Académique Documents
Professionnel Documents
Culture Documents
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
2% Thoriated
CONTENTS
32
38
42
Features
Departments
32
38
42
Lights, Camera...Welding
There are all kinds of welding going on in the movies
S. Skrjanc and G. Coleman
48
51
Editorial ............................4
Washington Watchword ..........6
Press Time News ..................8
International Update ............10
News of the Industry ............12
Business Briefs ..................20
Brazing Q&A ......................22
Aluminum Q&A ..................24
Product & Print Spotlight ......26
Coming Events....................54
Certification Schedule ..........60
Welding Workbook ..............62
Society News ....................63
Tech Topics ......................64
Guide to AWS Services ........84
Personnel ........................88
Welding School Profiles ........96
Classifieds ......................118
Advertiser Index ................120
On the cover: A custom trophy fabricated at the Warner Bros. Studios Metal
Shop in Burbank, Calif.
WELDING JOURNAL
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Nigel Scotchmer
Chair, WEMCO
APRIL 2014
Officers
President Dean R. Wilson
Welldean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Vice President John R. Bray
Affiliated Machinery, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
U. Aschemeier (Dist. 7), Miami Diver
R. E. Brenner (Dist. 10), CnD Industries, Inc.
D. J. Burgess (Dist. 8), University of Tennessee
N. C. Cole (Past President), NCC Engineering
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (At Large), The Harris Products Group
J. Knapp (Dist. 17), Gas and Supply
T. J. Lienert (At Large), Los Alamos National Laboratory
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), K. A. Phy Services, Inc.
W. R. Polanin (At Large), Illinois Central College
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
R. W. Roth (At Large), RoMan Manufacturing, Inc.
N. Saminich (Dist. 21), NS Inspection and Consulting
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
J. Stoll (Dist. 18), Bohler Welding Group U.S.
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), Ford Motor Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Wright Welding Technologies
YOU LISTENED.
YOU DELIVERED.
CONGRATULATIONS
VICTOR 100TH
ANNIVERSARY
CONTEST WINNERS!
WASHINGTON
WATCHWORD
BY HUGH K. WEBSTER
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
APRIL 2014
PRESS TIME
NEWS
Air Products Dedicates New Pipeline Training Facility
Air Products recently dedicated a new pipeline
safety training facility in La Porte, Tex., allowing for interactive training of its pipeline technicians who regularly install, inspect, and maintain the companys pipeline operations worldwide. Its being dedicated to Thomas D.
Fritsche, a 36-year company employee and
pipeline specialist who initiated the concept.
There are approximately 60 tasks performed
at specific times on our pipelines, with most requiring hands-on training. This facility will allow
our global pipeline technicians to receive necessary training, and to do so in a safe manner
Air Products employees check for an
without having to use active pipelines serving
electrical short on a pipeline flange at
customers, said Richard Boocock, vice presithe companys training site in La Porte,
dent, Global Operations at Air Products.
Tex. (Image courtesy of Air Products
The facility has a sampling of all the required
and Chemicals, Inc.)
tasks a pipeline technician would come across
in the pipeline environment, including associated welding, brazing, and ultrasonic testing; a
customer industrial gas delivery and meter station; cathodic protection; buried pipeline
probing and foreign pipeline crossing; and a pipeline coating station. Additionally, it
features working with automatic shut-off valves, so in the event of a disruption, these
can be turned off to isolate certain pipeline segments needing attention.
MEMBER
APRIL 2014
INTERNATIONAL
UPDATE
Technology Institute Installs
Energy-Reducing Upgrade
$82 million
$758 million
$1.1 billion
$8.2 billion
$578 million
$953 million
10
APRIL 2014
$2.8 billion
$370 million
$2.39 billion
$2.6 billion
$765 million
In 2010, the manufacture and application of joining technology represented $90.1 billion and provided employment to 1.2
million people in the EU;
In terms of production values, for devices and systems, total
production for the joining sector represented $11 billion, a
growth of 6% since 2007, of which 74% ($8.2 billion) was represented by welding, brazing, and cutting; 10% ($1.1 billion) by
robot systems; and 7% ($758 million) by adhesive bonding;
Production values for complementary goods and services
amounted to $10.4 billion, a decline of 42% from 2007, of which
welding consumables represented 27% ($2.81 billion), adhesives 25% ($2.57 billion), and gases 23% ($2.39 billion);
In terms of employment by application of joining technologies, out of a total of 1.2 million employees, 647,000 people
were employed as welders, 311,300 as welding inspectors,
researchers, designers, trainers, and robot operators, and
165,900 were joining-related personnel.
The study highlighted the relevance of the industry and its
role in increasing the competitiveness of companies worldwide.
NEWS OF THE
INDUSTRY
OSU, EWI, and U-M Cofound High-Tech Manufacturing Institute
The Ohio State University (OSU), along with Columbus-based
EWI, and the University of Michigan (U-M), are cofounders of a
consortium of universities, companies, and nonprofits that will establish a $148 million high-tech manufacturing research institute,
the White House recently announced. The institute will be based
in metropolitan Detroit.
The American Lightweight Materials Manufacturing Innovation Institute is expected to create 10,000 new jobs in the Midwest
in the next five years.
The Department of Defense awarded the team $70 million for
the new institute. Also, the state of Ohio has committed $10 million, and the OSU College of Engineering has committed $5 million. The remainder of the $148 million for the institute will come
from other team members.
We are proud to be working with such an outstanding founding group in establishing this important national institute, which Ohio State Welding Engineering Assoc. Prof. David Phillips
will bring together resources from industry, government, and aca- demonstrates robotic welding of lightweight metals.
demia to enhance the regions competitiveness, create opportunities for students, and generate economic growth, said OSU Interim President Joseph A. Alutto.
U.S. Senator Sherrod Brown and Representatives Joyce Beatty and Steve Stivers led letters in support of the proposal, signed by
Senator Rob Portman and Representatives Pat Tiberi, Tim Ryan, David Joyce, Bob Gibbs, Bill Johnson, and Brad Wenstrup.
In addition to EWI, OSU, and U-M, the team includes more than 50 other members.
Researchers at OSU and EWI will be engaged in executing research projects in collaboration with the government and industry
partners, training the next generation of workers in lightweight manufacturing, and transitioning results of their activities to commercial firms across the state and region.
The welding program at Tri-County Technical College is getting a boost from the shareholder-funded Duke Energy Foundation. The $50,000 grant will enable students to train and learn
skills in an accelerated one-year model that focuses on real-world
applications used in local industries.
continued on page 14
12
APRIL 2014
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PERFE TRAININ
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/ Training is what Fronius University is all about. We strive to keep our classrooms small and our material fresh;
allowing for a more personalized training environment. Students can expect interactive lectures, hands-on experience,
department (systemsupport.usa@fronius.com) for more information; we will go over our standard classes, or help
you put together a customized training package to meet your welding needs. Perfect training leads to perfect welds.
www.fronius-usa.com
www.facebook.com/fronius.usa
For Info, go to www.aws.org/ad-index
Works and SMF, recently located in this area, giving our graduates more job placement opportunities.
A $50,000 grant from the shareholder-funded Duke Energy Foundation will help Tri-County Technical College welding students. Pictured (from left) are Dr. Ronnie L. Booth, president of Tri-County;
Scott Miller, district manager for Duke Energy; George Acker, S.C.
vice president of external relations for Duke Energy; Paul Phelps,
welding program coordinator at Tri-County; and W. H. (Ham) Hudson, chair of Tri-Countys Commission.
Implementing an accelerated training program allows students to complete welding training in one year vs. the current
two-year degree model. It also requires dedicated space as students spend more lab time to achieve this one-year completion,
according to Paul Phelps, welding program coordinator.
Tri-Countys welding program is located at the Industrial Technology Center facility in Sandy Springs, S.C.
This grant will help meet the training needs of our 120 welding students and the workforce needs of our manufacturing partners, said John Lummus, vice president of economic and institutional advancement. Two new companies, McLaughlin Body
14
APRIL 2014
The University of Central Floridas (UCF) NanoScience Center, Orlando, Fla., is developing a program to make a graphenebased spray coating that would help industries fight corrosion.
We can use graphene and composite materials to produce
new ways for automotive, aerospace, oil and gas, the military,
and even the medical industries to take advantage of this extremely powerful material, said Sudipta Seal, director of the
NanoScience Technology Center and Advanced Materials
Processing Analysis Center.
The programs goal is to provide a cost-effective, large-area
polymer/graphene-based coating technology to strengthen mechanical components such as materials used for constructing aircrafts and cars, plus project materials such as gas and oil pipelines
from corrosion.
Garmor, Inc., a UCF spinout company that has licensed technology developed by NanoScience Center researchers Richard
Blair and David Restrepo, will assist with formulating the
graphene oxide. In addition, NanoScience Professor Lei Zhai
will focus on developing the material to host the graphene and
ensure the graphene keeps its electrical and mechanical performance when embedded.
Industry Notes
Sales Engineer Samantha Noland recently led a nexAir training seminar with instructors from Delta Technical College, Mississippi. She reviewed pulse welding and advanced technologies, different equipment characteristics, and left room for
Q&A. The instructors commented having a hands-on demo
following the presentation helped reinforce learnings.
Gdel, Inc., has transitioned all manufacturing of its thirdgeneration robot tracks for domestic markets to its headquarters in Ann Arbor, Mich. While some initial Trackmotion Floor
modules were fabricated and machined in Switzerland, the entire product line is now built in the United States.
Comau, Inc., Southfield, Mich., has been chosen by Elio Motors as its automation partner to provide powertrain and automated assembly systems for building its three-wheel vehicle.
Comau Body Welding Systems will design, build, and install
systems to assemble the vehicles welded space frame and apply
interior/exterior composite body panels to the frame.
WELDING JOURNAL
15
I want to encourage you to submit nomination packages for those individuals whom you feel
have a history of accomplishments and contributions to our profession consistent with the standards
set by the existing Fellows. In particular, I would make a special request that you look to the most
senior members of your Section or District in considering members for nomination. In many cases,
the colleagues and peers of these individuals who are the most familiar with their contributions, and
who would normally nominate the candidate, are no longer with us. I want to be sure that we take
the extra effort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nomination process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issue
of the Welding Journal. Please remember, we all benefit in the honoring of those who have made
major contributions to our chosen profession and livelihood. The deadline for submission is July 1,
2014. The Committee looks forward to receiving numerous Fellow nominations for 2015
consideration.
Sincerely,
Thomas M. Mustaleski
Chair, AWS Fellows Selection Committee
Fellow Description
DEFINITION AND HISTORY
The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for
distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional
stature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of the
individual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by:
Sustained service and performance in the advancement of welding science and technology
Professional recognition
RULES
1.
2.
3.
4.
5.
6.
7.
NUMBER OF FELLOWS
Maximum of 10 Fellows selected each year.
Description of significant technical advancements. This should be a brief summary of the candidates most
significant contributions to the advancement of welding science and technology.
Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited
in (1). Where possible, papers and articles should be designated as to whether they were published in
peer-reviewed journals.
Inventions and patents.
Professional recognition including awards and honors from AWS and other professional societies.
Meaningful participation in technical committees. Indicate the number of years served on these committees and
any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.).
Contributions to handbooks and standards.
Presentations made at technical conferences and section meetings.
Consultancy particularly as it impacts technology advancement.
Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology.
Participation on organizing committees for technical programming.
Advocacy support of the society and its technical advancement through institutional, political or other means.
Note: Application packages that do not support the candidate using the metrics listed above
will have a very low probability of success.
Supporting Letters
Letters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These
letters should address the metrics listed above and provide personal insight into the contributions and stature of the
candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.
Return completed Fellow nomination package to:
Wendy S. Reeve
American Welding Society
Senior Manager
Award Programs and Administrative Support
8669 Doral Blvd., #130
Miami, FL 33166
Telephone: 800-443-9353, extension 293
SUBMISSION DEADLINE: July 1, 2014
CLASS OF 2015
BUSINESS
BRIEFS
CRC-Evans Celebrates Grand Opening
of New Offshore Division Headquarters
Recent Acquisitions
The CRC-Evans Offshore team poses in the foyer of its new headquarters in Alness, Scotland.
CRC-Evans Pipeline International, Inc., recently celebrated
the grand opening of its new Offshore Division Headquarters in
Alness, Scotland. The two-story building features four wings and
a customized branded design. In addition, product samples and
demonstrations are available throughout the space with video
monitors showing presentations on notable projects.
Guests included CRC-Evans senior staff members and all local
company offshore employees. Stanley Oil and Gas President Jim
Cannon was also in attendance with the Scottish Governments
Minister for Energy, Enterprise and Tourism, Fergus Ewing, who
unveiled a commemorative plaque at the ceremony.
This signifies our growth within the Offshore Division, and
is a time to acknowledge every person, every joint welded and
coated by our teams in projects across the globe that have made
this day possible, said Cannon.
APRIL 2014
BRAZING
Q&A
Q: When we brazed Inconel 718 components in our vacuum furnace, the initial
results were marginal at best. The parts
are not bright and the filler metal did not
flow well. Someone suggested we may need
to more effectively clean the furnace prior
to brazing and use some titanium material as a getter in the furnace beforehand. Please explain what a getter is, and
how its use may help us.
A: By definition, a getter is a deposit of reactive material that is placed inside a vacuum system for the purpose of completing
and maintaining the vacuum. When gas
molecules strike the getter material, they
combine with it chemically or by adsorption. The use of clean titanium as a getter
prior to vacuum brazing sensitive base
metals is recommended, since all vacuum
chambers have leaks from the many fittings, connections, and seals.
Clean titanium machine turnings (Fig.
1) make excellent getters because they
present extensive surface areas to react
with any oxygen present in the vacuum
chamber.
The metal/metal-oxides curves (Fig. 2)
charts vacuum furnace temperature vs.
vacuum pressure. Each curved line charts
a particular metal oxide. The chromeoxide (Cr2O3) curve near the center of the
chart indicates we can get rid of Cr2O3 if
we are positioned to the right side of the
Cr2O3 curve. Thus, a vacuum furnace operating at about 2000F (1100C) and at a
vacuum level of about 101 torr, would
thermodynamically reduce (get rid of)
the oxide of chromium, leaving the
chromium free to alloy with the BFM.
Note that this chart also indicates that
operation at temperatures to the left of
the Cr2O3 curve is more oxidizing, i.e., the
combination of temperature and vacuum
level is not sufficient to remove oxides, but
is high enough to cause significant formation of that metal oxide. Thus, during
heating in a vacuum furnace, the oxides
continue to form as the metal gets hotter.
The rate of oxide formation slows down as
it approaches the oxide line for that metal,
and then as it moves to the right side of
that oxide line, only then can that particular oxide be reduced.
Notice the oxide curve for titanium
(TiO curve) indicates that as titanium
heats up in a vacuum furnace it will
steadily oxidize, but for that oxide to be
eliminated it must get to the right-hand
side of that curve. If you operate the vacuum furnace at about 104 torr, it would
have to run above 2700F (1500C) to accomplish that. This is not possible in shop
22
APRIL 2014
BY DAN KAY
vacuum brazing furnaces, therefore, when
titanium oxidizes in such a furnace, it will
hold onto that oxide layer strongly.
This is the reason titanium is an effective getter. By placing titanium in the vacuum furnace chamber, it will steadily oxidize during heating, removing much of the
oxygen present in the chamber. Since that
oxygen is tied up as an oxide on the titanium surface, it is not available to oxidize
the parts being brazed in the furnace. The
larger the surface area of the titanium exposed to the furnace atmosphere, the
greater will be its oxygen-scavenging capability, which is why titanium turnings
(Fig. 1) are more effective than the titanium pieces; and titanium-sponge materials work even better Fig. 3.
During vacuum furnace cycles, some
contaminants will outgas from the parts
being brazed and condense on the chamber surfaces. The outgassed materials may
come from brazing-paste binders (organic
materials) or some of the alloyed metallic
components in the base metals or from the
BFMs. When reheated in subsequent furnace runs, these contaminants may
revolatilize off the furnace walls and contaminate the parts being brazed.
Because of the high reactivity of titanium to many of these outgassing contaminants, titanium can be a very effective
getter of these materials when any of these
contaminants come in contact with titanium in the furnace chamber. Although
pure titanium would be optimal, any titanium alloy can be used with great effectiveness as a getter. And, since the TiO
curve is so far to the right side of the
Fig. 3 Ti sponge exposes the most surface area for maximum gettering effect.
side their hot zone during the brazing run,
to further protect the parts being brazed.
This is also quite acceptable if you want to
do that.
Note, it is important to prevent the titanium getter material from coming into
direct contact with any nickel-containing
metals, including stainless steels, since this
may cause a eutectic reaction between the
titanium and nickel. A low-melting eutectic alloy can readily form at about 1750F
(955C) when titanium and nickel alloys
touch. You can use ceramic (alumina)
sheets or crucibles to keep these metals
separated.
Following our first furnace cleanup
cycle, we discard the dark titanium turnings then repeat the cleanup cycle using a
fresh load of titanium turnings. These usually come out much lighter in color than
the turnings in the first run. When necessary, for a very dirty furnace, we run a third
cleanup cycle using fresh Ti turnings with
a thin sheet of titanium placed on top of
the turnings. If that titanium sheet can
then be folded back on itself without
breaking, we know the vacuum chamber is
very clean.
For further reading, see Vacuum Heat
Treatment by Daniel H. Herring, 2012,
Getter Materials, pp. 305309; BNP
Media II, LLC.
WELDING JOURNAL
23
ALUMINUM
Q&A
Q: Is there a reference source where I
can find information about the chemical
composition, mechanical properties, and
possibly other physical characteristics of
the various aluminum alloys and product
forms? I am looking for something that
will help me evaluate aluminum alloys to
select the most appropriate alloys and
tempers for use in specific welded fabrication applications.
BY TONY ANDERSON
Temper Designation Systems for Aluminum,
which provides a detailed description of
how the alloy and temper system is used.
The Aluminum Association is the registrar under this system with respect to the
designation and composition of aluminum
alloys and tempers registered in the
United States. It is also the registrar under
an international accord on the composition and designation of registered wrought
aluminum alloys.
This section provides great detail relating to the wrought and cast alloy designation system, and includes information
on temper designations for both strainhardened and thermally treated tempers.
This section also contains information on
the metallurgical aspects of aluminum,
nominal chemical compositions, AA
wrought alloys and similar foreign alloys,
specification cross reference, and mill
product specifications.
2. Typical Properties
24
APRIL 2014
WELDING JOURNAL
25
Podcast Explores
Nationwide Helium
Shortage
The Jackson Safety Hard Hat Interchange System allows for the quick insertion/release of a welding helmet or face
shield without users needing to remove
their hard hat for performing different
tasks. As an example, a worker can remove
the faceshield for cleaning then reposition it once done, or a welder can switch
from a welding hood to a faceshield when
moving from welding to grinding. The system also keeps users compliant with ANSI
Z87.1 2010 and features one-button action for quick release, vertical lock-in to
eliminate helmet/face shield creep, and
an audible click to ensure the user knows
their personal protective equipment is assembled correctly.
Kimberly-Clark Professional
www.kcprofessional.com
(800) 241-3146
26
APRIL 2014
The ATB AirBalancer is a lifting device that aids picking, lifting, moving, and
placing items by hand. Smooth operation
offered by the pneumatic powered mover
make it useful for assembly processes, repair, and industrial production tasks. In
addition, it meets needs with movement
speeds up to 2000 mm/s, and an automatic
load balancing feature allows operators
to move the load in zero-gravity mode. It
offers weight compensation for pre-
Revised Standard
Promotes Safer Facilities
The American National Standard for
Safe Use of Lasers (ANSI Z136.1), updated for the first time in seven years, is
now available for ordering. The standard
guides the safe use of lasers and laser systems by defining control measures for the
seven laser hazard classifications. Highlights include 19 new definitions of key
terms, an updated section on special qualifications for medical-related exposures,
A
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The Tweco Fabricator 141i, a multiprocess welding machine, runs off 115V household power and is useful for home
WELDING JOURNAL
27
and examples involving new exposure limits. The newly revised standard can be obtained from the information below.
The Laser Institute of America
www.lia.org/store
(800) 345-2737
The companys new nine-piece maintenance set includes a 10-in. flat bastard,
8- and 10-in. flat smooths, 10-in. mill bastard, 8- and 10-in. half round bastards, 10in. round bastard, 8-in. shoe rasp, and 6in. slim taper. The tools, enclosed in a convenient plastic pouch with reinforced
slots, are useful for general sharpening
and maintenance around the garage, work
sites, or manufacturing plants.
www.jtillman.com
(800) 255-5480
Mercer Abrasives
www.mercerabrasives.com
(800) 221-5202
Website Provides
Resources for Cutting
Tool Users
WELDING DOCUMENTATION
SIMPLIFIED
Prowrite
welders
Wps - Pqr - wpq
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Smart software. Serious service.
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APRIL 2014
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WELDING JOURNAL
29
Manufacturing
Flux Cored
Welding Wire
Cobalt
Nickel
Hardface
Stainless
Alloy Steel
Tool Steel
Maintenance
Forge Alloys
Custom Alloys
COR-MET, INC.
12500 Grand River Rd.
Brighton, MI 48116
PH: 800-848-2719
FAX: 810-227-9266
www.cor-met.com
sales@cor-met.com
For info, go to www.aws.org/ad-index
30
APRIL 2014
Hollywood Spotlight
Shines on Welding
toric origins date back to the 1920s, current physical production facilities on the
110-acre lot consist of 29 soundstages
with a 20-acre backlot. A complete production resource, its all hustle and bustle as golf carts pass by carrying tourists,
and fast-paced workers head to various
locations.
