Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
May 2013
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CONTENTS
30
42
Features
Departments
30
36
42
48
Editorial ............................4
Press Time News ..................6
News of the Industry ..............8
International Update ............12
Stainless Q&A ....................14
RWMA Q&A ......................20
Product & Print Spotlight ......24
Coming Events....................54
Certification Schedule ..........58
Conferences ......................60
Welding Workbook ..............62
Society News ....................65
Tech Topics ......................66
Guide to AWS Services ........86
Personnel ........................88
Classifieds ........................95
Advertiser Index..................96
On the cover: The fast-freezing slag system of all-position FCAW electrodes allows for better out-of-position welding capabilities. (Photo courtesy of The Lincoln Electric Co., Cleveland, Ohio.)
WELDING JOURNAL
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Mark B. Gramelspacher
Chair, RWMA
MAY 2013
Officers
President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
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
U. Aschemeier (Dist. 7), Miami Diver
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
R. E. Brenner (Dist. 10), CnD Industries, Inc.
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (At Large), Tri Tool, Inc.
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (Dist. 17), The Harris Products Group
W. A. Komlos (Dist. 20), ArcTech, LLC
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.
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. A. Rice (Past President), OKI Bering
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
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
TAKE A
WARRIOR
INTO
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prove it. Now theres an extraordinary machine thats as rugged and reliable as you are. Introducing Warrior
by ESAB. Designed with input from real-world welders like you and brought to life by ESABs leading-edge
engineering. Warrior is built with inverter technology and features a high-duty cycle, read-anywhere display,
and glove-friendly controls to give you the power to be your best, anywhere, anytime.
For more information, visit www.esabna.com/warrior or scan this QR code.
PRESS TIME
NEWS
GM Invests $332 Million for New Fuel-Efficient Powertrains
General Motors Co., Detroit, Mich., will invest nearly $332 million in four manufacturing sites to produce more fuel-efficient engines and transmissions.
The investment includes $215 million in Flint Engine Operations for a new small
Ecotec gas engine, part of a new engine family that includes three- and four-cylinder
variants with displacements from 1.0 to 1.5 L; $55.7 million in Toledo Transmission Operations for increased capacity and tooling to produce a new eight-speed automatic
transmission and an existing six-speed transmission; $31.7 million in Bay City Powertrain, including $19.2 million to produce components for a new V6 engine and $12.5
million to produce components for the small Ecotec gas engine; and $29.4 million in
Bedford Castings, including $19 million to produce components for the small gas engine and $10.4 million to produce components for the new eight-speed and existing sixspeed transmissions.
Also, GM is increasing powertrain investment in plants in Romulus and Saginaw,
Mich., to $646 million for supporting production of the new V6 engine. This consists of
a $41 million increase to $256 million for Saginaw Metal Castings Operations to produce castings for the new V6 engine and a $5 million increase to $390 million for Romulus Engine Operations to build the new V6 engines.
Combined, the two investments will retain about 1650 jobs at the six facilities.
MEMBER
MAY 2013
3 Gantries: with plasma & oxy-fuel torches that can cut up to a 10-inch
thick carbon steel plate and up to a 6.25-inch thick stainless steel plate
Quick-Drill (concurrent drill, tap, countersink & surface mill) capability
160-foot long by 17-foot wide water table
Contour beveling capability
NEWS OF THE
INDUSTRY
MAY 2013
Washington State Governor Jay Inslee welds the initials of his grandchild at the keel laying ceremony for the states newest ferry, Samish,
at Vigor Industrials Seattle shipyard. (Photo by Stuart Isett/Vigor.)
WELDING JOURNAL
This effort has seen support from the government and within the
steel industry due to its potential for cutting down energy use
and environmental emissions, particularly carbon dioxide. The
process utilizes direct gaseous reduction of fine iron concentrates
to make iron and is being powered by natural gas.
Berrys role in the project so far, and in the future, will be
bringing the technology to life through designing and manufacturing the equipment, enabling practical application.
The proper
positioner will
offer you a
number of
advantages:
PROFITS
10
MAY 2013
Industry Notes
Camfil Farr Air Pollution Control (APC), Jonesboro, Ark., a
producer of dust and fume collectors to clean up industrial
processes, plus an American Welding Society and International
Thermal Spray Association member, will now operate as Camfil Air Pollution Control (APC). The new Web address for the
company is www.camfilapc.com.
Engine manufacturers, including KOHLER Engines, are warning users of gas-powered lawnmowers and other outdoor power
equipment to be vigilant when fueling. Blends with more than
10% ethanol, such as E15 and E85, should not be used. They
can cause permanent, irreversible damage not covered under
warranty.
WELDING JOURNAL
11
INTERNATIONAL
UPDATE
New Facility Supports Solid-State Laser
Development
the sales organization and customers with technical training seminars and detailed research into material applications. It will also
provide materials analysis for other Sandvik business areas, specifically Sandvik Construction and Sandvik Machining Solutions.
MAY 2013
Westinghouse Electric Co. recently announced that its subsidiary, PCI Energy Services, LLC (PCI), has signed a contract
with Nucleoelctrica Argentina S.A. (NA-SA) to provide engineering, specialty pipe cutting, and welding services in support of
the replacement steam generator program at Argentinas
Embalse Nuclear Power Plant. This work is part of the overall
refurbishment program at Embalse to extend the plants life by
up to an additional 30 years.
Rubn Semmoloni, NA-SA project director, Life Extension
Embalse Nuclear Power Plant, said, NA-SA values the engagement and participation of PCI in the Embalse life extension project, which will further enhance plant safety and operation for
years to come.
Although the engineering scope of the work for the CANDU-6
pressurized heavy water reactor plant is underway, the major site
activities are expected to be executed during 2014.
STAINLESS
Q&A
BY DAMIAN J. KOTECKI
MAY 2013
Fig. 1 Sensitized 304 stainless steel. The chromium carbides responsible for sensitization
appear as black specks along the austenite grain boundaries.
Fig. 2 Graphic display of the effects of time and temperature on chromium carbide precipitation and intergranular corrosion (IC) in 304 stainless steel.
References
1. Krivsky, W. A. 1973. Stainless History, Metallurgical and Materials Transactions, Vol. 4, No. 6, pp. 14391477.
2. Folkhard, E. 1988. Welding Metallurgy of Stainless Steels. Springer-Verlag,
Vienna.
CH
NICAL INS
TI
T
E
CD
UT
WELDING JOURNAL
15
I want to encourage you to submit nomination packages for those individuals whom you feel
have a history of accomplishments and contributions to our profession consistent with the standards
set by the existing Fellows. In particular, I would make a special request that you look to the most
senior members of your Section or District in considering members for nomination. In many cases,
the colleagues and peers of these individuals who are the most familiar with their contributions, and
who would normally nominate the candidate, are no longer with us. I want to be sure that we take
the extra effort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nomination process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issue
of the Welding Journal. Please remember, we all benefit in the honoring of those who have made
major contributions to our chosen profession and livelihood. The deadline for submission is July 1,
2013. The Committee looks forward to receiving numerous Fellow nominations for 2014
consideration.
Sincerely,
Thomas M. Mustaleski
Chair, AWS Fellows Selection Committee
Base Copy: 01
Copy Changes:
Code Color:
275031 _501F
PO#:
Flat Size: 8.375 X 11.0
Blk, PANTONE 468 C
Fellow Description
DEFINITION AND HISTORY
The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for
distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional
stature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of the
individual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by:
Sustained service and performance in the advancement of welding science and technology
Professional recognition
RULES
1.
2.
3.
4.
5.
6.
7.
V.
NUMBER OF FELLOWS
Maximum of 10 Fellows selected each year.
Nomination packages for AWS Fellow should clearly demonstrate the candidates outstanding contributions to the advancement of welding science and technology. In order for the Fellows Selection Committee to fairly assess the candidates qualifications, the nomination package must list and clearly describe the candidates specific technical accomplishments, how they contributed to the advancement of welding technology, and that these contributions were sustained. Essential in demonstrating the
candidates impact are the following (in approximate order of importance).
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
BLIND PERF
Description of significant technical advancements. This should be a brief summary of the candidates most
significant contributions to the advancement of welding science and technology.
Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited
in (1). Where possible, papers and articles should be designated as to whether they were published in
peer-reviewed journals.
Inventions and patents.
Professional recognition including awards and honors from AWS and other professional societies.
Meaningful participation in technical committees. Indicate the number of years served on these committees and
any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.).
Contributions to handbooks and standards.
Presentations made at technical conferences and section meetings.
Consultancy particularly as it impacts technology advancement.
Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology.
Participation on organizing committees for technical programming.
Advocacy support of the society and its technical advancement through institutional, political or other means.
Note: Application packages that do not support the candidate using the metrics listed above
will have a very low probability of success.
Supporting Letters
Letters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These
letters should address the metrics listed above and provide personal insight into the contributions and stature of the
candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.
Return completed Fellow nomination package to:
Wendy S. Reeve
American Welding Society
Senior Manager
Award Programs and Administrative Support
8669 Doral Blvd., Suite 130
Doral, FL 33166
Telephone: 800-443-9353, extension 293
SUBMISSION DEADLINE: July 1, 2013
PAGE 1
01
CLASS OF 2014
Base Copy: 01
Copy Changes:
Code Color:
275031 _502B
PO#:
Flat Size: 8.375 X 11.0
Blk, PANTONE 468 C
V.
HOME ADDRESS____________________________________________________________________________________________________
CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________
PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________
TITLE/POSITION____________________________________________________________________________________________________
BUSINESS ADDRESS________________________________________________________________________________________________
CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________
ACADEMIC BACKGROUND, AS APPLICABLE:
INSTITUTION______________________________________________________________________________________________________
MAJOR & MINOR__________________________________________________________________________________________________
DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________
LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________
SIGNIFICANT WORK EXPERIENCE:
POSITION____________________________________________________________________________YEARS_______________________
SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE
SELECTED AS AN AWS FELLOW ACCOMPANY NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE INCORPORATED WITHIN THE CITATION CERTIFICATE.
SEE GUIDELINES ON REVERSE SIDE
SUBMITTED BY: PROPOSER_______________________________________________AWS Member No.___________________
Print Name___________________________________
The Proposer will serve as the contact if the Selection Committee requires further information. Signatures on this nominating form, or
supporting letters from each nominator, are required from four AWS members in addition to the Proposer. Signatures may be acquired
by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should
be submitted.
