fe or 0-120
WRC number.
Battery or AC powered
Large, backlit display
Automatic probe recognition
Statistical evaluation
USB interface
Multiple application memories
Bluetooth wireless technology
1-800-243-8417 1-860-683-0781 Fax: 1-860-688-8496
www.Fischer-Technology.com info@fischer-technology.com
Measurement
of the Ferrite Content in Austenitic
and Duplex Steel
FERITSCOPE
FMP30
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continued on page 30
For info go to www.aws.org/ad-index
April_Layout 1 3/19/13 2:35 PM Page 13
Feature
By Mary Ruth Johnsen
Some CWIs spend their careers
working for one company in one place
or at least in a limited geographic area;
others are vagabonds who practice
their profession all over the world.
Inspection Trends sought advice from
some inspectors with extensive
experience working outside the United
States on how to make the best of an
overseas assignment. Following is an
introduction to each of these men and a
quick rundown of where they have
worked overseas.
Ken Erickson is an AWS SCWI.
You know him as one of the authors of
The Answer Is. . . department of
Inspection Trends. He is manager of
quality for National Inspection &
Consultants, Inc., Ft. Myers, Fla. From
1990 to the present, Erickson has
worked in the following countries:
Spain, Brazil, Italy, Sweden, Korea,
Loas, Cambodia, Thailand, Singapore,
China, Hong Kong, Bangladesh, Japan,
Venezuela, Turkey, Canada, Mexico,
Holland, Scotland, and Poland. Most of
this work was involved with offshore
structures, electric power generation,
and aircraft. He mostly performed
quality control, nondestructive
examination, and project management
overseeing local contractors.
Jim Merrill, a CWI based in
California and a member of the AWS
D1 Structural Welding Committee, has
worked in many countries throughout
Asia, Europe, and South America, as
well as in Canada.
The first project I had would have
been around 1990 or so in Lima, Peru,
and that was a boiler deaerator for
Goodyear Tire & Rubber Co., Merrill
noted. Since then I have been
involved in a number of bridge and
electrical transmission projects that
have taken me overseas.
Jon Lambert, a former AWS
SCWI and advisor to a number of
committees related to the International
Tips for Working Overseas
This advice may help you cope when working in countries with different cultures and
languages
Steve Snyder and coworker Saravana performing ultrasonic testing on butt-
joint welds of the low- and high-pressure housing to pipe welds in Fakfak,
Indonesia. The temperature was about 110F that day. The low-pressure
housing (typically 30 or 36 in.) provides a location point for the drilling guide
base, and provides an interface for the 18
3
4-in. high-pressure housing. It is
important for this first string to be jetted or cemented in place correctly
because it is the foundation for the rest of the well.
Snyder is shown at the laydown yard in Fakfak inspecting subsea
wellhead drilling equipment prior to it being shipped offshore to an
exploratory well site.
Johnsen Feature IT Spring 2013_Layout 1 3/19/13 2:23 PM Page 15
Institute of Welding, currently works as
a freelance welding consultant
reviewing welding procedures for the
Ichthys LNG Project in Darwin,
Australia. He also presents API 570
and 510 seminars throughout Australia.
In 2011/2012, he held a short-term
contract position in New Zealand as a
quality assurance/quality control
manager. Beginning in 1998, he served
as a welding engineer/quality control
engineer in Mexico, then as a welding
supervisor and CWI in South Korea.
From January 2007 through November
2011, he was a welding engineer in
Kazakhstan, serving as the owners
representative for all welding aspects
of the Kashagan Project.
Among other tasks, Lambert
monitored the contractors technical
design team to ensure all welding
design was in accordance with the
technical requirements of the relevant
project specifications, codes, and
standards, and provided guidance to the
execution contract package managers
in the evaluation of technical queries,
project changes, and concession
requests with respect to welding and
nondestructive testing matters raised by
the execution contractors.
The majority of Steve Snyders
work during the past five years has
been in Southeast Asia. Snyder is an
AWS SCWI currently with Transocean
Deepwater Drilling, Houston, Tex.
Although I have traveled to some
extent domestically and internationally
pretty much over my entire career,
including about 14 different countries
outside of the U.S.A., I did not start
actually living overseas until 2008. He
started with a job in Shenzhen, China,
doing consulting and training groups of
Chinese workers about codes and
standards, then spent six months in
both Ho Chi Minh City (formerly
Saigon) and Vung Tau, Vietnam,
working with local welding schools to
assist them in complying with AWS
Accredited Test Facility programs. He
then traveled to Singapore and
Indonesia beginning in early 2011. He
spent a year in Singapore as the
technical manager for a subsea well
control overhaul and repair equipment
facility. My primary role there while
supervising a team of inspectors, a
welding engineer, and QC engineers
was to improve the welding and
fabrication operations and implement
phased array ultrasonic testing to
replace conventional radiography.
Language Barriers
When asked how they dealt with
language issues (did the people they
worked with speak English, did the
respondents speak the local language,
did they utilize the services of an
interpreter or simply use gestures), the
general concensus from all four
respondents was all of the above.
I have had the people I am
working with speak English, I have
made an effort to learn enough of the
language that I can survive when I am
deployed for long periods of time, and
yes, an interpreter, particularly in the
technical language is almost always a
must, Merrill said. And, of course,
on the shop floor a lot of both gestures
and picture drawing. I am of the
opinion that if you are going to be on a
long deployment, say a year or more,
the best thing to do is dive into both the
culture and the language. It is the only
way that you will understand why they
do things the way they do them.
Of all the countries in which
Snyder has worked, he found it hardest
to communicate in Vietnam. Many
tones of the Vietnamese language are
difficult to master and have an ear for,
he said. The Vietnamese did have
interpreters at times, and there were
those in high-ranking positions who
spoke English as well, but you had to
listen closely and talk slowly. I did
manage to pick up some Vietnamese;
however, just enough to look like I was
trying to learn the language. Snyder
found his ability to weld and to set up
and adjust inspection equipment helped
Jon Lambert and his wife, Karen. Lamberts overseas working experience
includes nearly five years in Kazakhstan.
Ken Erickson performing ultrasonic testing
on an offshore tension leg platform anchor
chain on a project in Sweden in the 1990s.
him because he could demonstrate to
workers what needed to be done. He
also found that while he did not speak
the language, he often could
understand what was being said at least
to a limited extent because he heard
similar conversations day after day.
In Kasakhtan, I had interpreters,
but I also speak and read the Russian
language, which is what most people in
Kazakhstan speak, Lambert said.
Kazakh is the areas other language and
has some similarities to Russian. Most
people in Kazakhstan speak at least a
little bit of English, he recalled. In
Korea, a combination of gestures was
used although many Koreans at least
understand a bit of the English
language. In Mexico, I had an
interpreter but I also learned the
language, and, of course, in New
Zealand and Australia, English is the
native language.
Erickson said he has never found
language differences to be an issue.
English is spoken at many locations
and, when not, you have to rely on
other means such as pictures, drawings,
and slower explanation. Remember to
be patient and take the extra time in the
beginning to ensure that all is being
understood correctly, he suggested.
Interpreters are always helpful but do
not rely on them as this is only a plus.
Erickson added that todays
technology, including smart phone
applications and computer language
translation programs, offer great help.
The stumbling blocks of language
difficulties are only minor
considerations, he said.
One of the biggest mistakes I see
new expats make is to go to a foreign
country and expect to find language
and customs the same as in the United
States, Merrill noted. A lot of people
expect everyone to speak English, eat
American food, drive like Americans,
etc. When going overseas people need
to embrace the culture they are in. If
they dont, they will only become
frustrated and unhappy. I have had to
send many technicians and engineers
home because they could not do this.
Learning the Work Customs
All four respondents said they
researched work and other customs in
the places where they would be
working themselves, which helped
increase their comfort levels, even
though some companies did provide
orientation programs. All found the
Internet to be a great source of
information but, as Erickson noted,
The in-country locals and expats can
provide you with the best information
for which the Internet does not
provide.
Depending on the country you are
in, simple things can create a very
embarrassing moment, Merrill said.
He offered some examples: In Korea,
you never fill your own glass; the other
members of the dinner party will fill
your glass, and you are expected to fill
theirs. In the Middle East, if you cross
your legs and point the bottom of your
shoes toward someone you have done
the equivalent of flipping someone the
bird in the United States. In China, you
can never say that someone has done
something wrong. There may be
something that is wrong but you can
never attach that to a person or you will
cause them to lose face, and you will
forever have an enemy no matter how
hard you try to fix the situation. So the
lesson to the reader is to understand the
little things that may be very different
in the U.S. culture and be sure you
understand them well enough that you
can integrate them into your daily
actions.
Snyder stressed the importance of
being patient and willing to adapt to
different situations.
Lambert found work customs to be
mostly the same all over. One thing
Ive found regardless of where Ive
worked, is in general terms, people are
people, and if we try just a little bit
we can get along with everyone.
Dealing with the Unexpected
The four men were asked to
describe a situation that made it clear
they were no longer in the United States.
All four have interesting tales to tell.
Being Handed a Baby
In Bangladesh, Erickson said,
westerners were called round eyes and
all were considered to be very wealthy.
On one occasion, a woman offered me
her baby to hold, he recalled. I refused
and found out later from the hotel front
desk that the woman would have then
left without the baby. Her hope would
have been that Erickson would take the
child to raise, providing a better life for
it than she could. This also happened
while I was riding a taxi one day.
Culinary Adventures
Merrill said there were so many
unusual situations it was hard to select
just one. But here is one that is not too
hard to understand. I was in Jiang Yin,
China, with one of my technicians,
Robert Mertz, and we were being taken
out to dinner by one of the local
fabricators. They took us to one of the
nicer restaurants in town for some local
foods.