Many TV sitcoms and dramas either
had been (ER, Friends, Gilmore Girls) or
currently are filmed on the premises (The
Big Bang Theory, Hart of Dixie, The Mentalist, Mike & Molly, Pretty Little Liars,
Shameless, Suburgatory, Two and a Half
Men, 2 Broke Girls). Daytime and nighttime talk shows are also recorded there,
including The Ellen DeGeneres Show
and Conan.
Scenes from several movies Blazing Saddles, Camelot, Ghostbusters, Juras-
APRIL 2014
BY KRISTIN CAMPBELL
Robin, Batman, and Superman are prominently featured in this Hall of Justice
three-story billboard along with Daffy
Duck, Sylvester, and Bugs Bunny, plus
other well-known animated characters.
On the WB lot, it covers the exterior of
Stage 3 and is seen daily by thousands
of commuters and tourists.
Fig. 1 From curbside, you wouldnt know whats hidden in this closed-off space, but
an overhead view of the WB Metal Shop reveals its large interior.
Fig. 2 Part of the Metal Shop team, posing on the factory floor in front of a press
brake, are (from left) Erlindo Sunga, Jay Walters, Alfonso E. Montejano, and Michael
Finn. (Not pictured: Miguel Atilano, Rodger Burko, Brant Goldreyer, and Juanita Myers.)
Department Head Jay Walters, originally from Tampa, Fla., started fabricating in high school and later enrolled
in welding classes at College of the
Canyons, Santa Clarita, Calif. He started
his career at the WB Studios in 2000 and
worked his way up from a sheet metal
mechanic to now managing the shop.
The fabrication process starts with a
project meeting, phone call, or a walkin, Walters said. A good percentage of
the shops clients are feature film, tele-
vision, and commercial art directors, production designers, and construction coordinators who will often provide blueprints and/or shop drawings.
Items have also been constructed
from line drawings on paper, hand gestures, and voicemail exchanges.
We do our best to nail down specifics
before the first cut is made, but in the
fast-paced entertainment industry where
turnaround times are always tight and
script revisions are made just days before
The Metal Shop employs eight people year round, including Walters, a shop
foreman, an assistant foreman, and a
core group of fabricators Fig. 2. When
extra craftsmen are needed, dependant
upon project demands, a union roster is
used for additional hiring.
Well-versed in metal fabrication, the
staff is proficient in performing multiple
processes, including flux cored arc welding (FCAW), gas metal arc welding
(GMAW), gas tungsten arc welding
(GTAW), and shielded metal arc welding (SMAW); various types of cutting;
rolling; braking; and finishing. A few of
the welders hold qualifications from the
American Welding Society and the City
of Los Angeles in SMAW and FCAW.
As to what welding process is selected
for each item, that depends on the job at
hand. While GMAW is used the most,
GTAW is usually chosen for aluminum
and stainless steel, and its typically
FCAW for I-beams.
Some of the craftsmen/welders are
more experienced with particular machines and processes, Walters said, and
are therefore assigned to a project based
on the specifications and need for a specific expertise.
33
Existing Equipment
The shop has a wide equipment range
representing many brands Fig. 3.
When it comes to purchasing new tools
or replacing broken equipment, thats
based on needs. Listed below is a sampling of whats available for use.
Multiple machines to handle FCAW,
GMAW, GTAW, and SMAW
Two lathes, built in the early 1940s
A 50-ton press brake, 10-ft hand box
brake, plus 10- and 8-ft hand brakes
Punch machine with a collection of
round, oval, and square dies
Hand-operated turrit punch
316-in.-capacity shearing machine
Rolling machine for tube, T, angle,
and flat bar with a capacity of up to 3
3 38
12- and 22-gauge sheet rollers
18-gauge hand crank bead roller
with a collection of dies
16-gauge circle cutting machine
Bandsaws for aluminum and steel,
plus cold, wet, and jig saws
Plasma cutting machine
Oxyacetylene torches
Drill presses
Ironworking and bending tools
Coring rig with bits from 2 to 8 in.
Electric and air-powered grinders.
34
APRIL 2014
Fig. 3 Michael Finn sets the cut depth on a shearing machine before using it on perforated mild steel. He has been with the shop for ten years and likes the creativity aspects that go along with what he does. The personal fulfillment of building something, Finn said, is also worthwhile.
Fig. 7 Erlindo Sunga uses GMAW on mild steel that serves as the frame for a prison
gate. He began his metal fabrication career at Universal Studios and moved to the WB
Metal Shop in the early 1980s. I love it, Sunga said.
35
Inspection Considerations
As for any examinations that need to
take place on welded fabrications, when
required, a deputy inspector is contracted. Two of the shops welders are
certified by the City of Los Angeles as
well to perform that type of work.
In-House Work
Welders at the shop have used their
skills in multiple ways not only to create
segments and displays on the WB lot, but
also for maintenance responsibilities.
Following are a few significant examples.
Superheroes Billboard
Off-Site Projects
Fig. 9 This table represents an example of the intricate custom furniture the shop
fabricates.
36
APRIL 2014
Late last year, an exhibit made promoting The Hobbit: The Desolation of
Smaug movie was installed near the TCL
Chinese Theatre at the Hollywood &
Highland Center Fig. 11. The dark
green scenery featured a sprawling arch
and dwarf statues as well as a throne and
columns with faux gold coins.
We did all the structural framing,
Walters said. He recalled putting bases in
order with 12-in. hot rolled plate; D-rings
of 2-in. tubes to schedule 80 pipe; and lifting points. On smaller parts, GMAW was
used; for bigger sections, SMAW was employed with 7018 electrodes.
This collaborative effort required as-
Fig. 10 There are many elements on the WB lot that the welders have created, including exterior monument signs for all the studio gate entrances. This one shown before being painted identifies gate 2.
sistance from many WB groups, including architectural and scenic art divisions, plus working off-site during
numerous late nights/early mornings.
Fig. 11 This Hobbit exhibit at the TCL Chinese Theatre, seen during installation, has dark
green scenery with an arch entrance and dwarf statues, plus a throne at its center and
columns containing faux gold coins.
WELDING JOURNAL
37
The Future of
Welding Education
A longtime educator sheds light on the
importance of welding to manufacturing
and the economy, and what path welding
education should take
BY W. RICHARD POLANIN
W. RICHARD POLANIN (rpolanin@icc.edu)
is professor and program chair, Manufac
turing Engineering Technology and Weld
ing Technology, Illinois Central College,
East Peoria, Ill. He is also an AWS
DirectoratLarge.
U.S. Manufacturing a
Critical Economic Sector
Unfortunately for the U.S. economy,
manufacturing jobs have continued to decline during the past three decades. Manufacturing as an economic sector provides wage and benefit structure above
the national average. Further, manufacturing better ensures a middle class. In
their book Manufacturing Matters, pub-
Based on the Plummer Memorial Education Lecture presented November 19 during FABTECH 2013, Chicago, Ill.
38
APRIL 2014
Development of Technical
Education
How will welding educators develop
the needed welding professionals? A
look at the evolution of technical education and learning theory provides suggestions for the future.
Development of
Learning Theory
As Western governments tried to mass
educate their citizens, schools for all ages
were organized. And, at the dawn of the
Industrial Revolution, companies tried
to mass train workers. The great exodus
from agriculture to manufacturing
began. During the Industrial Revolution
in Europe and North America, a large
need for educated and trained workers
resulted in significant changes in the
strategies for technical and, in part, liberal arts education.
To improve the efficiency of manufacturing output, both manufacturing and
education methods transformed. The
early part of the twentieth century also
gave rise to scientific studies into the way
we believed knowledge and skill was constructed and retained. Systematic approaches to studying human learning and
behavior ushered in the modern era of
educational thought. Specific schools of
educational thought began to form. Behaviorism, cognitive science, and constructivism treated the development of
knowledge and skill in different ways.
However, the formation of each school
of educational thought ensured that the
study of human learning would continue
to improve our ability to develop better
human learning methods.
Once again, education reformers developed improved methods for content
delivery and class organization. In the
Use of Information
Technology in Education
Newer schools of educational thought
provide guidance to how technology is
used to develop knowledge, especially
those schools that believe information
technology is an important part of modern educational methods. There is little
doubt that information technology and
communication systems have changed
the way we communicate. Yet, incorrect
knowledge and inappropriate use of
these systems remains a major challenge
to educators.
The use of information technology
systems provides an unbounded opportunity for educators in all disciplines to
help their students know more, find
more, and practice more, both guided by
the teacher and independently. The ability to instantly retrieve knowledge and
information on any subject allows teachers to challenge their students to achieve
at unprecedented levels.
No longer does acquisition of knowledge require a school, teacher, or book.
Anyone with access to the Internet, a
smart device, and the desire to learn
can obtain knowledge. Yet, when massive
open online course data are analyzed, an
interesting trend is revealed. The percentage of those who complete these
courses is dismally low, even for courses
offered by established universities.
Online courses require a set of specific skills including motivation, written
communication skills, and, of course,
computer navigation and typing skills.
Verification of completion of the course
remains another hurdle. Students applying for employment often need documentation of completion. Although
badges and certificates may be given by
organizations offering online learning,
only established colleges and universities
can provide online transcripts.
For welding jobs requiring technical
skills, proof of course completion or certification is required. But, for welding
skill jobs, a performance test is likely required. Online experience and virtual
welding experience does not give the
prospective employee the actual under-
WELDING JOURNAL
39
The author and students work to complete a hardness survey for a welding procedure qualification record.
the-hood experience needed to be successful when completing an entry-level
employment test or qualification test. Although virtual welding can help a welding student verify angles, hand positions,
and travel speeds, virtual welding is not
a substitute for guided practice and the
subtle changes in technique an experienced teacher can suggest.
Welding instructors have an opportunity to utilize online content from electrode and equipment manufacturers,
professional organizations, including
American Welding Online offered by the
American Welding Society, and do-ityourself welders. However, guidance by
an instructor ensures the information
gathered from online sources is accurate.
APRIL 2014
Success of Welding
Education
Welding education and technical education in general are uniquely situated in
America to accomplish improved student
achievement unlike many other general
education disciplines. Motivating students to achieve is often a balance of student readiness and the ability of a teacher
to articulate a clear skill and the path to
acquire that skill. Welding educators have
the opportunity to influence students to
Works Consulted
1. Cohen, S. S., and Zysman, J. 1987.
Manufacturing Matters. New York, N.Y.:
Basic Books, Inc.
2. Hanushek, E. A., Peterson, P. E.,
and Woessmann, L. 2012. Achievement
growth: International and U.S. trends in
student performance. Harvard Kennedy
School, PEPG Report No. 12-03.
3. Economic Modeling Specialists International. 2012. Occupational Report.
National Center for Welding Education
and Training, Elyria, Ohio.
4. Bureau of Labor Statistics. 2014.
Occupational Outlook Handbook. Washington, DC: U.S. Department of Labor.
5. Organization for Economic Cooperation and Development. OECD skills
outlook 2013: First results from the survey
of adult skills. OECD Publishing.
See Us at FabTech
Booth C3049
Call 800-544-5438 or
visit www.almmh.com
WELDING JOURNAL
41
Lights, Camera...Welding
Skilled fabrication crews creatively
hold production together in
Hollywood and beyond
APRIL 2014
Fig. 3 Some cars are fabricated entirely from the ground up while others are
modified from existing platforms.
43
Time Is Short
On top of the obvious challenges of
creatively designing and combining
aspects of different vehicles into one to
make them function as needed for filming, Moser, Clarke, and Pearson face
an even tougher hurdle tight time
constraints.
We sometimes have less than a week
to build a fleet of cars that need to be
done perfectly, on time and on budget,
Moser said. Sometimes we have to do it
overnight. There are times when our
welding machines run 24 hours a day to
meet production schedule demands.
For the film Looper, on which both
Moser and Clarke were involved, fabrication teams had five days to create
unique hover motorcycles (Fig. 4), a
process that involved from-scratch
design and a lot of cutting, welding, and
fabrication.
Clarke and Moser said they turned to
Lincoln Electric equipment for this job,
as well as other work that required intensive, constant welding on such substrates
as aluminum. They relied on Lincoln
Electrics Precision TIG 375 gas tungsten arc welding (GTAW) machine
for this high-visibility, fast-turnaround
project.
We need equipment that is reliable.
We cant have something breaking with
the kind of turnaround times we face,
Moser said. In this industry, there isnt
something called downtime.
APRIL 2014
Fig. 5 A set of prop vaults was fabricated in aluminum and prepared to look like
heavy wall steel for the 1995 Warner Brothers film Heat.
Bringing Toy
Legends to Life
One of the big advantages of fabricating for the entertainment industry
is the variety of projects that come your
way. In Los Angeles fabricator Paul
Clarkes case, he was given the opportunity to help bring the dream cars of
many a little boy to life, creating fully
functional, life-sized versions of popular Mattel Hot Wheels cars.
Mattel uses these cars for a variety
of promotional purposes, including
meet-and-greets at auto shows and
other live events and in videos on its
Hot Wheels website.
Clarke has worked on at least five
different Hot Wheels projects under
contract with PCW Brands, a sister
company to Northridge, Calif.-based
Picture Car Warehouse
One of those closest to his heart is
the Bone Shaker (Fig. 1) a replica
created from the ground up.
These toy cars only have exterior
features, none of which is appropriately sized for a real automobile,
Clarke said. You cant just scale your
design off of the toy. So you have to
start asking yourself questions, like,
How big would it be in real life? and
What kind of interior would it have?
We built it from scratch, Clarke
said, noting that his team created the
cars entire interior, based on its skeletal theme Fig. 2. We thought this
looked like a car from hell on the outside, so we wanted to be sure it looked
like that on the inside.
We built it as though it was a living, breathing entity, Clarke said.
This one is special.
Fig. 1 Built entirely from the ground up, the Bone Shaker is a fully
functioning car.
Fig. 2 The fully custom interior includes a number of features that extend the
skull-related theme of the car.
WELDING JOURNAL
45
Beyond Hollywood
While Hollywood remains the heart
of the U.S. entertainment industry,
changes in the economic environment increasingly have pushed film production
into states other than California, thanks
to tax breaks and other financial incentives. This means some of the work goes
to shops in other states, making businesses such as Pearsons find other ways
to land contracts and keep up with their
craft.
We no longer survive off of movies,
television commercials, and rock videos,
Pearson said, noting that his company has
branched out to creating sets and trusses
46
APRIL 2014
BY BILL WEHRMAN
This team of students put in extra hours to create a 6-ft alligator from scrap metal,
which sold for $200. Shown from left are Matthew Focht, Brett Eschliman, Instructor Curtis Willems, Zach Benn, and Jack Daniel.
Building Teams
One such enlightened instructor is
Curtis Willems, agricultural-education
instructor and National Board Certified
teacher at Highland High School, located
in the Phoenix suburb of Gilbert, Ariz.
He teaches two courses: introductory and
advanced Agriculture Fabrication and
Engineering (Ag Mechanics).
In our shop, students work in teams
of five people on a regular basis, said
Willems. Every semester, we also try to
work on a project as a class. Having 30
individuals work as a group helps kids un-
BILL WEHRMAN is communications manager, Victor Technologies, St. Louis, Mo., www.victortechnologies.com
48
APRIL 2014
Instructor Curtis Willems (far right) uses cutting and welding projects, such as the one that created this sculpture, to build
teamwork. Shown from left are Garrett Shafer, Ryland Barney, and Cody Gifford.
Extra Credit
To create a project outside of class,
each student puts in 25 to 30 hours of additional work. The potential to earn extra
WELDING JOURNAL
49
Brett Eschliman, shown cutting, said the key to teamwork is pitching in whenever
someone needs help. Eschliman, a student in the advanced Ag Mechanics class,
works with Juli Horvath to improve her oxyacetylene skills.
By the time these sophomores and
juniors finish the 2014 school year, We
have a head start on students who get a
bachelors degree and dont know what
to do with their lives, said Gifford. We
know right now some of the skills
well need for later, and that gets us
ahead of almost everyone else. Plus, its
good to learn welding as a life skill so you
dont have to hire people to fix stuff for
you. You can do it yourself.
Some of these students already have
a plan for what later involves. Gifford
intends to go to a welding school and
work for a fabrication shop near his
house. Shafer plans to explore machining at a technical college, and Daniel is
confident hell work in the construction
field. My dad, a career welder, told me
that welding would teach me a lot about
hard work, building, materials, measurements and reading blueprints, said
Daniel. All those skills transfer over into
other well-rounded careers, and it will
certainly give me better insight into construction.
Focht learned about Ag Mechanics
after an eighth-grade field trip to Highland High School. He thought the welding and plasma cutting were really cool
and signed up for what turned out to be
his favorite class. Unlike his classmates,
Focht does not plan an industry-related
career. He plans to attend Texas A&M,
go through its ROTC program and enter
the military as an officer. He does, however, clearly see the value of a welding
class.
Mr. Willemss class and these weld-
50
APRIL 2014
ing contests emphasize hard work, teamwork, and problem solving, said Focht.
Being an officer involves problem solving in terms of leading people and understanding that when stuff doesnt go
the way you planned it, you overcome the
challenge and accomplish a mission.
Appreciation
As is often the case with technical
classes, the requirements of the fabrication process inherently force students to
realize the value of their academic classes.
Through teamwork, Matt Focht, Jack Daniel, and Brett Eschliman (shown from left)
created this giant oxyacetylene torch and used a weed burner to simulate the flame.
Welding Personnel
Qualification the
European Way
The European Welding Federation aims through its
training and qualification programs and industry
partnerships to remove barriers to industry growth
ince the birth of the iron age, humans have been joining metals.
Welding played a critical role in the
industrial age as an enabler in the success of many industries that still thrive
today. Its pervasiveness has increased
with the discovery of new materials and
alloys that have created countless new
possibilities for the development of products in several industries, ranging from
healthcare to heavy manufacturing such
as the new class of super container vessels, the Triple-E. In most developed
countries, organizations have been created to support the ever-growing utilization of welding technologies. As a result
of the growing integration of countries
into the European Union, organizations
that would provide international support
for national members have been created.
One such organization is the European
Federation for Welding, Cutting and
Joining (EWF), www.ewf.be, a leading institution driving the qualification and
certification of professionals and companies. The EWF counts as its members the
welding institutes of Europe, which were
at its inception looking for opportunities
to harmonize the way qualification of
personnel in welding technology was
achieved in different countries.
This harmonization was the start of a
comprehensive training, qualification,
and certification system currently covering more than 30 qualification levels and
more than ten certification levels in a
wide range of professions in welding,
joining, and cutting technologies, a core
BY LUISA QUINTINO
LUISA QUINTINO (MLQuintino@isq.pt)
is executive director, EWF/IIW-IAB
Secretariat, Tagus Park, Portugal.
its inception has been to look for partnerships and opportunities that would
drive adoption and qualification of welding technologies to ensure that the new
technologies would be met by workers
possessing the required qualifications
and training.
That has been done both by pursuing
R&D projects linking industry and its associations, as well as driving partnerships
beyond Europes boundaries, supporting
through its systems the state of the art of
welding and providing best-in-class solutions for training, qualification, and certification. This approach has led to a sys-
WELDING JOURNAL
51
About EWF
The European Welding Federation,
is a pioneer in implementing a harmonized qualification and certification system for welding professionals.
Through European projects such as
Virtweld (virtual systems for welder
training) (Fig. 2), e-Weld (a distance
learning course for welding coordinators), and Weldiction (a dictionary of
welding terminology), EWF has been an
innovator in welding training methodologies. These also include B-Prof, in which
guidelines were developed for recognition of informal training of welders. In
other words, it would develop an integrated, modular system designed to provide necessary qualification to those
workers whose work experience should
be recognized to certify them as welders.
The organization is also addressing
the development of new technologies and
uses for welding through new projects
such as the following:
FlexiFab, a flexible fabrication of lightweight aluminum transport structures
using robotic friction stir welding
EMFWeld, an analysis of workers exposure to electromagnetic fields from
welding and nondestructive examination processes. Development of guidelines for risk assessment and of webbased risk assessment applications
Fig 3.
WeldaPrime, a self-repairable, zincfree, weldable anticorrosion primer for
steel protection
BondTest, an ultrasonic testing technique to characterize diffusion welds
in layered structures
LASHARE, a laser equipment assessment for high-impact innovation in the
European manufacturing industry
TailorWeld, tailored energy distributions for laser welding.
52
APRIL 2014
Manufacturing Rebound
In a recent article by Helmuth Ludwig
and Eric Spiegel published on the Strategy+Business website (www.strategy-business.com), a publication of the global
management consulting firm Booz & Co.,
a compelling case is made regarding the
rebound of the American manufacturing
industry with the benefit, as the article
points out, of a new wave of software innovation. Beyond job creation, manufacturing plays a vital role in promoting in-
apprenticeships and other experiencebased programs that will grow the U.S.
workforce.
Although this particular article is focused on the benefits brought forward by
the software industry, the same can be
said of welding and its application in
manufacturing projects throughout the
world. An easy connection could be made
to specific projects aimed at weight reduction in airplanes, cars, aerospace and
appliances. Each of those industries relies on complex welding technologies to
achieve this goal. That is where the work
being done by EWF and IIW, as well as
all their members, plays a key role by enabling possibilities and opportunities for
companies and welding professionals to
create new and vibrant businesses within
manufacturing, not hampered by a lack
of resources in developing their business
plans. The EWF looks forward to supporting this brave new world of opportunities in manufacturing through its
training, qualification, and certification
systems.
Fig. 3 The EMFWeld project studies the effects of electromagnetic waves in welding.
