WJ 2012 12 PDF

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
December 2012
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3 WELDING JOURNAL
CONTENTS
24 Reducing the Ecological Impact of Arc Welding
Some practical advice is offered for ways to reduce energy
consumption when welding
M. A. Purslow
28 Program Aids in Modeling Welding Thermodynamics
Examples are given how computational thermodynamics is
used to help design welding alloys and improve process
efficiency
P. Mason
32 Green: A Way of Life for Weld Tooling Company
A shop that specializes in manufacturing weld fixtures has
been recycling for so long, it has become second nature to its
operation
B. Kratz
38 Moving from Paper to Pixels
There is a way to save time and money with the use of welding
documentation software
D. Craig
Welding Journal (ISSN 0043-2296) is published
monthly by the American Welding Society for
$120.00 per year in the United States and posses-
sions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
$14.00 single issue for international. American
Welding Society is located at 8669 Doral Blvd.,
Doral, FL 33166; telephone (305) 443-9353. Peri-
odicals postage paid in Miami, Fla., and additional
mailing offices. POSTMASTER: Send address
changes to Welding Journal, 8669 Doral Blvd.,
Suite 130, Doral, FL 33166. Canada Post: Publi-
cations Mail Agreement #40612608 Canada Re-
turns to be sent to Bleuchip International, P.O. Box
25542,London, ON N6C 6B2
Readers of Welding Journal may make copies of
articles for personal, archival, educational or
research purposes, and which are not for sale or
resale. Permission is granted to quote from arti-
cles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
excluded from copyright.
Departments
Editorial ............................4
Washington Watchword ..........6
Press Time News ..................8
News of the Industry ............10
Aluminum Q&A ..................14
Brazing Q&A ......................16
Product & Print Spotlight ......18
Coming Events....................40
Certification Schedule ..........44
Society News ....................47
Tech Topics ......................48
Errata AWS D3.6M:2010 ......48
Underwater Welding Code
Guide to AWS Services ........64
Personnel ........................68
The American Welder
Learning Track ..................84
Fact Sheet ......................88
Welding Journal Index ..........96
Classifieds ......................108
Advertiser Index ................110
319-s Development of an Oxyrutile Electrode for Wet Welding
An experimental electrode developed for underwater welding
showed improved weld metal properties
V. R. Santos et al.
329-s Modeling of Human Welder Response to 3D Weld Pool
Surface: Part II Results and Analysis
An initiative was made to develop a model that simulates a human
welders response to a weld pool in an effort to improve intelligent
robotic systems
W. J. Zhang and Y. M. Zhang
338-s Theoretical and Empirical Validation of a Mobile
Robotic Welding Platform
A mobile robot welding system was investigated to expand the use
of robots for nontraditional fabrication of large products such as
ships
J. Stacy and S. Canfield
346-s Double Stage Plasma Arc Pipe Welding Process
A plasma arc system that utilized both the keyhole and conduction
modes was used to produce a desirable root weld in pipe
X. R. Li et al.
Features
Welding Research Supplement
The American Welder
32
78
73
December 2012 Volume 91 Number 12
AWS Web site www.aws.org
73 Selecting Fume Collectors for Welding Applications
The seven most important things to take into consideration
when searching for a cartridge fume-collection system are
addressed
G. Schreier
78 From the Lab to the Production Floor: Students Learn It All
Ferris State University welding students are benefiting from a
close working relationship with industry professionals
K. Packard et al.
December 2012_Layout 1 11/8/12 10:19 AM Page 3
EDITORIAL
My year as president of the American Welding Society (AWS) is rapidly winding
down, but I have seen enough positive changes in the past 12 months to keep me invig-
orated for a long time. Those of you who attended the AWS business meeting last
month in Las Vegas heard me speak about recent successes with our American
Welding Online training programs, the move of AWS into a new World Headquarters,
the Welding Merit Badge introduced by the Boy Scouts of America, and some of the
work we are doing in developing new business around the world. But, perhaps the
most important project AWS is involved in at the moment is the workforce develop-
ment program presently being managed through the AWS Foundation.
I am sure you are familiar with the scenario by now: 1) an aging workforce of skilled
professionals is declining by approximately 10% per year, primarily through retire-
ment; 2) an insufficient number of young people are entering the field to replace
them; and 3) the country is facing a shortfall of qualified people in many welding fields
that could reach 238,000 by 2019.
AWS is working diligently to address what we call the welder shortage, and many
programs have been put into place to inform students, parents, career counselors, and
even mid-career professionals of the numerous opportunities in the field of welding.
This is being done by publishing career guides, exhibiting at various trade shows, seek-
ing attention of print and broadcast media, and alerting public officials to the prob-
lem. However, the biggest and most visible step in workforce development may be the
launch of the AWS/Lincoln Electric Careers Trailer.
Lets take a look at how this latter initiative developed. A couple of years ago, I was
shown a welder training tractor-trailer that former AWS District Director Ken
Stockton had built. I was impressed, and I brought the idea of doing something simi-
lar to the AWS Board this time with computer-based virtual welding equipment
that has special appeal to young people. The trailer was formally launched at the 2011
FABTECH Show in Chicago. It has since taught many thousands more people about
job opportunities in welding as it has traveled across North America. This year, the
Welding Careers Trailer visited Ohios State of the State event, FABTECH Canada
in Toronto, the Boy Scouts Camporee in Ohio, the Indy 500 automobile race, the
Airventure Air Show in Wisconsin, several state fairs, the IMTS show in Chicago,
FABTECH 2012 in Las Vegas, and numerous other events.
And, this is just the beginning. We have a great deal of work to do in informing the
public about the importance of welding in our lives, the varied employment opportuni-
ties in this field, and how to get the training needed to start on this exciting career path-
way. Judging by media attention to our efforts, and by fast-growing enrollment in welder
training programs, weve got the publics attention. We also have the attention of weld-
ing and manufacturing organizations in other countries, which are facing similar kinds
of difficulties filling positions in the skilled trades. We have seen enthusiastic response
to our workforce development efforts from welding and trades organizations in Europe,
Asia, and Australia after all, its a worldwide problem demanding cooperative solu-
tions that serve to heighten the profile of welding technology everywhere.
Its been a short year as AWS president, but we have been able to launch a career-
building effort that will serve our industry, and our
country, long-term. I can think of few things more
gratifying than to see this come to pass.
DECEMBER 2012 4
Officers
President William A. Rice Jr.
OKI Bering
Vice President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
J. C. Bruskotter (Past President), Bruskotter Consulting Services
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (Dist. 22), Tri Tool, Inc.
R. A. Harris (Dist. 10), Total Quality Testing
D. C. Howard (Dist. 7), Concurrent Technologies Corp.
J. Jones (Dist. 17), Victor Technologies
W. A. Komlos (Dist. 20), ArcTech, LLC
R. C. Lanier (Dist. 4), Pitt C.C.
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
D. L. McQuaid (At Large), DL McQuaid & Associates
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. R. Polanin (Dist. 13), Illinois Central College
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
N. S. Shannon (Dist. 19), Carlson Testing of Portland
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Meeting the Welding
Workforce Shortfall Head-on
William A. Rice
AWS President
Editorial December 2012_Layout 1 11/9/12 1:21 PM Page 4
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Manufacturing Competitiveness Act
Passed by House
The House of Representatives, on a bipartisan vote, has ap-
proved the American Manufacturing Competitiveness Act of
2012 (H.R. 5865). This legislation will create a bipartisan Manu-
facturing Competitiveness Board consisting of 15 members, five
from the public sector appointed by the president including
two governors from different parties and ten from the private
sector appointed by the House and Senate, with the majority ap-
pointing three and the minority two in each chamber. The board
will conduct a comprehensive analysis of the U.S. manufacturing
sector, covering everything from trade issues to taxation, regula-
tion, and new technologies. Based on this analysis, it will develop
a strategy that includes specific goals and recommendations for
achieving them. The first strategy will be due in 2014 and the sec-
ond in 2018. The particular areas of focus include the following:
Elimination or repeal of regulations that create disadvantages
for U.S. manufacturers compared to foreign competitors;
Improvement of government policies and coordination of pol-
icy implementation;
Consolidation or elimination of government programs; and
Improvement of communication and interaction between gov-
ernment and the manufacturing community.
Public-Private Partnerships to Support
Manufacturing
Ten public-private partnerships have been awarded $20 mil-
lion to support manufacturing in the United States. The partner-
ships were selected through the Advanced Manufacturing Jobs
and Innovation Accelerator Challenge (AMJIAC), which is a
competitive multiagency grant process, to support initiatives that
strengthen advanced manufacturing at the local level. These pub-
lic-private partnerships consist of small and large businesses, col-
leges, nonprofits, and other local stakeholders that cluster in a
particular area. The funds will help the winning clusters support
local efforts to spur job creation through a variety of projects,
including initiatives that connect innovative small suppliers with
large companies, link research with the start-ups that can com-
mercialize new ideas, and train workers with skills that firms need
to capitalize on business opportunities.
The AMJIAC is a partnership between the Department of
Commerces Economic Development Administration, the Na-
tional Institute of Standards and Technology, the Department of
Energy, the Department of Labors Employment and Training
Administration, the Small Business Administration, and the Na-
tional Science Foundation.
FTC Issues Revised Green Guides
The Federal Trade Commission (FTC) has issued revised
Green Guides that regulate claims by companies about the en-
vironmental attributes of their products. Among other modifica-
tions, the guides caution companies not to make broad, unquali-
fied claims that cannot be substantiated, such as a product being
environmentally friendly or promoting sustainability. The
guides also clarify guidance on compostable, ozone, recyclable,
recycled content, and source reduction claims. The FTC has
brought several actions in recent years related to allegedly de-
ceptive recyclability, biodegradable, and environmental certifi-
cation claims as part of its overall effort to ensure that environ-
mental marketing is truthful and substantiated.
Bill Introduced to Limit Reach of
EPA Science Board
The Environmental Protection Agency (EPA) Science Advi-
sory Board (SAB) Reform Act (H.R. 6564), seeks to lessen the
influence of the SAB, which in recent years has been criticized
for being populated by persons who lack private sector experi-
ence and who receive grants from EPA, presenting possible con-
flicts of interest. Concern has also been expressed regarding the
lack of opportunity for the public or other interested parties to
offer comments on SAB recommendations. The SAB historically
has been quite influential in advising the EPA on regulations and
other initiatives. Defenders of the current SAB structure believe
that the body offers guidance unfettered by considerations unre-
lated to science.
This legislation would, among other measures, allow for pub-
lic participation and public comment opportunities, impose re-
quirements for balance, establish a conflict of interest policy, and
limit any nonscientific policy advice or recommendations from
the SAB.
Effectiveness of Agency Performance Laws
Questioned
A recent study by the Brookings Institution suggests that con-
gressional efforts over the past several years at improving the
overall management and performance of federal agencies have
been ineffective. The centerpiece of the strategy to enhance man-
agement effectiveness has been the creation of a federal per-
formance management system. This system consists of a set of
routines to measure and disseminate performance data, with the
hope that such data will be used to improve programmatic out-
comes. Importantly, federal law also requires agencies to develop
and publish performance plans and reports on a regular basis.
However, according to the study, agency managers indicate
that these systems only improve the establishment of perform-
ance goals and measurements for those goals, but have little or
no impact on the actual accomplishment of them.
U.S.-Panama FTA Imminent
Final implementation of the U.S.-Panama Free Trade Agree-
ment reportedly is imminent. The United States has taken all
steps necessary for finalization, and the FTA is now awaiting sig-
nature by the president of Panama.
Over 86% of U.S. exports of consumer and industrial prod-
ucts to Panama will become duty-free immediately, with remain-
ing tariffs phased out over ten years. The U.S. products that will
gain immediate duty-free access include information technology
equipment, agricultural and construction equipment, aircraft and
parts, medical and scientific equipment, environmental products,
pharmaceuticals, fertilizers, and agro-chemicals. United States
industrial goods currently face an average tariff of 7% in Panama,
with some tariffs as high as 81%.
WASHINGTON
WATCHWORD
DECEMBER 2012 6
BY HUGH K. WEBSTER
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
Contact the AWS Washington Government Affairs Office at
1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
hwebster@wc-b.com; FAX (202) 835-0243.
WW December_Layout 1 11/9/12 2:35 PM Page 6

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PRESS TIME
NEWS
Apples New iMac Constructed with Friction Stir Welding
The new Apple iMac has its front
and back panels joined by friction stir
welding (FSW). Originally, engineers
faced a challenge deciding what process
to use because the panels are too thin
to weld using traditional methods. They
searched for other ideas and found FSW
is commonly used on airplane wings,
rocket booster tanks, and other parts.
The process uses a combination of in-
tense friction-generated heat and pres-
sure to intermix the molecules of the two
aluminum surfaces. It also creates a
seamless, precise, and superstrong joint.
The new computer case design would
not be possible without it.
According to Apple, the case is 5-mm thin at its edge with up to 40% less volume
than the previous generation. To do this required inventing new technologies, pioneer-
ing new manufacturing techniques, and devising all-new ways to do more in less space.
United Stationers Signs Agreement to Acquire O.K.I.
United Stationers, Inc., Deerfield, Ill., recently announced its wholly owned sub-
sidiary, United Stationers Supply Co., has signed a stock purchase agreement to acquire
100% of the outstanding shares of O.K.I. Supply Co., Cincinnati, Ohio, the largest inde-
pendently owned welding, safety, and industrial products wholesaler in the country, for
an all-cash purchase price of $90 million. The transaction was expected to be completed
in November 2012, subject to customary closing conditions.
We are pleased to have the opportunity to join United Stationers and ORS Nasco,
and we see it as a perfect fit for our customers, suppliers, and company, said Bill Rice,
president/CEO of O.K.I. and AWS president. The scale and capabilities that this part-
nership represents uniquely positions us to bring additional value to our customers, en-
abling them to succeed in an evolving market.
GE, Manufacturing Institute, Alcoa, Boeing, and
Lockheed Martin Launch Coalition to Train U.S. Veterans
GE joined with business, digital, academic, and not-for-profit partners to launch a
new coalition, Get Skills to Work, that aims to train military veterans for advanced man-
ufacturing jobs, bolster the talent pipeline, and enhance American competitiveness.
The coalition will focus on accelerating skills training for U.S. veterans; helping
veterans and employers translate military skills to advanced manufacturing jobs; and
empowering employers with tools to recruit, get on board, and mentor veterans. It
will be managed by the Manufacturing Institute and supported through financial and
in-kind commitments from GE, Alcoa Inc., Boeing, and Lockheed Martin. The initial
investments will help 15,000 veterans translate military experience to corresponding
advanced manufacturing opportunities and gain technical skills needed to qualify for
these careers.
The coalition is seeking additional partners to meet its goal of reaching 100,000 vet-
erans by 2015. To learn more, visit www.GetSkillstoWork.org.
AWS Careers in Welding Trailer Earns Design Award
The AWS Careers in Welding Trailer recently won a silver 2012 Event Design Award
in the best mobile marketing vehicle category. The 53-ft, single expandable trailer
designed by MRA Experiential Tours and built by Triune Specialty Trailers features
650-sq-ft of exhibit space. It showcases five Lincoln Electric VRTEX 360 welding sim-
ulators along with interactive educational exhibits. Descriptions of each award-winning
project appeared in the November issue of Event Design magazine.
DECEMBER 2012 8
MEMBER
Publisher Andrew Cullison
Publisher Emeritus Jeff Weber
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coordinator Melissa Gomez
Design and Production
Production Manager Zaida Chavez
Senior Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Paneca
Senior Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Sylvia Ferreira
sferreira@aws.org
8669 Doral Blvd., Doral, FL 33166
(305) 443-9353 or (800) 443-9353
Publications, Expositions, Marketing Committee
D. L. Doench, Chair
Hobart Brothers Co.
S. Bartholomew, Vice Chair
ESAB Welding & Cutting Prod.
J. D. Weber, Secretary
D. Brown, Weiler Brush
T. Coco, Victor Technologies International
J. Deckrow, Hypertherm
D. DeCorte, RoMan Mfg.
J. R. Franklin, Sellstrom Mfg. Co.
F. H. Kasnick, Praxair
D. Levin, Airgas
E. C. Lipphardt, Consultant
R. Madden, Hypertherm
D. Marquard, IBEDA Superflash
J. Mueller, Victor Technologies International
J. F. Saenger Jr., Consultant
S. Smith, Weld-Aid Products
N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
R. Ranc, Ex Off., Superior Products
W. A. Rice, Ex Off., OKI Bering
R. W. Shook, Ex Off., American Welding Society
D. Wilson, Ex Off., Well-Dean Enterprises
Copyright 2012 by American Welding Society in both printed and elec-
tronic formats. The Society is not responsible for any statement made or
opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not in-
tended for use without independent, substantiating investigation on the
part of potential users.
Friction stir welding joins the new iMacs front
and back panels. (Photo courtesy of Apple.)
PTN DECEMBER 2012_Layout 1 11/9/12 1:32 PM Page 8
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DECEMBER 2012 10
NEWS OF THE
INDUSTRY
AWS District 8 Director Joe Livesay presented the Societys
Extraordinary Welding Award for Marking Time, a stainless steel
sundial sculpture at the I-40 Smith County Welcome Center,
Buffalo Valley, Tenn., to Knoxville Artist Preston Farabow on
October 9.
It is quite an honor to have been recognized for this award,
Farabow said.
The sundial incorporates markers representing all 95 coun-
ties in the state. It points true north with the angle of the main
structure precisely at 36.14 deg to correspond to the degrees of
latitude for the site.
We had a beautiful day for the dedication. I believe that it
was the first time I have been at the site when the solar time as
displayed by the sundial and local time (CST) were in agreement
with each other, Farabow added.
Approximately 35 people attended the ceremony, including
Don Sadler, director, Tennessee Technology Center at Crossville;
the mayor of Smithville; the Chamber of Commerce president;
DOT officials; Dave Porter, Red Boiling Springs School, a new
AWS SENSE school, and his class; and Josh Burgess, metallur-
gist, University of Tennessee, Knoxville. Following the event, a
BBQ lunch was served.
From concept to completion, it took more than three years
for Farabow to create the sculpture, which was dedicated on May
14, 2007. Welding techniques used were gas metal arc and gas
tungsten arc welding. Materials incorporated in the sculpture
include stainless steel, concrete, earth, and stone.
My intention with the sundial was simply to provide an op-
portunity to pause and watch time pass, Farabow explained.
The ceremony gave me yet another opportunity to pause, and
specifically to reflect on the role that iron workers and welders
have played in our history. Our country today exists in its promi-
nence in the larger world, in my opinion, largely due to the work
of welders. Shipbuilders, iron workers, blacksmiths, and fabrica-
tors all are responsible for what we regard as the structure of
America.
The AWS Extraordinary Welding Award, selected by the AWS
Past Presidents Committee, celebrates technical design for out-
standing development in welded fabrication, recognizing weld-
ing excellence in construction, fabrication, and manufacturing,
and designating those welded structures whose purpose has im-
portance in, or influence on, history.
This public art project was also created in partnership with
former First Lady of Tennessee Andrea Conte, the wife of Gov-
ernor Phil Bredesen (20032011), the Tennessee Arts Commis-
sion, Tennessee Department of Transportation, and the Ten-
nessee Department of Tourist Development.
(Top) The Marking Time stainless steel sundial sculpture at the I-40
Smith County Welcome Center, Buffalo Valley, Tenn., incorporates
markers representing the states 95 counties.
(Bottom) At a ceremony on October 9, AWS District 8 Director Joe
Livesay (left) and Knoxville Artist Preston Farabow pose with the
AWS Extraordinary Welding Award presented to the Marking Time
sundial.
Marking Time Sundial Earns AWS Extraordinary Welding Award
NI December 2012_Layout 1 11/8/12 1:38 PM Page 10
11 WELDING JOURNAL
Mechanic on a Mission Honored as a
PEOPLE Teacher of the Year
Brian Copes, an AWS member and pre-engineering teacher
at Calera High School, Calera, Ala., has recently been selected
by PEOPLE magazine as one of five winners in its first Teacher
of the Year Awards.
Last summer, Copes took ten of his students to Honduras,
where they fit 14 amputees with artificial legs fashioned from old
Toyota Corolla parts. The class assembled basic utility vehicles
as well to provide ambulance services to remote locations there.
He believes it is important not only to teach his students a skill
or trade, but also the soft skills required for todays job market.
My students eyes were opened to the importance of helping
others. This is practical education that uses real-world problem-
solving techniques...my students, and myself, perhaps will never
know how great of an impact they have had on the lives of these
Hondurans, Copes said.
To create the artificial legs, they designed parts using Solid-
Works software. Then, the drawings were used to cut the parts
on a CNC plasma cutting machine. The parts were bent and gas
metal arc welded. Students also experimented with gas tungsten
arc welding. Both steel and aluminum were explored for mate-
rial selection. A micrometer was used for measuring. Once the
parts were fabricated, they conducted a small assembly line to
put the legs together. Final tweaking took place at the end of this
process.
Fitting a person onsite took less than an hour. We invented
a universal socket that allowed us to fit the amputees in a short
time period, Copes explained.
On this project and others, the high schoolers put in more
than 2000 after school, community service hours.
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AWS Member Brian Copes and his students used old car parts to
fabricate artificial legs for amputees in Honduras.
DECEMBER 2012 12
In addition, Children Changing the World, a documentary about
these students, is being produced. This film will be used as an
inspirational tool to inspire both students and teachers around
the globe to dream big and change the world, Copes said.
The educators, nominated by readers and selected by PEO-
PLEs editors with guidance from an advisory board of educa-
tion professionals, were featured in the magazines October 22
issue and celebrated in New York at a luncheon. Each will re-
ceive $5000 ($4000 for their school and $1000 for themselves).
Advanced Resistance and Automotive
Technologies Abound at Sheet Metal
Welding Conference XV
Top engineering minds from across the globe attended Sheet
Metal Welding Conference (SMWC) XV, hosted by the Ameri-
can Welding Societys (AWS) Detroit Section and cosponsored
by EWI, to hear the latest developments on this years theme of
welding and joining materials for lightweight structures.
The successful hands-on workshop held October 2 at RoMan
Engineering Services, Inc., Livonia, Mich., focused on welding
advanced high-strength steel vs. cold rolled steel. Tutorial Chair
Jeff Hill wanted to try an interactive approach this time. Resist-
ance spot, projection, and gas metal arc welding demonstrations
allowed attendees to translate what they learned in lectures into
actual welds.
The technical portion October 35 at Schoolcraft Colleges
VisTaTech Center, Livonia, Mich., attracted nearly 150 partici-
pants. Students to leaders of major automotive companies and
tier-one/weld equipment suppliers heard 30 papers.
The conferences five sessions along with their leaders were
as follows: Resistance Welding and High-Strength Steel, Dr. Jerry
Gould of EWI; Modeling and Control, Dr. Murali Tumuluru of
United States Steel Corp.; Lasers and Friction Stir, Wes Doneth
of Fronius; Aluminum Resistance Welding, Dr. Michael
Karagoulis of General Motors; and Other Processes, Mike Palko
of Ford.
Dr. Mark D. Gugel, senior manufacturing project engineer,
global welding standards, General Motors, served as SMWC XV
chairman. He noted that this year the conference drew close to
100 authors; 25 staff members worked behind the scenes to make
it come together; and networking was valuable as individuals trav-
eled from overseas, including Europe and China, that could be
tied in with the automotive customer connection.
With the people who come here, this is the only venue for
the automotive joining industry doing thinner sheet metal, Gugel
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play portion of Sheet Metal Welding Conference XV are (from left)
John Bohr, Mark D. Gugel, and Tom Natale.
NI December 2012_Layout 1 11/9/12 11:02 AM Page 12
said, pointing out its impact.
Joe Beckham of Chrysler Group LLC served as SMWC XV
vice chairman while Menachem Kimchi of Welding Engineering
Consulting & Services, LLC, was the technical chairman.
Also, the evening of October 4, a vendor display open to the
public took place organized by Susann Morfino, sales represen-
tative, MJM Sales, Inc. Participants enjoyed visiting its 35 booths
exhibiting many company offerings, meeting with guests, and
dining on hors doeuvres made by the colleges culinary arts
students.
The next SMWC, a biennial event, is expected to be held in
2014. For details on obtaining conference proceedings, visit
www.awsdetroit.org.
ASTM Launches New Initiative to Address
Environmental Impacts of Products
ASTM Internationals new initiative is to be a program oper-
ator for Product Category Rules (PCR) and Environmental Prod-
uct Declarations (EPD), which will provide the venue for devel-
oping PCRs and verifying EPDs.
According to Timothy Brooke, vice president of certification,
training, and proficiency testing at ASTM International, the or-
ganizations program will provide scientifically based, quantifi-
able information about product parameters such as resource con-
sumption and ozone depletion, which will give businesses and
consumers an understanding of a products real impact on the
environment. Also, through its certification program, technical
advisory committees will oversee the development process for
the PCR.
13 WELDING JOURNAL
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continued on page 107
DECEMBER 2012 14
ALUMINUM
Q&A
BY TONY ANDERSON
Q: I have been informed of an Interna-
tional Standard, ISO 18273, Welding con-
sumables Wire electrodes, wires and rods
for welding aluminum and aluminum alloys
Classification. I have also been informed
that there is a new AWS A5.10, Specifica-
tion for Bare Aluminum and Aluminum-Alloy
Welding Electrodes and Rods, available. How
does this ISO standard compare to the
AWS standard, and does classification to
this ISO standard provide classification to
AWS A5.10? What are the changes to the
new A5.10 standard?
A: This is an interesting question, particu-
larly in light of some current developments
with the recently published new edition of
AWS A5.10. For the benefit of any readers
who are not familiar with AWS A5.10, this
specification prescribes requirements for
the classification of aluminum-alloy weld-
ing electrodes and rods for use with the gas
metal arc, gas tungsten arc, oxyfuel, and
plasma arc welding processes.
Before responding to your question, I
will provide some relevant information on
the latest edition of AWS A5.10, some
changes/additions to this document, and
how the new AWS document has been in-
fluenced by the ISO 18273 standard.
As the chairman of the AWS A5C Sub-
committee on Aluminum-Alloy Filler
Metals, which is responsible for the A5.10
standard, I have been working with the
subcommittee for the last two years to
prepare a revised A5.10. The previous
AWS A5.10/A5.10M:1999, Specification
for Bare Aluminum and Aluminum-Alloy
Welding Electrodes and Rods, was totally
independent of the ISO 18273 document.
However, the new AWS standard, AWS
A5.10/A5.10M:2012 (ISO 18273:2004
MOD), has integrated the International
Standard ISO 18273 within the new AWS
A5.10 publication.
To quote directly from the foreword of
the new AWS A5.10 publication, This
standard is the U.S. national adoption of
ISO 18273:2004, Welding consumables
Wire electrodes, wires and rods for welding
aluminum and aluminum alloys
Classification.
Adoption of the ISO 18273 standard
by the AWS A5 Committee on Filler Met-
als and Allied Materials is part of the gen-
eral policy adopted by the committee to
incorporate international filler metal stan-
dards within the relevant AWS A5 stan-
dards wherever practicable.
Q: How does this ISO standard compare
to the AWS standard, and does classifi-
cation to this ISO standard provide clas-
sification to AWS A5.10, Specification for
Bare Aluminum and Aluminum-Alloy
Welding Electrodes and Rods?
A: Again, to quote directly from the fore-
word of the new AWS A5.10 publication,
Classification in accordance with ISO
18273:2004 does not provide classification
in accordance with this document. The
primary reason for this nonclassification
is the ISO standard does not provide for
any other testing other than chemical
analysis of the filler metal material.
The AWS A5.10 requirements for clas-
sification include chemical analysis of
filler metal (similar in nature to ISO
18273) with additional weld testing re-
quirements to verify the soundness of weld
metal produced by gas metal arc welding
electrodes and the deposition character-
istics of the welding rod. As a result, the
AWS A5.10 standard specifies additional
required information such as the base
metal types required for weld test assem-
blies, welding and testing procedures to
be employed for weld testing, and results
required for passing the stipulated test in
order to meet classification requirements.
Many of the testing requirements in the
AWS A5.10 standard are associated with
radiographic testing used to demonstrate
the integrity of deposited weld metal.
Fig. 1 High-speed trains, many of which are being manufactured in China, often
make use of the ER5087 filler metal. The ER5087 is one of the many new aluminum
filler metal classifications listed in the new edition of AWS A5.10/A5.10M:2012 (ISO
18273:2004 MOD).
Aluminum Q and A December 2012_Layout 1 11/9/12 1:23 PM Page 14
15 15 WELDING JOURNAL
Therefore, a filler metal classified to AWS
A5.10 should meet the classification re-
quirements of ISO 18273. However, a filler
metal classified to ISO 18273 does not pro-
vide classification in accordance with the
requirements of AWS A5.10.
Q: What are the changes to the new A5.10
standard?
A: The principal changes to A5.10 have
been the inclusion of 38 new, predomi-
nantly European, aluminum filler metal
classifications. With the adoption of ISO
18273, the A5.10 standard now includes
the following additional classifications:
ER1070, R1070, ER1080A, R1080A,
ER1200, R1200, ER1450, R1450,
ER3103, R3103, ER4018, R4018,
ER4043A, R4043A, ER4046, R4046,
ER4047A, R4047A, ER5087, R5087,
ER5183A, R5183A, ER5187, R5187,
ER5249, R5249, ER5356A,R5356A,
ER5556A, R5556A, ER5556B, R5556B,
ER5556C, R5556C, ER5654A, R5654A,
ER5754, and R5754.
Other changes include modified beryl-
lium limits, which have been amended for
many of the filler metal classifications to
fall in line with the Aluminum Associations
requirement to not exceed 0.0003% (from
the previous 0.0008% limit). The range of
base metals for test assemblies has also been
expanded to include the use of more 6xxx
series materials, which will more easily sup-
port the use of extruded test assemblies
commonly used to assist with testing pro-
cedures. There has also been the addition
of one new filler metal that was not carried
over from the ISO standard.
One of the new filler metal classifica-
tions added from the ISO Standard is
ER5087. ER5087 is a filler metal increas-
ingly used in the relatively new, rapidly
developing industry of fast trains Fig.
1. Through modifications to the magne-
sium and manganese content of this 5xxx
series filler alloy, we see a high-perform-
ance filler metal that is often chosen for
this high-performance industry sector.
The new filler metal ER4943 has also
been added to the A5.10 standard.
ER4943 was not obtained from the ISO
standard, but added as a newly developed
filler metal that originated here in the
United States. As its number suggests, this
new filler metal is a modification to filler
alloy ER4043. ER4943, although heat
treatable, was developed primarily for its
improved as-welded strength over that of
the commonly used ER4043 filler metal.
Summary
The recently released AWS A5.10
standard is an adoption of ISO 18273.
This new standard has many new, pre-
dominantly European, filler metals in-
cluded within it. One new filler metal
classification that was developed in the
United States (ER4943) is also included
in the new edition. Filler metals that are
classified to ISO 18273 would not pro-
vide classification in accordance with
AWS A5.10 because the requirements for
classification within A5.10 stipulate test-
ing procedures that are not specified by
ISO 18273.
TONY ANDERSON is director of aluminum
technology, ITW Welding North America. He is
a Fellow of the British Welding Institute (TWI),
a Registered Chartered Engineer with the British
Engineering Council, and holds numerous posi-
tions on AWS technical committees. He is chair-
man of the Aluminum Association Technical
Advisory Committee for Welding and author of
the book Welding Aluminum Questions and
Answers currently available from the AWS.
Questions may be sent to Mr. Anderson c/o Weld-
ing Journal, 8669 Doral Blvd., Doral, FL 33166, or
via e-mail at tony.anderson@millerwelds.com.
Aluminum Q and A December 2012_Layout 1 11/9/12 1:23 PM Page 15
DECEMBER 2012 16
BRAZING
Q&A
BY TIM P. HIRTHE
Q: We are manufacturing refrigeration
lines consisting of a variety of copper tub-
ing joints. The joints are primarily copper
to copper but we do have some brass
valves and steel connections. We employ
dozens of hand brazers over several shifts
and have a tremendous variation in qual-
ity. We are using oxyacetylene torches. It
seems that everyone makes the joints
their own way. One of the most aggravat-
ing issues is that we have a great deal of
braze alloy teardrops and spatter. I am
sure we are using more braze alloy than is
necessary. I have included a photo for your
reference Fig. 1. My preference is to
find some other method of making these
joints. We are continually told that we
need to improve our training but it seems
to me to be a training nightmare. There
must be equipment we can use to mini-
mize our brazer variation. What can we do
to take the manual aspects out of the op-
eration to try to get some consistency?
A: In my experience, manual torch braz-
ing is the most difficult brazing process to
get under control. Generally, the process
and resultant quality are in the hands of
the operator. It has a tremendous number
of variables associated with it but the indi-
vidual brazer level of training, their dex-
terity, and willingness to listen are proba-
bly the most important.
As you mention, the first reaction is to
institute more training. Companies are
hesitant because they assume it will take a
great deal of time and when the operators
get back on the shop floor they will revert
to their bad habits anyway. That then re-
quires lots of management intervention to
keep things on track. Everyone is trying to
eliminate headaches, and Im sure the
continuation of manual torch brazing
seems to be a prescription for a long, ex-
tended headache. You are asking about
the alternative, which is to take the brazer
out of the decision-making process. That
requires standardizing the process and,
perhaps, adding equipment.
Your photo appears to show something
more like drippings than spatter. I realize
you want to find a magic bullet in the way
of equipment that will eliminate the
brazer problem, and, while there are
some things you can do in that regard,
dont abandon the idea of improving train-
ing. The photo would seem to indicate a
basic misunderstanding of the brazing
process. There are a few simple things you
can do to make improvements. The key
word is simple. If you try to overdo it with
training, the brazers may become over-
loaded with information and tune out.
The drippings in the photo are actually
teardrops that fell off instead of solidify-
ing on the parts. I have seen this before. It
typically comes from the brazer applying
the heat to the braze filler metal rather
than the metals being joined. Either that
or the brazers just blasted away at it and
kept adding filler until they were sure they
completed the joint, adding filler metal
until it fell off. The flame needs to be ap-
plied to the base metals. The braze filler
metal is then melted by touching it to the
heated joint. The molten braze filer metal
will not bond to the parts to be joined un-
less they are hot enough. That is a fairly
basic, but profound, concept. Focus your
training effort on that.
If you are going to revise your braze
training program, the first thing is to make
sure safety is addressed. I recommend
starting by consulting ANSI Z49.1, Safety
in Welding, Cutting and Allied Processes. It
does a great job of covering the things to
be concerned about in oxyfuel processes.
After safety, you should instruct the braz-
ers in the expected conduct of their jobs,
getting familiarized with their work areas,
process paperwork, components to braze,
and the like. This is quite a bit of informa-
tion and it doesnt leave a lot of time for
braze training. Dont try to make them ex-
perts, at least not right away. Focus on the
fundamentals. Regarding the drippings
and general overuse of braze filler metal,
showing them proper heating will go a
long way toward solving these problems.
There is a great deal of brazing training
available in the industry and I would rec-
ommend you tap into it. Much of it, how-
ever, deals with things like the metallurgy
of brazing, the design of braze joints, etc.
There is absolutely nothing wrong with
teaching the brazers on your line about
these subjects but you have a more acute
need. Your brazers cannot do anything
about joint designs, selection of base met-
als, selection of filler metals, and the like.
You certainly should listen to their input
about these matters, but what they really
need is training in how to properly heat
parts and how to add filler metal.
When talking to line brazers, you need
to focus on the basics. There is general
agreement on what the fundamentals are.
There is some variation depending on who
you talk to but basically it comes down to
these:
1. Joint clearances and joint design
2. Prebraze cleaning
3. Assembly and fixturing of compo-
nents
4. Fluxing
5. Heating the parts and adding filler
metal
6. Postbraze cleaning
Your focus with your line brazers
should be on items 4 and 5.
In summary, I suggest you do the
following:
1. Provide training with an emphasis
on proper heating and adding of filler
metal. Even without seeing them in action,
I would guess that the torches are set too
hot. People like to hear the torches hiss. It
is assumed that a hotter flame means a
faster production rate. To achieve a hotter
flame you crank up the oxygen. Increasing
the oxygen results in an oxidizing flame.
The best results in brazing, however, are
achieved with a reducing flame. It also re-
sults in a less oxidized part, improving the
aesthetics of the assembly and assisting
the braze alloy flow. Refer to Fig. 2.
The following is taken from AWS
Guidelines for Hand Soldering Practices:
Fig. 1 Examples of braze alloy drippings.
Brazing Q+A December_Layout 1 11/8/12 10:06 AM Page 16
17 WELDING JOURNAL
Heat the parts, not the filler metal.
Train the brazers to recognize what the
proper amount of heat is. Overheating or
underheating most likely will result in an
unsatisfactory joint.
Touch the filler metal to the heated
parts to flow the filler metal.
Only add sufficient filler metal to fill
the joint. Any filler metal outside the mat-
ing surfaces of the joint is an unnecessary
expense and serves no purpose. Signifi-
cant cost savings can be achieved by re-
ducing the amount of filler metal used.
2. Standardize brazing variables
throughout your plant.
Set all torches to the same fuel gas and
oxygen flow rates.
Utilize the same torch tip style for
each brazer. Different joints may require
different torch styles and tips.
Ensure that the proper braze alloy is
selected for each joint design and clear-
ance and that it is used consistently in all
brazing areas.
Ensure that the form of filler metal
(rod cross section and length) is consistent
among operators and departments.
3. Introduce equipment as it makes
sense.
Infrared sensors can be used to let the
brazer know when the proper brazing tem-
perature has been reached. Some devices
are available that feed the filler metal once
a predetermined brazing temperature is
reached.
You can cut your braze filler metal con-
sumption by making sure the brazers do
not overfeed a joint. Wire feeders that dis-
pense consistent amounts of braze filler
metal can be used to remove the decision
regarding how much braze alloy to add
from the brazer.
Units to control the flow rates of the
fuel gas and the oxygen can be used. These
can be locked out to prevent the operator
from changing the settings.
Or you can change from an oxyfuel
process to an alternative method. Hand-
held induction units are available. Induc-
tion can be controlled very precisely to
take the heating variable out of the control
of the brazer.
There is no simple answer to how to
make a manual torch brazing process
more consistent. The ideas listed here may
apply to some joint designs but not to oth-
ers. There are, however, a number of
things you can introduce to the operation
and plenty of resources available in the in-
dustry to help.
Fig. 2 Acetylene flame color guide.
From the AWS Guidelines for Hand Sol-
dering Practices.
This column is written sequentially by
TIM P. HIRTHE, ALEXANDER E.
SHAPIRO, and DAN KAY. Hirthe and
Shapiro are members of and Kay is an ad-
visor to the C3 Committee on Brazing and
Soldering. All three have contributed to the
5th edition of AWS Brazing Handbook.
Hirthe (timhirthe@aol.com) currently
serves as a BSMC vice chair and owns his
own consulting business.
Shapiro (ashapiro@titanium-braz-
ing.com) is brazing products manager at Ti-
tanium Brazing, Inc., Columbus, Ohio.
Kay (Dan@kaybrazing.com), with 40
years of experience in the industry, operates
his own brazing training and consulting
business.
Readers are requested to post their ques-
tions for use in this column on the Brazing
Forum section of the BSMC Web site
www.brazingandsoldering.com.

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dition, abilities are expanded to cost plastics compo-
nents, including piece parts and tooling costs. New base-
line cost models consist of the following: thermoform-
ing, structural foam and reaction injection molding,
cross-system cost integration, an internationalization
infrastructure, and automated bulk analysis for in-
creased throughput.
aPriori
www.apriori.com
(978) 371-2006
DECEMBER 2012 18
Software Platform Features New Baseline Cost Models
P and P December 2012_Layout 1 11/8/12 1:35 PM Page 18
19 WELDING JOURNAL
Laser Processing Cell
Offers Large Field of View
The Flex Lase Pro, a 3-axis scanner-
based laser processing cell, is equipped
with an IPG 2-kW single mode fiber laser
and Cambridge Technologies 3D high-
speed scanner head. Typical spot size at
mid-range field of view is approximately
20 microns. It is suited for prototyping,
process development, and production. Of-
fering a large field of view working area
(up to 1000 1000 mm) and Z axis, it can
laser weld, cut, or mark a nearly unlim-
ited range of parts and shapes. Laser,
chiller, fume exhaust, gas management,
and controls are on board. Within the class
1 enclosed laser workspace area, connec-
tions are provided for gas management,
pneumatics, and 110-V power.
Wayne Trail
www.waynetrail.com
(937) 295-2120
Software Integration Allows
Comparing Run Time Data
The company and Metamation have
released MetaQuote and MetaCAM. At-
tributes to the integration include the ca-
pability for information to be transferred
from the CAM system to MIETrak for cre-
ating quotes; tooling is assigned based on
Metacam settings; all information is trans-
ferred and stored within MIE Trak; data
is used in estimating formulas; and com-
paring run time data from any laser,
plasma, CNC turret, or water jet machine.
Additionally, the work order nesting fea-
ture allows users to group together jobs
on the shop floor that have similar oper-
ations. With the integration, work orders
that are part of a nest can be sent to Meta-
cams nesting module to be dynamically
nested. Its nesting module automatically
separates nest patterns by material and
thickness.
MIE Solutions
www.mie-solutions.com
(714) 786-6230
Eco-Friendly Generator
Runs with Zero Emissions
The MQ H2G EarthSmart hydrogen
fuel-cell powered generator is environ-
mentally friendly and pollution free. The
machine does not use fossil fuel sources.
It also operates clean with zero emissions
and can be used for inside and tunnel/un-
derground applications. The generator
can be operated for up to 26 h at full load
with a low noise level of 44 decibels at 23
ft. It requires minimal maintenance be-
cause there are virtually no moving parts
and no fuel to spill. According to Torsten
Erbel, vice president product manage-
ment, engineering and customer support
for the company, with one unit it is able
to displace 900 gal of diesel fuel per year
and eliminate 9.1 metric tons of CO
2
per
year.
Multiquip, Inc.
www.multiquip.com
(800) 421-1244
Manufacturer Launches
Upgraded Web Site
The manufacturing company has
launched an upgraded Web site featuring
its line of portable welding end prep tools,
pneumatic saws, and accessories for ma-
chining and cutting tube, pipe, pipelines,
boiler tube panels, and other metalwork-
ing applications. Highlighted is an ex-
panded search capability, which allows
users to select tools based on product type,
tool model, and tube size or application
of the tool. The search then offers a choice
DECEMBER 2012 20
of tools to select from, provides photos of
each, a description, key features, specifi-
cations, application photos, a parts list,
options, ordering information, and a RFQ
capability. The Web sites major cate-
gories include products, rentals, applica-
tions, news and events, about the com-
pany, and a user login to view order
history.
ESCO Tool
www.escotool.com
(800) 343-6926
Replacement Blades
Available for Scraper
The DuaLast edge technology
scraper blades are an addition to the
Scrape-N-Burr line. The dual working
edges of the easily replaceable blade are
formulated to hold up to repeated pound-
ing of steel on steel without shattering and
are long lasting. The blade can also be re-
freshed to factory edge specification by
following the included instructions. Tools
with this blade factory installed are avail-
able in 1- and 3-in. models. Replace-
ment blades are offered in 4- and 6-in.
sizes.
Innovative Product Ideas, LLC
www.scrapenburr.com
(920) 486-5351
Weld Simulator Combines
Software, Curriculum
The teachWELD welding simulator
for practicing welding and teaching vari-
ous welding techniques incorporates
hardware, software, and curriculum. Its
online, game-like interface gives students
a hands-on learning experience in basic
welding form and proper technique within
a virtual environment. Learning is evalu-
ated through diagnostic and welding in-
tegrity assessments for each welding ex-
ercise. The simulation gives students a
chance to explore this career path and also
reduce the use of welding materials.
Realityworks, Inc.
www.realityworks.com
(800) 830-1416
Software Helps Improve
Robotic Efficiency
RobotExpert software, a robotic sim-
ulation and programming system for
small- and medium-size manufacturers,
helps minimize downtime and increase
throughput for shop floor robots. It sup-
ports industry applications such as arc
welding, pick-and-place, and polishing. In
addition, the software enables the design,
simulation, optimization, and offline pro-
gramming of robotic applications. Featur-
ing a 3D environment, it combines the
simplicity to optimize robotic paths and
21 WELDING JOURNAL
improve cycle times with power to simu-
late virtual mockups of complete manu-
facturing cells and systems. It can be used
to generate the most suitable combination
of equipment to meet manufacturing
needs. It also provides an offline pro-
gramming and simulation tool.
Siemens PLM Software
www.siemens.com/plm/robotexpert
(972) 987-3000
Filter Contains GTA Mode
with Uphill Control
The iDF Intelligent-Darkening-Filter
was developed with feedback from welders.
It offers a standard shade adjustment 3/5-
14; autovariable shade adjustment 3/5-14;
special GTA mode with uphill and down-
hill control; and eight unique memory set-
tings allow customizing each helmet. The
filter is available in the modern Vision
helmet or the racing-inspired Python in
viewing areas large and Xtreme.
ArcOne
www.arc1weldsafe.com
(800) 223-4685
Biodegradable Aluminum
Brightener Removes Stains
Safe-Bright, a replacement for hydro-
fluoric acid and other acids used to
brighten aluminum, uses a new material
that received the EPA P2 Pollution Preven-
tion Award. It deoxidizes and brightens
aluminum surfaces, plus will not attack or
etch glass and is safe to use on painted sur-
faces, chrome-plated hydraulic rams, plas-
tic, and rubber seals. The product contains
no hydrochloric acid, does not produce cor-
rosive fumes or vapors, and has a low odor.
It will not dull or etch aluminum and is pro-
ductive for removing hard water/acid rain
stains from painted surfaces.
Fortrans, Inc.
www.fortransinc.com
(866) 958-7267
DECEMBER 2012 22
For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index
Metal Fabricator Publishes
New Brochure
The metal fabrication and machine
shop has published a new brochure high-
lighting its precision metal fabricating ca-
pabilities. Featured are the companys
services, including fabrication, machining,
vertical turning, welding, sawing, flame
cutting, punching, sandblasting, painting,
and assembly. The brochure may be re-
quested from the contact information
below.
TC/American Manufacturing
www.tcamerican.com
(320) 251-8616
Publication Designed for
Welding Engineers
Applied Welding Engineering: Processes,
Codes and Standards provides instruction
for the selection of the materials incorpo-
rated in the joint, joint inspection, and
quality control for the final product. The
books featured topics include an exposi-
tion of the science of metallurgy, welding
metallurgy and welding processes, nonde-
structive examination, and codes and stan-
dards. Other subjects include mechanical
properties and testing of metals, heat
treatment of steels, effect of heat on ma-
terial during welding, stresses, shrinkage
and distortion in welding, welding, corro-
sion-resistant alloys-stainless steel, weld-
ing defects and inspection, codes, specifi-
cations, and standards. The publication,
list price about $90, may be ordered from
the contact details listed.
Research and Markets Ltd.
www.researchandmarkets.com
(800) 526-8630
23 WELDING JOURNAL