When they brought out one of the
dishes and Robert looked at it, he
leaned over to me and said, Man, are
those maggots? I took a look and said,
No, they have feet. By the way, we
went on to enjoy the meal, but there
was nothing on the table that looked
like anything we were accustomed to.
A Trip to Nowhere
During his time in Kazakhstan,
Lambert needed to visit a vendor in
Taraz, a town located near the Chinese
and Kyrgyzstan border. Not the end of
the earth, but you could see it from
there, he recalled. Part of the Kazakh
policy for migrant workers was to
register their passports with Kazakh
police if they would be in country for
more than one week. As my travel was
over the Christmas and New Year
holidays, I asked my Human Resources
(person) if I could just have my hotel
manage getting my passport registered
with the police. (The hotel had
offered). I was given approval to do so
and my passport was returned a few
days later with a signature on my visa
stamp. I took that as okay.
Lambert stayed in Taraz for ten
days then boarded a train for an 8-h
ride. In the middle of the night, the
train stopped and the police came on
board.
Naturally they came to my cabin
and asked to see my passport. I handed
it over to them, and they had some
chatter between themselves. Then back
to me one of the officers made a pay
me gesture with his hands and smiled
saying George Bush. I smiled back
and pled ignorance. After about 15
minutes they left.
The next day, Lambert delivered his
passport to Human Resources who
literally freaked out and said I didnt
have a stamp in my passport the
signature meant nothing. I explained
about the police on the train on the
previous night and was told I could have
been removed from the train and would
have likely never been heard from again.
Human Resources had to send my
passport off to the Capitol with a very
hefty fine. I never knew how close Id
become to being another statistic until
talking to some local friends. Whew!
Polar Opposites
What made an impression on
Snyder was how often he was in
situations diametrically opposed to
what he was used to in the United
States or what could even occur from
one place to another in a very short
time.
He worked for a while in Fakfak
City, Papua, Indonesia, a remote city that
has the highest malaria rate in the
country and that has a heat index that
makes south Louisiana look like the
polar bear club on some days. His hotel
room included your very own mosquito
net with cold water shower. As he rode
to the job site, children ran after him
yelling bule man, which means white
man or expat. He would bring them
candy, which they treated as if it were
gold. Goats roamed the streets, and he
heard the calls for Muslim prayer ringing
out five times a day.
The area is still somewhat
controlled by the tribes, Snyder
recalled. The established law of the
government seems to not totally work
in Fakfak due to the hak ulayat,
which is the tribal law and still
dominant in regard to land control and
leadership. There were cases of
improvised explosive devices planted
and found in the warehouse while I
was working there as retaliations from
the local tribes over land they felt was
being taken that was still theirs or
because of decisions made by the local
law with oil exploration companies.
At an airport in Kaimana,
Indonesia, they had to request the
children get off the runway so Snyders
plane could land. He recalled playing
marbles with the children using dead
beetles.
Fakfak was a far different world
than that of the five-star lifestyle of
Singapore, which offers the best of the
best for living, dining, shopping, and
world art. No one could have trouble
adjusting there, he said. One day he
flew from Fakfak to Singapore, where I
went from a bed with mosquito netting
and cold water to fluffy pillows, warm
water, and fresh linens.
Additional Advice
You need to understand the
requirements of the country you plan to
work in so you arent surprised by the
cost and time it takes to get your
equipment to the job site, Merrill
advised.
Merrills work usually requires a
number of engineering technicians to
travel with him. These technicians
have always had multiple certifications
including CWI and ASNT Level II/III
in UT, MT, PT, and RT, so we have
always had the logistical issues of
getting equipment in and out of various
countries and the issue of dealing with
220 voltage vs. the U.S. 110 voltage
most of our equipment is wired for. We
have had to purchase a number of
pieces of equipment that can only be
used overseas in countries with 220 V.
In addition to voltage
considerations are the issues of getting
equipment through customs.
Sometimes there is a required tariff,
other times it will sit in customs
awaiting inspection, and other times
you can get it in the country without
any question or problem. I would also
add that there are many countries that
require a second tariff on the same
equipment when you are leaving the
country.
He added that people new to
working overseas need to understand
what medical resources are available
and how to get to them if they need
medical attention. Snyder also
mentioned the need for an international
medical plan.
Assuring you understand and
realize the tax consequences that may
be part of your contract is essential,
Snyder advised. It is best to be tax
equalized for any long-term
assignments to avoid more tax liability
than you would encounter if you would
stay working in the U.S.A. and making
the same salary. The consideration of
having to pay local taxes must be
worked out in your contract agreement
as well, and you should contact your
tax advisor accordingly.
If you like a routine, (working
overseas) is not for you, Snyder said.
The sights and sounds of arriving in a
place like Ho Chi Minh City with
about 8 million people, of whom likely
5 million are on scooters, is daunting at
first. Dont look nervous. Blend in.
Dont be flashy or stand out.
All four respondents echoed one
another in saying that U.S. citizens
working abroad must remember their
place in the host country.
Be respectful and mindful that
you are a guest in their country,
Lambert advised. All too often I see
my fellow Americans carrying an
arrogant attitude that wont win us any
friends. Be yourself but also be aware
that you are a guest. Try on the local
flavors, i.e., eat what the locals eat, not
in McDonalds or the local five-star
hotel. Keep your wits about you. Many
of us who work in construction or
heavy industry enjoy alcoholic
beverages. Be careful. Although travel
overseas is generally safe, one must
still be conscious and alert for
unexpected situations.
Erickson added, First and
foremost, realize and understand you
are not in the U.S. and do not expect
things as they are in the U.S. Each
country, although different, has a
wealth of history, sights, culture, etc.,
that should be respected and enjoyed.
Try to learn some basic words and
phrases, smile, and do not let the
differences discourage you. Each day
incorporate a new sentence or a basic
greeting. If you live outside your
comfort circle in a positive frame, your
days will become much more
interesting and enjoyable in a foreign
environment.
MARY RUTH JOHNSEN
(mjohnsen@aws.org)
is Editor of Inspection Trends.
Understand the
requirements of the
country you plan to
work in so you arent
surprised by the cost
and time it takes to get
your equipment to the
job site
Feature
Good Practices for Inspecting Austenitic Stainless Steel Tube and
Pipe Systems in Hygienic Applications
The AWS D18.1/D18.1M Specification is indispensable for establishing
weld inspection criteria
By Michael Lang
For clarity, this presentation is broken
down into four parts: expectations,
preconstruction weld sampling,
surveillance of construction activities,
and visual exam.
Expectations
Communication of expectations from
owner, to contractor, to inspector, and
finally to the welder is critical to
successful welding. Unfortunately, all
too often, AWS D18.1/D18.1M,
Specification for Welding of Austenitic
Stainless Steel Tube and Pipe Systems in
Sanitary (Hygienic) Applications, is not
known or specified during the project
planning phase. Yet this document holds
the criteria needed for the installation of
safe, quality systems. In cases like this,
the inspector should make the parties
aware of the document and its criteria.
It is the inspectors job to inspect. It is
not to engineer for the contractor , train
the welder, or help end users figure out
the quality their product requires.
Inspectors are there to apply the relevant
code and project specifications. The
inspector must have clear criteria, and
AWS D18.1/D18.1M is the definitive
specification recognized by the industry.
If the owner chooses not to follow
industry codes and specifications, there
should be a robust engineering argument
to support such judgment. Inspectors
should note any areas that are not AWS
D18.1/D18.1M compliant on the
appropriate inspection report.
The critical aspect of this scope is
that these systems carry commodities for
human consumption, and the inspector
is safeguarding the public health.
Preconstruction Weld
Sampling
Preconstruction weld sampling
(PWS) is an activity to prove the
combination of welder/operator ,
machine, WPS, and materials are
conducive to making repeatable quality
welds. The inspector needs to verify
PWS (Fig. 1) as acceptable per AWS
D18.1/D18.1M Sec. 6, then use it as a
standard during the production day . It
needs to be understood that every
change in size and/or thickness requires
a different set of PWSs. AWS
D18.1/D18.1M Sec. 5.2 is an excellent
source of information on sampling
procedures.
I have seen the PWS process missed
with the proposed solution being to do
samples after the fact. This might sound
good at first, but look deeper . Will you
have the same gas, tungsten, quality of
input power, and conditions? Obviously
not. At this point, you have a system of
indeterminate quality. There is a reason
it is called preconstruction weld
sampling.
Fig. 1 Example of preconstruction weld sampling.
Fig. 2 Typical dial indicator used to
check mismatch, convexity, concavity,
and other conditions.
Lang 4-13 IT._Layout 1 3/20/13 8:12 AM Page 19
Surveillance of Construction
Activities
Surveillance is another area that
requires good communication to be
successful. The owner needs to set the
criteria on surveillance, such as type of
inspections and frequency. This is where
the owner and inspector need to
establish the extent of examination. This
extent can then be communicated to the
contractor.
A key point to consider is that inside
diameter inspection opportunities are
limited. Develop a surveillance plan to
maximize visual inspection of these
areas.
Final Visual Exam
This needs to happen in two stages,
before and after postweld finishing or
conditioning. This gets to be an issue
when an inspector is called to look at a
weld and finishing has already been
performed. This makes it impossible to
properly visually examine the weld. At
this point, visual verification of bead
width, meandering, convexity,
concavity, etc., are no longer available.
These are issues that may require a cut-
out and replacement of the entire weld.