WELDING JOURNAL
53
COMING
EVENTS
Aluminium Brazil 2014. April 13. Centro de Exposies Imigrantes, So Paulo, Brazil. www.aluminium-brazil.com.
Metal & Steel Saudi Arabia 2014. April 710. Riyadh, Saudi Arabia. Visit www.metalsteelsaudi.com.
FABTECH India colocated with Weld India. April 1012. Pragati Maidan Exhibition Complex, New Delhi, India. Concurrent
with the 2014 Intl Congress of the IIW. Cosponsored by AWS,
FMA, SME, PMA, CCAI, and India Institute of Welding.
www.fabtechexpoindia.com.
April 2426. Savannah, Ga. Sponsored by ITSA, an AWS Standing Committee. itsa@thermalspray.org; www.thermalspray.org.
JOM, 18th Intl Conference on Joining Materials. April 2629.
Konventum LO-Skolen, Helsingr, Denmark. In association with
the Intl Institute of Welding, cosponsored by American Welding
Society, Japan Welding Society, Welding Technology Institute of
Australia, Brazilian Welding Society, and others. E-mail
jom_aws@post10.tele.dk; download brochure at www.aws.org/wj/
JOM-18-CallForPapers.pdf.
Aluminum Conference. April 2830. Hotel Monteleone, New Orleans, La. Sponsored by AWS. Aluminum industry experts will survey the state of the art in aluminum welding technology and practice. Contact P. Henry, phenry@aws.org; (800) 443-9353, ext. 215.
1st Smart Laser Processing Conference 2014. April 2224. Pacifico Yokohama, Yokohama, Japan. Organized by Japan Laser
Processing Society, colocated with Optics & Photonics Intl Congress 2014. www.jlps.gr.jp/slpc2014/.
2830. Atlanta, Ga. Sponsored by AWS and the Resistance Welding Manufacturing Alliance (RWMA), an AWS Standing Committee. Topics will include research results, projects, and industrial
experiences that describe significant advances in resistance welding technology. Visit www.aws.org/rwma, or contact P. Henry,
phenry@aws.org; (800/305) 443-9353, ext. 215.
54
APRIL 2014
JOIN-TRANS3 Third European Conference, Joining and Construction of Railway Vehicles. May 6, 7. An IIW-associated event.
Welding Training and Research Centre, SLV Halle GmbH, Halle
(Saale), Germany. www.jointrans.eu.
mfg4 colocated with MicroManufacturing Conference and Exhibits. May 68. Connecticut Convention Center, Hartford, Conn.
The Society of Manufacturing Engineers; (800) 733-4763;
www.mfg4event.com.
AKL 14, Intl Laser Technology Congress and Expo. May 79.
Aachen, Germany. Visit www.lasercongress.org/en/home/.
MMTS Montreal Mfg. Technology Show. May 1214. Place
Bonaventure, Montreal, Que., Canada. www.mmts.ca.
NDE Aerospace Materials and Structures IV. May 13, 14. Crowne
Plaza Hotel, St. Louis, Mo. American Society for Nondestructive
Testing, (800) 222-2768, www.asnt.org.
Great Designs in Steel Seminar. May 14. Laurel Manor Conference Center, Livonia Mich. Sponsored by The Steel Market Development Institute. Contact Adriana Van Duyn (586) 201-1643;
avanduyn@bianchipr.com.
8th Intl Expo Metal & Steel Middle East 2014/FABEX Middle
East 2014. May 1517. Cairo Intl Convention & Exhibition Center, Cairo, Egypt. Visit www.metalsteeleg.com.
WJS1235
WELDING JOURNAL
55
2325. Indianapolis, Ind. Sponsored by AWS. This program answers questions on the requirements to become an AWS Accredited Testing Facility (ATF), including skills training and curriculum. Contact P. Henry, phenry@aws.org; (800) 443-9353, ext. 215.
Digital Imaging XVII. July 2830. Crowne Plaza Hotel, Warwick,
R.I. American Society for Nondestructive Testing, (800) 222-2768,
www.asnt.org.
continued on page 58
56
APRIL 2014
NDE/NDT for Highways and Bridges: Structural Materials Technology (SMT) 2014. Aug. 2527. Grand Hyatt Washington, Washington, D.C. American Society for Nondestructive Testing, (800)
222-2768, www.asnt.org.
ASNT Annual Conference 2014. Oct. 2730. Charleston Convention Center, Charleston, S.C. American Society for Nondestructive Testing; (800) 222-2768; www.asnt.org.
7th Offshore Energy Expo and Conference. Oct. 28, 29. Amsterdam RAI, The Netherlands. Visit www.offshore-energy.biz.
Educational Opportunities
Acoustic Emission: The PACwin Software Suite. April 1517.
MISTRAS Group, Inc., 195 Clarksville Rd., Princeton Junction,
N.J. www.mistrasgroup.com/training/courses/pacwin.aspx.
ASSORTED PURGE
KITS AVAILABLE
PURGE MONITORS
(OXYGEN TO 1PPM)
58
APRIL 2014
Certified
Certified Weld
Welder
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Welders,
W
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Brazers
B
and
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Operators
Code
Process(
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Thickness,
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CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
SEMINAR DATES
LOCATION
Fresno, CA
May 49
Miami, FL
May 49
Albuquerque, NM
May 49
Oklahoma City, OK
May 49
Corpus Christi, TX
Exam only
Birmingham, AL
June 16
Hutchinson, KS
June 16
Spokane, WA
June 16
Bakersfield, CA
June 813
Pittsburgh, PA
June 813
Beaumont, TX
June 813
Miami, FL
Exam only
Hartford, CT
June 2227
Orlando, FL
June 2227
Memphis, TN
June 2227
Miami, FL
Exam only
Los Angeles, CA
July 1318
Jacksonville, FL
July 1318
Omaha, NE
July 1318
Cleveland, OH
July 1318
Phoenix, AZ
July 2025
Louisville, KY
July 2025
Kansas City, MO
July 2025
Waco, TX
July 2025
Sacramento, CA
July 27Aug. 1
Denver, CO
July 27Aug. 1
Miami, FL
July 27Aug. 1
Milwaukee, WI
July 27Aug. 1
Corpus Christi, TX
Exam only
Chicago, IL
Aug. 38
Baton Rouge, LA
Aug. 38
Portland, ME
Aug. 38
Las Vegas, NV
Aug. 38
Philadelphia, PA
Aug. 38
Charlotte, NC
Aug. 1015
Mobile, AL
Aug. 1015
Rochester, NY
Exam only
Seattle, WA
Aug. 1015
San Diego, CA
Aug. 1722
Minneapolis, MN
Aug. 1722
San Antonio, TX
Aug. 1722
Salt Lake City, UT
Aug. 1722
Miami, FL
Sept. 712
Idaho Falls, ID
Sept. 712
St. Louis, MO
Sept. 712
Houston, TX
Sept. 712
New Orleans, LA
Sept. 1419
Fargo, ND
Sept. 1419
Corpus Christi, TX
Exam only
Pittsburgh, PA
Sept. 28Oct. 3
Long Beach, CA
Oct. 510
Indianapolis, IN
Oct. 510
Tulsa, OK
Oct. 510
Nashville, TN
Oct. 510
Miami, FL
Exam only
Beaumont, TX
Oct. 1217
South Plainfield, NJ
Oct. 1217
Portland, OR
Oct. 1217
Atlanta, GA
Oct. 1924
Des Moines, IA
Oct. 1924
Detroit, MI
Oct. 1924
EXAM DATE
July 19
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the seminar/exam or
exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website
www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept. to confirm your course status before making
travel plans. For information on AWS seminars and certification programs, or to register online, visit www.aws.org/certification or call (800/305)
443-9353, ext. 273, for Certification; or ext. 455 for Seminars.
60
APRIL 2014
WELDING
WORKBOOK
Datasheet 347
Excerpted from the Welding Handbook, Vol. 1, ninth edition, and AWS A3.0, Standard Welding Terms and Definitions.
62
APRIL 2014
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
63
Tech Topics
Underwater Welding and Cutting Subcommittee Meets in New Orleans
The D3B Subcommittee on Underwater Welding and Cutting met in New Orleans, La., to work on the first edition of
A5.35/A5.35M, Specification for Covered
Electrodes for Underwater Wet Shielded
Metal Arc Welding and the 6th edition of
D3.6, Underwater Welding Code. Attending were Chair T. J. Reynolds, Vice Chairs
R. I. Murray and W. J. Couch, and AWS
Staff Secretary B. C. McGrath, AWS Dist.
7 Director U. W. Aschemeier, M. Borean,
G. M. Cain, J. D. Corbin, D. W. Craig, P. T.
Delaune, D. E. Drake, L. Goldberg, S. M.
Henderson, R. D. Holdsworth, B. E.
James, K. S. Peters, M. A. Pett, L. R. Rowland, L. W. Shupe, M. J. Skinkle, P. L.
Smith, W. W. St. Cyr, P. Szelagowski, B. T.
Walden, and T. C. West. Guests attending
the meeting included Michael Hielscher
and Joe Morgans, and member applicant
Martin Denault.
Revised Standard Approved by ANSI
A5.24/A5.24M:2014, Specification for
Zirconium and Zirconium-Alloy Welding
Electrodes and Rods
Standards for Public Review
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute in
1979. AWS rules require that all standards
be open to public review for comment during the approval process. The following
standards have been submitted for review
with the review expiration dates shown.
A5.5/A5.5M:201X, Specification for
Low-Alloy Steel Electrodes for Shielded
Metal Arc Welding. 3/10/14
B2.1-1/8-010:201X, Standard Welding
Procedure Specification (SWPS) for Gas
Tungsten Arc Welding of Carbon Steel to
Austenitic Stainless Steel (M-1, P-1, or M8, or P-8), 18 through 10 Gauge in the AsWelded Condition, with or without Backing. 4/14/14
B2.1-1/8-231:201X, Standard Welding
Procedure Specification (SWPS) for Gas
Tungsten Arc Welding with Consumable Insert Root followed by Shielded Metal Arc
Welding of Carbon Steel (M-1/P-1, Groups
1 or 2) to Austenitic Stainless Steel (M-8/P8, Group 1), 18 inch [3 mm] through 112 inch
[38 mm] Thick, IN309, ER309, and E30915, -16, or -17, or IN309, E309(L), and
E309(L)-15, -16, or -17, in the As-Welded
Condition, Primarily Pipe Applications.
4/14/14
C3.12M/C3.12:201X, Specification for
Furnace Soldering. 3/17/14
64
APRIL 2014
Members of the AWS Technical (TAC) and International Standards (ISAC) Activities Committees are shown during their meeting held Jan.
29, 30 at AWS World Headquarters in Miami.
AWS Counselor Robert Paul Matteson (center) is shown with AWS President Dean Wilson
(left) and Don DeCorte, an AWS past director-at-large. On Feb. 21, Matteson was formally
recognized for his induction into the 2014 Class of AWS Counselors during the WEMCO and
RWMA annual meeting held in St. Petersburg, Fla. Matteson, who spent most of his 50-year
career heavily involved in the RWMA (Resistance Welding Manufacturing Alliance) committee work and standards, received the award from Wilson and DeCorte in the presence of about
one-hundred association members, family members, and guests.
WELDING JOURNAL
65
Member-Get-A-Member Campaign
Listed below are the members participating in the 2014 AWS Member-Get-AMember Campaign. The campaign runs
from Jan. 1 through Dec. 31, 2014. Members receive five points for each Individual Member recruited and one point for
Gentry Wood
Gentry Wood,
AWS University of
Alberta
Student
Chapter, has been
nominated by Chapter Vice Chair Jordan Tsui to receive
the AWS Student
Chapter Member
Award.
Gentry
served as 20132014
Chapter chair and
66
APRIL 2014
Member Counts
March 1, 2014
Sustaining ......................................606
Supporting .....................................330
Educational ...................................676
Affiliate..........................................560
Welding Distributor........................47
Total Corporate ..........................2,219
Individual .................................59,690
Student + Transitional .................9,777
Total Members .........................69,467
AWS MEMBERSHIP
MEMBERS
ERSHIP APPLICATION
APPLICA
ATION
AT
4 Easy Ways to
o Join or Rene
Renew:
Mail: Form with your paymen
yment, to AWS
Online: www
w.aws.org/membership
CONTACT
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Check here if you learned of the Societyy thr
through an AWS Member? Memberss name:_______________________Member
name:_______________________Members # (if known):________
wn):________
Check here if you would prefer not to receive email updates on AWS programs,, new Member benefits
benefits, savings opportunities and events.
INDIVIDUAL MEMBERS
MEMBERSHIP
B
H
HIP
Please check each box that applies too the Membership or service
ser youd like,, and then add the cost
c together to get your Total Payment.
AWS INDIVIDUAL MEM
EMBERSHIP (One Year)..................................
Ye ..................................................................................................$84
................................................................$84
AWS INDIVIDUAL MEM
Years) SAVE $25 New Members Only....................................$143
EMBERSHIP (Two Ye
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Selections: WHH (9th Ed., Vol. 4) WHH (9th Ed., Vol. 3) WH (9th Ed., Vol. 2) WHH (9th Ed., Vol. 1)
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PHB-1 (Arc Welding Steel) PHB-2 (Visual Inspection)
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standar benefit for all student members.
STUDENT MEMBERSHIP TO
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PAYMENT
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Petroleum & coal
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Primaryy metal industries
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Machinery except
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Electrical equip.,., supplies
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Transportation
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SECTIONNEWS
District 1
BOSTON
FEBRUARY 5
Activity: Tom Ferri, Dist. 1 director, presented Scott Bengtson his Silver Member
Certificate Award for 25 years of service
to the Society.
CENTRAL MASS./R.I.
FEBRUARY 13
Activity: The Section hosted its fifth annual vendors night event at Greater New
Bedford Vo-Tech in New Bedford, Mass.
Shown at the Green & White Mts. tour are from left (front row) Justin Doty and Juan Contreras, (second row) Joshua Martin, Paul Martell, William Lima, Alex Fuller, Edgar Moldonado, Maduwa Hakazimana, Billy Drummond, Nyvek St. James, and Savannah Ford, (back
row) Jim Blanchard, David Rumph, Nathan Tracanna, Erica Flett, Jesse Lund, Jared
Rodgers, Darrell Brown, Cory Wilson, Justin Dodge, Chad Laundry, and Kyle Freeman.
CONNECTICUT
FEBRUARY 11
Speaker: Albert Moore, Senior CWI
Affiliation: Marion Testing & Inspection
Topic: Field repair of a 63-ton steel casting
Activity: This was a joint meeting with the
local ASM International chapter, headed
by Chair Sam Christy.
69
Parkside High School Student Chapter SkillsUSA contenders are from left (kneeling) Travis
Patten and Nick Parrish, and (standing) Daniel Churchill, Ryan Bell, Brandon West, Jacob
Doll, judge Chris Thompson, Daniel Filippelli, Advisor Biazzio Giordano, and Ty Hagel.
Shown at the Parkside CTE Student Chapter food drive are (from left) Jacob Doll, Treasurer Richard Mullins, Co-Chair Daniel Filippelli, and Advisor Biazzio Giordano Jr.
MAINE
JANUARY 23
Activity: The Section held its annual vendors night program at Southern Maine
Community College hosted by Mark
Legal, welding department head instructor. The companies making presentations
included Airgas, Thermadyne, Lincoln
Electric, ESAB, and Matheson Gases.
District 2
Parkside CTE
Student Chapter
JANUARY
Activity: Advisor Biazzio Giordano Jr. or-
70
APRIL 2014
PHILADELPHIA
JANUARY 8
Activity: South Jersey Welding Supply
hosted this event featuring demonstrations
of the latest technology in welding equipment by Charles Minnick, training director for the Miller Welding Technology
Center, who display a hobbyist model machine, and Tim Stout, a Miller district manager, who detailed a heavier-duty portable
welding machine. Attendees included
welding students from Camden County
College, and Jessica Mendoza who signed
the presentations for the hearing-impaired
attendees. Welding student Bart
Przeomiec won the door prize.
Shown at the Atlanta Section event are (from left) Ryan Blythe, Chair David Ennis, Zach
Myers, Sylvia Imm, Ankur Gupta, Tim Imm,and Garrett Nesmith.
District 3
District 4
SOUTHWEST VIRGINIA
JANUARY 30
Activity: The Section held a program on
welding titanium highlighted by a live teleconference feed from the Miller Electric
TIG Welding Unit in Appleton, Wis. The
presenters included District Manager Paul
Cseko, Regional Sales Manager Keith
Rzucidlo, and Representatives Mark
Kadlec, and Devan DePauw.
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
ATLANTA
JANUARY 23
Activity: Hope Peterson, Go Build communications manager, and Ryan Blythe of
Georgia Trade School, hosted this program at the school in Kennesaw, Ga. Peterson discussed the Go Build Georgia
program. Zach Myers, Kimberly
Clark/Jackson Safety Co., discussed corporate sponsorship for training and welding school programs.
Shown at the Florida West Coast Section program are (from left) Chair Charles Crumpton
III, Dist. 5 Director Carl Matricardi, and presenters Ray Monson and Albert Carr.
71
Holston Valley Section members are shown during their RCAM tour November 12.
The Holston Valley Section members are shown at the Omar Awning Co. in December.
Shown (from left) are South Carolina Section Chair Gale Mole, presenter Robert Harrison, and Ben Magrone, vice chair.
72
APRIL 2014
Nashville Section members are (from left) Daniel Stinson, Elizabeth Surface, Bob Williams, Don Yarbrourgh, Robert ONeal, Chris Ennis,
speaker Dusty Moore, Jerry Burke, Ronnie McCrary, Jonathan McDonald, Matt Montoya, and Michael Piercey.
SOUTH CAROLINA
PITTSBURGH
JANUARY 30
Activity: The Section visited Alpha Sheet
Metal Works in Ladson, S.C. Robert Harrison, welding foreman, conducted the
tour.
FEBRUARY 18
Speaker: Bob Stachel, executive VP
Affiliation: HRV Conformance Verification Associates
Topic: Construction of the Verrazano Narrows Bridge in New York
Activity: The program was held at Springfield Grill in Seven Fields, Pa.
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
District 7
COLUMBUS
NOVEMBER 20
Speaker: Ted Amlin, senior engineer
Affiliation: Parker Hannifin Corp.
Topic: High-pressure pipe couplings for
subsea environments
Activity: The program was held at Parker
Hannifin Corp. in Columbus, Ohio.
JANUARY 15
Speaker: Gary Katz, assoc. research fellow
Affiliation: Abbott Nutrition
Topic: Innovation! From Idea to Store
Shelf
Activity: The meeting was hosted by Abbott Nutrition in Columbus, Ohio.
District 8
CHATTANOOGA
JANUARY 23
Speaker: Gale F. Audier, wealth manager
Affiliation: Cartwright Hitching & Frazier
Topic: Financial advice for home-buying
and retirement planning
Activity: The program was held at Public
House in Chattanooga, Tenn.
HOLSTON VALLEY
NOVEMBER 12
Activity: The Section members visited the
Regional Center for Advanced Manufacturing (RCAM) in Kingsport, Tenn. Welding Instructors Jeff Frasier and Jon Cookson led the tour of the welder training facilities that include virtual arc welding
training equipment. The dinner was held
at Mamas House Restaurant.
DECEMBER 10
Activity: The Holston Valley Section
toured Omar Awning Co., in Johnson City,
Tenn., to study its aluminum welding and
fabrication facilities. Hosting the event
were Manager Bo Bennett and Welding
Specialist Tim Taylor. The dinner was held
at Harbor House Restaurant.
NASHVILLE
JANUARY 23
73
Mobile Section Secretary Brenda Amos displays the Sections banner at the January program.
Shown at the New Orleans Section sponsor-appreciation award presentation are (from left)
Dist. 9 Director George Fairbanks, Chair Aldo Duron, and ESAB representatives Tyler Vial,
speaker Jay Grinder, Kevin Meibaum, and Alyssa Templeton.
Shown at the Northwestern Pennsylvania Section program are (from left) Treasurer Marty
Siddall, speaker Wyatt Swaim, Chair Tom Kostreba, Secretary Don Adams, and Donna
Bastian, vice chair.
District 9
MOBILE
APRIL 2014
JANUARY 9
Speaker: Ryan ODell, district manager
Affiliation: Miller Electric
Topic: Semiautomatic pipe welding
Activity: Following the talk, ODell
demonstrated various pipe welding techniques assisted by Branden Muehlbrandt,
NEW ORLEANS
FEBRUARY 18
Speaker: Jay Grinder, applications engineer
Affiliation: ESAB Welding & Cutting
Topic: Flux core wire welding
Activity: ESAB sponsored this meeting at
the Landmark Hotel in Metairie, La., for
74 attendees. George Fairbanks, Dist. 9
director, and Chair Aldo Duron presented
Paul Hebert the District Director Award.
The Section Sponsor Award was presented
to ESAB representatives Tyler Vial, Jay
Grinder, Kevin Meibaum, and Alyssa Templeton. Brant Zeller discussed the Sections 16th annual fishing rodeo to be held
May 3 at C&M Marina in Laffite, La.
Detroit Section patrons are shown who made generous donations to the Sections scholarship fund during the past year.
Blackhawk Technical College Student Chapter members and Edgerton High School students pose with Welding Instructor Joe Mink (left)
and Dan Crifase, Student Chapter advisor.
District 10
DRAKE WELL
FEBRUARY 13
Activity: The Section discussed starting a
Student Chapter at Venango Technology
Center and plans for hosting the District
10 annual conference in Franklin, Pa.
NORTHWESTERN PA.