NOMINATING MEMBER:___________________________________NOMINATING MEMBER:___________________________________
Print Name___________________________________
Print Name___________________________________
AWS Member No.______________
AWS Member No.______________
NOMINATING MEMBER:___________________________________NOMINATING MEMBER:___________________________________
Print Name___________________________________
Print Name___________________________________
AWS Member No.______________
AWS Member No.______________
PAGE 2
COMPANY/CITY/STATE_____________________________________________________________________________________________
BLIND PERF
POSITION____________________________________________________________________________YEARS_______________________
COMPANY/CITY/STATE_____________________________________________________________________________________________
01
RWMA
Q&A
Q: I am trying to make resistance welding seams using a single-phase constant
current welding control and am having a
hard time holding the tolerance required
for this military project. We are using a
150-kVA seam welding machine with 38in.-wide welding wheels on 0.040-in. CRS.
The welding transformer tap switch is set
to the #1 position. I checked the learn
BY ROGER HIRSCH
table in the control and see that we are in
the 2530% range so I know I am not overworking the welding machine. Do you
have any suggestions?
A:
The problem here is a misunderstanding of how a resistance welding machine works. Because you are using the
control in this very low heat percentage
Gentec is a total solution provider for your welding, cutting, and gas control needs.
20
MAY 2013
range, the output of the welding transformer is a series of very small heat pulses
and a lot of spaces in between. This
makes control of the process very sensitive. No matter how good your control is,
it will be very difficult to achieve the desired results with this welding machine.
Welding machine size is also often misunderstood. The idea that you need a
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WELDING JOURNAL
21
tap switch setting that will produce the desired RMS welding current when the controls heat setting is between 60 and 90%.
The recommended upper limit of 90% is
to allow the welding control to have the
ability to increase heat to compensate for
incoming line voltage variations. It also
allows for changes in the welding machine
secondary impedance as ferrous metal of
the part is being pushed into the welding
machine throat.
There are several solutions to this type
of control problem:
The first is to set the welding machine
transformer tap switch to a lower number
and then use a higher weld heat setting.
Unfortunately, in your case, you are already at the lowest setting.
Next, use the correct size welding machine for the job. If you have a smaller
kVA seam welding machine, move the job
there. As an example, a 75-kVA seam
welding machine will probably find the
proper heat setting in the 60% range to
give control back to the system.
If this is not possible, and if you are
working on a 460-V power line, connect
the welding machine to a 230-V line with
the results as shown in Fig. 4. Be sure to
change the voltage select jumpers in the
control to 230 V. Now you will be in the
60% range since the line voltage amplitude will be lower and you will be using
more of each cycle of this line voltage
to create the desired RMS current for
welding. This will not increase the load on
the power lines since the turns ratio of the
welding transformer will remain the same.
Note that you can operate a 460-V
transformer on a 230-V line, but you cannot operate a 230-V transformer on a 460V line without damaging the transformer.
Compare this to Fig. 3, which shows
the same transformer operating on 460 V
at a 30% weld heat setting. You can easily see how much more stable the process
is when more of each half-cycle of current
is being used.
MAY 2013
Change of Address?
Moving?
Make sure delivery of your Welding Journal is not interrupted. Contact the Membership Department with your new address information (800) 443-9353, ext. 204; mtrujillo@aws.org.
REPRINTS REPRINTS
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Request for quotes can be faxed to (219) 874-2849.
You can e-mail FosteReprints at
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Stainless Steel
Mild Steel
InconelTM
hammer, 100 2-mm pins, and a replacement slide hammer knurled locking cam.
The Eastwood Co.
www.eastwood.com
(800) 343-9353
MAY 2013
The 2013 Welding Gear catalog introduces the new Jessi Combs womens line,
which includes the VIKING 1840 Series
SuperFlash
www.lincolnelectric.com
(888) 355-3213
www.fronius.com
(877) 376-6487
www.oxyfuelsafety.com
(888) 327-7306
WELDING JOURNAL
25
26
MAY 2013
Earplugs Available in
Three Damping Levels
The DI Red 25 dB is
a CE-certified industrial hearing protection
earplug that incorporates DEC sound technology. Available in
three damping levels,
this universal plug provides acoustic protection in a discrete miniature package and is designed for noisy environments, either at work or leisure. The
product allows air to enter the ear, reducing the occlusion effect normally experienced when using earplugs. All of the
companys products are designed to be interchangeable and upgradable to custom
fit molds.
Manufacturin
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elding Wire
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WELDING JOURNAL
27
Grinders Feature
High Power-to-Weight Ratio
The companys line of CP3850 industrial angle grinders and sanders offers a
high power-to-weight ratio with a 2.8-hp
motor. The CP3850, available in both 7and 9-in.-capacity models, weighs less
than 6 lb, allowing easier handling. Many
ergonomic features have been incorporated to improve operator comfort, safety,
and productivity, including a vibrationdamping multiposition side handle, auto
balancer, and integrated silencer. Safety
features include a double-action safety
lever and 270-deg swivel guard to protect
the operator from debris. The series is engineered for aggressive use in contouring,
deburring, cutting, and sanding in the metalworking, transformation, manufacturing, and energy industries.
Chicago Pneumatic
www.cp.com
(800) 624-4735
28
MAY 2013
BY TOM MYERS
TOM MYERS is a senior
applications engineer,
The Lincoln Electric Co.,
Cleveland, Ohio,
www.lincolnelectric.com.
Fig. 1 In years
past, a limited
number of FCAW-G
electrode options
were offered to
fabricators.
30
MAY 2013
tion of new materials, combined with demands for more customized, efficient
electrodes, manufacturers have been returning to their R&D drawing boards to
develop new gas shielded, flux cored consumables.
Fundamentals and
Advantages of FCAW
Electrodes
Flux cored electrodes were originally
developed as a higher productivity extension of shielded metal arc welding
(SMAW) electrodes. They are, in fact,
like a SMAW electrode turned inside out.
They consist of a steel tube (i.e., outer
steel sheath) with flux inside the tube or
at the electrodes core, hence the name,
flux core. Because of this design, the
electrode can be wound onto a coil or
31
32
MAY 2013
the years. While the use of a one-sizefits-all electrode for a wide range of applications can deliver adequate arc performance, the reach for a single electrode
to perform well in every application is
just too broad Fig. 3. As a result, the
arc is never optimized.
Why? One electrode used with both
100% CO 2 and mixed gas (i.e., 75%
Ar/25% CO2) has to have a fine chemical balance in order to meet the minimum and maximum mechanical property
requirements of its AWS classifications
with either type of shielding gas. Carbon
WELDING JOURNAL
33
MAY 2013
Application-Specific
FCAW Electrodes
Today, manufacturers of FCAW electrodes offer broad product lines, with
many electrodes designed for specific applications and industries. Examples of
more specialized FCAW-G electrodes include ones designed for the following
uses:
with one specific type of shielding gas
such as UltraCore 71C and UltraCore 71A85 from The Lincoln Electric Co.
for higher-strength steels (i.e., 80-,
90-, and 100-ksi minimum tensile
strength).
HD type for high-deposition, out-ofposition capability (i.e., UltraCore
HD-C and HD-M).
for exceptionally high deposition rates
in the flat and horizontal positions.
for improved low-temperature toughness properties.
SR type for stress-relieved applications.
for pipe welding applications such as
Pipeliner 81M, 101M, and 111M.
Electrode Design
Producing a successful FCAW-G electrode comes down to balance in the design and manufacture of the electrodes.
Manufacturers have worked to develop
FCAW-G consumables that consistently
meet mechanical properties, without
compromising quality and aesthetics.
They do so without taking it to the extreme. They avoid creating an electrode
Welding Resources
for When Youre
on the Go
A search found plenty
of free, easy-to-use,
welding-related apps
of each of their offerings to clarify the important features to consider when shopping for these items.
While many full-featured apps can be
downloaded free of charge, some free
apps are Lite versions that offer basic
versatility to promote purchasing the
Full version. Although some are limited in scope, a Lite version may be worth
checking out since the information it offers may be all you require for your daily
needs.
A bonus to using mobile apps is their
potential educational value. You can easily experiment with different metals,
material thicknesses, processes, etc., to
get a feel for how various processes work.
Following are brief descriptions of a
cross section of welding-related apps
available for free downloading onto your
smart phone or tablet. To search for these
and other apps, just Google your topic
or the apps name. You can often find
useful apps offered on welding equipment manufacturers Web sites. Check
for new apps online occasionally, since
they are added and updated daily.
HOWARD WOODWARD (woodward@aws.org) is associate editor, MARY RUTH JOHNSEN (mjohnsen@aws.org) is editor, and KRISTIN
CAMPBELL (kcampbell@aws.org) is associate editor of the Welding Journal. CARLOS GUZMAN (cguzman@aws.org) is editor of the
Welding Journal en Espaol.
36
MAY 2013
This app from 3M is designed for industrial hygienists and safety professionals who want rapid access to respirator
guide information on their smart phones.
The guide identifies facepieces, cartridges, and filters including an overview
of qualitative fit-testing protocols and
how to conduct the fit tests for a variety
of specific contaminants found in industrial environments Fig. 3A.
After the user enters the chemical
name, the app presents the companys
recommendations for the appropriate
type of respiratory protection for that
contaminant Fig. 3B. Included is a frequently asked questions section and
product catalog. Currently available for
Pipefitters Reference
App.
The first page presents three tabs labeled Transducers Physical Principles,
Characteristics of Ultrasonic Waves, and
Fundamental Principles of Ultrasonic
Wave Propagation.
Touching the Fundamental Principles
tab reveals three tabs for Snells Law Calculations, Geometry Calculations, and
Basic Skip Calculations. Touching the
Basic Skip tab, for example, opens a
screen for the user to enter wall thickness of the piece, refracted angle in the
piece, half skip, full skip, and sound path
numbers to complete the calculations.
WELDING JOURNAL
37
This app offers a wealth of information beginning with five opening tabs labeled PA Transducer Parameters, Wedge
Calculation, PA Inspection, Acoustic Parameters of Materials, and Glossary.
Touching the Parameters of Materials
tab opens tabs for selecting aluminum,
brass, copper, glycerine, lead, nickel,
Plexiglass, Rexolite, steel, titanium, and
water. Touching a materials tab presents
its long and transverse velocities, density
in g/cc, and the longitudinal and transverse acoustic impedances.