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A
rc welding processes consume a
great deal of energy and are widely
used in manufacturing. Practical
strategies for reducing energy consump-
tion are particularly important consider-
ing the need to create more eco-friendly
manufacturing environments. This arti-
cle explores practical strategies relating
to arc welding power source efficiency,
equipment setup, and welding technique
to reduce the ecological impact of widely
employed arc welding processes.
Improved Power Source
Efficiency
Power source technology has matured
significantly in recent decades. Modern
power supplies use significantly less en-
ergy when welding as well as when sitting
idle with the power on. Older trans-
former/rectifier power supplies have
poor energy conversion rates during
welding and have high idle power. In-
verter power supplies require less energy
when welding and have significantly
lower idle power. Inverter power supplies
with transistor technology are the most
efficient when welding and when idling,
and provide faster response times and
higher pulse frequencies. Figure 1 shows
power consumption while idling for three
different power supply types (Ref. 1).
Typical utilization for manual or semi-
automatic arc welding processes is 25%,
meaning the power supply is idling 75%
of the time. For a facility running three
shifts per day, five days a week, and 52
weeks per year at this utilization, a trans-
Reducing the Ecological
Impact of Arc Welding
BY MARC ALAN PURSLOW
MARC ALAN PURSLOW (mpurslow@ewi.org)
is an applications engineer, Arc Welding, EWI,
Columbus, Ohio.
Practical strategies are offered for
reducing energy consumption when
using various arc welding processes
Fig. 2 Power source efficiency vs. percent of rated load (Ref. 2).
Fig. 1 Idling power consumption for different welding power supply types (Ref. 1).
Purslow Feature December 2012_Layout 1 11/8/12 3:11 PM Page 24
25 WELDING JOURNAL
former-rectifier power supply will con-
sume 6177 kWh of power while idling. At
a cost of $0.11 per kWh, this results in a
yearly cost of $680 per power supply. An
inverter/transistor power supply will con-
sume only 749 kWh, resulting in a yearly
cost of $82 per power supply. In this ex-
ample, changing to a more efficient in-
verter/transistor power supply will result
in a yearly savings of $598 per power sup-
ply during idle time. For a facility with
25 power supplies, this savings is $14,925
per year.
In addition to using power supplies
that consume less power while idling,
turning power supplies off when not in
use is a simple method of reducing en-
ergy consumption. This can be accom-
plished by equipping power supplies with
an idle time-out feature. Newer power
supplies reduce power use by turning the
cooling fans on only when they are
needed.
Power Supply Rating
It is commonly believed that operat-
ing a power supply at or near its maxi-
mum rated load will cause damage or
cause it to operate less efficiently; how-
ever, the opposite is true. Operating a
power supply at a load below its rating
can significantly reduce its efficiency. As
indicated in Fig. 2, operating an 81% ef-
ficient power supply at only 25% of its
rated load decreases the operating effi-
ciency to approximately 65% (Ref. 2). By
using power supplies with a maximum
rated load closer to the expected operat-
ing parameters, manufacturers can take
better advantage of increased-efficiency
power sources and reduce energy
consumption.
Parameter Optimization
Parameters can be optimized to im-
prove the electrode melt-off efficiency,
allowing more material to be deposited
for a given amount of power consumed.
This can be accomplished by increasing
the welding current. While increasing the
current alone may not be an option due
to heat-input limitations, material thick-
ness, or an open-root joint preparation,
increasing the travel speed to maintain a
consistent current/travel-speed ratio may
resolve these issues. Figure 3 illustrates
the increase in pounds of filler metal con-
sumed per kWh of welding power at
three different current settings for sub-
merged arc welding in constant current
mode with a
3
32-in.-diameter electrode.
Increasing the welding current from 250
to 425 A resulted in a 21.4% increase in
the amount of steel filler metal consumed
per kWh of welding power. This means
that for the same amount of power,
a greater amount of filler metal will be
deposited.
Since no currently available welding
power supply is 100% efficient, typical
power supply efficiency ranges must be
used to convert the data provided in Fig.
3 into something more meaningful. Fig-
ure 4 provides pounds of steel filler metal
consumed per kWh of power for four dif-
ferent power supply efficiencies. These
data can be used to estimate a cost per
pound of filler metal deposited using the
appropriate deposition efficiency num-
ber and power cost per kWh.
Table 1 The Efect of Welding Current on Burn-Of Efciency
Current 250 A 425 A
Voltage 25 V 25 V
Cost of power $0.11/kWh $0.11/kWh
Deposition efciency 99% 99%
Power supply efciency 80% 80%
Steel fller deposited/kWh 0.727 lb 0.883 lb
Utilization 50% 25%
Arc-on hours 3120 h 1560 h
Yearly power consumption 24,375 kWh 20,719 kWh
Yearly power cost $2,681.25 $2,279.09
Yearly deposition (steel) 17,720.63 18,294.88
Fig. 3 Pounds of filler metal consumed
per kWh of welding power.
Fig. 4 Pounds of filler metal consumed
per kWh of welding power at different
power-supply efficiencies.
Purslow Feature December 2012_Layout 1 11/9/12 9:12 AM Page 25
DECEMBER 2012 26
Table 1 provides a comparison be-
tween a submerged arc welding power
supply operated at 250 vs. 425 A for one
year in a facility running three shifts per
day, five days a week, and 52 weeks per
year. By increasing the welding current
to 425 A, power consumption would be
decreased by 3656 kWh, the cost of power
would be decreased by $402, and the uti-
lization required to deposit the same
amount of steel filler metal would be re-
duced from 50% to less than 25%. For a
facility with 25 power supplies, this rep-
resents a savings of $10,054 in power
costs and the required arc-on time to do
the same amount of welding would be re-
duced by 39,000 hours.
Deposition Efficiency
Table 2 provides typical deposition
efficiency ranges for four consumable-
electrode arc welding processes. Ranges
are provided as deposition efficiency is
dependent on spatter level and/or stub
loss [shielded metal arc welding
(SMAW)]. Process parameters can have
a significant effect on the former, and
welder technique can impact the latter.
A straightforward method of decreas-
ing energy consumption is to change to
a process that has an inherently higher
deposition efficiency. There are, of
course, trade-offs for any such change
that must be considered. For instance,
gas metal arc welding (GMAW) has a
higher deposition efficiency than flux
cored arc welding (FCAW); however, it
is generally less tolerant to contaminants,
is more challenging to use out of posi-
tion, and requires a higher level of welder
skill.
Another method of decreasing energy
consumption is to increase the deposi-
tion efficiency of the arc welding process
currently being used. Since the deposi-
tion efficiency of a process determines
the percentage of filler material that is
actually deposited into the weld pool, in-
creasing it will increase productivity for
the same level of power consumption.
This can be accomplished by optimizing
parameters for improved arc stability and
droplet transfer to reduce spatter gener-
ation. A 5% increase in deposition effi-
ciency will result in at least a 5% increase
in the amount of consumed filler mate-
rial that is deposited into the weld joint.
Pulse vs. Constant
Voltage
Pulsed GMAW waveforms are used
to achieve spray transfer at a lower aver-
age current than welding in constant volt-
age (CV) mode by employing a peak cur-
rent and a background current. The peak
current promotes spray transfer while the
background current maintains the arc be-
tween pulses. Figure 5 illustrates the dif-
ference in current/wire-feed-speed ratios
for 0.045-in.-diameter wire for the
GMAW process in pulsed and CV weld-
ing modes.
At a wire feed speed of 350 in./min,
the welding current in CV mode was 265
A, while the welding current in pulse
mode was 235 A. This represents an
11.3% reduction in arc power.
tween robotic welding using CV GMAW
vs. pulsed GMAW for one year in a facil-
ity running three shifts per day, five days
a week, and 52 weeks per year. Due to
the reduction in average current, the cost
of power to operate one power supply
was decreased by $695. For a facility with
25 power supplies, this represents a sav-
ings of $13,900 in power costs.
Resistive Heating of the
Electrode
For a given wire-feed speed, the cur-
rent output of the power supply is af-
fected by the contact tip-to-work distance
(CTWD). Due to the effect of resistive
(I
2
R) heating, increasing the CTWD will
decrease the current needed to melt the
electrode or increase the deposition rate
for a given current. The effect is greater
for smaller-diameter wires since they
have a higher electrical resistance.
Figure 6 illustrates the effect of resis-
tive heating on 0.063-in.-diameter solid
Table 3 CV vs. Pulsed GMAW
Pulsed vs. CV CV Pulsed
Average current 265 A 235 A
Voltage 27 V 27 V
Utilization 80% 80%
Yearly power cost $6139 $5444
Table 2 Deposition Efciency Ranges for Consumable-Electrode Arc Welding
Processes (Ref. 3)
Welding Process Deposition Efciency (%)
Shielded metal arc welding (SMAW) 5575
Flux cored arc welding (FCAW) 8090
Gas metal arc welding (GMAW) 9097
Submerged arc welding (SAW) 9599
Fig. 5 Output current of pulsed vs. CV
GMAW.
wire using the GMAW process. In weld
trials conducted at EWI, at a CTWD of
0.75 in., the current output of the power
supply was 300 A. Increasing the CTWD
to 1.125 in. reduced the current output
by 23% to 230 A. Figure 6 also illustrates
that welding in CV mode with the ex-
tended CTWD still required 300 A, which
supports previous conclusions on the re-
duction in average current when using
pulsed GMAW.
tween a single robotic welding operation
with a 0.75-in. vs. 1.125-in. CTWD for
one year in a facility running three shifts
per day, five days a week, and 52 weeks
per year. Due to the reduction in aver-
age current, the cost of power was de-
creased by $1441. For a facility with 25
power supplies, this represents a savings
of $36,035 in power costs.
Power Loss Associated
with Cable Length and
Gauge
For the purpose of clarity, the previ-
ous examples have been calculated as-
suming zero power loss through the weld-
ing cables; however, some amount of
power loss is inevitable. Using an incor-
rect cable gauge can contribute signifi-
cantly to power loss, as can excessive
cable length. It can be calculated that at
a welding current of 300 A using 4/0
gauge cable, a set-up with 10-ft-long lead
and ground cables will result in approxi-
mately a 1.2% power loss. Increasing
both cables to 50 ft will increase the
power loss more than four times to ap-
proximately 6.1%. If the current-carry-
ing capacity of the cable gauge is ex-
ceeded, this effect becomes more signif-
icant, as illustrated in Fig. 7.
Using the same parameters as the ex-
ample above with a 0.75-in. CTWD, the
power loss associated with 10-ft-long
cable lengths will require an additional
682 kWh of power. The power loss asso-
ciated with 50-ft-long cable lengths will
require an additional 3648 kWh of power.
This represents an additional $401 of
power cost per power supply. For a facil-
ity with 25 power supplies, this represents
a savings of $10,033 in additional power
costs per year.
Conclusions
This article provides a number of
practical strategies for reducing energy
consumption for arc welding processes.
In addition to using more energy-
efficient power supplies that use less
power during welding and while idling,
significant improvements can be made by
implementing changes in equipment
setup and welding technique to reduce
the ecological impact of widely employed
arc welding processes.
27 WELDING JOURNAL
Table 4 0.75-in. vs. 1.125-in. CTWD
CTWD 0.75 in. 1.125 in.
Average current 300 A 230 A
Voltage 30 V 30 V
Utilization 80% 80%
Yearly power cost $6177.60 $4736.20
Fig. 6 Effect of CTWD on output current.
Fig. 7 Power loss vs. length of 4/0 cable.
References
1. Bird, Terry. 1993. Inverter
power sources: An efficient alterna-
tive. Welding Journal 72(1): 3740.
2. Welding Handbook, Vol. 2, 9th
Ed. 2001. Annette OBrien and Cyn-
thia Jenney, eds. Doral, Fla.: Ameri-
can Welding Society. p. 43.
3. Welding Handbook, Vol. 1, 8th
Ed. Leonard P. Connor, ed. Doral,
Fla.: American Welding Society.
p. 272.
DECEMBER 2012 28
T
he National Academies report on
Integrated Computational Materi-
als Engineering (ICME) published
in 2008 (Ref. 1) and President Obamas
announcement of the Materials Genome
Initiative (MGI) in June 2011 (Ref. 2)
highlights the interest in using computa-
tional methods to aid materials design
and process improvement that has been
growing over the last twenty years.
Integrated Computational Materials
Engineering is an approach to designing
components, the materials they are made
of, and their associated materials pro-
cessing methods by linking materials
models at multiple length scales. The
focus of ICME is on materials; that is,
understanding how processes produce
material structures, how those structures
give rise to material properties, and how
to select materials for a given applica-
tion. The Materials Genome Initiative is
a national initiative to double the speed
and reduce the cost of discovering, de-
veloping, and deploying new advanced
materials.
Aside from designing new alloys and
materials, understanding how to process
and join them are also critical factors to
consider before the new materials can be
deployed. For example, in 1985, accord-
ing to Babu (Ref. 3), Oak Ridge National
Laboratory researchers developed nickel
aluminides (Ni
3
Al) that have exceptional
properties, but there was almost a 15-
year delay in fully deploying these alloys
due to the lack of appropriate welding
processes and welding wire technologies.
Reducing the time to identify and evalu-
ate joining methods is also critical if
ICME and MGI are to reach their full
potentials.
Computational thermodynamics and
kinetics are core components of ICME
and MGI since they fundamentally link
the phases that form, and hence the mi-
crostructure, to the chemical composi-
tion of an alloy, and also the temperature
variations to which a material may be
subjected. They are also essentially the
driving forces for many of the phase
transformation reactions that take place
during materials processing. For more
than 25 years, researchers have success-
fully applied the CALPHAD (CALcula-
tion of PHAse Diagrams) approach
(Refs. 4, 5) a field of computational
thermodynamics to assist in alloy de-
sign and process optimization for many
different alloy types including steels and
ferrous-based alloys, Ni superalloys, Al,
Ti, Mg, etc. This article provides a few
examples of how CALPHAD-based tools
are also being employed to welding-
related applications.
A Basis for Computational
Thermodynamics and
Kinetics
By adopting the CALPHAD tech-
nique, all available thermochemical in-
formation both thermodynamic and
phase equilibria data is used to fit
model parameters used to describe the
Gibbs energy of individual crystallo-
graphic phases. The objective is to ob-
tain a consistent set of model parameters
that can describe the thermodynamic
properties of the system in a realistic way.
The Gibbs energy of each phase is de-
scribed by an appropriate thermody-
namic model dependent on its physical
and chemical properties, for example,
crystallography, type of bonding, order-
disorder transitions, and magnetic prop-
erties. These Gibbs energy functions,
which take into consideration chemical
composition and temperature depend-
ence, are obtained by the critical evalua-
tion of binary and ternary systems and
then, through the use of software such as
PAUL MASON (paul@thermocalc.com)
is with ThermoCalc Software Inc.,
McMurray, Pa.
BY PAUL MASON
Program Aids in Modeling
Welding Thermodynamics
Software related to the calculation
of phase diagrams is being used to
aid in the design of new alloys and
optimize the welding processes to
join them
Mason Feature December 2012_Layout 1 11/7/12 8:16 AM Page 28
29 WELDING JOURNAL
Thermo-Calc (Ref. 6), calculations for
multicomponent systems of industrial
importance can be made, based on the
constraints of composition and tempera-
ture and pressure for the system as a
whole.
Additionally, the CALPHAD method
can be extended to model atomic mobil-
ities and diffusivities in a similar way. By
combining the thermodynamic and mo-
bility databases, kinetic reactions during
solidification and subsequent heat treat-
ment processes can be simulated with the
use of other software such as DICTRA
and TC-PRISMA, which are computer
programs for simulating diffusion-
controlled phase transformations
and multiparticle precipitation kinetics
in multicomponent alloy systems,
respectively.
Through the use of such simulations,
it is possible to optimize alloy composi-
tions and filler materials, and predict op-
timal solidification processes and solu-
tion heat treatment temperature ranges,
thus reducing the number of time-con-
suming and costly experiments required
during a typical development cycle.
Applications of CALPHAD
Based Tools to Welding
Babu (Ref. 3) has published an exten-
sive review of the application of compu-
tational thermodynamic and kinetic sim-
ulations to joining of metals and alloys
(welding, brazing, soldering, and solid
state), but with 323 references, it is not
possible to summarize all of the differ-
ent examples covered by the review here.
However, the review identified the fol-
lowing general classifications:
Additionally, postweld heat treatment
could be added.
Four examples are described here.
Development of Welding
Consumables
Madeni et al. (Ref. 7) have used
Thermo-Calc in the development of a
filler metal for welding high-strength
steels using submerged arc welding. Cal-
culations were made using the software
to predict the amounts of carbides and
nitrides and the chemical composition,
under both equilibrium and nonequilib-
rium conditions. These data are impor-
tant because carbides and nitrides are im-
portant in the microstructural develop-
ment of weldments. Figure 1 shows a
step diagram, where the amount (mole
fraction) of carbonitrides predicted to
form under equilibrium conditions at dif-
ferent temperatures is plotted for the
welding wire composition Fe-0.05C-
0.2Si-1.84Mn-0.015P-0.002S-0.034Al-
0.066Nb-0.027V-0.01Cu-0.015Ti-0.13Cr-
0.2Mo-0.01N (all amounts in wt-%).
Such calculations can be made to show
the amounts and compositions of precip-
itates that may form and the temperature
range over which they are stable.
Nonequilibrium Solidification
Thermodynamic calculations can be
made to predict properties such as liq-
uidus and solidus temperatures and also
the phases to form from the liquid dur-
ing welding. According to Babu (Ref. 3),
weld researchers use this methodology
to understand phase stability in the heat-
affected zone for dissimilar materials and
dilution effects. However, equilibrium
calculations assume that as the weld
metal cools thermodynamic equilibrium
is achieved at every temperature, which
may not be realistic due to large differ-
ences in the diffusivity of elements in the
solid and liquid phases. It is well known
though that the diffusivity in liquid is
Fig. 1 Mole fraction of carbonitrides as a function of
temperature.
Fig. 2 Fraction solid as a function of temperature for IN939.
Liquid-gas equilibrium
Liquid-slag equilibrium
Inclusion formation
Liquid-solid interactions
Phases formed during equilibrium
and nonequilibrium solidification
Microsegregation during
solidification
Calculation of solidification rate
Prediction of heat-affected zone
grain boundary liquation.
DECEMBER 2012 30
many orders of magnitude greater than
in the solid, and as a result, the solute
distribution in the solid may be nonuni-
form leading to a depression of the
solidus temperature. This can be consid-
ered using the Scheil-Gulliver approach
that is incorporated into Thermo-Calc.
Figure 2 shows the calculated fraction
solid curve for an IN-939 Ni-based su-
peralloy comparing the Scheil-Gulliver
prediction with the equilibrium calcula-
tion (dashed line). What is apparent from
this figure is the larger freezing range cal-
culated for the Scheil-Gulliver predic-
tion compared with the equilibrium cal-
culation. Babu (Ref. 3) points out that
this enhanced solidification range is ex-
pected to promote solidification crack-
ing, and such calculations can be made
to indicate which alloys may be more sus-
ceptible to such cracking using such an
approach.
It should be stressed, however, that
equilibrium and Scheil-Gulliver calcula-
tions give two extreme conditions of weld
solidification, but neither of these ap-
proaches actually consider cooling rates,
or time. To consider these effects would
require a computational kinetics code,
such as DICTRA.
Postweld Heat Treatment
DICTRA is a software package for ac-
curate simulations of one-dimensional
diffusion in multicomponent alloys. As
mentioned previously, it can be used to
investigate microsegregation effects dur-
ing solidification taking into considera-
tion cooling rates and time. Another ap-
plication of the software is in regard to
postweld heat treatment.
Helander and gren (Ref. 8) simu-
lated the diffusion of a typical joint of a
stainless steel and a low-alloy steel in a
temperature range between 600 and
1200C and compared the calculated car-
bon concentration profiles with experi-
mental data at 650C. Diffusion simula-
tions were performed in the temperature
range between 600 and 1200C for 10 h
for two alloys comprising 18Cr-10Ni-
0.015C-Bal. Fe (stainless steel) and
0.1Cr-0.1Ni-0.2C-Bal. Fe (low-alloy
steel). For the lower temperature range
(600 to 850C), a ferritic layer was pre-
dicted to form in the low-alloy steel at
the interface between the steels, while
the stainless steel was predicted to car-
burize with carbide precipitates forming
in an austenite matrix. Comparison of the
experimental data to the simulations
shows the measured width of the ferritic
layer for a diffusion couple produced in
this temperature range is 530 m com-
pared with a predicted value of 560 m.
In the stainless steel, the carburized layer
had a measured width of 100 m com-
pared with a calculated value of 70 m.
This discrepancy corresponds to an un-
certainty in the carbon diffusivity of a fac-
tor of two, which is within the accuracy
reported by Jnsson (Ref. 9) in his as-
sessment. The authors concluded the re-
sults of the simulations were in general
agreement with practical experience and
noted that such simulations are used by
industry for optimizing the heat treat-
ment of composite tubes.
Design of a Weldable Alloy
Tancret (Ref. 10) has taken the use of
these tools one step further, and has de-
scribed a semiautomated procedure for
the design of an affordable, weldable,
creep-resistant superalloy. The approach
consists of automatically calculating the
equilibrium and Scheil out-of-equilib-
rium thermodynamic properties for a
large number of potential candidate alloy
compositions to determine their stability
at the expected service temperature,
their forging window and weldability
(through, for instance, the calculation of
brittle temperature range and volume
fraction) and also combining these with
predictions of creep rupture resistance
through the use of a neural network
model. By establishing criteria for poten-
tial candidate alloys, such as the vol-
ume fraction being less than 0.25 at 750C
to minimize the potential for cracking
and having a calculate creep rupture
stress of approximately 100 MPa at 750C
after 100,000 h, Tancret was able to
screen 7776 different compositions in a
nine-element system comprised of Ni, Cr,
Fe, W, Al, Ti, C, Si, and B, and identify
four potential candidate alloys for fur-
ther experimental testing.
Conclusions
The use of computational thermody-
namics and kinetic simulations are well
established in the areas of alloy design
and process optimization. While such
tools are being increasingly used to de-
sign alloys for the optimization of mate-
rial properties, that these materials often
need to be joined to other materials for
use in service should not be ignored.
While weld metallurgy is a complex, non-
equilibrium problem, such tools can give
insight and direction into understanding
the fundamental phenomena driving
these processes and thus accelerate
development and reduce the time and
costs associated with trial-and-error
experiments.
References
1. National Research Council. 2008.
Integrated Computational Materials Engi-
neering: A Transformational Discipline for
Improved Competitiveness and National
Security. Washington, D.C.: The National
Academies Press.
2. www.whitehouse.gov/sites/default/
files/microsites/ostp/materials_genome_ini
tiative-final.pdf
3. Babu, S. S. 2009. Thermodynamic
and kinetic models for describing mi-
crostructure evolution during joining of
metals and alloys. Int. Mat. Rev., Vol. 54,
No. 6, pp. 333367.
4. Kaufman, L., and Bernstein, H.
1970. Computer Calculation of Phase Di-
agram. New York, N.Y.: Academic Press
Inc.
5. Saunders, N., and Miodownik, A.
P. 1998. Calphad (calculations of phase
diagrams): A comprehensive guide. Perg-
amon Materials Series, Vol. 1, Ed. R. W.
Cahn (Oxford, UK: Elsevier Science
Ltd.).
6. Andersson, J. O., et al. 2002.
Thermo-Calc and DICTRA, Computa-
tional tools for materials science. CAL-
PHAD, Vol. 26, pp. 273312.
7. Madeni, J. C., et al. 2006. Thermo-
dynamic modeling using Thermo-Calc in
the development of specialty welding
consumables. Proc. American Welding So-
ciety. American Welding Society, Doral,
Fla.
8. Helander, T., and gren, J. 1997.
Computer simulation of multicomponent
diffusion in joints of dissimilar steels.
Met. Trans. A, Vol. 28A, pp. 303308.
9. Jnsson, B. 1994. Z. Metallkd, Vol.
85, pp. 502509.
10. Tancret, F. 2009. Computational
tools for the design of weldable and
creep-resistant superalloys. TMS, Supp.
Proc. Vol. 2, Mat. Characterization, Com-
putation and Modeling.
Software tools can reduce the time and costs
associated with trialanderror experiments
Call us at 800-782-2110 for a free quote on your
next project.
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DECEMBER 2012 32
F
or more than twenty years,
Rentapen, Inc., a machine tool de-
sign company located in Waukesha,
Wis., has been green.
The firm specializes in weld fixtures.
Rentapen helps manufacturers when
they are tooling their factories to pro-
duce a new product by providing the fol-
lowing: 3D CAD design services; build
of small- to medium-sized weld fixtures;
and a line of weld-tooling components
called RAPid Tooling Components.
The product line includes blocks, plates,
clamp risers, and shims Fig. 1.
This article not only details the com-
panys long-standing efforts to be green
but also its implementation of key prac-
tices to remain there.
Repeating the Three Rs
Reduce, Reuse, and Recycle
Rentapens owners were reducing,
reusing, and recycling long before Wis-
consin took action to require recycling
with a state law.
In the early 1990s Rentapen President
Susan Straley and Vice President George
Straley became part of a Household
EcoTeam program for people who
wanted to reduce resource consumption
and save money. Their group consisted
of about eight people who met periodi-
cally for several months and worked
through a manual along the way. Each
chapter focused on different areas
water consumption, paper, energy, trans-
portation, packaging, and purchases.
According to the Global Action Plan
International, It has been demonstrated
that, given effective leadership, engag-
Green:
A Way of Life
for Weld Tooling
Company
Rentapen Feature December 2012_Layout 1 11/7/12 3:40 PM Page 32
33 WELDING JOURNAL
ing as few as 510% of the households in
a housing estate in the EcoTeam program
will influence the behavior of the whole
community.
When the Straleys moved the business
from their home to an office, the prac-
tices of reducing, reusing, recycling, and
staying lean and green moved with it. In
2001, Rentapen started manufacturing,
and green values influenced that division.
Today, the company has grown to include
14 employees.
In 1990, the state of Wisconsin passed
the Solid Waste Reduction, Recovery,
and Recycling Law to create new ways to
manage solid waste as well as encourage
reduction, reuse, and recycling of solid
waste.
The Wisconsin recycling law requires
local governments to develop and imple-
ment recycling programs for 14 materi-
als now banned from municipal landfills
and incinerators, including corrugated
cardboard, glass bottles and jars, alu-
minum cans, and plastic food and bever-
age containers. The law also requires es-
tablishment of local ordinances and ed-
ucation of all residents, businesses, gov-
ernment agencies, and institutions about
recycling.
Rentapen has support from its waste
management companys recycling pro-
gram for its green efforts.
In Waukesha, Wis., Waste Manage-
ment, Inc., has a sorting facility. We can
put all our recyclables into one container,
and we do not have to spend time sort-
ing the cans from the paper, said Susan
Straley.
The co-mingling of the recyclables
helps simplify the whole process of train-
ing new employees and takes less space,
she added.
It costs Rentapen $20 per month for
the additional recycling dumpster. The
trash bin has a higher fee because of the
dumping fee for the trash hauler.
Good Shop Routines to Follow
Rentapen recycles all recyclable ma-
terials in both its factory and the office.
The companys shop manufactures its
BETHANY KRATZ (bethany@rentapen.com)
is the marketing assistant and duchess of
cost reductions at Rentapen, Inc.
(www.rentapen.com), Waukesha, Wis.
By recycling all its
materials, Rentapen
operates as green as
possible in both its
factory and office
BY BETHANY KRATZ
A few of the ways Rentapen has gone green
throughout the years includes setting up cut
files so any material left for recycling is minimal;
keeping minimal inventory, making for less
waste; and using cloth rags vs. paper towels. As
pictured, the companys 150-W Kern laser cuts
custom shims for a customer.
DECEMBER 2012 34
weld fixture components, known as
RAPid Tooling Components. The line
consists of blocks, plates, and clamp ris-
ers, which are created in a Haas Super
Mini Mill CNC machine Fig. 2A, B.
The line also includes RAPid Shims cut
on a Kern industrial cutting laser.
When Rentapens shop team receives
an order for blocks or plates, the mate-
rials needed stainless steel, aluminum,
mild steel, and so on are selected first.
The shop associate then considers mak-
ing the selection from the boxes of dis-
carded material that may be reused
before going to the inventory of new
material.
Next, the material is processed on a
band saw and then the CNC. Sawing,
grinding, and putting the finished holes
in the blocks produces scrap metal, which
goes into a basket to be recycled Fig.
3. This is a common practice in the man-
ufacturing industry and a way to recap-
ture some of the costs of the metal and
reduce waste. When bins get full, shop
associates call the scrap dealer, who picks
up the metal and pays the company for
it. In the first nine months of 2012,
Rentapen received more than $3500
from recycling its metal waste.
Making Weld Fixtures with
Left-over Scrap Metal
Last year, Rentapen sold a 4000-W
laser machine to focus more on its spe-
cialty, weld fixtures. Before completing
the sale, the company realized there was
a lot of left-over scrap metal still in the
factory inventory for cutting on the large
laser. So, before the equipment was
hauled away, the shop team came up with
a plan to use that metal. They cut it up
into smaller parts the mini-mill CNC
could handle or that could be easily cut
on the band saw. The metal was set aside
for later use for building weld fixtures or
tooling components. The old steel was
made useful through the shop teams in-
novation, plus a culture of cost cutting
and waste reduction.
Laser Machine Equals a
Clean Cutting Process
In 2004, Rentapen purchased a 150-
W Kern laser to cut its custom and stan-
dard metal shims, shim packs, and die-
sharpening shims see lead photo and
Fig. 4A, B.
The cleanliness of the process greatly
influenced the companys decision to use
laser cutting rather than water jet cutting
for precision adjustment shims. Water
Fig. 1 Rentapen President Susan
Straley holds a simple weld fixture
that contains many of the companys
RAPid Tooling Components.
Fig. 2 Examples of the companys
weld fixture components include the
following: A Customized RAPid
Blocks; B RAPid Plates RP02 in
bronze.
1
2A
2B
jets are messy and use a lot of water, ex-
plained George Straley.
Minimizing Metal between Shims
Metal adjustment shims are com-
monly used to finely adjust the location
of how a weld fixture holds the product
so that it is welded within dimension tol-
erances. A pack of thin metal shims is
placed between two components in a
weld fixture. The first component is fixed
in place while the second is attached to
the first component with the pack of
shims in between. Removing one shim or
adding one shim slightly adjusts the lo-
cation of the second component. This is
important to manufacturers who want to
have the products parts assemble easily
after being welded.
The program to nest the shims into a
cutting file minimizes the amount of
metal between shims Fig. 5A, B. A
small amount of metal is kept between
the shims for efficiency in handling them
when unloading the laser. However, the
amount of metal left is minimal, and
every bit is recycled. Rentapens staff de-
veloped a system to pick up the small
pieces that fall through the support grid
and place them into the recycling bin.
Made-to-Order Production Process
Saves Resources
Rentapen follows a minimal-waste
and made-to-order production process,
reducing inventory, which keeps storage
space to a minimum. This is beneficial
considering storage space has to be
heated/cooled and paid for. By using a
made-to-order production process, the
company not only saves on inventory
cost, which are passed on to its cus-
tomers, but it also saves resources.
We learned early on that our prod-
uct line is so versatile that we actually
have a billion versions of our products.
So for us to make them ahead of time to
try to anticipate our customers needs
would be fruitless and wasteful. Just-in-
time makes sense for us and our cus-
tomers, said Susan Straley.
Reusing Paper as a Packing
Material to Ship Orders
In addition, Rentapen uses recycled
paper for packaging in its shipping/re-
ceiving department Fig. 6. When pack-
ing products, the company uses new
boxes but old packing materials. With any
incoming packages, the peanuts and bub-
ble wrap are placed in a large box to be
reused in shipping its tooling compo-
nents. Each year, an old box of docu-
35 WELDING JOURNAL
Fig. 3 Metal chips from a band saw go into a basket
to then get recycled.
Fig. 4 Following are two shapes cut from the
companys 150-W Kern laser: A Die sharpening shims;
B custom shims.
3
4A 4B
ments is shredded, and the material is
used for shipping. All the paper in the of-
fices recycle bins is shredded and used
as shipping material. Employees are en-
couraged to bring in old newspapers for
use as packing material, too.
Office paper has a planned journey
at Rentapen. It travels from the printer
to the desk or boardroom or file. If it is
printed on only one side, then it moves
to the scratch paper box, said Susan
Straley.
The paper moves from the recycle bin
to the shredder, then to the packing ma-
terials box.
Efficient Practices
Carry over to the Office
Rentapen practices green manufac-
turing not only in its factory, but also in
the office. Every room has a trash bin and
a separate recycling bin. Because of
Waukesha Countys sorting service, a
simple blue waste basket serves to hold
all the recyclables: paper and plastic bot-
tles, plus aluminum and tin cans.
Using Cloth Towels, Reusable
Cups, and Much More
The company does not purchase
paper towels for the bathroom and
kitchen areas. Instead, it provides cloth
towels and rags that are washed weekly.
Instead of buying new towels and
rags, we try to buy them from rummage
sales and thrift shops. That saves money
and resources, said Straley.
At first, the Straleys were concerned
with washing the shop towels used in
Rentapens factory considering the oil
and metal shavings on them. However,
they consulted a water quality expert,
who stated that since after the company
washes the towels, the water goes
through the city sewer system, it was
okay. The quantity of towels is small and
the city has processes to clean up the oil
and metals before they go into the river.
Rentapen does not provide paper
plates or plastic silverware either.
Reusable plates, cups, and metal silver-
ware are used instead.
In the summer, the air conditioning is
kept at a more efficient temperature and
fans are used to keep the office and shop
comfortable.
In 2012, George and Susan Straley
purchased a water cooler for employees.
When selecting a supplier for drinking
water, they chose a company that reuses
the bottles over a less costly option where
bottles are not reused.
Most of the companys furniture was
purchased second-hand. When there is a
need to add a new desk or filing cabinet,
it starts checking out thrift stores.
Conclusion
Through various ways, Rentapen has
practiced green manufacturing for quite
some time and keeps on making strides
toward being even more environmentally
friendly. Fortunately, it also has seen
growth straight through the recession.
DECEMBER 2012 36
Fig. 5 A and B Rentapens nesting program allows mini-
mal scrap when cutting its custom and standard shims.
Fig. 6 Recycled scrap paper is used as packaging material
for shipping orders.
5A 5B
6

2% thoriateo thiro pass
erosion visible
Field Testing

astaras_FP_TEMP 11/7/12 3:45 PM Page 37
T
ake a moment to consider your cur-
rent document control system. Does
it involve copious amounts of paper
and time? Or perhaps you have devel-
oped home-brew documents within a
word-processing or spreadsheet program.
Given the power of the welding docu-
mentation products available today, you
would be doing yourself and your com-
pany a disservice by not taking a look at
the control and convenience they offer
you.
Electronic Documents
Welding procedures, procedure qual-
ifications, and welder qualifications are
all of vital importance to code-based
welding shops and fabricators. Sure these
can be designed with paper and pen, but
the sheer bulk of paper can make stor-
age and organization burdensome and
can represent a potential liability. Creat-
ing a new document with paper and pen
is innately time consuming when com-
pared to software, especially when that
software offers built-in document cre-
ation assistance.
Once you have experienced document
creation assistance, you will wonder why
DECEMBER 2012 38
Moving from Paper to Pixels
DAVID CRAIG (dcraig@thinkcei.com)
is sales manager, CEI, Blue Springs, Mo.
How welding documentation
software can save you time,
money, and headaches
BY DAVID CRAIG
Fig. 1 Todays software offers
advanced reporting features to
help reduce your workload.
Craig Feature December 2012_Layout 1 11/8/12 8:02 AM Page 38
you stuck with paper so long. This assis-
tance ranges from simply copying over
data from like fields between document
types to accessing built-in databases and
offering practical suggestions for filler
metals, gases, travel speeds, voltage, am-
perage, and other variables, all the way
up to providing high-level guidance and
qualified ranges based on code require-
ments, thereby practically generating the
documents for you, such as with
ProWrite software.
In addition to being time consuming,
paper documents are also difficult to
store and organize. They are susceptible
to fire, flood, and even time. Many peo-
ple are stunned when they find that their
photocopied duplicates have faded al-
most completely in only a decade, but this
is an all too common scenario. You can
alleviate some concerns by keeping du-
plicates off-site, but now you have dou-
bled your storage space requirements
and made it difficult to process any doc-
ument changes. When you instead cre-
ate and store your documents electroni-
cally, you can keep millions of documents
in a drive the size of a book, document
changes are accomplished with a few but-
ton clicks, and online storage gives you
access to your documents from any In-
ternet-enabled location.
Electronic documentation opens up
new possibilities. Where you would need
to copy and either fax or mail a paper
document, you can save an electronic
document as a PDF and send it by e-mail,
putting your documents in the recipients
hands in moments. Not only does this
make your life easier, it looks more pro-
fessional to your customers when you can
show clean, accurate documentation for
an upcoming or current job.
Welder Continuity
Tracking production welds over time
can be an issue even with just a handful
of welders. Keeping an eye on process
expiration can be difficult; should any-
one slip through the cracks, you have the
added expense of qualification tests that
could have been avoided. Welding docu-
mentation software makes managing
your welder continuity a very simple
process and may even take things a step
further by allowing you to track defect
and NDE information on your produc-
tion welds so you can stay on top of re-
jection rates.
Data and Reports
Trying to correlate usable data from
a filing cabinet full of paper can be a
nightmare. Spreadsheets have their uses,
but keeping data relevant and up to date
can be a huge undertaking. Finding a spe-
cific Welding Procedure Specification
(WPS) or Procedure Qualification
Record (PQR) among thousands of doc-
uments is virtually impossible without
dedicated software. Welder documenta-
tion software provides the ability to
search based on document-specific cri-
teria. This drastically reduces your time
spent looking for documents and can
help eliminate duplication. Search out a
qualified welder based on his or her suit-
ability for a particular application or,
even better, match up welders with new
WPSs based on their previous qualifica-
tion ranges under the guidance of code
rules and eliminate unnecessary testing.
The reports available in todays weld-
ing documentation software range from
simple listings of various documents cre-
ated in the software, to welders and their
continuity/expiration to massively com-
plex reports that blur the lines of tradi-
tional functionality by adding the ability
to apply code rules on the fly as a filter-
ing mechanism Fig. 1. It is even pos-
sible to create and use completely cus-
tomized reports.
The added convenience of electronic
documentation benefits your customers
as well. Job data can be gathered into a
single PDF that can then be emailed or
uploaded. Compare this to the time spent
gathering, copying, faxing or mailing, and
refiling paper documents.
Make the Change
The latest generation of welding doc-
umentation software can lead you down
the path toward better organization,
safer storage, and greatly improved us-
ability and accessibility of your informa-
tion. Add that to the time and money sav-
ings it offers and the question becomes
less should you use software? and more
why arent you already?
39 WELDING JOURNAL
Craig Feature December 2012_Layout 1 11/8/12 8:02 AM Page 39
COMING
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LAM 5th Annual Laser Additive Manufacturing Workshop.
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A powerhouse ventilator for the toughest jobs.
High quality industrial products: circulation fans, exhaust,
misting, evaporative cooling and infrared heat.
DECEMBER 2012 40
Coming Events Layout_Layout 1 11/8/12 1:34 PM Page 40
41 WELDING JOURNAL
GAWDA 2013 Spring Management Conf. April 1316. Grand
Hyatt Hotel and Convention Center, River Walk, San Antonio,
Tex. Gases and Welding Distributors Assn. www.gawda.org.
Society of Vacuum Coaters SVC TechCon 2013. April 2025.
Rhode Island Convention Center, Providence, R.I. www.svc.org.
JOM-17, Intl Conf. on Joining Materials. May 58. Konven-
tum Lo Skolen, Helsingr, Denmark. Institute for the Joining of
Materials (JOM) in association with the IIW. Cosponsored by
AWS, TWI, Danish Welding Society, Welding Technology Insti-
tute of Australia, University of Liverpool, Cranfield University,
Force Technology, and ABS (Brazilian Welding Assn.). E-mail
Osama Al-Erhayem at jom_aws@post10.tele.dk; www.jominsti-
tute.com/side6.html.
INTERTECH 2013, Superabrasive Materials, Principles, and
Applications for the Aerospace and Defense Industries. May 68.
Hyatt Regency Baltimore Harbor Hotel, Baltimore Md. Indus-
trial Diamond Assn. www.intertechconference.com.
POWER-GEN India & Central Asia, Renewable Energy World
Conf. & Expo, and HydroVision India. May 68. Bombay Exhi-
bition Centre, Goregaon, Mumbai, India. www.power-genindia.
com/index.html.
IIE Annual Conf. and Expo. May 1822. Caribe Hilton, San Juan,
Puerto Rico. www.iienet2.org/annual2.
44th Steelmaking Seminar Intl. May 1922. Tau Grande
Hotel Termas & Convention Arax, Estncia Parque do Barreiro,
s/n Arax - Minas Gerais, Brazil. Held by Brazilian Metallurgi-
cal, Materials, and Mining Assn. www.abmbrasil.com.br.
12th Intl Conf. on Application of Contemporary Non-Destructive
Testing in Engineering. Sept. 46. Grand Hotel Metropol, Por-
toroz, Slovenia. Sponsored by The Slovenian Society for Non-De-
structive Testing. www.fs.uni-lj.si/ndt.
66th IIW Annual Assembly and Intl Conf. on Automation in
Welding. Sept. 1117. Essen, Germany. Organized by DVS (Ger-
man Welding Society). www.dvs-ev.de/IIW2013/.
ASM Heat Treating Society Conf. and Expo. Sept. 1618, 2013. In-
diana Convention Center, Indianapolis, Ind. www.asminterna-
tional.org/content/Events/heattreat/.
18th Intl Schweissen & Schneiden Trade Fair. Sept. 1621. Messe
Essen, Essen, Germany. Sponsored by DVS (German Welding
Society). www.messe-essen.de/en/messeessen/index.html.
POWER-GEN Brasil 2013, HydroVision Brasil, and DistribuTech
Brasil. Sept. 2426. Transamerica Center, So Paulo, Brazil.
www.power-gen.com.
WESTEC. Oct. 1517, 2013. Los Angeles Convention Center, Los
Angeles, Calif. The Society of Manufacturing Engineers.
www.westeconline.com; (800) 733-4763.
Educational Opportunities
Laser Welding and Equipment Fundamentals. Jan. 17. Edison
Welding Institute, Columbus, Ohio. Call (614) 688-5049, e-mail
education@ewi.org.
DECEMBER 2012 42
Introduction to Ultrasonic Joining. Feb. 7. Edison Welding
Institute, Columbus, Ohio. Call (614) 688-5049, e-mail educa-
tion@ewi.org.
ASM Intl Courses. Numerous classes on welding, corrosion, fail-
ure analysis, metallography, heat treating, etc., presented in
Materials Park, Ohio, online, webinars, on-site, videos, and
DVDs; www.asminternational.org, search for courses.
Automotive Body in White Training for Skilled Trades and
Engineers. Orion, Mich. A five-day course covers operations,
troubleshooting, error recovery programs, and safety procedures
for automotive lines and integrated cells. Applied Mfg.
Technologies; (248) 409-2000; www.appliedmfg.com.
Basic and Advanced Welding Courses. Cleveland, Ohio. The
Lincoln Electric Co.; www.lincolnelectric.com.
Basics of Nonferrous Surface Preparation. Online course, six
hours includes exam. Offered on the 15th of every month by The
Society for Protective Coatings. Register at www.sspc.org/training.
Best Practices for High-Strength Steel Repairs. I-CAR courses
for vehicle repair and steel structural technicians. www.i-car.com.
Boiler and Pressure Vessel Inspectors Training Courses and
Seminars. Columbus, Ohio; www.nationalboard.org; (614) 888-
8320.
Canadian Welding Bureau Courses. Welding inspection courses
and preparation courses for Canadian General Standards Board
and Canadian Nuclear Safety Commission certifications. The
CWB Group, www.cwbgroup.org.
CWI/CWE Course and Exam. Troy, Ohio. A two-week prepara-
tion and exam program. Hobart Institute of Welding Technology;
(800) 332-9448; www.welding.org.
CWI/CWE Prep Course and Exam and NDT Inspector Training
Courses. An AWS Accredited Testing Facility. Courses held year-
round in Allentown, Pa., and at customers facilities. Welder
Training & Testing Institute; (800) 223-9884; info@wtti.edu;
www.wtti.edu.
CWI Preparatory and Visual Weld Inspection Courses. Classes
presented in Pascagoula, Miss., Houston, Tex., and Houma and
Sulphur, La. Real Educational Services, Inc. (800) 489-2890;
info@realeducational.com.
Consumables: Care and Optimization. Free online e-courses on
the basics of plasma consumables for plasma operators, sales,
and service personnel; www.hyperthermcuttinginstitute.com.
Crane and Hoist Training for Operators. Konecranes Training
Institute, Springfield, Ohio; www.konecranesamericas.com; (262)
821-4001.
Dust Collection Seminars. Free, full-day training on industrial
ventilation basics and OSHA, EPA, and NFPA regulations.
Presented throughout the year at numerous locations nation-
wide. Call Camfil Farr APC, (800) 479-6801.
EPRI NDE Training Seminars. Training in visual and ultrasonic
examination and ASME Section XI. Sherryl Stogner (704) 547-
6174; sstogner@epri.com.
weld engineering_FP_TEMP 11/7/12 3:40 PM Page 43
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION SEMINAR DATES EXAM DATE
Charlotte, NC Jan. 611 Jan. 12
Beaumont, TX Jan. 611 Jan. 12
Doral, FL Exam only Jan. 17
Long Beach, CA Jan. 27Feb. 1 Feb. 2
Denver, CO Jan. 27Feb. 1 Feb. 2
Doral, FL Jan. 27Feb. 1 Feb. 2
Pittsburgh, PA Jan. 27Feb. 1 Feb. 2
Corpus Christi, TX Exam only Feb. 9
Seattle, WA Feb. 38 Feb. 9
New Orleans, LA Feb. 1015 Feb. 16
Waco, TX Feb. 1015 Feb. 16
San Diego, CA Feb. 24March 1 March 2
Atlanta, GA Feb. 24March 1 March 2
Mobile, AL March 38 March 9
Kansas City, MO March 38 March 9
Houston, TX March 38 March 9
Norfolk, VA March 38 March 9
Milwaukee, WI March 38 March 9
Birmingham, AL March 1015 March 16
Indianapolis, IN March 1015 March 16
Portland, OR March 1015 March 16
Doral, FL March 1722 March 23
Chicago, IL March 1722 March 23
Boston, MA March 1722 March 23
Mobile, AL Exam only March 23
Rochester, NY Exam only March 23
York, PA Exam only March 23
Corpus Christi, TX Exam only April 6
Springfield, MO April 712 April 13
Dallas, TX April 712 April 13
Doral, FL Exam only April 18
Minneapolis, MN April 1419 April 20
Las Vegas, NV April 1419 April 20
Syracuse, NY April 1419 April 20
San Francisco, CA April 2126 April 27
New Orleans, LA April 2126 April 27
Nashville, TN April 2126 April 27
Annapolis, MD April 28May 3 May 4
Detroit, MI April 28May 3 May 4
St. Louis, MO Exam only May 4
Fresno, CA May 510 May 11
Doral, FL May 510 May 11
Albuquerque, NM May 510 May 11
Oklahoma City, OK May 510 May 11
Corpus Christi, TX May 510 May 11
Knoxville, TN Exam only May 18
9Year Recertification Seminar for CWI/SCWI (No exams
given)
For current CWIs and SCWIs needing to meet education require-
ments without taking the exam. The exam can be taken at any site
listed under Certified Welding Inspector.
LOCATION SEMINAR DATES
New Orleans, LA Jan. 611
Denver, CO Feb. 1015
Dallas, TX March 1015
Doral, FL April 712
Sacramento, CA April 28May 3
Charlotte, NC May 510
Certified Welding Supervisor (CWS)
Atlanta, GA Jan. 711 Jan. 12
New Orleans, LA April 1519 April 20
CWS exams are also given at all CWI exam sites.
Certified Radiographic Interpreter (CRI)
Seattle, WA Feb. 25March 1 March 2
Houston, TX April 1519 April 20
Las Vegas, NV May 610 May 11
The CRI certification can be a stand-alone credential or can
exempt you from your next 9-Year Recertification.
Certified Welding Sales Representative (CWSR)
CWSR exams will be given at CWI exam sites.
Certified Welding Educator (CWE)
Seminar and exam are given at all sites listed under Certified
Welding Inspector. Seminar attendees will not attend the Code
Clinic portion of the seminar (usually the first two days).
Certified Robotic Arc Welding (CRAW)
The course dates are followed by the location and phone number
Feb. 26; June 1721, Dec. 913 at
ABB, Inc., Auburn Hills, MI; (248) 3918421
Feb. 25March 1; May 2024, Aug. 1923, Dec. 26 at
Genesis-Systems Group, Davenport, IA; (563) 445-5688
March 4, Oct. 14 at
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Feb. 1115, April 2226, July 1519, Oct. 2125 at
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Jan. 21, March 25, May 20, July 22, Sept. 23, Nov. 18 at
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at:
MATC, Milwaukee, WI; (414) 297-6996
Certified Welding Engineer; Senior Certified Welding
Inspector
Exams can be taken at any site listed under Certified Welding
Inspector. No preparatory seminar is offered.
International CWI Courses and Exams Schedules
Please visit www.aws.org/certification/inter_contact.html.
Certification Seminars, Code Clinics, and Examinations
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 Web site
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. Apply early to avoid paying the $250 Fast Track fee.
DECEMBER 2012 44
Cert Schedule 2013_Layout 1 11/8/12 10:16 AM Page 44
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Join us in New Orleans for an exciting look into the world of shipbuilding!
Our featured speakers will cover a multitude of topics including robotics
and mechanized welding for shipbuilding applications, aluminum
applications, advanced welding processes and much more.
AWS Conferences & Exhibitions:
8
th
Shipbuilding Conference
February 26-27, 2013 / Wyndham Riverfront New Orleans
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 264.
Highlights
Learn about the progress of new and innovative
developments in shipbuilding.
Network with industry peers to discuss the best solutions for
business growth.
Information on new and emerging technologies being
developed for shipbuilding applications.
AWS Conference attendees are awarded 1 PDH
(Professional Development Hour) for each hour of
conference attendance. These PDHs can be applied
toward AWS recertifications and renewals.