FEBRUARY 12
Speaker: Wyatt Swaim, a.k.a., Mr. TIG
Affiliation: Weld.com and tigdepot.net
Topic: Motorsports welding and metallurgy
Activity: The meeting was held at Millcreek Mall in Erie, Pa.
District 11
Robert P. Wilcox, director
(734) 721-8272
rwilcox1@ford.com
DETROIT
FEBRUARY 13
Activity: The Section members toured the
Schuler, Inc., facility in Canton, Mich., to
Milwaukee Section members participated in a trivia contest. Shown from left are (standing)
Milan Blagojevick, Tyler Willingham, Nicholas Black, Thomas Johnson, Dan Galligan,
Jennifer Hildebrandt, Tim Keller, Jim Johannsen III, and (front) black-belt winners Kenneth Thomas and Scott Whitman.
study its hot stamping and hydroforming
operations. The presenters included
Daniel Hille, sales and product manager;
Jonathan Ball, sales manager; and Robert
Rich, vice president. The business meeting recognized the Sections patrons who
have donated more than $8500 to its scholarship fund during the fiscal year. The Section announced it has awarded more than
$37,000 in scholarships this year. The Section recognized ten of this years patrons
for their donations to the scholarship fund,
which total more than $8500.
District 12
Blackhawk T. C.
Student Chapter
JANUARY 31
Activity: Advisor Dan Crifase and Chapter members presented Edgerton High
School four welding positioner tables they
WELDING JOURNAL
75
Chicago Section members and guests are shown at the January meeting.
Boy Scouts are shown at the Indiana Sections welding merit badge training program.
MILWAUKEE
JANUARY 23
Activity: The Section held its second annual trivia night competition at AMF West
Lanes in Milwaukee, Wis. Six teams were
challenged to answer welding-related
questions on safety, nondestructive evaluation, and metallurgy. The participants included Milan Blagojevick, Tyler Willingham, Nicholas Black, Thomas Johnson,
Dan Galligan, Jennifer Hildebrandt, Tim
Keller, Jim Johannsen III, Kenneth
Thomas, and Scott Whitman.
Winners in the regional SkillsUSA welding contest hosted by the Indiana Section are (from
left) Samuel Humphrey, Michael Demiechili, Justin Hildrich, Jeffrey Sikes, and Austen Riley.
District 13
John Willard, director
(815) 954-4838
kustom_bilt@msn.com
CHICAGO
JANUARY 29
Activity: The Section board members met
at Krapils in Worth, Ill., for a business
meeting. Attending were Cliff and Anghelina Iftimie, Marty and Rita Vondra, Bob
Zimny, Kim Tichelar, Erik Purkey, Vicky
Landorf, Craig Tichelar, and Jeff
Stanczak.
APRIL 2014
FEBRUARY 12
Activity: The Section held its St. Valentine
dinner at Coopers Hawk Winery &
Restaurant in Burr Ridge, Ill., for 40 attendees.
St. Louis Section members and guests had a good time touring Jerry Haas Race Cars, Inc.
Attendees at the Kansas City Section panel discussion posed for a group shot.
District 14
INDIANA
FEBRUARY 1
Activity: The Section conducted the Indianapolis SkillsUSA regional welding contest. Serving as judges were Section Chair
Bennie Flynn, Gary Tucker, Gary Dugger,
Dist. 14 Director Bob Richwine, AWS Past
President Richard Alley, Dave Jackson,
Kyle Hutchison, and Tony Brosio. Five student welders qualified to compete in the
state contest: Samuel Humphrey, Michael
Demiechili, Justin Hildrich, Jeffrey Sikes,
and Austen Riley.
FEBRUARY 15
Activity: The Indiana Section hosted a Boy
Scout welding merit badge training program, organized by Past AWS President
Dick Alley, for scouts in Troop 133. Assisting with the training and hands-on welding were troop leaders Dennis Wilmer,
Bob Zetzi, and Andrew Kutschera. Alleys
grandson, Ricky Alley, was among the
scouts who earned his merit badge. The
event was held at the J. Everett Light Career Center in Indianapolis, Ind.
Ivy Tech C. C.
Student Chapter
FEBRUARY 1
Activity: The Student Chapter, led by Advisor Bob Richwine, Dist. 14 director, and
the Indiana Section hosted an open house
at the college in Anderson, Ind. The students demonstrated a virtual arc welding
Shown at the Kansas City Section panel discussion are (from left) Chair Grant Von Lunen,
panelists Dick Blaisdell, Joseph Vincent, Sam Newhouse, and Bob Worthington, and Past
Chair Jason Miles.
training system, blacksmithing techniques,
and various welding and metal-cutting
processes. About 150 people participated
in the event that also featured $3000 in
door prizes and refreshments.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
LOUISVILLE
JANUARY 23
Activity: The Section held a technical
meeting to discuss and practice brazing
and soldering copper, brass, stainless steel,
and aluminum parts. Jeff Szymik, district
sales manager for The Harris Products
Group, led the discussions and assisted
members with hands-on exercises joining
these metals. The program was held at
Kentucky Jefferson County Technical College in Louisville, Ky.
ST. LOUIS
JANUARY 23
Activity: The Section members visited
Jerry Haas Race Cars, Inc., in Fenton, Mo.,
to tour the facility. Jerry Haas gave a presentation, then conducted the tour.
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
KANSAS CITY
FEBRUARY 13
Activity: Professional Engineers Bob Worthington and Dick Blaisdell, and CWIs
Sam Newhouse and Joseph Vincent
formed a panel to answer a wide range of
questions from the attendees concerning
weld joint dimensions, WPS preparation,
postweld heat treatment, shielding gases,
heat-affected zones, welding chrome-moly
and stainless steels, and other topics. The
event was held at Metropolitan C. C. in
Kansas City, Mo.
WELDING JOURNAL
77
Shown at the East Texas Section program are (from left) Director-at-Large J. Jones, Dirk
Hughs, and Bryan Baker, Section chair.
Oklahoma City Section first-place bowling team members are (from left) Mike Carothers,
William Destea, Michael Wellner, and Marvin Gowdy.
Shown at the Oklahoma City Section February program are (from left) Ronnie Dose, Chair Cary Reeves, Juan Varragan, Tony Massey,
Keith Dennis, speaker Amy Milligan, Wesley Mann, Toby McEntire, and Roger Hobrock.
District 17
CENTRAL TEXAS
Posed at the Tulsa Section program are (from left) Dist. 17 Director Jerry Knapp, Chair
Paul Wittenbach, speaker J. Jones, and Secretary Charles Griffin.
78
APRIL 2014
NOVEMBER 5
Speaker: Charles Prause, welding instructor
Affiliation: Bosqueville High School
Topic: Training welding students for jobs
in the agriculture industry
Activity: Dist. 17 Director J. Jones presented Charles Prause the Educator of the
Year Award. The program was held at the
school in Bosqueville, Tex.
Olympic Section members and college students are shown at the January program.
EAST TEXAS
OCTOBER 26
Activity: Dist. 17 Director J. Jones presented the District Director Award to Red
Ball Oxygen for its support and facilitating the CWI seminar and exams. The
award was accepted by Steve Dowings at
Red Ball Oxygen in Shreveport, La.
JANUARY 16
Activity: The Section members toured Capacity of Texas, Inc., in Longview, Tex., a
supplier of tractor equipment and parts.
Director at Large J. Jones presented the
District Director Certificate Award to
Patrick Fagerquist, vice president of sales,
Harris Products. Jones presented a District Director Award to Luminant Academy for introducing welding courses into
its programs The award was received by
Dr. Dirk Hughs, academy director.
OKLAHOMA CITY
JANUARY 31
Activity: The Section hosted its annual
bowling tournament at Penn 44 Lanes in
Oklahoma City, Okla. The first-place team
members, representing W&W Steel, were
Mike Carothers, William Destea, Michael
Wellner, and Marvin Gowdy. Dan Andrews
had the highest score.
FEBRUARY 13
Speaker: Amy Milligan, manager, Southern distribution
Affiliation: Chart, Inc.
Topic: Cryogenics and liquid cylinders
Activity: Toby McIntire received the Oklahoma City Section Meritorious Award.
TULSA
JANUARY 28
Speaker: J. Jones, AWS director-at-large
Affiliation: The Harris Products Group,
district manager
Topic: Oxyfuel safety
Activity: The program was held at Oklahoma Technical College in Tulsa, Okla.,
for 46 attendees.
Attending the Houston Section students night program are (from left) presenter Barney
Burks, AWS Vice President John Bray, AWS President Dean Wilson, AWS Director at-Large
J. Jones, and presenter Grant Peltier.
District 18
HOUSTON
FEBRUARY 19
Activity: More than 250 people attended
the Sections annual students night program. AWS President Dean Wilson presented a slide show and Barney Burks and
Grant Peltier discussed the gas tungsten
arc welding (GTAW) process then led
hands-on demonstrations of various
GTAW torches. Welding student Ashton
Sarger was cited for earning first place in
the Texas SkillsUSA postsecondary welding contest and second place in the National SkillsUSA postsecondary contest.
John Bray, AWS vice president, and J.
Jones, AWS director-at-large, attended
the program.
District 19
OLYMPIC
JANUARY 21
Speaker: John Cale
Affiliation: Clover Park Technical College
79
Top photo: The Arizona Western College Institute of Welding Technology Student Chapter members and Boy Scouts pose at the February
welding merit badge clinic event. Bottom photo: Shown are Chapter members and others who participated in the October Welders Without
Borders Welding Thunder Team Fabrication Competition.
Shown at the CSMSC seminar are (from left) Prof. John Steele, Zhifen Wang, Prof. David Olson, Prof. Zhenzhen Yu, Nathan Switzner, presenter Prof. YuMing Zhang, Stephen Tate, Advisor Prof. Stephen Liu, Devon Gonzales, Erik Pfeif, Cheryl Hawk, and Ali AlShawaf.
80
APRIL 2014
Arizona Western College Institute of Welding Technology personnel manned an information booth at the January event.
Shown at the L.A./Inland Empire Section program are (from left) Paul May, Nabil Butris,
Tim Chubbs, Ladon Gilbert, and Chair George Rolla.
PUGET SOUND
FEBRUARY 6, 8
Activity: The Section members toured the
T-Baily, Inc., heavy construction plant in
Anacortes, Wash. On the following Saturday, Arthur Schnitzer and Josh Anderson
represented the Section at the Annual
Puget Sound Engineering Council Fair.
District 20
Shown at the San Francisco Section program are (from left) Mike Zinser, Dist. 22 Director
Kerry Shatell, and presenters Doug Williams and Galen Jaeger.
IDAHO-MONTANA
JANUARY 31
Speaker: Denis Clark, CWI, and chair,
AWS Safety and Health Committee
Affiliation: DEClark Engineering
Topic: Manganese exposure limits
Activity: Forty-two people attended this
seminar that provided 1.5 professional development hours. The class detailed the
81
District 21
L.A./INLAND EMPIRE
JANUARY 14
Activity: The Section hoste a panel discussion about the Certified Welding Inspector exam and requirements. Panel members included Paul R. May Jr. from Orange County Testing, and Nabil Butris,
Tim Chubbs, Ladon Gilbert, and Chair
George Rolla. Members of the local ASNT
chapter participated in this program, held
at Maggies Pub in Santa Fe Springs, Calif.
SAN FRANCISCO
FEBRUARY 5
Speaker: Doug Williams, P.E.
Affiliation: WeldEngineers.com
Topic: Structural steel bolting
Activity: The meeting, held at Spengers
Restaurant in Berkeley, Calif., attracted
79 attendees. Included was a demonstration of a Skidmore-Wilhelm tensioning device presented by Williams and Galen
Jaeger of California Erectors, Inc.
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
82
APRIL 2014
tions with industry and other organizations, and for contributions of time and effort on behalf of the Society.
George E. Willis Award
This award is given to an individual who promoted the advancement of welding internationally by fostering cooperative participation in technology transfer, standards rationalization, and promotion of industrial goodwill. It includes a
$2500 honorarium.
International Meritorious Certificate Award
This honor recognizes recipients significant contributions to
the welding industry for service to the international welding community in the broadest terms. The award consists of a certificate
and a one-year AWS membership.
AFFILIATE COMPANIES
Clark Machine Corp.
1000 Todds Ln.
Baltimore, MD 21237
Collins & Jewell Co.
43 Wisconsin Ave.
Norwich, CT 06365
CribMaster
1955 W. Oak Cir.
Marietta, GA 30062
Heartland Industrial Group
1003 Central Ave.
Fort Dodge, IA 50501
High Country Sales & Trading, Inc.
4950 S. Yosemite St., F2 #305
Greenwood Village, CO 80111
Hoff Mechanical, Inc.
2945 Tioga River Rd.
Lawrenceville, PA 16929
JCF Bridge & Concrete
1300B E. Gatlin Creek
Driftwood, TX 78619
MBA Industrial Trade & Consulting
PO Box 873
Gig Harbor, WA 98335
Nippon Sharyo USA, Inc.
2340 S. Arlington Heights Rd., #605
Arlington Heights, IL 60005
SUPPORTING COMPANIES
D/F Machine Specialties, Inc.
1750 Howard Dr.
North Mankato, MN 56003
Duomo Euroservices
Poligono Ind. El Llano,
Ave. Del Progreso, 7, Parcela No. 2
Villarrubia Santiago
Toledo 45360, Spain
Trinity Shoring Products, Inc.
594 Mendon Rd.
Union City, MI 49094
Zagros Tatbigh Kala Engineering &
Technical Inspection Co.
No. 266 above Sarmayeh Bank and Day
Bank, Ayatollah Kashani St.,
Tehran 11369, Iran
EDUCATIONAL INSTITUTIONS
Concordia Junior/
Senior High School
436 W. 10th St.
Concordia, KS 66901
Duncanville High School
900 W. Camp Wisdom
Duncanville, TX 75116
Knight Technical Institute
2900 Colmer Rd.
Moss Point, MS 39562
Mid-Michigan C. C.
1375 S. Clare Av.
Harrison, MI 48625
Midwest Technical Institute
554 Pitt Rd.
Brownsburg, IN 46112
Northshore Technical C. C.
Florida Parishes Campus
PO Box 1300, Greensburg, LA 70441
Hammond Campus
111 Pride Dr., Hammond, LA 70401
Sullivan Main Campus
1710 Sullivan Dr., Bogalusa, LA 70427
Olney Central College
305 N. West St.
Olney, IL 62450
Palmetto Academy for
Learning Motorsports
136 Rodeo Dr.
Myrtle Beach, SC 29579
Surry C. C.
630 S. Main St.
Dobson, NC 27017
Tarrant County College District
South Campus
5301 Campus Dr.
Fort Worth, TX 76119
Waelder Independent
School District
201 Hwy. 90 W.
Waelder, TX 78959
Winnsboro High School
409 Newsome St.
Winnsboro, TX 75494
WELDING JOURNAL
83
INTERNATIONAL SALES
TECHNICAL SERVICES
Dean R. Wilson
deanwilsonaws@gmail.com
Welldean Enterprises
151 Oak Tree Circle
Glendora, CA 91741
PUBLICATION SERVICES
Director, Operations
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Technical Activities Committee
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
MARKETING COMMUNICATIONS
Human Resources
Director
Lorena Cora.. lcora@aws.org . . . . . . . . . . . .(417)
MEMBER SERVICES
GOVERNMENT LIAISON SERVICES
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors federal issues of importance to the industry.
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
84
APRIL 2014
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between members and AWS headquarters.
CERTIFICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(273)
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all international certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Accreditation Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification programs, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
The future your future is on full display at FABTECH. From 1,400+ exhibits with end-to-end
solutions in metal forming, fabricating, welding and nishing, to the industrys leading education
and peer-to-peer networking, this is your opportunity to capitalize on the future.
The answers and know-how you need for the challenges of tomorrow can be found at FABTECH.
Visit fabtechexpo.com for complete event details. REGISTER TODAY!
PERSONNEL
PMPA Elects President
John F. Sweet has been elected president of the Powder Metallurgy Parts Assn.
(PMPA) based in
Minneapolis, Minn.
Sweet is president of
FMS Corp., Powder
Metal Div., a familyowned business that
uses powder technology with low-alloy
steels, stainless steels,
brass, bronze, softmagnetic materials,
John Sweet
and exotic alloys to
manufacture gears, cams, keyways, and
other parts.
Justin Fort
Jasen Friedrich
Fronius USA, Portage, Ind., announced Jasen Friedrich has joined the
company as area sales manager for Illinois and the eastern-half of Iowa and Missouri. Justin Fort was hired as area sales
manager for Arkansas and Oklahoma.
Friedrich has been in the welding industry for more than 15 years, most recently
as branch manager for an independent
welding distributor. Fort has worked on
the distribution side of welding sales for
the past 12 years, most recently in the
Oklahoma area.
J.Rusty Franklin
James R. Rusty
Franklin, an AWS
Counselor affiliated
with the Chicago
Section, has announced his intention to retire from
Sellstrom Mfg. Co.,
Schaumburg, Ill., at
the end of this year.
With the company for
28 years, Franklin
Flexovit USA,
Inc., Angola, N.Y.
has named Hendrik
H. Iliohan director of
sales and marketing,
responsible for accounts across the
United
States,
Canada, and Mexico.
With the company
Hendrik Iliohan
since 1989, Iliohan
most recently served
as global sourcing manager.
continued on page 90
88
APRIL 2014
PERSONNEL
WORK
W
ORK
SSMART
MART
RT
Bill DeHaven
Joe Farrell
90
APRIL 2014
Impact Testing
X-Ray Diffraction
Hydrogen Cracking
The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image and
impact of the welding industry. Election as a Counselor shall be based on an individuals career of
outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in the
welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the welding
industry. The individuals organization shall have shown an ongoing commitment to the industry, as
evidenced by support of participation of its employees in industry activities.
Leadership of or within an organization that has made a substantial contribution to training and
vocational education in the welding industry. The individuals organization shall have shown an
ongoing commitment to the industry, as evidenced by support of participation of its employee in
industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this
issue of the Welding Journal. The deadline for submission is July 1, 2014. The committee looks
forward to receiving these nominations for 2015 consideration.
Sincerely,
Lee Kvidahl
Chair, Counselor Selection Committee
CLASS OF 2015
COUNSELOR NOMINATION FORM
DATE_________________NAME OF CANDIDATE________________________________________________________________________
AWS MEMBER NO.___________________________YEARS OF AWS MEMBERSHIP____________________________________________
HOME ADDRESS____________________________________________________________________________________________________
CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________
PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________
TITLE/POSITION____________________________________________________________________________________________________
BUSINESS ADDRESS________________________________________________________________________________________________
CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________
ACADEMIC BACKGROUND, AS APPLICABLE:
INSTITUTION______________________________________________________________________________________________________
MAJOR & MINOR__________________________________________________________________________________________________
DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________
LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________
SIGNIFICANT WORK EXPERIENCE:
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE
SELECTED AS AN AWS COUNSELOR ACCOMPANY THE NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY
BE INCORPORATED WITHIN THE CITATION CERTIFICATE.
**MOST IMPORTANT**
The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All information and support material provided by the candidates Counselor Proposer, Nominating Members and peers are considered.
SUBMITTED BY:
PROPOSER_______________________________________________
AWS Member No.___________________
The proposer will serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include a
detailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the candidate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition
to the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.
www.aws.org
www
w.aws.org
.
International symposium on
Advances in
Resistance Welding
April 2830, 2014 / Atlanta
Challenges and Advances in W
Welding
elding Aluminum (Jerry Gould, EWI)
Challenges and Advances in W
Welding
elding of a New Generation of High Strength Steels (Murali Tumuluru,
Tumuluru, U.S. Steel)
Flash Welding
Techniques
echniques for Coil Joining of Advanced High Strength Steels
Welding T
Mike
ke Prokop (Taylor-Winfield)
Taaylor-Winfield) and Jerry Gould (EWI)
(T
Resistance Spot Welding
Welding Gun with Force Amplification
Jonny Kaars and Peter Mayr (Chemnitz University)
Development of Resistance Spot W
Welding
elding Process for Three-Sheet Lapped Joint
Yasuaki
Okita and Kenji Oi (JFE Steel)
Yasuaki
a
S
Development of a Solid-State Joining Process Incorporating Bi-Axial Deformation: Translationally
Translationally Assisted Upset
Jerry Gould and Sam Lewis (EWI)
Comparison of Resistance Spot Welding
Welding
Welding and Refill Friction Stir W
elding of Al 7075 Sheets
Y.
Waterloo),
Y. Chen, J. Hou, N. Zhou, M. Worswick,
Worswick, A. Gerlich (University of W
aterloo), K. Chan, and N. Scotchmer (Huys Industries)
Current Challenges and Status of Adaptive W
Welding
Technologies
elding T
echnologies
Pierre Barthelemy (ARO Welding)
Welding)
Non-Destructive Inspection of RSW of AHSS by Infrared Thermography
Zhili Feng (ORNL)
Small-Scale Resistance Welding
Welding for Medical and Industrial Applications
Girish Kelkar (WJM Technologies)
Teechnologies)
echnologie
Better Understanding of the Upset and Flash Welding
Welding as a Solid Phase Joining Process
Kin-ichi Matsuyama
Matsuyama (Osaka University)
Resistance Spot Welding
Welding of High Strength Dual Phase Steels
Murali Tumuluru
Tumuluru (U.S. Steel)
Influences of Tempered
Tempered Pulses on Resistance Spot Welding
Welding of Hot Press Forming Steels
J. Hou, D. Saha, S. Nayak, N. Zhou, A. Gerlich (University of W
Waterloo),
aterloo), K. Chan, and N. Scotchmer (Huys Industries)
Safety: Protecting Y
Your
Your
our
our Operators and Y
o Bottom Line
Ray Michelena (T.J.