The AWS D18.1/D18.1M Sec. 6 has
easy-to-understand inspection criteria
accompanied with illustrations Fig. 2.
The other area of concern for the
inspector is color or discoloration of the
inside diameter. Contained in AWS
D18.1/D18.1M, Fig. 3 shows dif ferent
levels of discoloration. This illustrated
example needs to be reviewed by all
parties to determine the desired
maximum discoloration that will be
allowed on the project. The inspector
should not be determining the quality in
this case; however, advising the owner
that more oxidation typically leads to
reduced corrosion-resistant properties is
appropriate. But again, the inspector
should not determine quality levels.
Systems as these can carry varied levels
of corrosive media that need to be
addressed by the owner s responsible
engineer.
Just from personal experience, I
typically see discoloration quality of 3
and less acceptable and easily attainable
with simple industrial grade argon purge
and shielding gas.
Some contributing factors that lead to
discoloration are moisture in the gas or
on the materials to be joined;
particulates from cleaning, and of f
gassing of cleaning solvent residue on
surfaces to be joined; grade of materials
surface finish; poor purge sealing; and
leaks in hoses and loose connections.
Keep This Standard Handy
This information presented is an
overview of some areas to watch for, and
good practice recommendations. I
recommend any inspector engaging in
this scope should possess and
understand the contents of AWS
D18.1/D18.1M.
Just think.What you inspect might be
the very same equipment that puts food
on your familys dinner table.
Fig. 3 Levels of discoloration.
MICHAEL LANG is chairman of
the AWS D10 Committee on Piping and
Tubing and a member of the AWS D18
Committee on Welding in Sanitary Applica-
tions.
It Used
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Enerflex General Manager
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For the full
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specialists
in 3D profiling
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Lang 4-13 IT._Layout 1 3/19/13 2:27 PM Page 20
Feature
By Chris T. Brown
Each day, inspectors perform
thousands of weld and component
inspections utilizing various inspection
methods including visual, liquid
penetrant, magnetic particle,
radiography, and ultrasonic techniques.
As inspectors we go through rigorous
training, experience requirements, and
qualification to become certified in our
inspection disciplines.
When I have the opportunity to
work with trainees, it seems their focus
and attention to detail is concentrated
and often intense. Their willingness to
seek advice, ask questions, and observe
experienced inspectors at work is
commendable. Typically, without
question, their desire to perform work
correctly, safely, and with confidence is
important to them. They recognize the
importance of what they are doing and
feel their work plays a key role in the
success of the final product.
A great deal of time, effort, and
expense is put into the initial
qualification and certification of these
new inspectors. Hours of book study
and research regarding the various
codes and standards are required to
pass the knowledge-based tests.
Hundreds of hours of on-the-job
training are required to pass the
demonstration tests. Once all of the
requirements for certification are
completed satisfactorily, the inspector
is certified to perform the work. When
a person enters the field as a certified
inspector for the first time everything is
new and can be somewhat
overwhelming. He or she is no longer a
casual observer or trainee collecting
experience hours without
accountability. Instead, the new
inspector now has the responsibility to
sign on the dotted line, to determine
pass or fail.
At this point in a young inspectors
career very little is routine. In fact,
what once appeared to be very simple
as a noncertified individual who was an
observer may seem surprisingly
difficult now that he or she has the
responsibility for acceptance or
rejection. Over a time period that
stretches from weeks to years, an
inspector becomes more experienced
and more confident about the
inspections being performed.
Familiarity with procedures, codes and
standards, and equipment begins to set
in. At some point all of the formal
training, book learning, and absolute
reliance on the codes, standards, and
procedures may become secondary or
even minimized by the experience the
person has obtained. Eventually, the
inspections being performed may
appear to become routine due to the
fact the inspector has performed
similar inspections multiple times,
using the same procedures, equipment,
and acceptance criteria time and time
again.
At some point, the inspector may
have his or her routine pretty much set
in stone with little room for
enhancement or change. Sometimes
Inspection Trends / Spring 2013
21
How to Handle Routine Inspections
Inspectors should not fall into the trap of thinking theyve seen it all before
Fig. 1 Ultrasonic examination being performed on heat exchanger supports.
Even if youve performed similar inspections in the past, you need to properly and
thoroughly prepare for each inspection job.
Brown Feature IT Spring 2013_Layout 1 3/19/13 2:28 PM Page 21
inspectors may even attempt to make
the requirements fit the inspection
technique they have become so
accustomed to in lieu of making the
inspection technique fit the
requirements. This is often done when
the pressures of schedule and cost
influence the work. When that happens,
it is time to step back and really
consider what you are trying to
accomplish.
At some point the inspector may
incorrectly assume that reference to the
codes, standards, and procedures is not
required or becomes less critical
because I have performed this
inspection a thousand times or I
already know what the code says. I
have even heard phrases such as this
is a better method than what the code
requires. Now, dont get me wrong, I
firmly believe there is no substitute for
field experience when it comes to
inspection. I also know that many
individuals are capable of keeping the
code requirements committed to
memory. However, over the years I
have found the best policy is to
challenge my memory by actually
taking the time to study the code book
and associated documents and validate
whether my memory is correct.
Sometimes my memory serves me
well; sometimes I discover my memory
is not quite right. Yes, I admit that I
have fallen into the trap of thinking I
know what the code says. It usually
takes a strong self check to bring me
back to the mentality I had as a new
inspector; that is, to prepare by
studying, asking questions, and
observing the process.
I was fortunate to have been
mentored and to work beside someone
whom I consider to be one of the most
respected and competent inspectors in
the nuclear industry. This individual
has many years of both welding and
inspection experience, and holds
multiple Level III certifications as well
as a welding engineering degree. He is
patient and takes his time to make sure
the job is performed correctly,
efficiently, and safely. He has a
tremendous capability for putting
things in their proper perspective when
it comes to cost, schedule, and safety,
something we all know is difficult to
do when we are up against the wall.
The Need for Preparation
It is hoped each inspector is
thoroughly prepared regarding the
component he or she is called upon to
inspect. The time it takes for proper
and thorough preparation typically
saves both time and money in the long
run Fig. 1. I have always believed
my preparation practices were above
average for performing inspections.
However, I recently had an experience
with a trainee that opened my eyes and
taught me a valuable career lesson with
regard to this topic. I was called upon
to perform multiple ultrasonic
inspections that I felt were going to be
just another set of routine inspections
that would fall within my comfort zone
toolbox of inspections. I had performed
what I thought were similar ultrasonic
inspections in the not-so-distant past.
Within minutes, I had in my mind the
path forward for completion of these
inspections. I immediately envisioned
the required flaw detector, transducers,
calibration standards, acceptance
criteria, qualified procedure(s), etc. I
believed we were ready to move
forward with very little effort.
As with many ultrasonic
inspection jobs, it is great to have a
second set of hands to help out. These
inspections were going to be
performed in a radiation/contaminated
area as well as a confined space. I felt
this would be a great job in which to
utilize the assistance of one of our
trainees, and which would also allow
him to receive some valuable
ultrasonic experience hours.
Whenever I work with trainees, I try
to emulate the methods my mentor
uses. While it would take extra time, I
felt it would be valuable for me to go
through the specification and
associated requirements in detail with
the trainee even though I felt I already
knew the scope and requirements of
the work.
However, within minutes of
reading through the specification, I
realized my first assumptions about
the inspections were off base and I
would need to adjust my path forward.
As we moved into the code
requirements, I again realized that
what I thought I knew was not totally
correct. To my surprise, multiple items
including personnel qualification, and
calibration and equipment
requirements were different from what
I remembered Fig. 2. While the
code requirements were not a great
deal different than my recollection,
had I moved forward without
Inspection Trends / April 2013
22
Fig. 2 Typical ultrasonic examination equipment for applications to the
requirements of AWS D1.1, Structural Welding Code Steel. Dont rely solely on
your memory, check the code requirements.
checking them, I would not have met
the specified code requirements.
At this point, I realized I was in a
serious self-check moment and I
needed to set aside all that I thought I
knew and treat this job as if I was
performing an exam for the first time.
In other words, we verified every
inspection requirement through the
specification, and applicable code and
procedure. Throughout the
verification process multiple questions
arose. After several conversations
with the designer, project engineer,
and other experienced inspectors, we
obtained the required equipment and
updated personnel certifications
through additional testing. In addition,
we made time available to gather
specific information about the welds,
including actual weld prep contours of
the unique joints. Through this
process, we were able to model the
ultrasonic sound paths for coverage
determination and understand the
geometric reflectors expected.
When the time came to do the
actual inspections, we felt well
prepared and ready to perform the
work. While the inspections did not go
off without some hitches, we were not
shocked or surprised by what was
identified throughout the inspection
process.
Lessons Learned
What did I learn through this and
similar experiences?
1. Challenge assumptions and
respect others who challenge your
assumptions even if they appear less
experienced or qualified.
2. Dont be afraid to ask a
question, even if you are the one
expected to know the answer.
3. Just because it is the way we
have always done it does not make it
right or mean the method cannot be
improved upon.
4. Be patient; approach issues
from different angles. Youll find
things do not always look the same
when you observe it from a different
viewpoint.
5. Thorough preparation is the best
path toward speedy inspection.
The bottom line is there is no such
thing as a routine inspection in our
business. Procedures are revised, codes
and standards are updated, and
equipment capability evolves.
Inspection capabilities are improving
every day. Ask yourself the question,
Am I keeping up or am I living in the
past?