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edu shipbuilding conf_FP_TEMP 11/6/12 3:12 PM Page 46
SOCIETYNEWS
SOCIETYNEWS
47 WELDING JOURNAL
Detroit Section Honors Welding Students
Supporting educational programs
and student scholarships are important
to the Detroit Section members and its
patrons, said Mike Palko, Detroit Sec-
tion chairman. He noted that the Sec-
tion has been donating about $35,000 an-
nually to student scholarships, but when
the American Welding Society an-
nounced it would, for a limited time,
match funds donated to new and exist-
ing named scholarships, the Section
elected to donate $350,000 to the AWS
Foundation.
The funds were presented to AWS
President Bill Rice and Monica Pfarr,
AWS corporate director workforce de-
velopment, Sept. 20 at the VistTaTech
Center, Schoolcraft College, in Livonia,
Mich. The event included a welding shop
open house in the afternoon, followed
by dinner, presentations by Bill Rice and
SkillsUSA competitor Alex Pazkowski,
and concluded with awarding $36,800 in
scholarships to 44 students.
BY HOWARD WOODWARD
woodward@aws.org
Forty-four students (above) received Detroit Section-sponsored scholarships totaling $36,800 at the Sept. 20 event.
Shown are (from left) AWS President Bill Rice, Detroit Section Chair Mike Palko, Secretary Andre Young, AWS Corporate Director Workforce
Development Monica Pfarr, and Scholarship Chair Wesley Doneth during the presentation of the Detroit Sections donation of $350,000 to the
AWS Foundation scholarship program.
Society News December_Layout 1 11/8/12 2:09 PM Page 47
DECEMBER 2012 48
Tech Topics
A2 Committee on Definitions and Symbols Meets in West Virginia
Shown are from left (front row) Chuck Ford, Pat Newhouse, and Stephen Borrero, (back row) Ted Hutton, Ben Grimmett, Dick Holdren,
Chris Lander, Larry Barley, J. P. Christein, and David Beneteau.
The A2 Committee on Definitions and
Symbols met October 35 at Oglebay Re-
sort and Conference Center in Wheeling,
W.Va., to continue its work on the main-
tenance of AWS A2.4, Standard Symbols
for Welding, Brazing, and Nondestructive
Examination, and AWS A3.0M/A3.0, Stan-
dard Welding Terms and Definitions includ-
ing Adhesive Bonding, Brazing, Soldering,
Thermal Cutting, and Thermal Spraying.
Attending the meeting were G1 Com-
mittee Chair Ted Hutton, A2 Chair Ben
Grimmett, A2B Subcommittee Chair Dick
Holdren, A2C Subcommittee Chair J. P.
Christein, Chris Lander, Larry Barley,
David Beneteau, Chuck Ford, Pat New-
house, and Stephen Borrero, AWS staff
secretary to the A2 Committee.
Standards for Public Review
A5.16/A5.16M:20XX (ISO 24034: 2010
MOD), Specification for Titanium and Ti-
tanium-Alloy Welding Electrodes and Rods.
$25. 12/3/12.
B5.16:20XX, Specification for the Qual-
ification of Welding Engineers. $25. 12/3/12.
F1.2:20XX, Laboratory Method for
Measuring Fume Generation Rates and
Total Fume Emission of Welding and Al-
lied Processes. $25. 11/26/12.
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute
(ANSI) in 1979. AWS rules, as approved
by ANSI, require that all standards be
open to public review for comment dur-
ing the approval process. The above re-
vised standards were submitted for pub-
lic review. Draft copies may be obtained
from R. ONeill, roneill@aws.org, ext. 451.
Standards Approved by ANSI
A5.4/A5.4M:2012, Specification for
Stainless Steel Electrodes for Shielded Metal
Arc Welding. Revised. 10/5/12.
A5.10/A5.10M:2012 (ISO 18273:2004
MOD), Welding Consumables Wire
Electrodes, Wires and Rods for Welding of
Aluminum and Aluminum-Alloys Classifi-
cation. Revised. 10/4/12.
G2.1M/G2.1:2012, Guide for the Join-
ing of Wrought Nickel-Based Alloys. Re-
vised. 10/16/12.
G2.3M/G2.3:2012, Guide for the Join-
ing of Solid Solution Austenitic Stainless
Steels. Revised. 10/16/12.
Technical Committee Meetings
All AWS technical committee meet-
ings are open to the public. To attend a
meeting, contact the committee secretary
as listed below. Call (800/305) 443-9353
at the extention shown. Visit www.aws.
org/technical/jointechcomm.html to learn
more about what technical committees
do, membership requirements, and to
apply for membership online.
Dec. 5, 6, Safety and Health Commit-
tee. Doral, Fla. S. Hedrick, 305.
AWS Members Get Low Rate for Laser Workshop
American Welding Society members will receive a discounted
fee to attend the Laser Institute of America (LIA) 5th Annual
Laser Additive Manufacturing Workshop to be held Feb. 12, 13,
2013, at Hilton Houston North Hotel in Houston, Tex. The two
societies have signed a cooperating society agreement wherein
AWS is listed as a Cooperating Society for the event and AWS
members receive the LIA member discount. For complete infor-
mation, visit www.lia.org/conferences/lam.
Errata AWS D3.6M:2010
Underwater Welding Code
The following errata, in addtion to previously announced
corrections (visit www.aws.org), have been identified and will
be incorporated into the next reprinting of this document.
Page 60, Figure 7.2, note 2b. Correct to .
Page 63, Figure 7.3, note a. Correct to .
Page 63, Figure 7.3, note b. Correct to .
Page 75, Figure 8.2, note 3b. Correct to .
Page 77, Figure 8.3, note b. Correct to .
49 WELDING JOURNAL
D14 Committee on Machinery and Equip-
ment seeks professionals in the design, pro-
duction, engineering, testing, and safe opera-
tion of machinery and equipment to prepare
and revise its documents. Contact E. Abrams,
eabrams@aws.org; ext. 307.
C2 Committee on Thermal Spraying seeks
educators, general interest, and users to up-
date its documents. Contact E. Abrams,
eabrams@aws.org; ext. 307.
D16 Committee on Robotic and Automatic
Welding seeks general interest and educators
to help revise its documents. Contact B. Mc-
Grath, bmcgrath@ aws.org; ext. 311.
D17J Subcommittee seeks members to
help revise D17.3/D17.3M, Specification for
Friction Stir Welding of Aluminum Alloys for
Aerospace Applications. Contact A. Diaz,
adiaz@aws.org; ext. 304.
J1 Committee on Resistance Welding
Equipment seeks educators, general interest,
and users to help develop its documents on
controls, installation and maintenance, cali-
bration, and resistance welding fact sheets.
Contact E. Abrams, eabrams@aws.org; ext.
307.
A5L Subcommittee on Magnesium Alloy
Filler Metals to assist in updating its docu-
ment. Contact R. Gupta, gupta@aws.org, ext.
301.
C4 Committee on Oxyfuel Gas Welding
and Cutting seeks general interest and edu-
cators to help review its documents. Contact
E. Abrams, eabrams@aws.org; ext. 307.
D14H Subcommittee on Surfacing and
Reconditioning of Industrial Mill Rolls to re-
vise AWS D14.7, Recommended Practices for
Surfacing and Reconditioning of Industrial Mill
Rolls. Contact E. Abrams, eabrams@aws.org;
ext. 307.
D8 Committee on Automotive Welding
seeks members to help prepare standards on
all aspects of welding in the automotive in-
dustry. Contact E. Abrams, eabrams
@aws.org; ext. 307.
D10P Subcommittee for Local Heat Treat-
ing of Pipe seeks members. Contact B. Mc-
Grath, bmcgrath@aws.org; ext. 311.
Opportunities to Contribute to AWS Welding Standards and Codes
District Meritorious and District Director Awards Announced
NOTE: LEARN MORE ABOUT TECHNICAL COMMITTEES AND APPLY FOR MEMBERSHIP ONLINE AT www.aws.org/technical/jointechcomm.html.
District Meritorious Award
Mike Vincent, Kansas City Section, was
nominated to receive the District Meritori-
ous Award at the District 16 conference.
District Director Awards
The District Director Award provides a
means for District Directors to recognize in-
dividuals and corporations who have con-
tributed their time and effort to the affairs of
their local Section and/or District.
Tom Ferri, District 1 director, nominated:
Gil Trigo, Montreal Section
Michel Marier, Montreal Section
Harland Thompson, District 2 director,
nominated:
Herb Browne, New Jersey
Alfred Fleury, New Jersey
Pat Grillon, New Jersey
Mike Chomin, Philadelphia
Joseph Nedorezov, Philadelphia
Joe Kass, Long Island
Thomas Colasanto, New York
Roy Lanier, District 4 director, nominated:
Tidewater Section, #121
Charlotte Section, #140
Northeastern Carolina Section, #137
Carolina Section, #87
Southwest Virginia Section, #179
Central Piedmont Community College
Student Chapter
Rowan Carbarrus Community College
Student Chapter
Wake Tech Community College Student
Chapter
The Roberts Co., North State Steel Stu-
dent Chapter
J. Jones, District 17 director, nominated:
Ralph Johnson, Tulsa Section
Todd Morris, Tulsa Section
Debbie Rudichuk, Tulsa Section
Paul Stanglin, North Texas Section
Debra Stanglin, North Texas Section
Clayton Roszell, Lincoln College of Tech-
nology, North Texas Section
Casey Cordell, North Texas Section
Anita Holstien, Ozark Section
Brian Chatcherine, Ozark Section
Kenny McCoy, Ozark Section
College of the Ozarks, Ozark Section
Oren Reich, Central Texas Section
Texas State Technical College, Central
Texas Section
Kilgore Jr. College, East Texas
Cody Edward, East Texas
Dale Flood, District 22 director, nominated:
Aleda Vaughn, Sacramento Valley
Brandon Beattie, Sacramento Valley
Nathan Flatt, Sierra Nevada
Member-Get-A-Member Campaign
Listed are standings as of Oct. 16, 2012. See
page 65 of this Welding Journal for a complete
list of rules and a prize list, or visit
www.aws.org/mgm. Call the AWS Membership
Dept. at (800) 443-9353, ext. 480, with questions
about your member-proposer status.
Winners Circle
Listed below are the sponsors of 20 or more
Individual Members per year, since June 1, 1999.
The superscript denotes the number of years the
member has earned Winners Circle status if
more than once.
E. Ezell, Mobile
10
J. Compton, San Fernando Valley
7
J. Merzthal, Peru
2
G. Taylor, Pascagoula
2
L. Taylor, Pascagoula
2
B. Chin, Auburn
S. Esders, Detroit
M. Haggard, Inland Empire
M. Karagoulis, Detroit
S. McGill, NE Tennessee
B. Mikeska, Houston
W. Shreve, Fox Valley
T. Weaver, Johnstown/Altoona
G. Woomer, Johnstown/Altoona
R. Wray, Nebraska
Presidents Roundtable
M. Pelegrino, Chicago 16
E. Ezell, Mobile 12
R. Fulmer, Twin Tiers 10
P. Strother, New Orleans 9
A. Tous, Costa Rica 9
Presidents Club
W. Komlos, Utah 7
J. Smith, San Antonio 6
C. Becker, Northwest 5
L. Webb, Lexington 4
A. Bernard, Sabine 3
P. Brown, New Orleans 3
D. Buster, Eastern Iowa 3
C. Daon, Israel 3
G. Gammill, NE Mississippi 3
D. Jessops, Mahoning Valley 3
R. Wright, San Antonio 3
Presidents Honor Roll
W. Larry, Southern Colorado 2
E. Norman, Ozark 2
A. Sam, Trinidad 2
D. Saunders, Lakeshore 2
A. Vogt, New Jersey 2
M. Wheeler, Cleveland 2
W. Wilson, New Orleans 2
D. Wright, Kansas City 2
R. Zabel, SE Nebraska 2
Student Member Sponsors
W. England, West Michigan 33
H. Hughes, Ozark 31
S. Siviski, Maine 24
M. Arand, Louisville 22
G. Gammill, NE Mississippi 21
B. Scherer, Cincinati 19
R. Munns, Utah 18
S. Lindsey, San Diego 17
E. Norman, Ozark 16
D. Pickering, Central Arkansas 13
J. Daugherty, Louisville 12
S. Robeson, Cumberland Valley 12
D. Saunders, Lakeshore 11
A. Theriot, New Orleans 10
A. Duron, Cumberland Valley 10
J. Boyer, Lancaster 9
G. Seese, Johnstown-Altoona 8
C. Schiner, Wyoming 8
R. Zabel, SE Nebraska 7
R. Udy, Utah 7
T. Buckley, Columbus 6
R. Fuller, Green & White Mountains 6
R. Richwine, Indiana 5
W. Wilson, New Orleans 5
J. Reed, Ozark 4
G. Sieper, Kansas 4
P. Strother, New Orleans 4
DECEMBER 2012 50
Sustaining Company
Cavagna North America, Inc.
50 Napoleon Ct.,
Somerset, NJ 08873
Representative: David S. Ellis
www.cavagnagroup.com
The Cavagna Group, founded in 1949, is a
supplier of equipment and fittings for com-
pressed gases, gas storage, and control. It re-
lies on eight vertically integrated production
units in Italy and seven additional units in other
countries. With its distribution network of an
additional 15 commercial business units, it
services customers worldwide, including the
major oil companies and producers of com-
pressed gases containers and the original
equipment manufacturers of gas appliances.
Supporting Companies
J. E. Johnson, Inc.
1550 E. Virginia Dr.
Midland, MI 48642
Southwest United Industries, Inc.
422 S. St. Louis Ave.
Tulsa, OK 74120
Affiliate Companies
Big R Bridge, LLC
PO Box 1290, Greeley, CO 80632
Borrelli Steel Fabricators, LLC
2800 Industrial Way
Vineland, NJ 08360
Eagle Crest Enterprises , LLC
403 B Quillens Point Ln.
Smithfield, VA 23430
JNE Welding
3915 Thatcher Ave.
Saskatoon, SK S7R1A3
Canada
K.E.M. Welding
11 Lindbergh Trail
Rockaway, NJ 07866
Saber Engineering & Fabrication, Inc.
3261 Armstrong Ln.
Hillsborough, OH 45133
Special Testing & Consulting, LLC
144 Toledo St.
Farmingdale, NY 11735
Star Metal Fabrication, Inc.
707 Nelson Ln.
Wharton, TX 77488
Titan Contracting Services
7463 Varna Ave.
North Hollywood, CA 91605
Wenatchee Quality Welding & Fabrication
5830 Sunset Hwy.
Cashmere, WA 98815
Educational Institutions
College of Western Idaho
1464 University Dr.
Boise, ID 83706
Echols Middle School
2701 Echols Ave.
Northport, AL 35476
New River Community & Technical College
Greenbrier Valley Campus
101 Church St.
Lewisburg, WV 24901
Northern Industrial Training
1740 N. Terrilou Ct.
Palmer, AK 99645
Pickens County Career and
Technology Center
990 Chastian Rd.
Liberty, SC 29657
San Felipe Del Rio C.I.S.D.
100 Memorial Dr.
PO Box 420128
Del Rio, TX 78840
Starke County Initiative for
Lifelong Learning Center
1300 Kloeckner Dr.
Knox, IN 46534
AWS Member Counts
November 1, 2012
Grades
Sustaining ......................................549
Supporting.....................................349
Educational ...................................606
Affiliate..........................................479
Welding Distributor........................50
Total Corporate ..........................2,033
Individual .................................58,346
Student + Transitional .................9,558
Total Members.........................67,904
The fall Membership Committee
meeeting was held at The Lincoln Elec-
tric Co. headquarters in Cleveland, Ohio.
Committee member Jim Appledorn, U.S.
distributor sales manager for Lincoln,
served as host. Following the meeting, the
committee members toured the company
facilities, including the Electrodes Div.
Participating in the business meeting were
AWS Vice President David Landon, past
AWS President Lee Kvidahl, District 2 Di-
rector Harland Thompson, District 20 Di-
rector Bill Komlos, District 22 Director
Dale Flood, David Trees, Jim Appledorn,
AWS Senior Associate Deputy Director
Cassie Burrell, and Rhenda Kenny, Di-
rector, Member Services.
New AWS Supporters
Shown during the Membership Committees business meeting at The Lincoln Electric Co. are (from left) Lee Kvidahl, David Trees, Cassie
Burrell, Jim Appledorn, AWS Vice President David Landon, Rhenda Kenny, Bill Komlos, Harland Thompson, and Dale Flood.
Membership Committee Meets at Lincoln
51 WELDING JOURNAL
SECTIONNEWS
SECTIONNEWS
District 1
Thomas Ferri, director
(508) 527-1884
thomas_ferri@victortechnologies.com
Students are shown working on a welded wind chime assignment at summer classes con-
ducted by Connecticut Section members.
BOSTON
SEPTEMBER 28
Activity: Thomas Ferri, Dist. 1 director,
presented the District Educator of the
Year Award to Robert Petrino. Petrino is
the lead teacher in the Metal Fabrication
and Welding Department at South Shore
Regional Technical School in Hanover,
Mass. The presentation was made at the
school.
CONNECTICUT
Activities: During the summer months, As-
nuntuck Community College Welding De-
partment Head Steve Goodrow, Director
of Manufacturing Technologies Frank
Gulluni, and Welding Instructor Carole
del Vecchio presented two-week-long
welding training courses to local 7th and
8th grade students. On Oct. 19, the Sec-
tion relocated its technical library to the
college in Enfield, Conn. These resources
are available to all AWS members and to
students in the colleges welding technolo-
gies programs. For information, contact
Goodrow or del Vecchio at (860) 253-3167.
MAINE
SEPTEMBER 12
Activity: Welding instructor David Hart-
ley received the Section Educator of the
Year Award from Vice Chair Pat Kein. The
presentation was made at a gathering of
students and faculty at Northern Penob-
scot Technical High School in Lincoln,
Maine.
SEPTEMBER 18
Activity: The Maine Section members met
at the Fastco Corp. fabrication shop in Lin-
coln, Maine, to present Jon Ferreira the
Section Certified Welding Inspector
(CWI) of the Year Award. Vice Chair Pat
Kein presented the award.
Robert Petrino (left) is shown with Thomas
Ferri, District 1 director, at the Boston Sec-
tion award-presentation event.
David Hartley (left) displays the Section Ed-
ucator Award certificate presented by Pat
Kein, Maine Section vice chair.
Shown at the Maine Section Sept. 18 program are (from left) Joel Stanley, Vice Chair Patrick
Kein, Jon Ferreira, Alan Smith, and Scott Smith.
Connecticut Section members (from left)
Steve Goodrow, Frank Gulluni, and Carole
del Vecchio taught middle school students
how to weld during the summer.
DECEMBER 2012 52
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
Shown at the Maine Section meeting are (from left) Chair Jim Kein, Mark Legel, Bob Bernier,
and Patrick Kein.
Philadelphia Section members are shown at the Miller Electric Mfg. Co. facility with Harland Thompson, District 2 director, assisting with
banner-support duties.
Shown during the New Jersey Section tour of Sheet Metal Workers Local 22 Training Center
are (from left) Vice Chair Jim Dolan, presenters Frank Martino and Charles Beelitz, and
District 2 Director Harland Thompson.
SEPTEMBER 27
Activity: The Maine Section executive
board met at Ocean Gardens Restaurant
in Lincoln, Maine, to plan future Section
events. Attending were Chair Jim Kein,
Mark Legel, Bob Bernier, and Patrick
Kein.
Miller Electric Mfg. Co. facility in Swedes-
boro, N.J. Charlie Minnick, Northeast
training coordinator, presented demon-
strations of gas tungsten arc and sub-
merged arc welding (SAW). District Man-
ager Tim Stout discussed the SAW process.
Harland Thompson, District 2 director, at-
tended the event.
NEW JERSEY
OCTOBER 16
Activity: The Section members toured the
Sheet Metal Workers Local 22 Training
Center in Cranford, N.J. Conducting the
program were Frank Martino and Charles
Beelitz, welding instructor and training co-
ordinator, respectively.
PHILADELPHIA
OCTOBER 17
Activity: The meeting was held at the
Presenter Charlie Minnick (left) is shown
with Ken Temme, Philadelphia Section
chair.
Tim Stout discussed submerged arc welding
at the Philadelphia Section program.
53 WELDING JOURNAL
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
District 3
Michael Wiswesser, director
(610) 820-9551
mike@welderinstitute.com
District 4
Roy C. Lanier, director
(252) 321-4285
rlanier@email.pittcc.edu
The Southwest Virginia Section members are shown during their tour of Altec Industries.
Shown at the Atlanta Section program are (from left) District 5 Director Carl Matricardi,
Chair David Ennis, host John Sweigart, and presenter George Fairbanks, District 9 director.
Shown during the South Carolina Section tour are (from left) Eric Carlson, presenter Fred
Carlson, Tom Wickel, Johnny Bargesser, and Chair Gale Mole.
Atlanta Section Chair David Ennis (right)
receives the District Educator Award from
Carl Matricardi, District 5 director.
tendees. Contact Chairman Charles
Crumpton, charles@crumptonws.com,
about upcoming events.
CALENDAR
Jan. 9: Alex Klahm will discuss light-
house restoration
Feb. 13: Tour GMF Industries
March 2: Annual golf tournament
SOUTH CAROLINA
SEPTEMBER 20
Activity: The Section members visited
Streit USA Armoring, LLC, in North
Charleston, S.C., to study the fabrication
SOUTHWEST VIRGINIA
OCTOBER 18
Altec Industries facility in Daleville, Va.
The program was conducted by David
Owens.
ATLANTA
SEPTEMBER 13
Speaker: George Fairbanks, District 9 di-
rector, owner
Affiliation: Fairbanks Inspection and Test
ing, LLC
Topic: Inspecting and repairing cracks in
large cast weldments at a paper mill
Activity: David Ennis, Section chair, re-
ceived the District Educator Award from
Carl Matricardi, District 5 director. The
event was hosted by Southern Polytechnic
State University in Marietta, Ga., and John
Sweigart, director of the Engineering
Technology Dept.
FLORIDA WEST COAST
OCTOBER 10
Speaker: Heather Gilmer, QC manager
Affiliation: Tampa Tank, Inc.
Topic: Phased array ultrasonic inspection
in the steel and bridge industries
Activity: The program was held at Fron-
tier Steakhouse in Tampa, Fla., for 22 at-
DECEMBER 2012 54
of armored vehicles. Fred Carlson, pro-
duction supervisor, presented the history
of the company then conducted a tour of
the production lines for the South Carolina
Section members and guests.
NIAGARA FRONTIER
OCTOBER 4
Speaker: Marty Sidall
Affiliation: The Lincoln Electric Co.
Topic: The VRTEX360 virtual reality arc
welding trainer
Activity: The event was held at the Inter-
national Brotherhood of Boilermakers
Local Lodge 7 in Orchard Park, N.Y. Par-
ticipating in the demonstration were
Lodge Apprentice Coordinator Mark
Felschow, Section board member Howard
Johns, and Fred Schmidt, Section chair.
Miriah Gaudy, a BOCES, Batavia, N.Y.,
welding student, demonstrated the equip-
ment.
NORTHERN NEW YORK
OCTOBER 2
Activity: The Section members met at
Local 7 Plumbers & Steamfitters Training
Center in Latham, N.Y., to tour the facil-
ity. Dan Bliven, high-purity tubing weld-
ing instructor, conducted the program.
Highlights included the clean room for
nano-tech welding, brazing hospital pip-
ing, and orbital welding of
1
8-in.-diameter
stainless steel tube.
DAYTON
AUGUST 14
Activity: Members of the Section joined
members of the AWS D16 Committee on
Robotic and Automatic Welding for a
demonstration of the first net shape
GTAW manufacturing process to be incor-
porated in the University of Dayton (UD)
Advanced Production Research Labora-
tory. The demonstration was conducted by
Larry Barley, a welding engineer at OTC
Robots, Tipp City, Ohio, and Darryl
Swann, OTC national sales manager and
a member of a D16 Subcommittee. Engi-
neering student Christian Stuck volun-
teered to serve as the first president of the
new UD Student Chapter.
Northern Westmoreland
Student Chapter
SEPTEMBER
Activity: The Student Chapter held a meet-
ing at the technology center in New Kens-
ington, Pa. The presenters included Advi-
sor Jeremy Dawson and Chair Michael
Shafer.
PITTSBURGH
SEPTEMBER 11
Activity: The Section toured the Bug-O
Systems International facility in Canons-
burg, Pa. The program was headed by Chip
Cable, president; Norm Sted, vice presi-
dent, sales and marketing; and Mark
Binder, vice president, operations.
OCTOBER 9
Speaker: Matt Bosley, applications engi-
neer
Affiliation: Capture 3D
Topic: Automated inspection using 3D dig-
ital scanning
Activity: The talk included a demonstra-
tion of the ATOS high-resolution 3D scan-
ning equipment for measuring both intri-
cate geometric parts and objects as large
as a military transport aircraft. This Pitts-
burgh Section program was held at Spring-
field Grille in Mars, Pa.
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
District 7
Don Howard, director
(814) 269-2895
navigatorlost@hotmail.com Shown at the Niagara Frontier Section program are (from left) Howard Johns, Mark Felschow,
presenter Marty Sidall, and Fred Schmidt, Section chair.
Welding student Miriah Gaudy is shown
working with the virtual reality arc welding
trainer at the Niagara Frontier Section event.
Presenter Larry Barley (right) demonstrates robot programming at the joint Dayton Section
and D16 Committee program.
Dan Bliven (left) receives a presenter gift
from Larry Hidde, chair, Northern New York
Section.
55 WELDING JOURNAL
CHATTANOOGA
SEPTEMBER 18
Tennessee Valley Authority (TVA) Rac-
coon Mountain Pumped-Storage Power
Plant to study the operation of the hydro-
electric power station and the TVAs fos-
sil-fueled and nuclear power systems. The
tour guides at the Visitors Center were
Tony Giggy, Al Burzese, and Jim Sexton.
HOLSTON VALLEY
OCTOBER 16
Speaker: Zack Estes, territory sales man-
ager
Affiliation: ESAB Welding and Cutting
Topic: Safety with oxyfuel cutting and
welding equipment
Activity: The program was held at Mamas
House Restaurant in Kingsport, Tenn.
District 9
George Fairbanks Jr., director
(225) 473-6362
ts@bellsouth.net
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
The Northern Westmoreland Student Chapter members are shown at their recent meeting.
The Holston Valley Section members and guests are shown at the October program.
Pittsburgh Section members are shown during their September tour of Bug-O Systems.
Shown during the Pittsburgh Section September tour are (from left) Mark Binder, Chair John
Menhart, Chip Cable, and Norm Sted.
Pittsburgh Section members are shown during the October event.
Presenter Matt Bosley (left) is shown with
John Menhart, Pittsburgh Section chair, at
the October meeting.
Tony Giggy discussed construction of the
Raccoon Mountain project for the Chat-
tanooga Section members.
DECEMBER 2012 56
Lawson State C. C. Student Chapter members are shown at their October meeting.
Speaker Jackie Morris (right) is shown with
Johnny Dedeaux, Mobile Section chair.
Bill Rice (right), AWS president, is shown
with Mike Palko, Detroit Section chair.
Speaker Alex Pazkowski is shown with Mike
Palko, Detroit Section chair.
Scholarship winner Cameran Kuperus (left) is shown with Marilyn and Amos Winsand, an
AWS past treasurer, at the Detroit Section program.
Speaker Damian Kotecki (right) is shown
with Mike Sherman, Cleveland Section chair.
Lawson State C. C.
Student Chapter
OCTOBER 9
Activity: Sixty-three attendees visited Oxy-
lance, Inc., in Birmingham, Ala., for
demonstrations of its exothermal process
used in underwater steel-cutting opera-
tions. The lecture included setting up the
oxyfuel gas cutting (OFC) equipment and
how it works, with emphasis on OFC safety
regulations. Greg Cain, vice president of
operations, conducted the program.
MOBILE
OCTOBER 11
Speaker: Jackie Morris, owner
Affiliation: Morris Marine Consulting,
LLC
Topic: Hand-held inspection gauges
Activity: Morris demonstrated the correct
use of inspection gauges and discussed the
AWS CWI test tool kit. The program was
held at Original Oyster House in Spanish
Fort, Ala., for 51 attendees, including Dis-
trict 9 Director George Fairbanks and
welding students from Locklin Tech.
CLEVELAND
OCTOBER 9
Speaker: Damian Kotecki, president
Affiliation: Damian Kotecki Welding Con-
sultants, Inc.
Topic: How to convert good stainless steel
filler metal into bad welds
Activity: The event was held at St. Paul Hel-
lenic Center in North Royalton, Ohio.
DETROIT
SEPTEMBER 20
Speaker: Bill Rice, AWS president
Affiliation: OKI-Bering, CEO
Topic: Future of the welding community
Activity: The Section held its students
night program at VisTaTech Center,
Schoolcraft College, in Livonia, Mich. Alex
Pazkowski discussed his experiences com-
peting in the SkillsUSA welding competi-
tions. The Amos and Marilyn Winsand
Scholarship was awarded to Cameran Ku-
perus. Rice and Robert Wilcox, District 11
director, presented The Dalton E. Hamil-
ton Memorial CWI of the Year Award to
Viji Kuruvilla. The Section presented a
$350,000 donation to the AWS Founda-
tion. See photos and story on page 47.
District 10
Richard A. Harris, director
(440) 338-5921
richaharris@windstream.net
District 11
Robert P. Wilcox, director
(313) 949-3676
rwilcox1@ford.com
57 WELDING JOURNAL
District 12
Daniel J. Roland, director
(715) 735-9341, ext. 6421
daniel.roland@us.ncantieri.com
District 13
W. Richard Polanin, director
(309) 694-5404
rpolanin@icc.edu
District 14
Robert L. Richwine, director
(765) 378-5378
bobrichwine@aol.com
NORTHWEST OHIO
JULY 6
Activity: The Section hosted its annual
Donald J. Leonhardt golf outing to raise
funds for scholarships for Owen Commu-
nity College students. The event co-chairs
were Mike Rogers, Tony Duris, and Mark
Scalise. Competing were 16 four-member
teams. District 11 Director Robert P.
Wilcox attended the outing, held in Toledo,
Ohio.
LAKESHORE
SEPTEMBER 20
Fox Valley Tool & Die, Inc., facilities in
Kaukauna, Wis., to study operations in its
main plant. Heading the tour were Pete
Uvass, president; Brian Tetzlaff, vice pres-
ident; and Mark Dennis, manufacturing
manager, who discussed its precision ma-
chining, jig grinding, and EDM operations.
The business meeting was held at Hyland
House Supper Club for 24 attendees.
MADISON-BELOIT
SEPTEMBER 26
Speaker: Anton Stute, Section chair
Affiliation: Madison Area Technical Col-
lege
Topic: Job opportunities in welding
Activity: The Section convened at the col-
lege to meet with the instructors and stu-
dents and tour the welding facilities. On
hand to demonstrate equipment and an-
swer questions were Rob Stinson with Lin-
coln Electric, James Maynard with Miller,
Dave Gilbertson with Encompass of Madi-
son, Ben Newcomb with Badger Welding
Supplies, and Jim Chapman with Airgas.
Anton Stute was recognized for his serv-
ices as Section chair.
RACINE-KENOSHA
OCTOBER 2
Activity: The Section members visited
Racine Metal-Fab, Ltd., to study its light-
gauge metal fabrication operations. The
presenters were Scott Lucas, president;
and Ralph Fechhelm, director of opera-
tions.
INDIANA
OCTOBER 4
Activity: Dick Alley, an AWS past presi-
dent, served as MC for the Sections
awards presentation program held at
Shapiros Deli in downtown Indianapolis.
Honored were its past Image of Welding
Award winners: District 14 Director
Robert Richwine, Chair Bennie Flynn, past
AWS President Richard Alley, Wally and
Jay Brant from Indiana Oxygen, Pat and
Matt Garten from Sutton Garten, and
Fritz Pring and Jack Laudig from West-
Guides for the Lakeshore Section tour are
(from left) Fox Valley Tool & Die executives
Pete Uvass, Mark Dennis, and Brian Tetzlaff.
Madison-Beloit Section members are shown at the September program.
Racine-Kenosha Section members are shown during their tour of Racine Metal-Fab.
Anton Stute (left) receives his chairmans
appreciation award from Levi George at the
Madison-Beloit Section program.
Shown at the Madison-Beloit Section event
are Madison Area Technical College stu-
dents (from left) Drew Nafzger, Jake Olson,
and Nick Neuburg.
DECEMBER 2012 58
field Steel. Section CWI of the Year
Awards were presented to Bennie Flynn,
Tony Brosio, and Gary Dugger. Section
Meritorious Awardees were David Jack-
son, Josiah Miller, and Steve Gillig. Tony
Brosio received the Section Private Sector
Instructor Award, and Mike Anderson re-
ceived the Section Educator Award. The
District CWI of the Year Award was pre-
sented to Jack Laudig. Bennie Flynn re-
ceived the District Private Sector Award.
Eric Cooper and Rick Ferguson received
District 14 Director Awards from Direc-
tor Robert Richwine. Attending were In-
diana Section Student Chapter members.
LEXINGTON
SEPTEMBER 20
Speaker: Jim Nye, district manager
Affiliation: Miller Electric
Topic: Gas metal arc welding
Activity: Gordie Hall, Coy Hall, and Karl
Watson received District Director Awards
and Scott Stringer received the Section
Educator Award. Students Luke Williams,
Frank Stringer, and David Hoff received
$500 scholarships. Attending were weld-
ing instructors Shawn Gannon with Blue
Grass C. C. and Karl Watson with Somer-
set C. C. About 70 members, students, and
guests attended the event.
Shown at the Indiana Section awards-presentation program are (from left) Chair Bennie Flynn, Dick Alley, Tony Brosio, Pat and Matt
Garten, Fritz Pring, Jack Laudig, Gary Dugger, District 14 Director Bob Richwine, and Jay and Wally Brant.
Dick Alley (far left), an AWS past president, is shown with Indiana Section Student Chapter members.
Shown at the Lexington Section program are (from left) Shawn Gannon, Luke Williams,
Chair Frank McKinley, Frank Stringer, David Hoff, and Karl Watson.
Lexington Section awardees are (from left) Gordie Hall, Coy Hall, Scott Stringer, and Karl
Watson with Chair Frank McKinley.
59 WELDING JOURNAL
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
ST. LOUIS
SEPTEMBER 20
Activity: The Section members visited the
Missouri Equipment Co. facility to study
its operations. The tour was conducted by
Charlie Klapp, vice president. Attending
were Chair Tully Parker, Rick Suria, Pat
Cody, John Crowe, Eric Spencer, Steve
Fults, Heath Wells, Vic Shorkey, Mike
Kamp, Chris Johnson, Gale Mizner, and
Susan Crowe.
NORTHWEST
SEPTEMBER 20
Activity: Mike Hanson served as MC for
the Sections 75th anniversary open house
and banquet held at Sundance Golf and
Bowl in Dayton, Minn. The presenters in-
cluded Dave Lynnes, District 15 director;
Chair Jay Gerdin; Gold Member Don Pe-
terson; Life Members Mark Falconer,
Bruce Danielson, and Dean Hambleton;
Silver Member Bob Sands; Mace Harris,
Randy Anderson, Dan Johnson, Dana
Sorenson, and Laura Savin, representing
St. Paul College.
SASKATOON
SEPTEMBER 28
Activity: The Section participated in the
Steel Day open house held at the Supreme
Steel Saskatoon facilities. The event in-
cluded a factory tour and a presentation
on software used by the company for ana-
lyzing steel structure designs.
KANSAS
OCTOBER 11
Speaker: Jack Minser, technical sales
manager
Affiliation: Victor Technologies
Topic: Oxyfuel safety
Activity: The Section held its second an-
nual student night program at Hutchinson
Community College in Hutchinson, Kan.
KANSAS CITY
SEPTEMBER 13
Speaker: Steve Donner
Affiliation: Kansas City Codes Adm.
Shown at the St. Louis Section tour are (from left) Eric Spencer, Charlie Klapp, Steve Fults, Chair Tully Parker, Heath Wells, Vic Shorkey,
Rick Suria, Pat Cody, Mike Kamp, John Crowe, Chris Johnson, Susan Crowe, and Gale Mizner.
Shown at the Northwest Sections 75th anniversary banquet are Chair Jay Gerdin (kneel-
ing) and (from left) Dean Hambleton, Bruce Danielson, Mace Harris, Randy Anderson,
Bob Sands, MC Mike Hanson, Dan Johnson, Dana Sorenson, and Don Peterson.
Shown at the Saskatoon Section program are (from left) Huawei Guo, Chair Ike Oguocha,
Akindele Odeshi, and Paul Fraser.
Jack Minser discussed oxyfuel safety for stu-
dents at the Kansas Section program.
DECEMBER 2012 60
District 17
J. Jones, director
(940) 368-3130
jjones@victortechnologies.com
District 18
John Bray, director
(281) 997-7273
sales@afliatedmachinery.com
Topic: Qualification of fabricators and spe-
cial inspectors
Activity: Chair Mike Vincent received the
District Meritorious Award from Dennis
Wright, District 16 director. The program
was held at Johnny Cs Restaurant in
Kansas City, Mo.
OCTOBER 11
Speaker: Randy Carrel
Affiliation: S1ngle Source, Inc.
Topic: Prepping metal and welds for paint
Activity: The program was held at Johnny
Cs in Kansas City, Mo.
HOUSTON
SEPTEMBER 19
Speaker: Dan Allford, president
Affiliation: ARC Specialties
Topic: Submerged arc welding and robots
Activity: Eugene Bickford and Cary Roth
received Life Member certificates for 35
years of service to the Society. Members
recognized for serving at the Instruction
Institute and Student Certification Day
events were Chair Justin Gordy, Justin
Kirby, Scott Witkowski, Bryan Suarez,
Dan Jones, Tripp Fulmer, Albert Stredny,
and Andre Horn. The program was held
at Bradys Landing in Houston, Tex.
RIO GRANDE VALLEY
SEPTEMBER 12
Speaker: John Bray, District 18 director
Affiliation: Affiliated Machinery, Inc.
Topic: The District 18 and IIW conferences
Activity: Ray Rivera addressed the 18 stu-
dents attending the program about AWS
Scholarships. Israel Garza, a welding in-
OCTOBER 17
Activity: Chair Mike Vincent and several
Kansas City Section members attended an
advanced process pipe welding seminar
presented by Lincoln Electric in Lenexa,
Kan. The topics included GTA orbital
welding and GMA and FCA welding using
the new surface tension transfer and wave-
form control technologies.
MID-PLAINS
SEPTEMBER 20
Activity: The Section members joined
members of the SME Southeast Nebraska
Chapter 222 for dinner and a tour of Hor-
nady Mfg. Co., Grand Island, Neb., a sup-
plier of ammunition products.
Kansas Section members and students are shown at the October event.
Kansas City Section members and guests are shown at the October 11 program.
Kansas City Section members are shown at the Lincoln Electric seminar Oct. 17.
Shown at the October Kansas City Section
program are (from left) Chris Self, Chair
Mike Vincent, and speaker Randy Carrel. Speaker Dan Allford (right) is shown with
Grant Peltier, Houston Section secretary.
Gene Bickford (right) receives the Life Mem-
ber certificate from Grant Peltier, secretary,
at the Houston Section program.
61 WELDING JOURNAL
structor at Joe Calvillo Technology Cam-
pus, discussed the schools three-year
welding program.
SAN ANTONIO
SEPTEMBER 11
Speaker: John Bray, District 18 director
Affiliation: Affiliated Machinery, Inc.
Topic: The District 18 and IIW conferences
Activity: Attending the program were 48
students from Alamo College and the Flo-
resville High School Student chapter ac-
companied by Advisor Clifton Rogers. The
event was held at Don Pedro Mexican
Restaurant in San Antonio, Tex.
BRITISH COLUMBIA
OCTOBER 16
Speaker: Rick Brown, metallurgist
Affiliation: Ifastgroupe
Topic: Fasteners 101 Anatomy of the
bolted joint
Activity: Following the presentation,
Shown at the Houston Section program are Chair Justin Gordy (front) and (standing from left) Justin Kirby, Scott Witkowski, Bryan Suarez,
Dan Jones, Tripp Fulmer, Albert Stredny, and Andre Horn.
Attendees at the Rio Grande Valley Section are shown at the September program.
Shown at the British Columbia Section program are (from left) Rob Third, Richard Reyes,
and Brad Moe.
Rick Brown receives a speaker gift from Pat
Newhouse at the British Columbia meeting.
Phil Formento (left) receives an olympic-size
speaker gift from Sjon Delmore, Olympic
Section chair.
District 19
Neil Shannon, director
(503) 201-5142
neilshnn@msn.com
DECEMBER 2012 62
Olympic Section attendees are shown at the October program.
Colorado School of Mines Student Chapter members enjoyed a tour of Wolf Robotics.
Idaho/Montana Section members are from
left (standing) Tevan Boersma and Chair
Paul Tremblay, (seated) Dale Mortenson,
William McPherson, and Ofilia Tremblay.
Shown during the Colorado School of Mines Student Chapter Trinity Industries tour are (from left) Advisor Stephen Liu, Sindhu Thomas,
Ali AlShawaf, speaker Steve Smith, Scott Nelson, speaker Blake Craft, Stephen Tate, Kin-Ling Sham, Erik Pfeif, Steven Klimowicz, and
Josue Mushidi.
Utah Section and ASM International Utah Chapter members are shown during their tour of Shaw NAPTech, Inc., in September.
63 WELDING JOURNAL
Brown offered the attendees a hands-on
demonstration of various structural bolted
fasteners. Richard Reyes received a Bruce
Third Welding Scholarship and a one-year
AWS membership presented by Rob Third
and Brad Moe, British Columbia Section
scholarship chairman.
OLYMPIC
OCTOBER 16
Speaker: Phil Formento
Affiliation: ESAB Welding & Cutting
Topic: History and advancements of the
subarc welding process
Activity: The program, attended by about
60 members and guests, was held at Bates
Technical College in Tacoma, Wash.
SAN FRANCISCO
OCTOBER 2
Speaker: Dean Wilson, AWS vice presi-
dent
Affiliation: Well-Dean Enterprises, presi-
dent
Topic: Recent AWS major milestones
Activity: The program was held at
Spengers Restaurant in Berkeley, Calif.
Colorado School of Mines
Student Chapter
SEPTEMBER 25
Activity: Advisor Stephen Liu took his
Chapter members to Wolf Robotics in Fort
Collins, Colo., to study its operations.
OCTOBER 9
Speakers: Steve Smith, VP engineering,
and Blake Craft, chief welding engineer
Affiliation: Trinity Industries
Topic: Trinity Industries operations
District 20
William A. Komlos, director
(801) 560-2353
bkoz@arctechllc.com
District 21
Nanette Samanich, director
(702) 429-5017
nan07@aol.com
District 22
Dale Flood, director
(916) 288-6100, ext. 172
d.ood@tritool.com
Activity: The Student Chapter members
hosted the program at Colorado School of
Mines in Golden, Colo.
IDAHO/MONTANA
SEPTEMBER 11
Speaker: Jean-Francois Villard, head,
CEA laboratory
Affiliation: French Alternative Energies
and Atomic Energy Commission (CEA)
Topic: Instrumentation development for
the future Jules Horowitz Reactor
Activity: The Section members joined
members of the local IEEE Chapter and
Idaho Section of the American Nuclear
Society for this program, held at the Cen-
ter for Advanced Energy Studies, Idaho
Falls, Idaho.
UTAH
SEPTEMBER 20
Activity: The Utah Section joined mem-
bers of the Utah Chapter of ASM Inter-
national to tour Shaw NAPTech, Inc., in
Clearfield, Utah. Firdosh Kavarana, man-
ager, and senior metallurgist, Bending
Div., conducted the tour and explained the
companys methods for induction bending
of pipe and tube.
AWS Vice President Dean Wilson chats with
Sharon Jones, San Francisco Section co-
chair.
William Irrgang Memorial Award
This award is given to the individual who has done the most
over the past five years to enhance the Societys goal of advanc-
ing the science and technology of welding. It includes a $2500
honorarium and a certificate.
Honorary Membership Award
This award acknowledges eminence in the welding profes-
sion, or one who is credited with exceptional accomplishments
in the development of the welding art. Honorary Members have
full rights of membership.
Nat. Meritorious Certificate Award
This award recognizes the recipients counsel, loyalty, and
dedication to AWS affairs, assistance in promoting cordial rela-
tions with industry and other organizations, and for contribu-
tions of time and effort on behalf of the Society.
George E. Willis Award
This award is given to an individual who promoted the ad-
vancement of welding internationally by fostering cooperative
participation in technology transfer, standards rationalization,
and promotion of industrial goodwill. It includes a $2500 hono-
rarium.
Intl Meritorious Certificate Award
This honor recognizes recipients significant contributions to
the welding industry for service to the international welding com-
munity in the broadest terms. The award consists of a certificate
and a one-year AWS membership.
November 1, 2013, is the deadline for submitting nomina-
tions for the 2014 Prof. Koichi Masubuchi Award.
This award is presented each year to one person, 40 years
old or younger, who has made significant contributions to the
advancement of materials joining through research and devel-
opment. Nominations should include a description of the candi-
dates experience, list of publications, honors, and awards, and
at least three letters of recommendation from fellow researchers.
This award is sponsored by the Dept. of Ocean Engineering at
Massachusetts Institute of Technology (M.I.T.), this award in-
cludes a $5000 honorarium.
E-mail your nomination package to Todd A. Palmer, assis-
tant professor, The Pennsylvania State University,
tap103@psu.edu.
The deadline for nominating candidates for the following awards is December 31 prior to the year of the awards presentations.
Contact Wendy Sue Reeve, wreeve@aws.org; (800/305) 443-9353, ext. 293.
Candidates Sought for Welding-Related Awards
DECEMBER 2012 64
Guide to AWS Services
8669 Doral Blvd., Ste. 130, Doral, FL 33166
(800/305) 443-9353; FAX (305) 443-7559; www.aws.org
Staff phone extensions are shown in parentheses.
AWS PRESIDENT
William A. Rice
brice@oki-bering.com
1411 Connell Rd.
Charleston, WV 25314
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
Chief Financial Officer
Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
Executive Assistant for Board Services
Gricelda Manalich.. gricelda@aws.org . . . . .(294)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
IT Network Director
Armando Campana..acampana@aws.org . .(296)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
Human Resources
Director, Compensation and Benefits
Luisa Hernandez.. luisa@aws.org . . . . . . . . .(266)
Director, Human Resources
Dora A. Shade.. dshade@aws.org . . . . . . . . .(235)
International Institute of Welding
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
GOVERNMENT LIAISON SERVICES
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors fed-
eral issues of importance to the industry.
CONVENTION and EXPOSITIONS
Director, Convention and Meeting Services
Matthew Rubin.....mrubin@aws.org . . . . . . .(239)
ITSA International Thermal
Spray Association
Senior Manager and Editor
Kathy Dusa.kathydusa@thermalspray.org . . .(232)
RWMA Resistance Welding
Manufacturing Alliance
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
Brazing and Soldering
Manufacturers Committee
GAWDA Gases and Welding
Distributors Association
Executive Director
John Ospina.. jospina@aws.org . . . . . . . . . .(462)
Operations Manager
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401)
INTERNATIONAL SALES
Managing Director, Global Exposition Sales
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . .(297)
Corporate Director, International Sales
Jeff P. Kamentz..jkamentz@aws.org . . . . . . .(233)
Oversees international business activities involving
certification, publication, and membership.
PUBLICATION SERVICES
Department Information . . . . . . . . . . . . . . . . .(275)
Managing Director
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
National Sales Director
Rob Saltzstein.. salty@aws.org . . . . . . . . . . .(243)
Society and Section News Editor
Howard Woodward..woodward@aws.org . .(244)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
MARKETING COMMUNICATIONS
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Section Web Editor
Henry Chinea...hchinea@aws.org . . . . . . . . .(452)
MEMBER SERVICES
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between Section members and AWS
headquarters.
CERTIFICATION SERVICES
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all inter-
national certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Certification Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification pro-
grams, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Director, Education Development
David Hernandez.. dhernandez@aws.org . . .(219)
AWS AWARDS, FELLOWS, COUNSELORS
Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards, Fellow, Counselor nom-
inees.
TECHNICAL SERVICES
Managing Director
Andrew R. Davis.. adavis@aws.org . . . . . . .(466)
International Standards Activities, American Coun-
cil of the International Institute of Welding (IIW)
Director, National Standards Activities
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Manager, Safety and Health
Stephen P. Hedrick.. steveh@aws.org . . . . . .(305)
Metric Practice, Safety and Health, Joining of Plas-
tics and Composites, Welding Iron Castings, Per-
sonnel and Facilities Qualification
Managing Engineer, Standards
Brian McGrath .... bmcgrath@aws.org . . . . .(311)
Structural Welding, Methods of Inspection, Me-
chanical Testing of Welds, Welding in Marine Con-
struction, Piping and Tubing
Senior Staff Engineer
Rakesh Gupta.. gupta@aws.org . . . . . . . . . .(301)
Filler Metals and Allied Materials, International
Filler Metals, UNS Numbers Assignment, Arc
Welding and Cutting Processes
Standards Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Thermal Spray, Automotive, Resistance Welding,
Machinery and Equipment
Stephen Borrero... sborrero@aws.org . . . . .(334)
Brazing and Soldering, Brazing Filler Metals and
Fluxes, Brazing Handbook, Soldering Handbook,
Railroad Welding, Definitions and Symbols
Alex Diaz.... adiaz@aws.org . . . . . . . . . . . . . .(304)
Welding Qualification, Sheet Metal Welding, Air-
craft and Aerospace, Joining of Metals and Alloys
Patrick Henry.. phenry@aws.org . . . . . . . . . .(215)
Friction Welding, Oxyfuel Gas Welding and Cut-
ting, High-Energy Beam Welding, Robotics Weld-
ing, Welding in Sanitary Applications
Senior Manager, Technical Publications
Rosalinda ONeill.. roneill@aws.org . . . . . . .(451)
AWS publishes about 200 documents widely used
throughout the welding industry
Note: Official interpretations of AWS standards
may be obtained only by sending a request in writ-
ing to Andrew R. Davis, managing director, Tech-
nical Services, adavis@aws.org.
Oral opinions on AWS standards may be ren-
dered, however, oral opinions do not constitute of-
ficial or unofficial opinions or interpretations of
AWS. In addition, oral opinions are informal and
should not be used as a substitute for an official
interpretation.
AWS FOUNDATION, INC.
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
Gerald D. Uttrachi
Executive Director, Foundation
Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Corporate Director, Workforce Development
Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
The AWS Foundation is a not-for-profit corpora-
tion established to provide support for the educa-
tional and scientific endeavors of the American Weld-
ing Society.
Promote the Foundations work with your financial
support. Call (800) 443-9353, ext. 212, for complete
information.
Expand your credentials with an endorsement that fulfills your recertification requirements.
Recertification every nine years requires either 80 hours of documented continuing
education, retaking the Part B Practical Exam, or an endorsement to your certification.
You can do this at any time, so why not do it now and secure the prestige and enhanced
career potential of a credential in an additional welding code or skill?
www.aws.org/certification
(800) 443-9353 ext 273
A CWI or SCWI can take a Supplemental Inspection Exam anytime during the nine-year cycle.
Qualifying for and passing one of these exams meets the requirements for recertification.
Endorsements are listed on your endorsement card. Endorsements require passing a
two-hour exam on one of the following:
Seminars to prepare you for the two-hour exam on D1.1 or API 1104 are available at numerous
seminar sites across the country.
One other stand-alone credential can serve as an endorsement credit and also fulfills your
recertification requirement. At any time during your nine-year cycle, if you meet the prerequisites,
you can apply to become certified as an AWS Certified Radiographic Interpreter (CRI).
The five-day CRI seminar is designed to ensure that you have the knowledge to properly assess
indications produced on radiographic media. It will prepare you for the CRI certification exam, which
is given at the end of each seminar week. This is a valuable certification that fulfills your
nine-year requirement. Upcoming seminars and exams for CRI are:
Seattle Feb. 25 - Mar. 2

Houston Apr. 15-20

Las Vegas May 6-11
If you dont want to take any exams at all, you can fulfill the 80-hour education requirement by
attending a six-day AWS 9-Year Recertification Course. Courses are scheduled for:
New Orleans Jan. 6-11
Denver Feb. 10-15
Dallas Mar. 10-15
Miami Apr. 7-12
One more option is to recertify by taking the Part B CWI Practical Exam. This exam and refresher
Visual Inspection Workshop seminars, are offered at convenient CWI seminar/exam sites across
the country.

ASME Section IX, B31.1 &
B31.3 Boiler & Pressure Vessel

ASME Section VIII, Div. 1 &
Section IX Boiler & Pressure Vessel

Structural Drawing Reading

AWS D1.1 Structural Welding

AWS D1.2 Aluminum

AWS D1.5 Bridge

AWS D15.1 Railroad

API 1104 Pipeline
Even if your nine-year recertification
deadline is years away, you can fulfill
it now with a CWI
endorsement.
Plan ahead.

CWI or SC AA

CWI or SCWI can take a Supplemental Inspection Exam anytime during the nine-year cycle.



API 1
W AAW
W AAW
W AAW
W AAW
seminar sites across the country

Seminars to prepare you for the two-hour exam on D1.1 or

104 Pipeline API 1
WS D15.1 Railroad
WS D1.5 Bridge
D1.2 Aluminum WS
elding WS D1.1 Structural W
Seminars to prepare you for the two-hour exam on D1.1 or

elding
Section IX Boiler & Pressure V

ASME Section VIII, Div
B31.3 Boiler & Pressure V

104 are available at numerous API 1 Seminars to prepare you for the two-hour exam on D1.1 or

ess X Boiler & Pressure VVe
. 1 & ASME Section VIII, Div
essel er & Pressure VVe
104 are available at numerous

essel

Seattle Feb. 25 - Mar
is given at the end of each seminar week.
you can apply to become certified as an
recertification requirement.