(T
T.J. Snow Co.)
Co
Adaptive Control Capabilities Enable a Sealed Air/Gas T
Tight
Weld
ight Continuous Seam W
eld
Robert Cohen (WeldComputer)
(WeldComputer)
Adaptive Control Regulates Consistency of Flash Weld
Weld Process While Reducing Power Consumption
Robert Cohen (WeldComputer)
(WeldComputer)
Modeling RWS
RWS of AHSS from Process to Performance
Zhili Feng (ORNL)
Effects of Specimen Geometry and Material Strength on the T
Test
Testing
est Results in the Mechanized Peel T
esting
Shinobu Satonaka, Chihiro Iwamoto (Kumamoto University), and Kin-ichi Matsuyam
Matsuyamaa (Osaka University)
Influence of Electrode and Welding
Welding
Welding Parameters During Resistance Spot W
elding of Hot-Stamped Ultra-High Strength Steel Sheets
D.C. Saha, S.S. Nayak, P.
A.P.. Gerlich (University of Waterloo),
P. Penner,
Pennerr, Y.
Y. Zhou,
Z
A.P
Waterloo),
aterl
a
K.R. Chan, N. Scotchmer (Huys Industries),
B. Gocke (Afyon Kocatepe University), and E. Biro (ArcelorMittal)
Development of In-Process Welding
Welding
Welding Current and Electrode Force Control Process for Indirect Spot W
elding
Muneo Matsushita, Rinsei Ikeda, and Kenji Oi (JFE Steel)
Electrical Considerations from the Utilities V
View
iew
Mark Siehling (RoMan Manufacturing)
Co-sponsored by
Visit
Visit www.aws.org/conferences
www
w.aws.org/conferences
..aws.org/conferen
or call (800) 443-9353 ext 234
A ST
STANDING
ANDING COMMITTEE OF
A tabletop exhibition and reception will follow the two keynotes on the afternoon of Monday,
Monday
dayy, April 28th.
Conference will adjourn
adjourn in the early afternoonn of Wednesday,
Wednesday
e
y, April 30th.
APRIL 2014
Ademinsa
Centroamericana S.A.
Ademinsa - Group of Companies
Latin-America, is a reliable training
source for CWI, CWS, SCWI, and
CWSR Seminars. Training and certification according to SNT-TC-1A on
NDT and PdM (8 methods), Preparatory seminars are offered for certified
inspectors on API 653, 570, 510 and
580. As well as technical services on all
NDT methods. Events in more than 15
Countries. English and Spanish classes
available.
Advanced Technology
Institute
ATI provides diploma and AOS
degree programs in the practical aspects of construction and repair of
equipment and structures built with
steel and aluminum. Our staff is AWS,
CWI, CWE certified. We instruct
all-position welding in the four most
common processes: SMAW, GMAW,
GTAW and FCAW. Students will
train in the use of modern welding
equipment and tools, and learn basic
metallurgy and blueprint reading. Students may test in 6G pipe certification
in accordance with AWS D1.1. ATI
offers financial assistance for those
who qualify and graduate employment
services. Certified to operate by
SCHEV in Virginia.
Founded 1908
Bellingham Technical
College Welding Rodeo
BTCs 12 annual team welded sculpture
competition, auction, and welding skills
challenge will be held on Friday and
Saturday, May 16th and 17th 2014. The
theme for the 2014 event is earth, wind,
and fire. This 2 day event will showcase
10 teams in the sculpture competition
which culminates by auctioning off the
completed sculptures and the proceeds
going toward scholarships for students in
the welding program. This year marks the
second year of the welding skills challenge.
This part of the event has 3 classifications
of contestants. The first is for high school
students, the second is for college students
and the third is for professionals. Each
category will be assessed by an AWS-CWI
and prizes awarded for the best quality per
AWS D1.1, acceptable bead profile. The
skills challenge is a first come first serve
and the public is invited both days to see
the sculptures being created and to cheer
on the skills competitors. Contact us for
more information nor visit our website.
Baker College
Since 1911 Baker College has been
preparing people for new careers.
Today were Americas leading, notfor-profit, career college. The Welding
Program at Baker is available at both
the certificate and associate degree
levels and provides students with the
knowledge and skills necessary for
entry-level employment in the welding
industry. Welding is available at our
Cadillac, Cass City, Flint, and Owosso
campus locations. Housing options
are available in Flint, Owosso, and
Cadillac.
Bellingham Technical
College Welding
Technology Program
Founded 1956
97
98
APRIL 2014
Founded 1975
Drew Duffy
Admission CDA Welding Program
Jacksonville, FL 32208
(888) 974-2232 toll free (904) 766-7736
Fax: (904) 766-7764 www.cdawelding.com
Central Piedmont
Community College
James Turner Institute of
Welding Technology
Founded 1963
PO Box 35009
Charlotte, NC 28235
(704) 330-2722
www.cpcc.edu/welding
XIAN, CHINA
+86-29-85407368
wpeace@126.com
www.ccic-csn.com
WELDING JOURNAL
99
Dabney S. Lancaster
Community College
Founded 1967
Scott Laslo,
Program Coordinator
(614) 287-2653
slaslo1@cscc.edu
550 E. Spring St.
Columbus, OH 43215
www.cscc.edu
Cutech Group
Cosumnes River College Welding Program offers a brand new welding facility
equipped with the latest ESAB, Miller
and Lincoln Electric Technology. The 30
welding stations shop is outfitted for
each student to perform FCAW, SMAW,
GMAW and GTAW processes. A
Cincinnati plate shear with a by 6
capacity, two Iron Workers, two
beveling track cutting torches and two
belt sanders are on hand for students to
prepare plate and pipe certifications to
ASME, API and AWS standards in a
time efficient manner.
Graduate
students can enter the work force with a
class 5 Industrial truck license, a 10 hour
OSHA safety card, overhead crane and
rigging skills and welder certifications.
Students can receive an Associate
Degree in Welding Technology, or earn
welding certificates in Welding Code
Regulations or fabrication technology.
Jason Roberts
(916) 691-7386
8401 Center Parkway
Sacramento, CA 95823
robertj@crc.losrios.edu
100 APRIL 2014
Earlbeck Gases
& Technologies
Eastern Maine
Community College
Don Hodges
8204 Pulaski Highway
Baltimore, MD 21237
(410) 687-8400
Dhodges@earlbeck.com
www.earlbeck.com
Founded 1960
Forsyth Technical
Community College
Founded 1966
Fortis Institute
Erie, PA
George T. Baker
Aviation School
Fortis College
Cincinnati, OH
The welding program at FORTIS
starts with a review of various basic
math applications and an introduction
to oxyfuel cutting and welding
processes. The oxyfuel processes
provide a solid foundation for all
types of welding applications including
shielded metal arc welding (SMAW),
gas metal arc welding (GMAW), and
gas tungsten arc welding (GTAW).
The use of destructive and nondestructive testing will ensure students
have a thorough understanding of
what constitutes a quality weld.
Fortis College
Ravenna, OH
The welding technology program at
FORTIS College teaches industrial
welding applications, craft skills,
welding mathematics and important
career development techniques for
individuals wanting to specialize in
welding, cutting, soldering, or brazing.
Students will have a hands-on
experience and learn to find practical
solutions to problems and a thorough
understanding of what constitutes
a quality weld when enrolling in
the welding program at FORTIS in
Ravenna.
Founded 1965
Harper College
Harper College offers an AAS degree
in Welding Technology and an AAS
in Advanced Manufacturing with
emphasis in metal fabrication. The
College also offers certificates in Basic
and Advanced Welding, Basic Pipe
Welding, and Welding Fabrication.
Harper's program prepares students to
pass American Welding Society Level I
(Entry Welder) and Level II (Advanced
Welder) testing. The College also
provides custom training in welding
and fabrication for employees of
area businesses.
Kurt J. Billsten
Coordinator of Manufacturing
Technology
1200 West Algonquin Rd.
Palatine, IL 60067
(847) 925-6149
Fax: (847) 925-6049
kbillste@harpercollege.edu
www.harpercollege.edu
Hill College
Founded 1923
Welding Department
2112 Mayfield Parkway
Cleburne, TX 76033
(817) 556-2809 ext. 201
Email: bbennett@hillcollege.edu
www.hillcollege.edu
Hobart Institute of
Welding Technology
Founded 1930
(800) 646-WELD
www.hohokustrades.com
Hutchinson Community
College
HCC offers a Certificate, Associate
Degree and customized industry
training in welding technology.
The program instructs all welding
processes, as well as experience
in fabrication and manufacturing
methods. The welding and employability skills taught result in excellent
job opportunities upon graduation.
Morning, afternoon, and evening
classes are available. Welding
programs are located in Hutchinson
and Newton, KS.
1300 N. Plum
Hutchinson, KS 67501
(620) 665-3502
www.hutchcc.edu/weldit
Tim Evans - evanst@hutchcc.edu
(620) 728-8141 in Hutchinson
Mandee Buchholz
buchholzm@hutchcc.edu
(316) 283-7000 in Newton
WELDING JOURNAL 103
Randy Humpherys
humprand@isu.edu, (208) 282-4473
Lucas Bloxham
bloxluca@isu.edu, (208) 282-3500
David Erickson
ericdav2@isu.edu, (208) 282-3500
Illinois Valley
Community College
Founded 1924
Paul Leadingham
Welding Program Coordinator
815 N. Orlando Smith Road
Oglesby, IL 61348
(815) 224-0319
paul_leadingham@ivcc.edu
www.ivcc.edu
104 APRIL 2014
Catherine Bovell
4501 Amnicola Highway
Chattanooga, TN 37406-1097
(423) 697-4434
ISTUC
Founded 2001
catherine.bovell@chattanoogastate.edu.
Corona, California
(800) 897-WELD
chancy@integritywelds.com
www.ktc.edu
click on the link to the
respective campus
Lakeshore Technical
College
Located between Milwaukee and
Green Bay, WI on the eastern shore
of Lake Michigan. Lakeshore Technical College has trained manufacturing
workers for over 100 years. Today,
LTC offers welding programs in its
new spacious Center for Manufacturing Excellence with state-of-the-art
Miller welding equipment. LTC has
added classes of 30 new welding
students and 8 fabrication technicians
to meet local employer demand.
Utilizing multiple entry points, LTC
programs have you work-ready in 27
weeks.
Lansing Community
College
Founded 1957
Lee College
Lee College was established in
1934, the founders of the college were
interested in providing a strong
academic curriculum and a comprehensive technical/vocational curriculum. In 1936, the vocational program
was initiated. Lee College now offers
some daytime, but mostly evening
classes for credit in welding, welding
inspection, pipefitting, millwright,
machining, instrumentation and electrical. Lee College also awards
NCCER certification to meet industry
and contractors needs. The welding
program consists of S.M.A.W.,
G.M.A.W, flux core, print reading,
welding codes, metallurgy, and safety
core classes.
Lynnes
Welding Training, Inc.
The School That Sparks
Your Future!
Founded 2006
Lou Dessellier
Welding Instructor
970 Pickett St N
Bayport MN 55003
(651) 779-2700 ext 2576
Fax: (651) 779-2792
Merrill Institute
The Merrill Institute is a manufacturing, welding training, and testing
(ATF) facility in Alma, Michigan.
Courses are facilitated by AWS
CWI/CWEs utilizing state-of-the art
equipment. Our instructors provide
real world application and expertise
while promoting a safe work environment. 85% of the training will be
hands-on within a live manufacturing
environment, learning the most
common welding processes such
as GMAW (MIG), GTAW (TIG),
FCAW (Flux-Core), and SMAW
(Stick). Upon successful completion
of the course, students will receive an
AWS SENSE Certification.
Mid-Plains
Community College
Missouri Welding
Institute
Founded 2002
Founded 1994
Moraine Park
Technical College
Schenectady, NY 12304
Jeffrey Daubert, Vice President
1-800-396-6810 or
(518) 374-1216
welding@capital.net
www.modernwelding.com
Monroe County
Community College
Founded 1964
National Polytechnic
Institute
The underwater welding course is
four weeks long and designed to
prepare students to obtain high
quality shielded metal arc welding
(SMAW) skills both above and below
the water. The course follows the
guidelines of AWS D3.6M 2010
standards. Emphasis is on the
performance of high quality, defectfree, wet welds while preparing the
student to obtain (3F) vertical welder
certification for underwater welding,
class B fillet welds. Call 1-800-4323483 for more information.
Donovan Rhodes
Greenbrier Valley Campus
(304) 647-6560
drhodes@newriver.edu
Brad Veneri
Advanced Technology Center
(304) 929-3301
bveneri@newriver.edu
www.newriver.edu
NDSCS-Wahpeton
800 Sixth St. North
Wahpeton, ND 58076
(800) 342-4325
NDSCS-Fargo
1305 19th Avenue North
Fargo, ND 58102
(701) 231-6900
Email: joel.johnson@ndscs.edu
www.ndscs.edu/welding
Northeast Wisconsin
Technical College
Northeast Wisconsin Technical College
offers training in welding at our
Green Bay, Marinette and Sturgeon Bay,
Wisconsin campuses, and by contract at
worksites nationwide. NWTC welding
graduates attain knowledge in print reading, layout, fabrication, and metallurgy
to apply to building and repairing metal
components using the major welding
processes. Our students can weld to
AWS and ASME codes and function as
maintenance welders, qualified welders,
structural welders, welder/fabricators, and
pipe welders. NWTC offers the Weld
Inspection fundamentals and practical
courses to prepare a student for the
Certified Welding Inspection exam.
NWTC is also an AWS Student Chapter.
Northwestern
Michigan College
Founded in 1951
Northwestern Michigan College offers a one year, hands-on welding program which prepares students to take
American Welding Society welder
qualification tests to become Certified
Welders. The program prepares
students with no experience to take
up to four welder qualification (certification) tests in two semesters. Small
class size provides personal attention
from instructors. Courses are
designed, structured, and sequenced
by welding process for flexibility.
Program facility, equipment, lab, and
ventilation system are state of the art.
Chuck Hunt
Welding Program Coordinator
1701 E Front Street
Traverse City, MI 49686
(231) 995-1300
Fax: (231) 995-2022
chunt@nmc.edu
Northwest State
Community College
Northwest State Community College
is a public, two-year college based in
Archbold, Ohio. NSCC has more than
70 degree and certificate programs,
plus noncredit courses on 300+
subjects. NSCC offers a short-term
technical certificate in industrial
welding. Students are trained in MIG,
TIG, and stick for plate and pipe in
beginning and advanced classes.Graduates are prepared to take the American Welding Society certification tests.
Odessa College
The Odessa College Welding
Technology Department offers a full
range of certificate and associate
degree options. This AWS Educational
Institution member is a SENSE
affiliated program and follows the
WELD-ED national curriculum to
offer training in OFW, PAC, CAC-A,
SMAW plate and pipe, GMAW, FCAW,
GTAW, and SAW processes along with
specialized courses in metallurgy, NDE,
layout and fabrication. The training
facilities are designed around 75 welding stations and an advanced process
area in four newly renovated and
specialized lab areas with three classrooms. Odessa College sponsors a
newly formed AWS Student Chapter.
201 W. University
Odessa, TX 79764
(432) 335-6474
James Mosman CWI
http://www.odessa.edu/dept/welding
Pennsylvania College of
Technology
Penn State affiliate since 1989
Jimmie F. Johnson
AWS CWI/CWE
Welding Program Coordinator
(803) 535-1299
Fax: (803) 535-1365
johnsonjf@octech.edu
www.octech.edu
William Presby
Welding Instructor
presbb@portlandschools.org
(207) 874-8165
Fax: (207) 874-8170
3 Nablos St.,
Cairo, Egypt, Postal Code: 12411
www.qualitycontrol-egypt.com
Rochester Arc +
Flame Center
Rochester Arc + Flame Center is a
privately owned training facility that
offers welding training to the public.
The business has partnered with
Monroe Community College to offer
The Welding and Fabrication
Certificate a 20-week, 360-hour
intensive program designed to produce entry-level welder/fabricators.
Certificate programs in SMAW,
GMAW, GTAW, and pipe welding are
also offered. All programs emphasize
safety, technique, print reading and
soft skills. Customized training,
inspection, metallurgy and NDE are
also specialties.
Rockford, Illinois
(815) 921-3015
(815) 921-3010
Mike Merriman
Email:
m.merriman@rockvalleycollege.edu.
www.rockvalleycollege.edu
Sol y Sol
Sol y Sol offers a comprehensive range of
products and services to cover most welding
needs, representing only top quality welding
brands. It offers education and certification
for welding engineers, welding inspectors,
and welders. Equipment sales and rental for
welding, cutting, induction heating, and
positioning, as well as consumable supplies
of welding and brazing products. Sol y Sol
also offers technical assistance on material
selection, weld quality, and productivity
improvement. Along with welder safety gear
and accessories. Quality inspection products
for VT, MT, and PT testing methods. Sol y
Sols team of internationally qualified and
experienced professionals is ready to
help with your most demanding welding
challenges.
C/ Ro Tajo, Nave 1
45530 Santa Olalla Toledo - SPAIN
+34 925 797 688 / +34 672 063 303
info@solysol.com.es
www.solysol.com.es
Lincoln Campus
Mark Hawkins, Program Co-Chair
(402) 437-2694
mhawkins@southeast.edu
Dan Zabel, Program Co-Chair
(402) 437-2692
dzabel@southeast.edu
College Admissions Office
Lincoln (402) 437-2600
Southeast Oklahoma
School of Welding
Southeast Oklahoma School of
Welding was founded in McAlester,
Oklahoma in July 2013 by two welders
John Allen and Will Roberts. After
20+ years working in the industry,
they realized that there is a great need
for quality welders and fabricators.
SEOSW offers two main courses:
Master Welder and Pipeline Welder
which both include fabrication training.
Summit College
Summit College, located in the Inland
Empire, was founded in 1991 in
Colton, California and is nationally accredited by ACCET. Summit offers
two welding programsweldingadvance and welding-basic. Weldingadvance helps prepare students for
valuable certifications, such as ASME
Section 9, API 1104, and AWS D1.1.
This program also steers students
toward jobs on the big projects, like
high-pressure steam pipes, offshore oil
rigs, and cross-country pipeline.
Colton Campus
851 S. Cooley Dr.
Colton, CA 92324
(909) 422-8950
www.SummitCollege.edu
Tennessee College of
Applied Technology
Nashville
The Welding Technology program is
designed to give the students the
necessary classroom instruction and
practical welding experience necessary for entry-level job performance.
Basic practical experience is gained by
repetition of welding positions in
GMAW, GTAW, SMAW, oral, written
and performance tests are given to
measure the students proficiencies.
The day program requires twelve
months to complete. The evening
program requires eighteen months to
complete. Awards: combination
welders diploma and certificates.
Tri-County Technical
College
Founded 1965
7900 Highway 76
P.O. Box 587
Pendleton, SC 29670
(864) 646-1405
pphelps@tctc.edu
United Technical
Welding Academy
United Technical Welding Academy, an
advanced training institution, offering
occupational training and certifications in
accordance with AWS SENSE program.
AWS CWE and welding engineers
develop custom training courses to create
experienced skilled trades personnel
for your company in such areas as
structural assemblies, robotics, aerospace,
automotive, die repair and pipe. Our
metallurgical/weld laboratory develops
written procedures, welds, tests and
qualifies your company PQR/WPS
(steel, stainless, aluminum, etc.). Welding
simulator, welder qualifications, ASNT
NDT inspection services, and training.
CWI services are also provided.
Vatterott
Educational Centers
Combination Welding
Taught by professionals experienced
in the field, the welding program
provides courses in blueprint reading,
project management, welding techniques and gas metal arc welding.
The program introduces welding
theories, safety requirements, cutting
techniques, and welding terminology.
Training progresses to include gas
tungsten arc welding, project management, and advanced blueprint reading.
Welding is offered at Fairview Heights,
Illinois as well as Missouri locations
including Northpark (St. Louis),
Joplin and Kansas City. Learn more at
Vatterott.edu
Washtenaw
Community College
Weld-Ed
Waubonsee Community
College
The Welding Technology program
at Waubonsee Community College
offers students options of two certificates, as well as an Associate in
Applied Science Degree. Class sizes
are small to ensure students get
focused and individualized attention.
Waubonsee's welding program includes classes in each of the basic
processes including: OFW, TB, OFCA, PAC, SMAW, GMAW, FCAW, and
GTAW. Additionally, the curriculum
includes four courses specifically
devoted to pipe welding with GTAW
and SMAW in all positions.
Welder Skill
WELDER SKILL is a training and
qualification school in the field of
welding manufacturing. Our personnel
have 12 years of experience and our
facilities are equipped to provide the practice of welding processes. WELDER
SKILL offers the following services:
Welder qualification in the SMAW,
GTAW, GMAW, and FCAW processes,
consulting for companies in the field of
welding manufacturing, Free conferences
to schools, universities and companies
in the welding manufacturing field.
WELDER SKILL has the following
recognitions: An AWS Educational
Institution Membership and the Colombian Association of Welding and Non
Destructive Testing.
White Mountains
Community College
Its pretty simple here at WMCC. We
teach hands-on welding skills. We use
cutting edge equipment. We create
professionals. Spend your time on new
equipment learning new processes in
our new 24-booth lab (or connected
virtual welding lab). Have regular
demos and recruiting visits from
industry. Get a certificate in welding
technology or pipe welding or an
Associates Degree (fall of 2014). Get
a great job. Keep on welding.
7of 6thOctoberSt.