The Lincoln Electric Co.s CheckPoint app allows viewing live welding
machine status and production reports
on mobile devices Fig. 4.
The Norton Abrasives grinding app offers calculators for a coolant, dressing parameter, and wheel speed. The portable
grinder product selector has areas for selecting the application, material, and primary/secondary attributes. Postal codes
can be entered in the distributor locator
lookup. The application inquiry features
options for general information, machine
tool, abrasive and dressing products, work
material, and operational factors. Also
provided are sections for logging into an
abrasive connection site and contacting
the company Fig. 5.
The app is available for iOS and
Android operating systems on mobile
devices.
10
Fig. 4 Lincolns app enables exploration of a robots in limit, out of limit,
and total welds.
38
MAY 2013
11
14
Fig. 7 Lindquists app acts as a reference guide to work around tool production needs.
today? An AZ list has keywords from
aluminum extrusion tooling to zinc die
cast dies. By clicking on each term, suggested materials from low to high production value are found. Another area
for materials can also be explored.
In addition, users can obtain a
quote/order, discover the companys history, and find contact details.
The app is compatible with the iPhone
(3GS, 4, 4S, and 5); iPod touch (3rd, 4th,
and 5th generations); and iPad.
12
Fig. 8 Users plug a few pieces of information into ESABs Welding Parameters Set-Up Guide and receive data that
can be used to set up their welding machine and adjust it to their specific application requirements.
13
The Code 313 app (Fig. 9) is a calculator for interpreting industrial radiographs in accordance with ASME B31.3,
Process Piping. The apps developer
warns that the app does not replace the
code itself, nor the need to have the code,
but is a calculator to help you verify your
own interpretation. To use the app, you
The Welding Pro app by Certilas Nederland BV, a maker of welding consumables in The Netherlands, provides weld
cost calculations for fillet welds, and single-V, double-V, and double bevel butt
joints Fig. 10. It allows users to quickly
compare labor, gas, and filler metal costs.
Users pick the type of weld they will be
making (fillet or groove), then select
welding process, amperage, duty cycle,
type of electrode, etc. Users also designate whether they are welding steel,
stainless steel, or aluminum. While the
app is set up for metric units and euros,
a tap on the settings button allows users
to switch to Imperial Standard units and
dollars. It also displays the most recent
calculations and users can designate certain calculations as favorites that can
be stored and retrieved later. Requires
Android 2.2 and up or iOS 4.3 or later.
39
15
Troubleshoot
Resistance Spot
Welding.
The Resistance Spot Welding Troubleshooting App by Miyachi Unitek offers a quick guide to solving common
problems found in the RSW process
Fig. 11. The sharp interface is simple to
use and is well laid out. There are four
main menus or tabs: Instructions, Guidelines, Troubleshoot, and Info. By tapping
on the Troubleshoot tab, the user is able
to choose from a variety of possible symptoms or problems: overheating of weldment, discoloration, weak weld, insufficient nugget, metal expulsion, sparking,
inconsistent welds, electrode damage,
and electrode sticking. Solutions are presented in four categories: material, electrode, weldhead, and power supply.
Additionally, the user selects one of
four priority levels, according to the most
likely cause of the problem. For example, if overheating of weldment is the
most likely cause of the problem, select
Priority 1 and the app reveals that it may
be caused by excess time. This suggestion
appears in the Power Supply Related
field. Tap on this field and a possible solution is shown (in this case, Decrease
weld time in steps of 510% ...).
Although the solutions presented in
this app are brief and may not cover all
variables, its a good starting point for
professionals and a worthwhile tool for
educational purposes. This Miyachi
Unitek app is available for iPad, iPhone,
and Android.
16
Growing Catalog of
Welding Calculators.
17
40
MAY 2013
support in Australia, Canada, China, Europe, South East Asia, and the United
States.
The app is compatible with the iPhone
(3GS, 4, 4S, and 5); iPod touch (3rd, 4th,
and 5th generations); and iPad. It requires iOS 5.0 or later.
Improving Surfacing
Performance with GMAW
The synchronized polarity gas metal
arc welding technique shows
promise for applying coatings where
the risk of perforating the base
material is a critical factor
Table 1 Weld Beads Obtained in the Flat Position on an ABNT 1020 Carbon Steel Plate (AWS ER70S-6) Wire with Diameter of
1.2 mm, Mixture of Ar and O2, Welding Speed of 348 mm/min, and Current of 250 A
Test
Polarity
DCEP
7.2
DCEN
11.7
42
MAY 2013
Cross section
source output polarity with the torch position in relation to its oscillatory motion.
Welders discard the use of DCEN with
solid electrodes as an option because of
the allegation that the electric arc is unstable and produces a globular metal
transfer with a significant amount of spatter. The geometry of the bead deposited
is unsuitable due to the low wettability,
which results in an almost circular cross
section that can lead to discontinuities
due to incomplete fusion at the joints
with adjacent weld beads. However, for
coating operations, other characteristics,
such as low levels of penetration and dilution, are required.
Recent studies on the GMAW process
with DCEN polarity have verified, via
high-speed digital filming, that the type
of shielding gas has a significant influence on metal transfer behavior and weld
bead geometry (Ref. 1). Good results
were obtained with an appropriate composition of argon and oxygen. The metal
43
44
MAY 2013
Fig. 6 The equipment setup for demonstrating the validity of the synchronized polarity gas metal arc welding technique.
Values
436
1.5
12.0
8.0
11.5
270
250
WELDING JOURNAL
45
Fig. 7 A The weld bead obtained with the SP-GMAW technique; B cross section
of the weld bead.
Conclusions
The SP-GMAW technique offers a
real possibility for the application of
coatings where the risk of perforating the
base material is a critical factor. This is
due to the achieved appropriate geometric characteristics for the task of coating
surfaces, such as shallow penetration, a
surface with almost no undulation, and
good dimensional ratio (width/height) of
the weld beads.
The coating criteria adopted in the SPGMAW technique for the overlap of adjacent beads produced good results in the
flat welding position. There is no increase
in the height of the weld layer due to this
overlap. The maximum undulation generated was lower than 0.3 mm. The weld
layers produced do not present discontinuities and have an excellent visual
aspect with the presence of very little
spatter.
The use of DCEN polarity during
times that extend beyond the period of
drop transfer should not be discarded. If
used with certain wires in conjunction
46
MAY 2013
Fig. 9 A The coating obtained with the SP-GMAW process; B a cross section of
the coating.
with adequate gas mixtures and a suitable current range, it can represent a
good alternative for specific cases of
welding. However, this technology requires pieces of equipment that communicate with each other and considerable
dedication in the qualification of the set
of variables and parameters for the
GMAW process as well as for automatic
torch displacement.
Acknowledgments
The authors are grateful to the team
at Labsolda/UFSC whose efforts made
this multidisciplinary task possible and
to the Brazilian government agency
CNPq and the company Tractebel Energia for financial support.
References
1. Souza, D., Rezende, A. A., and
Scotti, A. 2009. A qualitative model to
explain the polarity influence on the fu-
sion rate in the MIG/MAG process. Revista Soldagem & Inspeo 14(3):
192198.
2. Pickin, C. G., Willams, S. W., and
Lunt, M. 2011. Characterization of the
cold metal transfer (CMT) process and
its application for low dilution cladding.
Journal of Materials Processing Technology 211(3): 496502.
3. Ueyama, T., Tong, H., Harada, S.,
and Passmore, R. 2005. AC pulsed
GMAW improves sheet metal joining.
Welding Journal 84(2): 4046.
4. Cirino, L. M. 2009. Study on the effects of polarity in direct and alternate
current TIG and MIG/MAG welding
processes. Masters thesis. PosMec/
UFSC, Florianpolis, Brazil.
5. Puhl, E. B. 2011. Development of
MIG/MAG welding technologies for
productivity and quality enhancement by
means of negative polarity. Masters thesis. PosMec/UFSC, Florianpolis, Brazil.
6. Labsolda: Operation Manuals.
Available at www.labsolda.ufsc.br/projetos/manuais/manuais.php. Instituto de
Mecatrnica. Accessed June 14, 2012.
For info go to www.aws.org/ad-index
WELDING JOURNAL
47
BY ALEXEI YELISTRATOV
ALEXEI YELISTRATOV
(alexeiyel@yahoo.com) is a
research associate.
Fig. 1A Effect of welding current and shielding gas on droplet frequency for GMAW with 116in. (1.6mm) welding wire
(Ref. 3); B effect of welding current (current density) on drop transfer mode for GMAW with 116in. (1.6mm) welding
wire ER70S3 in shielding gas mixture Ar + 5% O2 (Ref. 7).
48
MAY 2013
tions are the same. There is, however, another important feature of this constricting force: When current-carrying cross
sections are different, an axial electrodynamic force is created. This force directs
from lesser cross section to the larger
one. Welding current undergoes change
in the current-carrying cross sections during its path from the welding wire to the
anode spot Fig. 2. This is similar to
conduction angle (Refs. 3, 5).
Electrodynamic forces can be directed
up (Fig. 2) when the anode spot size is
smaller than the diameter of the electrode at low-current globular transfer in
GMAW. In this case, the electrodynamic
force and surface tension force acted
jointly to support the droplet on the tip of
the electrode (wire). This force can be directed down when the anode spot area
becomes larger than the cross section of
the electrode at high-current, spray
transfer with GMAW in Ar+CO 2/O 2
mixtures (Refs. 4, 5).
49
Experimental Procedures
The experiments were performed
using direct current, electrode positive
(DCEP) GMAW head with constant voltage (CV) power supply. Used throughout
these experiments were mild steel plates
7.87 2.36 0.39 in. (200 60 10
mm), AWS ER 70S-3 welding wire 116 in.
(1.6 mm) diameter, and various shielding
gases (100% CO2; 20% CO2 + 80% Ar;
10% CO2 + 90% Ar; 5% CO2 + 95%
Ar). The shielding gas mixture flow rate
was 42 ft3/h (20 L/min). The welding current and voltage were recorded. Highspeed photography (4000 f/s) was used to
capture droplet measurements. The geometrical sizes of the droplets and droplet
frequency were measured from the image
on the screen. The anode spot size was
measured from the image on the screen
by measuring the size of the bright spot
on the outer side of the droplet. This indirect method is acceptable for evaluation of low-scale objects in the electric arc
zone (Ref. 4). The variations in measured
droplet size were 5%, and in anode spot
size were 1015%.