. 2 ttle Feb. 25 - Mar r.

is given at the end of each seminar week.
you can apply to become certified as an
At any time during your nine-year cycle, if you meet the prerequisites, recertification requirement.
. seminar sites across the country

. 15-20 Apr Houston

This is a valuable certification that fulfills your is given at the end of each seminar week.
WS Certified Radiographic Interpreter A you can apply to become certified as an
At any time during your nine-year cycle, if you meet the prerequisites,

1 egas May 6-1 Las VVe
This is a valuable certification that fulfills your
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One more option is to recertify by taking the Part B CWI Practical Exam.
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ear Recert WS 9-YYe A attending a six-day

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Denver Feb. 10-15
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This exam and refresher One more option is to recertify by taking the Part B CWI Practical Exam.
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aws cert (9 yr. cert)_FP_TEMP 11/7/12 11:09 AM Page 67
PERSONNEL
DECEMBER 2012 68
Lincoln Names Two
Directors
The Lincoln Electric Co., Cleveland,
Ohio, has appointed Frank Armao direc-
tor of aluminum welding technology and
promoted Bruce Chantry to director of
marketing, North America. Armao, who
is chairman of the AWS D1G Subcom-
mittee on Aluminum Structures, will col-
laborate with both the aluminum welding
technology teams at the Cleveland head-
quarters and at Lincolns subsidiary In-
dalco Alloys, a producer of aluminum
wire products based in Ontario, Canada.
He previously served 13 years as director,
application engineering and country man-
ager, Korea, for Lincolns Asia-Pacific
business unit. With the company for 17
years, Chantry most recently served four
years as a portfolio manager for welding
equipment.
Taylor-Wharton Fills Key
Posts
Taylor-Wharton
International, LLC,
Mechanicsburg, Pa.,
a supplier of pressure
vessels and precision
valves, has hired
David Barr to head
its newly created liq-
uefied natural gas
(LNG) business unit
as vice president and
general manager.
Claus Emmer was named director of ap-
plications development, and Bobby Cush-
man was appointed director of global
LNG sales. Barr most recently worked for
Lubrication Technologies, Inc., where he
developed a LNG distribution business in
Minnesota. Emmer has extensive experi-
ence with MVE, Inc., working with su-
perinsulated cryogenic vessels. Cushman
worked ten years selling capital equip-
ment and fluids to the cryogenic industry.
Auburn Mfg. Appoints VP
Auburn Manufacturing, Mechanic
Falls, Maine, a provider of high-tempera-
ture textiles for protective welding cloth-
ing and other industrial applications, has
named Garrett
VanAtta to the newly
created position of
vice president of in-
novation engineer-
ing. Previously,
VanAtta managed
textile operations and
engineering at Po-
lartecs Malden Mills
facilities in Maine
and Massachusetts,
and most recently served as president of
SPX Communications Technology.
Member Milestone
Damian J. Kotecki, a past AWS president, AWS Fellow and Life Member, recently
received two prestigious awards for his contributions to the industry. The American
National Standards Institute (ANSI) presented Dr. Kotecki with the Finegan Stan-
dards Medal, which honors an individual who has shown extraordinary leadership in
the development and application of voluntary standards. The Welding Institute
(TWI) awarded him its most prestigious award, the Brooker Medal, in recognition of
his personal contribution to the science, technology, and industrial exploitation of
metal joining. It recognizes high industrial, research, or educational responsibility of
a character which has beneficially influenced the advancement of metal joining tech-
nology. Dr. Kotecki is president of Damian Kotecki Welding Consultants, Inc., and
writes Stainless Q & A, a bimonthly column in Welding Journal. Prior to his retire-
ment, he served The Lincoln Electric Co. as technical director for stainless and high
alloy product development. He contributes his expertise to many AWS technical com-
mittees including serving as chair of the A5 Committee on Filler Metals and Allied
Materials. Kotecki has received numerous AWS awards, including Comfort A. Adams
Memorial Lecture, James F. Lincoln Gold Medal, William Irrgang, R. D. Thomas Me-
morial, R. D. Thomas International Lecture, George E. Willis, Prof. Dr. Ren Wasser-
man Memorial, A. F. Davis Silver Medal, International Meritorious Certificate, and
Warren F. Savage Memorial.
Dr. Kotecki (left) receives the TWI
Brooker Medal from TWI President
John Baxter.
James Pauley (left), chairman of the
ANSI board of directors, presents the
Finegan Standards Medal to Damian
Kotecki.
Frank Armao Bruce Chantry
David Barr Claus Emmer
Bobby Cushman
Garrett VanAtta
continued on page 70
Personnel Dec._Layout 1 11/8/12 1:41 PM Page 68
awo.aws.org
Online Welding Safety Certificate Course
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Three-hour self-paced course covers electric shock, vision and skin protection,
ventilation, fire protection, handling of gases, and much more.
Sample seminar at awo.aws.org/seminars/safety
OSHAestimates that
4 out of every 1,000
welders will
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their working lifetime
Online elding Safet W Online y Certificate Course elding Safety Certificate Course y Certificate Course
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Sample seminar at awo.aws.org/seminars/safety Sample seminar at awo.aws.org/seminars/safety Sample seminar at awo.aws.org/seminars/safety
edu awo safety_FP_TEMP 11/6/12 3:10 PM Page 69
PERSONNEL
DECEMBER 2012 70
Ervin Industries Appoints
General Sales Manager
Ervin Industries,
Inc., Ann Arbor,
Mich., has promoted
Joe McGreal to gen-
eral sales manager,
responsible for the
North American sales
of AMASTEEL and
AMACAST metal
abrasives. With the
company for 13 years,
McGreal most re-
cently served as a salesman and district
sales manager for the Iowa region.
NAWIC Installs Officers
The National Association of Women in
Construction, Fort Worth, Tex., has in-
stalled Cindy Johnsen as its 58th national
president 20122013, succeeding Judy
DeWeese, San Antonio, Tex., Chapter.
Johnsen, an office administrator III for
Granite Construction Co., has been a
member of the associations San
Bernardino-Riverside, Calif., Chapter
since 1997. Also installed were Yasmine A.
Branden, Portland, Ore., Chapter, as
president-elect; Sandy K. Field, Houston,
Tex., Chapter, as treasurer; and Connie M.
Leipard, Central Missouri Chapter, as
secretary.
Fronius Names Tennessee
Sales Manager
Fronius has ap-
pointed Rick Whit-
field to serve as area
sales manager work-
ing out of the Chat-
tanooga, Tenn., loca-
tion. Whitfield has
many years of experi-
ence in the welding
automation field in
sales management
and marketing of ad-
vanced welding automation equipment.
Intelligrated Appoints
Senior Sales Engineer
Intelligrated, Cincinnati, Ohio, an
automated material-handling solutions
provider, has appointed Paul Hensley to
senior sales engineer for the companys
Cincinnati-based central regional opera-
tions. Hensley, who
has more than 20
years of material-
handling sales expe-
rience, most recently
served as a contract
manager for Jackson-
Madison County
General Hospital
and as director of
global operations for
NCR.
Laboratory Testing Fills
New Post
Laboratory Test-
ing, Inc., Hatfield,
Pa., has promoted
Frank Peszka to the
newly created posi-
tion of director of
quality. Most re-
cently, Peszka served
six years as quality as-
surance manager.
IMS WaterJet Names
Marketing Director
IMS WaterJet, Inc., Waterbury, Conn.,
has hired Kevin Dokla as director of mar-
keting. Prior to joining the company,
Dokla held marketing leadership posi-
tions at Eemax, Inc., Pyramid Technolo-
gies, Office Depot Co., and Cendant, Inc.
Noble Gas Makes Staff
Changes
Noble Gas Solutions, Albany, N.Y.,
has named Wayne Geraci plant and distri-
bution manager, and promoted Mark
Stagliano to customer service manager.
Geraci previously worked at Vertis Com-
munications as engineering project man-
ager. Stagliano, with the company since
2008, previously served as asset manager.
CGW-Camel Adds Three
Managers
CGW-Camel Grinding Wheels, Niles,
Ill., has appointed Rich Bomba, Dana
Cash, and Brett Luedtke as new territory
managers. Bomba will service Illinois and
northern Indiana. Cash is assigned to ac-
counts in Missouri, Kansas, Iowa, and Ne-
braska. Luedtke will work in Minnesota,
Wisconsin, upper peninsula of Michigan,
and North and South Dakota. Bomba pre-
viously worked as a senior civil specialist
at Hilti. Cash previously was a channel
partner manager at ZOLL Medical Corp.
Luedtke previously served as a regional
sales manager at DGI Supply.
Obituary
James F. Colosimo Sr.
James F. Colosimo Sr., 75, died Oct. 1
in Harrison Township, Mich. A member
of the AWS Detroit Section for 45 years,
he achieved Gold Member status with 50
years of AWS membership this year. He
graduated from the Eveleth High School
and the University of Notre Dame where
he was a four-year football letterman. He
started working in the welding industry in
1962 at A. O. Smith Corp. where he
served as a sales-
man, district man-
ager, and automo-
tive account man-
ager in Detroit.
While there, he was
instrumental in de-
veloping the first
CO
2
arc welded
wheel system for the
Motor Wheel Corp.
replacing its former
methods using re-
sistance welding or rivets. He also devel-
oped the first dual wire drive system for
semiautomatic welding, integration and
installation of the first production elec-
tric robots for gas metal arc welding at
the Ford Frame Plant, and in conjunction
with ASEA, installed the first laser track-
ing system for gas metal arc welding in
the auto industry. Colosimo also colabo-
rated with Alloy Rods and Tri-Mark to
develop the 4409 series of stainless steel
core wires. In 1970, he founded Michigan
Arc Products where he served as CEO
until his death. He was a member of the
Notre Dame Club of Detroit, North
Channel Yacht Club, the Detroit Curling
Club, and a charter member of the Robot
Division of the Society of Mechanical
Engineers. He is survived by Carol, his
wife of 50 years, a son, two daughters, a
brother, and ten grandchildren.
continued from page 68
Joe McGreal
Rick Whitfield
Paul Hensley
Frank Peszka
James Colosimo
Personnel Dec._Layout 1 11/8/12 1:41 PM Page 70
buyer's guide_FP_TEMP 11/6/12 1:37 PM Page 71
awo.aws.org
Mathematics is a necessary part of a welding professionals activities. However, math can be
complicated and confusing for beginners, and difficult for adults who havent used math principles
awhile. This course provides a combination of clear step-by-step verbal and visual explanations that
make each mathematical concept easy to understand and remember. Topics include place value,
simplification, estimation, measurement, and the addition, subtraction, multiplication and division of
whole numbers, fractions, decimals and mixed numbers. Practical exercises allow welders, welding
students, supervisors and inspectors to apply basic math skills to various aspects of the welding
process. Eighteen PDHs are provided through this course toward AWS recertification.
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simplification, estimation, measurement, and the
make each mathematical concept easy to unde
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edu awo math_FP_TEMP 11/6/12 3:09 PM Page 95
THE AMERICAN WELDER
73 WELDING JOURNAL
A
well-designed and maintained car-
tridge dust and fume collection
system can help to prevent respira-
tory and health problems and keep weld-
ing operations in compliance with regu-
latory requirements. Such a system will
properly filter welding fumes and other
hazardous contaminants, and the
cleaned air can be recirculated back into
the facility or exhausted outside. These
systems use self-cleaning mechanisms
that pulse dust off the filters, allowing
the units to run for extended periods
between filter change-outs.
This article addresses the seven most
important points to consider in selecting
a collector that will not only protect
workers and achieve compliance, but will
also run efficiently and reliably. The first
three points relate to the three agencies
that impact compliance: Environmental
Protection Agency (EPA), Occupational
Safety and Health Administration
(OSHA), and National Fire Protection
Association (NFPA).
1. Achieving EPA Rule 6x
Compliance
For years, many plants dealt with
welding fumes by simply exhausting
them outside. The latest EPA National
Emission Standard for Hazardous Air
Pollutants Rule 6x changed all that. This
standard encompasses all manufacturing
processes using materials that contain
0.1% of cadmium, lead, nickel, or
chromium, and any material that con-
tains 1% manganese, which includes
most welding rods and wires. Simply
stated, in any 20-min test period, there
can be no more than 3 min of visible
emissions (zero opacity) from these
types of processes. The standard spells
out the monitoring and test methods
required for compliance and outlines
control techniques that may be used.
Though this standard went into effect
July 2011, many companies remain
unaware of it, apart from some larger
facilities that have launched proactive
programs to achieve compliance. Rule 6x
is directly applicable to most welding
shops. It is in force now, and everyone
engaged in welding must be knowledge-
able about what actions are required.
Selecting Fume Collectors for
Welding Applications
BY GREG SCHREIER
GREG SCHREIER (filterman@farrapc.com)
is metalworking market manager, Camfil Farr
Air Pollution Control, Jonesboro, Ark.
Choosing a cartridge fumecollection
system that will protect welders
and operate efficiently involves
study and attention to details
Fig. 1 Shown is an example of an ambi
ent fume and dustcollection system that
recirculates filtered air back into the plant
downstream of the collector. A recirculat
ing system is the best way to maximize
return on investment by conserving the
shops heated or cooled air.
Camfil Farr December_Layout 1 11/7/12 3:34 PM Page 73
THE AMERICAN WELDER
DECEMBER 2012 74
One corrective strategy is to use a
dust and fume collector with high-
efficiency cartridge filtration. Cartridge
filtration is identified in the regulation
as an acceptable control device to elimi-
nate visible emissions and will, in many
cases, be the solution of choice.
2. Meeting OSHA PEL
Requirements
When air is exhausted outdoors, the
EPA Rule 6x applies as above. Should
you opt instead to recirculate the filtered
air downstream of the dust collector
rather than exhausting it outside (Fig. 1),
the indoor air must still comply with
OSHAs permissible exposure limits
(PELs). OSHA has established PELs for
hundreds of dusts based on an 8-h time-
weighted average (TWA) exposure. The
OSHA PEL for welding fume is 5
mg/m
3
, which is three times stricter than
the PEL for nuisance dust.
To verify a dust collector complies
with emission thresholds, require your
equipment supplier to provide a written
guarantee stating the maximum emis-
sions rate for the equipment over an 8-h
TWA. Filter efficiency stated as a per-
centage is not an acceptable substitute,
even if the supplier promises 99.9% effi-
ciency. OSHAs concern is to protect the
breathing zone of workers by ensuring
that the contaminants in the air are
below established limits.
Regulatory compliance is not the
only reason for keeping indoor emission
levels as low as possible. Workers are
healthier and more productive when the
indoor air is clean. They experience
fewer headaches and sinus congestion
and a reduction in more serious upper-
respiratory ailments. Clean shop air also
prevents the buildup of nuisance dust on
electrical control panels, circuit boards,
inspection equipment, and paperwork
that can interfere with everyday
operations.
3. Complying with NFPA
Standards
It is also necessary to stay up to date
on the relevant NFPA standards. A good
starting point is NFPA 654, Standard for
the Prevention of Fire and Dust
Explosions from the Manufacturing,
Processing and Handling of Combustible
Particulate Solids. This is an all-encom-
passing standard on how to design a safe
dust-collection system. It also references
other relevant explosion-prevention
standards including NFPA 68, Standard
on Explosion Protection by Deflagration
Venting; NFPA 69, Standard on Explosion
Prevention Systems; and NFPA 484,
Standard for Combustible Metals.
Its important to note that grinding
and other finishing operations that are
often performed in the welding area can
generate explosive dust. These processes
need to be taken into account, along with
the welding operations, when reviewing
the NFPA standards with your dust col-
lection equipment supplier to determine
the best methods for compliance.
4. Safeguarding against
Fire/Explosion Hazards
The NFPA states that a hazard analy-
sis, conducted either internally or by an
independent consultant, is needed to
assess risk and determine the required
level of fire and explosion protection.
When it comes to explosion protection,
the first step is to determine the explo-
sive index (Kst) and maximum pressure
(Pmax) characteristics of your dust. Any
dust above 0 Kst is considered to be
explosive, and the majority of dusts fall
into this category. If there is no explosion
protection in place, even a very low Kst
dust could result in an OSHA citation.
Spark generation is another concern.
Raw carbon steels are often coated with
oil before welding. When oil is exposed
to heat, some of it burns and turns to
ash. The oil that doesnt get hot enough
Fig. 2 This dust collector features an
explosion vent that opens when a prede
termined pressure is reached inside the
collector. During a combustible dust explo
sive event, the excess pressure and flame
front are vented to a safe area.
THE AMERICAN WELDER
75 WELDING JOURNAL
to combust transforms into an airborne
mist that can enter the collector and
accumulate on the air ducts and filters. If
a spark enters the system, a fire can
result.
The best way to safeguard against
these hazards is to work with an experi-
enced equipment supplier who can help
with testing to determine the dusts haz-
ardous properties; make engineered rec-
ommendations based on experience with
similar workplaces; and provide the fire-
and explosion-prevention technologies
that will work best for your specific
applications.
Passive and active explosion protec-
tion. Explosion protection systems may
be either passive or active. Passive sys-
tems usually incorporate mechanical
devices on both the dust collector and
connected ducting systems. An example
is an explosion vent on the dust collector
that opens at a preset pressure to direct
the pressure and flame fronts from an
explosion to a designated safe area
Fig. 2. Mechanical dampers are typically
used in the inlet and outlet ducting sys-
tems to create mechanical barriers to
block these fronts. The valves commonly
incorporate flaps or some other device
that moves to block the open passage of
the ducting.
The NFPA defines safe zones as being
located outside. When dust collectors
are located inside a building and too far
from an outside wall, or outside with no
practical safe zone around them, partic-
ulate retention and flame-arresting
devices are commonly utilized. These
devices are usually bolted over the
explosion vents to reduce particulates
from escaping in quantities that could
further support combustion, while
reducing the heat of an explosion to safe
levels.
Active systems commonly employ
electronic monitoring devices to control
other devices actions during an explo-
sive event. Chemical isolation and chem-
ical suppression are examples of active
systems. When these devices are used in
the ductwork, they are commonly
referred to as chemical isolation as
they create a chemical barrier inside the
ducting that isolates the explosion inside
the dust collector from processes up
and/or downstream of the system. When
they are used on the dust collector itself,
they are referred to as chemical sup-
pression as they work at suppressing
the explosion inside the dust collector to
a minimal event. Both of these systems
commonly utilize sensors to monitor the
pressure inside the dust collector and
within milliseconds can trigger the
release of the chemical agent inside the
dust collector and/or ducting.
Other fire-protection technologies
include conventional sprinkler systems
and systems that can detect sparks using
infrared sensors that release water to
extinguish the sparks before they can
enter the collector. Mechanical spark-
arresting devices include drop-out boxes,
perforated screens, and other devices
that create torturous paths for the sparks
and embers so they have more time to
burn out and lose their heat. Well-
designed arrestors direct the sparks away
from the filter media while adding very
little static pressure losses to the system.
Adding flame-retardant filter media can
provide an extra measure of protection.
Dust collectors with vertically mount-
ed filter cartridges offer reduced fire and
explosion risks. Vertically mounted sys-
tems also reduce the dust load on the fil-
ters to help minimize this hazard.
With horizontally mounted car-
tridges, dust can become trapped in the
pleats in the upper-third of the filters
Fig. 3. This trapped dust can burn even if
the filter media is fire retardant.
5. System Configurations
There are three general types of car-
tridge dust- and fume-collection systems
suitable for use with welding processes:
Source capture systems are popular
for applications involving small parts
and fixture welding. They typically uti-
lize a flexible source-capture arm or a
complete enclosure around the opera-
Fig. 3 Horizontally mounted cartridges, shown above, allow dust
to become trapped in the pleats in the upperthird of the filters, cre
ating a potential fire hazard. Vertically mounted systems reduce
the dust load on the filters and help minimize this hazard.
Fig. 4 The integrated safety monitoring filter shown here pre
vents collected dust from reentering the workspace should a leak
occur in the dust collectors primary filtering system.
THE AMERICAN WELDER
DECEMBER 2012 76
tion, such as a glass enclosure around a
robotic weld cell. This approach is usual-
ly limited to smaller work areas.
Hoods are often utilized for medium-
size areas with a footprint of 12 20 ft
or less. Curtains or hard walls may be
added to create a booth or enclosure
when workplace conditions permit.
Ambient systems use a central collec-
tor or a number of smaller collectors to
filter all the air in the shop. An ambient
system is more practical to control fumes
in a facility with multiple operations.
Various welding processes, large parts,
and stitch welding are examples of oper-
ations that are well suited to ambient
collection.
The best fume-collection system for a
given operation is not always obvious
and should not be selected by simply
searching the Internet. It is wiser to con-
sult a sales engineer who specializes in
industrial dust- and fume-collection
equipment who can evaluate your opera-
tion and conduct a site survey. The selec-
tion process is multifaceted and must
take a number of factors into account.
Analyzing the situation begins by
addressing the current problems the new
dust collector must resolve. Is the cur-
rent equipment plugging? Are fires
occurring? Are health and/or OSHA
concerns driving the need for cleaner
indoor air? Is excessive noise a concern?
Where will the collector be located? Will
it be outdoors or inside? If indoors, will
the equipment be installed at ground
level or on a mezzanine? What is the
ceiling height? A collector that offers a
small footprint and low-profile design
options can offer the greatest flexibility.
Consider the process factors as well.
What are the processes, the contami-
nants to be collected, hours of operation,
work conditions, electrical requirements,
airflow, pressure ratings, etc.? How do
the fixtures operate? How do positioners
hold the metal parts during welding?
How large are the parts? What second-
ary operations are being performed?
Considering all of these factors will
help determine whether a source-
capture arm, a hood, or an ambient sys-
tem is best for a particular application.
Dust testing, too, is an essential part of
the selection process. The tests should
determine both the physical characteris-
tics of the dust as well as the fire and
explosion risks involved.
6. Optimizing the Safety
Features
The ease of maintenance should be
considered. The filters, drums, or barrels
should be positioned for easy access and
servicing, and the filters should slide in
and out of the housing readily. Avoid
equipment using threaded connections
on the filter access doors or hoppers
because dust leakage is possible when
the threads are not tightened properly.
OSHA-compliant platforms and
caged ladders should be used to prevent
accidents when workers access the col-
lector for service.
A safety monitoring filter (Fig. 4),
sometimes called a secondary or afterfil-
ter, is a good investment and is a
required component in a recirculating
dust-collection system that filters air
from a list of specific hazardous materi-
als. It contains a bank of high-efficiency
air filters to prevent collected dust from
reentering the workspace should a leak
occur in the dust collectors primary fil-
tering system. Ductwork and a transition
section are usually required to connect
this secondary filter module to the dust-
collection system, but new integrated
designs are available in which the safety
filter is mounted on top of the collector
so that additional floor space is not
required.
Fan noise can be an important safety
concern. Noise can cause worker fatigue,
hearing loss, and other health problems.
Consider using silencers or customized
noise reducers in the design of your dust
collector.
7. Determining the Total
Cost of Ownership
It is not just the initial purchase price
but total cost of ownership that counts.
Consider the operating and maintenance
costs and compressed-air requirements.
Consider designs that incorporate green
features such as variable-frequency
drives and premium efficiency fan
motors to reduce your energy costs. A
reputable equipment supplier can proj-
ect these costs to recommend the best
ways to reduce the total cost of owner-
ship and get the most out of the dust col-
lector performance.
Finally, a safety monitoring filter is a
required component in a recirculating
dust collection system and can help to
meet todays more stringent emission
requirements. Where feasible, the best
way to maximize return on investment is
through use of a recirculating system. By
recycling heated or cooled air back
through the plant, the cost to replace
that conditioned air is eliminated. Many
plants report annual energy savings with
a payback ranging from one to three
years. Also, dust collectors in welding
shops with high ceilings can often
improve the efficiency of a heating sys-
tem by taking hot air off the ceiling and
delivering it at ground level.
Supplementary Reading
EPA National Emission Standard for
Hazardous Air Pollutants Rule 6x.
www.epa.gov/ttn/atw/6x/6xpg.html.
OSHA Permitted Exposure Limits
(PELs), www.osha.gov/SLTC/pel.
NFPA Standards. www.nfpa.org.
National Fire Protection Association
(NFPA), 1 Batterymarch Park, Quincy,
MA 02169; www.nfpa.org.
NFPA 68: Standard on Explosion
Protection by Deflagration Venting (2007).
NFPA 69: Standard on Explosion
Prevention Systems (2008).
NFPA 484: Standard for Combustible
Metals (2012).
NFPA 654: Standard for the
Prevention of Fire and Dust Explosions
from the Manufacturing, Processing and
Handling of Combustible Particulate
Solids (2006).
Occupational Safety & Health
Administration (OSHA), 200
Constitution Avenue, Washington, DC
20210; www.osha.gov.
OSHA Combustible Dust National
Emphasis Program (Reissued)
Directive Number: CPL 03-00-008;
effective date March 11, 2008.
OSHA Permissible Exposure Limits
(last updated 10-30-2006).
U.S. Environmental Protection
Agency (EPA), 1200 Pennsylvania Ave.,
NW, Washington, DC 20460;
www.epa.org.
Rule and Implementation Information
for Nine Metal Fabrication and Finishing
Area Source Categories 40 CFR Part 63
Subpart 6X; July 23, 2008.
Become Certified in Robotic Arc Welding
and Join the Ranks of the Elite
in the Robotics Industry
2013 SEMINAR/EXAM SCHEDULE
AWS understands the need for certified individuals within the robotic arc welding industry. In response to this need, a program based on
the AWS QC19 and D16.4 specifications, has been developed.
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Robotic Arc Welding Technicians or Operators.
For more information regarding this program, including how to become an AWS Approved Testing Center, visit our website today
at www.aws.org/certification/CRAW or call (800) 443-9353 ext. 298 (email linda@aws.org).
To schedule training and testing to become certified in robotic arc welding, contact one of these AWS Approved Testing Centers.
Colorado //Wolf Robotics //4600 Innovation Drive //Fort Collins, CO 80525 //(970) 225-7736// Darren Pape
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Certified in Robotic Arc Welding ecome B

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2013 SEMINAR
Milwaukee Area Technical College // Wisconsin
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obotics R lf Wo / /// rado lo Co

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1200 South 71st Street // Milwaukee Area Technical College
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est Allis, W W // 00 South 71st Streett
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aws cert (robotic arc wldg)_FP_TEMP 11/6/12 3:08 PM Page 77
THE AMERICAN WELDER
DECEMBER 2012 78
F
erris State University (FSU) is in
the business of producing welding
engineering technology graduates
and not just any ordinary ones. They
are training students to enter emerging
markets and use their knowledge to
oversee the many welding technologies
theyll find there.
Trends in the automotive, energy,
heavy equipment manufacturing, and
welding equipment industries are no
mystery to these students. Thats just
one of the reasons the school has such a
high demand for graduates and also why
they boast a more than 95% job place-
ment for those leaving with a bachelors
degree from FSUs welding engineering
technology program.
The Big Rapids, Mich.-based welding
program has been around since 1955 and
in that time has evolved from a one-year
certificate skill training program to a
bachelor of science degree that teaches
process selection, nondestructive exami-
nation, welding procedure development,
and equipment specification. Students
also study automation, weldment design,
welding metallurgy, and project manage-
ment. They learn how to weld using gas
tungsten arc (GTA), gas metal arc
(GMA), shielded metal arc (SMA), and
other processes.
Securing Insight and
Support from Industry
In addition to the guidance of their
professors, students have the opportuni-
ty to meet regularly with industry profes-
sionals to help keep them apprised of the
welding technologies and job opportuni-
ties available in the marketplace.
Recently, Hobart Brothers and MAXAL
representatives had the chance to talk
about opportunities with their compa-
nies and the markets they serve, and to
provide students with insight into devel-
opments in filler metal technology.
Hobart Brothers has employed many
FSU graduates over the years and, as
with many other companies, continues to
maintain strong bonds with the program
and also provide instructors for technical
support.
Hobart Brothers and MAXAL are
also among several companies that pro-
vide filler metal and equipment dona-
tions that help support the program.
They recently gave FSU a large donation
of SMAW electrodes and tubular wires,
including metal-cored and flux-cored
wires, along with aluminum GMAW and
KEITH PACKARD is segment manager,
power generation, and DERICK RAILLING is
product manager, global onshore pipeline,
for Hobart Brothers Co. (hobart@hobart-
brothers.com,
www.hobartbrothers.com), Troy, Ohio.
BRIAN FARKAS is a national account man-
ager for MAXAL International, Inc.
(www.maxal.com), Traverse City, Mich.
For more information on Ferris State Uni-
versitys welding engineering technology
department, contact Jeff Carney, associate
professor and program coordinator, at
carneyj@ferris.edu.
Thanks to recent industry donations
and hands-on training, welding
engineering technology students at
Ferris State University experience
real-world career preparation
BY KEITH PACKARD,
DERICK RAILLING, AND
BRIAN FARKAS
From the Lab to the
Production Floor:
Students Learn It All
Packard and Farkas AW Feature December 2012_Layout 1 11/8/12 8:08 AM Page 78
THE AMERICAN WELDER
79 WELDING JOURNAL
GTAW wire, and to help guide the stu-
dents in their proper usage. A day was
spent working in the labs with students
and conducting a seminar on metal-
cored wires and aluminum filler metals
Figs. 13.
We appreciate and encourage the
support that all the welding equipment
and filler metal manufacturers provide
us, said William England, technical
instructor Fig. 4. Our students really
benefit from it, and thats whats
important.
The Program
Yesterday and Today
The welding department at FSU
offered a certificate program to its stu-
dents from its inception until the 1970s
when it established an associate degree
program. It then expanded the curricu-
lum by graduating its first four-year
bachelors degree recipients in 1986.
Professor Kenneth Kuk joined the staff
in 1985 to start the bachelor of science
program and has served as the patriarch
of it since, teaching all of the Hobart
Brothers welding engineers who have
graduated with the four-year degree, as
well as fellow instructors England and
Jeff Carney (see lead photos), associate
professor and program coordinator, who
has been with the department since
1996.
Earning Associate and
Bachelor Degrees
Today, the university has what
England calls a true two plus two
welding program, which is also accredit-
ed by the Engineering Technology
Accreditation Commission (ETAC/
ABET). The resulting degrees are an
associate in applied science in welding
technology and a bachelor of science in
welding engineering technology.
Whereas an associate degree at a
community college is often focused on
meeting the needs of that region and
preparing students to go right in the
workforce, ours is designed to build into
the bachelors degree, he explained.
Our students can leave the program
after two years and find gainful employ-
ment or they can build on that founda-
tion for another two years and become a
welding engineer.
England estimates that approximate-
ly 60% of students continue on for their
bachelors degree.
Jeff Carney, an associate professor and
program coordinator at Ferris State
Universitys welding engineering
technology department, demonstrates
and discusses welding technique with
student Jeremy Brewster.
THE AMERICAN WELDER
DECEMBER 2012 80
Training Details
For the first two years, students learn
to master oxyacetylene, SMAW, GTAW,
and GMAW processes, as well as solder-
ing, brazing, and plasma cutting, com-
pleting coursework that consists of both
lectures and hands-on labs. Labs are
three hours a day, four days a week.
To show the competency of their skills
during the second semester of their
sophomore year, students are required
to complete a capstone project. They
design and fabricate projects ranging
from dog carriers and syrup cookers to
wood stoves, boiler systems, and log
splitters the choice is theirs. Or they
can opt to complete a project needed by
someone in the community.
Fig. 1 Brian Farkas of MAXAL International
demonstrates aluminum welding to students
during a visit to the welding technology lab.
Fig. 2 Keith Packard, segment manager,
Hobart Brothers, assesses a completed weld
and provides feedback to student Keith
Zebell.
Fig. 3 Derick Railling, product manager,
Hobart Brothers, demonstrates uphill weld-
ing with metal-cored wire.
1 2
3
THE AMERICAN WELDER
81 WELDING JOURNAL
Those students who are accepted into
the competitive bachelor of science pro-
gram spend their junior and senior years
studying and applying themselves to the
engineering technology side of welding,
including weldment design and automa-
tion. They culminate their knowledge, as
in their sophomore year, with a capstone
project that incorporates a cradle to
grave concept, including the design,
engineering, fabrication, testing, and
management of a project from the
ground up, using all the knowledge they
have amassed from their studies.
Operating Testing
Equipment
In addition to the design and welding
instruction, students also have the
opportunity to use the departments test-
ing equipment to gauge their progress
Fig. 5. The labs contain tensile and weld
bend-testing equipment, and there is
also a nondestructive examination lab
where the students can make assess-
ments. The space, which the school ren-
ovated in recent years, also serves as a
study and gathering area for students.
Benefits of the
FSU Approach
One of the first things thats immedi-
ately noticeable when visiting the weld-
ing laboratories at FSU isnt just the
noise or busyness of them (although
there is plenty of both), but rather its
the focus and independence of the stu-
dents during their labs Fig. 6.
According to Carney, that autonomy
is essential for the students to grow their
skills.
Theres a lot of trial and error to
what theyre doing, he explained. Its
all about cause and effect. The students
refine their skills by learning how to look
at a weld, determine what might be
wrong with it and how to fix it. We help
them along the way, of course, but the
process of learning how welding works is
absolutely necessary for them to become
proficient welding engineers.
England expands on that philosophy,
adding, FSU is focused on producing
plant-level welding engineers. Here stu-
Fig. 4 William England (far right), techni-
cal instructor at FSU, assesses students
welding wire selection during a lab. Others
shown from left are Matt Brandt, Brad
Williamson, and John Delboy.
Fig. 5 Welding engineering students
gather in the departments nondestructive
examination lab to complete coursework.
4
5
THE AMERICAN WELDER
DECEMBER 2012 82
dents develop the ability to think criti-
cally and troubleshoot, and they have the
hands-on experience to back up the the-
ories they learn.
Learning Valuable Skills
from Project Work
In the first two years of study, stu-
dents are given a set amount of small
projects, typically 18, to complete during
a semester. The projects involve weld
preparation and completing various
types of welds for which each student
must determine and refine the welding
parameters. Welding instructors, like
Dave Murray, associate professor, are
always on hand to help. Murray has been
with the program since 1981 and moves
throughout the lab, working side by side
with students to consult with them on
everything from the placement of welds
on their capstone projects to testing
welds and prepping materials.
The Importance of
Real-Life Relevance
Another part of refining student skills
is to incorporate real-world applications
in the curriculum, including designing
weldments for various industries and
determining the financial ramifications
of them. Such training becomes especial-
ly important for third- and fourth-year
students, said Jeff Hardesty, assistant
professor, when they begin to focus on
welding automation.
Our goal isnt just to teach students
to be proficient programmers, he
explained, but more importantly, we
teach them how to spec out and design
the robotic cells and fixtures, trou-
bleshoot, and be able to put automation
into production in the real world. They
need to be able to produce good welds,
and that might involve knowing when
and how to seam track or creating a cer-
tain fixture for the application.
Hardesty adds that learning how to
deal with different materials and filler
metals is also essential for students to
apply their knowledge in the real world.
They learn about metal-cored wires and
flux-cored wires, for example, including
the best applications for each and how to
set the proper welding parameters for
them.
Where to Next?
All students enrolled in the bache-
lors degree program are required to
complete an internship between their
junior and senior year. The internships
take place at welding equipment or filler
metal manufacturers, and also manufac-
turers throughout the heavy equipment,
automotive, and energy sectors. About
half of those internships, according to
Hardesty, lead to full-time employment
with the company after graduation.
Hobart Brothers is an active partici-
pant in the internship program with FSU
and continues to hire interns for full-
time employment, including two recent
graduates, Robert Fox and Blain Guy.
The school has a career placement
center that assists in locating these
internships, as well as placing graduates
in companies in emerging markets.
Counselors keep in close contact with
companies, and members of the depart-
ment say they receive calls daily, if not
multiple times a day, from companies
looking to recruit welding engineers.
Staying Ahead of the
Curve
Because industry demands change,
instructors in the welding engineering
technology program at FSU know that
their curriculum and focus will also have
to change if they are to keep their grad-
uates at the leading edge.
This program is an evolving con-
cept, said England. We are still devel-
oping, and we always will be. Its what
sets this program apart from the rest.
Fig. 6 Student Greg Jonker practices
making welds. Lab work in FSUs welding
technology program consists of multiple
projects that students must complete each
semester and test for quality.
foundation_FP_TEMP 11/6/12 3:22 PM Page 83
THE AMERICAN WELDER
LEARNING TRACK
DECEMBER 2012 84
D
uring the past 25 years, many
improvements have been imple-
mented at Florence Darlington
Technical College (FDTC) in Florence,
S.C., but one of the most significant is
the increase in enrollments in the weld-
ing department growing from 12 to
188 students. The college has also
become an American Welding Society
Accredited Test Facility, authorized to
test and certify welders Fig. 1.
Reasons for the Growth
While there are a number of reasons
for this growth in welder training, much
of the credit goes to recommendations
from the colleges Welding Advisory
Board members and to the efforts of
Ross Gandy (Fig. 2), director of the
Advanced Welding and Cutting Center,
as most of this growth occurred during
his 13-year tenure. Since Gandy plans to
retire at the end of this year, it is appro-
priate to publish some of his ideas that
helped to turn the welding program
around.
When Gandy accepted the position as
director of the training facility, the col-
lege president advised him to treat it
like a business. Gandy has done that
very well by focusing on the customer.
While many educators may consider
the student their only customer, Gandy
contends the industries hiring his weld-
ing graduates are also his customers, as
well as all of the sources that help to sup-
port the colleges welding education
programs.
Gandy wears a number of hats. He
serves as the director for the center,
business manager responsible for seeing
students meet the needs of fabricators
and increasing enrollments to meet
demands, department head for the weld-
ing curriculum program responsible for
course content, personnel, etc., and pro-
gram manager for the continuing educa-
tion segment of the center. In that later
duty, FDTC works with local industry to
develop and teach programs specifically
How Florence Darlington Technical
College Grew Its Welding Program
Committed instructors coupled with an active
advisory board and responsive college manage
ment proves to be a winwin relationship for
both the college and local industry
BY GERALD D. UTTRACHI
GERALD D. UTTRACHI (guttrachi@aol.com) is
a past AWS president, president of WA
Technology, chair of the AWS Foundation
Board of Trustees, and an active member of
the Welding Advisory Board at Florence
Darlington Technical College in Florence, S.C.
Fig. 1 The Florence Darlington Technology Centers welding
training facility is an AWS Accredited Test Facility.
Uttrachi Learning Track_Layout 1 11/7/12 1:22 PM Page 84
THE AMERICAN WELDER
85 WELDING JOURNAL
designed to fit their special needs. For
example, Honda needed some of the
companys welders trained to use gas
metal arc welding to join thin-wall tubing
in the all-terrain vehicle (ATV) produc-
tion area. Gandy developed the course
to Hondas specific requirements. He
also arranged for Honda to donate sam-
ples of the thin-wall tubing for the class-
es so their welders could practice weld-
ing on actual production parts. This
enhanced their training experience and
spared the college the expense of pur-
chasing these materials.
Custom Training Courses
Since companies typically request
these custom training courses be held in
the evening, Gandy provides either a
daytime welding instructor, if one is
available, or he hires a part-time instruc-
tor to conduct the training.
At FDTC, the regular welding cur-
riculum programs require all instructors
have a college degree and education
training; the continuing education class-
es require only that trainers possess
good welding and teaching skills. These
special classes can be conducted as need-
ed since they are not tied to the regular
semester dates.
The Welding Advisory Board
The colleges Welding Advisory
Board has been very supportive and is
responsible for helping to improve the
effectiveness of the colleges welding
programs. The board meetings, held sev-
eral times a year at the college, are
attended by about 20 industry represen-
tatives. Following a barbecue dinner pre-
pared by the college staff, they discuss
the skills most needed by the local indus-
tries to provide excellent feedback to the
college staff on how to adjust their cur-
riculums to better train their students to
fill these jobs. The board members also
help in other ways.
In the past, when Gandy expressed a
need for tools and equipment for a new
shop project, a board member would
often donate just what he needed. One
company offered a press brake for a
sheet metal forming project and another
company volunteered to transport the
machine to the college facility. In addi-
tion to working with the advisory board
members, Gandy stays in contact with
the welding fabricators in the area. He
visits the shops to learn first-hand what
welder skills are in demand.
LEARNING TRACK
Fig. 2 Ross Gandy, director of welding at
the college, worked 13 years to customize
his training to fit the needs of local
industries.
Fig. 3 A student is shown during the
intensive 12week, 40h/week pipe welding
course.
THE AMERICAN WELDER
DECEMBER 2012 86
What the Employers Want
Gandy noted that in addition to hir-
ing workers with good welding skills, the
employers want workers with good work
ethics. Gandy stresses this in his classes
to make reliability and punctuality
important parts of his training programs.
He requires his students to be on time
for classes, and punishes excessive late-
ness with a lower grade or remedial
action. He also insists that his students
dress appropriately for their classes.
Gandy impresses upon his students that
a good work ethic and proper dress can
go a long way toward improving their
chances for getting a good-paying job.
As an example, Gandy cited a request
from a local fabricator to provide 15
welders to help build cabs for tractors.
The college trained 20 students to the
fabricators requirements. After com-
pleting the course, 15 students passed
the welding qualification tests. The com-
pany representatives then interviewed
the students and opted to hire all 15
qualified welders and, in addition, hired
the remaining five students to work in
other construction areas since they were
impressed by the students demeanor.
Pipe Welder and Fitter
Programs
Recently, the college seized another
opportunity to serve the community and
grow its welding program when two
South Carolina power companies
expressed the need to hire qualified
welders to help build nuclear power
plants. Both companies agreed to finan-
cially support a pipe-welding program to
their specifications. They also volun-
teered an instructor to assist with the
training to get the program started. The
program the college developed is now a
continuing education program presented
at its Pipe Welding Academy. The course
is a 40-h/week, 12-week-long certificate
program. The facility has grown to
include 30 welding booths dedicated to
pipe-welder training Fig. 3.
To be accepted into this advanced
program, a student must first pass flat
plate welding tests in two positions with
a GTAW (gas tungsten arc welded) root
and SMAW (shielded metal arc welded)
fill passes. The students train by making
pipe welds in various materials and sizes,
including welds made under restricted-
access conditions. After passing the final
test, the students are qualified as pipe
welders. Representatives from both
power companies attended the qualifica-
tion testing to witness the students
results, and they hired the successful
graduates for their projects.
The weld test the power companies
require is a difficult 6G position butt
joint weld in heavy-wall, 16-mm (
5
8-in.)
pipe with a 70-mm (2
3
4-in.) OD with a
75-deg, single-bevel joint preparation.
The root weld is made with GTAW
and fill and cap passes with SMAW. The
weld has to pass visual and bend tests.
Although the college has offered this
pipe-welding course for less than three
years, it has qualified 150 students.
The success of the pipe-welding pro-
gram prompted the participating power
companies to ask the college to develop
a pipe-fitter program. In response,
FDTC hired Rick Butler (Fig. 4), an
experienced pipe fitter and construction
supervisor, to write the course. Butler
developed a 16-week program that fea-
tures math instruction designed for pipe
Fig. 4 Pipe fitting instructor Rick Butler
developed the college pipe fitter training
programs.
Fig. 5 The students assembled this com
plex assembly of pipes and fittings near the
shop ceiling while standing on scaffolding
to simulate the conditions they will incur on
the job in power plants.
LEARNING TRACK
THE AMERICAN WELDER
87 WELDING JOURNAL
fitters and layout students. In his classes,
Butler stresses the proper use of tools
including industrial pipe-preparation
equipment donated to the school by E.
H. Wachs.
To simulate actual working conditions
the students may encounter on the job,
the course requires students to interpret
engineering plans then, working on scaf-
folding, fabricate and tack weld a com-
plex pipe layout mounted near the lab
ceiling Fig. 5.
One thing Butler laments is that
many companies have eliminated the
position of fitters helper, a job category
that was common when he started in the
business. Fitter helpers were apprentices
who learned the trade from working with
the skilled fitters. Today, welder fitter
skills are only taught in schools.
The power companies were so satis-
fied with the graduates from these two
pipe programs that they asked FDTC to
develop another course to train pipe
valve technicians. Pipe valve technicians
were needed for their repair, rebuild,
and test operations. A typical nuclear
power plant has about 60 miles of piping
and many thousands of valves. Some
valves are welded in place and can be
rebuilt on site. Many of these valves have
pneumatic or motor-driven actuators.
The college hired Mike Ward to develop
a course of study to cover all of these
skills. The course is currently offered as
a five-week certificate program. Its grad-
uates are also in demand from other
companies specializing in valve mainte-
nance contracting.
Working with a Shipyard and
Local High Schools
Recently, a large shipyard contacted
the school in search of graduate welders
who would consider working in the Gulf
Coast area. Twelve students accepted the
offer, and took the written and practical
tests administered by the shipyard. All
passed. Several graduates took the ship-
yards test for welding in restricted
spaces, and they passed as well.
The college also works closely with
three local high schools and has
approved students from one of the
schools to earn college credits toward a
FDTC welding program. High school
welding students who take the required
tests in their junior and senior years, can
get credit for one-third of the college
requirements. A skilled high school stu-
dent can then attend FDTC for one year,
and after passing the qualification tests,
can take the 12-week pipe-welding pro-
gram. Students who successfully com-
plete this program often are offered jobs
paying $20/h or more at a power plant.
An important point to growing a
welder training program is to heed the
customers needs then develop the pro-
grams to fill their needs. Florence
Darlington Technical College has suc-
ceeded in growing its welding programs
by working with its Welding Advisory
Board members, local businesses, and
high schools, and providing custom-
designed courses taught by experts in the
field to train students for the skills in
current demand.
LEARNING TRACK
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THE AMERICAN WELDER
DECEMBER 2012 88
FACT SHEET
Bevel, V-groove, and U-groove joint
designs may be specified for the welding
of steel components. Among the
processes that can be used to create
bevels angular edge shapes is oxy-
gen cutting or gouging. The beveling of
plate edges in preparation for welding is
necessary in many applications to ensure
the proper dimensions and fit and to
accommodate standard welding tech-
niques. Plate edges can be beveled with
the use of a single torch or multiple
torches operating simultaneously.
Although single-torch beveling can be
accomplished manually, beveling is best
done by machine for accurate control of
the cutting variables. When cutting
bevels with two or three torches, plate-
riding devices should be used to ensure a
constant tip position above the plate.
Following are definitions of some of
the terms related to bevels:
Bevel Angle. The angle between the
bevel of a joint member and a plane per-
pendicular to the surface of the member.
Bevel Face. The prepared surface of a
bevel edge shape (see Fig. 1G and H).
Depth of Bevel. The perpendicular
distance from the base metal surface to
the root edge or the beginning of the
root face.
Groove Angle. The included angle
between the groove faces of a weld
groove.
Bevel Radius. The radius used to
form a J-edge shape (see Fig. 1B and E).
Root Opening. A separation at the
joint root between the workpieces (see
Fig. 1A, E, and D).
Terms Related to Bevels
Excerpted from Welding Handbook, Vol. 2, 9th Edition, and AWS A3.0M/A3.0:2010, Standard Welding Terms and Definitions, Including
Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying.
Fig. 1 Bevel angle, bevel face, depth of bevel, groove angle, bevel radius, and root opening.
Fact Sheet_Layout 1 11/9/12 1:25 PM Page 88
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cracking as well as provide information on preventive measures.
Gain practical knowledge on the types and causes of weld cracking.
Network with industry peers to discuss the best solutions for business growth.
AWS Conference attendees are awarded 1 PDH (Professional Development Hour)
for each hour of conference attendance. These PDHs can be applied toward AWS
recertifications and renewals.
Weld Cracking Conference
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For the latest conference information and registration visit our web site
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edu cracking conf_FP_TEMP 11/6/12 3:11 PM Page 89
PROFESSIONAL PROGRAM ABSTRACT SUBMITTAL
ANNUAL FABTECH SHOW
Chicago, IL - November 18-21, 2013

Submission Deadline: March 15, 2013
(Complete a separate submittal for each paper to be presented.)
Primary Author (Full Name):
Affiliation:
Mailing Address:

City: State/Province Zip/Mail Code Country:
Email:
Co-Author(s):
Name (Full Name):
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Address:
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State/Province
Zip/Mail Code
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Address:

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Address:

City:
State/Province:
Zip/Mail Code:
Country: E-Mail:
Answer the following about this paper
Original submittal? Yes No Progress report? Yes No Review paper? Yes No Tutorial? Yes No
What are the welding/Joining processes used?
What are the materials used?
What is the main emphasis of this paper? Process Oriented Materials Oriented Modeling
To what industry segments is this paper most applicable?
Has material in this paper ever been published or presented previously? Yes No
If Yes, when and where?
Is this a graduate study related research? Yes No
If accepted, will the author(s) present this paper in person? Yes Maybe No
Keywords: Please indicate the top four keywords associated with your research below

Guidelines for abstract submittal and selection criteria:
Only those abstracts submitted on this form will be considered. Follow the guidelines and word limits indicated.
Complete this form using MSWord. Submit electronically via email to mventura@aws.org
Technical/Research Oriented Applied Technology Education
New science or research.
Selection based on technical merit.
Emphasis is on previously unpublished
work in science or engineering relevant to
welding, joining and allied processes.
Preference will be given to submittals with
clearly communicated benefit to the
welding industry.
New or unique applications.
Selection based on technical merit.
Emphasis is on previously
unpublished work that applies known
principles of joining science or
engineering in unique ways.
Preference will be given to submittals
with clearly communicated benefit to
the welding industry.
Innovation in welding education at all
levels.
Emphasis is on education/training
methods and their successes.
Papers should address overall
relevance to the welding industry.

Check the category that best applies:

Technical/Research Oriented Applied Technology Education
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Proposed Title (max. 50 characters):
Proposed Subtitle (max. 50 characters):
Abstract:
Introduction (100 words max.) Describe the subject of the presentation, problem/issue being addressed and its
practical implications for the welding industry. Describe the basic value to the welding community with reference to
specific communities or industry sectors.

Technical Approach, for technical papers only (100 words max.) Explain the technical approach, experimental methods
and the reasons why this approach was taken.

Results/Discussion (300 words max.) For technical papers, summarize the results with emphasis on why the results
are new or original, why the results are of value to further advance the welding science, engineering and applications.
For applied technology and education papers, elaborate on why this paper is of value to the welding community,
describe key aspects of the work developed and how this work benefits the welding industry and education.

.Conclusions (100 words max.) Summarize the conclusions and how they could be put to use how and by whom.

NOTE: Abstract must not exceed one page and must not exceed the recommended word limit given above
Note: The Technical Program is not the venue for commercial promotions of a company or a product. All presentations should avoid
the use of product trade names. The Welding Show provides ample opportunities for companies to showcase and advertise their
processes and products.
Return this form, completed on both sides, via email to mventura@aws.org

MUST BE RECEIVED NO LATER THAN MARCH 15, 2013
general corporate_FP_TEMP 11/6/12 1:37 PM Page 92
POSTER ABSTRACT SUBMITTAL
ANNUAL FABTECH SHOW
Chicago, IL November 18-21, 2013

Submission Deadline: April 19, 2013
(Complete a separate submittal for each poster.)
Primary Author (Full Name):
School/Company:
Mailing Address:

City: State/Province: Zip/Mail Code: Country:
Email:
Poster Title (max. 50 characters):
Poster Subtitle (max. 50 characters):
Co-Author(s):
Name (Full Name):
Affiliation:
Address:

City:
State/Province:
Zip/Mail Code:
Country: Email:
Name (Full Name):
Affiliation:
Address:

City:
State/Province:
Zip/Mail Code:
Country: Email:
Poster Requirements and Selection Criteria:
Only those abstracts submitted on this form will be considered. Follow the guidelines and word limits indicated.
Complete this form using MSWord. Submit electronically via email to mventura@aws.org or print and mail.
Any technical topic relevant to the welding industry is acceptable (e.g. welding processes & controls, welding procedures, welding design,
structural integrity related to welding, weld inspection, welding metallurgy, etc.).
Submittals that are incomplete and that do not satisfy these basic guidelines will not be considered for competition.
Posters accepted for competition will be judged based on technical content, clarity of communication, novelty/relevance of the subject & ideas
conveyed and overall aesthetic impression.
Criteria by category as follows:
(A) Student (B) Student (C) Student (D) Professional
Students enrolled in 2 yr. college
and/or certificate programs at time
of submittal.
Presentation need not represent
actual experimental work. Rather,
emphasis is placed on
demonstrating a clear
understanding of technical
concepts and subject matter.
Practical application is important
and should be demonstrated.
For students enrolled in
baccalaureate engineering or
engineering technology programs
at the time of submittal.
Poster should represent the
students own experimental work.
Emphasis is place on
demonstrating a clear
understanding of technical
concepts and subject matter.
Practical application and/or
potential relevance to the welding
industry is important and should
be demonstrated.
For students enrolled in graduate
degree programs in engineering or
engineering technology at time of
submittal.
Poster should represent the
students own experimental work.
Poster must demonstrate technical
or scientific concepts. Emphasis is
placed on originality and novelty of
ideas presented.
Potential relevance to the welding
industry is important and should be
demonstrated.
For anyone working in the welding
industry or related field.
Poster must demonstrate technical
or scientific concepts. Emphasis is
placed on original contributions
and the novelty of the presentation.
Potential relevance to the welding
industry is important and should be
demonstrated.
(E) High School
Junior or Senior high school
students enrolled in a welding
concentration at the time of
submittal.
Presentation should represent
technical concepts and application
to the welding industry.
Practical application and creativity
are important and should be
demonstrated.

Check the category that applies:
(A) Student 2-yr. or
Certificate Program
(B) Student 4-yr.
Undergraduate
(C) Graduate
Student
(D) Professional (E) High School
Poster Title (max. 50 characters):
Poster Subtitle (max. 50 characters):
Abstract:
Introduction (100 words) Describe the subject of the poster, problem/issue being addressed and its practical implications for the welding
industry.

Technical Approach & Results (200 words) Explain the technical approach. Summarize the work that was done as it relates to the subject of
the poster.

.
Conclusions (100 words) Summarize the conclusions and how they could be used in a welding application.