Inspection Trends / Spring 2013
23

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CHRIS T. BROWN
(Christopher.Brown@inl.gov)
is ISI/Weld Engineer with the Advanced
Test Reactor, Idaho National Laboratory,
Idaho Falls, Idaho. He is an ASNT Level
III in UT and ET and an AWS CWI.
exempt from safety rules, insurance
requirements, and other responsibilities
that are required of the rest of the
contractors on the job. However, many
inspectors have gotten away with being
negligent in this area, at least until they
get caught or someone gets hurt.
As you can see, there is much to
be considered regarding going into
business for yourself, and there are
many more items that are not discussed
here. Every aspect of setting up your
business is just as important as your
decision to become a CWI.
These concerns should not be
ignored until the IRS is standing at
your door, or until you receive a letter
from someone elses attorney. If you
truly want to be self-employed as a
Certified Welding Inspector then you
need to prove you have the habits and
attitude that truly represent the
profession you are entering from the
very beginning and get your business
set up properly.
You will need to do a lot of
research regarding your location and
application, and there are always
multiple possibilities as to how to
accomplish the task. The question is:
Are you willing to be a businessman as
well as a CWI? If not, you should
probably consider being an employee
in some capacity that requires the
services of an AWS CWI rather than
going it on your own.
BRENT E. BOLING
(inspector@arctechwelding.com)
is president of Arc-Tech Welding, Inc.,
Prescott Valley, Ariz. He is also an
AWS/CWI with a Bolting Endorsement, an
ASNT Level II in VT, and chair of the
AWS Arizona Section.
CUSTOH RPRINTS

T R E N D S
N I R P R H O T SST U C
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4 4 1 9
Boling Feature IT Spring 2013_Layout 1 3/19/13 2:03 PM Page 26
The Answer Is By K. Erickson and A. Moore
Q: What are the primary test result
differences in WPS qualification of
reduced-section tension tests between
AWS D1.1, Structural Welding Code
Steel, and ASME Boiler and
Pressure Vessel Code (BPVC),
Section IX?
A: (from K. Erickson) Both AWS D1.1
and ASME BPVC, Section IX, provide
specific information relative to the
dimensioning of the weld samples prior
to testing, but there are some minor
differences when evaluating the test
results.
AWS D1.1 simply states that the
tensile strength of the base metal
cannot be less than the minimum
specified tensile range of the base
metal used for testing. The base metal
tensile strengths are listed in AWS
D1.1, Table 2.1.
The ASME criteria are more
detailed regarding both the material
type(s) and the temperature, also the
material P-Number type, and thickness
have to be considered.
One key difference is that ASME
does permit accepting tensile values
less than the specified tensile strength
of up to 5%, provided the specimen
breaks either in the base metal outside
the weld or in the weld interface
location.
Before qualifying any weld
procedure, it is imperative that the
correct base materials are confirmed
coupled with the proper filler metal to
be used.
A questionable situation would be to
weld standard A106 Grade C pipe
using a minimum tensile strength of 70
ksi with E6010 (60 ksi) filler metal.
Although it is possible that the filler
metal strength, if welded properly,
could exceed 70 ksi in tensile value, it
is only classified for 60 ksi, which is
less than the tensile strength of the base
material used.
Q: I have three questions regarding
working with the ASME Boiler and
Pressure Vessel Code (BPVC). We are
constructing a large project that
requires us to meet ASME B31.3.
The fluid service is classified as High
Pressure by the owner. The project
involves several contractors, each is
responsible for different parts of the
project. The prime contractor is
doing the welding on site. The prime
contractor has subcontracted a
portion of the work to a sub-tier
contractor who is also welding
onsite. The sub-tier contractor has
subcontracted some of the off-site
work to a different contractor who is
responsible for the fabrication of
skids that are packaged units
consisting of filters, piping, electric
motors and pumps, and the
connecting piping and valves. My
questions are:
1. Can the on-site contractors
utilize the same qualified welding
procedures submitted by the sub-tier
contractor who is assembling the
skids in a shop?
2. If the contractors onsite are not
permitted to use the WPSs submitted
by the skid manufacturer, can they
pool their resources to have a third
party qualify the WPSs so they can
both use the same WPSs on site?
3. Can the on-site contractors, i.e.,
both the prime contractor and the
subcontractor, send their welders to
a third-party testing company to
qualify and certify their welders?
A: (from A. Moore) You have an
interesting situation that is not unique.
As a general principle, the ASME
requires each contractor to qualify and
certify both the WPSs and the welders.
The ASME BPVC is comprised of
several sections, each addresses different
aspects of design, materials selection,
fabrication, and inspection. The sections
are interrelated, that is to say, no one
section is self-sustaining. The
construction codes, that is Section I for
Power Boilers, Section III for Nuclear
Construction, Section VIII for Unfired
Pressure Vessels, etc., refer to other
sections of the code to provide specific
details on the subjects of materials of
construction (Section II), nondestructive
testing (Section V), and the qualification
and certification of welding and brazing
procedures and welders and brazers
(Section IX). The interesting thing about
working to ASME requirements is one
must never forget that the construction
code can and often does modify or take
exceptions to Section V and Section IX.
Back to my earlier statement: each
contractor is always required to
qualify and certify his or her own
welding procedure specifications
(WPS) by testing. That statement is
true. The WPS is qualified by welding
a typical groove detail. The welding
variables used to weld the test coupon
and the test results are recorded in a
document called the PQR. So far, so
good. The conditions and
requirements of how to qualify the
WPS are delineated in ASME BPVC,
Section IX.
Article V of Section IX includes an
exception to the statement I just
made. Article V lists several Standard
Welding Procedure Specifications
(SWPs) that can be purchased from
AWS. The SWPS are exempt from the
tests required in Article I and Article II
of Section IX. There is a condition
attached to using a SWP; basically, the
contractor qualifies a welder who
follows the SWPS to demonstrate they
can implement the SWPS.
Now, going back to the project you
are working on. You state the project
specification specifies ASME B31.3
and the fluid service is High Pressure.
High Pressure Fluid Service invokes
specific requirements on the contractor
regarding the design, materials of
construction, fabrication, and
inspection. Where B31.3 allows the use
of certain SWPSs that are listed in
Section IX, Article V: B31.3 for High
Pressure Fluid Service does not allow
them to be used. The chapter
specifically states that each contractor
must always qualify the WPSs used
for construction. The only part of the
qualification effort the contractor can
subcontract is the nondestructive
testing and mechanical testing.
The Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specific
informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.
continued on page 30
The Answer Is Moore_Layout 1 3/20/13 8:16 AM Page 27
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continued from page 13
The Answer Is
The welders must be qualified by the
contractor as well. ASME Section XI has
a provision that allows the contractors
who are members of an association to
qualify welders as a joint effort. The
welders so qualified can go from one
participating contractor to another
without having to be requalified each
time. However, there is a condition
attached; each participating contractor
must have a representative present when
the welder is being tested and each
contractor must accept the test sample
and the test results.
It is my understanding of the
requirement that the contractors
representative must be an employee who
is authorized to act in that capacity. In
other words, it is not acceptable for the
contractor to send the welder to a third-
party testing agency to be qualified and
certified unless the contractor has an
employee present to supervise, examine,
and accept the welders test coupon.
Once again, the requirements of
Section IX are modified when the owner
invokes B31.3 and specifies High
Pressure Fluid Service. Once again, the
construction code says the contractor
must qualify and certify the welder. The
welder who participated in the
qualification program previously
described is not acceptable for High
Pressure Fluid Service.
In summary, ASME always requires
the use of qualified welding procedures
and welders.
ASME sometimes permits the use of
SWPSs purchased from AWS.
ASME may permit the welders to be
qualified by others, as in the case
described where all the participating
contractors are present when the welders
are tested.
ASME B31.3 for High Pressure Fluid
Service takes an exception to the use of
SWPs.
My answers to your three questions
are as follows:
1. No, the contractors cannot share
the WPS submitted by one of the
contractors. Quoting from B31.3;
K328.2.2 Procedures Qualification by
Others, Qualification of welding
procedures by others is not permitted.
2. No, for the same reason as above.
3. No, each contractor must qualify
and certify the welders they employ.
Quoting from B31.3; K328.2.3
Performance Qualification by Others,
Welding performance qualification by
others is not permitted.
continued from page 27
Inspection Trends encourages question
and answer submissions. Please mail to
the editor at mjohnsen@aws.org.
KENNETH ERICKSONis manager of qual-
ity at National Inspection & Consultants,
Inc., Ft. Myers, Fla. He is an AWS Senior
Certified Welding Inspector, an ASNT Na-
tional NDT Level III Inspector in four meth-
ods, and provides expert witness review and
analysis for legal considerations.
ALBERT J. MOORE JR. is vice president,
Marion Testing & Inspection, Canton,
Conn. He is an AWS Senior Certified
Welding Inspector and an ASNT ACCP
NDT Level III. He is also a member of the
AWS Certification Committee and the
Committee on Methods of Inspection of
Welds.
pg 30_Layout 1 3/19/13 2:34 PM Page 30
JUNE 2013 54
T
he search for oil and gas has never
been as intense as it is today; the
easy oil has been found. Today, the
search focuses on previously too expen-
sive to obtain oil and gas, specifically
subsea and shale formation drilling.
These new discoveries often involve ex-
posure of equipment to high levels of H
2
S
(hydrogen sulfide) gas, which is highly
corrosive to many materials. To prevent
corrosion on valves, pipes, and other oil
field equipment, the exposure zone is
often protected with a high alloy weld
overlay deposit, for example Inconel
625, through a process known as
cladding. Successful cladding for these
highly corrosive environments requires
near-perfect weld integrity and thorough
weld inspection.