Shoubra El-Khaima, Qalubeia,
EgyptCairo
(020)44745555
Fax: (020) 44745555 Ext.:266
ewa@ewa.org.eg
www.ewa.org.eg
Facebook.com/EWA.Cairo
SLV Mnchen
Ihr Partner fr
Schweitechnik
Schachenmeierstrae. 37
80636 Mnchen, Germany
www.slv-muenchen.de
WELDING JOURNAL 113
ESAB Welding & Cutting Products, Florence, S.C., has implemented the new European EN ISO Standard 17916 for the
safety of thermal cutting machines. All cutting systems manufactured at its Karben, Germany, facility will meet these safety
requirements. The company also has a partnership with
RoboVent Product Group, Inc., for developing high-performance robotic welding systems in North America.
Tri Tool, Inc., Rancho Cordova, Calif., a manufacturer of
portable precision equipment, introduced a new brand identity. The double T symbolizes the companys name while the
new tagline is Building Performance.
Bernard, Beecher, Ill., offers online configurators that allow
customizing the companys four semiautomatic gas metal arc
gun lines Q-Gun, S-Gun, T-Gun, and TGX at
bernardwelds.com/configuremygun.
A large supplier of electric resistance welded pipes has completed installing a new 800-kW HAZControl technology dual
(induction/contact) solid-state, high-frequency welding machine at one of its North American facilities. The producer
chose Thermatool Corp., East Haven, Conn., to meet the American Petroleum Institute standards required by its customers.
Jeff Loding, the third-generation GTW Welding Supplies
owner, has recently opened a new branch in Ionia, Mich., with
the help of Manager Larry Scheurer.
The Welder Training & Testing Institute, Allentown, Pa., has
received its second accreditation to ISO/IEC 17025 in the field
COMING EVENTS
continued from page 58
of nondestructive examination. The #3430.02 new scope includes visual, liquid penetrant, magnetic particle, ultrasonic,
and radiographic inspections.
The Lincoln Electric Co., Cleveland, Ohio, has a new partnership with the World of Outlaws STP Sprint Car Series and the
World of Outlaws Late Model Series, Concord, N.C.
Hypertherm recently announced a LEED Gold designation for
its new manufacturing facility in Lebanon, N.H. The 160,000sq-ft facility, in operation for about a year, received a total of
62 points from the U.S. Green Building Council.
Evana Automation Specialists, Evansville, Ind., integrated
eight Motoman robots into a new powder coating line for a
commercial wheel manufacturer by providing bases, guarding,
and end-of-arm tools for the customer-supplied robots.
Tooling U-SMEs Competency Framework, a new tool available this spring, allows companies to combat the increasing
talent shortage and achieve stronger workforce performance
while providing development pathways and career growth opportunities for their employees. Its made up of more than 60
defined job role competency models.
Herr-Voss Stamco, Callery, Pa., recently engineered, manufactured, and integrated a new 3-roll flattener into FerrouSouths existing cut-to-length line in Iuka, Miss.
Solar Atmospheres of Western PA has been awarded Nadcap
Merit status for vacuum heat treating and brazing of metals.
This rank also means that it has been granted an accreditation
that lasts two years through January 2016.
Linde LLC, Murray Hill, N.J., recently signed a contract to
supply liquid oxygen, nitrogen, and argon to Technical Alloy
and Industrial Gas, Houston, Tex.
May
New
Orleans
Ma
ay 28 29,, 2014 / Hotel Monteleone,
Monteleone, N
ew O
rleans
aluminum-industryy
A distinguished panel of aluminum-industr
experts
willl survey
experts wil
sur vey the state of the art
art in aluminum
welding
technology
w
elding tec
hnolog
oggy and practice.
practice.
Earn
Ear
n PDHs
PDHs toward
toward your
yoour AWS
AWS recertification
recertification when yyou
oou attend this conference.
conffeerence.
Register
gister Early and Save
Visit
V
isit www.aws.org/conferences
www
w..aws.org/c
.aws.org/conferences or call (800) 443-9353 ext 234.
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Educational Resources
Obituaries
PERSONNEL
continued from page 90
Harry W. Ebert
Member Milestones
Jorge J. Perdomo
Jorge J. Perdomo, active with the AWS
Houston Section, has been named by
NACE, The Corrosion Society, to receive its Technical
Achievement Award.
His citation reads,
Dr. Perdomo is recognized for his practical approach on
solving corrosionrelated problems of
pressure equipment
via failure analysis,
materials selection,
Jorge Perdomo
life assessment, prediction, and repair methods in the oil and
gas, refining, petrochemical, and pulp and
paper industries. Perdomo, with ExxonMobil Research and Engineering Co.,
Equipment Div. Welding & Metallurgy, Baytown, Tex., is an 11-year AWS
member. He serves on the AWS Technical Papers Committee, is a Principal Reviewer for the Research Supplement of
the Welding Journal, and serves on the
Houston Section Education Committee.
Paul Phelps
Paul Phelps, a member of the AWS
Western Carolina Section, has been
awarded the prestigious A. Wade Martin
Innovator of the Year Award at the South
Carolina Technical
Education Association conference in
February. The award
recognizes individuals in the technical
college system who
employ innovative
approaches to meet
the ever-changing
needs in the techniPaul Phelps
cal education arena
and whose achievements assist in statewide economic development and the education of students.
Phelps has served as program coordinator for the welding program at Tri-County
Technical College where the programs
enrollment has steadily increased from
60 to 120 students. Phelps assists local
companies with prehire assessment, fabrication training, weld testing, quality improvement, and writing procedures. He
helped design and build the colleges
43,000-sq-ft Industrial Technology Center that houses the welding and HVAC
programs. In 2007, Phelps received the
Section Educator Award.
Michael D. C. Moles
Michael D. C.
Moles, P.E., 66, died
Feb. 13 in Toronto,
Canada, where he
was an adjunct professor at the University of Toronto, Department of Mechanical and Industrial
Engineering, teachMichael Moles
ing a graduate course
on advanced ultrasonic inspection techniques. A long-time
member of the nondestructive testing
community, he received his PhD in metallurgy in 1972 from the University of
Cambridge and MBA from McMaster
University in 1984. A member of AWS for
ten years, he also was active with ASME,
ASTM, ASNT, and CINDE.
Your published paper posted on the AWS Web site for FREE
access worldwide (www.aws.org/w/a/research/index.html)
No page charges
Welding
Welding Journal
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EDUCATION OPPORTUNITIES
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SALE OR RENT
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awkeye Borescopes
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(800) 443-9353, ext. 220
Sandra Jorgensen
sjorgensen@aws.org
(800) 443-9353, ext. 254
gradientlens.com/welding
800.536.0790
email: joe@joefuller.com
Phone: (979) 277-8343
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Experimental
Introduction
In the 1980s, ceramic abrasive was
introduced, which contained a submicron,
microcrystalline grain size (Ref. 1). When
used correctly, these abrasives fracture in
small pieces, maintaining wheel sharpness
while minimizing wheel wear. In subsequent years, different varieties of these
abrasives were produced, including a grit
that was manufactured with a specific
geometry an engineered-shape abrasive
which was created through an extrusion
process to yield the spaghetti grit with
an aspect ratio of 4:1 and later 8:1 (Ref. 1).
Recently, a new abrasive type has been
developed a microcrystalline ceramicgrit with a unique, engineered shape taking the form of a thick triangle.
Unfortunately, little to no scientific information is available on the material-removal mechanisms or wear mechanisms of
this abrasive, other than some broad statements on the manufacturers website
claiming longer tool life and less pressure
to remove the same amount of material,
but without any supporting scientific information. Moreover, it is not uncommon
for abrasives producers to make broad
JEFFREY
BADGER
(www.thegrinding
doc.com) works independently as The Grinding
Doc, a consultant in grinding, assisting companies
around the world in improving their grinding operations, Austin, Tex.
KEYWORDS
Engineered-Shape Abrasive
Coated Abrasive
Ceramic Grit
Test Setup
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
Plunge
Disc A, 80
Disc B, 80+
Disc C, 36
Disc D, 36
Disc E, 36+
0.8 m
1.2 m
4 m
4 m
6 m
Feather
0.4 m
0.5 m
3 m
3 m
4 m
less of the removal rate achieved. A forcetransducer was used to measure this force,
giving a value of FN ~10 lb (45 Newtons).
The specific energy, e, is typically calculated by e=P/Q, where P is the grinding
power in watts and Q is the materialremoval rate in mm3/s (Ref. 2). However,
the material-removal rate in weld grinding
is not constant. Therefore, specific energy
was calculated from first principles by
e=W/V
(1)
P ( t ) dt
(2)
Grinding was performed with two 80mesh discs and three 36-mesh discs. One
80-mesh disc and one 36-mesh disc each
contained engineered-shape abrasive.
(Mesh is a measure of grit size, which can
be approximated in standard abrasives by
dg = 15.2/M, where dg is the average grit
diameter in mm and M is the mesh size.)
The patent for the engineered-shape
abrasive (Ref. 3) states the abrasive is triangular shaped of various sizes and thicknesses, with tapered edges of various
angles, which allow the abrasive to stand
on end at various angles, giving different
attack angles. Grooves are put into one
side of the abrasive which, according to
the patent, give advantages in manufacturing and in self-sharpening (Ref. 3).
Results
80-Mesh Discs
Disc A, 80
Disc B, 80+
Disc C, 36
Disc D, 36
Disc E, 36+
Vf (mm3)
Dr (mm3/mm2)
8,200
63,000
9,100
9,100
>>31,000
1.1
8.5
1.2
1.2
>>4.2
Figure 5 shows wear depth vs. the number of segments ground for disc A and disc
B. Because the disc is not dressed, the
height of the single layer of the grits varies
drastically around the area of the disc, similar to a single layer in electroplated
wheels (Ref. 4). In addition, initially the
disc will not contact on all areas. ThereWELDING JOURNAL 109-s
WELDING RESEARCH
WELDING RESEARCH
H and L, high
Disc A, new
H and L, low
Disc A, worn
45N (mm3/45N)
e (J/mm3)
30
30
3
3
20 (100% higher)
10 (50%)
110 (+69% higher)
65
fore, there will be a large scatter in measurements, as shown in the figure. However, if the average value is taken, the
general trend of rapid initial wear is apparent, as the high grits are either knocked
out or flattened, with the spread in measurements decreasing as the disc wears. In
disc B, which contains the engineeredshape abrasive, the initial spread is
smaller, perhaps owing to the more uniform height of the upright abrasives. In addition, it can be seen that disc wear is also
rapid and then steady.
Discussion
G-Ratio D-Ratio
material ground away at disc failure, Vf, divided by the active abrasive area, As, according to Dr = Vf /As. Results are given
in Table 2.
Disc Ratio, Dr
(3)
38
18
9
10
4.5
Cg (grits/mm2)
5.4
2.5
1.3
1.4
0.6
4.212
1.75.6
started off at a
much
higher
value, around
=
46
45N
mm3/s/45N, before dropping
and then increasing again
and then slowly
decreasing. A
line-fit shows a
steady decrease
in cutting ability.
In spite of this, Fig. 10 Worn 36-mesh grits.
at the end of its
life, the cutting
ability of disc B
had decreased
only 20% and was still achieving a higher
material-removal rate than disc A had
achieved when new.
Specific energy is an inverse measure
of the efficiency of the process. A higher
specific energy means that more energy
was required to remove the same amount
of material, i.e., the process is less efficient. In general, low specific energies are
desirable and indicate a grinding process
with more cutting and less rubbing. The
relationship between 45N and specific
energy is shown in Fig. 7. Here a direct
correlation can be seen between the two,
with increasing cutting ability giving a corresponding low specific energy. It is interesting to note that, although discs
containing the engineered-abrasive gave
higher values of 45N and lower values of
e, there does not appear to be a difference
in the curve for discs containing the engineered-shape abrasive compared to discs
containing the standard-shape abrasive. It
can also be seen that the material-removal
WELDING RESEARCH
Fig. 8 Trochoidal vs. straight path for surface grinding and face grinding.
WELDING RESEARCH
Disc A, 80
Disc B, 80+
Disc C, 36
Disc D, 36
Disc E, 36+
portion of cutting over rubbing. These values can be compared to the values obtained here for the 80-mesh discs at the
same material-removal parameters, as
shown in Table 3. At 45N = 30, Hahn and
Lindsay obtained a value of e = 20 J/mm3,
whereas Disc A (at segment 1) gave a
value of e = 10 J/mm3 (50%). At 45N =
3, Hahn and Lindsay obtained a value of e
= 110 J/mm3, whereas Disc A (at segment
8) gave a value of e = 65 J/mm3 (59%).
In both cases, the specific energy for the
Vw (mm/s)
hmax (m)
0.15
0.25
0.19
0.22
0.39
0.31
0.59
0.70
0.73
1.50
disc was about half of that of standard cylindrical grinding. This indicates that there
may be something inherently more efficient
with disc grinding than with plunge grinding, regardless of the grit shape.
Disc grinding is a form of facegrinding. The chip shape in face grinding
is different from the chip shape in standard plunge grinding. In plunge grinding
the grit follows a trochoidal path where, in
up-grinding, the grit contacts the workpiece with an effective chip thickness of
zero and then increases to its maximum
chip thickness near the exit point (Ref. 6),
as shown in Fig. 8. (In down-grinding, it
enters at maximum chip thickness and
exits at an effective chip thickness of zero.)
At the entrance, the contact mode is rubbing regardless of the sharpness of the grit
because of the zero chip thickness. Then,
if the grit is sufficiently sharp, the contact
mode shifts to plowing and then cutting. If
the grit has a wear flat, the period of rubbing will be longer or the grit may only rub
and not cut.
In face-grinding, the grit enters at maximum chip thickness and maintains this
chip thickness throughout (Ref. 6). Therefore, if the chip thickness is sufficiently
large to form a chip, it will form this chip
at the entrance point, avoiding the rubbing
regime. This may explain why the grits in
the new standard-shape abrasive were able
to achieve such low specific energies they
avoided the rubbing regime. As will be
seen later, it may also explain why even
The submicron grain size of ceramicabrasive increases its toughness (Ref. 1).
To function properly, the forces acting on
the grits during grinding need to be sufficiently large to induce microfracture of the
grits (Ref. 7). This is achieved with a large
maximum chip thickness. If this chip thickness is not sufficiently large, the grits become dull, resulting in excessive rubbing
and a significant increase in grinding
forces and specific energy. An electronmicroscope image of a grit in a worn,
properly functioning ceramic-grit grinding
wheel is shown in Fig. 9. Here the microfracturing at the grain tip can be seen.
An electron-microscope photo of a disc
C, containing standard abrasive, at the end
of its life is shown in Fig. 10. Several extremely dull, standard-shape grits can be
seen. Figure 11 shows disc B, containing
the engineered-shape abrasive, at the end
of its life. In the foreground the worn area
of the disc can be seen; in the background
the unused area can be seen. In both the
standard-shape abrasive and the engineered-shape abrasive, the grits appear
very worn.
The appearance of dull grits in the
standard-shape-abrasive disc is not surprising considering the large specific energies and low material-removal rates at the
end of its useful life. The appearance of
dull grits in the engineered-shape-abrasive
disc, in contrast, is surprising. It appears
that the grits in the engineered-shapeabrasive disc are not self-sharpening but,
rather, they are developing wear flats.
Wear flats are detrimental to grinding
performance and drastically increase specific energies. This has been measured in
numerous grinding operations for a vari-
WELDING RESEARCH
hardnesses. These are also given, for 80mesh and 36-mesh wheels (Ref. 8).
In the standard-shape abrasive, grit
densities were on the lower end of the
spectrum of values given by Shaw. This is
not surprising considering that dressing in
grinding, which does not occur in discs,
will bring more grits to the surface. The
grit density in the engineered-shape abrasive was much lower, with Cg in the standard-abrasive discs being around 2.2 times
Cg for the engineered-shape abrasive.
WELDING RESEARCH
6
183
54.9
60
3.05
33.5
36.6
Disc B
69
16
20.5
60
0.27
12.5
12.77
Production Times
Although the engineered-shape-abrasive discs gave much longer life in both grit
sizes, this is unlikely to be their primary
advantage. A longer disc life is a benefit,
but not if the disc does not cut well.
Welders are more interested in achieving
higher material-removal rates, i.e., they
want to be able to grind quickly and with
minimal effort while achieving an acceptable surface finish.
If the end-of-life criterion is taken as
either disc failure, i.e., a final stripping
away of the grits; or 45N dropping below
9 mm3/s (in this case a cutting time greater
than 100 s for one segment); then disc A
is able to grind 6 segments before a disc
change is required and disc B is able to
grind 69 segments before a disc change is
required. Applying the criterion above, the
average time to cut one segment was 54.9
s for disc A and 20.5 s for disc B. Therefore, to grind a volume of 1,000,000 mm3
(1M mm3) would require 183 discs when
using disc A and 16 discs when using disc
B. If it is assumed that the disc is in contact
with the workpiece for half the time, with
the rest being checking of the work, etc.,
that gives a grinding time of 33.5 h for disc
A and 12.5 h for disc B. If a disc change requires 60 s, then the total time to remove
1M mm3 of material is around 37 h for disc
A and 13 h with disc B. These figures are
given in Table 6.
The only apparent drawback in using the
engineered-shape-abrasive disc appears to
be the rougher apparent surface finish. If
this is problematic, it can be solved by either
Conclusions
1) In disc grinding, discs containing engineered-shape abrasives in an upright,
thick, triangular form give higher initial
material-removal rates than discs containing standard-shape fused abrasive, with no
significant decrease in material-removal
rates through its life.
2) In disc grinding, engineered-shape
abrasive dulls, but it is able to cut at high
material-removal rates and low specific
energies in spite of this dulling. This may
be due to the near 0-deg rake angle just
below the dull region.
3) In disc grinding, engineered-shape
abrasives may, at least in part, have a chipformation process similar to turning, with
chip formation in front of the grit.
4) In disc grinding, engineered-shape
abrasives give very low specific energies, in
the region of 5 J/mm3, even when dull.
This appears to be due to chip-formation
in front of the grit and the large maximum
chip thickness at the grit entrance in face
grinding.
5) In disc grinding, standard-shape
abrasives give lower specific energies than
in plunge grinding. This appears to be due
to the large maximum chip thickness at the
grit entrance in face grinding, which avoids
some of the rubbing and plowing in plunge
grinding seen in the trochoidal path before
the transition to cutting.
6) In disc grinding, discs containing engineered-shape abrasives are able to re-
Acknowledgments
Funding for this project was provided
solely by The Grinding Doc Consulting.
This study was performed independently by
Dr. Jeffrey Badger without the knowledge
of any of the companies whose products
were tested. The author would like to thank
Mark Jackson and, in particular, the late
Stephen Malkin for their valuable input.
References
1. Marinescu, I., Hitchiner, M., Uhlmann, E.,
Rowe, W., and Inasaki, I. 2007. Handbook of Machining with Grinding Wheels. CRC Press.
2. Rowe, W. B. 2009. Principles of Modern
Grinding Technology. William Andrew.
3. Patent U.S. 2010/ 014 6867. June 17, 2010;
Shaped Abrasive Particles with Grooves, 3M Innovative Properties Co., St. Paul, Minn.
4. Shi, Z., and Malkin, S. 2003. An investigation of grinding with electroplated CBN wheels.
Annals of the CIRP, 52/1: 267.
5. Bhateja, C. 1982. Grinding, Theory, Techniques, and Troubleshooting. Society of Manufacturing Engineers.
6. Malkin, S., and Guo, C. 2008. Grinding
Technology: Theory and Applications of Machining
with Abrasives, Second Edition.
7. Badger, J. 2012. Microfracturing ceramic
abrasives in grinding. ASME 2012 International
Manufacturing Science and Engineering Conference MSE 2012, Notre Dame, Ind.
8. Shaw, M. C. 1996. Principles of Abrasive
Processes. Oxford.
9. Badger, J., and Torrance, A. A. 2000. A
comparison of two models to predict grinding
forces from wheel surface topography. International Journal of Machine Tools & Manufacture,
pp. 10991120.
10. Kannappan, S., and Malkin, S. 1972. Effect of the grain size and operating parameters on
the mechanics of grinding. ASME Journal of Engineering for Industry (8): 844842.
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
The influences of contact pressures (2 to 47 kPa) and amounts of filler metal (Cu9Sn-7Ni-6P with 0.04 to 0.64 mm thickness) on the microstructure and strength of
Cu-alloy (Cu-35Zn-3Pb) brazing joints were evaluated for joint characteristics, i.e.,
joint thickness, microstructure, and strength. Insufficient contact pressure and filler
metal resulted in the formation of cavities within the joint. The causes of cavities were
imperfect wettability of melted filler metal on substrate surfaces as well as entrapped
gas within joints. At low contact pressure and a small amount of filler metal, a significant amount of Cu3P was drawn into an opening and formed Cu3P phases at the
middle of the joint. At high contact pressure and a large amount of filler metal, the
flux and excess melted Cu3P were pressured out of an opening; therefore, joint microstructure was a uniform combination between Cu3P and Cu-Zn-Sn phases. Joint
strength was influenced by the formation of cavities and Cu3P phase. Cavities were
the sites of crack initiation due to their high stress concentration. Consequently,
cracks propagated through brittle phases of Cu3P and cavities, coalesced to other
cracks, and caused final fracture. After minimizing the formation of cavities and Cu3P
phases, the joint strength was 346 MPa, which was about 86% of the substrate
strength.
Introduction
In automobiles, the air-cooled heat exchanger (radiator) has an important role
in engine efficiency and weight. Generally,
aluminum radiators are used in passenger
cars because of their good thermal conductivity, lightweight, and easy joints.