Return this form, completed on both sides, via email to mventura@aws.org
MUST BE RECEIVED NO LATER THAN April 19, 2013
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Welding Fundamentals
AWSs American Welding Online is introducing a self-paced online seminar designed to
provide technical knowledge and insight to non-welders who work in the welding and
fabricating industry.
Welding Fundamentals is an approximately 14-hour course that can be taken at your own
speed and convenience. The course provides a fundamental overview of welding, focusing
on the most widely used welding processes. Fundamental instruction is presented on
welding theory, equipment, safety, weld design, metallurgy, welding inspection, and quality
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Professional Development Hours and a certificate of completion will be provided upon
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For more information, visit American Welding Online at
.aws.org

edu awo fundamentals_FP_TEMP 11/6/12 3:24 PM Page 95
WELDING JOURNAL
INDEX
A Composite Solder Alloy Preform for High-Temperature
Lead-Free Soldering Applications W. Liu, P. Bachorik,
and N.-C. Lee, (July) 50
A Holistic Study of Automated Plasma System Costs J. P.
Kinos and D. Ott, (Nov) 28
Aluminum in the Auto Industry, Whats New for Welding
N. Scotchmer and K. Chan, (Jan) 34
Aluminum on Ships An Overview, Welded G. A. Mir-
gain, (March) 43
Aluminum, Recent Advances in Solid-State Joining of .
Grong, (Jan) 26
Aluminum, Selecting Equipment for Welding T. Burns,
(Jan) 52
An IIW Primer D. J. Kotecki and T. M. Mustaleski, (Feb)
28
Answers to FAQs about Welding Automation D. Imus,
(Nov) 38
Arc Welding Potential, Unlocking Your Gas Metal P. A.
Blomquist, (April) 28
Auto Industry, Whats New for Welding Aluminum in the
Automating On-Site Beveling, Cutting, and Welding N.
Drake and B. Malkani, (Aug) 38
Automation, Answers to FAQs about Welding D. Imus,
(Nov) 38
AWS Enters New Era with World Headquarters H. M.
Woodward, (Nov) 42
Benches for Fun and Fund-Raising, Welded H. Woodward,
(March) 93
Beveling, Cutting, and Welding, Automating On-Site N.
Brazed Steel Components, Defect Assessment of C.
Leinenbach, M. Koster, A. Lis, and H. J. Schindler, (July)
42
Brazing Alloys, Managing Precious Metal Volatility in G.
Alexy, (July) 60
Brazing Filler Metals for Joining Titanium, Evaluating Low-
Temperature T. Eckardt, B. Hanhold, D. Petrasek, S. Sat-
tler, A. Benatar, and A. Shapiro, (Feb) 45
Brazing Materials, Cost Benefits of Preformed and Premixed
J. Kapur, (Feb) 51
Brazing, The Effects of Rework on D. G. Stroppa, T.
Hermenegildo, J. Unfried S., N. Oliveira, and A. J.
Ramirez, (Feb) 41
Bridge, Narrow Gap Electroslag Is Process of Choice for
Welding San Francisco-Oakland Bay B. Turpin, D.
Danks, J. Callaghan, and W. Wood, (May) 24
Build Your Own Campfire Grill B. Pelky, (March) 48
Building a Welding Career from the Ground Up (April) 45
Building Demand for Tradeswomen (Sept) 81
Cable, How to Pick the Right-Sized Welding A. F. Manz
(March) 91
Campground to the Welding Lab, Scouts Move from the
(June) 121
Career from the Ground Up, Building a Welding (April) 45
Cells to Fabricate Wind Towers, Equipping Welding B.
Williams and M. Vandenberg, (Jan) 48
Choosing a Surface Coating Technology T. Peters and T.
Glynn, (Sept) 32
College Welding Program Update, Community D. Postleth-
waite, (April) 33
Community College Welding Program Update D. Postleth-
waite, (April) 33
Corrosion Resistance when Welding Stainless Tube and Pipe,
Maintaining J. Cuhel and D. Benson, (Nov) 46
Cost Benefits of Preformed and Premixed Brazing Materials
J. Kapur, (Feb) 51
Cutting, and Welding, Automating On-Site Beveling, N.
Cutting for Medical Devices, Fiber Lasers Perform Precision
(April) 52
Cutting Process is Best for Your Application?, Which Metal
M. Avila, (Oct) 32
Defect Assessment of Brazed Steel Components C. Leinen-
bach, M. Koster, A. Lis, and H. J. Schindler, (July) 42
Digitized and Ready to Travel, The Welding Journal: C. Guz-
man, (Sept) 46
Ecological Impact of Arc Welding, Reducing the M. A.
Purslow, (Dec) 24
Electroslag Is Process of Choice for Welding San Francisco-
Oakland Bay Bridge, Narrow Gap B. Turpin, D. Danks,
J. Callaghan, and W. Wood, (May) 24
Engine-Driven Welding Machine?, What Do You Need in an
J. Leisner and J. Gitter, (May) 38
Equipment for Welding Aluminum, Selecting T. Burns,
(Jan) 52
Equipping Welding Cells to Fabricate Wind Towers B.
Evaluating Low-Temperature Brazing Filler Metals for Join-
ing Titanium T. Eckardt, B. Hanhold, D. Petrasek, S. Sat-
Exchange Drives the 65th IIW Assembly, Technology A.
Cullison, (Oct) 48
Fabrication Support Is Vital to Weld Quality, On-Site W. C.
LaPlante, (Oct) 54
FABTECH (Oct) 60
FABTECH 2011 A. Cullison, M. R. Johnsen, K. Campbell,
and C. Guzman, (Jan) 38
FABTECH Comes to Canada (March) 40
Factors that Affect Hexavalent Chromium Emissions S.
Ferree and F. Lake, (Aug) 29
Failures, Six Ways to Prevent Weld J. Bundy, (Feb) 30
Fiber Lasers Perform Precision Cutting for Medical Devices
(April) 52
Finishing Stainless Steel Welds for Food Processing Equip-
ment D. Long, (July) 30
Flux Cored and Metal Cored Electrodes, New AWS Spec De-
tails D. Crockett, (March) 51
Food Processing Equipment, Finishing Stainless Steel Welds
for D. Long, (July) 30
Forward on the Job, Putting Your Best Foot M. Reilly,
(Aug) 54
From the Lab to the Production Floor: Students Learn It All
K. Packard, D. Railling, and B. Farkas, (Dec) 78
Fume Collectors for Welding Applications, Selecting G.
Schreier, (Dec) 73
DECEMBER 2012 96
Part 1 WELDING JOURNAL
SUBJECT INDEX
VOLUME 91
WJ Index 2012_WJ Index 2006 11/8/12 10:42 AM Page 96
Good Design Plus Early Inspection Equals High Productivity
J. Noruk and J.P. Boillot, (Sept) 26
Green: A Way of Life for Weld Tooling Company B. Kratz,
(Dec) 32
Green Technology, Thermal Spray Wins as a R. S. Brun-
house, P. Foy, and D. R. Moody, (Sept) 41
Headquarters, AWS Enters New Era with World H. M.
Woodward, (Nov) 42
Hexavalent Chromium Emissions, Factors that Affect S.
Ferree and F. Lake, (Aug) 29
High-Frequency Welding of Stainless Steel, What to Consider
before L. D. Frame, (Nov) 34
How Multiple Weld Repairs Impact Maraging Steel B.
Ahmed, F. Tariq, N. Naz, and R. A. Baloch, (Oct) 38
How Often Can Joints Be Cut and Rewelded in Low-Carbon
Steel? A. Gonalves de Mello Jr., G. S. Crisi, E. Vitor,
and R. A. Lopes Da Silva, (Feb) 25
How Todays Power Sources Aid Pulsed GMAW L. Barley,
(April) 48
How to Pick the Right-Sized Welding Cable A. F. Manz,
(March) 91
How Would Lower Limits for Manganese Affect Welding?
P. Blomquist and D. Chute, (Aug) 42
Hybrid Process Welds Thick-Walled Tubes M. O. Gebhardt,
A. Gumenyuk, and M. Rethmeier, (June) 55
IBSC 2012 Attracts Worldwide Audience K. Campbell,
(July) 38
Industrial Arts, Unleash Your Inner Creativity: Explore K.
Campbell, (June) 115
Inspection Equals High Productivity, Good Design Plus Early
J. Noruk and J.P. Boillot, (Sept) 26
Is Small Town America the New Face in Welding? B.
Wehrman, (May) 44
Lab to the Production Floor: Students Learn It All, From the
Lasers Perform Precision Cutting for Medical Devices, Fiber
(April) 52
Lead-Free Soldering Applications, A Composite Solder Alloy
Preform for High-Temperature W. Liu, P. Bachorik, and
N.-C. Lee, (July) 50
Low-Carbon Steel?, How Often Can Joints Be Cut and
Rewelded in A. Gonalves de Mello Jr., G. S. Crisi, E.
Vitor, R. A. Lopes Da Silva, (Feb) 25
Maintaining Corrosion Resistance when Welding Stainless
Tube and Pipe J. Cuhel and D. Benson, (Nov) 46
Managing Precious Metal Volatility in Brazing Alloys G.
Alexy, (July) 60
Manganese Affect Welding?, How Would Lower Limits for
P. Blomquist and D. Chute, (August) 42
Maraging Steel, How Multiple Weld Repairs Impact B.
Medical Devices, Fiber Lasers Perform Precision Cutting for
(April) 52
Metal Cored Electrodes, New AWS Spec Details Flux Cored
and D. Crockett, (March) 51
Modeling Welding Thermodynamics, Program Aids in P.
Mason, (Dec) 28
Modern Power Source Technology Drives Process Improve-
ment T. McEllis, (April) 38
Moving from Paper to Pixels D. Craig, (Dec) 38
Moving Laser Research from the Lab to Industry F. Sci-
ammarella, (May) 50
Narrow Gap Electroslag Is Process of Choice for Welding San
Francisco-Oakland Bay Bridge B. Turpin, D. Danks, J.
Callaghan, and W. Wood, (May) 24
Need for Weld Purity Drives Purging Methods M. J.
Fletcher, (July) 36
New AWS Spec Details Flux Cored and Metal Cored Elec-
trodes D. Crockett, (March) 51
New Face in Welding?, Is Small Town America the B.
Wehrman, (May) 44
New Processes and Metal Cored Wire Combine to Improve
Pipe Fabrication J. Cuhel and K. Packard, (June) 68
Oilfield Operations, Welding Supports Prudhoe Bay W. C.
LaPlante, (June) 62
On-Site Fabrication Support Is Vital to Weld Quality W. C.
LaPlante, (Oct) 54
Orbital Welding for Power Plant Construction, Using On-Site
T. E. Gittens, G. R. Lacey, and M. Kent, (June) 51
Oxyfuel Safety: Its Everyones Responsibility J. Hender-
son, (Aug) 48
Phased Array Testing of Resistance Spot Welds J. K. Na,
(Sept) 36
Pipe Fabrication, New Processes and Metal Cored Wire Com-
bine to Improve J. Cuhel and K. Packard, (June) 68
Pixels, Moving from Paper to D. Craig, (Dec) 38
Plasma System Costs, A Holistic Study of Automated J. P.
Kinos and D. Ott, (Nov) 28
Power Plant Construction, Using On-Site Orbital Welding for
Power Source Technology Drives Process Improvement, Mod-
ern T. McEllis, (April) 38
Precious Metal Volatility in Brazing Alloys, Managing G.
Alexy, (July) 60
Program Aids in Modeling Welding Thermodynamics P.
Mason, (Dec) 28
Projection Welding Basics, Spot and L. H. McDevitt, (Sept)
81
Pulsed GMAW, How Todays Power Sources Aid L. Barley,
(April) 48
Purging Methods, Need for Weld Purity Drives M. J.
Fletcher, (July) 36
Putting Your Best Foot Forward on the Job M. Reilly, (Aug)
54
Recent Advances in Solid-State Joining of Aluminum O.
Grong, (Jan) 26
Reducing the Ecological Impact of Arc Welding M. A.
Purslow, (Dec) 24
Repairs Impact Maraging Steel, How Multiple Weld B.
Research from the Lab to Industry, Moving Laser F. Sci-
ammarella, (May) 50
Resistance Spot Welds, Phased Array Testing of J. K. Na,
(Sept) 36
Retrofit, Ten Signs Youre Ready for an Automated Plasma
T. Rice and D. Ott, (Feb) 34
Rewelded in Low-Carbon Steel?, How Often Can Joints Be
Cut and A. Gonalves de Mello Jr., G. S. Crisi, E. Vitor,
R. A. Lopes Da Silva, (Feb) 25
Robots in the Weld Shop: More than Just Welding V. Man-
gold, (Nov) 52
Safeguarding Your Vision J. Bulan, E. Cull, and F. Stupczy,
(Aug) 54
Safety: Its Everyones Responsibility, Oxyfuel J. Hender-
son, (Aug) 48
Scouts Move from the Campground to the Welding Lab
(June) 121
Selecting Equipment for Welding Aluminum T. Burns,
(Jan) 52
Selecting Fume Collectors for Welding Applications G.
Schreier, (Dec) 73
Shop: More than Just Welding, Robots in the Weld V. Man-
97 WELDING JOURNAL
DECEMBER 2012 98
Ahmed, B., Tariq, F., Naz, N., and Baloch, R. A. How Mul-
tiple Weld Repairs Impact Maraging Steel, (Oct) 38
Alexy, G. Managing Precious Metal Volatility in Brazing
Alloys, (July) 60
Avila, M. Which Metal-Cutting Process is Best for Your
Application?, (Oct) 32
Bachorik, P., Lee, N.-C., and Liu, W. A Composite Solder
Alloy Preform for High-Temperature Lead-Free Soldering
Applications, (July) 50
Baloch, R. A., Ahmed, B., Tariq, F., and Naz, N. How Mul-
Barley, L. How Todays Power Sources Aid Pulsed GMAW,
(April) 48
Benatar, A., Shapiro, A., Eckardt, T., Hanhold, B., Petrasek,
D., and Sattler, S. Evaluating Low-Temperature Brazing
Filler Metals for Joining Titanium, (Feb) 45
Benson, D., and Cuhel, J. Maintaining Corrosion Resist-
ance when Welding Stainless Tube and Pipe, (Nov) 46
Blomquist, P. A. Unlocking Your Gas Metal Arc Welding
Potential, (April) 28
Blomquist, P., and Chute, D. How Would Lower Limits for
Manganese Affect Welding?, (Aug) 42
Boillot, J.P., and Noruk, J. Good Design Plus Early In-
spection Equals High Productivity, (Sept) 26
Brunhouse, R. S., Foy, P., and Moody, D. R. Thermal Spray
Wins as a Green Technology, (Sept) 41
Bulan, J., Cull, E., and Stupczy, F. Safeguarding Your Vi-
sion, (Aug) 58
Bundy, J. Six Ways to Prevent Weld Failures, (Feb) 30
Burns, T. Selecting Equipment for Welding Aluminum,
(Jan) 52
Callaghan, J., Wood, W., Turpin, B., and Danks, D. Narrow
Gap Electroslag Is Process of Choice for Welding San Fran-
cisco-Oakland Bay Bridge, (May) 24
Campbell, K., Cullison, A., Johnsen, M. R., Woodward, H.
Welding Researchs New Talent Pool, (May) 33
Campbell, K., Guzman, C., Cullison, A., and Johnsen, M. R.
FABTECH 2011, (Jan) 38
Campbell, K. IBSC 2012 Attracts Worldwide Audience,
(July) 38
Campbell, K. Unleash Your Inner Creativity: Explore In-
dustrial Arts, (June) 115
Chan, K., and Scotchmer, N. Whats New for Welding Alu-
minum in the Auto Industry, (Jan) 34
Chute, D., and Blomquist, P. How Would Lower Limits for
Manganese Affect Welding?, (Aug) 42
AUTHORS FOR FEATURE ARTICLES
gold, (Nov) 52
Six Ways to Prevent Weld Failures J. Bundy, (Feb) 30
Solder Alloy Preform for High-Temperature Lead-Free Sol-
dering Applications, A Composite W. Liu, P. Bachorik,
and N.-C. Lee, (July) 50
Solid-State Joining of Aluminum, Recent Advances in O.
Grong, (Jan) 26
Spot and Projection Welding Basics L. H. McDevitt, (Sept)
81
Stainless Steel Welds for Food Processing Equipment, Finish-
ing D. Long, (July) 30
Stainless Steel, What to Consider before High-Frequency
Welding of L. D. Frame, (Nov) 34
Stainless Tube and Pipe, Maintaining Corrosion Resistance
when Welding J. Cuhel and D. Benson, (Nov) 46
Students Learn It All, From the Lab to the Production Floor:
Surface Coating Technology, Choosing a T. Peters and T.
Glynn, (Sept) 32
Talent Pool, Welding Researchs New A. Cullison, M. R.
Johnsen, H. Woodward, and K. Campbell, (May) 33
Technology Exchange Drives the 65th IIW Assembly A.
Cullison, (Oct) 48
Ten Signs Youre Ready for an Automated Plasma Retrofit
T. Rice and D. Ott, (Feb) 34
The Effects of Rework on Brazing D. G. Stroppa, T.
Hermenegildo, J. Unfried S., N. Oliveira, and A. J.
Ramirez, (Feb) 41
The Welding Journal: Digitized and Ready to Travel C. Guz-
man, (Sept) 46
Thermal Spray Wins as a Green Technology R. S. Brun-
house, P. Foy, and D. R. Moody, (Sept) 41
Tips for Preparing and Selecting Tungsten Electrodes J.
Sprinkle, (June) 111
Titanium, Evaluating Low-Temperature Brazing Filler Metals
for Joining T. Eckardt, B. Hanhold, D. Petrasek, S. Sat-
Tooling Company, Green: A Way of Life for Weld B. Kratz,
(Dec) 32
Tubes, Hybrid Process Welds Thick-Walled M. O. Geb-
hardt, A. Gumenyuk, and M. Rethmeier, (June) 55
Tungsten Electrodes, Tips for Preparing and Selecting J.
Sprinkle, (June) 111
Undertaking a Complex Underwater Repair D. Phillips,
(March) 32
Underwater Repair, Undertaking a Complex D. Phillips,
(March) 32
Unleash Your Inner Creativity: Explore Industrial Arts K.
Campbell, (June) 115
Unlocking Your Gas Metal Arc Welding Potential P. A.
Blomquist, (April) 28
Using On-Site Orbital Welding for Power Plant Construction
Welded Aluminum on Ships An Overview G. A. Mir-
gain, (March) 43
Welded Benches for Fun and Fund-Raising H. Woodward,
(March) 93
Welding Researchs New Talent Pool A. Cullison, M. R.
Johnsen, H. Woodward, and K. Campbell, (May) 33
Welding Supports Prudhoe Bay Oilfield Operations W. C.
LaPlante, (June) 62
What Do You Need in an Engine-Driven Welding Machine?
J. Leisner and J. Gitter, (May) 38
What to Consider before High-Frequency Welding of Stain-
less Steel L. D. Frame, (Nov) 34
Whats New for Welding Aluminum in the Auto Industry
Which Metal-Cutting Process is Best for Your Application?
M. Avila, (Oct) 32
Wind Towers, Equipping Welding Cells to Fabricate B.
Worldwide Audience, IBSC 2012 Attracts K. Campbell,
(July) 38
99 WELDING JOURNAL
Craig, D. Moving from Paper to Pixels, (Dec) 38
Crisi, G. S., Vitor, E., Lopes Da Silva, R. A., and Gonalves
de Mello Jr., A. How Often Can Joints Be Cut and
Rewelded in Low-Carbon Steel?, (Feb) 25
Crockett, D. New AWS Spec Details Flux Cored and Metal
Cored Electrodes, (March) 51
Cuhel, J., and Benson, D. Maintaining Corrosion Resist-
ance when Welding Stainless Tube and Pipe, (Nov) 46
Cuhel, J., and Packard, K. New Processes and Metal Cored
Wire Combine to Improve Pipe Fabrication, (June) 68
Cull, E., Stupczy, F., and Bulan, J. Safeguarding Your Vi-
sion, (Aug) 58
Cullison, A. Technology Exchange Drives the 65th IIW As-
sembly, (Oct) 48
Cullison, A., Johnsen, M. R., Campbell, K., and Guzman, C.
Cullison, A., Johnsen, M. R., Woodward, H., and Campbell,
K. Welding Researchs New Talent Pool, (May) 33
Danks, D., Callaghan, J., Wood, W., and Turpin, B. Narrow
Drake, N., and Malkani, B. Automating On-Site Beveling,
Cutting, and Welding, (Aug) 38
Eckardt, T., Hanhold, B., Petrasek, D., Sattler, S., Benatar, A.,
and Shapiro, A. Evaluating Low-Temperature Brazing
Farkas, B., Packard, K., and Railling, D. From the Lab to
the Production Floor: Students Learn It All, (Dec) 78
Ferree, S., and Lake, F. Factors that Affect Hexavalent
Chromium Emissions, (Aug) 29
Fletcher, M. J. Need for Weld Purity Drives Purging Meth-
ods, (July) 36
Foy, P., Moody, D. R., and Brunhouse, R. S. Thermal Spray
Frame, L. D. What to Consider before High-Frequency
Welding of Stainless Steel, (Nov) 34
Gebhardt, M. O., Gumenyuk, A., and Rethmeier, M. Hy-
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Gittens, T. E., Lacey, G. R., and Kent, M. Using On-Site
Orbital Welding for Power Plant Construction, (June) 51
Gitter, J., and Leisner, J. What Do You Need in an Engine-
Driven Welding Machine?, (May) 38
Glynn, T., and Peters, T. Choosing a Surface Coating Tech-
nology, (Sept) 32
Gonalves de Mello Jr., A., Crisi, G. S., Vitor, E., and Lopes
Da Silva, R. A. How Often Can Joints Be Cut and
Grong, . Recent Advances in Solid-State Joining of Alu-
minum, (Jan) 26
Gumenyuk, A., Rethmeier, M., and Gebhardt, M. O. Hy-
Guzman, C., Cullison, A., Johnsen, M. R., and Campbell, K.
Guzman, C. The Welding Journal: Digitized and Ready to
Travel, (Sept) 46
Hanhold, B., Petrasek, D., Sattler, S., Benatar, A., Shapiro, A.,
and Eckardt, T. Evaluating Low-Temperature Brazing
Henderson, J. Oxyfuel Safety: Its Everyones Responsibil-
ity, (Aug) 48
Hermenegildo, T., Unfried S., J., Oliveira, N., Ramirez, A. J.,
and Stroppa, D. G. The Effects of Rework on Brazing,
(Feb) 41
Imus, D. Answers to FAQs about Welding Automation,
(Nov) 38
Johnsen, M. R., Campbell, K., Guzman, C., and Cullison, A.
Johnsen, M. R., Woodward, H., Campbell, K., and Cullison,
A. Welding Researchs New Talent Pool, (May) 33
Kapur, J. Cost Benefits of Preformed and Premixed Braz-
ing Materials, (Feb) 51
Kent, M., Gittens, T. E., and Lacey, G. R. Using On-Site
Kinos, J. P., and Ott, D. A Holistic Study of Automated
Plasma System Costs, (Nov) 28
Koster, M., Lis, A., Schindler, H. J., and Leinenbach, C. De-
fect Assessment of Brazed Steel Components, (July) 42
Kotecki, D. J., and Mustaleski, T. M. An IIW Primer, (Feb)
28
Kratz, B. Green: A Way of Life for Weld Tool Company,
(Dec) 32
Lacey, G. R., Kent, M., and Gittens, T. E. Using On-Site
Lake, F., and Ferree, S. Factors that Affect Hexavalent
Chromium Emissions, (Aug) 29
LaPlante, W. C. On-Site Fabrication Support Is Vital to
Weld Quality, (Oct) 54
LaPlante, W. C. Welding Supports Prudhoe Bay Oilfield
Operations, (June) 62
Lee, N.-C., Liu, W., and Bachorik, P. A Composite Solder
Leinenbach, C., Koster, M., Lis, A., and Schindler, H. J. De-
Leisner, J., and Gitter, J. What Do You Need in an Engine-
Driven Welding Machine?, (May) 38
Lis, A., Schindler, H. J., Leinenbach, C., and Koster, M. De-
Liu, W., Bachorik, P., and Lee, N.-C. A Composite Solder
Long, D. Finishing Stainless Steel Welds for Food Process-
ing Equipment, (July) 30
Lopes Da Silva, R. A., Gonalves de Mello Jr., A., Crisi, G. S.,
and Vitor, E. How Often Can Joints Be Cut and
Malkani, B., and Drake, N. Automating On-Site Beveling,
Cutting, and Welding, (Aug) 38
Mangold, V. Robots in the Weld Shop: More than Just
Welding, (Nov) 52
Manz, A. F. How to Pick the Right-Sized Welding Cable,
(March) 91
Mason, P. Program Aids in Modeling Welding Thermody-
namics, (Dec) 28
McDevitt, L. H. Spot and Projection Welding Basics, (Sept)
81
McEllis, T. Modern Power Source Technology Drives
Process Improvement, (April) 38
Mirgain, G. A. Welded Aluminum on Ships An
Overview, (March) 43
Moody, D. R., Brunhouse, R. S., and Foy, P. Thermal Spray
Mustaleski, T. M., and Kotecki, D. J. An IIW Primer, (Feb)
28
Na, J. K. Phased Array Testing of Resistance Spot Welds,
(Sept) 36
Naz, N., Baloch, R. A., Ahmed, B., and Tariq, F. How Mul-
Noruk, J., and J.P. Boillot Good Design Plus Early In-
spection Equals High Productivity, (Sept) 26
Oliveira, N., Ramirez, A. J., Stroppa, D. G., Hermenegildo, T.,
and Unfried S., J. The Effects of Rework on Brazing,
DECEMBER 2012 100
(Feb) 41
Ott, D., and Kinos, J. P. A Holistic Study of Automated
Plasma System Costs, (Nov) 28
Ott, D., and Rice, T. Ten Signs Youre Ready for an Auto-
mated Plasma Retrofit, (Feb) 34
Packard, K., and Cuhel, J. New Processes and Metal Cored
Wire Combine to Improve Pipe Fabrication, (June) 68
Packard, K., Railling, D., and Farkas, B. From the Lab to
Pelky, B. Build Your Own Campfire Grill, (March) 48
Peters, T., and Glynn, T. Choosing a Surface Coating Tech-
nology, (Sept) 32
Petrasek, D., Sattler, S., Benatar, A., Shapiro, A., Eckardt, T.,
and Hanhold, B. Evaluating Low-Temperature Brazing
Phillips, D. Undertaking a Complex Underwater Repair,
(March) 32
Postlethwaite, D. Community College Welding Program
Update, (April) 33
Purslow, M. A. Reducing the Ecological Impact of Arc
Welding, (Dec) 24
Railling, D., Farkas, B., and Packard, K. From the Lab to
Ramirez, A. J., Stroppa, D. G., Hermenegildo, T., Unfried S.,
J., Oliveira, N. The Effects of Rework on Brazing, (Feb)
41
Reilly, M. Putting Your Best Foot Forward on the Job, (Au-
gust) 54
Rethmeier, M., Gebhardt, M. O., and Gumenyuk, A. Hy-
Rice, T., and Ott, D. Ten Signs Youre Ready for an Auto-
mated Plasma Retrofit, (Feb) 34
Sattler, S., Benatar, A., Shapiro, A., Eckardt, T., Hanhold, B.,
and Petrasek, D. Evaluating Low-Temperature Brazing
Schindler, H. J., Leinenbach, C., Koster, M., and Lis, A. De-
Schreier, G. Selecting Fume Collectors for Welding Appli-
cations, (Dec) 73
Sciammarella, F. Moving Laser Research from the Lab to
Industry, (May) 50
Scotchmer, N., and Chan, K. Whats New for Welding Alu-
minum in the Auto Industry, (Jan) 34
Shapiro, A., Eckardt, T., Hanhold, B., Petrasek, D., Sattler, S.,
and Benatar, A. Evaluating Low-Temperature Brazing
Sprinkle, J. Tips for Preparing and Selecting Tungsten Elec-
trodes, (June) 111
Stroppa, D. G., Hermenegildo, T., Unfried S., J., Oliveira, N.,
and Ramirez, A. J. The Effects of Rework on Brazing,
(Feb) 41
Stupczy, F., Bulan, J., and Cull, E. Safeguarding Your Vi-
sion, (Aug) 58
Tariq, F., Naz, N., Baloch, R. A., and Ahmed, B. How Mul-
Turpin, B., Danks, D., Callaghan, J., and Wood, W. Narrow
Unfried S., J., Oliveira, N., Ramirez, A. J., Stroppa, D. G., and
Hermenegildo, T. The Effects of Rework on Brazing,
(Feb) 41
Vandenberg, M., and Williams, B. Equipping Welding Cells
to Fabricate Wind Towers, (Jan) 48
Vitor, E., Lopes Da Silva, R. A., Gonalves de Mello Jr., A.,
and Crisi, G. S. How Often Can Joints Be Cut and
Wehrman, B. Is Small Town America the New Face in Weld-
ing?, (May) 44
Williams, B., and Vandenberg, M. Equipping Welding Cells
to Fabricate Wind Towers, (Jan) 48
Wood, W., Turpin, B., Danks, D., and Callaghan, J. Narrow
Woodward, H., Campbell, K., Cullison, A., and Johnsen, M.
R. Welding Researchs New Talent Pool, (May) 33
Woodward, H. M. AWS Enters New Era with World Head-
quarters, (Nov) 42
Woodward, H. Welded Benches for Fun and Fund-Raising,
(March) 93
101 WELDING JOURNAL
Adhesive Placement in Weld-Bonding Multiple Stacks of Steel
Sheets J. Shen, Y. S. Zhang, X. M. Lai, and P. C. Wang,
(Feb) 59-s
Aluminum 2024, Ultrasonic Soldering of Shape Memory NiTi
to R. Hahnlen, G. Fox, and M. Dapino, (Jan) 1-s
Aluminum Alloys with High-Power Diode Laser, Weldability of
J. M. Snchez-Amaya, Z. Boukha, M. R. Amaya-Vzquez,
and F. J. Botana
Aluminum Sheet in the Automotive Industry A 30 Year His-
tory, Joining J. E. Gould, (Jan) 23-s
An Evaluation of the Cross-Tension Test of Resistance Spot
Welds in High-Strength Dual-Phase Steels D. J. Radakovic
and M. Tumuluru, (Jan) 8-s
Analysis of Thermal Cycle during Multipass Arc Welding C.
S. Pathak, L. G. Navale, A. D. Sahasrabudhe, and M. J.
Rathod, (May) 149-s
Arc Characteristics in Pulsed-GMA Welding with Acute Groove
Angles R-H. Kim, G-D. Choi, C-H. Kim, D-W. Cho, and
S-J. Na, (April) 101-s
Artificial Neural Network Prediction of Weld Geometry Per-
formed Using GMAW with Alternating Shielding Gases
S. W. Campbell, A. M. Galloway, and N. A. McPherson,
(June) 174-s
Austenitic Stainless Steel Solidification Modes Characteriza-
tion, Reagent Selection in M. A. Valiente Bermejo, (May)
133-s
Automotive Industry A 30 Year History, Joining Aluminum
Sheet in the J. E. Gould, (Jan) 23-s
Beam Diagnostic Tools, Identifying Performance Differences in
Transmissive and Reflective Laser Optics Using J. Blecher,
T. A. Palmer, S. M. Kelly, and R. P. Martukanitz, (July) 204-s
Brazing of Copper-Beryllium Alloy (C17200) Using Silver-
Based Interlayer, Partial Transient Liquid Phase Diffusion
M. M. Atabaki, (Feb) 35-s
Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P, Study on
Vacuum Z. Zhong, J. Zhou, X. Shen, and X. Ling, (Sept)
237-s
Characterization of Three-Dimensional Weld Pool Surface in
GTAW W. Zhang, Y. Liu, X. Wang, and Y. M. Zhang,
(July) 195-s
Composite and AISI 1030, Continuous Drive Friction Welding
of Al/SiC S. elik and D. Gne, (Aug) 222-s
Consumable on the Properties of Gas Metal Arc Welded EN
1.4003-Type Stainless Steel, Effect of the E. Taban, A.
Dhooge, E. Kaluc, and E. Deleu, (Aug) 213-s
Continuous Cooling Transformation Behavior in the CGHAZ
of Naval Steels X. Yue, J. C. Lippold, B. T. Alexandrov, and
S. S. Babu, (March) 67-s
Continuous Drive Friction Welding of Al/SiC Composite and
AISI 1030 S. elik and D. Gne, (Aug) 222-s
Copper-Beryllium Alloy (C17200) Using Silver-Based Inter-
layer, Partial Transient Liquid Phase Diffusion Brazing of
Cracking and Ductility-Dip Cracking, Susceptibility of IN740 to
HAZ Liquation J. E. Ramirez, (April) 122-s
Cracking in Welding High-Strength Pipeline Steel with Cellu-
losic Electrodes, Effects of Welding Direction and Position on
Susceptibility to Weld Transverse S. Sarafan, F. M. Alek
Ghaini, and E. Rahimi, (June) 182-s
Cracking Susceptibility of Ni-Based Superalloys as a Function of
Strain Rate, Temperature, and Alloy Composition, Strain-
Age D. A. Metzler, (June) 163-s
Design Considerations of Graded Transition Joints for Welding
Dissimilar Alloys G. J. Brentrup, B. S. Snowden, J. N.
DuPont, and J. L. Grenestedt, (Sept) 252-s
Design of Experiment and Goal Programming Application for
the GMAW Process Y. T. I, F. Elaldi, F. Pakdil, and N. E.
I. Pek, (April) 106-s
Developing an Alternative Heat Indexing Equation for FSW
J. A. Querin and J. A. Schneider, (March) 76-s
Development of an Oxyrutile Electrode for Wet Welding V.
R. Santos, M. J. Monteiro, F. C. Rizzo, A. Q. Bracarense, E.
C. P. Pessoa, R. R. Marinho, and L. A. Vieira, (Dec) 319-s
Dissimilar Alloys, Design Considerations of Graded Transition
Joints for Welding G. J. Brentrup, B. S. Snowden, J. N.
Dissimilar Metal Joints, Fatigue Behavior of Electron Beam
Welded A. alik, M. S. Karaka, and R. Varol, (Feb) 50-s
Double Stage Plasma Arc Pipe Welding Process X. R. Li, Z.
Shao, and Y. M. Zhang, (Dec) 346-s
Dual-Phase Steels, An Evaluation of the Cross-Tension Test of
Resistance Spot Welds in High-Strength D. J. Radakovic
Ductility-Dip Cracking, Susceptibility of IN740 to HAZ Liqua-
tion Cracking and J. E. Ramirez, (April) 122-s
Effect of the Consumable on the Properties of Gas Metal Arc
Welded EN 1.4003-Type Stainless Steel E. Taban, A.
Effect of Titanium Content on Microstructure and Wear Re-
sistance of Fe-Cr-C Hardfacing Layers Y. F. Zhou, Y. L.
Yang, D. Li, J. Yang, Y. W. Jiang, X. J. Ren, and Q. X. Yang,
(Aug) 229-s
Effects of FSW Parameters on Joint Properties of AlMg3 Alloy
Z. Barlas and U. Ozsarac, (Jan) 16-s
Effects of Welding Direction and Position on Susceptibility to
Weld Transverse Cracking in Welding High-Strength Pipeline
Steel with Cellulosic Electrodes S. Sarafan, F. M. Alek
Electrode for Wet Welding, Development of an Oxyrutile V.
Electron Beam Welded Dissimilar Metal Joints, Fatigue Behav-
ior of A. alik, M. S. Karaka, and R. Varol, (Feb) 50-s
Estimating the Cooling Rates of a Spot Welding Nugget in
Stainless Steel Y. Zhang, T.-J. Ma, H.-X. Xie, Y.-M. Tan,
and P.-Y. Li, (Sept) 247-s
Failure Mode Transition in AISI 304 Resistance Spot Welds
M. Pouranvari and S. P. H. Marashi, (Nov) 303-s
Fatigue Behavior of Electron Beam Welded Dissimilar Metal
Joints A. alik, M. S. Karaka, and R. Varol, (Feb) 50-s
Ferrite Determination in Stainless Steels, Predictive and Meas-
urement Methods for Delta M. A. Valiente Bermejo,
(April) 113-s
Fluid Flow and Solidification in Welding: Three Decades of Fun-
damental Research at the University of Wisconsin S. Kou,
(Nov) 287-s
Fracture Toughness of Simulated Heat-Affected Zones in
NUCu-140 Steel B. M. Leister and J. N. DuPont, (Feb)
53-s
Friction Stir Welded Joints, Improvement of Formation Quality
for R.-D. Fu, R.-C. Sun, F.-C. Zhang, and H.-J. Liu, (June)
169-s
Friction Welding of Al/SiC Composite and AISI 1030, Continu-
ous Drive S. elik and D. Gne, (Aug) 222-s
Part 2 RESEARCH
SUPPLEMENT SUBJECT INDEX
VOLUME 91
DECEMBER 2012 102
FSW Parameters on Joint Properties of AlMg3 Alloy, Effects of
Fundamental Research at the University of Wisconsin, Fluid
Flow and Solidification in Welding: Three Decades of S.
Kou, (Nov) 287-s
Gas Tungsten Arc Welding Using an Arcing Wire J. S. Chen,
Y. Lu, X. R. Li, and Y. M. Zhang, (Oct) 261-s
Gases, Artificial Neural Network Prediction of Weld Geometry
Performed Using GMAW with Alternating Shielding S.
W. Campbell, A. M. Galloway, and N. A. McPherson, (June)
174-s
Glass to Kovar Alloy with Cu-Ni-Sn-P, Study on Vacuum
Brazing of Z. Zhong, J. Zhou, X. Shen, and X. Ling,
(Sept) 237-s
GMAW, Ultrasonic Wave Assisted Y. Y. Fan, C. L. Yang, S.
B. Lin, C. L. Fan, and W. G. Liu, (March) 91-s
GTAW, Characterization of Three-Dimensional Weld Pool Sur-
face in W. Zhang, Y. Liu, X. Wang, and Y. M. Zhang, (July)
195-s
Hardfacing Layers, Effect of Titanium Content on Microstruc-
ture and Wear Resistance of Fe-Cr-C Y. F. Zhou, Y. L.
(Aug) 229-s
Heat-Affected Zones in NUCu-140 Steel, Fracture Toughness
of Simulated B. M. Leister and J. N. DuPont, (Feb) 53-s
Heat Indexing Equation for FSW, Developing an Alternative
J. A. Querin and J. A. Schneider, (March) 76-s
Hexavalent Chromium from Stainless Steel Welding, Selecting
Processes to Minimize M. Keane, A. Siert, S. Stone, B.
Chen, J. Slaven, A. Cumpston, and J. Antonini, (Sept) 241-s
High-Frequency Induction Welded Pipe, Numerical Analysis of
a Y. Han and E. L. Yu, (Oct) 270-s
Human Welder Response to 3D Weld Pool Surface: Part 1
Principles, Modeling of W. J. Zhang and Y. M. Zhang,
(Nov) 310-s
Human Welder Response to 3D Weld Pool Surface: Part II
Results and Analysis, Modeling of W. J. Zhang and Y. M.
Zhang, (Dec) 329-s
Identifying Performance Differences in Transmissive and Re-
flective Laser Optics Using Beam Diagnostic Tools J.
Blecher, T. A. Palmer, S. M. Kelly, and R. P. Martukanitz,
(July) 204-s
Improvement of Formation Quality for Friction Stir Welded
Joints R.-D. Fu, R.-C. Sun, F.-C. Zhang, and H.-J. Liu,
(June) 169-s
Improving Supermartensitic Stainless Steel Weld Metal Tough-
ness S. Zappa, H. G. Svoboda, N. M. Ramini de Rissone,
E. S. Surian, and L. A. de Vedia, (March) 83-s
Joining Aluminum Sheet in the Automotive Industry A 30
Year History J. E. Gould, (Jan) 23-s
Laser-Enhanced GMAW, Nonlinear Modeling of Dynamic
Metal Transfer in Y. Huang, Y. Shao, and Y. M. Zhang,
(May) 140-s
Laser Optics Using Beam Diagnostic Tools, Identifying Per-
formance Differences in Transmissive and Reflective J.
Blecher, T. A. Palmer, S. M. Kelly, and R. P. Martukanitz,
(July) 204-s
Laser, Weldability of Aluminum Alloys with High-Power Diode
and F. J. Botana
Modeling of Human Welder Response to 3D Weld Pool Surface:
Part 1 Principles W. J. Zhang and Y. M. Zhang, (Nov)
310-s
Modeling of Human Welder Response to 3D Weld Pool Surface:
Part II Results and Analysis W. J. Zhang and Y. M.
Zhang, (Dec) 329-s
Naval Steels, Continuous Cooling Transformation Behavior in
the CGHAZ of X. Yue, J. C. Lippold, B. T. Alexandrov,
and S. S. Babu, (March) 67-s
Neural Network Prediction of Weld Geometry Performed
Using GMAW with Alternating Shielding Gases, Artificial
S. W. Campbell, A. M. Galloway, and N. A. McPherson,
(June) 174-s
Nonlinear Modeling of Dynamic Metal Transfer in Laser-
Enhanced GMAW Y. Huang, Y. Shao, and Y. M. Zhang,
(May) 140-s
Numerical Analysis of a High-Frequency Induction Welded Pipe
Y. Han and E. L. Yu, (Oct) 270-s
Partial Transient Liquid Phase Diffusion Brazing of Copper-
Beryllium Alloy (C17200) Using Silver-Based Interlayer
Pipe, Numerical Analysis of a High-Frequency Induction
Welded Y. Han and E. L. Yu, (Oct) 270-s
Pipe Welding Process, Double Stage Plasma Arc X. R. Li, Z.
Pipeline Steel with Cellulosic Electrodes, Effects of Welding Di-
rection and Position on Susceptibility to Weld Transverse
Cracking in Welding High-Strength S. Sarafan, F. M. Alek
Plasma Arc Pipe Welding Process, Double Stage X. R. Li, Z.
Predictive and Measurement Methods for Delta Ferrite Deter-
mination in Stainless Steels M. A. Valiente Bermejo,
(April) 113-s
Programming Application for the GMAW Process, Design of
Experiment and Goal Y. T. I, F. Elaldi, F. Pakdil, and N.
E. I. Pek, (April) 106-s
Properties of AlMg3 Alloy, Effects of FSW Parameters on Joint
Pulsed-GMA Welding with Acute Groove Angles, Arc Charac-
teristics in R-H. Kim, G-D. Choi, C-H. Kim, D-W. Cho, and
S-J. Na, (April) 101-s
Reagent Selection in Austenitic Stainless Steel Solidification
Modes Characterization M. A. Valiente Bermejo, (May)
133-s
Resistance Spot Welded TRIP Steel, Second Pulse Current in
Effects on the Microstructure and Mechanical Behavior V.
H. Baltazar Hernandez, Y. Okita, and Y. Zhou, (Oct) 278-s
Resistance Spot Welds, Failure Mode Transition in AISI 304
Resistance Spot Welds in High-Strength Dual-Phase Steels, An
Evaluation of the Cross-Tension Test of D. J. Radakovic
Robotic Welding Platform, Theoretical and Empirical Valida-
tion of a Mobile J. Stacy and S. Canfield, (Dec) 338-s
Scaling Themocapillary Weld Pool Shape and Transport Vari-
ables in Metals P. S. Wei and H. J. Liu, (July) 187-s
Second Pulse Current in Resistance Spot Welded TRIP Steel
Selecting Processes to Minimize Hexavalent Chromium from
Stainless Steel Welding M. Keane, A. Siert, S. Stone, B.
Soldering of Shape Memory NiTi to Aluminum 2024, Ultrasonic
R. Hahnlen, G. Fox, and M. Dapino, (Jan) 1-s
Solidification in Welding: Three Decades of Fundamental Re-
search at the University of Wisconsin, Fluid Flow and S.
Kou, (Nov) 287-s
Spot Welding Nugget in Stainless Steel, Estimating the Cooling
Rates of a Y. Zhang, T.-J. Ma, H.-X. Xie, Y.-M. Tan, and
P.-Y. Li, (Sept) 247-s
Spot Welds in High-Strength Dual-Phase Steels, An Evaluation
Alek Ghaini, F. M., Rahimi, E., and Sarafan, S. Effects of
Welding Direction and Position on Susceptibility to Weld
Transverse Cracking in Welding High-Strength Pipeline
Steel with Cellulosic Electrodes, (June) 182-s
Alexandrov, B. T., Babu, S. S., Yue, X., and Lippold, J. C.
Continuous Cooling Transformation Behavior in the
CGHAZ of Naval Steels, (March) 67-s
Amaya-Vzquez, M. R., Botana, F. J., Snchez-Amaya, J. M.,
and Boukha, Z. Weldability of Aluminum Alloys with
High-Power Diode Laser, (May) 155-s
Antonini, J., Keane, M., Siert, A., Stone, S., Chen, B., Slaven,
J., and Cumpston, A. Selecting Processes to Minimize
Hexavalent Chromium from Stainless Steel Welding,
(Sept) 241-s
Atabaki, M. M. Partial Transient Liquid Phase Diffusion
Brazing of Copper-Beryllium Alloy (C17200) Using Silver-
Based Interlayer, (Feb) 35-s
Babu, S. S., Yue, X., Lippold, J. C., and Alexandrov, B. T.
Baltazar Hernandez, V. H., Okita, Y., and Zhou, Y. Second
Pulse Current in Resistance Spot Welded TRIP Steel Ef-
fects on the Microstructure and Mechanical Behavior,
(Oct) 278-s
Barlas, Z., and Ozsarac, U. Effects of FSW Parameters on
Joint Properties of AlMg3 Alloy, (Jan) 16-s
Blecher, J., Palmer, T. A., Kelly, S. M., and Martukanitz, R. P.
Identifying Performance Differences in Transmissive
and Reflective Laser Optics Using Beam Diagnostic Tools,
(July) 204-s
Botana, F. J., Snchez-Amaya, J. M., Boukha, Z., and Amaya-
Vzquez, M. R. Weldability of Aluminum Alloys with
Boukha, Z., Amaya-Vzquez, M. R., Botana, F. J., and
103 WELDING JOURNAL
AUTHORS FOR RESEARCH SUPPLEMENTS
of the Cross-Tension Test of Resistance D. J. Radakovic
Stainless Steel, Effect of the Consumable on the Properties of
Gas Metal Arc Welded EN 1.4003-Type E. Taban, A.
Stainless Steel, Estimating the Cooling Rates of a Spot Welding
Nugget in Y. Zhang, T.-J. Ma, H.-X. Xie, Y.-M. Tan, and
P.-Y. Li, (Sept) 247-s
Stainless Steel Welding, Selecting Processes to Minimize Hexa-
valent Chromium from M. Keane, A. Siert, S. Stone, B.
Stainless Steels, Predictive and Measurement Methods for Delta
Ferrite Determination in M. A. Valiente Bermejo, (April)
113-s
Strain-Age Cracking Susceptibility of Ni-Based Superalloys as a
Function of Strain Rate, Temperature, and Alloy Composi-
tion D. A. Metzler, (June) 163-s
Study on Vacuum Brazing of Glass to Kovar Alloy with Cu-Ni-
Sn-P Z. Zhong, J. Zhou, X. Shen, and X. Ling, (Sept) 237-
s
Superalloys as a Function of Strain Rate, Temperature, and
Alloy Composition, Strain-Age Cracking Susceptibility of Ni-
Based D. A. Metzler, (June) 163-s
Supermartensitic Stainless Steel Weld Metal Toughness, Im-
proving S. Zappa, H. G. Svoboda, N. M. Ramini de Ris-
sone, E. S. Surian, and L. A. de Vedia, (March) 83-s
Surface: Part 1 Principles, Modeling of Human Welder Re-
sponse to 3D Weld Pool W. J. Zhang and Y. M. Zhang,
(Nov) 310-s
Surface: Part II Results and Analysis, Modeling of Human
Welder Response to 3D Weld Pool W. J. Zhang and Y. M.
Zhang, (Dec) 329-s
Susceptibility of IN740 to HAZ Liquation Cracking and Ductil-
ity-Dip Cracking J. E. Ramirez, (April) 122-s
Theoretical and Empirical Validation of a Mobile Robotic Weld-
ing Platform J. Stacy and S. Canfield, (Dec) 338-s
Thermal Cycle during Multipass Arc Welding, Analysis of C.
S. Pathak, L. G. Navale, A. D. Sahasrabudhe, and M. J.
Rathod, (May) 149-s
Thermocapillary Weld Pool Shape and Transport Variables in
Metals, Scaling P. S. Wei and H. J. Liu, (July) 187-s
Titanium Content on Microstructure and Wear Resistance of
Fe-Cr-C Hardfacing Layers, Effect of Y. F. Zhou, Y. L.
(Aug) 229-s
Toughness of Simulated Heat-Affected Zones in NUCu-140
Steel, Fracture B. M. Leister and J. N. DuPont, (Feb) 53-
s
Toughness, Improving Supermartensitic Stainless Steel Weld
Metal S. Zappa, H. G. Svoboda, N. M. Ramini de Rissone,
E. S. Surian, and L. A. de Vedia, (March) 83-s
Transfer in Laser-Enhanced GMAW, Nonlinear Modeling of
Dynamic Metal Y. Huang, Y. Shao, and Y. M. Zhang,
(May) 140-s
Transformation Behavior in the CGHAZ of Naval Steels, Con-
tinuous Cooling X. Yue, J. C. Lippold, B. T. Alexandrov,
and S. S. Babu, (March) 67-s
Transition in AISI 304 Resistance Spot Welds, Failure Mode
Transition Joints for Welding Dissimilar Alloys, Design Consid-
erations of Graded G. J. Brentrup, B. S. Snowden, J. N.
TRIP Steel, Second Pulse Current in Resistance Spot Welded
Tungsten Arc Welding Using an Arcing Wire, Gas J. S. Chen,
Y. Lu, X. R. Li, and Y. M. Zhang, (Oct) 261-s
Ultrasonic Soldering of Shape Memory NiTi to Aluminum 2024
R. Hahnlen, G. Fox, and M. Dapino, (Jan) 1-s
Ultrasonic Wave Assisted GMAW Y. Y. Fan, C. L. Yang, S.
B. Lin, C. L. Fan, and W. G. Liu, (March) 91-s
Validation of a Mobile Robotic Welding Program, Theoretical
and Empirical J. Stacy and S. Canfield, (Dec) 338-s
Weldability of Aluminum Alloys with High-Power Diode Laser
and F. J. Botana, (May) 155-s
Weld-Bonding Multiple Stacks of Steel Sheets, Adhesive Place-
ment in J. Shen, Y. S. Zhang, X. M. Lai, and P. C. Wang,
(Feb) 59-s
Wet Welding, Development of an Oxyrutile Electrode for V.
Snchez-Amaya, J. M. Weldability of Aluminum Alloys
with High-Power Diode Laser, (May) 155-s
Bracarense, A. Q., Pessoa, E. C. P., Marinho, R. R., Vieira, L.
A., Santos, V. R., Monteiro, M. J., and Rizzo, F. C. De-
velopment of an Oxyrutile Electrode for Wet Welding,
(Dec) 319-s
Brentrup, G. J., Snowden, B. S., DuPont, J. N., and Grenest-
edt, J. L. Design Considerations of Graded Transition
Joints for Welding Dissimilar Alloys, (Sept) 252-s
alik, A., Karaka, M. S., and Varol, R. Fatigue Behavior
of Electron Beam Welded Dissimilar Metal Joints, (Feb)
50-s
Campbell, S. W., Galloway, A. M., and McPherson, N. A.
Artificial Neural Network Prediction of Weld Geometry
Performed Using GMAW with Alternating Shielding
Gases, (June) 174-s
Canfield, S., and Stacy, J. Theoretical and Empirical Vali-
dation of a Mobile Robotic Welding Platform, (Dec) 338-s
elik, S., and Gne, D. Continuous Drive Friction Weld-
ing of Al/SiC Composite and AISI 1030, (Aug) 222-s
Chen, B., Slaven, J., Cumpston, A., Antonini, J., Keane, M.,
Siert, A., and Stone, S. Selecting Processes to Minimize
(Sept) 241-s
Chen, J. S., Lu, Y., Li, X. R., and Zhang, Y. M. Gas Tung-
sten Arc Welding Using an Arcing Wire, (Oct) 261-s
Cho, D-W., Na, S-J., Kim, R-H., Choi, G-D., and Kim, C-H.
Arc Characteristics in Pulsed-GMA Welding with Acute
Groove Angles, (April) 101-s
Choi, G-D., Kim, C-H., Cho, D-W., Na, S-J., and Kim, R-H.
Cumpston, A., Antonini, J., Keane, M., Siert, A., Stone, S.,
Chen, B., and Slaven, J. Selecting Processes to Minimize
(Sept) 241-s
Dapino, M., Hahnlen, R., and Fox, G. Ultrasonic Solder-
ing of Shape Memory NiTi to Aluminum 2024, (Jan) 1-s
De Vedia, L. A., Zappa, S., Svoboda, H. G., Ramini de Ris-
sone, N. M., and Surian, E., S. Improving Supermarten-
sitic Stainless Steel Weld Metal Toughness, (March) 83-s
Deleu, E., Taban, E., Dhooge, A., and Kaluc, E. Effect of
the Consumable on the Properties of Gas Metal Arc
Welded EN 1.4003-Type Stainless Steel, (Aug) 213-s
Dhooge, A., Kaluc, E., Deleu, E., and Taban, E. Effect of
DuPont, J. N., and Leister, B. M. Fracture Toughness of
Simulated Heat-Affected Zones in NUCu-140 Steel, (Feb)
53-s
DuPont, J. N., Grenestedt, J. L., Brentrup, G. J., and Snow-
den, B. S. Design Considerations of Graded Transition
Elaldi, F., Pakdil, F., Pek, N. E. I., and I, Y. T. Design of
Experiment and Goal Programming Application for the
GMAW Process, (April) 106-s
Fan, C. L., Liu, W. G., Fan, Y. Y., Yang, C. L., and Lin, S. B.
Ultrasonic Wave Assisted GMAW, (March) 91-s
Fan, Y. Y., Yang, C. L., Lin, S. B., Fan, C. L., and Liu, W. G.
Fox, G., Dapino, M., and Hahnlen, R. Ultrasonic Solder-
Fu, R.-D., Sun, R.-C., Zhang, F.-C., and Liu, H.-J. Im-
provement of Formation Quality for Friction Stir Welded
Joints, (June) 169-s
Galloway, A. M., McPherson, N. A., and Campbell, S. W
Gases, (June) 174-s
Gould, J. E. Joining Aluminum Sheet in the Automotive
Industry A 30 Year History, (Jan) 23-s
Grenestedt, J. L., Brentrup, G. J., Snowden, B. S., and
DuPont, J. N. Design Considerations of Graded Transi-
tion Joints for Welding Dissimilar Alloys, (Sept) 252-s
Gne, D., and elik, S. Continuous Drive Friction Weld-
ing of AI/SiC Composite and AISI 1030, (Aug) 222-s
Hahnlen, R., Fox, G., and Dapino, M. Ultrasonic Solder-
Han, Y., and Yu, E. L. Numerical Analysis of a High-Fre-
quency Induction Welded Pipe, (Oct) 270-s
Huang, Y., Shao, Y., and Zhang, Y. M. Nonlinear Model-
ing of Dynamic Metal Transfer in Laser-Enhanced GMAW,
(May) 140-s
I, Y. T., Elaldi, F., Pakdil, F., and Pek, N. E. I. Design of
Jiang, Y. W., Ren, X. J., Yang, Q. X., Zhou, Y. F., Yang, Y. L.,
Li, D., and Yang, J. Effect of Titanium Content on Mi-
crostructure and Wear Resistance of Fe-Cr-C Hardfacing
Layers, (Aug) 229-s
Kaluc, E., Deleu, E., Taban, E., and Dhooge, A. Effect of
Karaka, M. S., Varol, R., and alik, A. Fatigue Behavior
50-s
Keane, M., Siert, A., Stone, S., Chen, B., Slaven, J., Cumpston,
A., and Antonini, J. Selecting Processes to Minimize
(Sept) 241-s
Kelly, S. M., Martukanitz, R. P., Blecher, J., and Palmer, T. A.
(July) 204-s
Kim, C-H., Cho, D-W., Na, S-J., Kim, R-H., and Choi, G-D.
Kim, R-H., Choi, G-D., Kim, C-H., Cho, D-W., and Na, S-J.
Kou, S. Fluid Flow and Solidification in Welding: Three
Decades of Fundamental Research at the University of
Wisconsin, (Nov) 287-s
Lai, X. M., Wang, P. C., Shen, J., and Zhang, Y. S. Adhe-
sive Placement in Weld-Bonding Multiple Stacks of Steel
Sheets, (Feb) 59-s
Leister, B. M., and DuPont, J. N. Fracture Toughness of
Simulated Heat-Affected Zones in NUCu-140 Steel, (Feb)
53-s
Li, D., Yang, J., Jiang, Y. W., Ren, X. J., Yang, Q. X., Zhou, Y.
F., and Yang, Y. L. Effect of Titanium Content on Mi-
Layers, (Aug) 229-s
Li, P.-Y., Zhang, Y., Ma, T.-J., Xie, H.-X., and Tan, Y.-M.
Stainless Steel, (Sept) 247-s
Li, X. R., Shao, Z., and Zhang, Y. M. Double Stage Plasma
Arc Pipe Welding Process, (Dec) 346-s
Li, X. R., Zhang, Y. M., Chen, J. S., and Lu, Y. Gas Tung-
Lin, S. B., Fan, C. L., Liu, W. G., Fan, Y. Y., and Yang, C. L.
DECEMBER 2012 104
Ling, X., Zhong, Z., Zhou, J., and Shen, X. Study on Vac-
uum Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P,
(Sept) 237-s
Lippold, J. C., Alexandrov, B. T., Babu, S. S., and Yue, X.
Liu, H. J., and Wei, P. S. Scaling Themocapillary Weld Pool
Shape and Transport Variables in Metals, (July) 187-s
Liu, H.-J., Fu, R.-D., Sun, R.-C., and Zhang, F.-C. Im-
Liu, W. G., Fan, Y. Y., Yang, C. L., Lin, S. B., and Fan, C. L.
Liu, Y., Wang, X., Zhang, Y. M., and Zhang, W. Charac-
terization of Three-Dimensional Weld Pool Surface in
GTAW, (July) 195-s
Lu, Y., Li, X. R., Zhang, Y. M., and Chen, J. S. Gas Tung-
Ma, T.-J., Xie, H.-X., Tan, Y.-M., Li, P.-Y., and Zhang, Y.
Marashi, S. P. H., and Pouranvari, M. Failure Mode Transi-
tion in AISI 304 Resistance Spot Welds, (Nov) 303-s
Marinho, R. R., Vieira, L. A., Santos, V. R., Monteiro, M. J.,
Rizzo, F. C., Bracarense, A. Q., and Pessoa, E. C. P. De-
(Dec) 319-s
Martukanitz, R. P., Blecher, J., Palmer, T. A., and Kelly, S. M.
(July) 204-s
McPherson, N. A., Campbell, S. W., and Galloway, A. M.
Gases, (June) 174-s
Metzler, D. A. Strain-Age Cracking Susceptibility of Ni-
Based Superalloys as a Function of Strain Rate, Tempera-
ture, and Alloy Composition, (June) 163-s
Monteiro, M. J., Rizzo, F. C., Bracarense, A. Q., Pessoa, E. C.
P., Marinho, R. R., Vieira, L. A., and Santos, V. R. De-
(Dec) 319-s
Na, S-J., Kim, R-H., Choi, G-D., Kim, C-H., and Cho, D-W.
Navale, L. G., Sahasrabudhe, A. D., Rathod, M. J., and
Pathak, C. S. Analysis of Thermal Cycle during Multi-
pass Arc Welding, (May) 149-s
Okita, Y., Zhou, Y., and Baltazar Hernandez, V. H. Second
(Oct) 278-s
Ozsarac, U., and Barlas, Z. Effects of FSW Parameters on
Joint Properties of AlMg3 Alloy, (Jan) 16-s
Pakdil, F., Pek, N. E. I., I, Y. T., and Elaldi, F. Design of
Palmer, T. A., Kelly, S. M., Martukanitz, R. P., and Blecher, J.
(July) 204-s
Pathak, C. S., Navale, L. G., Sahasrabudge, A. D., and Rathod,
M. J. Analysis of Thermal Cycle during Multipass Arc
Welding, (May) 149-s
Pek, N. E. I., I, Y. T., Elaldi, F., and Pakdil, F. Design of
Pessoa, E. C. P., Marinho, R. R., Vieira, L. A., Santos, V. R.,
Monteiro, M. J., Rizzo, F. C., and Bracarense, A. Q. De-
(Dec) 319-s
Pouranvari, M., and Marashi, S. P. H. Failure Mode Transi-
tion in AISI 304 Resistance Spot Welds, (Nov) 303-s
Querin, J. A., and Schneider, J. A. Developing an Alterna-
tive Heat Indexing Equation for FSW, (March) 76-s
Radakovic, D. J., and Tumuluru, M. An Evaluation of the
Cross-Tension Test of Resistance Spot Welds in High-
Strength Dual-Phase Steels, (Jan) 8-s
Rahimi, E., Sarafan, S., and Alek Ghaini, F. M. Effects of
Ramini de Rissone, N. M., Surian, E. S., De Vedia, L. A.,
Zappa, S., and Svoboda, H. G. Improving Supermarten-
sitic Stainless Steel Weld Metal Toughness, (March) 83-s
Ramirez, J. E. Susceptibility of IN740 to HAZ Liquation
Cracking and Ductility-Dip Cracking, (April) 122-s
Rathod, M. J., Pathak, C. S., Navale, L. G., and Sahasrabudhe,
A. D. Analysis of Thermal Cycle during Multipass Arc
Ren, X. J., Yang, Q. X., Zhou, Y. F., Yang, Y. L., Li, D., Yang,
J., and Jiang, Y. W. Effect of Titanium Content on Mi-
Layers, (Aug) 229-s
Rizzo, F. C., Bracarense, A. Q., Pessoa, E. C. P., Marinho, R.
R., Vieira, L. A., Santos, V. R., and Monteiro, M. J. De-
(Dec) 319-s
Sahasrabudhe, A. D., Rathod, M. J., Pathak, C. S., and Navale,
L. G. Analysis of Thermal Cycle during Multipass Arc
Snchez-Amaya, J. M., Boukha, Z., Amaya-Vzquez, M. R.,
and Botana, F. J. Weldability of Aluminum Alloys with
Santos, V. R., Monteiro, M. J., Rizzo, F. C., Bracarense, A. Q.,
Pessoa, E. C. P., Marinho, R. R., and Vieira, L. A. De-
(Dec) 319-s
Sarafan, S., Alek Ghaini, F. M., and Rahimi, E. Effects of
Schneider, J. A., and Querin, J. A. Developing an Alterna-
tive Heat Indexing Equation for FSW, (March) 76-s
Shao, Y., Zhang, Y. M., and Huang, Y. Nonlinear Model-
(May) 140-s
Shao, Z., Zhang, Y. M., and Li, X. R. Double Stage Plasma
Shen, J., Zhang, Y. S., Lai, X. M., and Wang, P. C. Adhe-
Sheets, (Feb) 59-s
Shen, X., Ling, X., Zhong, Z., and Zhou, J. Study on Vac-
(Sept) 237-s
Siert, A., Stone, S., Chen, B., Slaven, J., Cumpston, A., An-
tonini, J., and Keane, M. Selecting Processes to Mini-
mize Hexavalent Chromium from Stainless Steel Welding,
(Sept) 241-s
Slaven, J., Cumpston, A., Antonini, J., Keane, M., Siert, A.,
Stone, S., and Chen, B. Selecting Processes to Minimize
105 WELDING JOURNAL
(Sept) 241-s
Snowden, B. S., DuPont, J. N., Grenestedt, J. L., and Bren-
trup, G. J. Design Considerations of Graded Transition
Stacy, J., and Canfield, S. Theoretical and Empirical Vali-
dation of a Mobile Robotic Welding Platform, (Dec) 338-s
Stone, S., Chen, B., Slaven, J., Cumpston, A., Antonini, J.,
Keane, M., and Siert, A. Selecting Processes to Minimize
(Sept) 241-s
Sun, R.-C., Zhang, F.-C., Liu, H.-J., and Fu, R.-D. Im-
Surian, E. S., De Vedia, L. A., Zappa, S., Svoboda, H. G., and
Ramini de Rissone, N. M. Improving Supermartensitic
Stainless Steel Weld Metal Toughness, (March) 83-s
Svoboda, H. G., Ramini de Rissone, N. M., Surian, E. S., De
Vedia, A., and Zappa, S. Improving Supermartensitic
Taban, E., Dhooge, A., Kaluc, E, and Deleu, E. Effect of
Tan, Y.-M., Li, P.-Y., Zhang, Y., Ma, T.-J., and Xie, H.-X.
Tumuluru, M., and Radakovic, D. J. An Evaluation of the
Cross-Tension Test of Resistance Spot Welds in High-
Strength Dual-Phase Steels, (Jan) 8-s
Valiente Bermejo, M. A. Predictive and Measurement
Methods for Delta Ferrite Determination in Stainless
Steels, (April) 113-s
Valiente Bermejo, M. A. Reagent Selection in Austenitic
Stainless Steel Solidification Modes Characterization,
(May) 133-s
Varol, R., alik, A., and Karakas, M. S. Fatigue Behavior
50-s
Vieira, L. A., Santos, V. R., Monteiro, M. J., Rizzo, F. C.,
Bracarense, A. Q., Pessoa, E. C. P., and Marinho, R. R.
Development of an Oxyrutile Electrode for Wet Welding,
(Dec) 319-s
Wang, P. C., Shen, J., Zhang, Y. S., and Lai, X. M. Adhe-
Sheets, (Feb) 59-s
Wang, X., Zhang, Y. M., Zhang, W., and Liu, Y. Charac-
GTAW, (July) 195-s
Wei, P. S., and Liu, H. J. Scaling Themocapillary Weld Pool
Shape and Transport Variables in Metals, (July) 187-s
Xie, H.-X., Tan, Y.-M., Li, P.-Y., Zhang, Y., and Ma, T.-J.
Yang, C. L., Lin, S. B., Fan, C. L., Liu, W. G., and Fan, Y. Y.
Yang, J., Jiang, Y. W., Ren, X. J., Yang, Q. X., Zhou, Y. F.,
Yang, Y. L., and Li, D. Effect of Titanium Content on
Microstructure and Wear Resistance of Fe-Cr-C Hardfac-
ing Layers, (Aug) 229-s
Yang, Q. X., Zhou, Y. F., Yang, Y. L., Li, D., Yang, J., Jiang,
Y. W., and Ren, X. J. Effect of Titanium Content on Mi-
Layers, (Aug) 229-s
Yang, Y. L., Li, D., Yang, J., Jiang, Y. W., Ren, X. J., Yang, Q.
X., and Zhou, Y. F. Effect of Titanium Content on Mi-
Layers, (Aug) 229-s
Yu, E. L., and Han, Y. Numerical Analysis of a High-Fre-
quency Induction Welded Pipe, (Oct) 270-s
Yue, X., Lippold, J. C., Alexandrov, B. T., and Babu, S. S.
Zappa, S., Svoboda, H. G., Ramini de Rissone, N. M., Surian,
E. S., and De Vedia, L. A. Improving Supermartensitic
Zhang, W., Liu, Y., Wang, X., and Zhang, Y. M. Charac-
GTAW, (July) 195-s
Zhang, F.-C., Liu, H.-J., Fu, R.-D., and Sun, R.-C. Im-
Zhang, W. J., and Zhang, Y. M. Modeling of Human
Welder Response to 3D Weld Pool Surface: Part 1 Prin-
ciples, (Nov) 310-s
Zhang, W. J., and Zhang, Y. M. Modeling of Human
Welder Response to 3D Weld Pool Surface: Part II Re-
sults and Analysis, (Dec) 329-s
Zhang, Y. M., and Zhang, W. J. Modeling of Human
Welder Response to 3D Weld Pool Surface: Part 1 Prin-
ciples, (Nov) 310-s
Zhang, Y. M., and Zhang, W. J. Modeling of Human
Welder Response to 3D Weld Pool Surface: Part II Re-
sults and Analysis, (Dec) 329-s
Zhang, Y. M., Chen, J. S., Lu, Y., and Li, X. R. Gas Tung-
Zhang, Y. M., Huang, Y., and Shao, Y. Nonlinear Model-
(May) 140-s
Zhang, Y. M., Li, X. R., and Shao, Z. Double Stage Plasma
Zhang, Y. M., Zhang, W., Liu, Y., and Wang, X. Charac-
GTAW, (July) 195-s
Zhang, Y., Ma, T.-J., Xie, H.-X., Tan, Y.-M., and Li, P.-Y.
Zhang, Y. S., Lai, X. M., Wang, P. C., and Shen, J. Adhe-
Sheets, (Feb) 59-s
Zhong, Z., Zhou, J., Shen, X., and Ling, X. Study on Vac-
(Sept) 237-s
Zhou, J., Shen, X., Ling, X., and Zhong, Z. Study on Vac-
(Sept) 237-s
Zhou, Y., Baltazar Hernandez, V. H., and Okita, Y. Second
(Oct) 278-s
Zhou, Y. F., Yang, Y. L., Li, D., Yang, J., Jiang, Y. W., Ren, X.
J., and Yang, Q. X. Effect of Titanium Content on Mi-
Layers, (Aug) 229-s
DECEMBER 2012 106
Bug-O Donates Modular Drive Equipment
to Hobart Institute of Welding Technology
A new piece of automated welding equipment that will en-
hance training demonstrations at the Hobart Institute of Weld-
ing Technology (HIWT) was recently donated by Bug-O Sys-
tems, Inc., Canonsburg, Pa. Jeff Nelson, a welding engineer at
the company, coordinated the contribution.
The modular drive system allows custom configuring of one
machine for various applications and runs on a standard Bug-O
Systems Rail. The modular design allows reconfiguring the unit
for straight line cutting or welding. At its center is the master
drive unit that houses the motor, speed control board, power sup-
ply, and clutch. Among the control module features are a digital
readout and control knob for longitudinal travel speed, plus a
weave speed control of up to 100 in./min.
Mark Campbell and Dave Campbell, representatives for Bug-
O Systems Weld Tooling Corp., explained the operation to Ho-
bart Institutes technical instructor staff, including Elmer Swank,
Chuck Ford, Tom Sumerix, Russ Shurtz, and Nelson Morales.
In related news, HIWT has also been named a Military
Friendly School for 2013 by Victory Media, Inc., ranking the
institute in the top 15% of all colleges, universities, and trade
schools nationwide doing the most to embrace Americas mili-
tary service members, veterans, and spouses as students and to
ensure their success on campus.
SME Releases Manufacturing Education
Strategy to Solve Job Skills Gap
The Society of Manufacturing Engineers (SME), Dearborn,
Mich., recently revealed a national action plan, Workforce Imper-
ative: A Manufacturing Education Strategy.
The white paper calls for manufacturers, educators, profes-
sional organizations, and government to coordinate and stan-
dardize efforts at reversing the skills gap crisis and preparing a
skilled workforce for high-tech manufacturing jobs.
In addition, the report calls on all stakeholders to work to-
gether to close this gap through the following efforts: attracting
more students into manufacturing; articulating a standard core
of manufacturing knowledge; improving the consistency and qual-
ity of manufacturing education; integrating manufacturing top-
ics into science, technology, engineering, and mathematics edu-
cation; developing faculty who deliver a world-class manufactur-
ing education; and deploying resources to accomplish these goals.
To download a copy, visit sme.org/WorkforceImperative.
Bellman-Melcor Celebrates 50 Years
On August 19, Bellman-Melcor, LLC, Tinley Park, Ill., cele-
brated its 50th anniversary. The event was commemorated with
a reception held at the Tinley Park Convention Center to honor
current and former employees as well as industry professionals
who helped make the company a leader in the brazing and sol-
dering consumables industry. Guests enjoyed a casino-night
theme during which cash and prizes were awarded.
Bellman-Melcor was founded in 1962 by Richard Campbell
and Carl Osterman Sr., who worked together at a manufacturer
of brazed contact materials owned by Campbells cousin. Today,
the company has more than 35 full-time employees, all of whom
work to produce more than 600 million quality fabricated parts
sold to more than 300 companies in 18 countries. Employees and
representatives are also active in the AWS C3 Committee on
Brazing and Soldering, and the Brazing and Soldering Manufac-
turers Committee.
Olympic Steel to Expand Operations
Pennsylvania Governor Tom Corbett recently announced
Olympic Steel, Inc., will expand its steel processing facility in
Franklin County, creating at least 90 new manufacturing jobs.
The company ultimately elected to expand its Chambersburg
plant to better serve East Coast customers. It will create these
new jobs within three years, plus invest $11 million to purchase
new equipment and provide training to new employees. In addi-
tion, it received a $400,500 funding offer from the Department
of Community and Economic Development.
Industry Notes
Intelligrated, an automated material handling solutions
provider, relocated its Midwest operations to expanded fa-
cilities in Woodridge, Ill., that provides more space for engi-
neering, project management, and sales personnel.
New West Energy Services, Inc., Calgary, Alb., Canada, com-
pleted its previously announced transaction with Porterco
Welding Ltd., acquiring its operating assets.
The American Society of Safety Engineers is joining with the
Occupational Safety and Health Administration and National
Institute of Occupational Safety and Health to support a new
Fall Prevention Campaign (http://stopconstructionfalls.com/).
NLB Corp. opened a regional branch facility in Crown Point,
Ind., to provide users in the Chicago area and upper midwest
with water jet pump units, accessories, training, and service.
107 WELDING JOURNAL
A modular drive system that will benefit students at the Hobart In-
stitute of Welding Technology has been donated by Bug-O. Shown
(from left) are Elmer Swank, Russ Shurtz, Mark Campbell, Tom
Sumerix, Dave Campbell, Nelson Morales, and Chuck Ford.
Guests at the Tinley Park Convention Center pose with Bellman-
Melcor Founder/CEO Richard Campbell and his wife, June (cen-
ter), in honor of the companys 50th anniversary.