As with all welding, the first yield
quality is extremely important. This is es-
pecially true for cladding because if the
H
2
S can penetrate the high-alloy cladded
material and contact the carbon steel
backing, the underlying material will cor-
rode and failure will occur in time. The
clad deposit is examined using liquid pen-
etrate to ensure that there are no surface
discontinuities, and straight beam ultra-
sonic testing is used to verify the cladding
thickness. If discontinuities are identi-
fied, they must be surgically removed,
and the area prepped for repair welding.
The liquid penetrate examination is then
repeated.
Equipment Selection Is
Critical to Success
Specialized cladding equipment is
used to deposit the weld overlay. Because
of its controlled penetration and high
Cladding Faces the
Challenges of Oil and
Natural Gas Drilling
Cladding a valve body at an intersecting
bore requires tight control of parameters.
Consider these the factors before
setting up a cladding operation
WM. JEFF HOFFART is an automation
specialist with Fronius USA (www.fronius-
usa.com). Fronius International GmbH is an
Austrian-based company with its USA sub-
sidiary headquartered in Portage, Ind. Sales
and Service centers are located in
Chattanooga, Tenn., and Brighton, Mich.
BY WM. JEFF HOFFART
Hoffart 6-13_Layout 1 5/16/13 1:07 PM Page 54
55 WELDING JOURNAL
arc-on time, a welding process of choice
is gas tungsten arc welding (GTAW) uti-
lizing hot wire addition. Most often,
0.045-in. wire is used, but some compa-
nies will also use 0.035- and
1
16-in. wire
diameters. To maximize the weld deposit
quality, pulse welding power supplies are
used for both the GTAW process and hot
wire addition. Although many pulse
welding power supplies are available in
the industry, they are not all created
equal, and close attention should be paid
to the selection process. When Inconel
or austenitic stainless is used for the weld
deposit, the selected pulse power supply
must have a wide range of pulse settings
to enable fine adjustment of the arc. In
addition, the GTAW power supply and
the hot wire power supply are best linked
via software to enable peak performance.
Because of its virtual infinite control, a
digitally designed power supply can pro-
vide the best all-around weld deposit
chemistry and weld bead profile.
Fig. 1 Multiaxis control system for
cladding a valve.
JUNE 2013 56
Precise Placement and
Intersecting Bores
Require Computer Control
Computer-controlled motion equip-
ment ensures the exact placement of each
weld bead and superior control of the
welding process. The equipment must
also be designed to handle high preheat
and interpass welding temperatures. This
is accomplished by utilizing water cool-
ing systems on all critically exposed
equipment torches, boom arms, cam-
eras, etc. Further complicating the equip-
ment design is the welding positioning
accuracy needed to clad valves with mul-
tiple intersecting bores and/or differently
shaped bores.
For example, a valve bore is often po-
sitioned vertically for cladding because
the intersecting bores on the outside of
the valve prevent easy rotational move-
ment in the horizontal position. The in-
tersecting bores require the cladding
equipment to turn off and on at each in-
tersecting point. To handle these differ-
ently shaped bores, intersecting bores,
and/or ring faces, the system must have
a multiaxis control system Fig. 1.
Pipe Cladding
The cladding of pipe provides its own
host of challenges. A variety of pipe
lengths are often clad, with the longest
being 42 ft. When welding pipe, the
square feet of weld deposit can be enor-
mous; therefore, throughput must be
high because the linear requirements in
most applications can be many miles. Re-
quirements of a few hundred feet to more
than 40 miles have been completed
and/or contemplated. Cladding equip-
ment used to clad pipe must use multi-
ple GTAW arcs working simultaneously.
Therefore, the boom arm must be robust,
and a means of visualization is also criti-
cal Fig. 2. All aspects of the equipment
Fig. 3 Cladding control system with monitoring and recording capabilities.
Fig. 2 Pipe cladding system with
visual monitoring.
must be water cooled because weld times
for a single 40-ft pipe can literally be days,
depending on the inside diameter.
Maintaining Quality
Because H
2
S is highly corrosive, weld
integrity must be good, and weld inspec-
tion must be thorough. To ensure the
maximum level of quality, cladding
equipment should offer constant moni-
toring and recording capabilities of all
the welding parameters amps, volts,
wire speed, travel speed, and shielding
gas. If oscillation is used, the stroke width
and stroke speed should also be moni-
tored and recorded.
Some cladding equipment offers vi-
sual monitoring and recording capabili-
ties (Fig. 3), which are highly desirable
especially in situations with poor access
to the weld deposit. Although many
things can cause weld quality issues such
as incorrect welding parameters, dirty
wire or weld surface, etc., the most com-
mon problem is operator error in not en-
suring that the tungsten remains clean
enough to allow a well-defined arc pro-
file and ensure proper weld bead tie-in
and overall profile.
Operating Parameters
A complete understanding of welding
process parameters is essential when per-
forming cladding. Depending on the
cladding application, a wide range of
welding process parameters can be de-
ployed. Once the proper equipment has
been chosen, the optimization of the
welding process variables must be estab-
lished and qualified. See Table 1 for an
abbreviated list of welding process pa-
rameters for hot wire GTAW and the in-
fluence they have on weld quality and
throughput. Please note that this is a gen-
eral overview; welding parameters can be
intermixed to achieve a wide variety of
outcomes.
Is Cladding for You?
With a host of variables to consider,
a company that elects to enter the
cladding business must have a thorough
understanding of the products that will
be clad and the throughput that will be
required to meet their market demands.
Here are just a few examples of the
questions that should be addressed while
investigating equipment options:
What is the desired deposited clad
chemistry?
Is oscillation required?
How many square feet must be clad
in a given time period?
What is the maximum/minimum
bore length?
What is the maximum/minimum
bore diameter?
What shapes of bore and ring faces
must be clad?
What are the number and sizes of
intersecting bores?
For companies contemplating adding
cladding to their capabilities, attention
to detail is imperative to success. Success
or failure will be achieved by how well a
company chooses:
The required cladding equipment
Throughput capability
Durability
Serviceability
Responsiveness of the equipment
manufacturers service support
Preventative Maintenance Schedule
Machine Operators
Minimize turnover
Provide ongoing operator and
maintenance training.
Finally, a company that enters into the
cladding market needs to have someone
available on staff or via supplier or
consultant who has an excellent un-
derstanding of welding parameters
so that the maximum throughput and
overall cladding deposit quality can be
optimized.
Growing Need for
Cladding
Because of the changing demands in
oil and gas exploration, the need for
cladding will intensify in the coming
years. Cladding technology has been ac-
cepted by the industry as the standard
when corrosion is a factor in oil field
equipment design. Successfully applying
cladding material is directly related to:
1) the equipment that is used, 2) the skill
level of the operators to ensure the
proper use of the equipment, and 3) the
development of optimum welding pa-
rameters. If these three specific areas are
properly addressed, the cladding com-
pany and their customers can be ensured
that the maximum cladding quality will
always be deposited.
57 WELDING JOURNAL
Table 1 Process Parameter Infuence on Weld Quality
Welding Parameter Infuence
Welding speed Bead profle and throughput
Balancing welding speed with arc amperage and wire feed speed is critical to
achieving optimum results
Step distance Bead profle in the tie-in zone
Wire diameter Bead profle
Optimizing the wire size to the available heat input provides maximum weld
pool control
Wire feed speed Throughput
Higher wire feeds provide more coverage (in.
2
)
Shielding gas Throughput and bead profle
Some gas mixtures permit higher wire feed speeds because of the melt rate
JUNE 2013 58
T
ube-to-tube sheet mechanized
welding is not new. The technology
originally developed in the
United States has been utilized in the
heat exchanger fabrication market going
back some 40 years. What is new is the
evolution of orbital welding technology
and the role its playing in bringing heat
exchanger fabrication back to the United
States.
Largely due to competitive pressures,
U.S. heat exchanger fabrication began
transitioning overseas about 15 years
ago. Lower labor and material costs
drove companies to look outside the
United States to build these devices. Re-
cently, however, U.S.-based heat ex-
changer fabrication has undergone a
resurgence as newer, larger, and more
complex exchanger designs have come
online and users have demanded an ever-
higher level of performance and quality.
This outsourcing trend took its toll on
tube sheet orbital welding manufactur-
ers. As the outsourcing trend gathered
steam, domestic demand for tube-to-tube
sheet applications dried up, with the first
generation of orbital welding systems
largely disappearing from the market-
place. Now that this fabrication is return-
ing stateside, many progressive compa-
nies are looking at the newest generation
of orbital welding systems to deliver the
speed, quality, repeatability, and rugged
duty cycles needed to remain competi-
tive in a global economy Fig. 1.
Todays orbital
welding systems
deliver the speed,
quality, and ease
of use that can
help companies
stay competitive
BY MARK LESKA
Technology Drives U.S.
Heat Exchanger Resurgence
(MLeska@ehwachs.com) is
senior marketing coordinator,
ITW Orbital Cutting & Welding,
E. H. Wachs/Orbitalum
Products, Lincolnshire, Ill.
Fig. 1 The newest generation of tube-to-tube
sheet welding systems are more compact,
durable, faster, and easier to operate.
Leska Feature June 2013_Layout 1 5/16/13 1:14 PM Page 58
59 WELDING JOURNAL
These orbital welding systems can
help American companies remain com-
petitive in a global marketplace, making
it financially attractive to fabricate in the
United States. This is particularly true
with complex, restricted space or highly
technical exchanger applications. Todays
orbital welding systems are more com-
pact, powerful, durable, faster, and eas-
ier to program and operate than ever be-
fore.