However, the brazing joint of aluminum
alloys loses its strength at temperatures
higher than 150C. At present, the higher
service temperature of the engine is driven
by the requirements of high power output
as well as low energy consumption. Thus,
copper and brass alloys become good alternative materials for automobile radiators because of their high thermal conductivity, strength, and service temperature.
It is known that there are basic requirements to achieve sound brazing
A. HASAP, N. NORAPHAIPHIPAKSA, and C.
KANCHANOMAI (kchao@engr.tu.ac.th) are
with the Department of Mechanical Engineering,
Faculty of Engineering, Thammasat University,
Pathumthani, Thailand. HASAP is also with the
Material Properties Analysis and Development
Centre, Thailand Institute of Scientific and Technological Research, Pathumthani, Thailand.
KEYWORDS
Brazing
Copper Alloy
Filler Metal
Contact Pressure
Shabtay et al. (Ref. 1) found that brasstube and copper-fin radiators could withstand high operating temperatures (0 to
300C) without substantial loss in
strength, i.e., the tensile strength of brasstube alloys decreased from 400 to 260
MPa, and the tensile strength for copperfin alloys decreased from 350 to 260 MPa.
Li et al. (Ref. 2) have evaluated the thickness losses of Cu foil in contact with
melted Cu-P and Cu-Ag binary alloys at
different temperatures. They found that
the amount of dissolved copper in Cu-P
liquid alloys was larger than that in Cu-Ag
liquid alloys. Zhang et al. (Ref. 3) have
brazed copper to copper in a vacuum condition using phosphor-copper filler metal.
They found that the joint structure consisted of hypoeutectic alloys. The primary
phase was copper solid solution (-Cu)
and silver solid solution (-Ag) while the
eutectic phase was copper solid solution
(-Cu), silver solid solution (-Ag), and
Cu3P.
Elmer et al. (Ref. 4) brazed oxygenfree copper (UNS C10100) in a highvacuum atmosphere using alloy shims
(2550 m thickness) and sputter deposit
coating (13 m layer) of Ag, Au, and AuNi alloy as filler metals. Although some
porosities in joints were found for both
filler metal, the tensile strength of the
brazed joints was about 75% of that of the
copper substrate (230 MPa). Merlin et al.
(Ref. 5) have studied induction and laser
beam brazing of Cu-Zn-Ni alloys using
Cu50-AgZn50 filler metal in a reducing
gas atmosphere. The flux has been used to
dissolve oxide during brazing; however,
the oxide layer and porosity occurred in
the joint due to localized overheating.
Karamis et al. (Ref. 6) have investigated
the microstructures and nonconformances of joined zones in brazed copper
tubes widely used in solar collector manufacturing. They found that zone cleaning
to be brazed was an important factor in
preventing porosities. The tendency for
porosity increased when the filler metal
contained elements such as Zn and Cd.
The clearance between substrates is
one of the major concerns in brazing to ensure that the capillary force is high enough
to draw the melted filler metal into an
opening. In practice, the opening clearance could hardly be maintained at high
temperature due to the dimension change
from thermal expansion. Accordingly, it is
believed that the contact pressure between substrates should be controlled instead of an opening clearance during braz-
Cu
Zn
Ni
Fe
Si
Sn
Pb
Mn
Co
Al
Substrate
Filler metal
61.8
77.4
34.7
0.07
7
0.18
<0.0005
0.24
9.3
3.03
<0.0003
6.3
0.01
0.003
WELDING RESEARCH
WELDING RESEARCH
Yield Strength
(MPa)
Tensile Strength
(MPa)
Elongation at 30-mm
Gauge Length (%)
Grain Size
(m)
Hardness
(HV)
As drawn
440
516
8.23
613
Annealed at
450oC for 2 h
225
415
20.5
115
Annealed at
600oC for 1 h
168
398
34.5
10
96
Annealed at
600oC for 2 h
158
400
32.4
11
92
strength. The universal tensile test machine (Instron 5969 with 50-kN load cell
and 0.5 mm/min crosshead speed) was
used in the present work. The tensile tests
were repeated three times, and the joint
strengths were averaged. The error bars
showing the minimum and maximum values of repeated tests were added into the
results. The fractures of tensile specimens
were investigated using an optical microscope.
Finite Element Analysis
=
v
+ ( )
y
+ 6 ( 2 + 2 + 2 )
yz
xy
xz
(1)
where x, y, z are the normal stress components in a rectangular Cartesian coordinate while xy, yz, xz are the shear stress
components in a rectangular Cartesian coordinate. The sizes of element were varied
WELDING JOURNAL 119-s
WELDING RESEARCH
Fig. 7 Relationships between joint thickness and contact pressure at various filler metal
thicknesses.
Fig. 8 Micrograph and EDS analysis of brazing joint A (2-kPa contact pressure and 0.04mm filler metal thickness).
WELDING RESEARCH
until the invariance of the numerical results was satisfied. Then, the independency of numerical results on mesh density
was confirmed. The size of fine elements
was 5 m while that of coarse elements
was 100 m. The total amount of element
was approximately 70,000 elements.
The far-field stress () of 50 MPa was
applied to simulate elastic deformation of
the brazed joint. The elastic modulus (E)
of 97 GPa and Poissons ratio (v) of 0.3
were used for both substrate and brazing
alloys. As a ratio between localized Von
Mises equivalent stress and far-field
stress, a stress concentration factor (SCF)
was calculated, i.e. SCF = v/. The contour plots of SCF were compared between
various brazed joints.
WELDING RESEARCH
Fig. 10 Microstructures of brazed joints. A 2-kPa contact pressure and 0.04-mm filler metal thickness; B 47-kPa contact pressure and 0.04-mm filler
metal thickness; C 2-kPa contact pressure and 0.64-mm filler metal thickness; and D 47-kPa contact pressure and 0.64-mm filler metal thickness.
Fig. 12 Relationships between joint strength and contact pressure at various filler metal thicknesses.
WELDING RESEARCH
Fig. 13 Failures of brazing joints. A 2-kPa contact pressure and 0.04-mm filler metal
thickness; B 47-kPa contact pressure and 0.04-mm filler metal thickness; C 2-kPa
contact pressure and 0.64-mm filler metal thickness; and D 47-kPa contact pressure
and 0.64-mm filler metal thickness.
brazing joint.
Since the Cu3P phase forms at the middle of joints A and B (Fig. 10), the cracks
can easily propagate through the Cu3P
phase (Fig. 13). Thus, strengths of joints A
and B are similar (Fig. 12), and influenced
by both cavities and Cu3P phase. Although
the combination between Cu-Zn-Sn and
Cu3P phases is observed for joint C (Fig.
10), the large size and high amount of
spherical cavities (Fig. 6) can reduce the
load-bearing area of a joint. Therefore,
the strength of joint C is dominated by the
influence of cavities, which results in low
joint strength (Fig. 12).
A different crack path is observed for
joint D (47 kPa contact pressure and 0.64
mm filler metal thickness), i.e., crack
propagates through both the joint-substrate interface and joint. Since the cavities and Cu3P phase within joint D are significantly less than other joints, the strain
mismatch at joint-substrate interface is
likely the main driving force for crack initiation. A number of cracks initiate and
propagate at the joint-substrate interface,
then they coalesce to others. The coalescence of these cracks occurs across the
joint (Fig. 13). At high magnification, it is
observed that these cracks propagate
through the Cu3P phase. Since the size
and amount of spherical cavity and Cu3P
phase are significantly smaller than those
of other joints, the highest average
strength is obtained for joint D, i.e., 346
MPa or about 86% of substrate strength.
Based on the present findings, the
high-strength, Cu-alloy brazing joint could
be achieved by employing the appropriate
brazing, plus proper combination between
contact pressure and amount of filler
metal. The influences of contact pressure
and amount of filler metal on joint defects,
joint microstructure, and joint strength
are understood. These understandings
also provide some guidelines for practitioners to obtain successful Cu-alloy brazing, e.g. 1) a selection of contact pressure
and amount of filler metal to avoid defects
and weak phase microstructure, and 2) a
compromise between joint strength and
amount of filler metal (optimize cost of
filler metal). It is recommended that the
present brazing should be performed with
47 kPa contact pressure and 0.64 mm filler
metal thickness.
Conclusion
The influence of contact pressure (2 to
47 kPa) and amount of filler metal (0.04 to
0.64 mm thickness) on the microstructure
and strength of the Cu-alloy brazed joint
has been evaluated. The findings can be
summarized as follows:
1. Furnace brazing of the Cu-Zn alloy
with a Cu-Sn-Ni-P filler metal is sensitive
to oxidation, i.e., the effectiveness and
consistency of the cleaning process as well
as a controlled environment are necessary.
Successful brazing can be achieved by
using a flux and a nitrogen atmosphere.
2. Both contact pressure and the
amount of filler metal influence joint characteristics, i.e., joint thickness, joint microstructure, and joint strength. Insufficient contact pressure and filler metal
result in the formation of cavities within
the joint; the causes of cavities are imperfect wettability of the melted filler metal
on substrate surfaces as well as entrapped
gas within the joint.
3. At low contact pressure and a small
amount of filler metal, a significant
amount of Cu3P is drawn into the opening,
and the Cu3P phases form at the middle of
the joint. At high contact pressure and a
large amount of filler metal, the flux and
excess melted Cu3P are pressured out of
opening; therefore, joint microstructure is
Acknowledgment
The authors would like to acknowledge
support from the C. H. Wattanayont Co.,
Ltd., the Thailand Research Fund
(TRFIUG5280003), Thailand Commission on Higher Education of Thailand (National Research University Project), National Research Council of Thailand
(NRCT), and National Metal and Materials
Technology Center (MTEC), Thailand.
References
1. Shabtay, Y. L., Ainali, M., and Lea, A.
2004. New brazing processes using anneal-resistant copper and brass alloys. Materials and
Design 25(1): 8389.
2. Li, Y. N., Peng, Z. L., and Yan, J. C. 2012.
The dissolution mechanism of copper weld
brazing with Cu-based brazing alloys. Materials
Science Forum 697698: 394398.
3. Zhang, P. L., Yao, S., Ding, M., Lu, F. G.,
and Lou, S. N. 2010. Microstructural analysis in
the vacuum brazing of copper to copper using a
phosphor-copper brazing filler metal. International Journal of Materials Research 101(11):
14361440.
4. Elmer, J. W., Klingmann, J., and Van Bibber, K. 2001. Diffusion bonding and brazing of
high purity copper for linear collider accelerator structures. Physical Review Special Topics
Accelerators and Beams 4(5): 1227.
5. Merlin, M., Crepaldi, I., Garagnani, G. L.,
and Trebbi, L. 2009. Influence of the brazing
process parameters on the microstructural
characteristics of copper alloy joints. Welding
International 23(8): 606615.
6. Karamis, M. B., Tasdemirci, A., and Nair,
F. 2003. Microstructural analysis and discontinuities in the brazed zone of copper tubes. Journal of Materials Processing Technology 141(3):
302312.
7. ASTM E8M, Standard Test Method for
Tension Testing of Metallic Materials. Volume
3.01, Annual Book of ASTM Standards. 2004.
8. ASTM E92, Standard Test Method for
Vickers Hardness of Metallic Materials. Volume
3.01, Annual Book of ASTM Standards. 2003.
9. United States Patent Number 5190596,
Method of brazing metal surfaces, 1993.
10. ABAQUS Users Manual. ABAQUS Inc.,
2006.
11. erban, V. A., Codrean, C., Uu, D., and
Opri, C. 2009. Amorphous alloys for brazing
copper based alloys. The 13th International
Conference on Rapidly Quenched and
Metastable Materials. Dresden, Germany: IOP
Publishing.
12. Lide, D. R. 2002. CRC Handbook of
Chemistry and Physics. Florida: CRC Press.
13. Sim, R. F., and Willingham, J. A. 1987.
Copper phosphorus based (self-fluxing) brazing alloys used for joining copper and its alloys.
FWP Journal 27(7): 3339.
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
To prevent oxidation of the weld zone inside the pipe, high-quality welding of
stainless steel pipe requires gas purging. Gas tungsten arc (GTA) welding of the 304H
pipes commonly used in refinery applications was done with and without purging gas.
For purging gases argon (Ar), nitrogen (N2), Ar+N2, and N2+10% hydrogen (H2)
were used, respectively. The aim was to determine the effects of purging gases on the
microstructural, corrosion, tensile, bend, and impact toughness properties of the
welded joints. Macro sections of the welds were investigated as well as microstructures. Chemical composition of the weld metal of the joints was obtained by glow discharge optical emission spectroscopy (GDOES). Leco analyzers were used to obtain
the weld root N2, O2, and H2 contents. The ferrite content of the beads was measured with a Ferritscope, and Vickers hardness (HV10) values were measured. Intergranular and pitting corrosion tests were applied to determine the corrosion resistance of the welds. The various purging gases affected corrosion properties as well
as the amount of the heat tints that occurred at the roots of the welds. As obtained
by Leco N2-O2-H2 analysis, a significant increase occurred in the root bead N2 content from 480 to 820 ppm for no-purged and N2-purged welds, respectively. As a result, the ferrite content of the root beads decreased to about 6 Ferrite Number when
changing the purge gas to N2 instead of no purging. However, mechanical properties
were not considerably affected due to purging. 304H steel and 308H consumable
compositions would permit use of N2, including gases for purging, without a significantly increased risk of hot cracking.
Introduction
For the high-quality stainless steel pipe
welds required for power plants, petrochemical facilities, pharmaceutical, brewery, and food-processing factories, the gas
tungsten arc welding (GTAW) process is
preferred (Ref. 1). Weld root quality of
stainless steel pipe and tubes can be ensured by removing the air from the fusion
zone using an inert purging gas. Unsatisfactory purging results in formation of ferrochromium layers of colored oxide films
commonly referred to as heat tints.
Oxygen (O2) contamination in stainless steel welding causes dross or sugaring, referred to in the sanitary industry as
an oxide layer on the root surface of the
weld bead. This is a rough, pitted, and
E. TABAN (emel.taban@yahoo. com) and
E. KALUC are with Kocaeli University
(KOU) Welding Research, Education and
Training Center, and the KOU Engineering
Faculty, Dept. of Mechanical Engineering,
Kocaeli, Turkey. T. S. AYKAN is with
Turkish Petroleum Refineries Corp., Izmit
Refinery, Technical Control and R & D
Dept., Kocaeli, Turkey.
124-s APRIL 2014, VOL. 93
KEYWORDS
304H
GTAW
Purging
Microstructure
Corrosion
Si
0.22
Mn
1.45
Cr
18.00
Mo
0.32
Ni
9.05
Al
0.06
Co
0.07
Cu
0.35
Nb
0.02
Ti
0.01
V
0.06
W
0.02
Fe
Bal.
% Elongation
40
WELDING RESEARCH
Welding Setup
Fig. 2 Photomacrographs of welded 304H pipes. A 04H NP; B 04H A; C 04H N; D 04H
AN; E 04H NH.
WELDING RESEARCH
with a 20-mm mandrel diameter and 180deg bending angle. Subsized notch impact
test samples were extracted transverse to
the welds and through thickness with
notches positioned at the weld metal center
(WM), at the HAZ; 2 mm away from the
weld interface (FL+2 mm) and at base
metal (BM). The impact toughness testing
was done at 20, 20, 40, and 60C.
C
0.040.08
Si
0.5
Mn
1.7
Other
Ferrite Content
Position,
Number of
Total Layers
04H NP
04H A
PA,
04 N
root + 5
filler passes
04 AN
04 NH
Welding
Speed
(mm/s)
Total Heat
Input
(kj/mm)
0.701.00
0.951.81
7.37
5.05
0.901.72
5.5
Interpass
Temp. (C )
100150
0.61.65
5.7
0.701.81
5.38
WELDING RESEARCH
WELDING RESEARCH
Chemical Composition
Cap pass
04H-NP
0.13-0.16
Min: 7.3;
Max: 8.7
(Average 8)
8.011.5
Fig. 5 Photomicrographs of the root side dispalying the intergranular corrosion test samples of the
welds. A 04H NP; B 04H A; C 04H N; D
04H AN; E 04H NH.
ical strength but without the associated disadvantages related to precipitation of carbides and carbon nitrides. No failures were
detected after bending, which indicated
good corrosion resistance. Photomacrographs of the corrosion test samples are presented in Fig. 5, including root sides of the
joints.
Due to the relatively high carbon content of the 304H base metal compared to
304L grade, the risk for intergranular corrosion of the 304H grade would be higher
compared to that of the 304L grade. Thus,
to detect the possible susceptibility to intergranular corrosion, testing in accordance with TS EN 3157/EN ISO 3651-2
was applied by immersing the samples in a
boiling solution of sulfuric acid-copper
sulfate for 20 h followed by bending the
samples.
Nitrogen was added to the shielding
and/or purging gas mainly to improve pitting corrosion resistance but also to improve mechanical strength to some extent.
Corrosion resistance at the root side was
also increased by using pure N2 or N2 with
510% H2 in the purging gas. Higher N2 levels and exposure to higher temperature for
extended periods would end up affecting
the properties of the welds, since N2 in
austenitic stainless steels plays a role similar
to that of carbon in increasing the mechan-
04-AN
04-NH
Min: 3.8;
Min: 0.97;
Min: 4.1;
Min: 2.8;
Max: 4.8
Max: 2.0
Max: 5.1
Max: 3.7
(Average 4.3) (Average 1.5) (Average 4.6) (Average 3.3)
7.59.5
7.48.8
7.38.2
7.7-9.1
Table 5 Chemical Analysis of the Weld Metal of GTAW Welded 304H Pipes
Welded Joint Code
4H NP
4H A
4H N
4H AN
4H NH
C
0.10
0.02
0.07
0.07
0.05
Si
0.15
0.22
0.16
0.20
0.28
Mn
1.64
1.69
1.68
1.63
1.68
Cr
19.80
19.80
19.20
19.70
19.90
Mo
0.06
0.09
0.05
0.08
0.06
Ni
9.50
9.93
9.17
9.39
9.54
Al
0.05
0.06
0.04
0.05
0.04
Co
0.03
0.03
0.03
0.03
0.03
Cu
0.12
0.12
0.12
0.12
0.10
Nb
0.01
0.02
0.01
0.01
0.01
Ti
0.01
0.01
0.01
0.01
0.01
V
0.04
0.04
0.04
0.04
0.04
W
0.03
0.05
0.02
0.02
0.02
Fe
Bal.
Bal.
Bal.
Bal.
Bal.
Table 6 Leco Analysis of the Root Beads of GTA Welded 304H Pipes
Welded joint code
4H NP
4H A
4H N
4H AN
4H NH
480
448
819
470
793
N2 (ppm)
487
484
442
445
820
819
478
474
790
797
260
88
73
66
54
O2 (ppm)
265 260
89
80
75
71
64
62
50
58
H2 (ppm)
2.02 1.87 1.92
1.90 3.80 3.11
1.03 1.90 1.53
1.95 2.0 2.18
2.43 3.08 3.29
Table 7 HV10 of the 304H Pipe GTAW Welds without and with Various Purge Gases
Location of the
Measurement
Root pass
Base metal
04HNP
179181
193
04HA
168170
191
04NH
183186
181
WELDING RESEARCH
WELDING RESEARCH
istry Departments of the Refinery and contributions of IWE Mehmet Bilgen and Asil
Celik Corp. are very much appreciated.
References
1. Bergquist, E. L., Huhtala, T., and Karlsson,
L. 2011. The effect of purging gas on 308L TIG
root pass ferrite content. Welding in the World
3/4, 55: 5764.
2. Saggau, R. 2005. Investigation of the effect
of yellow heat tints on the pitting corrosion behavior of welded stainless steels. PhD thesis,
Technical University Carolo Wilhelmina at
Braunschweig.
3. degard, L., and Fager, S. A. 1993. The pitting resistance of stainless steel welds. Australasian Welding Journal, Second quarter, 2426.
4. Fletcher, M. 2006. Gas purging optimizes
root welds. Welding Journal 85(12): 3840.
5. Sewell, R. A. 1997. Gas purging for pipe
welding. Welding and Metal Fabrication.
6. Andersen, N. E. Welding stainless pipes,
key technology for process industry applications.
Svetsaren 1/2; 5356.
7. Petersens, A. F., and Runnerstam, O. 1993.
Selecting shielding gases for welding of stainless
steels. Svetsaren 47: 2; 1115.
8. Cuhel, J., and Benson, D. 2012. Maintaining corrosion resistance when welding stainless
tube and pipe. Welding Journal 91(11): 4750.
9. Li, L. J., and Davis, T. 2007. Effect of purging gas oxygen levels on surface structure and mechanical properties of GTA welded Type 304
stainless sanitary tube. Journal of Advanced Materials 39(4): 1419.
10. McMaster, J. 2008. Using inert gases for
weld purging. Welding Journal 87(5): 4044.
11. Gooch, T. G. 2010. Welding new stainless
steels for the oil and gas industry. The Welding Institute, March, 16 pages.
12. D18.1/D18.1M:2009, Specification for
Welding of Austenitic Stainless Steel Tube and Pipe
Systems in Sanitary (Hygienic) Applications.
American Welding Society, Miami, Fla.
13. Tusek, J., and Suban, M. 2000. Experimental research of the effect of hydrogen in
argon as a shielding gas in arc welding of high
alloy stainless steel. Intl Journal of Hydrogen Energy 25: 369376.
14. Lippold, J. C., and Kotecki, D. J. 2005.
Welding Metallurgy and Weldability of Stainless
Steels. John Wiley & Sons, New Jersey.
15 MIG welding stainless steel gas mixes.
www.weldreality.com/stainlesswelddata.htm. Visited on May 19, 2010.