NEWS OF THE INDUSTRY
continued from page 13
DECEMBER 2012 108
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DECEMBER 2012 110
ALM Materials Handling Positioners . . . . . . . . . . . . . . . . . . . .87
www.almmh.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 544-5438
Arc Machines, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
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Astaras, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
www.e3tungsten.com . . . . . . . . . . . . . . . . . . . . . .web contact only
Atlas Welding Accessories, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .22
www.atlaswelding.com . . . . . . . . . . . . . . . . . . . . . .(800) 962-9353
AWS Certification Services . . . . . . . . . . . . . . . . . . . . . . .67, 72, 77
www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353
AWS Education Services . . . . . . . . . . . . . . . . . . . . . .46, 69, 89, 95
www.aws.org/education/ . . . . . . . . . . . . . . . . . . . . .(800) 443-9353
AWS Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
www.aws.org/foundation/ . . . . . . . . . . . . . . . . . . . .(800) 443-9353
AWS Membership Services . . . . . . . . . . . . . . . . . . . . . . . . . .71, 92
www.aws.org/membership/ . . . . . . . . . . . . . . . . . . .(800) 443-9353
C-spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
www.weldoffice.com . . . . . . . . . . . . . . . . . . . . . . . . .(877) 977-7999
Camfil Farr Air Polution Control . . . . . . . . . . . . . . . . . . . . . . . . .2
www.camfilfarrapc.com . . . . . . . . . . . . . . . . . . . . .(800) 479-6801
Champion Welding Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
www.championwelding.com . . . . . . . . . . . . . . . . . .(800) 321-9353
Commercial Diving Academy . . . . . . . . . . . . . . . . . . . . . . . . . . .23
www.commercialdivingacademy.com . . . . . . . . . . .(888) 974-2232
Computer Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
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Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
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Diamond Ground Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . .21
www.diamondground.com . . . . . . . . . . . . . . . . . . .(805) 498-3837
Divers Academy International . . . . . . . . . . . . . . . . . . . . . . . . . .19
www.diversacademy.com . . . . . . . . . . . . . . . . . . . . .(800) 238-3483
ESAB Welding & Cutting Products . . . . . . . . . . . . . . . . . . . . . . .5
www.esabna.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 372-2123
ESSEN Dubai, UAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
www.arabia-essen-welding-cutting.com . . .+49(0)201-72 44-649
ESSEN Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354-s
www.schweissen-schneiden.com . . . . . . . . . . .+1.9 14.9 62-13 20
Flex-Cable, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
www.flexcable.com . . . . . . . . . . . . . . . . . .(800) 245-3539, ext. 114
Fronius Perfect Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
www.fronius-usa.com . . . . . . . . . . . . . . . . . . . . . . .(810) 220-4414
Gedik Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
www.gedikwelding.com . . . . . . . . . . . . . . . . . . .+90 216 378 50 00
Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
www.greinerindustries.com . . . . . . . . . . . . . . . . . .(800) 782-2110
Hobart Institute of Welding Technology . . . . . . . . . . . . . . . . . .41
www.welding.org . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 332-9448
Industrial Maid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
www.industrial-maid.com . . . . . . . . . . . . . . . . . . . .(877) 624-3247
Intercon Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
www.intercononline.com . . . . . . . . . . . . . . . . . . . . .(800) 665-6655
KMT Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
www.kmtsaw.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(269) 321-8860
Lincoln Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC
www.lincolnelectric.com . . . . . . . . . . . . . . . . . . . . .(216) 481-8100
OTC Daihen, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
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Schaefer Ventilation Equipment . . . . . . . . . . . . . . . . . . . . . . . . .40
www.schaeferfan.com . . . . . . . . . . . . . . . . . . . . . . .(800) 779-3267
Select Arc, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC
www.select-arc.com . . . . . . . . . . . . . . . . . . . . . . . . .(937) 295-5215
Stoody/Victor Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
www.stoody.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(866) 279-2628
Thermal Dynamics/Victor Technologies . . . . . . . . . . . . . . . . . . .7
www.thermaldynamicsautomation.com . . . . . . . .(866) 279-2628
Triangle Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
www.trieng.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(781) 878-1500
Uniweld Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
www.uniweld.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 323-2111
Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
www.weldengineering.com . . . . . . . . . . . . . . . . . . .(508) 842-2224
Weld Hugger, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
www.weldhugger.com . . . . . . . . . . . . . . . . . . . . . . . .(877) 935-3447
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INDEX
Introduction
Considering the growing number of
offshore floating production platforms in
operation, as well as the economic limita-
tions for dry docking these structures, wet
welding by shielded metal arc welding
(SMAW) is a very attractive technique for
maintenance and structural repairs (Ref.
1). Wet welds are classed as A and B ac-
cording to AWS D3.6M:2010, Underwater
Welding Code (Ref. 2). For Class A welds,
the requirements of toughness, strength,
ductility, hardness, and bending are simi-
lar to those required by the main engi-
neering codes for atmospheric welding.
There are very few reports in the literature
about achieving Class A in wet welding.
Class B welds are considered welds with
limited structural quality, where both the
tests applied for procedure qualification
and the acceptance criteria are less strict.
The improvement of wet weld quality has
been based on the improvement of the
commercially available atmospheric weld-
ing electrodes that presented the best
weldability and operability underwater.
Rutile-based electrodes are generally pre-
ferred due to their good operability. Com-
mercial electrode evaluations as well as
new coating compositions were made by
Stalker (Ref. 3), Nbrega (Ref. 4), Gooch
(Refs. 5, 6), West (Ref. 7), Liu (Ref. 8),
Ibarra (Ref. 9), and Sanchez-Osio (Ref.
10). The general conclusions of these
works can be summarized as follows:
Austenitic electrodes are susceptible to so-
lidification cracking and formation of
bands of hard martensite along the fusion
boundaries; ferritic electrodes have the
best performance and are divided into two
groups: rutile-based electrodes and iron
oxide-based (oxidizing) electrodes. The
former have good arc stability and other
running characteristics as well as tensile
strength and toughness. The oxidizing
electrodes have low diffusible hydrogen
content (H
dif
) and poor operability. In
general, oxidizing electrodes have a rough
bead surface, and the slag is difficult to re-
move. The main properties of weldments
made by rutile- and oxidizing-type elec-
trodes in terms of weld metal properties
and weldability are summarized in Table 1.
In the 1970s, Nobrega (Ref. 4) carried
out work to develop an electrode with the
combined properties of the rutile- and ox-
idizing-type electrodes. In spite of the
good results achieved, no commercial
electrode based on this development can
be found on the market today.
Due to expectations that the need for
underwater structural maintenance on off-
shore production platforms will grow, the
wet welding consumables (WWC) project
was launched to develop an oxyrutile elec-
trode for wet welding. The participants in
this project are two universities, an oil
company, and an electrode manufacturer.
The main aim was to develop an electrode
based on iron oxide and titanium oxide
with improved mechanical properties min-
imizing the H
dif
. Also, operability should
SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 2012
Sponsored by the American Welding Society and the Welding Research Council
Development of an Oxyrutile Electrode
for Wet Welding
An experimental electrode improved weld metal properties such as
diffusible hydrogen, porosity, and ductility when wet welding
in shallow waters on structural ship steels
BY V. R. SANTOS, M. J. MONTEIRO, F. C. RIZZO, A. Q. BRACARENSE,
E. C. P. PESSOA, R. R. MARINHO, AND L. A. VIEIRA
KEYWORDS
Underwater Welding
Wet Welding
SMAW
Covered Electrodes
Diffusible Hydrogen
Electrode Development
Oxidizing Electrode
Oxygen
V. R. SANTOS, M. J. MONTEIRO, and F. C.
RIZZO are with the Materials Engineering Depart-
ment, Pontifcia Universidade Catlica do Rio de
Janeiro, Rio de Janeiro, Brazil. A. Q.
BRACARENSE is with the Mechanical Engineer-
ing Department, Universidade Federal de Minas
Gerais, Belo Horizonte, Brazil. E. C. P. PESSOA is
with the Instituto Federal de Educao, Cincia e
Tecnologia de Minas Gerais, Betim, Brazil. R. R.
MARINHO is with the PETROBRAS Research
Center, Rio de Janeiro, Brazil. L. A. VIEIRA is with
ESAB Indstria e Comrcio Ltda., Contagem,
Minas Gerais, Brazil.
ABSTRACT
The present paper describes the experimental development of an oxyrutile electrode.
The aim of this experimental work was to improve the weld metal mechanical proper-
ties and minimize the diffusible hydrogen content compared to existing commercial
electrodes. Eighteen batches of electrodes were produced in industrial facilities. Nickel
and molybdenum were added to strengthen the weld metal. Most welding trials were
carried out using laboratory simulations and also by divers in the sea at 10 m depth,
thereby aiming for qualification up to 20 m according to AWS D3.6M:2010. The me-
chanical properties, chemical composition, porosity, and microstructures of the weld
metal among other features are presented. For comparison, three commercial elec-
trodes were also tested. The results and the progress toward achievement of structural
Class A welds are discussed. Most of the experimental electrodes had low porosity and
very few weld metal microcracks. The diffusible hydrogen content in this work was
equivalent to that of typical oxidizing electrodes. Generally, in comparison to the results
reported in the literature, the oxyrutile electrodes developed here showed lower poros-
ity and had superior performance in terms of toughness and ductility. Overall, the re-
sults represent a significant improvement in the quality of wet welds, and most of them
consistently exceeded the requirements for Class A.
319-s WELDING JOURNAL
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be improved in relation to the typical oxi-
dizing types. Welding trials were carried
out in simulated depths of 10 m in the lab-
oratory and in the open sea, aiming pro-
cedures qualification for up to 20 m
according to AWS D3.6M:2010. The open
sea tests aimed a prequalification of two
wet welding procedures, applicable up to
20 m in order to enlarge the options for
the repair designer concerning the elec-
trode selection.
The first phase of the WWC project was
to select an optimized coating composition
as a base line for further developments. The
main criteria were to achieve the lowest pos-
sible H
dif
, improve weldability, and maxi-
mize the rutile content. The second phase
targeted the improvement of weld metal
properties with the addition of alloying ele-
ments. The improvement of operability was
again included in the second phase, but this
development step is not presented in this
paper. Commercial electrodes were also
tested. Results have already been published
(Refs. 12, 13).
The aim of the present paper is to de-
scribe the development of the WWC project
and present selected results emphasizing
weld metal mechanical properties and dif-
fusible hydrogen. Other features of the weld
metal such as porosity and microstructure
are also presented. Comparisons with the
state-of-the-art electrodes are made, and
the progress toward achievement of struc-
tural Class A welds is discussed.
Experimental Methods
Welding tests in Phase 1 of the WWC
project were carried out in the laboratory
by a mechanized gravity system at 0.5 m
water depth. This low depth was chosen in
order to guarantee that the experiments
could maximize the influences of the base
electrode coating composition and mini-
mize the influences of other variables that
could be affected by pressure, like pres-
ence of pores and weld metal chemical
composition. Eight experimental electrode
batches were produced for Phase 1. These
electrodes were named 1E to 8E accord-
ing to the increasing rutile content. The
coating formulations were based on the
combination of hematite (Fe
2
O
3
) ranging
from 40 to 60 wt-%, rutile (TiO
2
) ranging
from 5 to 25 wt-%, and silica (SiO
2
) rang-
ing from 10 to 40 wt-%, which totaled 85
DECEMBER 2012, VOL. 91 320-s
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Table 1 Comparative Properties of Rutile and Oxidizing Type Electrodes Based on Literature Data
Rutile Electrodes Oxidizing Electrodes
Weld metal chemical composition (Refs. 1113) Increasing depth decreases manganese Low sensitivity to depth. High oxygen and
and silicon and increases oxygen. low manganese and silicon at all depths.
Diffusible hydrogen (Refs. 1417) High (< 90 mL/100 g). Decreases Medium (< 20 mL/100 g). As low as 13 mL/100 g
with increasing pressure. has been reported.
Porosity (Refs. 1823) Increases considerably with depth Increases moderately with
depth in shallow waters. (<30 m)
Mechanical strength (Refs. 11, 2428) Class E 70XX is commonly achieved. Low-strength deposits. Class E 60XX
is commonly achieved.
Ductility (Refs. 12, 26, 28) Low elongation (< 15%) in the tensile test. Possible to achieve elongation
Decreases with depth. around 20% up to 20 m.
Toughness (Refs. 29, 30) Commonly meets the requirements Commonly meets requirements of the
of the main standards or codes. main standards or codes.
HAZ hydrogen cracking (Refs. 31, 32) High cracking susceptibility for C Low cracking susceptibility for
> 0.15% and C.E. > 0.38%. structural steels in general.
WM hydrogen cracking (Refs. 12, 13) High cracking susceptibility in general. Low cracking susceptibility in general.
Fig. 1 Influence of TiO
2
/(Fe
2
O
3
+ SiO
2
) in the
coating on the diffusible hydrogen (tests at 0.5 m
welding depth).
Fig. 2 Microstructures. A CR; B CGR; C
FGR. Representative of experimental electrode
(1E to 8E) weld metal microstructures. Nital 2%.
Welding depth: 0.5 m.
A B
C
wt-%. The remaining 15 wt-% had invari-
ant amounts of binding agents, gases and
slag formers, and arc stabilizers. The coat-
ing composition of the best electrode in
this phase was applied as the base compo-
sition for further improvements in Phase
2. In this second phase, Ni and FeMo were
added to improve mechanical properties
by alloying the weld metal.
In Phase 2, 25 experimental electrode
batches were produced. In this phase, the
aim was to improve the weld metal prop-
erties by adding Ni and Mo and also to im-
prove operability by arc stabilizers and
minor additions of exothermic substances.
The electrodes named 1A, 2A, and 3A had
increasing additions of Ni. The electrodes
5A to 10A had increasing additions of Ni
plus Mo. The alloying additions, made by
Ni powder and Fe-Mo, never exceeded
3% and the reduction of the other ingre-
dients of the base formulation were pro-
portionally distributed. Therefore, it is
assumed that no relevant differences
would occur between either the oxiding
potential and operational behavior of the
electrodes 1A10A, with the exception for
electrode 9A, which received an extra ad-
dition of arc stabilizer compounds. The re-
maining experimental electrodes were
those designed to improve operability, and
their results do not belong in the scope of
this paper. The commercial electrodes
tested were named 1C (oxidizing type),
and 2C and 3C (rutile type) electrodes.
Most of tests in Phase 2 were performed
in the laboratory by a mechanized gravity
system at pressure equivalent to 10 m
water depth. Some manual welding trials
were made in the open sea down to 10 m
with electrodes 9A and 2C. A few labora-
tory tests with selected electrodes were
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Fig. 3 Groove joints welded at 10 m equivalent depth. A Elec-
trode 8A surface aspect; B electrode 2C surface aspect; C elec-
trode 8A transversal section; D electrode 2C transversal section.
Table 2 Summary of Welding Conditions According to Depth
Phase Electrode Code Laboratory 0.5 m Laboratory 10 m Laboratory 20 m Open sea 10 m
1 1E to 8E X
2 1A and 2A X X X
2 3A, 5A to 8A X
2 4A X X
2 9A X X
2 10A X
Commercial 1C and 3C X X X
Commercial 2C X X X X
Table 3 Electrodes Steel Rod and Base Metal Compositions (wt-%)
C Si Mn P S Cr Ni Mo Cu
Electrodes steel rod Min spec. 0.04 0.40
Max spec. 0.08 0.02 0.60 0.01 0.015 0.05 0.1 0.05 0.05
Typical 0.06 0.01 0.47 0.0065 0.011 0.025 0.04 0.004 0.028
Base metal ASTM A36 0.15 0.20 0.85 0.022 0.007 0.023 0.012 0.008
Base metal ASTM AH 36 0.16 0.23 1.41 0.016 0.006 0.01 0.01 0.001 0.01
A B
C
D
performed at 0.5 m water depth and at
pressure equivalent to 20 m to evaluate
the influence of pressure. The test matrix
for the whole project according to the
welding depth is presented in Table 2.
All electrodes had 3.25-mm diameters
and were 350 mm long. Commercial elec-
trodes 2C and 3C were provided with a
waterproof coating; however, the manu-
facturers did not disclose the composition
and application techniques. The electrode
1C and the experimental electrodes were
coated by dipping in a vinyl varnish. Elec-
trodes steel rods and base metal composi-
tions are presented in Table 3.
In the laboratory, welding tests were
carried out with a welding power source
operating on direct current electrode neg-
ative (DCEN) at a nominal 160 A. A tank
with capacity of 200 L was used for the
welds at 0.5 m water depth. A hyperbaric
welding simulator was used for the welds
of 10 m and 20 m equivalent depth. All the
welds were carried out in fresh water with
a mechanized gravity system and using the
drag technique in the flat position and
with an electrode angle of 60 deg. The
welding voltage and current were moni-
tored by an acquisition system with a rate
of 1000 Hz. The weld beads were de-
posited in V grooves with an opening
angle of 45 deg, root opening of 3.25 mm,
and 13.0 mm depth, machined on ASTM
A36, 16 280 150 mm plates.
Qualified AWS D3.6 Class B welders
carried out the open sea welding tests. The
power source was an electronic constant
current characteristic, specially built for
wet welding, operating on DCEN at a
nominal 160 A. The weld beads were de-
posited in V grooves with backing, an
opening angle of 45 deg, a root opening of
10 mm, and a root face of 3 mm. Base ma-
terials were ASTM AH36 16 280 150
mm plates.
A gas chromatography analyzer carried
out the diffusible hydrogen measurements
according to AWS A4.3, ASTM E260, and
E355. All samples were welded at 0.5 m.
The chemical composition (except oxy-
gen) was defined using optical emission
spectrometry. A gas analyzer (LECO) was
used for the oxygen content.
Metallographic preparation was car-
ried out by conventional polishing and
etching techniques. The quantities of the
weld metal columnar region (CR), coarse
grain reheated region (CGR), and fine
grain reheated region (FGR) were meas-
ured under 50 magnification in the cross
section, along a 10-mm line, perpendicu-
lar to the plate surface, located in the cen-
ter of the weld. The relative quantities of
microconstituents were determined by
counting points, applying a grid of 100
points over images with 500 magnifica-
tion. The grain size in the FGR was deter-
mined by the intersection method with
500 magnification.
Energy X-ray dispersive spectroscopy
(EDS) was used to determine the chemi-
cal composition of at least 6 inclusions
with diameters between 4 and 8 m.
Vickers hardness loads of 1 and 10 kgf
were used to measure the weld metal
hardness. The all-weld tensile tests were
prepared in accordance with AWS
D3.6M:1999. The samples were 5 mm in
diameter and had a 25-mm gauge length,
or dimensions that are indicated in the
table footnotes.
In the laboratory welding tests, 5000
voltage and current readings were ac-
quired between the 10th and 15th second.
The following parameters were calculated:
average current (I
ave
), average voltage
(V
ave
), current arc stability index (S
i
), volt-
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Fig. 4 Porosity as a function of depth for selected experimental and com-
mercial electrodes.
Fig. 5 Quantitative weld metal transverse crack evaluation in longitudinal
sections of groove welds as a function of pressure
Fig. 6 Macrographs of groove joints welded at 10 m in open sea. A
Electrode 9A; B electrode 2C.
A B
age arc stability index (S
v
), and indicative
number of short circuits (N
sc
). The pa-
rameter S
i
is defined as the ratio of maxi-
mum to minimum values of current.
Similarly, for voltage, the values of S
v
are
defined as the ratio of maximum to mini-
mum values of voltage. The following ap-
proach was used to calculate the values of
S: for each 10 points (0.01 second), values
of current were taken and the maximum
current (I
max
) was divided by the mini-
mum current (I
min
) obtaining 500 values
of S for each weld. With these values, the
average S was calculated. A short circuit
was assumed when any voltage value was
numerically lower than 5 V.
Geometrical bead reinforcement
(R/W) and penetration (P/W) aspect ra-
tios related to the bead width (W) were
measured on transverse sections of the
bead on plate trials.
Results
Phase 1 Electrodes 1E to 8E
(Tests at 0.5 m)
Diffusible Hydrogen. The results of dif-
fusible hydrogen measurements at 0.5 m
for the experimental electrodes (1E to 8E)
are listed in Table 4. For comparison, re-
sults for commercial electrodes are pre-
sented in the same table: typical rutile (2C
and 3C) and oxidizing (1C) electrodes.
Diffusible hydrogen values from the ex-
perimental electrodes are much lower
than the rutile electrodes and near to the
oxidizing electrode values. The influence
of the coating rutile content on the dif-
fusible hydrogen for the experimental
electrodes is shown in Fig. 1. As the
TiO
2
/(Fe
2
O
3
+ SiO
2
) ratio increases,
there is a tendency for the diffusible hy-
drogen to increase.
Weld Metal Chemical Composition
Table 5 lists the results of the weld metal
chemical composition for experimental
electrodes and, for comparison, commercial
electrodes. Despite the variations of rutile
and iron oxide contents, there was not a sig-
nificant change in the weld metal chemical
composition for the experimental elec-
trodes. The low contents of Mn and Si,
which are deoxidizer elements, are charac-
teristic of oxidizing-type electrodes (Refs.
36, 12, 13). Rutile electrodes 2C and 3C
had higher Si and Mn contents compared to
the high oxygen potential electrode 1C and
the experimental electrodes. Electrodes 2C
and 3C had consistently lower oxygen con-
tents in the weld metal.
Microstructural Aspects
The quantitative results of microstruc-
tural characterization for the experimental
electrodes (1E to 8E) are listed in Table 6.
The columnar region is formed predomi-
nantly by proeutectoid ferrite for all elec-
trodes. Some regions of polygonal ferrite
and side plate ferrite can also be observed.
This fact is a consequence of the low carbon,
manganese, and silicon contents, which are
characteristic of oxidizing-type electrodes.
No significant microstructural differences
were observed between the experimental
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Table 4 Diffusible Hydrogen Measured from Samples Welded at 0.5 m Water Depth
(mL/100 g)
Electrode Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Average
1E 21.0 24.7 19.2 21.6
2E 13.3 15.7 11.3 13.4
3E 25.6 34.3 33.1 23.3 22.7 27.8
4E 26.8 13.6 17.3 17.6 18.8
5E 17.4 19.4 20.3 19.0
6E 16.6 13.4 16.2 23.9 17.5
7E 15.4 21.4 28.1 16.3 30.3 22.3
8E 40.4 56.2 20.9 25.2 32.7 35.1
1C 18.7 24.5 18.1 20.4
2C 85.1 105.2 78.9 72.3 85.4
3C 98.8 101.4 91.4 97.2
Table 5 Weld Metal Chemical Composition (wt-%)
Electrode Mn Si P S C O Ni
1E 0.041 0.013 0.016 0.010 0.012 0.270 0.019
2E 0.041 0.012 0.015 0.008 0.022 0.242 0.021
3E 0.046 0.014 0.016 0.008 0.015 0.310 0.112
4E 0.072 0.070 0.019 0.009 0.016 0.320 0.029
5E 0.047 0.008 0.023 0.008 0.019 0.267 0.019
6E 0.049 0.015 0.021 0.031 0.011 0.255 0.024
7E 0.064 0.034 0.036 0.014 0.013 0.264 0.025
8E 0.044 0.009 0.025 0.007 0.014 0.276 0.019
1C 0.033 0.010 0.015 0.007 0.055 0.261 2.020
2C 0.513 0.384 0.014 0.009 0.070 0.092 0.069
3C 0.343 0.199 0.026 0.007 0.090 0.11 0.026
(a) Welding depth: 0.5 m.
Table 6 Quantitative Microstructural Characterization
Electrode PEF + PF + SPF
in the CR (%) CR (%)
b
CGR (%)
b
FGR (%)
b
FGS (m)
Average St. Dev
1E 100 25 13 62 8.0 1.8
2E 100 37 10 53 8.8 1.9
3E 100 27 9 64 7.3 1.5
4E 100 31 10 59 8.3 1.7
5E 100 26 9 65 6.9 1.4
6E 100 27 16 57 10.2 2.2
7E 100 38 10 52 7.3 1.1
8E 100 37 15 48 5.6 1.1
CR: columnar region. CGR: coarse-grain region in reheated zone. FGR: fine-grain region in reheated zone. PEF: pro-eutectoid ferrite. PF: polygonal ferrite. SPF: side plate ferrite. FGS: grain diame-
ter in FGR.
(b) Average for 3 transversal sections.
electrodes. The exception is the variation of
the grain size in the fine-grain region, which
may be attributed to variations in welding
parameters and conditions. Representative
images of the microstructures are shown in
Fig. 2. A large amount of nonmetallic inclu-
sions can be observed. The fine-grain region
corresponds to the major part of the weld
metal for all experimental electrodes.
Mechanical Properties
The average hardness and Charpy val-
ues are listed in Table 7. The low hardness
and toughness values are typical of oxidiz-
ing-type electrodes. No consistent influ-
ence of rutile contents on hardness could
be noticed. Toughness seems to be slightly
increased with increasing rutile content.
These results are in agreement with mi-
crostructural analysis, which shows a non-
significant influence of rutile content in
the microstructure. The small variation of
toughness may be attributed to a small de-
crease of the grain size in the FGR with
increasing rutile content.
Analysis of Nonmetallic Inclusions
The results of EDS analysis are sum-
marized in Table 8. For comparison, the
results of the commercial electrodes are
also tabulated. Two groups of electrodes
can be identified. The group represented
by the commercial rutile electrodes 2C
and 3C has high Mn, Si, and Ti and low Fe
contents according to the lower oxidizing
potential of these electrodes. The group
represented by the experimental and com-
mercial 1C electrodes has high Fe and al-
most no Ti, indicating high oxidizing
potential during welding. The additions of
rutile did not induce a measurable effect
on the composition of the inclusions, since
it was not possible to identify significant
differences between the results of elec-
trodes 1E to 8E.
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Table 7 Weld Metal Hardness and Toughness
Hardness (HV1) Charpy V 0C (J)
Electrode Average St. Dev. Average St. Dev.
1E 174 5 22.6 3.3
2E 152 2 15.0 1.5
3E 180 10 30.4 7.7
4E 153 2 21.3 6.3
5E 162 6 27.1 10.0
6E 148 4 22.6 5.1
7E 152 1 25.5 4.3
8E 179 7 37.3 6.8
Table 8 Chemical Composition of Inclusions in the Weld Metal for Experimental and Commercial Electrodes
(a)
(wt-%)
Fe Mn Si Ti O
St. St. St. St. St.
Electrode Average Dev. Average Dev. Average Dev. Average Dev. Average Dev.
1E 66.3 4.2 3.5 0.9 4.8 2.2 0.0 25.5 1.4
2E 65.7 6.6 3.3 1.5 6.3 3.0 0.0 25.8 2.0
3E 66.6 3.9 4.6 1.1 3.9 1.9 0.0 24.9 1.2
4E 59.9 7.0 6.3 3.3 6.8 2.7 0.0 26.9 1.8
5E 54.7 10.0 6.7 1.9 9.7 5.1 0.0 28.8 3.3
6E 65.5 6.7 4.6 1.3 4.6 3.3 0.0 25.3 2.2
7E 64.7 4.0 5.9 1.9 4.0 1.3 0.0 25.0 0.9
8E 59.2 11.1 6.4 3.3 7.3 4.8 0.0 27.1 3.2
1C 55.8 7.6 7.3 2.7 8.5 3.1 0.0 28.3 2.0
2C 11.8 5.6 24.1 1.5 15.7 4.2 11.9 5.5 36.4 2.3
3C 12.5 5.5 20.7 2.9 20.7 5.5 7.3 2.5 38.3 3.1
Fig. 7 Charpy results of oxyrutile electrodes compared with the ones avail-
able in the technical literature (Refs. 1, 3, 4, 6, 7, 12, 27, 28, 33, 36, 3841,
43). Oxyrutile data for 10 and 20 m are from WWC project.
Fig. 8 Elongation results of oxyrutile electrodes compared with the ones
available in the technical literature (Refs. 1, 3, 4, 7, 12, 27, 28, 33, 36, 3843).
Oxyrutile data for 10 and 20 m are from WWC project. Minimum requirements
for high-strength steels (HSS) and low-strength steels (LSS) are represented by
dashed lines.
The main requirement for selecting the
best performance electrode in Phase 1 was
the diffusible hydrogen content. There-
fore, to compare operational features
only, the four lowest H
dif
electrodes were
considered. The results are listed in Table
9. Although the electrode 2E (Table 4)
had the lowest diffusible hydrogen result
(13.4 mL/100 g), the electrode 6E (17.5
mL/100 g) was selected as the basis for
Phase 2 based on its better operational
performance, as indicated by lower N
sc
and higher V
ave
and P/W. The higher ru-
tile content in the coating was also consid-
ered an important feature of the electrode
6E. The other weld metal properties (Ta-
bles 4 to 8) in general did not show suffi-
cient differences between the
experimental electrodes to influence the
final choice.
Phase 2 Electrodes 1A to 10A
(Tests at 10 m)
The typical weld metal surface and
transverse aspects for experimental oxyru-
tile electrodes (8A) and for commercial
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Table 9 Operability Parameters for the
Lowest Diffusible Hydrogen Electrodes
2E 4E 5E 6E
V
ave
22 25 20 27
I
ave
161 162 166 160
S
v
2.0 1.6 2.2 1.6
S
i
1.5 1.7 1.4 1.5
N
sc
/5s 95 36 215 10
R/W 0.18 0.17 0.23 0.16
P/W 0.15 0.18 0.18 0.24
Table 10 Weld Metal Properties of V-Grooved Joints Welded in the Laboratory at 10-m Simulated Depth Except for Diffusible Hydrogen Tests,
which Samples Were Welded at 0.5 m
Electr. Y.S. U.T.S. Elong. Hardness (HV10)
(b)
Charpy V 0C (J)
(c)
Side Bend Porosity H
dif
(mL/100 g)
(c)
(MPa)
(a)
(MPa)
(a)
(%)
(a)
(%)
Aver. Min/Max Aver. Min/Max 2T
(d)
Aver. Min/Max
1A 398 462 19.0 172 158/180 50 48/51 4/5 0.14 20.9 14.6/30.6
2A 399 464 13.8 155 151/157 58 56/61 4/7 0.13 18.8 15.6/24.0
399 461 18.4
3A 407 482 20.0 190 174/220 52 48/54 4/4 0.021
417 479 18.8
4A 421 486 16.4 180 172/190 5/6 0.15 21.4 14.5/28.7
427 493 20.00
5A 410 483 27.2 187 172/206 50 48/52 0.09
6A 437 505 16.4 181 173/186 1/4 0.03 20.7 16.0/27.7
7A 423 493 15.6 193 172/226 54 52/56 0.06
441 504 23.4
8A 412 534 18.8 184 177/190 46 46/46 0/4 0.28 50.0 27.1/71.1
464 487 8.6
9A 441 515 16.0 174 171/177 2/5 0.26 30.8 20.2/53.8
463 533 21.6
440 513 23.0
10A 434 496 10.2 194 184/218 51 50/54 0.014
(a) All-weld-metal tension tests for each specimen. Lowest elongation values correspond to a higher incidence of weld defects in the tensile specimen.
(b) Average of five indentations minimum.
(c) Average for three specimens minimum. Samples welded at 0.5 m.
(d) Number of approvals/number of tests.
Table 11 Chemical Composition (wt-%),Amount of Fine Grain Region (area %) and Minimum Grain Size (m) in the Weld Metal
Electrode
1A 2A 3A 4A 5A 6A 7A 8A 9A 10A
C 0.052 0.024 0.031 0.054 0.034 0.048 0.027 0.037 0.053 0.040
Si 0.009 0.018 0.010 0.014 0.011 0.015 0.022 0.016 0.016 0.019
Mn 0.048 0.048 0.048 0.046 0.047 0.046 0.058 0.049 0.047 0.057
Ni 2.01 1.82 2.70 2.55 1.98 2.55 2.17 2.56 2.37 2.52
Mo 0.00 0.00 0.00 0.05 0.09 0.10 0.125 0.11 0.18 0.20
FGR (area %) 76 87 69 81 74 75 56 79
FGS (m) Average 3.9 3.7 3.7 2.9 3.1 2.8 3.0 3.1 3.1
Std. Dev. 0.7 0.4 0.3 0.3 0.4 0.3 0.3 0.4 0.4
P content range: 0.016 to 0.044 wt-%
S content range: 0.008 to 0.015 wt-%
(a) Multipass V-grooved joints welded in laboratory at 10 m simulated depth.
Fig. 9 Porosity results of oxyrutile electrodes
compared with the ones available in the technical
literature (Refs. 12, 18, 33, 27, 43). Oxyrutile data
are from WWC project.
rutile-type electrodes (2C) are shown in
Fig. 3. The weld made with electrode 2C
exhibited a superior bead surface and a
higher porosity level.
Table 10 lists some selected weld metal
properties emphasizing mechanical proper-
ties related to the project phases in which
the main target was the improvement of
strength, ductility, and toughness by adding
alloying elements and keeping diffusible hy-
drogen and porosity at low levels. The ulti-
mate tensile strength (UTS) and elongation
results are mostly higher than 490 MPa and
14%, respectively, which are the minimum
levels required for AWS D3.6 Class A
welds. Hardness and Charpy tests data con-
formed to the same criteria. The rather un-
usually low porosity and diffusible hydrogen
levels responsible for obtaining elongation
values in the order of 20% should be noted.
Approval in the bend tests according to the
AWS D3.6 Class A criteria were not consis-
tently achieved. Failures occurred from
small defects such as pores despite the good
weld metal ductility.
The weld metal chemical compositions
as well as the main microstructural fea-
tures responsible for promoting strength,
toughness, and ductility are presented in
Table 11. High amounts of the fine-grain
region can be observed. Small grain size in
the reheated zone indicates the beneficial
effects of Ni and Mo alloying made in the
Phase 2 of the project.
Figure 4 shows the influence of equiv-
alent water depth on porosity for selected
electrodes. The experimental electrodes
show very little sensitivity to increasing
pressure in the range studied.
An evaluation of the incidences of hy-
drogen cracks in the weld metal as a func-
tion of pressure was carried out by manual
counting on transversal sections micro-
scopic images. The results are shown in
Fig. 5. It is interesting to note the sharp
decrease of crack incidences with depth
for rutile type electrodes particularly for
electrode 3C. The lower crack incidence
for electrode 3C compared to electrode
2C in the welding at 10 m was consistent
with its lower weld metal hardness (~164
HV10). The value obtained for electrode
2C was ~209 HV10. Moreover, diffusible
hydrogen for rutile electrodes is consid-
ered to decrease with increasing pressure
(Ref. 34). Diffusible hydrogen and hard-
ness are assumed to be the main control-
ling factors of weld metal cracking in wet
welding. As a general tendency in this
work, it is pointed out that oxidizing and
oxyrutile electrodes showed lower inci-
dence of weld metal microcracks. A survey
for weld metal microcracks in all the Phase
2 samples welded at 10 m with oxyrutile
electrodes revealed practically no cracks.
Results of Open Sea Tests
Electrodes 2C and 9A were selected
for the open sea tests aiming for prequal-
ification of procedures with both types of
electrodes for welding high-strength struc-
tural ship steels. The electrode 9A was
chosen because it produced welds in labo-
ratory with UTS above 513 MPa and good
elongation results, reaching reliably the
UTS requirement for E70XX class, as
shown in Table 10. Tables 12 and 13 list the
mechanical properties and microstructural
characterization related to the joints
welded by divers down to 10 m, respec-
tively. Both electrodes had tensile strength
higher than 490 MPa compatible with
E70XX class. The commercial electrode
2C had low ductility. The bending test re-
sults for both electrodes satisfied the AWS
D3.6M:2010 Class B requirements but not
the Class A requirements. The fine-grain
region was the predominant region for the
electrode 9A in both field and laboratory
tests. Figure 6 shows macrographs for both
electrodes in which lower porosity and
smaller amount of columnar regions are
related to electrode 9A.
Discussion
Regarding the development of an opti-
mized base composition of an oxyrutile
electrode (objective of Phase 1), the tests
performed at 0.5-m water depth indicated
a composition in which the rutile oxide
content was maximized without changing
significantly the H
dif
comparing to a typi-
cal oxidizing commercial electrode (both
are in the order of 20 mL/100 g). These re-
sults are in accordance with results ob-
tained by other authors (Refs. 36, 1317)
and accredit oxyrutile electrodes for weld-
ing higher carbon equivalent and carbon
content steels without hydrogen cracking
compared to rutile electrodes. Regardless
of the different rutile contents in the coat-
ings of electrodes 1E to 8E, no significant
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Table 12 Weld Metal Mechanical Properties of Multipass V Butt Joints
f
Electrode Y.S. U.T.S. Elong Rupture Stress Hardness Charpy V Side Bend Side Bend
(MPa)
(a)
(MPa)
(a)
(%)
(a)
(MPa)
(b)
(HV10)
(c)
0C (J)
(d)
2
2
/
3
T
(e)
6T
(e)
9A 488 547 14.4 527/515 221 42.3 2/4 4/4
Min Max Min Max
201 229 38 46
2C 488 506 6.4 527/494 223 44.0 0/4 4/4
Min Max Min Max
194 250 42 47
(a) All-weld-metal tension tests for each specimen.
(b) Transversal tensile test.
(c) Average of five indentations minimum.
(d) Average for three specimens minimum.
(e) Number of approvals/number of tests.
(f) Welding at open sea down to 10 m.
Table 13 Weld Metal Microstructural Characterization on Multipass V Butt Joints
(d)
Electr. Cracks Porosity Weld metal regions Weld metal micro-constituents FGS (m)
(number per cm
2
) (%) (%) (%)
CR CGR FGR AF PEF FSP PF AFC Aver. Std. Dev.
9A 0.0 0.09 2 30 68 3.4 2.8 1.0 89.0 3.8 2.3 0.3
2C 62.0 0.32 30 27 43 21.3 22.3 2.8 51.8 1.7 3.0 0.4
CR: Columnar region; CGR: Coarse-grain region; FGR: Fine-grain region; AF: Acicular ferrite;
PEF: Pro-eutectoid ferrite; FSP: Ferrite with second phase; PF: Polygonal ferrite. FGS: Ferritic grain size in the FGR
(a) Welding at open sea down to 10 m.
changes in the weld metal and nonmetallic
inclusions in the chemical composition
were observed, as well as no observable
changes in the microstructural features.
Hardness and toughness seemed to show a
small increase with rutile content, but the
data were limited in extent and may not be
statistically significant. However, this was
not considered to be an important factor
for electrode selection in this phase of the
work. As the only powerful strengthening
mechanisms for high-oxygen weld metals
in wet welding are grain refinement and
solid solution, electrode selection criteria
were restricted to diffusible hydrogen and
operability. In view of these two proper-
ties, the electrode 6E was selected as the
basis for the composition development in
Phase 2.
In terms of improving the mechanical
properties, the addition of the alloying el-
ements Ni and Mo to the weld metal was
successful for most electrode batches as
shown in Table 10. The toughness meas-
ured by Charpy energy exceeds the limits
required by the AWS D3.6M:2010, Under-
water Welding Code. The tensile strength
results show that it is possible to overcome
the lower boundary value of 490 MPa re-
quired for class E70XX. Considering the
achievement of Class A welds, the ductil-
ity results, expressed by elongation and
bending, are promising. For the base metal
yield strength higher than 350 MPa, the
minimum limits for the values of elonga-
tion (14%) and bending (180 deg) were
mostly achieved. These good results of
ductility are associated not only to the high
portion of the reheated region and small
grain size (Table 11), but also to the low
porosity and absence of cracks in the weld
metal as shown in Table 10 and Figs. 35.
The open sea results shown in Table 13
are useful to point out significant differ-
ences between microstructural features for
rutile and oxyrutile electrodes tested in
this project. In the oxyrutile type, the very
low content of acicular ferrite is counter-
balanced by the higher proportion of the
fine-grain region and polygonal ferrite.
According to Table 12, both electrodes
tested in the open sea had tensile strength,
hardness, and toughness results compati-
ble to electrodes class E70XX and the re-
quirements of AWSD3.6M:2010 Class A.
It is well known that especially in wet
welding, the properties of the weldments
depend strongly on several operational
factors, such as welders skills, sea condi-
tions, visibility, and other factors. The
open sea test results were similar to the
laboratory test results, suggesting that the
properties of the oxyrutile electrodes de-
veloped are reproducible and consistent
with laboratory results at depths up to 10
m. Nevertheless, considering their limited
number, other welding trials at sea are
necessary to assure the performance
under real conditions of the oxyrutile elec-
trodes developed in this project. For this
purpose, more welding trials with divers
will soon be performed.
The ductility of the experimental elec-
trode 9A measured by elongation and
bending results indicates an enhancement
in the achievable quality of wet welding
compared to the state of the art. At this
stage of the project, the bending test is
considered the main barrier to butt joint
weld procedure qualifications in AWS
D3.6 Class A.
The low ductility, typical of rutile wet
weld metal deposits in shallow waters, re-
ported by several authors (Refs. 7, 9, 28,
33) and confirmed in this project, is at-
tributed mainly to the presence of trans-
verse microcracks in the weld metal (Refs.
12, 13). The cracking phenomenon tends
to diminish with increasing pressure ac-
cording to Fig. 5. Two factors may explain
this feature: 1) the reduction of the dif-
fusible hydrogen, and 2) the reduction of
the weld metal hardness and yield strength
caused by the Mn and Si losses. Ando and
Asahina (Ref. 34) reported that diffusible
hydrogen decreases and porosity increases
with increasing pressure and a pore gas
composition of almost 100% hydrogen was
observed. Consistently, Santos et al. (Ref.
12) reported a decrease in the incidence of
HAZ hydrogen cracks with increasing
pressure. So, the occurrence of cold crack-
ing both in the weld metal and HAZ
seems to be dependent on the porosity.
The present results (Figs. 4, 5) suggest that
the hydrogen trapping in the pores is the
main mechanism responsible for this. The
pores can operate as sinks for the hydro-
gen atoms during their movement to the
metal surface and HAZ, thereby reducing
the amount of available hydrogen for the
cold cracking process.
In order to demonstrate the signifi-
cance of the present results to the state of
art in wet welding, plots of some critical
properties (toughness, ductility, and
porosity, Figs. 7 to 9, respectively) were
made. In these figures, results for the ex-
perimental electrodes 1A to 10A are com-
pared to data collected from the literature.
Regarding Charpy results, it is well known
that toughness has not been a significant
problem in wet welding in shallow waters,
as confirmed in Fig. 7. In this present lit-
erature survey, the commonly adopted
minimum of 27 J is exceeded for all rutile
and oxyrutile electrodes. Oxidizing and
acid electrodes sometimes failed. The re-
sults for oxyrutile electrodes were in gen-
eral the highest and, despite the scattering
presented in the results at 10 m, are con-
sistent regarding the possibility of obtain-
ing Class A welds. The lowest result (46 J)
is probably related to higher porosity and
diffusible hydrogen contents, according to
Table 10. Regarding ductility, it is well
known that good elongation results con-
stitute the strongest barrier to produce
structural quality welds at any depth. In
this literature survey, the 14% minimum
elongation established by D3.6M:2010 for
high-strength steels has not been consis-
tently reported until now Fig. 8. Also
depicted in Fig. 8, three events for rutile
electrodes and ten for oxidizing electrodes
can be observed above the 14% border-
line. Nevertheless, despite the high scat-
tering caused by the presence of defects in
some tensile specimens, most of the oxi-
rutile results reported (~80%) exceeded
the 14% borderline, demonstrating an in-
creased feasibility of obtaining qualifica-
tion in Class A. Regarding porosity, the
very low values for oxyrutile electrodes
seem to be strongly associated to their low
diffusible hydrogen content. Regardless of
the method used by other authors to meas-
ure the porosity, it can be assumed that the
results presented in Fig. 9 distinguish the
oxyrutile electrodes from the others. It is
also important to note the repeatability in
the porosity results obtained for oxyrutile
electrodes and the high agreement with
the results obtained in the open sea tests
(Table 13). In summary, toughness, elon-
gation, and porosity results related to
oxyrutile electrodes are consistently better
compared to the rutile-type electrodes.
The most significant progress achieved in
this work is the consistent set of elonga-
tion results opening up new possibilities
for qualification in Class A. Low porosity
and absence of microcracks are under-
stood here to be the main features re-
sponsible for this breakthrough.
Conclusions
The diffusible hydrogen content of
about 20 mL/100 g achieved in the develop-
ment of oxyrutile electrodes is approxi-
mately equivalent to the content of typical
oxidizing electrodes and considerably lower
than the typical contents of the rutile-type
electrodes. Low porosity and the absence of
weld metal microcracks were consequently
achieved as well as enhanced operability re-
lated to the commercial oxidizing electrode.
In Phase 1, all-weld-metal-compositions
had low Mn and Si and high oxygen con-
tents as well as iron-rich inclusions. These
features are typical of high oxidizing poten-
tial electrodes and similar to those observed
for the commercial oxidizing electrode
tested. The additions of Ni and/or Mo were
effective in strengthening the weld metal.
Based on the present results, class E70XX
electrodes for wet welding can be manufac-
tured. In general, compared to the results
obtained in the literature, the electrodes de-
veloped here showed lower porosity and
presented superior performance in terms of
toughness (Charpy energy) and ductility
(elongation).
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The elongation results represent the
most significant contribution of the pres-
ent work in the search for upgraded weld
metal mechanical properties, focusing on
wet welding of structural ship steels in
shallow waters.
Acknowledgments
The authors wish to express their grat-
itude to professors Sidnei Paciornick and
Marcos Henrique de Pinho Maurcio from
PUC-Rio for images acquisition and pro-
cessing; Continental Servios Martimos
Ltd. for the diving resources in the open
sea tests; and the Brazilian Council for Sci-
entific and Technological Development
CNPq for graduate scholarships.
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Introduction
The goal of this study on human welder
behaviors is to establish a dynamic model
for a novice welders adjustment on the
welding current in response to the ob-
served 3D weld pool surface during a com-
plete-joint-penetration process. That is to
establish a model that correlates the
welders responses (model output) to the
characteristic parameters (inputs) of the
3D weld pool surface. In Part 1 of this
paper (Ref. 1), the principle of a human
welders behavior was analyzed. A vision-
based sensing system was used to record in
real time the human welders responses
and the 3D weld pool geometry character-
ized by three parameters the length,
width, and surface convexity of the weld
pool. Preparation experiments were de-
signed and conducted to improve the
welders response consistency and deter-
mine the welders response time interval
as determined by the transition time and
response delay.
With the improved consistency and
knowledge about the transition time and
welder response delay, the foundation to
model the welders responses were estab-
lished in Part 1 of the paper. However, dy-
namic variations in the welding speed
need to be applied to generate more dy-
namic weld pools in order to accurately
identify and model the welders responses
to the dynamic weld pool surface. To this
end, as the second part of the study, this
paper is devoted to the design of dynamic
experiments as well as use of the resultant
data to model and analyze a welders dy-
namic responses.
The design of the dynamic experiments
is presented in the experimental method
section. In the identification method sec-
tion, these methods are briefly introduced.
The modeling of the welders responses
and the analysis of resultant models are
detailed in the modeling and static re-
sponse analysis parts of the modeling of
response to weld pool surface section, re-
spectively. In the improved modeling and
understanding of human welder response
section, based on the analysis for the mod-
eling of response to weld pool surface sec-
tion, the welders previous responses are
included to improve the response model.
To verify the resultant model, further ex-
periments were conducted, and the verifi-
cation of the model using the data from
those experiments is detailed in the verifi-
cation and discussion section. The conclu-
sion is drawn in the final section.
Experimental Method
In order to identify the model of the
welders dynamic responses to the 3D
weld pool surface, dynamic experiments
with random welding speed variations will
be conducted. These dynamic experi-
ments should be similar to those con-
ducted in the adaptation process. To this
end, there are five welding speeds to be
used in the dynamic experiments, as fol-
lows: 1, 1.25, 1.5, 1.75, and 2.0 mm/s.
Hence, for each experiment, the welding
speed is randomly changed among the five
welding speeds. To determine how fre-
quently the speed change should be made,
the average transition time of the welding
process can be used as a reference. From
Part I, the average transition time is 8.7 s,
Modeling of Human Welder Response to
3D Weld Pool Surface: Part II
Results and Analysis
This paper is devoted to the design of dynamic experiments as well as
use of the resultant data to model and analyze a welders dynamic responses
BY W. J. ZHANG AND Y. M. ZHANG
KEYWORDS
Human Welders Behavior
Modeling
3D Weld Pool Surface
Gas Tungsten Arc Welding
(GTAW)
W. J. ZHANG and Y. M. ZHANG
(ymzhang@engr.uky.edu) are with the Institute
for Sustainable Manufacturing and Department
of Electrical and Computer Engineering, Univer-
sity of Kentucky, Lexington, Ky.
ABSTRACT
Understanding and modeling a human welders responses to a 3D weld pool sur-
face may help develop intelligent welding robotic systems and train welders faster.
In this first effort on modeling a human welders behavior, a novice welders ad-
justment on the welding current as a response to the 3D weld pool surface as char-
acterized by its width, length, and convexity is studied. The first part of the paper
used an innovative machine vision system to measure/record in real time the spec-
ular 3D weld pool surface from experiments and conducted preparation experi-
ments to reduce the inconsistencies in the welders responses as well as determine
the welders delay and time intervals of the process response. In this part of the
paper, experiments are designed to produce random changes in the weld pool using
random welding speeds in order to model the response of the welder to a dynamic
weld pool surface. The fluctuating weld pool surface and welders adjustments on
the welding current are recorded. Through the least squares algorithm, various
models with different structures are identified to correlate the current adjustment
to the 3D weld pool surface. It is found that the human welders responses are not
only related to the 3D weld pool surface but also rely on the welders previous ad-
justments. The resultant model has been verified by further experiments for its ef-
fectiveness in predicting the welders responses.
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Zhang Supplement Part 2 December 2012_Layout 1 11/9/12 1:26 PM Page 329
including the time delay of the welder, the
welders response time, and the settling
time of the weld pool. In this sense, the
speed change interval should be shorter
than the transition time, since it is not nec-
essary for each speed to last till the weld
pool fully resumes its steady state. There-
fore, in this study, the time interval for
each change is set to be 6 s.
Each experiment
has two periods. The
constant speed period
and random speed pe-
riod use a constant
welding speed and a
randomly changing
welding speed, respec-
tively. The purpose of
the constant speed pe-
riod is to allow the human welder to bring
the welding process to the desired com-
plete-joint-penetration state, and the ran-
dom speed period is to produce the dy-
namic weld pool for the human welder to
respond. The duration of the constant
speed period is set at 18 s, long enough to
establish a steady state for the welding
process. The duration for the random
speed period is 120 s. The arc length is set
at the same constant in each experiment in
[2, 5 mm], i.e., 2, 3, 4, and 5 mm. Other ex-
perimental settings are shown in Table 1 in
Part I of this paper.
The data from one experiment will be
used to identify the model. This will then
be verified using data from all other ex-
periments. The arc length used in the
identification experiment that produces
the data to identify the model is 3 mm. The
results of the identification experiment
are shown in Fig. 1. It is found in Fig. 1A
that the current controlled by the human
welder basically follows the tendency of
the welding speed changes. Since the weld
pool dimension varies significantly as the
welding speed fluctuates, the human
welder adjusts the current afterward. Fig-
ure 1B and C show that the tendency of the
current adjustment is appropriately oppo-
site to the length and width fluctuation.
The waveform of convexity as shown in
Fig. 1D basically coincides with the cur-
rent variation. The variations in the weld
pool surface geometry and the current in-
dicate that the human welder reduces the
current as the weld pool length or width
raises, and increases it as the weld pool
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Fig. 1 Identification experiment. A Current and speed; B length, current, and speed; C width, current, and speed; D convexity, current, and speed.
All variables are plotted using the normalized scale. The range for each variable is given in each plot and corresponds to [0, 1] in the normalized scale.
Table 1 Resultant Models of the Human Welder Response with One Input
Inputs r Models
Length 1.9023 0.132 i
k
= 0.070ll
k4
+ 0.20371
k5
+ 0.2968l
k6
1.9215
Width 1.9068 0.1 i
k
= 0.2287w
k 3
+ 0.1376w
k4
+ 0.2819w
k5
0.7828
Convexity 1.8222 0.32 i
k
= 39.3114h
k 3
+ 3.2639 h
k4
38.3469h
k5
0.4715
Fig. 2 Backside weld bead from the identification experiment.
A
C
B
D
convexity rises.
Figure 2 shows the backside weld bead
obtained from the identification experi-
ment. The weld bead width varies approx-
imately periodically. That indicates the
human welder did not adjust the current
fast and accurately enough to compensate
for the effect of the welding speed change
on the weld pool geometry. It needs to
point out that this is, of course, not re-
quired because not every skilled welder
could even control the weld bead constant
under frequent and substantial changes in
the welding speed. In this study, this type
of variation is produced on purpose in
order to identify how the welder responds
to the dynamic weld pool surface.
Identification Method
In the last section, the design of the dy-
namic experiments is detailed, and exper-
iments are conducted. Before the welder
response is modeled using data from these
experiments, the methods for model es-
tablishment used in the field of system
identification (Refs. 2, 3) from experi-
mental data are introduced in this section.
System identification has been studied
for many years and is now a standard
method to extract dynamic models (Refs. 2,
3). It can be classified into two categories,
i.e., continuous time and discrete time.
Human welders always scan the weld pool
with a certain frequency during the welding
process, and the more skilled the human
welder is, the slower frequency of scan is
needed. Therefore, it is reasonable to apply
discrete identification methods in this study
to identify the model of the human welders
behavior. To determine the data acquisition
frequency, the scan frequency of a human
welder can be considered as a reference. In
this study, the data acquisition frequency se-
lected is 2 Hz.
Model Structure
In this study, the characteristic param-
eters selected to de-
scribe the front-side
weld pool geometry are
the width (w), length
(l), and convexity (h).
That is,
= [w l h] (1)
According to the
principle of a human
welders behavior de-
tailed in Part 1 of this
study, it is reasonable
to assume that a welder
would control the weld-
ing process such that
the geometric parame-
ter set approaches to
the desired dimension
*:
* = [w* l* h*] (2)
where w*, l*, and h* are
the desired parameters for the width,
length, and convexity, respectively. In this
sense, the adjustment on the current (i.e.,
the current adjustment, i) made by the
welder at the present instant k is to bring
close to * intuitively, the welder makes
the adjustment based on the difference of
his newest observation (k d 1) (the
delay is included) from *:
i(k) = g(1)((k d 1) *)
+ e(k) (3)
where g(1) = [g
1
w
, g
1
l
, g
1
h
] is the gain vec-
tor, and e(k) is the error. More generally,
a welder with a minimal skill should not
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H
Fig. 3 Estimation of the welders response using the models with the sin-
gle input. A Estimation using the length; B estimation using the
width; C estimation using the convexity.
Table 2 Resultant Models of the Human Welder Response with Two Inputs
Inputs r Models
Length + Width 1.8994 0.14 i
k
= 0.0181l
k4
0.4124l
k5
+ 0.8868l
k6
+0.0316w
k4
+0.6415w
k5
0.6716w
k6
2.041
Width + Convexity 1.7406 0.418 i
k
= 0.7345w
k2
+ 0.71w
k3
0.9675w
k4
+ 0.9814w
k5
+ 43.7353h
k2
35.8699h
k3
+ 51.3075h
k4
54.2302h
k5
0.5067
Length + Convexity 1.7239 0.436 i
k
= 1.1.902l
k2
+ 1.6078l
k3
2.0024l
k4
+1.4957l
k5
+55.3252h
k2
66.1454h
k3
+ 79.8977h
k4
66.0899h
k5
+ 0.1113
A
C
B
make the adjustment i(k) only based on
the newest difference (delay is included
again) but also based on additional
previous differences as follows:
where g(j) = [g
j
w
, g
j
l
, g
j
h
]s, j = 1, 2, ...Mare
the gain vectors, and Mis the order of the
response model. Because * is a constant
vector, model (4) gives
where is a constant
Identification Method
To estimate gains from
experimental data, Model 5
can be rewritten as
i(k) =
M, d