Orbital Weld Preparation
In both manual and mechanized weld-
ing, the quality of the finished weld is di-
rectly related to the quality of the weld
preparation. Rather than using circular
saws with saw guides or grinding wheels
that leave burrs, uneven wall thickness,
melted tube debris, or a crooked cutline,
a precision tube saw such as one of the
GF series from Orbitalum Tools pro-
duces a finished edge that is ready for
many orbital welding applications.
Some applications require squaring
(or facing) the cut edge further. In
Fig. 2 Facing machine tools deliver a perfectly square, burr-free edge with no gaps
or misalignments for orbital welding.
Fig. 3 Full autofacing machine tools such as shown here speed weld preparation on the hundreds of tube-to-tube sheet welds
used in a typical heat exchanger.
these cases, a facing machine tool
is used to create a perfectly square,
burr-free edge, eliminating gaps
and misalignments to ensure the
weld fitup is uniform and consistent
Fig. 2. When the weld joints are
properly prepped, an orbital weld-
ing operator can minimize the weld
rejection rate, making an orbital
saw, tube facer, and orbital welding
system essential tools for mechani-
cal contractors and fabricators.
In specialized tube sheet appli-
cations, a consistent extension of
the tube (stickout) may be re-
quired before the welding process
begins, and here again automation
can be highly beneficial. An exam-
ple is the BRB 2 full autofacing ma-
chine tool, which is designed with
an automatic stop feature to pro-
duce repeatable extension in a pro-
duction setting. This machine au-
tomates the clamping procedure,
rotation speed, and feed rate for
higher productivity than manual
beveling Fig. 3.
E. H. Wachs and Orbitalum
Tools, divisions of ITW Orbital Cut-
ting & Welding, have joined forces
to be a global supplier of orbital
tube and pipe cutting, beveling, and
welding products.
Orbital Welding
Basics
The basic premise of orbital tube
sheet welding is simple utilizing
a standard GTAW process, the
welding torch is mechanically ro-
tated around the tube end while
adding welding wire (strength weld)
or fusion only (seal weld). The or-
bital welding system, through its
programming, maintains the opti-
mum arc to ensure a high-quality,
highly repeatable finished weld. Al-
though its possible for a skilled
manual welder to achieve similar
results, the challenge of producing
consistent, repetitive welds hour
after hour and day after day be-
JUNE 2013 60
Fig. 4 The challenge of producing consistent, repetitive welds
becomes greater if operator fatigue becomes a factor.
Fig. 5 Microprocessor-controlled welding heads shown weld-
ing tube-to-tube sheet on a heat exchanger.
Fig. 6 Split frame rotating ring cutting equipment
sectioning welded shell, leaving a beveled, weld-
ready finish.
comes greater if operator fatigue be-
comes a factor Fig. 4.
A key point to remember is that or-
bital welding systems are mechanized,
and not automatic in the truest sense.
Theyre not AI (artificial intelligence)
smart like in a science fiction movie.
Even the best orbital welding systems are
not a substitute for a skilled welder in
fact, skilled welders become the best can-
didates to quickly master the equipment.
Skilled welders have the ability to
read a weld pool, allowing them to
make any needed adjustments in the pro-
gram development phase. They adapt
quickly to the equipment, in effect be-
coming a supervisor directly monitoring
and managing the welding process as op-
posed to attempting to replicate exact-
ing, tedious, and repetitive eye, hand, and
arm motions.
All the changes a welder normally
makes in a relatively uncontrollable man-
ner regarding amps, arc voltage, wire
feed, and travel speed while manual
welding becomes easily controllable with
orbital welding systems by using inputs
into a prequalified program.
Tube-to-Tube Sheet
Welding Basics
While tube-to-tube sheet welding can
be complex (particularly in the context
of box header applications), the basic
concept is fairly simple: A series of tubes
is welded to a (typically circular) end
plate called the tube sheet Fig. 5. The
61 WELDING JOURNAL
Fig. 7 Flush welds are usually fusion seal welds; recessed and extended
are typically strength welds with wire added.
Fig. 8 Box header applications require custom
length mandrels based on the reach or R dimen-
sion.
Fig. 9 Box header applications
are one of the more difficult
manual welding operations.
entire tube and tube sheet assembly
(called the bundle) is then enclosed in an
outer vessel (called the shell), creating a
finished heat exchanger.
A significant portion of this work is
repair and refurbishing, taking an exist-
ing device, opening the shell, replacing
some or all the tubes in the bundle, and
reinstalling it back into the shell. This
outer shell can be either bolted together
or welded, and is typically reused on re-
pair and refurbishing projects.
For welded shells, exterior-mounted
split frame rotating ring cutting machines
(Fig. 6) and other types of cutting ma-
chines are useful for sectioning (open-
ing) them for repair. These machines
produce a precision beveled, weld-ready
surface that facilitates quick onsite re-
assembly without the hot work permits
torches and hand grinding may require.
Due to the repetitive nature of the
tube-to-tube sheet welding task, heat ex-
changer fabrication and repair is a prime
candidate for mechanized orbital weld-
ing. In building or refurbishing these
components, hundreds and even thou-
sands of tubes require weld prep and
welding. These tube-to-tube sheet welds
generally fall into one of three types:
flush, recessed, or extended, also known
as protruding or stickout Fig. 7.
The flush profile is usually a seal
weld, an autogenous fusion weld with no
filler metal added. Recessed and ex-
tended are typically strength welds,
where filler metal is added for additional
strength or to join dissimilar metals. On
extended profiles, the dimension (D) of
the extension typically must be uniform.
Heat exchanger engineers specify the
weld profile based on the usage and pres-
sures under which the unit will operate.
The high quality and consistency of-
fered by microprocessor-controlled or-
bital welding leads directly to enhanced
productivity with fewer defects. Orbital
welding systems are often the best solu-
tion where repeatability, quality, and
strength of the finished welds are
critical.
Orbital welding systems enhance pro-
ductivity in other less obvious ways. Or-
bital systems allow your entire workforce
the opportunity to deliver near-perfect,
defect-free welds on a consistent basis.
It also frees up welders for tasks that sim-
ply cannot be economically mechanized.
Orbital welding systems are designed to
be operated by workers of all skill levels,
from novices to industry pros, although
training is recommended for every skill
level to minimize the learning curve.
Box Header Applications
A specialized application related to
heat exchanger work is the box header
design, where an outer box used for heat
transfer purposes requires the use of spe-
cialized equipment for mechanized weld-
ing. In this application, the torch must
reach through access holes in the outer
wall of the box, referred to as the plug
sheet, to the inner tube sheet where the
actual weld is performed. This process
requires weld heads with custom length
mandrels for the R or reach dimension
Fig. 8.
Box header tube-to-tube sheet weld-
ing is one of the more difficult manual
welding operations. It requires a high
level of dexterity, skill, experience, and
a dose of patience Fig. 9. In these ap-
plications, orbital welding solutions can
yield improvements in weld consistency
and productivity.
JUNE 2013 62
Complementing our lines of saws and facers, Orbitalum
orbital welders are ideal for beginners and pros alike.
165 & 300 Amp Power Supplies with 10.5 Color Display
Intuitive, Single Knob Control with Auto Programming
Full Range of Welding Heads from .125 to 6 Tube
Powerful 300CA Power Supply for Heavy Usage
Lightweight, Portable, Compact, Easy to Operate
165CA Power Supply with Integrated Water Cooling
Optional Orbitwin Switching Unit - Two Heads, One Power Supply
North American Sales, Service, Parts and Rentals by E.H. Wachs.
These systems are in stock and available for immediate shipment.
For additional information and the name of the Orbitalum
representative near you, contact us at 800.323.8185 or visit us
online at ehwachs.com.
E.H. WACHS | 600 Knightsbridge Parkway | Lincolnshire, Illinois 60069
T: +1.847.537.8800 | F: +1.847.520.1147 | orbitalum@ehwachs.com | ehwachs.com
Cut. Prep. Weld. One Source.
YOU KNOW OUR SAWS & FACERS
NOW EXPERIENCE ORBITALUM
ORBITAL WELDING SYSTEMS
JUNE 2013 74
P
ipeline welding (Fig. 1) is a com-
petitive business, and every con-
tractor must bid aggressively. They
have had to be competitive in their time-
lines for completion and, of course, in
pricing to meet the needs of the financial
constraints often seen today. Contractors
frequently wait long periods from the
time they place their respective bids be-
fore they receive an approval to begin
their portion of the contract. However,
once approval is confirmed, there is often
extreme pressure from many sides to
start and complete the work in a short pe-
riod of time and on budget. To meet these
time and budget constraints, pipeline
contractors must constantly consider
one important measurable function
efficiency.
Efficiency on a Pipeline
Welding professionals are often con-
fronted with the question of improving
efficiency. Whenever a comparison be-
tween welding processes is considered,
the efficiency of the process is crucial to
the final decision. Efficiency can be sim-
ply defined as the amount of work ac-
complished in a given period of time
compared to the total time for the job.
One common standard for efficiency in
welding is pounds of weld metal de-
posited per hour, commonly referred to
as deposition efficiency. This measure-
ment is very useful when comparing one
welding process to another.
Deposition efficiency compares the
actual amount of weld metal in the com-
pleted joint with respect to the total
weight of the electrode used. For exam-
ple, submerged arc welding (SAW) has
a high efficiency, whereas shielded
metal arc welding (SMAW) has a lower
efficiency.
JEFF NELSON
(jnelson@weld.com) is
application manager, Bug-O
Systems, Canonsburg, Pa.
Presented is a look at the special
requirements associated with
welding pipelines
BY JEFF NELSON
Fig. 1 Workers are shown aligning pipe
sections, a critical operation necessary to
ensure proper fitup prior to both manual
and automated welding operations.