Computational Model of
the Surface Tension Force
Significant measurement errors can
occur when studying the arc zone conditions using direct methods such as
probes, thermocouples, etc. Practical calculation of the surface tension force for
GMAW conditions is impossible because
there are no reliable supporting data.
Therefore, in this work, a qualitative
method was used to study the influence of
50
MAY 2013
Effects of Temperature
An electrical heater without the lower
vessel was installed below the droplet formation extension and moved up toward
the extension. When the heater was in the
upper position, the size of the droplets
changed. The droplets lengthened in the
direction of the heater from 0.019 to
WELDING JOURNAL
51
0.047 in. (0.5 to 1.2 mm), and their diameters decreased from 0.177 to 0.149 in.
(4.5 to 3.8 mm). The drop transfer frequency increased from 4043/s to
5053/s.
MAY 2013
Acknowledgment
The author would like to acknowledge
Dr. A. Lesnewich for reviewing the manuscript and for his valuable suggestions.
References
1. Soderstrom, E. J., and Mendez, P.
F. 2008. Metal transfer during GMAW
with thin electrodes and Ar-CO2 shielding gas mixture Welding Journal 87(5):
124-s to 133-s.
2. Hu, J., and Tsai, H. L. 2006. Effects
of current on droplet generation and arc
plasma in gas metal arc welding. Journal
of Applied Physics, 100, Article No.
053304.
3. Rhee, S., and Kannatey-Asibu, E.
Jr. 1992. Observation of metal transfer
during gas metal arc welding. Welding
Journal 71(10): 381-s to 386-s.
4. Kim, Y. S., McEligot, D. M., and
Eagar, T. W. 1991. Analysis of electrode
heat transfer in gas metal arc welding.
Welding Journal 70(1): 20-s to 31-s.
5. Jones, L. A., Eagar, T. W., and Lang,
J. H. 1998. Images of a steel electrode in
Ar-2%O2 shielding gas during constant
current gas metal arc welding. Welding
Journal 77(4): 135-s to 141-s.
6. Subramaniam, S., White, D. R.,
Jones, J. E., and Lyons, D. W. 1998.
Droplet transfer in pulsed gas metal arc
welding of aluminum. Welding Journal
77(11): 458-s to 464-s.
7. Soderstrom, E. J., Scott, K. M., and
Mendez, P. F. 2011. Calorimetric measurement of droplet temperature in
GMAW. Welding Journal 90(4): 77-s to
84-s.
8. Wang, F., Hou, W., Kannatey-Asibu,
E., Schultz, W., and Wang, P. 2003. Modelling and analysis of metal transfer in gas
metal arc welding. Journal of Physics D:
Applied Physics 36, pp. 11431152.
9. Choo, R. T. C., Mukai, K., and
Toguri, J. M. 1992. Marangoni interaction of a liquid droplet falling onto a liquid pool. Welding Journal 71(4): 139-s to
146-s.
COMING
EVENTS
Pipeline Conf. June 4, 5. Houston, Tex. Sponsored by the American Welding Society (800/305) 443-9353, ext. 264;
www.aws.org/conferences.
54
MAY 2013
Follow us:
Scan code to
watch video.
18th Beijing-Essen Welding & Cutting Fair. June 1821. New International Expo Center, Shanghai, China. www.beijing-essenwelding.com/en/index.htm.
Third VDI Congress, Lightweight Design Strategies in Vehicles. July 3, 4. Wolfsburg, Germany. Sponsored by VDI Wissensforum, Assn. of German Engineers. www.vdi.de/leichtbau.
Codes and Standards Conf. July 16, 17. Orlando, Fla. To include
AWS D1, Structural Welding Code Steel, ASME Boiler and Pressure Vessel Code, API pipeline codes, MIL specs and ISO standards. Sponsored by the American Welding Society (800/305) 4439353, ext. 264; www.aws.org/conferences.
59th Annual UA Assn. of Journeymen and Apprentices of the
Plumbing and Pipefitting Industrys Instructor Training Program. Aug. 1117, Washtenaw Community College, Ann Arbor,
Mich. www.visitannarbor.org/news/detail/ann-arbor-welcomes-the59th-annual-united-association-instructor-training-p.
12th Intl Conf. on Application of Contemporary Non-Destructive
Testing in Engineering. Sept. 46. Grand Hotel Metropol, Portoroz, Slovenia. Sponsored by The Slovenian Society for Non-Destructive Testing. www.fs.uni-lj.si/ndt.
LPPDE-North America. Sept. 911. Savannah, Ga. Lean Product
& Process Development Exchange, Inc. Address e-mail to
lppde@leanfront.com.
66th IIW Annual Assembly. Sept. 1117. Essen, Germany. Organized by DVS (German Welding Society). www.dvsev.de/IIW2013/.
56
MAY 2013
16th Annual Aluminum Conf. Sept. 17, 18. Chicago, Ill. Sponsored by the American Welding Society (800/305) 443-9353, ext.
264; www.aws.org/conferences.
Educational Opportunities
Brazing School Fundamentals to Advanced Concepts. May
1416 (Hartford, Conn.); Oct. 2224 (Greenville, S.C.); Nov.
1921 (Simsbury, Conn.). www.kaybrazing.com/seminars.htm;
dan@kaybrazing.com; (860) 651-5595.
CWI Preparation Courses: June 37, Aug. 1923, Nov. 1115.
D1.1 Endorsement: June 7, Aug. 23, Nov. 15; D1.5 Endorsement:
May 31, Aug. 16; API Endorsement: May 30, Nov. 8. All courses
and endorsements held at Welder Training & Testing Institute,
1144 N. Graham St., Allentown, Pa. www.wtti.com; (610) 8209551, ext. 204.
Nominate them!
The Image of W
Welding
eld
ding A
Awards
w
wards Program recogn
recognizes
nizes outstanding
achievement in the following categories:
Individual
Section
Large Business
(welding products)
(A
WS local chapter)
(AWS
Small Business
Educator
Distributor
Educational Facility
(any or
organization
ganization that conducts welding
education or training)
Media
31, 2013
For more
more informatio
information
on and to submit a nomination
nomin
nation form online,
visit www.aws.org/awards/image.html
www.aws.org/awards/image.html
/awards/image.html or call
ca 800-443-9353.
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION
SEMINAR DATES
Birmingham, AL
June 27
Hutchinson, KS
June 27
Spokane, WA
June 27
Miami, FL
Exam only
Bakersfield, CA
June 914
Pittsburgh, PA
June 914
Beaumont, TX
June 914
Corpus Christi, TX
Exam only
Hartford, CT
June 2328
Orlando, FL
June 2328
Memphis, TN
June 2328
Jacksonville, FL
July 712
Omaha, NE
July 712
Cleveland, OH
July 712
Miami, FL
Exam only
Phoenix, AZ
July 1419
Los Angeles, CA
July 1419
Louisville, KY
July 1419
Waco, TX
July 1419
Milwaukee, WI
July 1419
Corpus Christi, TX
Exam only
Sacramento, CA
July 2126
Kansas City, MO
July 2126
Denver, CO
July 28Aug. 2
Miami, FL
July 28Aug. 2
Philadelphia, PA
July 28Aug. 2
Chicago, IL
Aug. 49
Baton Rouge, LA
Aug. 49
Portland, ME
Aug. 49
Las Vegas, NV
Aug. 49
Mobile, AL
Aug. 1116
Charlotte, NC
Aug. 1116
Rochester, NY
Exam only
San Antonio, TX
Aug. 1116
Seattle, WA
Aug. 1116
San Diego, CA
Aug. 1823
Minneapolis, MN
Aug. 1823
Salt Lake City, UT
Aug. 1823
Anchorage, AK
Exam only
Miami, FL
Sept. 1520
Idaho Falls, ID
Sept. 1520
St. Louis, MO
Sept. 1520
Houston, TX
Sept. 1520
New Orleans, LA
Sept. 2227
Fargo, ND
Sept. 2227
Pittsburgh, PA
Sept. 2227
Indianapolis, IN
Sept. 29Oct. 4
Miami, FL
Orlando, FL
Denver, CO
Dallas, TX
July 2126
Aug. 1823
Sept. 1520
Oct. 611
EXAM DATE
July 20
Sept. 28
Oct. 19
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the
seminar/exam or exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application
deadline dates by visiting our website www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification
Dept. to confirm your course status before making travel plans. For information on AWS seminars and certification programs, or
to register online, visit www.aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.
Apply early to avoid paying the $250 Fast Track fee.
58
MAY 2013
awo.aws.org
METALLURGY
ME
TA
ALL
LURGY
G
CONFERENCES
Pipeline Conference
June 4, 5
Houston, Tex.
The transportation of oil and natural gas through cross-country pipelines has never been as vigorous as it is now, and greater
growth lies ahead with welding in the thick of it. For many
decades, the stick electrode has been a driving force behind the
construction of these lines, and it is still very much in the drivers
seat. But in order to cut costs, owners have started to use X80, a
lighter-weight, higher-strength linepipe steel. The same cellulosic electrodes used on the more conventional steels are inadequate for X80 steel. This has opened the door for low-hydrogen
electrodes and mechanized welding.
The keynote address to this important AWS conference will
be delivered by Brian Laing, president of CRC-Evans Pipeline
International. A seasoned veteran of the pipeline industry, Laing
once worked for NOVA (now TransCanada), as a welding
engineer. Following is a breakdown of the other speakers and
their topics.
Robin Gordon, senior vice president of Microalloying International Inc., will present the current status of Grade X80 pipeline
technology and highlight the technical challenges that must be
addressed before considering its use.
Paul Tewss presentation on Specimen Quality for Fatigue
Test Girth Welds should be of interest to every pipeline owner.
Tews, who is operating out of the UK at present, is the principal
For more information, please contact the AWS Conferences and Seminars Business Unit at (800) 443-9353, ext.
223, or e-mail ablanco@aws.org. You can also visit the Conference Department Web site at www.aws.org/conferences
for upcoming conferences and registration information.
For info go to www.aws.org/ad-index
60
MAY 2013
Join together.
Meet over 1,000 exhibitors and experts from all over the world.
Discover innovative solutions in joining, cutting and surfacing.
Take advantage of the opportunities in the industrys hot spot.
Join your industry in Essen!
For Info go to www.aws.org/ad-index
WELDING
WORKBOOK
Datasheet 340
Shielding Gas
Characteristics
Aluminum
100% argon
35% argon/65% helium
25% argon/75% helium
Best metal transfer and arc stability; least spatter; good cleaning action.