M, d
(k)
+ e(k) (7)
where
M, d
= (, g(1), g(2),...,
g(M)) (8)
M, d
(k) = (1, (k d 1),
(k d 2),...,(k d
M)) (9)
Identification of the
human welders response
model is to estimate
M, d
from the experimental data
{i(k),
M, d
(k)}s (k = d +
M + 1, d + M + 2, ..., N).
The most popular parame-
ter estimation method is the
least squares algorithm (Refs. 46) that
minimizes the sum of the squared model
errors as follows:
to produce the least square estimate
M, d
.
The standard least squares algorithm can
be used to analytically compute
M, d
and
the corresponding J(
M, d
) from the data
{i(k),
M, d
(k)}s (k = d + M+ 1, d + M
+ 2, ..., N). For a given model order Mand
response delay d, its number of parame-
ters in
M, d
is known.
Identification of the human welders
response model is as follows: 1) for a given
number of parameters, use the least
squares algorithms to calculate all possible
models (with different M and d) and cor-
responding sums of the squared model er-
rors, and then select the one with the min-
imal sum of the squared model errors as
the model for this number of parameters;
2) increase the number of parameters and
use the F test (Ref. 7) to determine if the
resultant reduction in the sum of the
squared errors due to this increase is sig-
nificant; 3) if significant, increase the
number of parameters again; otherwise,
the model before the increase gives the
identified model. Once the model is finally
selected/identified, its accuracy is meas-
ured by the standard deviation
A time delay has been proposed because
of the neuromuscular and central nervous
latencies. The existence of this time delay
has been verified and estimated in the first
part of the paper. It should be noted that
this time delay varies according to the phys-
ical health/mental conditions, skill level of
the human welder, and other human-
dependent and environmental factors. It
might vary from time to time during the
same welding process. Further, the delays
for the three weld pool surface characteris-
tic parameters might not be exactly the
same. Also, it might not be an integer in the
discrete-time model (Ref. 8). However, it
can be approximated to an integer, which
can be determined through the model iden-
tification process as aforementioned in the
proposed identification method.
Modeling of Response to
Weld Pool Surface
Modeling
With the introduction of model structure
and identification method in the last sec-
tion, the modeling of a human welders re-
sponse from the experimental data is con-
ducted in this section.

i k g j k d j
e
j
M
( ) = ( )( ( ) *)
+
=1

(( ) (4) k

i k g j k d j
e k
j
M
( ) = ( ) ( )
+ + ( )
=1
(5)
=

g j
j
M
( ) (6)
=1
*
J
i k
M,d
M,d
k d M
N
M,d
( ) min
( )
1
=
= + +

M,d
k ( ) (10)
2

( )
J N d M
M, d
(11) /
W
E
L
D
I
N
G

R
E
S
E
A
R
C
H
Fig. 4 Estimation of the welders response using the models with
two inputs. A Estimation using the length and width; B esti-
mation using the length and convexity; C estimation using the
width and convexity.
A
C
B
^
^
^
^
W
E
L
D
I
N
G

R
E
S
E
A
R
C
H
Fig. 5 Estimation of the welders response using the models with three inputs. A Estimation of current adjustment; B estimation of current.
A subset of the three characteristic pa-
rameters may be used to model a human
welders response first to see if all of the
three parameters are needed. Using the
data shown in Fig. 1 and the identification
method given in the previous section, three
models in Table 1 that only use one of the
three characteristic parameters are first
identified. The current adjustments esti-
mated using the resultant models are
shown in Fig. 3. Correlation coefficient r in
Table 1 measures the strength and direction
of a linear relationship between measured
and estimated output (i) in this study
(Ref. 9). The model with a higher accuracy
is expected to obtain a higher correlation
coefficient. Figure 3 and Table 1 show that
the model using the convexity as its input
obtains the smallest standard deviation and
the highest correlation coefficient. It is be-
cause the convexity of the weld pool, when
the arc pressure is given, reduces as the
backside weld pool width increases because
a greater backside weld pool width allows
more liquid metal to be pushed from the
front surface of the weld pool.
As can be seen from Fig. 3 and Table 1,
none of the three models in Table 1 matches
the estimated current adjustments well
with the measured ones. This indicates that
the human welders response might depend
on more than one characteristic parameter
of the weld pool surface. Hence, models
with more inputs are identified.
The resultant models with two input pa-
rameters are presented in Table 2. The cur-
rent adjustments estimated using the re-
sultant models are shown in Fig. 4.
According to the models in Table 2, the
human welder adjusts the current based on
the weld pool surface 1 to 3 s ago. Also, the
two models using the convexity as one of
their inputs better modeled the welders re-
sponse. However, the two models that used
the convexity show no significant differ-
ences in terms of the standard deviation or
correlation coefficient. It is probably be-
cause the welding speed has a significant ef-
fect on the weld pool size, but a slight im-
pact on the weld pool appearance, i.e., the
length-to-width ratio does not vary signifi-
cantly. That means the width and length
fluctuate approximately proportional dur-
ing our experiment that changes the weld-
ing speed to change the weld pool.
The resultant model with all three geo-
metric parameters is shown in Equation 12.
The standard deviation of model in estimat-
ing the current adjustment is 1.713, which is
smaller than those of the three models with
two inputs shown in Table 2, and the correla-
tion coefficient is 0.448. The current adjust-
ments estimated using the resultant models
are shown in Fig. 5A. Figure 5B is the com-
parison between the measured current and
estimated current obtained by the model.
i
k
= 1.3066l
k2
+ 2.4704l
k3
3.1688l
k4
+ 1.8859l
k5
0.8893w
k3
+ 0.9658w
k4
+ 0.5371w
k5
0.6277w
k6
+ 55.2372h
k2
63.4404h
k3
+ 90.8986h
k4
96.1477h
k5
+ 17.5644h
k6
+ 0.2077 (12)
Table 3 ARX Models of the Human Welder Response
Inputs r Models
Length + Width 1.5722 0.571 i
k
0.4725i
kl
+ 0.1366i
k2
=0.6097l
k3
2.2283l
k4
+ Convexity +1.6137l
k5
1.2675w
k3
+ 1.7667w
k4
+ 0.0930w
k5
0.6088w
k6
+ 30.3658h
k3
+ 19.6357h
k4
67.6373h
k5
+ 18.7761h
k6
Table 4 Z-Transfer Functions of the ARX Model
Model z-transfer function
A'
lwh
(z) = z
3
(z
2
0.4725z + 0.1366)
Length + Width + Convexity A"
lwh
(z) = z
4
(z
2
0.4725z + 0.1366)
B
l
lwh
(z) = 0.6097z
2
2.2283z +1.6137
B
w
lwh
(z) = 1.2675z
3
+ 1.7667z
2
+ 0.0930z 0.6088
B
h
lwh
(z) = 30.3658z
3
+19.6357z
2
67.6373z + 18.7761
A
B
Static Response Analysis
A human welder always tries to control the state of the welding
process approaching the desired state, and the desired state of the
weld pool geometry is contained in the constant of the model in
Equation 5. The desired state * can be obtained by solving the
static state equations of the models in Tables 1 and 2. The static
state equation of the model using the convexity as the input is
shown in Equation 13. The static state equations of the last two
models in Table 2 are shown, respectively, in Equations 14 and 15.
I = 4.2284H 0.4715 (13)
W
E
L
D
I
N
G

R
E
S
E
A
R
C
H
Fig. 8 Step responses of the ARX model. A Length step response; B width
step response; C convexity step response. Because the output is i, all the step
responses settle down back to approximately zero. The integration of the step re-
sponse gives the net change in the welding current due to the step change in one
of the characteristic parameters. In A, the integration is negative. This implies that
the welder reduces the current as a response to an increased weld pool length. In
B, the integration is negative. The welder again reduces the current as a response
to an increased weld pool width. In C, the integration is positive. The welder in-
creases the current as a response to an increased convexity.
Fig. 6 Estimation of the welders response using the ARX model that uses
all three characteristic parameters.
Fig. 7 Comparison of the ARX model estimated welding current with the
measured current. The ARX model makes use of the width, length, and con-
vexity calculated from the 3D weld pool surface as the weld pool characteris-
tic parameters, and the previous adjustments on the welding current to predict
the welders adjustment on the welding current.
A
B
C
I = 0.0106W+ 4.9427H 0.5067 (14)
I = 0.0891L + 2.9876H + 0.1113 (15)
where I is the current adjustment at static
state; W, L, and H are the width, length,
and convexity of the weld pool at static
state. As the welding process approaches
the desired state assessed by the human
welder, the welder stops changing the cur-
rent. The current adjustment equals zero.
In this sense, the W, L, and H are the de-
sired state of the weld pool geometry, i.e.,
W = w*, L = l*, and H = h*. Solving
Equations 13 to 15, the resultant desired
state * is as follows:
* = [4.1934 4.9933 0.1115] (16)
It is reasonable for the human welder to
choose the set of the geometric parameters
as the desired state given the specific set-
tings for the experiment detailed in the pre-
vious experimental method section. It can
be seen in Fig. 2, the backside weld bead
width varies greatly during the process since
the welder does not perform well enough to
keep the width consistent. However, it is an
indication of the welders skill in execution
of the current output, and irrelevant to the
desired state the human welder wants to
maintain. Also, the desired state of weld
pool geometry can be verified by estimating
the constant in the model with the three in-
puts shown in Equation 12. The static state
equation of the model can be written in the
following equation:
I = 0.1191L 0.0141W+ 3.8121H
+ 0.2077 (17)
Substituting Equation 16 into 17, and
letting I = 0, the estimated constant in
Equation 14 is obtained as the following:
= 0.2287 (18)
The estimated value matches the value
in the model with a 0.021 difference, which
may be caused by the accuracy of the
model in predicting the human welders
response. Also, the disturbance/noise dur-
ing the data-acquisition process might
contribute some of the difference. Fur-
ther, it is found that the estimated con-
stants coincide with constants in the mod-
W
E
L
D
I
N
G

R
E
S
E
A
R
C
H
Table 5 Poles and Zeros of the ARX Model
Inputs Poles and zeros
A
lwh
(z): [0.23630.2842i, 0,0,0], A"
lwh
(z): [0.23630.2842i, 0,0,0,0]
Length + Width+ Convexity B
l
lwh
(z): [0.9952, 2.6596], B
w
lwh
(z): [0.52, 0.95710.0823i]
B
h
lwh
(z): [1.9509, 0.9812, 0.323]
Fig. 9 The prediction of the human welders response using model H
lwh
(z). A Estimation of current adjustment with arc length 4.0 mm; B estimation
of current with arc length 4.0 mm; C estimation of current adjustment with arc length 5.0 mm; D estimation of current with arc length 5.0 mm.
A
C
B
D
els listed in Tables 1 and 2.
Furthermore, according to the static
state equation of the model shown in
Equation 17, the human welder tends to
reduce the current as the length or width
grows, and increases the current as the
convexity of the weld pool rises. The coef-
ficient of the width in the model is smaller
than other coefficients in the model, while
the convexity has the largest coefficient in
the model. That indicates the welder is
more sensitive to the convexity and length,
and less sensitive to the width of the weld
pool during the welding process.
Improved Modeling and
Understanding of Human
Welder Response
Although the model with all three
characteristic parameters is more accurate
than those with less characteristic param-
eters in predicting the welders responses,
the estimated current adjustment still
does not quite well fit the measured one.
To better understand and predict the
welders behavior, lets analyze below.
The following model, referred to as the
auto-regressive with exogenous terms
(ARX) model, is the general structure to
describe discrete-time linear systems:
y(k) = a(1)y(k 1) + ... + a(M
1
)y(k M
1
)
+ b(1)u(k d 1) + ...
+ b(M
2
)u(k d M
2
) + e(k) (19)
where u is the input, y is the output, d is
the delay, e is the disturbance, and a(l), (l
= 1, ..., M
1
), b(j), (j = 1, ..., M
2
) are the
model parameters of the system. The MA
(moving-average) model
y(k) = b(1)u(k d 1) + ...
+ b(M
2
)u(k d M
2
) + e(k) (20)
is one of its simplified structure. It may ad-
equately describe certain discrete-time dy-
namic processes but not all discrete-time
dynamic processes. The model in Equa-
tion 5, intuitively proposed based on our
analysis and understanding of a human
welders response, is apparently an MA
model with as the inputs and i as the
output. Its less than ideal accuracy may
have been caused by its inadequacy in de-
scribing the human welders dynamic re-
sponse process. If this is the case, use of
the more general ARX model structure
may improve the model accuracy signifi-
cantly and help us better understand the
behavior of the human welder.
Based on the above analysis, the fol-
lowing ARX model structure is proposed
to improve the modeling accuracy for the
human welders response:
The inclusion of i(k 1), ..., i(k M
1
)
into the model basically introduces the
welders previous actions. If this inclusion
can better predict the welders adjust-
ments on the welding current, it would
suggest that the welder not only depends
on the weld pool surface but also on his
previous actions to adjust the welding cur-
rent. Our understanding of the human
welders behavior would be improved.
The parameter estimation and model
structure identification for ARX models
are similar as those for MA models and
standard in the system identification liter-
ature (Refs. 1012). Since all three char-
acteristic parameters are found necessary,
the ARX models with all three character-
istic parameters are identified. The result-
ant model is listed in Table 3, and the
model results are shown in Figs. 6 and 7.
As can be seen from Table 3, the present
adjustment at instant k on the current i
k
depends on the characteristic parameters
3 through 6 periods previously, i.e., k 3
to k 6. Hence, the welder makes an ad-
justment on the current based on the weld
pool he observed approximately 1.5 to 3 s
previously. There is a difference from 1 to
3 s given by the less accurate intermediate
model in Table 2, but this difference is con-
sidered insignificant.
As can be seen, in general, the ARX
model well matches the estimated current
adjustments to the measured current ad-
justments except a few current peaks
Fig. 6. The ARX model is much better
than the MA models in Table 2 for pre-
dicting the human welders response. That
indicates the human welders adjustment
on the current does also depend on his
previous responses/actions. Figure 7
shows the comparison between the meas-
ured current and estimated current using
the ARX model. Since the experiment is
conducted by a newly trained welder for
this study who may frequently overre-
act/underreact during the operation, it is
understandable that the steep current ad-
justments cannot, and should not, be fit
well using the model. A model can possi-
bly better estimate the skilled human
welders response with fewer sudden cur-
rent changes and randomness in the weld-
ing process.
In order to analyze the models prop-
erties, the ARX model is written in z-
transfer functions (Ref. 13), shown in
Table 4. The poles and zeros of the z-trans-
fer function are listed in Table 5.
It can be seen that all the poles of the
=
+ +
i k a l i k l
b j k d j e
l
M
( ) ( ) ( )
( ) ( )
=1
1
(( ) (21)
=1
2
k
j
M

W
E
L
D
I
N
G

R
E
S
E
A
R
C
H
Fig. 10 Standard deviations and correlation coefficients of the model using data from the verification experiments at different arc lengths. A Standard de-
viation of the model; B correlation coefficients of the model.
A
B
model are inside the unit circle in Z-plane,
which means that the model as the con-
troller in Table 4 is asymptotically stable
(Ref. 14), which is easily understood. In
fact, the human welder makes the adjust-
ment on the welding current as an intelli-
gent controller. This controller can and
should be able to deliver a stable welding
process despite his limited experience
training. Hence, the model for the
welders response should be stable. Fur-
ther, there is only one pair of conjugate
poles. The oscillation frequency of the
transition responses is
lwh
= 1.7543 rad/s (22)
The settling time for the unit step re-
sponse is approximately 4 s, as can be seen
in Fig. 8. Because the welding process is
dynamic, the transition time discussed in
the first part of the paper is approximately
the sum of the settling times for the con-
troller and welding process. It is much
longer than that of the controller, which is
approximately 4 s as discussed above.
Another characteristic of the model is
that it is a nonminimum phase system
(Ref. 15), since there are zeros outside the
unit circle in Z-plane as shown in Table 5.
Per literature (Refs. 16, 17), this often
leads to relatively large overshoot/under-
shoot. Such oscillations can be observed
from the simulated step responses shown
in Fig. 8. It is suspected that the model for
a skilled/experienced welder would exhibit
much less significant oscillations.
Verification and Discussion
Due to the consistency of the human
welders performance, the obtained model
should have a similar performance to pre-
dict the current in other experiments. To
further verify the model, the verification
experiments are designed and conducted
as discussed in the experimental method
section. To produce an acceptable distri-
bution of the welding parameters to en-
sure the validity of the resultant model,
each experiment is conducted at a con-
stant arc length in [2, 5 mm], i.e., 2, 3, 4,
and 5 mm. For each arc length setting,
there are five experiments conducted with
the random welding speed signal.
Figure 9 shows the estimated cur-
rent/current adjustment obtained by the
model using the data from two of the ver-
ification experiments under different arc
lengths. It can be seen that the estimated
current adjustments predict all the ten-
dencies of the measured current adjust-
ments, although there are some high and
steep measured values at which the esti-
mation cannot follow in magnitude. More-
over, the curves of the estimated and
measured current coincided well.
The standard deviation and correlation
coefficient are the criteria to evaluate the
performance of the model when applied to
different verification experiments. All the
standard deviations and correlation coeffi-
cients obtained for the model to estimate
the current adjustments in the verification
experiments are shown in Fig. 10A and B,
respectively. The square and error bar for
the experiments at each arc length in the fig-
ures are the mean value and the range of the
two values is from the verification experi-
ments conducted at this particular arc
length. The average standard deviation is
about 1.6 A. The correlation coefficients at
the different arc lengths in Fig. 9 vary almost
within the same range around their mean
values. The average correlation coefficient
of all the verification experiments is about
0.56. However, the mean correlation coeffi-
cient at arc length 5 mm is smaller than that
in the other three arc lengths. It is possibly
because as the arc length increases, the cur-
rent required for the same penetration state
is higher. Then, during the experiments, the
human welder needs to adjust the current in
a large range. That might have increased in-
accuracy in predicting the current adjust-
ments using the model. Other than that, the
model shows a consistent performance in
predicting the human welders response on
the adjustment of the current during the
verification experiments.
Conclusion
This paper modeled adjustments on
the welding current made by a human
welder in response to the 3D weld pool
surface, as characterized by its length,
width, and convexity, to maintain a consis-
tent complete joint penetration in gas
tungsten arc welding (GTAW). The dy-
namic changes in the weld pool surface
were produced by conducting experiments
using randomly changed welding speeds
from 1.00 to 2.00 mm/s. Under the exper-
imental conditions used, the following
were found:
The human welder makes the adjust-
ment on the welding current based on the
current and previous weld pool surfaces.
The adjustment on the welding cur-
rent by the human welder requires the
length, width, and convexity of the weld
pool surface to model adequately. From
the established model, the human welder
responds to the weld pool surface he ob-
served approximately 1.5 to 3 s previously.
The human welder makes the adjust-
ment on the welding current also based on
the previous adjustments he has made 1 s
prior.
It is noted from the identification and
verification results that the adjustments
on the welding current cannot be fully pre-
dicted. This is expected because of the rel-
atively limited skills of the novice human
welder and the inconsistency of his opera-
tion/concentration. The modeling errors
are a reflection of the human welders skill
level and concentration.
Acknowledgments
This work is funded by the National Sci-
ence Foundation under grant CMMI-
0927707. We wish to thank Yi Lu and
Yukang Liu for their assistance on experi-
ments and graphics, and Lee Kvidahl for his
technical guidance on manual pipe welding.
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IEEE Transactions on Automatic Control 48(8):
13891393.
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Introduction
Expanding the use of robotics in indus-
tries that manufacture large products,
such as shipbuilding, is a relatively new en-
terprise. In general, every ship is unique.
Further, the size and scale of a typical ship
combined with the high costs associated
with dry docks or real estate immediately
adjacent to the launch location has led to-
ward a common manufacturing technique
in which the structural components of the
ship are assembled in multiple locations
with only the final assembly occurring in
the most expensive location. Some aspects
of a common assembly line technique are
used; however, due to the part/component
differences, the assembly process is con-
stantly changing from part to part. There
are, however, significant benefits that can
be achieved through increasing the level
of automation within the shipbuilding
process in the United States (Ref. 1). The
same discussion applies to the Electric
Power Generation Industry (EPI), in par-
ticular, steam plants and wind-energy
production.
A number of researchers are investi-
gating nontraditional robotic manufactur-
ing techniques based on nonserial
architecture, movable-base robotic ma-
nipulators in the shipbuilding and similar
industries. These efforts have resulted in
several alternative approaches for au-
tomating manufacturing processes in un-
structured environments. One approach
employs mobile, legged robotic platforms.
Some examples of this approach are the
ROWER project (Ref. 2), demonstrating
a large-legged robot designed to travel
through the hull of a ship while perform-
ing welding tasks and Robug (Ref. 3), a
smaller-legged platform used for inspec-
tion and potential manufacturing pur-
poses. Another approach is based on a
cable-driven system with a multi-degree-
of-freedom end effector. RoboCrane
(Ref. 4) developed by NIST provides an
example of this system. A third approach
uses large-wheeled mobile robots to tra-
verse the welding site. A large, wheeled
platform that carries a six-axis robot called
NOMAD (Ref. 5) is intended for welding
large-scale structures such as those found
in earth-moving equipment and bridge-
fabrication industries. Several groups
have been pursuing smaller, mobile climb-
ing robots for welding. One such approach
uses wheeled robotic systems, for exam-
ple, the two-wheeled mobile robot de-
signed specifically for fillet welds in lattice
(Ref. 6). Another approach utilizes con-
tinuous-track robotic systems, which gen-
erally use attractive elements, such as suc-
tion cups, magnets, and gripping feet, that
allow these systems to climb (Refs. 710).
This research is driven by the need for im-
proved tools for manufacturing tasks such
as welding in large-scale manufacturing
systems such as shipbuilding.
While this research has resulted in a
large number of conceptual designs and
prototypes for mechanized or robotic
welding, there is a continued need to vali-
date these designs and bring them into
commercial practice. An important step
includes documented weld verification
process, but this procedure has not been
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Theoretical and Empirical Verification of a
Mobile Robotic Welding Platform
A mobile robotic welding robot will be verified both theoretically and empirically
using AWS and ASTM standards
BY J. STACY AND S. CANFIELD
J. STACY is a graduate student, and S. CAN-
FIELD (scanfield@tntech.edu) is professor, Ten-
nessee Technological University, Cookeville, Tenn.
KEYWORDS
Robotics
Gas Metal Arc Welding
Automation
Shipbuilding
ABSTRACT
Traditional robotic welding, common in industries such as automotive production,
becomes impractical in industries that use unstructured manufacturing techniques,
such as shipbuilding. This is due in part to the scale of the manufactured systems and
the size and locations of the weld. In these unstructured manufacturing environments,
the state of the art for mechanized welding has historically consisted of a fixed-track
system with a mechanical welding carriage that operates along the track. However, al-
ternative mechanized welding approaches that make use of developments from the
field of mobile robotics are being pursued. One such example is the semiautonomous
Mobile Robotic Welding System (MRWS). The MRWS is a lightweight mobile ma-
nipulator consisting of a two-degrees-of-freedom mobile platform and a three-
degrees-of-freedom torch manipulator. The MRWS is capable of climbing ferrous sur-
faces by the use of permanent magnet tracks and positioning the welding torch along
a weld joint. This system is designed to mechanize the welding process for a variety of
weld joints with minimal setup time. Setup consists of placing the MRWS on the sur-
face to be welded and driving to the intended weld joint. In order to be utilized in a
manufacturing environment, such a system must be verified for the welding process it
is performing. This paper demonstrates and verifies the MRWS as a valid alternative
for mechanized welding in unstructured environments. The verification process con-
sists of two components: design validation based on theoretical analysis of the MRWS
system models to prove the weld process requirements can be met, followed by an em-
pirical verification based on AWS weld test specifications for a specific, commonly
used welding process. The design validation focuses on the two primary differences
between the MRWS and proven fixed-track mechanized welding systems, torch mo-
tion control on a mobile platform, and impact of the MRWS magnetic feet on the weld
process. The empirical verification was performed on a vertical groove weld on mild
steel with uphill progression, 3G-PF.
Stacy Supplement December 2012_Layout 1 11/9/12 1:37 PM Page 338
reported in the literature for any mobile
robotic systems. For the purposes of this
paper, weld verification is defined as the
process of confirmation by examination of
objective evidence that the specified re-
quirements have been fulfilled, where the
specified requirements are those given in
AWS B2.1:2005 and D1.1/1.1M:2002
(Refs. 11, 12). This is based on the defini-
tions and processes presented in Ref. 13.
Furthermore, weld validation is defined as
the process of confir-
mation by examination
of objective evidence
that the requirements
for a specific intended
use can be consistently
fulfilled (Ref. 13). Vali-
dation of the weld
process is a general re-
quirement for most
shipyard joining
processes, and in many
cases is demanded by
the customer (e.g., U.S.
Navy). The validation
process must encom-
pass both the operator as well as the
equipment used to perform the weld. The
validation process generally consists of a
combination of training and weld verifica-
tion (based on AWS weld process qualifi-
cation), leading to certification of weld op-
erators. Traditional welding equipment,
such as power supplies, are inherently a
part of the weld verification testing. Since
the fixed-track mechanized welding sys-
tems have been in service for a number of
years, there is evidence that these meet
validation standards, although a lack of
validation examples are present in the lit-
erature (Ref. 14). This paper demon-
strates and verifies a method for mecha-
nized welding in shipbuilding and related
industries that offers an alternative to the
fixed-track systems. The method is based
on the mobile, climbing skid-steer plat-
form with welding gun manipulator called
the Mobile Robotic Welding System
(MRWS) as described in Ref. 8. The
MRWS is able to weld in various locations
and orientations, including flat, vertical,
horizontal, and overhead. The MRWS is
designed to be a weld mechanization tool
that requires very little setup time when
compared to a fixed-track system. The
fixed-track system requires a track to be
accurately positioned and attached along
the weld joint prior to the welding process.
The time for track setup must be added to
the weld time to get an overall process
time. The use of a mobile robotic welding
system eliminates the vast majority of the
setup and take-down time, which im-
proves the overall productivity of weld
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Fig. 1 MRWS overall system. Fig. 2 MRWS overall control block diagram.
Fig. 3 Control pendant.
Fig. 4 MRWS frame orientation and degrees of freedom.
mechanization.
In addition, this paper presents a
method to demonstrate a level of weld val-
idation for new, robotic welding systems.
This is performed based on theoretical
validation of the robotic welding machine
at the time of design; therefore, it may be
termed design validation (Ref. 13). The
theoretical analysis focuses on the portion
of the MRWS that deviates from the fixed-
track system design. In particular, the
MRWS is based on a kinematic arrange-
ment that is significantly different from
that of the fixed-track system to achieve
similar gun motions. Further, the MRWS
relies on a high magnetic flux density in
the local vicinity of the weld joint while the
fixed-track systems use a much lower mag-
netic flux to attach the track to the struc-
ture (and often other forms of mechanical
attachment of the track to the welding sur-
face are used). The theoretical analysis
builds a justification for validation by com-
paring with existing mechanized weld sys-
tems. The empirical verification applies to
the complete MRWS system through the
AWS B2.1:2005 and D1.1/1.1M:2002
method for a specific weld type and orien-
tation (Refs. 11, 12).
The remainder of this paper proceeds
in the following order. First, a brief
overview of the MRWS system is provided
followed by a theoretical analysis and de-
sign validation approach of the MRWS for
the welding process. Then, an empirical
weld verification of a gas metal arc weld-
ing (GMAW) vertical groove weld on mild
steel with uphill progression, 3G-PF, that
was welded using the MRWS platform, is
performed. The paper is completed with
concluding remarks on the validation of
the overall system.
MRWS Overview
The MRWS is a mobile robot based on
two continuous permanent magnet tracks.
The robot can climb ferrous (steel) struc-
tures in any orientation. The robot weighs
approximately 60 lb and has a payload ca-
pacity of 100 lb that consists primarily of a
commercial wire feeder, welding gun, gun
manipulator, and sensor package. The
robot has onboard sensors, processing,
and a control algorithm that allows it to
operate in a semiautonomous fashion.
The robot platform consists of two sym-
metric endless chain track units with at-
tached magnetic feet. The magnetic track
units provide propulsion to the robot
while adhering to ferrous surfaces, allow-
ing for welding in all positions. Also con-
tained in each track unit is a suspension
that aids in adhering to an uneven welding
surface. Drive power is provided by DC
brushless motors, and the control is a com-
bined system of drivers and microcon-
troller to provide a closed-loop system.
Figure 1 shows the MRWS as a field-ready
system.
Robot navigation is defined globally by
the operator through remote control,
while the robot locally uses operator in-
puts to close the loop on gun trajectory
control. During operation, the welder ob-
serves the weld in situ and makes gun tip
position input and speed corrections as
needed. An overview of the robot control
diagram is shown in Fig. 2.
The robot platform supports a five-
degree-of-freedom gun manipulator to pro-
vide local control of the gun. The gun travel
angle is adjusted manually, while the gun
translation, perpendicular to the weld joint,
is actuated with a brushless DC motor, the
work angle is adjusted by a geared servo
motor, and the height of the contact tip is
controlled by a linear actuator. Coordinated
control of the robot platform motion and
gun manipulator is provided by the onboard
processor, allowing the gun motion to pro-
duce a variety of desired weld patterns. The
gun manipulator is independently sus-
pended from the platform to isolate it from
any motion disturbances, as well as keep the
gun adjustments relative to the surface local
to the weld.
The weld operator interacts with the
robot through a robot-control pendant,
shown in Fig. 3. The control pendant al-
lows the operator to drive the robot man-
ually or to supervise its semiautonomous
operation, and to define the weld motion
characteristics such as forward and trans-
verse speeds, dwell times, weld patterns,
etc., remotely.
Theoretical Validation of the
MRWS for Welding Processes
Theoretical Validation Overview
This section presents a theoretical
basis for validating the MRWS for welding
processes. When comparing the MRWS
system with existing fixed-track welding
systems, two fundamental differences
arise in their design and operation that
have the potential to impact the welding
processes: 1) kinematic differences in
achieving desired motions of the gun, and
2) variation in how tractive forces are gen-
erated between the welding platform and
the surface on which the weld is per-
formed. These are addressed in order in
the following sections.
Theoretical Validation Based on Motion
Control
The ability of the MRWS to provide
necessary motion control is directly influ-
enced by its kinematic arrangement. The
gun motion is described by its position and
time derivatives: gun velocity, accelera-
tion, and so forth. To perform a desired
weld, the gun must follow a specified weld
trajectory in a smooth manner. This tra-
jectory consists of both the geometric de-
scription of the gun position along with
gun velocities and accelerations along the
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Fig. 6 Manipulability ellipses surrounding the MRWS platform.
Shaded and hatched regions are the MRWS platform.
Fig. 5 Fixed track frame orientation and degrees of freedom.
path. A smooth trajectory requires, at a
minimum, the ability to specify both robot
position and velocity throughout the path
motion. The kinematic arrangement of
the MRWS defines the geometric position
and velocity characteristics, and this is val-
idated by comparing these capabilities in
turn with an accepted reference system.
For this work, the reference system is a
fixed-base track system with mobile car-
riage. These fixed-track systems are well
accepted for mechanized weld processes
(for example, Bug-O, Gullco, and Koike
track systems) (Ref. 14).
Considerations for gun position: For
theoretical validation of gun position con-
trol, the gun manipulator on the MRWS
must span the gun position space provided
by the reference system while avoiding inte-
rior singularities (positions on the interior
of the workspace in which the robot loses
one or more degrees of freedom (dof)). The
position kinematics of the MRWS system
are compared to that of the reference sys-
tem. Note that for this comparison, the
mechanisms to control the work angle,
travel angle, and gun plunge (tip depth) are
considered common to both systems, and
are not included in this analysis.
The MRWS is a mobile manipulator
system consisting of a 2-deg-of-freedom
tracked mobile platform connected in se-
ries with a 3-deg-of-freedom Prismatic-
Revolute-Prismatic (P-R-P) serial gun ma-
nipulator. Prismatic and revolute refer to
the type of single-degree-of-freedom
joints used to form the gun manipulator. It
is assumed that the mobile platform is on
a planar surface. Figure 4 provides a
schematic of the MRWS with gun manip-
ulator. Frames {I}, {R}, and {T} denote
the inertial, robot chassis centroid, and
gun tip frames, respectively, and repre-
sents the rotation of {R} with respect to
{I}. The left and right tracks are actuated
with inputs
l
and
r
, while d
2
,
w
, d
3
are
the inputs to the P-R-P gun manipulator.
The length of the track is given by l while
the distance between the centerline of the
tracks is given by 2b. To consider the posi-
tion kinematics, assume that the robot
frame translates along the weld axis (x) by
a distance d
1,MRWS
, while the gun manip-
ulator translates in a direction transverse
to the weld axis in the plane of the surface.
Then, a kinematic description of gun mo-
tion with the work angle and travel angle
removed is given as
where d
1,MRWS
is the robot translation
along the weld joint from the mobile unit,
d
2,MRWS
is the translation of the toolbar
and d
3,MRWS
is the translation along the
gun (plunge).
Figure 5 presents a kinematic diagram
of a fixed-base track system for mecha-
nized welding. This kinematic description
of the gun motion from the reference sys-
tem is given as
Comparing Equations 1 and 2 demon-
strates that the MRWS spans the gun po-
sition space of the reference system as
long as
d
1,MRWS
d
1,ref
d
2,MRWS
d
2,ref
d
3,MRWS
d
3,ref (3)
which can be satisfied by the mechanical
system design. Further, it is noted that no
interior singularities exist when the work
angle and travel angle are removed from
the system kinematics.
Considerations for gun velocity: To
provide smooth trajectories offered by the
reference system, the MRWS must match
the velocity capabilities of the reference
system. While validation of the MRWS
gun positioning capability was intuitive
and involved a direct comparison of the
geometric positioning behavior of the
MRWS with the reference system, consid-
eration of the velocity behavior is less in-
tuitive. However, the process will proceed
in a similar manner by comparing the ma-
nipulability ellipsoids (Ref. 15) of the
MRWS to the reference system. The ma-
nipulability ellipsoid is a geometric repre-
sentation of the velocity characteristics of
a manipulator based on a singular value
decomposition of the Jacobian matrix of
the manipulator where the singular vec-
tors define the direction, and the singular
values define the magnitude of the axes of
the manipulability ellipse (Refs. 15, 16).
When placed in context with the welding
process, a manipulability ellipse defined in
the plane of the welding surface gives a
measure of the maximum end-effector ve-
locity that can be achieved based on a unit
set of input joint velocities. Motion in any
desired direction within the welding plane
can be found as the length of a line paral-
lel to that direction that passes through
the center of the ellipse and is bounded by
its edges (Ref. 16). For purposes of vali-
dation, the MRWS system is said to be val-
idated for motion control if its manipula-
bility ellipse spans a majority (75% or
more) of the corresponding manipulabil-
ity ellipse for the reference track-based
system. The comparisons are performed
in the following manner. Based on the
kinematic arrangement of the MRWS
(shown in Fig. 4) and reference system
(shown in Fig. 5), the kinematic relation-
ships between joint level and gun velocity
are described in the form of the manipu-
T
d
d
d
TMRWS
I
MRWS
MRWS
=
1 0 0
0
0 1
1
2
3