Maximizing Pipeline
Welding Efficiency
Bug-O layout_Layout 1 5/16/13 1:25 PM Page 74
75 WELDING JOURNAL
Electrical efficiency how much
electrical power is consumed in order to
perform a given weld is another con-
cern. Both of these efficiency concerns
are readily applied in the fabrication
shop environment, but how does any of
this translate to welding a pipeline?
On a pipeline, efficiency can be
viewed simply as, How many acceptably
welded joints are completed per day.
The critical element in this sentence is
the phrase acceptably welded. As with
all welding applications that are subject
to stringent codes and specifications, it is
important to not just perform a certain
number of welds in the allotted time, but
that the welds made be able to pass the
criteria for acceptability. Therefore, we
have two issues to consider as we ask our
question about efficiency. First, we must
perform the welds as quickly as practical.
Second, every weld must be of the high-
est quality. If both of these criteria are
met, your efficiency will be high.
Making the Weld Quickly
The shielded metal arc process is the
standard used around the world for weld-
ing pipelines. It is a robust process that is
familiar not only to welders, but to many
nonwelders. Most procedures for this
process are prequalified. Prequalified
means there are preestablished welding
parameters that have been found to pro-
duce acceptable quality welds if these
procedures are followed. For pipeline
work, the downhill progression is typi-
cally used. The welders trained to per-
form these welds are masters in their
craft and have outstanding manual tech-
nique and dexterity.
Readily available trade publications
provide us with some basic welding pro-
cedure data for downhill pipe welding.
The root pass is typically performed with
a
5
32-in.- (4.0-mm-) diameter cellulose-
covered electrode. As a rule of thumb, for
a
5
32-in. electrode, the welding time for
one electrode should be approximately
one minute and the length of weld should
be approximately the same as the length
of electrode consumed. Assuming the
typical stub loss for SMAW, the resulting
travel speed is approximately 12 in./min.
Of course, this is very sensitive to the
fitup and the joint preparation, but we
will use this value of 12 in./min only as a
value for comparison (Ref. 1). The face
of the root bead is typically very convex
and must be ground in order to eliminate
the possibilities of slag inclusions during
the next pass. This same electrode is also
used to make the next pass referred to as
the hot pass. The remaining passes,
the fill and cap passes, are typically
made using
3
16-in.- (5.0-mm-) diameter
electrodes.
Let us assume we are welding a 24-in.,
XHY pipe. This pipe has a standard wall
thickness of in. Given that wall thick-
ness, it is common to expect it to require
seven weld passes to fully fill and rein-
force the weld joint. With a 24-in. diame-
ter, we have a circumferential weld
length of approximately 75.4 in. To make
this joint, it is common to have a welder
positioned on each side of the pipe so we
can divide that weld length in half. We
can further assume that as the required
bead width increases as the joint prepa-
ration increases, the welding travel speed
will necessarily be reduced. For our con-
sideration, we will assume a reduction of
10% in travel speed for each successive
pass after the root and hot pass.
In Table 1, Case I, it is shown that the
total arc time for seven passes of SMAW
downhill would be slightly greater than 28
min. This is the actual arc-on time. This
Fig. 2 A welder make a root pass
using a semiautomatic process.
JUNE 2013 76
does not include the time needed to grind
the face of each weld to be certain that
the slag has been completely removed.
Further, these calculations do not include
any time required for the welder to
change electrodes.
Let us now consider an alternate
method to perform this weld. This
method utilizes the combined technolo-
gies of The Lincoln Electric Co. Surface
Tension Transfer (STT) performed
semiautomatically for the root pass along
with a mechanized gas shielded flux
cored arc welding (FCAW-G) process for
the fill and cap passes.
The root pass is certainly most criti-
cal to the integrity of the weld joint
whether performed with SMAW or semi-
automatically Fig. 2. Due to the na-
ture of the handling of the pipes prior to
joining along with the required speed
during the fitting process, the fitup of
every weld joint is inconsistent. Given
this reality of the pipeline, it is therefore
recommended that the weld be per-
formed semiautomatically by hand. As
with SMAW, the unmatched eye-hand co-
ordination and experience of a trained
pipe welder are critical to the success of
the weld. However, since STT provides
higher weld deposition, the typical com-
bined root and hot pass of SMAW is re-
duced to a single pass, which is typically
greater in thickness than the combined
root/hot pass.
The strong and thick root pass will now
allow the FCAW-G process to be em-
ployed using mechanized travel and mo-
tion control. Using a rail-mounted trac-
tor system, the next passes can be made
continuously in an uphill progression
from the bottom of the pipe to the top.
Equipment such as the Piper Bug and
Piper Plus systems from Bug-O Systems
provide continuous control and travel.
Installing either of these systems takes
only a few minutes. They are lightweight,
portable, and easy to pick up and maneu-
ver by one person. Once lifted onto the
rail system, coupled into place and the
welding starts, the system continues with-
out stopping until that pass is complete.
As can be seen in Table 1, Case II, the
actual travel speed for each pass is con-
siderably slower than the corresponding
pass associated with the SMAW down-
hill process (Case I). However, due to the
much higher deposition rate of these
processes, fewer passes are required. The
assumption that travel speed must be re-
duced as the joint width increases is still
valid. As a result of the much higher dep-
osition rate, the time to complete the
weld using the mechanized method is
22.21 min. This results in an improve-
ment of more than 5 min/weld joint. As
in Case I, this is only the time that the
arc is on and weld metal is being de-
posited. Since there are fewer passes, the
total time required to grind the face of
Table 1 Comparison of SMAW and Combined Processes
Case I SMAW Downhill Case II STT Root, Mechanized FCAW-G
Uphill Fill and Cap
Travel Weld Travel Weld
Pass Speed Time Pass Speed Time
(in./min) (min) (in./min) (min)
1 12.00 3.14 1 9.00 4.19
2 12.00 3.14 2 7.00 5.39
3 10.80 3.49 3 6.30 5.98
4 9.72 3.88 4 5.67 6.65
5 8.75 4.31
6 7.87 4.79
7 7.09 5.32
Total Arc Time SMAW 28.07 Total Arc Time STT and FCAW-G 22.21
Note: Pipe diameter = 24 in., circumference = 75.4 in., two welders, all weld lengths = 37.70 in., travel speed reduc-
tion each pass =10%.
Fig. 3 The compact mechanized system
incorporates a pendant that provides full
functional control for the welder.
each weld to remove any traces of slag is
reduced also.
Making a High-Quality
Weld
There are various ways to address the
concerns for higher weld quality. An ob-
vious way is to provide more effective
welder training. This, however, is not as
easy as it might seem, since the success
of training manual welders depends
greatly on the amount of time allowed
and each individuals personal ability.
Another way to improve weld quality is
to mechanize the welding process so that
the welding rod or gun and current can
be computer controlled to ensure the
welds will be consistently duplicated
using the welding procedure approved by
the welding inspector, and client or gov-
erning body on the job.
If high-quality welds can be consis-
tently duplicated, joint after joint, with
fewer defects, cut outs, and repairs,
pipeline construction speeds up, thus sav-
ing time and money. For example, it can
cost a United States contractor $5000 on
average to cut out and repair or replace
a poor weld on a 24-in. pipe. Addition-
ally, it takes hours and two additional
workers to perform this type of repair. If
there are many such repairs to be made
on a large cross-country pipeline, it is
clear how the time lost is a great concern
to meeting the aggressive deadlines con-
tractors often face today. However, the
cost of the lost time for the repairs is not
the only worry to contractors; it is also
the growing dollar cost to perform these
types of repairs.
Since every weld joint must be accept-
able under the specification and code
being applied, the SMA process when ap-
plied to pipe requires exceptionally well-
trained and competent welders. Even
then, defects can result from the numer-
ous stops and starts required for the
welders to change electrodes, or reposi-
tion themselves to continue welding or
relieve cramping caused by uncomfort-
able out-of-position welds. Most pipe
welders can make a stop then restart with
no problem, but these locations are sites
for possible defects. At each of these lo-
cations, there is an increased risk for slag
inclusions and other quality defects that
might have to be repaired at a later date.
By eliminating nearly all of these starts
and stops, a michanized system can vir-
tually eliminate the possibility of these
defects occurring.
Mechanized pipe-welding systems
place the welding operator in a position
as more of an observer and quality con-
troller Figs. 3, 4. While the welders
might still need to get into some of the
cramped and uncomfortable positions,
their role is to monitor and adjust the
weld. The actual welding is performed by
the motion-control of the systems car-
riage and steerable linear weaver using
automatic height control. The welders
job is to steer the welding arc, left or
right, while the automatic height sensing
maintains proper electrical extension.
The welding operator has complete con-
trol of the system to maximize welding
rate and quality.
Qualified welding operators monitor
and control the process, making adjust-
ments as their training dictates. In this
way, all welds are made at the most effi-
77 WELDING JOURNAL
Fig. 4 A welder monitors the operation of a pipe welding machine.
cient rate according to project protocol
and meet preapproved and preset proce-
dures, so as to achieve the highest level
of weld quality.
Improving Pipe Weld
Efficiency and Quality
Simply put, the michanized systems
utilize a set of rails that clamp onto the
pipe to guide and a computerized, auto-
mated welding carriage system travels the
rails to weld the fill and cap passes. The
Piper Bug and Piper Plus systems utilize
a wire feeder and Lincoln Electric Power
Wave power source capable of produc-
ing different types of waveforms. The
systems provide precise, repeatable mo-
tion and path control of the welding
process ensured by a process monitoring
system that provides complete control
over all aspects of the process. This con-
trol increases welding efficiency and the
quality of every weld.