Higher heat input than 100% argon; improved fusion characteristics on
thicker material; minimizes porosity.
Highest heat input; minimizes porosity; least cleaning action.
Magnesium
100% argon
Argon + 2070% helium
Carbon steel
Improves arc stability; produces a more fluid and controllable weld pool;
good fusion and bead contour; minimizes undercutting; permits higher
speeds than pure argon.
High-speed mechanized welding; low-cost manual welding.
Stainless steel
Improves arc stability; produces a more fluid and controllable weld pool;
good fusion and bead contour; minimizes undercutting on heavier
stainless steels.
Provides better arc stability, coalescence, and welding speed than
1% oxygen mixture for thinner stainless steel materials.
100% argon
Argon/helium
Titanium
100% argon
Shielding Gas
Characteristics
Carbon Steel
100% CO2
Stainless steel
Low-alloy steel
Aluminum, copper
magnesium, nickel, and
their alloys
MAY 2013
Pipelines Conference
June 4th 5th / Houston, TX
Join us in Houston for the debut of the AWS Pipeline Welding Conference! Our featured
speakers will cover a multitude of topics including the welding of high strength X80 pipe
steels, orbital processes used in pipeline construction throughout the world, the new FRIEX
system from Belgium and many other exciting topics.
Highlights
Learn about the progress of new and innovative developments
in pipeline welding.
Network with industry peers to find the best solutions for
business growth.
AWS Conference attendees are awarded 1 PDH (Professional
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 224.
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
The D1 Committee on Structural Welding met at AWS World Headquarters the week of Feb. 25.
Shown are (from left) AWS Vice President David McQuaid, past D1 Chair Donald Rager,
AWS Executive Director Ray Shook, D1 Chair Duane Miller, and Allen Sindel, D1 vice chair.
65
Damian J. Kotecki (right) receives his 30year service award pin from Harry Wehr,
chairman, A5 Committee on Filler Metals
and Allied Materials, on March 5, during the
annual meetings in Orlando, Fla. Kotecki
was cited for his many contributions to the
A5 Committees.
Tech Topics
New Standards Projects
Development work has begun on the
following revised standards. Affected individuals are invited to contribute to their
development. Contact Staff Secretary A.
Diaz, adiaz @aws.org; ext. 304. Participation on AWS Technical Committees is open
to all persons.
B2.1-1/8-010:20XX, Standard Welding
Procedure Specification (SWPS) for Gas
Tungsten Arc Welding of Carbon Steel to
Austenitic Stainless Steel (M-1, P-1, or S-1
to M-8, P-8, or S-8), 18 through 10 Gauge,
in the As-Welded Condition, with or without
Backing. Stakeholders: Manufacturers,
welders, CWIs, engineers.
B2.1-1/8-231:20XX, Standard Welding
Procedure Specification (SWPS) for Gas
Tungsten Arc Welding with Consumable Insert Root followed by Shielded Metal Arc
Welding of Carbon Steel (M-1/P-1/S-1,
Groups 1 or 2) to Austenitic Stainless Steel
(M-8/P-8/S-8, Group 1), 18 through 112 Inch
Thick, IN309, ER309, and E309-15,-16, or
-17, or IN309, ER309(L), and ER309(L)15, -16, or -17, As-Welded Condition, Primarily Pipe Applications. Stakeholders: Manufacturers, welders, CWIs, and welding engineers.
D9.1M/D9.1:20XX, Sheet Metal Welding
Code. Stakeholders: Those involved in the
production and qualification of nonstructural sheet metal applications such as heating, ventilating, and air conditioning systems, food processing equipment, architectural sheet metal, and in the acceptance of
welding and braze welding of nonstructural
sheet metal components.
66
MAY 2013
D16 Committee on Robotic and Automatic Welding seeks members in the general interest and educational fields to help
revise its documents. B. McGrath, bmcgrath@aws.org.
G2D Subcommittee on Reactive Alloys
seeks volunteers to update guides for the
fusion welding of titanium and titanium
alloys, and fusion welding of zirconium
and zirconium alloys. A. Diaz,
adiaz@aws.org.
J1 Committee on Resistance Welding
Equipment seeks educators, general interest, and users to develop standards on
controls, installation and maintenance,
calibration, and resistance welding fact
sheets. E. Abrams, eabrams@aws.org.
A5K Subcommittee on Titanium and
Zirconium Filler Metals. Seeks professionals in the field to update specifications
for welding electrodes and rods of titanium, zirconium, and their alloys. A. Diaz,
adiaz@aws.org.
WELDING JOURNAL
67
tions with industry and other organizations, and for contributions of time and effort on behalf of the Society.
George E. Willis Award
This award is given to an individual who promoted the advancement of welding internationally by fostering cooperative participation in technology transfer, standards rationalization, and promotion of industrial goodwill. It includes a
$2500 honorarium.
International Meritorious Certificate Award
This honor recognizes recipients significant contributions to
the welding industry for service to the international welding community in the broadest terms. The award consists of a certificate
and a one-year AWS membership.
and select the awards category or e-mail Wendy Sue Reeve, senior manager, awards programs, wreeve@aws.org.
A maximum of ten individuals per year may be selected as
Distinguished Welders as determined by the Selection Committee. Nominations shall remain valid for three years. If the maximum number of Distinguished Welders allowed under the rules
is reached, the remaining candidates will be deferred for consideration the next year, consistent with their time eligibility. If less
than the maximum number are awarded, the remaining candidates will be deferred for consideration the following year, consistent with their time eligibility.
68
MAY 2013
Affiliate Companies
Big B Welding Service
64016 Arcola Railroad Ln.
Roseland, LA 70456
Cab Construction Co.
1532 1st Ave.
Mankato, MN 56001
ESGA Ingenieria en Estructura S.A. de
C.V., Prolongacior de Recursos
Hidraulicos #6
La Loma Tlalnepantla 54060, Mexico
FM Stainless, LLC
1524 Ray Mountain Rd.
Ellijay, GA 30536
JRV Construction Enterprises, Inc.
891 Aura Rd.
Glassboro, NJ 08028
Leading Edge Mfg.
303 Chemin Metairie Rd.
Youngsville, LA 70592
McMenimen Design and Fabrication
3100 Cedar Bay Dr.
Melbourne, FL 32934
Webb Diving Services
6409 Rutledge Pike
Knoxville, TN 37924
Westar d.b.a. Quik-Shor
13217 Laureldale Ave.
Downey, CA 90242
Supporting Companies
Al Yousuf Enterprises
215, Aisha Bldg., Office No. 1
SVP Rd., Dongri, Mumbai
Maharashtra 400009, India
Hickey Metal Fabrication
873 Georgetown Rd.
Salem, OH 44460
Educational Institutions
ARPEC (Air Conditioning, Refrigeration & Pipefitting Education Center)
13201 NW 45th Ave.
Opa-locka, FL 33054
Birmingham Ironworkers
Training Program Trust
2828 4th Ave. S.
Birmingham, AL 35233
Carrollton Area Career Center
305 E. 10th St.
Carrollton, MO 64633
Cerro Coso Community College
3000 College Height Blvd.
Ridgecrest, CA 93555
Mastbaum AVTS High School
3116 Frankford Ave.
Philadelphia, PA 19134
Midlands Technical College
1260 Lexington Dr.
West Columbia, SC 29170
Muskegon Community College
221 S. Quarterline Rd.
Muskegon, MI 49442
Nueces Canyon High School
200 Taylor St.
Barksdale, TX 78828
Pitt Community College
2064 Warren Dr.
Winterville, NC 28590
Tennessee Technology Center at Crump
3070 Hwy. 64, PO Box 89
Crump, TN 38327
White Deer ISD - Agriculture Dept.
604 Doucette
White Deer, TX 79097
Welding Distributors
ACIT (USA), Inc.
6333 Hazelwood Ln. SE
Bellevue, WA 98006
WELDING JOURNAL
69
Member-Get-A-Member Campaign
Listed are the members participating in
the 20122013 campaign. Standings as of
March 18, 2013. See page 83 of this Welding Journal for campaign rules and prize list
or visit www.aws.org/mgm. For information,
call the Membership Department
(800/305) 443-9353, ext. 480.
Winners Circle
Sponsored 20 or more Individual Members per year since June 1, 1999. The superscript denotes the number of times the member achieved this status if more than once.
E. Ezell, Mobile10
J. Compton, San Fernando Valley7
J. Merzthal, Peru2
G. Taylor, Pascagoula2
L. Taylor, Pascagoula2
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 Guild
Sponsored 20+ new Individual Members
M. Pelegrino, Chicago 30
E. Ezell, Mobile 22
Presidents Roundtable
Sponsored 919 new Individual Members
R. Fulmer, Twin Tiers 10
W. Blamire, Atlanta 9
A. Tous, Costa Rica 9
P. Strother, New Orleans 9
Presidents Club
Sponsored 38 new Individual Members
D. Galigher, Detroit 7
W. Komlos, Utah 7
J. Smith, San Antonio 6
C. Becker, Northwest 5
L. Webb, Lexington 4
D. Wright, Kansas City 4
T. Baber, San Fernando Valley 3
J. Bain, Mobile 3
A. Bernard, Sabine 3
J. Blubaugh, Detroit 3
P. Brown, New Orleans 3
D. Buster, Eastern Iowa 3
C. Daon, Israel Section 3
G. Gammill, NE Mississippi 3
B. Hackbarth, Milwaukee 3
S. Jaycox, Long Island 3
D. Jessop, Mahoning Valley 3
70
MAY 2013
D. Saunders, Lakeshore 3
J. Turcott, Rochester 3
A. Winkle, Kansas City 3
R. Wright, San Antonio 3
R. Zabel, SE Nebraska 3
Presidents Honor Roll
Sponsored 2 Individual Members
G. Cornell, St. Louis
M. Depuy, Portland
D. Hayes Jr., Louisville
J. Helfrich, Tri-River
P. Host, Chicago
H. Hughes, Mahoning Valley
J. Kline, Northern New York
L. Kvidahl, Pascagoula
W. Larry, Southern Colorado
G. Lawrence, N. Central Florida
J. Mansfield, Philadelphia
E. Norman, Ozark
A. Sam, Trinidad
D. Saunders, Lakeshore
C. Shepherd, Houston
G. Solomon, Central Pennsylvania
A. Sumal, British Columbia
C. Villarreal, Houston
J. Vincent, Kansas City
A. Vogt, New Jersey
J. Vorstenbosch, International
M. Wheeler, Cleveland
L. William, Western Carolina
W. Wilson, New Orleans
J. Winston, St. Louis
Student Member Sponsors
Sponsored 4+ new Student Members
H. Hughes, Mahoning Valley 106
A. Theriot, New Orleans 47
B. Scherer, Cincinnati 39
D. Saunders, Lakeshore 36
W. England, Western Michigan 33
R. Bulthouse, Western Michigan 31
R. Hammond, Greater Huntsville 28
T. Geisler, Pittsburgh 24
S. Siviski, Maine 24
R. Zabel, SE Nebraska 24
B. Cheatham, Columbia 23
C. Kochersperger, Philadelphia 23
M. Arand, Louisville 22
D. Bastian, NW Pennsylvania 21
G. Gammill, NE Mississippi 21
F. Oravets, Pittsburgh 20
J. Theberge, Boston 20
J. Johnson, Madison-Beloit 19
V. Facchiano, Lehigh Valley 18
J. Falgout, Baton Rouge 18
R. Munns, Utah 18
S. Lindsey, San Diego 17
R. Richwine, Indiana 17
SECTIONNEWS
Shown at the Central Mass./R.I. Section vendors night event are from left (front row) Chair
Paul Mendez, District 1 Director Tom Ferri, Douglas Desrochers, and Robert Winschel,
(back row) Brendon Pequita, and Tim Kinnaman.