0 1
0
,
,
,MMRWS
0 0 0 1
1

( )
T
d
d
d
T ref
I
refS
ref

0 1
0
=
1 0 0
0
0 1
1
2
3
,,
,,
,,,
( )
ref
0 0 0 1
2


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Fig. 8 Manipulability ellipse of the platform as the theta of the plat-
form changes about the weld joint.
Fig. 7 Manipulability ellipses at points A, B, and C.
lator Jacobian (see appendix for details).
A singular value decomposition of the sys-
tem Jacobians is then carried out to define
the manipulability ellipse of each respec-
tive manipulator. The results are shown
for the output axes lying in the plane of the
welding surface as shown in Figs. 68.
From the kinematic solution, it is noted
that in a fixed-base track system, the ma-
nipulability ellipse is a unit circle and in-
variant with respect to actual mounting
position of the gun while on the MRWS,
the gun mounting location does play a role
in determining the manipulability of the
gun. This is shown in Fig. 6, where the ma-
nipulability ellipse of the MRWS (solid
lines) and the fixed track system (dashed
lines) are compared at
various locations rela-
tive to the MRWS plat-
form. In this figure, an
outline of the MRWS
is shown for scale pur-
poses. From Fig. 6, the
manipulability of the
MRWS is seen to be
symmetric about the
local frame {R} x and y
axes of the MRWS
platform. Three loca-
tions are identified on
Fig. 6 in which to consider gun placement
in detail: point A (leading edge of MRWS
platform), point B (corner of MRWS plat-
form), and point C (side of MRWS plat-
form). Each gun location is shown in de-
tail in Fig. 7. From Fig. 7, it can be seen
that in all three positions, the manipula-
bility ellipse of the MRWS with gun ma-
nipulator largely spans that manipulability
of the fixed-track system kinematics. The
minimum coverage occurs at location A,
where the MRWS manipulability ellipse
intersects 79% of the fixed track manipu-
lability ellipse. This implies, based on the
proposed criteria of 75% minimum cover-
age, that the MRWS provides acceptable
motion control for all weld applications in
which fixed-track mechanization is used.
In addition to gun-mounting location,
the MRWS kinematics demonstrates de-
pendence on the orientation between the
platform longitudinal axis and weld axis
(, Fig. 3). The manipulability ellipse of
the MRWS with gun located at point A
(Fig. 6) is compared with the fixed track
system for increasing values of from 5 to
35 deg in Fig. 8, and the area of intersec-
tion is constant at 79%. From Fig. 8, it can
be seen that the effect of MRWS orienta-
tion is a rotation of the manipulability el-
lipse and does not change the area of in-
tersection with the manipulability ellipse
of the fixed-track system. Thus, this
demonstrates that the MRWS provides ac-
ceptable motion for all weld applications
and is invariant to the alignment between
the MRWS platform and the weld joint.
Tractive Magnet Interaction with the
Welding Process
The MRWS generates tractive forces
with the welding surface through a track
consisting of a series of permanent mag-
nets. The number and density of these
tractive magnets are much greater than
that commonly found on fixed-track weld-
ing systems. The introduction of a mag-
netic field to the welding process can in-
terfere with the welding process through
magnetic arc blow and must be investi-
gated to determine positions where the
magnetic flux will not interfere with the
welding arc. The MRWS track is designed
to contain the magnetic field generated by
the magnetic feet to a small region en-
compassing the tracks, and to position the
welding process outside of this region. To
evaluate the track design, a finite element
analysis (FEA) model of the MRWS-
generated magnetic field is studied, vali-
dated with empirical data, and used to de-
fine acceptable locations for the welding
gun. The acceptable regions are defined as
those that demonstrate a magnetic field less
than the allowable field as identified for typ-
ical welding processes. These values are
shown for a variety of welding processes in
Table 1, which is adapted from Ref. 17.
An analysis of the magnetic field asso-
ciated with the tracks of the MRWS ad-
hering to -in.-thick steel is presented in
Fig. 9. The plot color scale for FEA results
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Fig. 9 Average magnetic field strength in the plate due to tractive magnets.
Fig. 10 Macroscopic picture of the as-deposited weld bead.
Table 1 Effects of Magnetic Arc Blow on Different Welding Processes
Welding Process 010 gauss 1020 gauss 2040 gauss More than 40 gauss
GTAW no effect arc instability arc blow severe arc blow
GMAW no effect no effect arc instability arc blow
SAW no effect no effect no effect arc instability
Table 2 Welding Process Parameters
Welding Parameters
Current (A) 110
Voltage (V) 17.5
Wire Speed (in./min) 120
Trim Setting 0.97
Gas Flow Rate, ft
3
/h 35
(95%Ar + 5%O
2
)
Travel Speed (in./min) 2 to 4
Contact Tip to Work Distance (in.) 1/2 (nominal)
Electrode 0.045 ER70S-6E
Forward Torch Angle (deg) 12
are defined so that the gray region is an av-
erage magnetic flux greater than 10 gauss
while the blue regions are less than 10
gauss. Therefore, the gun should not be lo-
cated in gray regions due to potential mag-
netic arc interaction (a magnetic flux
higher than 10 gauss). All blue areas
around the tracks are suitable regions for
any of the welding processes listed in Table
1. The numerical analysis is reinforced
with physical testing of the MRWS in the
same arrangement. The MRWS was
placed on a large (assumed semiinfinite,
given robot size to sheet ratio) -in.-thick
sheet of steel and an AlphaLab, Inc., DC
Gaussmeter M1HS was used to measure
the normal component of magnetic flux
around the mobile platform. The meter
readings were compared with the numeri-
cal analysis and demonstrated strong
agreement with the FEA results. Further-
more, in-service welding has been done in
a variety of gun positions in the blue re-
gion shown in the FEA plots. During these
welds, no visible magnetic arc blow was
seen, and no defects typical of magnetic
interference were found.
The results of this analysis and physical
testing demonstrate that the MRWS offers
suitable regions for gun positioning that will
satisfy the limits of all welds demonstrated
in Table 1. In particular, the focused appli-
cations for the MRWS are the short-arc
GMAW process (second row) and pulse-arc
GMAW process (similar requirements to
gas tungsten arc welding (GTAW), first row,
Table 1). Therefore, these analyses demon-
strate that the MRWS meets the weld
process requirements for GMAW and
GTAW applications that are employed on
other mechanized platforms.
MRWS Empirical Verification
Empirical Verification Overview
This section presents an empirical
basis for verifying the MRWS for a spe-
cific welding process. The process chosen
was a GMAW vertical groove weld on
mild steel with uphill progression, 3G-PF.
This weld process was viewed as a com-
mon weld joint performed in a typical
shipyard. The empirical test is based on
the American Welding Society (AWS)
procedure qualification for a vertical
groove weld. The test methods required
for a groove weld are visual examination,
tension test, and guided bend test (root
bend) (Ref. 11). All tests performed com-
ply with the American National Stan-
dards Institute (ANSI) AWS
D1.1/D1.1M:2002 standards (Ref. 12).
The experimental setup and equipment
are outlined followed by the experimen-
tal results. Accordingly, a detailed dis-
cussion of how the samples compared to
the AWS specifications are presented.
Experimental Setup and Procedure
The test samples were fabricated using
the MRWS with a Lincoln Electric Power
Wave 455 welding machine, and Power
Feed 10 wire feeder, set up for pulsed
spray gas metal arc welding. The weld was
performed on 0.5-in.-thick ASTM A36
structural steel using a B-U2a-GF groove
type with 0.125-in. steel backing. The weld
groove had a 45-deg angle and a root
opening of in. The electrode used was
0.045-in.-diameter ER70S-6E, and the gas
mixture was 95% argon 5% oxygen at a
flow rate of 35 ft
3
/h. Three weld passes
were completed, each using a trapezoidal
weave pattern. The welding machine was
utilized in pulse program mode with set-
tings of 17.5 V, 110 A, 120 in./min wire
speed, and 0.97 trim setting. The MRWS
settings used were 24 in./min travel
speed, 0.5-in. contact tip-to-work distance
(CTWD), and 12 deg of forward gun
angle. Weave speed and dwell times were
varied during the process to create a uni-
form bead.
Once welded, a visual inspection was
performed, and metallurgical samples
were removed. The steel backing was re-
moved, and the plate was machined flat
(eliminating the curvature due to welding
distortion). Tensile and root bend test
specimens were then cut from the welded
plate in accordance with the AWS specifi-
cation. Reduced section tensile samples
were loaded using an MTS 810 servo-
hydraulic load frame. All samples were
loaded until failure at a constant displace-
ment rate of 0.200 in./min. Base metal re-
duced section tensile samples were also
prepared to get a more accurate value of
the tensile strength of the A36 steel whose
published tensile strength has a wide
range of 58,00079,800 lb/in.
2
of possible
values. Root bend test samples were also
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Fig. 11 Stress vs. displacement overlay.
Fig. 12 Macroscopic surface of the root bend test
sample.
Table 3 Ultimate Tensile Strength Data
Summary
Reduced Section Tensile Test Data (ksi)
Base Metal 1 73.5
Base Metal 2 73.2
Weld Sample 1 73.9
Weld Sample 2 75.0
Weld Sample 3 74.1
Weld Sample 4 75.7
Weld Sample 5 75.3
Table 4 Root Bend Convex Surface Void
Size Summary
Root Bend Test Void Size (in.)
Void 1 0.040
Void 2 0.020
Void 3 0.045
Void 4 0.034
Void 5 0.028
prepared from the same weld sample. The
bend samples were bent in a hydraulic
guide bend test fixture with a main die di-
ameter of 1.50 in. and deformed to an in-
cluded angle of 80 deg. The convex surface
was then inspected for inclusions and dis-
continuities as called for in the AWS
specification.
Test Data
Visual inspection of the as-deposited
welds was completed using macroscopic
and microscopic devices. The microstruc-
ture of the weld cross section was studied
to investigate the weld nugget and pene-
tration depth. The force-displacement
tensile test data were converted to stress-
displacement by using the initial starting
cross-sectional area from each sample.
Matlab software was used for data pro-
cessing and to extract the maximum ten-
sile strength value of each sample data set.
Table 3 outlines the maximum tensile
strengths of the samples. The welded ten-
sile samples did break in the weld area and
were subsequently inspected for any in-
complete fusion or inclusions that would
have acted as a failure initiation site. The
samples were found to have complete fu-
sion and no inclusions were visible on the
macroscopic scale. The root bend test
samples were inspected for any disconti-
nuities or voids on the convex surface of
the sample. Table 4 shows the representa-
tive void measurements on convex surface
for the bend test samples; only a small
number of voids are visible and all voids
were measured using digital calipers.
Test Results and Discussion
Here, each individual area of the AWS
specification is addressed with its appropri-
ate test data. The acceptance criteria is
given followed by how the MRWS test sam-
ple met the requirements for qualification.
Visual inspection of the as-deposited weld:
AWS states the weld should be free of
cracks, all craters shall be filled to full cross
section of the weld, the face of the weld
should be flush with the surface of the base
metal and merge smoothly with the base
metal, no undercut should exceed 0.031 in.,
and, finally, the root shall be inspected and
there should be no evidence of cracks, in-
complete fusion, or inadequate joint pene-
tration. Figure 10 shows a macroscopic pic-
ture of an as-deposited weld and the
polished and etched cross section of a weld
performed with the MRWS. The macro-
scopic photograph shows adequate weld re-
inforcement and no visual cracks, under-
cuts, or voids. The cross section of the weld
nugget, as-deposited (etched with Nital so-
lution), has adequate penetration of all
three passes and there are no voids or in-
complete fusion of the weld.
Reduced section tensile samples: AWS
states that the tensile samples can break in
the welded area as long as tensile strength
is no less than the published minimum ten-
sile strength of the base material, in this
case A36 structural steel whose published
tensile strength is 58,00079,800 lb/in.
2
.
This published range is very large and,
therefore, base metal tensile samples are
included to get a better understanding of
the tensile strength of the base metal. Fig-
ure 11 shows the stress vs. displacement
overlay plot of seven reduced section ten-
sile samples, five welded and two base
metal samples. It is shown that the welded
samples reached a higher stress level than
the base metal samples, the red horizontal
line of the graph represents the maximum
value for the base metal samples. It should
be noted that the welded samples did
break in the welded area; however, post-
failure inspection did not reveal any inclu-
sions or areas with incomplete fusion.
Root bend samples: AWS states that the
convex surface of the bent sample should
be examined for surface discontinuities,
all discontinuities shall not exceed the fol-
lowing dimensions: 0.125 in. measure in
any direction on the surface, 0.375 in.
the sum of the greatest dimension of all
discontinuities exceeding 0.031 in. but less
than or equal to 0.125 in., 0.250 in. maxi-
mum corner crack length. The tested sam-
ples show very little discontinuities on the
convex surface and had no corner crack-
ing. Figure 12 shows a macroscopic view of
the convex surface with the major discon-
tinuities highlighted; the vertical lines are
positioned just outside of the root of the
weld to base metal interface, which is
barely visible. No edge cracking was seen,
and this is a clear indication of the pene-
tration depth of the root pass achieved
using the MRWS.
Conclusions
The MRWS is a mobile welding robotic
platform designed to perform the same
types of welds currently mechanized using
fixed-track systems. The advantage of the
MRWS is that it eliminates the majority of
setup time associated with fixed-track sys-
tems. The MRWS can eliminate a large
portion of the nonvalue-added time in set-
ting up for a mechanized weld. This paper
demonstrates the validity of the MRWS in
performing GMAW-type welds on plate
steel. This validation process consisted of
two parts: theoretical validation consider-
ing kinematic arrangement, motion con-
trol capability, and magnetic interaction,
and empirical verification based on the
AWS qualification standards for a 3G-PF
vertical groove weld. For theoretical vali-
dation, kinematic arrangement and mag-
netic field interaction are identified as the
primary differences between the MRWS
and traditional, track-based mechanized
weld tools. The motion-control capability
(which stems from the kinematic arrange-
ment) of the MRWS was validated by com-
paring the ability to track smooth trajec-
tories as defined by the reference system
through comparison of the positioning
and velocity characteristics. When com-
paring the positioning capability, it was
demonstrated that the MRWS can meet
the positioning requirements at the design
stage through range of motion of the
transverse and plunge axes. When com-
paring the velocity capability, it was noted
that the MRWS met the imposed require-
ments with a manipulability ellipse that
spanned 75% or more of the reference
manipulability ellipse for all gun locations
and orientation of the MRWS to the weld
joint. This is deemed as an acceptable (val-
idated) standard. The magnetic field in-
teraction was tested by again comparing
possible gun locations with an allowable
magnetic field induced by the magnetic
tracks. This comparison showed the
MRWS was well within the limits for all
welding types defined. Finally, an empiri-
cal weld test was performed to AWS and
ASME specifications. All tests called for
by the AWS qualification were met or ex-
ceeded by the weld performed by the
MRWS demonstrating a verified system
for this weld configuration. This is an im-
portant step forward for the introduction
of mobile robotic fabrication in unstruc-
tured environments. The ability for
mobile welding robots to perform welds
that can be certified and pass stringent
qualifications is an essential step in in-
creasing the level of automation in un-
structured manufacturing environments.
References
1. Ang, M. H. Jr., Lin, W., and Lim, S. 1999.
Walk-through programmed robot for welding
in shipyards. Industrial Robot, Vol. 26, No. 5, pp.
377388.
2. Gonzalez De Santos, P., Armada, M. A.,
and Jimenez, M. A. 2000. Shipbuilding with
Rower. IEEE Robotics and Automation Maga-
zine, Vol. 7, No. 4, pp. 3543, Dec.
3. Luk, B. L., Cooke, D. S., Galt, S., Collie,
A. A., and Chen, S. 2005. Intelligent legged
climbing service robot for remote maintenance
applications in hazardous environments. Robot-
ics and Autonomous Systems, Vol. 53, No. 2, pp.
142152, Nov. 30.
4. Albus, J., Bostelman, R., and Dagalakis,
N. 1993. NIST RoboCrane. Journal of Robotic
Systems, Vol. 10, No. 5, pp. 709724, July.
5. Mulligan, S., Melton, G., Lylynoja, A.,
and Herman, K. 2005. Autonomous welding of
large steel fabrications. Industrial Robot: An In-
ternational Journal, Vol. 32, No. 4, pp. 346349.
6. Kam, B. O., Jeon, Y. B., and Kim, S. B.
2001. Motion control of two wheeled welding
mobile robot with seam tracking sensor. Proc.
ISIE 2001 IEEE Int. Symposium on Industrial
Electronics, Vol. 2, pp. 851856.
7. Pan, J., Yan, B., Gao, L., Zhang, H., Lu,
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Q., and Jin, K. 2005. Crawl type robot tackles
difficult jobs. Welding Journal 85(1): 50.
8. OToole, A., and Canfield, S. L. 2010. De-
veloping a kinematic estimation model for a
climbing mobile robotic welding system. Proc.
of the 2010 ASME International Design Engi-
neering Technical Conferences, Montreal, Que.,
Canada, Aug. 1518, DETC2010-28878.
9. Canfield, S. L., Beard J. W., and
Munukutla, S. 2003. A mobile robot for auto-
mated boiler tube inspection. Thermal Power
Generation Best Practices & Future Technologies
International Conference, New Delhi, India,
Oct. 1013.
10. Canfield, S. L., Beard, J. W., Coffey, M.
R., and Halcomb, S. M. 2005. Robotic inspec-
tion in power plants. ISA 51st Annual Instru-
mentation Symposium, Knoxville, Tenn., May
10.
11. AWS B2.1:2005, Specification for Weld-
ing Procedure and Performance Qualification.
Miami, Fla.: American Welding Society.
12. ANSI/AWS D1.1/D1.1M:2002, Struc-
tural Welding Code Steel. Miami, Fla.: Amer-
ican Welding Society.
13. Steinmeier, D. 2009. Validating the re-
sistance welding process. Welding Journal
88(12): 42.
14. Product Case Study File; Langfields Sec-
tion Welds - Pipe KAT Orbital Welding System.
2011. www.gullco.com/weldingautomationspe-
cialapplications.html.
15. Spong, M. W., Hutchinson, S., and
Vidyasagar, M. 2006. Robot Modeling and Con-
trol. Hoboken, N.J.: John Wiley and Sons, Inc.
16. Gardner, J. F., and Velinsky, S. A. 2000.
Kinematics of mobile manipulators and impli-
cations for design. Journal of Robotic Systems
17(6), pp. 309320, June.
17. Blakeley, P. J. 1991. Magnetic arc blow
Causes and remedies. Welding & Metal Fab-
rication, Vol. 59, No. 7, pp. 401404, Aug./Sept.
18. Diverse Technologies. 2009. Magnetic
effect on the welding process. home.btcon-
nect.com/diversetech/layer2/zeropr.htm, Dec. 11.
Appendix
The MRWS is a 5-deg-of-freedom mo-
bile manipulator with input vector q is
given as
with
and
l
,
r
are left/right track inputs and d
2
,
w
, d
3
are the inputs to the P-R-P gun ma-
nipulator. The direct kinematics of the
mobile tracked portion of the robot sys-
tem can be given (Ref. 8) as
where v
R
I
is the velocity of {R} with re-
spect to {I} given in the {I} frame, R
R
I
=
R
z
() the rotation operator project {R} to
{I} and
with x
ic
, y
lic
, y
ric
the coordinates locating
the instant centers of the contact portion
of the left and right track in the {R} frame.
The direct kinematics of the manipula-
tor portion of the MRWS can be written as
where v
R
T
is the velocity of {T} with re-
spect to {R} given in the {R} frame, and
is the Jacobian of the gun manipulator,
whose pose is described relative to the {R}
frame as
where c
w
= cos(
w
), s
w
= sin(
w
), l
0
, l
1
are
the offsets along x
R
and z
R
, respectively, to
the gun and
w
= /2 when the work
angle is ignored.
The kinematics of the base (A3) and
manipulator (A5) can now be combined to
define the kinematics of the mobile ma-
nipulator as
or
where S(o
n
) is the skew symmetric matrix
of o
n
, and o
n
is given as the fourth column
of the homogenous transformation T
T
R
.
This yields the MRWS system Jacobian
matrix as
with
v Jq
R K
R K
q
R J
R J
I
T
I
R
I
R
I
R
I
R
= =
|
|
|
|
|
|
|
|
|
|
+
|

1
2
1
1
2
||
|
|
|
|
|
|
|
|
+
( )
|
|
|
|
|
|
|
|
|
|
=
q
R S o K
O
q I
R
n
T
2
2
3 2
1
RR K S o K R J
R K R J
I
R
n I
R
I
R
I
R
1 2 1
2 2
+
( ) ( )
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
q
q
1
2
(A9)
J
J
J
TM
=
|
|
|
|
|
|
|
|
=
1
2
0 0 0
1
0
0
3
3 2
d s c
d c sw
w w
w

1 0
0 0 0
0 0 0
(A
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
66)
T
l
s c
T
R
w w
=

0 1 0
0
0
0
0 0
2
d
c s l
w w
1
00 1
(A7)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
v v v d Jq
I
T
I
R
R
T I R
T
R
= + + =
(A8)
v J q
T
R
TM
=
2
(A5)
q q
d
d
l
r
w 1 2
2
3
( =
|
|
|
|
|
|
|
|
=
|
|
|
|
|
|
|
|
|
|
|
|
, AA2)
v R K q
I
R
I
R
eq
=
1
(A3)
K
K
K
y y
y
eq
ric lic
r
=
|
|
|
|
|
|
|
|
|
|
=
( )
( )
( )
1 3 2
2 3 2
1
iic lic
ic ic
r y r
x r x r
0 0
0 0
0 0
r r
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
(A4)
q
q
q
=
|
|
|
|
|
|
|
|
1
2
(A1)
J
j j
=
11 12 3
21
s ss d sc
j
w w
22 3
j c cs d
w
0 0
cc
w
0 c
3 w w
d s
0 0 0 0
0
c
0 0 0 s
r
y y
r
y y
lic ric lic ric

0 0 0
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(A10)
j
r d c y c l s x s c cd
y y
ic
lic ric
11
2 0 2 3
( =
+ +
( )
( )
ric
AA11)
j
r d c y c l s x s c cd
y y
ric ic
lic ric
12
2 0 2 3
=
+ +
( )
( )
((A12)
j
r d s y s l c x c c sd
y y
ric ic w
lic ric
21
2 0 3
( =

( )
( )
AA13)
j
r d s y c l c x c c sd
y y
lic ic
lic ric
22
2 0 w 3
=
+ + + +
( )
( )
((A14)
c s =
( )
=
( )
cos , sin (A15)
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Introduction
Plasma arc welding (PAW) introduced
by Gage in 1957 (Ref. 1) offers certain ad-
vantages. As an extension of gas tungsten
arc welding (GTAW), PAW uses a constrict-
ing nozzle/orifice to create a plasma arc that
has a higher heat density. This increased
heat density not only provides higher arc
temperatures, but also a much stronger arc
force. In general, its most widely used con-
figuration is the transferred arc PAW, in
which the plasma arc is formed between the
tungsten electrode and workpiece as shown
in Fig. 1. Its welding current is generally set
to be direct current electrode negative
(DCEN) in order to provide better control
of the energy release (Ref. 2). In addition,
since the plasma arc is highly constricted
compared with electrical arcs in GTAW
process, the arc length has an excellent lin-
ear relationship with the arc voltage under
the same welding current. As a result, a
measurement of arc voltage may indicate
the arc length more accurately to better re-
flect the penetration. In this paper, the
transferred arc PAW is studied for pipe
welding.
The transferred arc PAW process typi-
cally operates in either keyhole or melt-in
(conduction) mode (Ref. 3). The special
torch used in PAW has a constraining ori-
fice (Ref. 4) designed to deliver a highly
constrained plasma jet. Keyhole mode can
obtain much deeper penetration com-
pared with other arc welding processes. In
this mode, the plasma jet melts the work-
piece and displaces the molten metal to
form a keyhole or deep narrow cavity
(Ref. 5). By doing this, the plasma jet is
able to heat the workpiece through the
whole thickness, giving keyhole PAW high
penetration capability (Ref. 6). On the
other hand, melt-in mode, with reduced
penetration capability, is suitable for join-
ing thin sections (0.0251.5 mm or
0.0010.060 in.), making fine welds at low
currents, and joining thicker sections (up
to 3 mm or 0.125 in.) at high currents. The
operation of melt-in mode is similar to
that of GTAW process.
Repeated experiments show that weld
beads made by keyhole PAW typically
have relatively large and irregular ID
(inner diameter) reinforcements associ-
ated with a considerable amount of spat-
ter. On the other hand, those made by
melt-in PAW show large ID weld beads
that may cause excessive convexity around
12 oclock and concavity around 6 oclock.
To resolve these issues, the authors pro-
pose the double-stage PAW process, which
combines keyhole and melt-in mode into
a single welding procedure.
Experimental System
A controlled PAW system is illustrated
in Fig. 2. In the control system (left block
in Fig. 2), control/feedback signals are iso-
lated and filtered to avoid possible dam-
ages to the embedded control
system/computer and reduce noises. The
embedded controller is programmed to
obtain feedback signal measurements
from the welding process. The control al-
gorithm considers these measurements as
controller inputs and calculates to deter-
mine the output that is the welding cur-
rent. A Thermal Arc PWH-3A plasma
welding torch was selected to conduct
PAW experiments. The torch was powered
by a constant current (CC) welding ma-
chine. The polarity of the power supply
was set to be DCEN. The torch was water-
cooled by the coolant recirculator inside
the power supply. Pure argon was used as
the shielding gas, plasma gas, as well as
backside purging gas for the pipe. Also, to
Double Stage Plasma Arc Pipe
Welding Process
An innovative arc process is developed to produce consistent complete joint
penetration pipe welds of desired inner diameter convexity on open root joints
at all positions with 50% heat input reduction
BY X. R. LI, Z. SHAO, AND Y. M. ZHANG
KEYWORDS
Keyhole Mode
Melt-in Mode
Penetration Control
Pipe Welding
Net Heat Input
X. R. LI, Z. SHAO, and Y. M. ZHANG are with
Adaptive Intelligent Systems, LLC, Lexington,
Ky. Y. M. ZHANG (ymzhang@engr.uky.edu) is
also with the Department of Electrical and Com-
puter Engineering and Institute for Sustainable
Manufacturing, University of Kentucky, Lexing-
ton, Ky.
ABSTRACT
Plasma arc welding (PAW) keyhole mode uses highly penetrating plasma jets to pro-
duce narrow inner diameter (ID) beads but causes bead irregularity, undesirable wetting
angles, and spatter. For the melt-in mode, plasma jets are less penetrating and greater
heat inputs are needed to achieve the needed penetration. As a result, wider weld beads
are produced similarly as gas tungsten arc welding (GTAW). For orbital pipe welding, re-
duced heat inputs and weld pools are needed to reduce the ID convexity around 12
oclock and achieve the needed convexity around 6 oclock. To this end, a novel PAW
mode, namely the double-stage PAW, is proposed that uses a keyhole stage to build a par-
tially penetrated keyhole and then a melt-in stage to finally reach complete joint pene-
tration. While the keyhole stage helps reduce the heat inputs and weld pools, the melt-in
stage finishes the complete penetration at reduced impacts from the plasma jets pro-
ducing the desired weld bead geometry and regularity. A closed-loop control system has
been developed to adaptively determine the duration of the melt-in stage using arc sig-
nals to assure the complete joint penetration. Extensive experiments have been con-
ducted on stainless steel pipes around the full circumferance producing smooth weld
beads of moderate width with no spatter. In comparison with keyhole PAW, bead geom-
etry and regularity are significantly improved with slightly increased net heat inputs. In
comparison with melt-in PAW and GTAW, the net heat input is reduced approximately
40% resulting in 40% reduction in ID weld bead width.
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avoid possible operation variations, all ex-
periments were conducted with an orbital
pipe welding system.
To demonstrate the effectiveness of the
proposed double stage PAW process,
Schedule 10 Grade 304 stainless steel pipes
with 3.5-in. OD (outer diameter) was se-
lected to conduct the experiments. Its alloy
composition is listed in Table 1. Square butt
joints without an intentional root opening
were welded without filler metal.
Observation of Problems
The PAW process gives different per-
formances in keyhole and melt-in modes.
For keyhole mode, the highly constricted
arc is capable of reaching complete joint
penetration rapidly. However, due to the
high-penetration capability, the weld bead
produced with keyhole mode tends to have
large ID reinforcement (convexity on the
backside bead). At the same time, there
may be spatter blown out of the weld pool
by the strong plasma jet. On the other hand,
for melt-in mode, its moderate penetration
capability resembles that of the GTAW
process, which is capable of generating
smooth weld beads. However, the welding
current needs to be in-
creased considerably
in order to produce
complete penetration
on same joints. The
melt-in mode thus can
only be used to weld
pipes with thicknesses
much less than those
that can be welded
with the keyhole mode. In addition, since
heat input is increased, the weld pool be-
comes large and sometimes collapses may
occur. Experimental results are presented
below to demonstrate these issues with
these two modes.
Welds Made in Keyhole Mode
The weld beads produced by keyhole
PAW are sensitive to a number of welding
parameters including welding speed, weld-
ing current, flow rate and composition of
plasma/shielding gas, electrode setback,
torch standoff distance, etc. (Refs. 7, 8).
Extensive studies have been conducted on
keyhole PAW at the University of Ken-
tucky Welding Research Laboratory. Ef-
fective methods have been proposed,
implemented, and tested for the control of
the keyhole PAW process (Refs. 912).
With the control system developed in Ref.
13, welding parameters can be adjusted to
generate a consistent weld bead in the
presence of various disturbances. Its prin-
ciple is to pulse the welding current to in-
tentionally produce a varying weld pool
and associated varying arc voltage and
then determine the weld penetration
depth from the arc voltage measurements
(Ref. 14). During the peak current period,
the welding torch stays at the same spot to
gain accurate measurement of arc length
from the arc voltage signal and to deter-
mine if the desired penetration has been
achieved. During the low-current base pe-
riod, the torch moves for a certain fixed
distance to the next spot and waits for the
next pulsing control period.
Fig. 1 Basic principle of the plasma arc welding process.
Fig. 2 Structure of the controlled PAW experimental system.
Fig. 3 Weld bead made by the keyhole PAW process. A Front side of
the weld; B back side of the weld.
Table 1 Alloy Composition (%) of Grade
304 Stainless Steel Pipes
Carbon 0.08
Manganese 2.0
Silicon 0.75
Phosphorus 0.045
Sulfur 0.03
Chromium 18.0~20.0
Molybdenum 2.00~3.00
Nickel 8.0~12.0
Nitrogen 0.10
Table 2 Major Welding Parameters for Keyhole PAW Specimen
Parameter Value Unit
Base period 800 ms
Base current 20 A
Peak period Adjusted ms
Peak current 110 A
Travel speed 1.22 mm/s
Shielding gas flow rate 15 ft
3
/h
Plasma gas flow rate 2.0 ft
3
/h
Electrode setback 2.0 mm
Orifice diameter 1.75 mm
A
B
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One of the specimens welded by con-
trolled keyhole PAW was produced with
major welding parameters listed in Table
2. Its weld bead is shown in Fig. 3.
To operate in keyhole mode, a relatively
small orifice diameter is needed. A rela-
tively large plasma gas flow rate is also
needed to further enhance the penetration
capability of the plasma jet. Then, the com-
plete joint penetration can be obtained
through the strong penetration capability of
the plasma jet. The resultant weld beads on
both sides are narrow (compared with
GTAW). However, strong penetrating
plasma jets also cause problems for keyhole
mode. Complete joint penetration is ob-
tained by punching a hole with a strong
plasma jet inside the liquid weld pool such
that a small portion of the melted metal in-
side the weld pool may be blown away as
spatter. Immediately after welding, small
particles of spatter were found inside the
pipe. At the same time, solidified weld
beads on the ID of the pipe exhibited geo-
metrical irregularities and excessive con-
vexities (over 2 mm reinforcement).
Welds Made in Melt-in Mode
As comparison, experiments with melt-
in mode PAW were also conducted. The
equipment, controller, as well as control al-
gorithms remained the same. To consider-
ably reduce the penetration capability,
welding parameters were modified as listed
in Table 3. A typical specimen welded with
melt-in mode is shown in Fig. 4.
To reduce the penetration capability,
the orifice diameter was increased and the
plasma gas flow rate was reduced. Due to
the weakened arc force, a larger heat input
had to be used by increasing the welding
current in order to achieve the desired
penetration. After these adjustments, the
process could operate in melt-in mode and
produce complete penetration, but it re-
sembled the behavior of the GTAW
process.
With fine-tuned welding parameters,
complete joint penetration welds were pro-
duced under melt-in mode. The weld bead
was smooth without undercut and large
convexity, similar to that made by the
GTAW process. The smooth weld bead met
visual inspection requirements. However,
due to the weak penetration capability,
complete penetration can only be guaran-
teed in a small welding speed range, which
makes it difficult for manual welding prac-
tice. Furthermore, the HAZ is large because
the weld penetration is achieved by conduc-
tion of heat under melt-in mode. The ex-
cessive heat input (compared with keyhole
mode) generates a large weld pool, which
may occasionally collapse.
Double-Stage PAW Process
The double-stage PAW process is pro-
posed to avoid problems and combine ad-
vantages in keyhole and melt-in modes.
Principles of Operation
In GTA pipe welding, a human welder
may adjust the welding current to com-
pensate for changes in welding conditions
Fig. 4 Weld bead made by the melt-in PAW process. A Front side of the weld; B back side of the weld.
Fig. 5 Principle of the double-stage PAW process.
Fig. 6 Flowchart for the proposed double-stage
PAW procedure.
Table 3 Welding Parameters for Melt-In PAW Process Test
Base time 600 ms
Base current 30 A
Peak time Adjusted ms
Peak current 125 A
3
/h
3
/h
A B
Li 12-12_Layout 1 11/9/12 1:29 PM Page 348
(welding position, joint opening, etc.). For
PA pipe welding, due to the narrow range
of operable welding current, a pulsing
welding current is preferred. A pulsing
current also makes the weld pool dynamic
and the resultant dynamic weld pool pro-
vides the basis for the penetration control
method proposed in this paper.
To be specific, the proposed pulsing
PAW process has two periods: peak and
base. Each peak period has two stages. The
first stage is to use a keyhole mode type of
operation to penetrate rapidly. However,
this stage stops before the keyhole fully pen-
etrates to the backside of the workpiece in
order to prevent the problems in a normal
keyhole mode aforementioned. Then, a
melt-in mode type of operation follows as
the second stage to continue and finish the
establishment of complete joint penetration
but in a smoother and slower manner with a
much lower penetration capability. The
weaker penetration capability similar as in
GTAW can produce smooth complete joint
penetration welds eliminating the geomet-
rical irregularities. That is, the first stage
achieves a penetration depth with a minimal
heat input and the second stage finishes the
complete penetration establishment process
using an arc similar to a GTA weld. Smooth
and relative narrow welds may be produced
in the second peak stage. The base period
further reduces the heat input to freeze the
liquid metal before the next peak period be-
gins. The proposed method is illustrated in
Fig. 5.
A preliminary control scheme with ref-
erence to Fig. 5 is proposed as follows:
1) Initialization of process, including
welding parameters and control parame-
ters;
2) Output the base current I
b
for the
base period T
b
;
3) Output the first peak current I
p1
for
the first peak period of T
p1
. Both I
p1
and
T
p1
are empirically determined;
4) Switch to the second peak current
I
p2
and then wait for a short period (typi-
cally less than 50 ms);
5) Sample the arc voltage and calculate
an average each 10 ms as the voltage
measurement V
p
;
6) For each four consecutive V
p
meas-
urements (e.g., at t
1
, t
2
, t
3
, t
4
, as in Fig. 5),
a linear model (or high order models in fu-
ture studies) is fitted by the least square
method;
7) The slope of the fitted curve is then
compared with a predetermined criterion.
If the slope is larger than the criterion (de-
sired penetration is not reached), go to
Step 5. Otherwise, jump to Step 2 to start
the next control pulse period.
The flowchart in Fig. 6 further illus-
trates the above control scheme.
The period and parameters for the first
stage determine how deeply the penetra-
tion is established. A deeper first-stage
penetration reduces the heat input of the
proposed process and width of the result-
ant weld beads but increases the chance
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Fig. 7 Top position weld bead made by the double-stage PAW process. A Front side of the weld; B back side of the weld.
Fig. 8 Side position weld bead made by the double-stage PAW process. A Front side of the weld; B back side of the weld.
Table 4 Welding Parameters for Double Stage PAW Process
Base period 800 ms
Base current 20 A
First stage period 200 ms
First stage current 110 A
Second stage period Adjusted ms
Second stage current 60 A
Penetration criterion 0.0 for side position
0.2 for top position V/s
0.4 for bottom position
Shielding gas 100% Argon
3
/h
Plasma gas 100% Argon
3
/h
Purging gas 100% Argon
Standoff distance 3.0 mm
A
B
A B
Li 12-12_Layout 1 11/9/12 1:29 PM Page 349
for the occurrence of normal keyholes and
corresponding problems. A less deep first-
stage penetration increases the heat input
and width of the weld beads but reduces
the chance for the occurrence of normal
keyholes and corresponding problems.
They need to be experimentally deter-
mined based on the requirements on weld
bead widths and heat inputs and the toler-
ance to possible keyhole occurrences.
In the second stage, the welding current is
reduced from that in the first stage, resulting
in a smaller arc force and less penetration
capability. However, although the weld pool
depression is reduced, it is still pronounced
and greater than that in GTAW. This still
pronounced local depression of the weld
pool under the plasma jet relates the devel-
opment of the weld pool depression to arc
length. As a result, the arc voltage may
measure the dynamic development of the
weld pool in the second stage and be used to
control and achieve smooth weld beads with
acceptable bead widths on both sides of the
pipe. From the beginning of the second
stage, the second peak current continues to
supply heat input into the weld pool. As a
result, the ID width of the weld pool may
still increase such that the weld pool de-
pression increases further. The develop-
ment of the weld pool in the second stage
may finally reach an equilibrium due to the
reduced heat input and arc pressure, in
which the desired weld pool widths on both
sides of the pipe are achieved, correspon-
ding to the second stage peak welding cur-
rent setting. Also, with the reduced arc force
in the second stage, the weld bead is also
smooth at this equilibrium. In order to stop
the second peak period at the equilibrium, a
closed-loop control is needed to determine
the weld pool development by sampling and
analyzing the arc voltage signal in real-time.
The penetration criterion defined in the
control algorithm reflects the desired arc
voltage slope near the equilibrium. By
changing the criterion in a small range, the
heat input in each pulse can be adjusted to
compensate the influence from different
welding positions.
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Fig. 9 Bottom position weld bead made by the double-stage PAW process. A Front side of the weld; B back side of the weld.
Table 5 Measurements of Weld Bead Geometry for Three Positions
Welding Position Top Side Bottom
OD bead width (mm) 9 8 9
OD reinforcement (mm) 0.5~0.8 0.2~0 0.5~0.8
ID bead width (mm) 4~5 4~5 4~5
ID reinforcement (mm) 0.3~0.8 0~0.2 0.3~0.7
Fig. 10 Measured variables from the double-stage welding process on
the top position sample pulse No. 1.
Fig. 11 Measured variables from double-stage welding process on top position
sample pulse No. 2.
Fig. 12 Comparison of overall peak period for
all three welding positions.
A
B
Weaving torch orbital welding test
Weaving torch orbital welding test
Li 12-12_Layout 1 11/9/12 1:29 PM Page 350
Switching PAW Mode
For experiments conducted with a sin-
gle (either keyhole or melt-in) mode, the
plasma torch configuration and welding
conditions can be set up in advance and
then be kept unchanged during the entire
welding process. However, for the pro-
posed double-stage PAW method, the
PAW process needs to switch from keyhole
to melt-in mode in real-time. For pipe
welding, complete joint penetration is the
first priority, and the plasma torch should
be configured to assure it. The challenge
is how to switch from keyhole to melt-in
mode with a torch configured for keyhole
mode. This question can be simplified as
how to reduce the penetration capability
of plasma arc during welding operation. To
find an acceptable solution, several key
factors affecting penetration capability
should be considered.
The physical configuration of the
plasma torch is one of the most important
factors in determining penetration capa-
bility. A smaller orifice diameter can pro-
vide better mechanical constriction.
Larger electrode setback can achieve sim-
ilar effects. However, during welding op-
eration, it is not practical to change any of
them. Hence, the torch configuration is so
determined that the penetration capabil-
ity is just sufficient for keyhole operation.
The plasma gas flow rate is another key
factor determining the penetration capa-
bility. The PAW process is sensitive to this
parameter. A simple adjustment of plasma
gas flow rate from 2.0 to 1.0 ft
3
/h can con-
siderably reduce the penetration capability
and change the operation mode from key-
hole to melt-in. It is technically possible to
use an adjustable flow control valve, and
the gas flow rate can be controlled by ex-
ternal electrical signals. However, this flow
rate control mechanism has a relatively
large time delay compared with the
needed pulse period of welding current.
The valve reaction to the control signal
and the flow rate change from the gas sup-
ply to the torch end both take time. There-
fore, similar to torch configuration, the
plasma gas flow rate is set to a level that is
just sufficient for keyhole operation.
The welding current controls the pene-
tration capability and heat input of the
plasma arc. With a reduced welding current,
the heat input may become insufficient to
achieve complete joint penetration if a sin-
gle melt-in mode is used. However, since
the complete penetration penetration is al-
most achieved in the first stage, the estab-
lishment process for complete joint
penetration penetration may still be able to
continue and finish with the reduced heat
input. This operation status is considered a
quasi-melt-in mode. As an electrical pa-
rameter, the welding current can be easily
adjusted by the control system in real-time.
Therefore, the transition from keyhole to
quasi-melt-in mode is switched by adjusting
the welding current.
There are other welding conditions and
parameters that also affect the penetration
capability, such as coolant recirculation
rate, overall torch size and rating, and dis-
tribution of plasma gas. However, in com-
parison with the parameters/variables
aforementioned, their real-time adjust-
ments are even more difficult.
Experiment Results and Analysis
With the algorithm proposed above,
extensive tests were conducted with dif-
ferent welding and control parameter
combinations to find optimal parameters.
Experimental Condition and Setup
For 304 stainless steel pipe described
previously, two pieces of 3.5-in. OD
Schedule 10 pipes were fitted without root
opening. A set of optimal welding param-
eters as listed in Table 4 were obtained
based on repeated experiments. The weld-
ing current was reduced from 110 A in the
first stage to 60 A in the second stage in
the peak period. With longer time dura-
tion than the first stage, the quasi-melt-in
second stage can provide sufficient heat
input to finish with a smooth full penetra-
tion weld bead.
The penetration criterion indicates the
slope of arc voltage used to determine if
the second stage period needs to continue
or stop. Once the increase on the arc volt-
age starts to decrease or stop, an equilib-
rium status may have been established for
the given second stage current such that
the second stage needs to stop to start the
base period to cool the liquid metal down.
The criterion is changed according to
welding position because the equilibrium
is the balance among the penetration
state, arc pressure, and welding position
dependent gravitational force. The change
in this criterion achieved weld bead con-
sistence with the welding position.
At the beginning of each experiment, the
plasma torch rested at the starting point,
and welding current increased gradually
from zero to the initial welding current (e.g.,
60 A) in a period called initialization period,
typically around 5 to 10 s. This period was
performed as pre-heating, and routine pe-
riods for the proposed double-stage process
start after the end of the initialization pe-
riod. For pulsing operation, the plasma
torch movement also changed in different
welding current level. In the first and sec-
ond stage peak period, the torch rested to
gain penetration and accurate arc voltage
measurements. In the base period, the torch
moved along the pipe joint at a constant
speed to the next spot.
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Table 6 Comparison of Net Heat Input in Unit Weld Bead Length
Welding Process Keyhole PAW Melt-in PAW Double Stage PAW GTAW
Base period time (ms) 800 600 800 N/A
Base period current (A) 20 30 20 N/A
Base period voltage (V) 18 19 18 N/A
First stage peak period time (ms) 250 350 200 N/A
First stage peak period current (A) 110 125 110 N/A
First stage peak period voltage (V) 25 26 25 N/A
Second stage peak period time (ms) N/A N/A 300 N/A
Second stage peak period current (A) N/A N/A 60 N/A
Second stage peak period voltage (V) N/A N/A 21 N/A
GTAW current (A) N/A N/A N/A 120
GTAW arc voltage (V) N/A N/A N/A 17
Travel speed (mm/s) 1.22 1.22 1.22 1.22
Total heat input (J/mm) 999 2021 1246 1672
Arc efficiency (%) ~47 ~47 ~47 ~67
Net heat input (J/mm) 470 950 586 1120
Typical backside bead width (mm) 3~4 ~10 5~6 9~11
Li 12-12_Layout 1 11/9/12 1:29 PM Page 351
The ultimate goal is to use the double-
stage process for the 5G fixed position, in
which the pipe joint is fixed and the plasma
torch moves around the joint circumfer-
ence. In the beginning, only the top position
was tested to prove the feasibility of the
method. Then, side and bottom/overhead
positions were tested. It was found that al-
though the same penetration criterion can
still produce complete joint penetration in
all positions. By changing the penetration
criterion according to the welding position,
more consistent weld beads around the pipe
joint circumference were achieved. Typical
experiment results for these three positions
are demonstrated in next section. In the fu-
ture, an accelerometer will be installed on a
manual plasma welding torch. In this way,
penetration criterion can be adjusted auto-
matically with the changing welding posi-
tion.
Double-Stage PAW Experiment Results
and Analysis
Closed-loop controlled experiments
were conducted for top, side, and bottom
positions. By changing penetration crite-
rion in a small range, smooth and consis-
tent welds with similar backside weld
beads were obtained for all three posi-
tions. The produced weld beads are illus-
trated in Figs. 79. The measured weld
bead geometry is listed in Table 5.
By visual inspection, the backside weld
bead widths for all three positions are be-
tween those produced by keyhole and melt-
in mode alone. Compared with keyhole
mode, the weld bead made by double-stage
PAW has less reinforcement on the backside
and no spatter. This indicates that complete
penetration is guaranteed by the first peak
period, but there is no over penetration
(large reinforcement) due to the quasi-melt-
in second peak period. On the other hand,
compared with melt-in mode, the backside
weld bead width made by double-stage
PAW is narrower, which means reduced
heat input and less chance to get melt
through. In addition, due to automatically
controlled heat input/second peak period,
the weld beads produced in all three posi-
tions have similar bead width on both sides
of the pipe joint, which in turn verified the
control effect. Therefore, by visual inspec-
tion alone, the double-stage PAW process
not only successfully combined the advan-
tages of keyhole and melt-in mode
processes, but also successfully eliminated
the problems with those two processes.
During double-stage PAW experi-
ments, welding current and arc voltage sig-
nals were also measured and recorded by
data acquisition system. Figures 10 and 11
illustrate two typical pulses selected from
a welding experiment on top position.
At the beginning of each pulse, the first
peak period applied 110 A of welding cur-
rent to achieve the keyhole and penetration
rapidly. It can be observed from both Figs.
10 and 11, after a short transitional stage
(around 50 ms), arc voltage starts to in-
crease, which means that the plasma arc is
making penetration pushing the weld pool
surface toward the backside of the pipe
joint. At the end of the first peak period, the
arc voltage tends to continue to increase. If
the keyhole stage continues after this point,
complete joint penetration would be
achieved at keyhole mode, but the associ-
ated problems would also occur. Instead of
continued strong arc force, welding current
is switched to a lower level into the quasi-
melt-in second stage. With reduced pene-
tration capability and heat input, the weld
pool first bounces back from deep keyhole
and then the complete joint penetration es-
tablishment is finished under the weaker arc
force resulting in smooth weld beads.
From Figs. 10 and 11, it is noticed that
the arc voltage reduced considerably after
the switching from first to second peak pe-
riod. This reduction is caused by the
bouncing back of the weld pool and also
the reduction in the welding current. Dur-
ing the quasi-melt-in second stage, extra
heat input is added to the weld pool and
the arc length tends to increase. This trend
is reflected by the slow increase of the arc
voltage, since the arc length and arc volt-
age have a linear relationship under a con-
stant welding current. By the end of
second peak period, the weld pool has
reached an equilibrium status, in which
the heat input cannot make any further
weld pool development (arc length in-
crease). The process then switches to the
base period for the weld pool to solidify
while preparing for the next control cycle.
By repeating this process, consistent com-
plete joint penetration weld beads can be
produced.
It can be observed that the second peak
period in Fig. 11 lasts 100 ms longer than
in Fig. 10. This increase of duration was
automatically determined by the control
algorithm. It might have been caused by a
less deep penetration established during
the first stage. More heat input was
needed from the second peak period in
order to reach the equilibrium status.
Therefore, longer time was needed for the
arc voltage slope to become flat (arc volt-
age stop increasing). Similar adjustments
in the second peak period time were typi-
cal in welding experiments for all three po-
sitions. Therefore, the proposed control
algorithm can effectively adjust the heat
input in each pulse to ensure the estab-
lishment of smooth complete joint pene-
tration weld beads.
For different welding positions around
the circumference, different penetration
criteria were set to reflect different re-
quirements for heat input. The average
peak period time (including both first and
second stages) of all pulses under three
different welding positions are compared
and illustrated in Fig. 12.
It can be seen, although there is varia-
tions in the peak period for each given
welding position, their average values re-
flect the different settings of the penetra-
tion criteria. The penetration criteria for
all three positions are 0.0 for side position,
0.2 for top position, and 0.4 for bottom po-
sition. The averaged peak period exactly
reflected the penetration criterion setting.
The variation of peak period during each
pulse in a given welding position reflects
the weld pool condition, weld joint varia-
tion, and specific welding position.
Heat Input Analysis
With previous experimental results,
comparisons were made for heat inputs de-
livered to the workpiece (net heat input)
among GTAW process and three PAW
process operation modes, i.e., keyhole,
melt-in, and double-stage modes. A number
of studies have been conducted to investi-
gate the heat input and arc efficiency in arc
welding processes (Refs. 1518). For the
proposed double-stage PAW process, the
primary objective was to produce complete
joint penetration with reduced net heat
input. Arc efficiency gives a quantitative
measurement of the fraction of total arc en-
ergy delivered to the workpiece. The total
energy generated by the power supply can
be easily calculated based on the arc voltage
and welding current measurement. Refer-
ring to the arc efficiency results from (Ref.
16), a general comparison is possible for
PAW and GTAW processes.
As introduced earlier, all three modes of
PAW process were operated in a pulsing
manner. Not only welding current, the
travel of the plasma torch was also pulsing
(staying still in the base period while move
during the peak period). In order to com-
pare with continuously moving GTAW
process, net heat input in unit length was
used. The calculated total energy input and
arc efficiency from Ref. 6 were used first to
determine the energy delivered into the
workpiece. Travel speed and manner were
then taken into consideration to calculate
the net heat input in unit length. A compar-
ison is made and listed in Table 6.
In Table 6, all the period times and weld-
ing currents were records from the embed-
ded controller. For the arc voltage,
variations existed under a constant welding
current, and only the average value was
used to determine total energy input. Travel
speed was set to constant on the orbital pipe
welding system and can be considered ac-
curate. Although a range is needed for pre-
cise calculation with arc efficiency, it is
sufficient to compare using only average arc
efficiency for each process because their net
heat inputs differ significantly.
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For the PAW process, plasma arc col-
umn generates considerably more heat
compared with the GTAW process. Using
the same welding current, the arc voltage
for the PAW process is much larger than
that of GTAW, which can be seen in Table 6.
However, the majority of the arc column
heat is not transferred into the workpiece.
From net heat input data in Table 6, it
can be clearly observed that the four
processes under comparison can be divided
into two groups. The one with the net heat
input around 1000 J/mm includes melt-in
PAW and the GTAW processes. This ex-
plains why the melt-in PAW produces welds
similar to those using the GTAW process.
Although the plasma arc voltage is larger
under the same welding current, its net heat
input delivered to the work-piece is compa-
rable to that of the GTAW. Keyhole and
double-stage PAW processes are in the
group with a net heat input around 500
J/mm. As a result, the weld beads with
smaller backside width were produced.
Compared with keyhole PAW mode, the
double-stage PAW does not increase the net
heat input delivered in to the workpiece.
The combination of two modes of PAW not
only reduced net heat input (compared with
melt-in mode), but also significantly im-
proved the weld bead (compared with key-
hole mode), with smaller backside
reinforcement, moderate backside width,
and no spatter.
Conclusions
The double-stage PAW process has
been proposed, designed, and imple-
mented as a novel welding process.
The innovative double-stage PAW
process successfully combines the advan-
tages and eliminates the problems associ-
ated with keyhole PAW and melt-in PAW
to produce the desired complete joint pen-
etration welds.
The double-stage PAW process reduces
the weld pool width and heat input ap-
proximately 50% from the GTAW.
The feedback control of the second
stage period helps achieve the desired con-
sistence of welds despite the difference in
the weld position.
The voltage-based control of the sec-
ond stage period is suitable for implemen-
tation at manufacturing sites.
Experiments confirmed the effective-
ness of the proposed double-stage PAW
process and its feedback control method.
Acknowledgment
This work is funded by the Navy SBIR
Program under contract N00024-08-C-
4111 and the Kentucky Cabinet for Eco-
nomic Development (CED) Office of
Commercialization and Innovation under
agreement KSTC-184-512-08-048.
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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING

seminar sites across the country

Section IX Boiler & Pressure V

B31.3 Boiler & Pressure V

. 2 ttle Feb. 25 - Mar r.

. 15-20 Apr Houston

DECEMBER 2012, VOL. 91 336-s

341-s WELDING JOURNAL

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