As with any welding process, it is nec-
essary for the welding operator to qual-
ify the weld procedure before starting any
project. This is true for all types of auto-
mated and mechanized systems. The pro-
posed welding procedure will go through
an extensive weld-certification process.
The test welds are inspected and ap-
proved. While developing the weld, all
welding parameters such as wire feed
speed, travel speed, weaving data, etc.,
are stored in the control box. Once ap-
proved, all settings that have been devel-
oped and saved can be stored either
within the box itself or on a standard USB
storage device. These data can also be
saved to a personal computer for per-
manent storage. Additionally, these data
can be loaded onto as many welding units
as is required, assuring the project man-
ager that the parameters used to create
the welds are the same along the entire
string and all welds will be made the same
way.
Whichever system is chosen, it is clear
that the combination of the semiauto-
matic process for root pass welding along
with mechanized FCA welding for the fill
and cap passes can help to improve pipe
welding efficiency through increased
deposition rates and improved weld
quality.
Reference
1. Welding Pressure Pipelines & Piping
Systems, Stick C2.420. 2002. The Lincoln
Electric Co., Cleveland, Ohio.
JUNE 2013 78
June13FAB_Cover.indd 2 5/21/13 11:26 AM
76 The FABRICATOR April 2013
By Steve Massey
S
ubmerged arc welding (SAW) is a welding
process that can deliver high deposition
rates and deep penetration at a very rapid
pace. Heavy-duty fabricators, such as those that
work with fat plate, girth welds in pipe, and spiral
pipe mills, have embraced the technology to help
them optimize production.
Of course, metal fabricator are always looking
for increases in productivity. Te goal is simple:
If a company can increase the number of jobs on
the shop foor, it can bring in additional revenue to
grow the bottom line.
A metal fabricators doesnt have to look far to
fnd technology advancements that can help it
boost the performance of its SAW process. A few
techniques, such as increased stick-out, twin-wire,
and tandem welding, are widely used and proven in
production environments to help meet increased
productivity goals.
Looking Behind the Flux
Before discussing those production enhancement
approaches, however, it might be helpful to un-
derstand just what is occurring during the SAW
process.
Te welding process frst emerged in the 1930s as
a means to weld straight-line seams on pipe. It grew
in popularity because of production benefts that
couldnt be matched by welding processes that
were more manually intensive.
Like many other welding processes, SAW begins
with an electrode that extends from a contact
tube. A solid wire or a cored wire can be used for
this process. If cored wire is used, the SAW equip-
ment typically doesnt need any modifcations
when compared to the solid-wire equipment set-
up. Cored wire may deliver higher deposition rates,
and the powder inside the wire infuences welding
chemistry and mechanical properties of the joint,
which may not be possible with solid wires.
An electric current passing between the elec-
trode and the workpiece creates an arc that melts
the wire, the metal surface, and the fux. Te fux is
the granulated material that feeds through a hop-
per tube and is deposited right before the actual
welding zone. As the fux is consumed, it protects
the welding pool from the outside environment
and also may impart characteristics to the fnal
joint.
Typically, an automated carriage is used to move
the welding torch and fux hopper tube steadily
down the welding seam. Likewise, automated wire
feeding and voltage and current control are nec-
essary to maintain precise control of the welding
parameters. SAW can be done manually, but those
applications are very rare nowadays. Tose weld-
ers experienced in running this type of operation
semi-automatically are few in number, and those
that can are nearing retirement.
As the welding torch moves ahead, the fux is
melted and solidifes to form slag on top of the just-
welded bead. Tis slag has to be removed, either
with a simple hammer-like tool or an automated
surface preparation tool.
SAW benefts are pretty evident. Te controlled
process leads to a high-quality and repeatable weld
with little risk of incomplete fusion because of the
deep penetration. It delivers a high deposition rate,
as high as 100 pounds per hour when using mul-
tiple electrodes. Te fux helps to eliminate weld
spatter and fumes. Travel speeds for SAW can reach
up to 150 inches per minute.
Sticking With Stick-out
Metal fabricators looking for a low-cost produc-
tivity boost might want to consider increasing
stick-out (see Figure 1)the distance between the
contact tip and the workpiece. Tis enhancement
technique is as simple as it sounds, and operation-
ally it is identical to regular SAW (see Figure 2).
Increased stick-out,
twin-wire welding,
and tandem welding
can boost productivity
of a process already
known for high
deposition rates
Figure 1
Deposition rates for submerged arc welding can be in-
creased by simply extending the length of the electrode.
to boost
submerged arc
welding performance
w
a
y
s
Welding
Wire
Wire Feed Unit
Metal
Flux
Power
Source
Flux
Hopper
Figure 2
A metal fabricator electing to use the increased stick-out
method will fnd that it is nearly identical to a typical
single-wire SAW operation. Similar solid or cored wires
can be used, as well as a DC power source.
April13FAB_SubmergedArc.indd 76 3/21/13 11:07 AM
April 2013 The FABRICATOR 77
Typically, stick-out for SAW is 0.75 to 1.5 in. More
stick-out might call for the distance to be increased
to 2.25 in.
When increased stick-out is applied, the welding
wire is preheated because of the increase in resis-
tance from the wire being exposed. Tis results in
an increase in wire feed speed for a given current
level, which translates into a higher deposition rate.
From a technical point of view, the rate of heat gen-
eration is governed by the I
2
R principle, where I is
the welding current and R is the resistance of the
welding wire from the contact point to the arc.
Taking an increased stick-out approach might
cause some to worry about the wire being unable
to maintain strict alignment with the weld line. But
that isnt a concern with the development of non-
conductive materials that provide consistent elec-
trode placement. Tese nonconductive tips look
very similar to regular contact tubes, but come in
various lengths, depending on how much stick-out
is used. Tey come with an adapter that allows
them to screw into the normal tip location on the
torch.
Taking on Twin-wire Welding
Fabricators still looking for even higher deposition
rates may want to consider twin-wire welding (see
Figure 3).
Tis technique calls for feeding two electrodes
through one wire-feeding unit and into the same
welding pool (see Figure 4). Both wires are fed at
the same speed and have the same electrical po-
tential. AC or DC power can be used, depending
on the combination of deposition and penetration
required for the application.
Twin-wire welding can be used on a typical 1,000-
amp power supply that would normally be used
for single-wire SAW. Also, this twin-wire approach
does not require any more fux when compared to
the single-wire method.
Te additional wire can present some difculties,
but fabricators dont have to worry about feeding
complications. Te wire-feeding unit contains a
third drive roll mounted on the shaft to create an
additional groove for feeding the second wire.
Keeping the wires in line with the direction of
travel can be a challenge. Adding wire straighteners
can help address this issue.
Metal fabricators can tweak the wire spacing
by changing the contact block between the wires.
Contact blocks of diferent dimensions are avail-
able for changes in wire spacing.
Tackling Tandem SAW
For even greater deposition rates and more control
of the welding process, metal fabricators might
fnd tandem SAW to be the right productivity en-
hancer (see Figure 5).
Tandem SAW typically has at least two indepen-
dent arcs operating in the same weld pool and po-
sitioned to follow the direction of the torch. Each
wire relies on its own feed unit. Up to fve arcs
could be applied in tandem to achieve substantial-
ly higher deposition rates (see Figure 6).
With this method, a metal fabricator can control
each wire independently and even operate one in
DC and the other in AC or variable polarity. For
example, one of the most common applications
is to use DCEP on the lead arc to achieve greater
penetration and AC on the trail arc for increased
deposition. Some systems even can operate both
arcs in AC.
Advanced control technology is not necessary
to run this multiarc process if a DC lead and AC
trail are used. In fact, well-defned welding pro-
cedures and an experienced welder running the
equipment are the keys to getting the most out of
this SAW process.
Tese three productivity enhancements for SAW
can help a metal fabricator address a need to boost
productivityor perhaps even address a change
in mechanical properties of a weld, if necessary. A
thorough knowledge of the application, desired
outcomes, and process variations can help a metal
fabricator make the best decision when it comes to
improving SAW performance.
Steve Massey is engineering manager, arc welding
and materials, EWI, 1250 Arthur E. Adams Drive,
Columbus, OH 43221-3585, 614-688-5000, www.
ewi.org.
Metal fabricators looking
for a low-cost productivity
boost might want to consider
increasing stick-out
the distance between the
contact tip and the workpiece.
Figure 3
Specialized equipment simplifes the potential complex-
ity of feeding two wires into the same weld pool during
SAW.
Welding
Wire
Welding
Wire
Wire Feed Unit
Metal
Flux
Power
Source
Flux
Hopper
Figure 4
With two wires feeding into the same weld pool, this
SAW process can lead to deposition rates 20 percent to
30 percent higher than traditional single-wire SAW.
Welding
Wire
Welding
Wire
Welding
Wire
Welding
Wire
Wire Feed Unit
Wire Feed Unit
Metal
Flux
Power
Source
Power
Source
Flux
Hopper
Figure 5
Tandem SAW represents a higher capital equipment in-
vestment for metal fabricators when compared to ba-
sic single-wire and twin-wire SAW, but the potential for
greater deposition rates and the ability to tailor the weld
are attractive to some larger companies. For example,
tandem SAW is more commonly found in industries such
as shipbuilding and pipe manufacturing.
Figure 6
Because of the independently controlled arcs, tandem
SAW can lead to deposition rates that are almost dou-
ble that of single-wire SAW.
April13FAB_SubmergedArc.indd 77 3/21/13 1:34 PM

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