Shown at the Green & White Sections tour of Structal-Bridges are (from left) Sherry Morin, Jennifer Eastley, Ann Thompson, Richard
Mann, Gerry Ouelette, Geoff Putnam, District 1 Director Tom Ferri, Ernie Plumb, Rich Fuller, tour guide Daryl Hastings, Gary Buckley,
Phil Witteman, Feona Lund, John Steel, Perley Lund, and Chris Young.
District 1
CENTRAL MASS./R.I.
FEBRUARY 28
Activity: The Section held its fourth annual welders and vendors night event at
Greater New Bedford Vo-Tech High
School. Featured were hands-on demonstrations of new welding and cutting equipment and presentations by local steel and
welding-supply companies. The presenters
included New Bedford Vo-Tech welding instructors Paul Mendez and Brendon Pe-
quita, Section chair and vice chair, respectively. District 1 Director Tom Ferri participated in the event.
CONNECTICUT
FEBRUARY 26
Activity: The Section held a students night
program at Bristol Technical High School
in Bristol, Conn., for 65 attendees. The
schools culinary department provided the
meals. Attending were representatives
from local businesses who discussed their
products and services and answered the
students questions. Assisting with the
event were Section Chair Steve Goodrow,
Treasurer Walter Chojnacki, Joseph Han-
71
District 2
LONG ISLAND
FEBRUARY 21
Speaker: Tom Gartland, Section vice chair
Affiliation: Trilogy Lab, LLC
Topic: Welding Kooks headers
Activity: The program was held in Wantagh, N.Y. District 2 Director Harland
Thompson attended the program.
PHILADELPHIA
Shown at the Long Island Section program are from left (front row) Tom Gartland, Chair
Brian Cassidy, and Alex Duschere, (back row) Barry McQuillan, Ray OLeary, Jessie Provler,
District 2 Director Harland Thompson, and Ken Messemert.
Shown at the March Philadelphia Section program are (from left) District 2 Director Harland Thompson, with Dave Schaffer, Bert Riendeau, Charlie Minnick, Chair Ken Temme,
and Tim Stott.
FEBRUARY 7
Speaker: Frank Hauser
Affiliation: Divers Academy International
Topic: Techniques for testing underwater
welds
Activity: Members of the local chapter of
ASNT attended this program. District 2
Director Harland Thompson and Chair
Ken Temme presented the District Director Certificate Award to Mike Chomin, immediate past chair. The program was held
at the Crown Plaza in Trevose, Pa.
MARCH 13
Speakers: Dave Schaffer, Airgas East; Bert
Riendeau, Airgas Northeast; Charlie Minnick, Miller Electric; and Tim Stott, Miller
Electric
Topics: Schaffer discussed AC balance
control; Riendeau spoke on welding codes
made friendly; Minnick talked about traditional welding machine technology; and
Stott detailed advances in modern inverter
machines
Activity: Philadelphia Section Chair Ken
Temme presented the District CWI of the
Year Award to Bill Mowbray of Scheck
Mechanical Contractors; and Section Educator of the Year Awards to Walt Emerle,
training director, Plumbers and Pipefitters
Local 322; Dan Roskiewich, Gloucester
County Institute of Technology; and Charlie Minnick from Miller Electric. The
event was hosted by Plumbers and Pipefitters Local 322, a Section supporter, represented by Jim Kehoe, business manager.
District 3
Mike Chomin (left) receives the District Director Award from District 2 Director Harland Thompson at the February Philadelphia Section event.
72
MAY 2013
District 4
Philadelphia Section members display their awards (from left) Dan Roskiewich, Charlie
Minnick, Bill Mowbray, Chair Ken Temme, Walt Emerle, and Harland Thompson, District
2 director.
Tidewater Section members are shown during their tour of Catalina Cylinders in February.
Attendees are shown at the ASME-Triangle Section career panel program in February.
CHARLOTTE
CALENDAR
MAY 3
13th Annual Intercollegiate
Welding Competition
Central Piedmont C. C., Charlotte, N.C.
Contact Chair Ray Sosko
(704) 330-4487
TIDEWATER
FEBRUARY 21
Activity: The Section members visited
Catalina Cylinders East, Cliff Impact
TRIANGLE
FEBRUARY 5
Activity: A career panel consisting of six
senior members of the local chapter of
ASME and Russell Wahrman from the
AWS Triangle Section convened at North
Carolina University in Raleigh, N.C., to
share their experiences in the industry and
answer questions for the college students.
District 4 Director and Section Chair Stuart Harris expressed an interest in making the career panel program with ASME
an annual event.
WELDING JOURNAL
73
Florida West Coast golfers get ready to tee off at the Sections 21st annual tournament.
Participants are shown at the North Central Florida Section-sponsored welding contest.
Working the Florida West Coast Section raffle-ticket fund-raiser were (from left) Walt Arnold,
Bill Machnovitz, Raymond Monson, and Al Sedory.
First-place team members at the Florida West Coast tournament are (from left) Walt Arnold,
Jack Garrison, Don Chadwell, and Mike Gates.
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
MAY 2013
MARCH 2
Activity: The Section hosted its 21st annual golf outing to raise funds for its scholarship program to assist local welding students. More than 50 members, guests, and
sponsors participated in the event. The
first-place team members, scoring 14
under par, were Walt Arnold, Jack Garrison, Don Chadwell, and Mike Gates.
FEBRUARY 12
Activity: The Section conducted a welding
contest at Community Technical Adult Education Center in Ocala, Fla., for 11 student and 8 professional welders. Joey Pyles
from Townley Industries won the professional title with runner-up Jennifer Skyles,
Section chair, with SPX Industries. Jacob
Underhill from Bradford Union Area Ca-
Pittsburgh Section and ASNT members are shown at the March program.
Shown at the Tri-State Boy Scout merit badge training session are (kneeling) Allen Black
and (from left) Calvin Roach, Xristopher Popoff, Devin Ames, John Saunders, David Hay,
Cody Finley, Andy Hall, Sean McKinley, Fred Hammers, and Chad Bowen.
reer Technical Center earned the top student welder honor with Tommy Taylor taking second place. Sebastian Rodriguez
from Tech Simulation showed attendees
how to test their skills using a virtual arc
welding training system.
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
District 7
COLUMBUS
MARCH 19
Speaker: Angie Rybalt, outreach manager
Affiliation: American Electric Power
(AEP)
Topic: How AEP support services can help
businesses reduce power consumption
Activity: The program was held at La Scala
Restaurant in Columbus, Ohio.
DAYTON
TRI-STATE
FEBRUARY 12
Activity: The Section conducted a Boy
Scout welding merit badge workshop at
Miami Valley Career Technology Center
in Clayton, Ohio, for 66 Scouts. Career
Center students assisted the Section members to instruct the Scouts on the proper
welding techniques. Chuck Ford, Section
student affairs chair, and Chair Chris Lander led the activity.
JANUARY 8, 10, 15
Activity: Fred Hammers, owner of Hammers Industries, and Health and Safety
Manager Cody Finley hosted and trained
a Boy Scouts welding merit badge class.
The hands-on shop training was taught by
Shop Manager Calvin Roach, Andy Hall,
and John Saunders. Earning their welding badges were David Hay, Xristopher
Popoff, and Chad Bowen of Troop 63,
Devin Ames of Troop 790, Sean McKinley
of Troop 50, and Allen Black of Troop 92.
The training was conducted at the Hammers Industries facilities near Huntington,
W.Va.
FEBRUARY 16, 17
Activity: The Dayton Section members
participated in Tech Fest 2013 presented
by the Affiliated Societies of Dayton to interest grade school students in science and
technology. The Section members talked
to students about careers in welding and
presented live demonstrations of automated welding using a Motoman robot.
PITTSBURGH
MARCH 12
Speaker: Wes Williams, staff engineer
Affiliation: First Energy Corp.
Topic: Procedure for repair of cracks in the
Unit 2 Nuclear Reactor head
Activity: Members of the local chapter of
ASNT International Chapter, headed by
Chair Robert Saunders, attended this program, held at Springfield Grille in Mars,
Pa.
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
CHATTANOOGA
FEBRUARY 16
Activity: The Section held its student welding competition at Sequoyah High School
in Soddy Daisy, Tenn., hosted by the Sequoyah High School Student Chapter. The
top scorers in the high school category
were Dustin Luthringer, Colton Jones, and
Dexter McSpaden. The postsecondary category winners were Mauricio Gayton Jr.,
Eric Vennie, and Darren Vincent.
WELDING JOURNAL
75
HOLSTON VALLEY
MARCH 12
Speaker: Gary Roberts
Affiliation: Airgas, automation specialist
Topic: Airgas University online training
Activity: Nominations for Section officers
were received for presentation at the April
meeting. The program was held at Mamas
House Restaurant in Kingsport, Tenn.
Shown are the participants in the Chattanooga Section/Sequoyah High School Student
Chapter welding contest.