First Measurement
before Testing
Weight Measurement
after 24 h
Weight Measurement
after 48 h
Weight Measurement
after 72 h
Total Loss
04H-NP
04H-A
04H-N
04H-AN
04H-NH1
128.176
126.425
124.953
120.187
125.798
126.574
125.105
122.408
118.278
123.782
125.241
124.084
121.685
117.563
123.045
125.092
123.953
121.414
117.348
122.868
3.084
2.472
3.538
2.839
2.929
Table 9 Transverse Tensile Test Results of the GTA Welded 304H Pipes with Various Purging Gases
Welded Joint Code
04H NP
04H A
04H N
04H AN
04H NH
ReH (N/mm2)
431459
427429
405428
412455
423461
Rp 0,2 (N/mm2)
436466
435440
408440
435461
430463
Rm (N/mm2)
645675
644649
619621
636657
629648
% Elongation
36,70
42
32
32
36
Fracture Location
Base metal
Base metal
Base metal
Base metal
Base metal
ABSTRACT
The aim of this study was to evaluate the weldability and tensile shear failure load
of a 2-mm-thick 5754 aluminum alloy sheet (a typical automotive structural material)
joined via ultrasonic spot welding at various energy levels from about 2300 to 5800 J.
The temperature changes at the weld center were monitored during welding. It was
observed that the temperature rise rate and peak temperature increased rapidly with
increasing welding energy. At an energy level between about 5000 and 5500 J, a peak
temperature of more than 500C was reached, leading to significant softening of the
sheets required for proper joining, and a failure load of over 4 kN was achieved. With
increasing welding energy, the interface was observed to change from a wavy line with
some characteristic tree-like bifurcation to discontinuous voids or cracks, and to complete disappearance, corresponding to a progressively expanding joining area from the
periphery to the center of the weld and an increasing tensile shear failure load.
Introduction
Ultrasonic spot welding (USW) is a
solid-state process in which two sheet materials are joined by the application of ultrasonic vibrations at a frequency of ~20
kHz and an amplitude of 2075 m under
a moderate pressure, where the vibrations
are applied parallel to the interface between the sheets (Refs. 14). A solid-state
weld can be achieved via a high-frequency
relative motion between the sheets, coupled with severe plastic deformation and
mechanical interlocking, as well as a
chemical bond involving diffusion (Refs.
58). Compared with resistance spot welding, USW can join aluminum car body
panels at lower energy consumption, using
only 0.61.3 kJ per weld, and create a
C. Y. ZHANG (cyzhang@nwpu.edu.cn) and D.
L. CHEN (dchen@ryerson.ca) are with Dept. of
Mechanical and Industrial Engineering, Ryerson
University, Toronto, Ont., Canada. ZHANG is
also with Science and Technology on Thermostructural Composite Materials Laboratory,
Northwestern Polytechnical University, Xian,
Peoples Republic of China. A. A. LUO is with
Dept. of Materials Science and Engineering, Dept.
of Integrated Systems Engineering, The Ohio
State University, Columbus, Ohio.
KEYWORDS
Ultrasonic Spot Welding
Aluminum Alloy
Tensile Shear
Temperature Monitoring
WELDING RESEARCH
Fig. 2 Schematic illustration of the top view of the bottom sheet, showing
the location of a thermocouple for monitoring the interface temperature
change during USW.
WELDING RESEARCH
Fig. 3 Variation of temperature at the center of the weld with time during
USW at different levels of welding energy.
Experimental
Procedure
USW was reported to reach a peak temperature ranging 35~65% of melting
point of the material. Siddiq and Ghassemieh (Ref. 21) explained the ultrasonic
welding process of 3003 Al alloy by considering a combined effect of both surface
(friction) and volume (plasticity) softening. The coefficient of friction was observed to increase with increasing temperature until a specific temperature, and
then decrease.
Furthermore, the previous USW investigations were mainly carried out using
relatively thin sheets of up to about 1.2
mm. Since Al alloys possess high electrical
and thermal conductivities, the specimen
thickness would play an important role in
the weldability. It was unknown whether a
higher energy input is needed for joining a
thicker sheet, how the temperature and
microstructure would change during
USW, and whether the failure mode would
remain the same. The present study was,
therefore, aimed at examining the temperature change profile during USW and
Ultrasonic spot welds were made on a 2mm-thick wrought 5754-O Al-alloy sheet,
with the nominal composition listed in
Table 1 (Ref. 22). The sheet was cut into
80 15 2-mm test coupons. The length
of the coupons was parallel to the rolling
direction. The surface of the coupons was
prepared by grinding in the direction perpendicular to the coupon length using
#80 emery papers, which gave rise to an
estimated surface roughness (R a) of
about 140 nm.
The test coupons were overlapped for 20
mm along the length direction, forming an
overlapped area of 15 20 mm2 for the lap
welding, as shown in Fig. 1. The welds were
positioned at the center of the overlapped
area. The ultrasonic vibration direction during welding was parallel to the longitudinal
direction of the test coupon. A dual-head,
wedge-reed-type MH2026DWR welding
machine from Sonobond, Inc., West
Chester, Pa., configured with a power controller was used for the welding experi-
Cr
Mn
Mg
Al
Composition, wt-%
0.3
0.5
3.1
Bal
Fig. 4 A Lower magnification; B higher magnification SEM backscattered electron images of the cross section of the spot weld made with a welding
energy value of 2580 J.
Fig. 5 A Lower magnification; B higher magnification SEM backscattered electron images of the cross section of the spot weld made with a welding
energy value of 2839 J.
Table 2 Comparison of the Weldability of Several Al Alloy Sheets with Various Thicknesses
Material
Processing Parameter
1-mm
AA6111-T4
Failure Load
Fracture Mode
Source
3.4 kN
Button pull-out
(Refs. 7, 12)
3.5 kN
Button pull-out
(Ref. 20)
(Ref. 2)
4.7 kN
Present
0.127-mm
1100
0.9-mm
AA6111-T4
2-mm
Clamping force: 1.64 kN,
5754
Welding energy: 4500~5500 J
Temperature rise: ~500C
WELDING RESEARCH
Fig. 6 SEM backscattered electron images of a joint welded with an energy value of 3242 J. A In the center of the spot weld; B near the periphery of the
spot weld.
WELDING RESEARCH
Fig. 7 SEM backscattered electron images of a joint welded with an energy value of 5287 J. A In the center of the spot weld; B near the periphery of the
spot weld.
Failure Mode
Figure 9 shows a
macroscopic view of
the failed samples
welded at different energy levels after lap
shear tests. Although
the welds fractured
basically along the
weld interface, i.e., in
the form of debonding, different extents of bending of the
failed samples were observed. While the
restraining shims were used to maintain
the alignment and minimize the rotation
of the joints, it is inevitable that the spot
weld would inherently experience a rotation. Accordingly, the rotation of the
welds could lead to the bending when the
sample was loaded in tension gradually.
More bending occurred for the samples
welded at higher levels of energy. For the
weld produced with a lower energy of
2196 J (Fig. 9A), the separated sheets remained almost flat. With increasing welding energy to about 3000 J, a certain extent of bending occurred (Fig. 9B). For
the weld made with an energy value of
5287 J, the separated sheets bent significantly, which can be clearly seen in Fig.
9C. The stronger the weld was, the higher
the load and plastic deformation were,
and the higher the degree of bending was.
Fractography
to the left end of the region, several secondary cracks are seen, which occurred
during the tensile shear. It suggests that
the base material should reach its fracture
strength and the fracture initiated in that
area. Figure 10B shows a 3D image of the
bonded zone. It is seen that the zone was
basically flat with a certain amount of
ridges at such a low magnification. A magnified image (Fig. 10C) of the bonded
zone shows a characteristic dimple fracture, where the elongated dimples indicate the shear fracture via void formation/nucleation, growth, and coalescence.
Figure 10D shows the failure mode in the
center region of the fracture surface.
Apart from some small, isolated dimples
and tearing ridges, the predominant feature in the center area is the scrubbing
lines parallel to the loading direction. The
scrubbing lines are generated due to abrasion or galling of asperities of the microscale roughness of the ground sheet surfaces (Refs. 11, 22).
The dimensions of the welds were observed to remain almost constant, regardless of the change in the welding energy.
However, the fraction of the bonded zone
increases and the insufficiently bonded
center zone decreases, as shown in Fig. 11
for the joint made with a higher welding
energy of 5287 J. In the border area at the
left end of Fig. 11A, a big crack can be seen
in the low-magnification SEM image. The
3D view of the boxed area in Fig. 11A reveals that the crack penetrated into the
WELDING JOURNAL 135-s
WELDING RESEARCH
D
C
WELDING RESEARCH
Fig. 10 Fracture surface of the weld made with an energy value of 2196 J. A Macroscopic view of the spot weld button; B 3D view of the bonded zone,
marked by A in Fig. 10A; C dimple-rupture failure mode in the bonded zone; D fracture appearance in the center area of the weld.
Discussion
The formation of a joint in the ultrasonic welding of metals is a complex
process that occurs rapidly under conditions of rubbing action and cyclic deformation at a very high frequency (20 kHz)
with a relatively small amplitude arising
from the ultrasonic vibration. The highfrequency rubbing action generates friction heat and rapid temperature increase
depending on the welding energy applied
Fig. 3. From the cross-section images
shown in Figs. 47 and the failure load
presented in Fig. 8, the quality of the ultrasonic spot welded joints and the tensile
shear failure load increased with increasing welding energy up to about 5287 J at
which the maximum failure load was
achieved. This is a result of the weld area
expanding gradually across the weld interface and the rapid softening of the material as the temperature rose more quickly
Fig. 3. During USW, the microscopic
cyclic strain amplitude dynamically
changed as the weld developed and there
was a complex coupling of the sonotrode
tips with the sheets, accompanied by
acoustic feedback from the parts. Gener-
WELDING RESEARCH
Fig. 11 Fracture surface of the weld made with an energy value of 5287 J. A Macroscopic view of the spot weld button; B 3D view of the bonded zone,
marked by A in Fig. 11A; C dimple-rupture failure mode in the bonded zone; D fracture appearance in the center area of the weld.
atures and more softened material resulted in a better joint, as seen in Figs. 38.
For example, at an energy level of about
5000 J, a peak temperature of as high as
535C has been achieved (Fig. 3), resulting
in a significant loss of strength and effectively improving the softness since the
melting point of this alloy was reported to
be about 600C (Ref. 14). While no hightemperature tensile tests were directly
conducted in the present study, other researchers have reported the considerable
change of yield strength with the temperature. When temperature increased from
room temperature to 371C, the yield
stress fell from 393 to ~28 MPa for 2024T6 alloy and from 115 to 29 MPa for 5154O Al alloy (Refs. 22, 29). It was clear that
a faster temperature rise and higher peak
temperature achieved at a higher level of
welding energy corresponded to a higher
extent of softness and better plastic deformability, thus enhancing the welding
ability of the alloy. As a result, the failure
load increases with increasing welding energy. However, if too high energy was
used, the resulting larger amplitude of ultrasonic vibration could lead to fatigue
damage at the high frequency, whereupon
tween the two sheets being welded increased more rapidly (Fig. 3), and the
sheets became more softened, leading to
more expanding microjoints toward the
center of the weld and a higher lap tensileshear failure load. However, the subsequent decrease in weld strength (Fig. 8)
seen for higher welding energy was related
to the increasing penetration of the
sonotrode tips into the sheet surfaces,
which causes thinning of the weld area.
The above results indicate that the
welding quality of the 5754 Al alloy sheets
progressively improved. In addition, in
agreement with the previous knowledge
(Refs. 7, 12), the welding mechanisms of
the Al alloy involve solid-state deformation, mechanical interlocking, as well as
the formation and progressive spreading
of microwelds. The microjoint density increases with increasing welding energy.
Therefore, it can be concluded that the
weld interface should vary in a similar way
for the thin alloy sheet. However, a higher
welding energy is required for welding the
thicker sheets. This can be seen from Table
2, where the weldability of Al alloys with
different thicknesses was summarized. It
is clear that a higher welding energy is
WELDING JOURNAL 137-s
Conclusions
WELDING RESEARCH
The authors would like to thank the Natural Sciences and Engineering Research
Council of Canada (NSERC) and AUTO21
Network of Centers of Excellence for providing financial support. C. Y. Zhang gratefully acknowledges the financial support
138-s APRIL 2014, VOL. 93
ABSTRACT
The interaction of convective forces in the weld pool of spot gas tungsten arc
(GTA) welding of AISI 1018 steel was examined experimentally and numerically
in this research work. To alter the effect of buoyancy convection in the weld pool,
the multigravity research welding system (MGRWS) was used to investigate highgravity conditions during the welding process. Thus, we were able to examine the
interaction of buoyancy convection with Marangoni effect and Lorentz force; this
interaction determines the penetration of the weld. Different welding conditions
were simulated numerically using the finite-element analysis software COMSOL
Multiphysics. This software allowed calculation of the fluid flow and heat transfer
in the weld pool as a function of gravity level. The numerical results of the weld
geometry showed reasonable agreement with the experimental data. The results
show that the depth of penetration and the size of the weld zone decrease as the
gravity increases. However, for gravity levels greater than 4g the changes in the
depth and width of the weld zone were found to be negligible.
Introduction
Investigation of fluid flow and heat
transfer in the welding process is necessary in order to predict important factors
such as weld zone (WZ) and heat-affected
zone (HAZ) shape/size, cooling rate, thermal stresses, and possibly formation of defects. Beside the Marangoni effect and
electromagnetic forces, gravity-driven
buoyancy-induced flow is one of the major
factors that drive the flow of molten metal
in the weld pool (WP). This buoyancy
force, depending on the mass-density variation in the pool, can reduce or enhance
the Marangoni and electromagnetic
effects (Ref. 1).
Many studies have been conducted in
the last few decades to investigate the fluid
flow and heat transfer numerically and experimentally in welding processes, especially for gas tungsten arc welding
(GTAW). Researchers numerically modeled this welding process either separately
from the arc by assuming a heat flux and a
current density distribution on the top surA. BAHRAMI (bahrama@clarkson.edu) is a
PhD candidate; D. K. AIDUN is professor and
chair of the Mechanical and Aeronautical Engineering (MAE) Dept., and D. T. VALENTINE is
associate professor in the MAE Dept. at Clarkson
University, Potsdam, N.Y.
KEYWORDS
Gas Tungsten Arc Welding
(GTAW)
Weld Pool
High Gravity
Convective Forces
Buoyancy
Marangoni Effect
Lorentz Force
Fluid Flow
Heat Transfer
Computational Methodology
The GTA welding process on lowcarbon steel coupons under different gravity levels are considered in this study.
Schematic representation of the geometry
WELDING RESEARCH
WELDING RESEARCH
Table 1 Thermophysical Properties and Arc Parameters Used in the Numerical Simulation
Property Name
Value
Ambient temperature
Liquidus temperature
Solidus temperature
Boiling temperature
Heat of fusion
Heat of vaporization
Solid specific heat
Liquid specific heat
Solid thermal conductivity
Liquid thermal conductivity
Solid density
Liquid density
Volume thermal expansion of liquid
Dynamic viscosity
Effective radius of current density distribution
Effective radius of heat source
Vacuum permeability
Convective heat transfer coefficient
Surface emissivity
Arc efficiency
293K
1802 K (Ref. 25)
1770 K (Ref. 25)
3200 K (Ref. 26)
240 kJ/kg (Ref. 25)
6340 kJ/kg (Ref. 26)
750 J/kgK (Ref. 25)
840 J/kgK (Ref. 25)
39.4 W/mK (Ref. 25)
36.5 W/mK (Ref. 25)
7530 kg/m3 (Ref. 25)
7150 kg/m3 (Ref. 25)
1.2104 /K (Ref. 25)
6.3103 kg/(m.s) (Ref. 25)
4.5 mm
3.5 mm
410-7 N/A2
20 W/m2K
0.75
75% (Calibrated with experiment at 1 g)
u
2
+ u u = P + u + Gr
1
+ Rm j B + K u
u
Ro
(1)
where u*, t*, P*, , j*, B*, and * are di-
TL3 g
Rm =
Ro =
v2
0 I 2
2 l v2
v
2 L2
3r
3I
j ( r ) = 2 exp 2
ature, a surface, Marangoni force drives
ri
ri
the flow. This effect is applied as a surface stress boundary condition. Surface
(2)
tension in molten Fe-S alloys is known to
be a function of temperature and sulfur
where I is the electric current and ri is the
activity. The equation correlated by
effective radius of the current density disSahoo et al. (Refs. 22, 23) for the temtribution. The bottom surface of the BM
perature gradient of surface tension is
domain is the ground and all the other
applied in this investigation.
boundaries are considered as electrically
1018
Fe
Bal
C (wt-%)
0.150.20
Mn (wt-%)
0.600.90
Si (wt-%)
0.150.30
P (wt-%)
<0.04
S (wt-%)
<0.03
WELDING RESEARCH
WELDING RESEARCH
12 V
150 A (DCEN)
Pure argon (14 L/min)
W+2%ThO2, 2.4 mm, flat tip
5 mm
3 mm
15 s
1 g, 1.9 g, 3.6 g, 6.7 g
Lorentz force. Finally, the Non-Isothermal Flow module is applied to solve for
the velocity and temperature fields; the
gravity-induced buoyancy and Lorentz
forces are added to the fluid flow model as
source terms and Marangoni effect is applied to the top surface as a weak form
contribution (Ref. 24). The discretization
of the fluid flow is set to P2+P1, which
means quadratic for velocity and linear for
pressure. The discretization for the heat
transfer is set to quadratic. A very fine unstructured triangular mesh with maximum
element size of 0.05 mm was applied to the
weld pool domain while the mesh in the
solid domain is coarser with maximum element size of 0.5 mm. The total number of
triangular elements is 11,941 with an average element quality of 0.979. A fully coupled time-dependent solver with maximum time step of 0.1 s was used to solve
the system of equations. The simulations
were repeated for different gravity levels
using a parametric sweep capability. This
capability helps significantly in postprocessing the computational results.
Experimental Procedure
High-gravity environments were performed in the Clarkson University experimental facility with the multigravity research welding system (MGRWS) Fig.
3. The MGRWS, with an arm length of
1.15 m, is capable of rotating up to 86
rev/min, which imposes a g of 10 g (1 g =
9.81 m/s2) on the test specimen. The welding box is pivoted to the arm so that g is
always perpendicular to the bottom of the
box or the workpiece.
Samples of 1018 steel in the size of
25.4 25.4 6.3 mm were prepared.
Table 2 itemizes the composition of 1018
steel used in this study. Coupons were
polished and cleaned with acetone prior
to welding. The samples were subjected
to the spot GTAW process with the parameters listed in Table 3.
Results and
Discussion
C
Fig. 8 Velocity field in the weld pool for three
B 3.5 g; C 7 g.
After loading the sample into the sample holder, the MGRWS was first brought
up to the rotation speed of interest, i.e.,
the speed that provided the desired glevel (g). At this moment, the arc was
turned on and a spot weld at the center of
the sample was performed for an arc time
of 15 s. The machine continued to rotate
at the set rev/min for an additional 5 s to
allow for solidification and cooling under
the same condition. Subsequently, the
system was brought to rest to extract the
workpiece. The welding experiment was
performed for four simulated gravity levels as indicated in Table 3.
The welded samples were sectioned
by a diamond saw, polished, and macroetched for evaluating the WZ profile.
The WZ was photographed using a 20
stereomicroscope. The depth (d) and
width (w) of the WZ were accurately
measured using ImageJ software.
WELDING RESEARCH
tFig. 9 Maximum velocity inside the weld pool and on the surface, and
their ratio (VM/VS).
WELDING RESEARCH
centrally outward vortex (vortex A) is generated adjacent to the surface. In this vortex, the buoyancy convection and the
Marangoni convection have the same direction of flow while the Lorentz force induced convection has the opposite direction of flow.
Deeper in the WP the effect of surface
flow due to Marangoni convection is negligible; therefore, within the WP the
Lorentz and buoyancy forces, with opposing flow directions along the centerline,
determine the net fluid flow. Since the
Lorentz force is dominant, a centrally
downward flow is induced in the WP. The
maximum speed of the molten metal near
the core of vortex A at the interface is two
to more than four times the maximum velocity along the centerline adjacent the
core of vortex B; the quantitative predictions of these observations are discussed
in a subsequent paragraph. Although vortex B is not as strong as vortex A, vortex B
covers a larger area in the interior portion
of the WP, as illustrated in Fig. 8A.
By comparing the velocity fields in Fig.
8B, C, it is observed that vortex B becomes
weaker at higher g levels. By increasing
buoyancy force, the net driving force
within the weld pool, which is the result of
the two opposing forces, viz., the Lorentz
and the buoyancy forces, vortex B becomes weaker and the speed of the molten
metal within a relatively large region near
the bottom of the WP almost vanishes at
highest g level.
Finally, the effect of gravity on the
maximum velocity at the surface and the
maximum velocity along the centerline of
the WP are presented in Fig. 9. As illustrated in the figure, the maximum velocity
along the centerline of the WP, VM, decreases by increasing the gravity level.
After the gravity level of 4 g, the velocity
curve levels off and approaches zero; it is
at this and higher g levels that the region
near the bottom of the WP where the
speed of the fluid is negligible. The surface
velocity, VS, increases up to a gravity factor of 4 and then starts to decrease slightly.
Conclusions
The effect of enhanced gravity on the
fluid flow and heat transfer that determine
the WP geometry in the spot GTA welding
process of 1018 low-carbon steel was studied. The MGRWS was used to obtain experimental results while the finite-element method coded in COMSOL was
applied to perform numerical simulations.
Reasonable agreement of WP geometry
between experimental and numerical simulations confirmed the validity of the
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