The top-scoring welders in the Chattanooga Section/Sequoyah High School Student Chapter contest are (from left) Eric Vennie, Dexter McSpaden, Dustin Luthringer, Colton Jones,
Darren Vincent, and Mauricio Gayton Jr.
NORTHEAST TENNESSEE
FEBRUARY 12
Activity: The Section hosted its annual students day event at Tennessee Technology
Center (TTC) in Knoxville for about 230
students from local schools. The event included talks on welding careers, complimentary lunch, welding demonstrations,
and a tour of the Technology Center. Attending were high school welding instructors Steve Linn (TTC Knoxville), Jeff Hankins (Oak Ridge), Jim Thomas (South
Doyle), Rick Johnson (Grainger), Tim
Steelman (Morgan County), Michael Hurt
(TTC Jacksboro), Mike Russell (TTC
Harriman), and District 8 Director Joe
Livesay (TTC Crossville).
NORTHEAST MISSISSIPPI
FEBRUARY 21
Activity: The Section sponsored a students night and equipment demo event
featuring the Lincoln Electric mobile display unit. Lincoln salesman Ron Martucci
demonstrated the equipment.
Speaker Gary Roberts (red sweater) is shown with the Holston Valley Section members.
District 9
BIRMINGHAM
Students are shown at the Northeast Tennessee Sections students day event.
FEBRUARY 27
Activity: The Birmingham Section and
Lawson State C. C. Student Chapter members held a welding seminar at Plumbers
and Pipefitters Local 372 in Duncanville,
Ala. Exhibitors included Victor, Lincoln
Electric, Miller Electric, Airgas Welding
Supply, and Harris Equipment.
Central Alabama
Student Chapter
MAY 2013
MARCH 7
Speaker: Craig Ray
Topic: Jobs in underwater welding and
commercial diving
Activity: The program was held in the Central Alabama Community College welding
shop in Alexander, Ala. Attending were D.
J. James, Emily Hatfield, Daniel Arnberg,
Brandon Fraser, Robin Holt, Zack Adams,
Chris Floyd, Walter Whatley, Colton
Stroud, and Craig Ray.
NEW ORLEANS
FEBRUARY 26
Speaker: Nancy Cole, AWS president
Affiliation: NCC Engineering
Topic: The welding industry
Activity: Past AWS President John and
wife Donna Bruskotter hosted a reception
for Nancy Cole at their home in Slidell, La.
District 9 Director George Fairbanks was
among the Sections guests who attended
the event.
MARCH 19
Speaker: Jason Lange
Affiliation: Lincoln Automation, Inc.
Topic: Controlling welding fumes
Activity: IWS Gas & Supply, represented
by President Moussy Chassion, provided
the door prizes and sponsored this New
Orleans Section program at Caf Hope in
Marrero, La., for 66 members, students,
and guests. Alfred Marshall, an apprentice with Ironworkers No. 58, was the 50/50
prize winner.
District 10
District 10
MARCH 9
Activity: The District held its second CWI
Roundtable event at Babcock & Wilcox
Commercial in Euclid, Ohio. The event offers CWIs an opportunity to share their
experiences and opinions. The 20 participants discussed a number of topics, including qualification records, welding procedure specifications, welder performance
qualification records, and the proper way
to issue welder certification papers.
Central Alabama Student Chapter members are shown at their March meeting.
DRAKE WELL
JANUARY 18
Activity: The Section participated in the
SkillsUSA competition hosted by the New
Castle School of Trades in New Castle, Pa.
The top welders were Joseph Crate,
Robert Ackerson, and Conner Biggs.
77
The New Orleans Section attendees are shown at the reception held at the Bruskotters home.
MAHONING VALLEY
Shown at the New Orleans Section event are (from left) Tommy Callahan, Mike Massicot,
Jimmy Gibbs, Moussy Chassion, and Chair Aldo Duron.
MARCH 14
Speaker: Jim Hannahs, PE, CWI
Topic: Metals and processes used to build
NASCAR vehicles
Activity: The meeting, held at Mahoning
County Career & Technical Center in Canfield, Ohio, was attended by about 90
members and guests.
NORTHWESTERN
PENNSYLVANIA
FEBRUARY 13
Speaker: Marty Siddall, technical sales
representative/automation specialist
Affiliation: The Lincoln Electric Co.
Topic: New technologies in robotic welding
Activity: The meeting was held at Tri State
Business Institute in Erie, Pa.
District 11
Shown at the New Orleans Section March program are (from left) Moussy Chassion, Matt
Howerton, speaker Jason Lange, and Chair Aldo Duron.
78
MAY 2013
NORTHWESTERN OHIO
FEBRUARY 27
SPEAKER: Curt Wilsoncroft, regional sales
representative
Affiliation: Victor Technologies
Topic: Carbon arc and oxygen lance cutting
Activity: The program was held at Owens
Community College in Perrysburg, Ohio,
for 41 attendees. Following the talk, the
group visited the welding lab where Wilsoncroft demonstrated the cutting processes
and members had a hands-on opportunity
to experiment with the equipment.
Shown at the Drake Well Section SkillsUSA competition are (from left) Robert Ackerson,
Tyler Hoffman, Joseph Crate, Chad Hajec, Joseph Steiner, and Conner Biggs.
District 12
RACINE-KENOSHA
FEBRUARY 22
Speaker: Chris Boycks, CWI
Topic: The shortage of skilled qualified
welders and fabricators
Activity: The seventh annual District 12
winter meeting was hosted by Jay Manufacturing Co. in Oshkosh, Wis. Dan
Roland, District 12 director, presented
Chair Dan Crifase the Dalton E. Hamilton Memorial CWI of the Year Award and
the District Meritorious Award to Vice
Chair Ken Karwowski.
Drake Well Section members are from left (front row) Robert Fugate, Colin Young, Justus
Burk, Bailey Hagerty, Dan Bubenhiem, William Brownlee, Travis Crate, and Ward Kiser;
(back row) Rolf Laemmer, Erick Speer, Joe Crate, and Troy Braden.
District 13
John Willard, director
(815) 954-4838
kustom_bilt@msn.com
CHICAGO
FEBRUARY 13
Activity: The Section hosted its annual St.
Valentines Day dinner party at Coopers
Hawk Winery & Restaurant in Chicago,
Ill., for 35 attendees.
Shown at the February Racine-Kenosha Section event are (from left) Chair Dan Crifase,
District 12 Director Dan Roland, and Ken
Karwowski.
District 14
INDIANA
FEBRUARY 9, 10
Activity: The Section conducted the regional SkillsUSA welding contest at J. E.
L. Career Center in Indianapolis, Ind., for
20 participants. Four secondary and four
postsecondary welding contestants were
selected to compete in the state welding
contest. Working the event were Bob Richwine, District 14 director; Chair Bennie
Flynn; Gary Dugger; and Gary Tucker.
WELDING JOURNAL
79
SkillsUSA welding contestants are shown during the Indiana Section event.
FEBRUARY 27
Activity: The Indiana Section members
toured the Don Schumacher Racing facility in Brownsburg, Ind. Mike Lewis, senior vice president, conducted the tour.
LEXINGTON
FEBRUARY 28
Speaker: Tony Noah
Affiliation: The Lincoln Electric Co.
Topic: Pulse welding
Activity: Incoming Chair Coy Hall presented the Section CWI of the Year Award
to Sherman Cook, an instructor at Rockcastle County Technical School. Rose
Whitaker and Rosa McCallum were presented $250 scholarship awards. Fifty
members and guests attended the program.
ST. LOUIS
DECEMBER 21
Activity: The Section held its holiday party
at Cee Kay Supply, Inc., in St. Louis, Mo.
Company owner Tom Dunn was cited for
his generous support and the services he
has offered to the Section over the years.
In recognition, Jerry Simpson presented
Dunn the District 14 Meritorious Award.
Angela Harrison is shown with Dennis Pickering at the Arkansas Welding Expo.
Mike Lewis led the Indiana Section members on a tour of Don Schumacher Racing.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
MAY 2013
Tom Dunn (left) receives the District 14 Meritorious Award from Jerry Simpson at the St.
Louis Section holiday party.
District 17
J. Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
Speaker Dennis Pickering (kneeling) and attendees are shown at the February Central Arkansas Section meeting.
CENTRAL ARKANSAS
NOVEMBER 1
Activity: The Section participated in the
Arkansas Welding Expo presented by
WELSCO, Inc., at Verizon Arena in Little Rock, Ark. Angela Harrison, WELSCO
president, was presented the Section Meritorious Award. More than 700 students
attended the event to learn about job opportunities from Monica Pfarr, AWS corporate director, workforce development,
who held presentations for them titled
Let the Sparks Fly. Vice Chair Dennis
Pickering, a welding instructor at
Arkansas Career Training Institute, made
presentations at the expo.
JANUARY 17
Speaker: Dennis Pickering, vice chairman
Affiliation: Arkansas Career Training Institute, welding instructor
Topic: Welding codes and standards
Activity: The program was held at the institute in Hot Springs, Ark.
FEBRUARY 11
Speaker: Dennis Pickering, vice chairman
Affiliation: Arkansas Career Training Institute, welding instructor
Topic: The AWS scholarship program
Activity: The meeting was held at Arkansas
State University in Heber Springs, Ark.
Shown at the East Texas Section program are (from left) Student Chapter Chair Michael
Florczykowski, Chair Bryan Baker, Yoni Adonyi, speaker Tom Siewert, Robert Warke, and J.
Jones, District 17 director.
EAST TEXAS
LeTourneau University S. C.
FEBRUARY 21
Speaker: Tom Siewert, AWS director-atlarge
Affiliation: NIST (ret.)
Topic: Analysis of the collapse of the World
Trade Center buildings
Activity: The program was held at LeTourneau University in Longview, Tex. Attending were District 17 Director J. Jones,
Chair Bryan Baker, Student Chapter Chair
Michael Florczykowski, Prof. Materials
Joining Engineering Yoni Adonyi, and
Robert Warke, associate professor, materials joining.
Shown at the Tulsa Section program are (from left) AWS President Nancy Cole, Todd Morris, Charles Griffin, Ralph Johnson, Ray Wilsdorf, and J. Jones, District 17 director.
TULSA
FEBRUARY 9
Activity: The Section hosted a dinner to
celebrate St. Valentines day with the
ladies. Nancy Cole, AWS president, attended the event. Todd Morris and Ralph
Johnson received District Director Certificate Awards, and Charles Griffin was presented the Private Sector Instructor
Award. Ralph Johnson and Ray Wilsdorf
received Dalton E. Hamilton Memorial
CWI of the Year Awards.
WELDING JOURNAL
81
Attendees are shown at the Houston Section instructors institute held February 22.
Shown at the Houston Section booth at the Houstex show are (from left) Sam Gentry,
Luanne Bray, John Stoll, and John Bray, District 18 director.
Alaska Section members and guests are shown at the February program.
Members and students are shown at the Spokane Section program in January.
District 18
Shown during the British Columbia Section
tour are Brad Moe and speaker John Shaw.
82
MAY 2013
HOUSTON
FEBRUARY 22
Activity: The Section held its seventh annual instructors institute hosted by Andre
Horn and the Industrial Welding Academy
staff. Thirty welding instructors attended
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Transportation equip. boats, ships
Transportation equip. railroad
Utilities
Welding distributors & retail trade
Misc. repair services (incl. welding shops)
Educational Services (univ., libraries, schools)
Engineering & architectural services (incl.
assns.)
Q q Misc. business services (incl. commercial labs)
R q Government (federal, state, local)
S q Other
Job Classification (Check ONE only)
01 q President, owner, partner, officer
02 q Manager, director, superintendent (or
assistant)
03 q Sales
04 q Purchasing
05 q Engineer welding
20 q Engineer design
21 q Engineer manufacturing
06 q Engineer other
10 q Architect designer
12 q Metallurgist
13 q Research & development
22 q Quality control
07 q Inspector, tester
08 q Supervisor, foreman
14 q Technician
09 q Welder, welding or cutting operator
11 q Consultant
15 q Educator
17 q Librarian
16 q Student
18 q Customer Service
19 q Other
Technical Interests (Check all that apply)
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card.
q
q
q New
r Yes r No
ADDRESS
A
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Ferrous metals
Aluminum
Nonferrous metals except aluminum
Advanced materials/Intermetallics
Ceramics
High energy beam processes
Arcwelding
Brazing and soldering
Resistance welding
Thermal spray
Cutting
NDT
Safety and health
Bending and shearing
Roll forming
Stamping and punching
Aerospace
Automotive
Machinery
Marine
Piping and tubing
Pressure vessels and tanks
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Structures
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01
Idaho-Montana Section members are shown during their tour of Spudnik Equipment Co.
LAKE CHARLES
FEBRUARY 20
Speaker: John Bray, District 18 director
Affiliation: Affiliated Machinery
Topic: Whats new at AWS
Activity: The dinner and program were
held at Logans Roadhouse Restaurant in
Lake Charles, La.
BRITISH COLUMBIA
FEBRUARY 20
Speaker: John Shaw, VP, government relations and business development
Affiliation: Seaspan Vancouver Shipyards
Topic: Update on the National Shipbuilding Procurement Strategy
Activity: Following a catered dinner and
the talk, the Section members were guided
on a tour of the Seaspan Vancouver Shipyards by AWS member Brad Moe.
SPOKANE
JANUARY 16
Speaker: Russ Loveland
Affiliation: Western States Equipment Co.
Topic: Maintaining large construction
equipment
Activity: The program was held at Spokane
Community College in Spokane, Wash.,
for 39 attendees.
District 20
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
FRESNO
FEBRUARY 21
Activity: The Section members met for a
demonstration of the Tri Tool AdaptArc
orbital welding system. Dale Flood, Tri
Tool project manager, an AWS directorat-large, and past District 22 director, conducted the program for about 45 attendees. Attending were District 22 Director
Kerry Shatell, Kent Baucher, a past District 22 director, and Theo Davis, an instructor at Fresno City College.
SACRAMENTO VALLEY
JANUARY 16
Speaker: Mark Paavola, administrator of
apprenticeship ad training
Affiliation: Sheet Metal Workers Assn.
Topic: Employment opportunities in the
sheet metal trade
Activity: Paavola and David Perez detailed
the training program used by the center.
IDAHO-MONTANA
District 19
ALASKA
FEBRUARY 20
Speaker: Marty Anderson, chair, ASNT
Alaska chapter
Affiliation: Alaska Technical Training, Inc.
Topic: Nondestructive welding inspection
technologies
Activity: The program was held for 21 attendees in Anchorage, Alaska.
FEBRUARY 13
Activity: The Section members visited
Spudnik Equipment Co., in Blackfoot,
Idaho, to tour the facility. The facility designs and manufactures potato planting,
cultivating, harvesting, and handling
equipment. Wes Woodland, shift supervisor, led the program.
District 21
International
GERMANY
CALENDAR
Essen, Germany
SEPT. 1117
66th IIW Annual Assembly
2013 Intl Trade Fair
Joining, Cutting, Surfacing
SEPT. 16, 17
Intl Conf. on Automation in Welding
SEPT. 1621
Young Welders Competitions
www.iiw2013.com
WELDING JOURNAL
85
INTERNATIONAL SALES
TECHNICAL SERVICES
Nancy C. Cole
nccengr@yahoo.com
NCC Engineering
2735 Robert Oliver Ave.
Fernandina Beach, FL 32034
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Chief Financial Officer
Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
VP Sales and Marketing
Bill Fudale..bfudale@aws.org . . . . . . . . . . . . .(211)
VP Technology and Business Development
Dennis Harwig..dharwig@aws.org . . . . . . . . .(213)
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
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)
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
86
MAY 2013
MARKETING COMMUNICATIONS
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
MEMBER SERVICES
Department Information . . . . . . . . . . . . . . . . .(480)
Sr. Associate Executive Director
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
Department Information . . . . . . . . . . . . . . . . .(273)
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all international certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Certification Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification programs, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
The AWS Foundation is a not-for-profit corporation established to provide support for the educational and scientific endeavors of the American Welding Society.
PERSONNEL
senior manager exports, and John Blicha
to director of corporate communications.
Goldner will manage the companys sales
offices in Central and South America and
the Middle East. Most recently, Goldner
served as export market development
manager, targeting industrial markets in
Central and South America. Blicha has
Andrew Goldner
John Blicha
6
6
6
6
6
6
6
6
66
6
6
6 6
6
6
6 6
+!3!6-/042
6
6
2% Thoriated
6
6
6
6
6 6
6 6
6 6
6 6
6
6 6
6
6 6
6
6
6
6
6
6
6
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6 6
6
6
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6
6 6
63-2.+34
6
6
6 6
6 6
6
6
6
63-2.+34
after 3 passes
The American Welding Society Foundation, Inc., Doral, Fla., has elected Becky
Tuchscherer to serve on its board of
trustees. Her term runs through 2015.
Tuchscherer is group vice president, commercial welding, for Miller Electric Mfg.
Co., where she has worked since 1988. She
is an AWS member and has served on the
AWS Finance Committee. The AWS
Foundation was established in 1991 to
support programs
that ensure the
growth and development of the welding
industry. Its focus is
on providing scholarships for welding students and pursuing
welder workforce development issues.
Becky Tuchscherer
E3
after 8 passes
5-364)432-4!6!-/64246
2"/6-/6+624%-346-2*.3+)6
4)./06!$!34%6-/6+6
6./6
'.'46.36+6
6./6+))6
62+/6+''2-6
6)./4+263
E362+/6+''2-66)./4+263
Mike Edwards
Mike Safford
continued on page 90
88
MAY 2013
Centerline Names RW
Account Manager
Centerline (Windsor) Ltd., Windsor,
Ont., Canada, has named Greg Van Dyke
account manager specializing in resistance welding consumables and automation component
products. Van Dyke
has ten years of experience in the resistance welding field,
most recently with
Resistance Welding
Products Ltd., and
the Tuffaloy Group of
Greg Van Dyke companies.
Caster Concepts, Albion, Mich., a supplier of heavy-duty casters and wheels, has
named Jamie Long
director of sales.
Prior to joining the
company,
Long
served as national
sales manager for
Hotsy Corp., a division of Karcher
North America, a
manufacturer
of
high-pressure cleanJamie Long
ing systems.
90
MAY 2013
Member Milestones
Damian J. Kotecki
Damian J. Kotecki, an AWS Fellow,
PE, a past AWS president, and worldrenowned authority on welding stainless
steels, has been appointed to the Board
of
Advisors
of
Abakan, Inc., Miami,
Fla. The announcement states in part,
Dr. Kotecki brings
43 years of welding
expertise as well as
his extensive technical and business netDamian Kotecki work to the Board of
Advisors, as Abakan
transitions its CermaClad large-area
cladding technology into full commercial
production. Dr. Koteckis extensive experience in welding research, pipeline failure analyses, welding training and specifications, welding procedure development,
quality assurance, and stainless/high-alloy
welding filler metal and product development will help assure the companys products incorporate the highest levels of
technical excellence. Kotecki chairs the
A5D Subcommittee on Stainless Steel
Welding and the International Standards
Activities Committee. He is also a past
chair of the IIW Commission II Arc
Welding and Filler Metals, and authors
the bimonthly Stainless Q&A column in
the Welding Journal. He conducted welding research projects and pipeline failure
analyses for the Battelle Memorial Institute, served as director of research for
Teledyne McKay, and most recently retired as the technical director for stainless
and high-alloy product development for
The Lincoln Electric Co.
awo.aws.org
Understanding
Understanding
Welding
Welding Symbols
Knowledge of weld joint terminology is essential for all levels of the welding design and production process. Use
of proper terms makes it much easier for welding personnel to communicate about various fit-up and welding
problems encountered during the fabrication process. A welding inspector
inspecto
s ability to read and interpret welding
inspectors
plans correctly is essential to properly inspecting a piece or part.
WS 2.4:2012, starting with a module on orthographic views, joint
AWS
This in-depth course walks the user through A
types, and weld types. Then the course dives into the various types of welds and clarifies the rules and usage of
welding symbols.
geometry,, groove welds, fillet welds, plug and slot welds, spot and
This self-paced course covers basic joint geometry
projection welds, and stud, seam, surfacing, and edge welds. Rounding out the seminar is a module on brazing
terms and symbols and non-destructive testing symbols. Interactive practice problems include an explanation of
each solution, and chapter quizzes will solidify the knowledge and prepare you for the proficiency exam.
The seminar is approximately 12 hours long and concludes with a final test.
The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image and
impact of the welding industry. Election as a Counselor shall be based on an individuals career of
outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in the
welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the welding
industry. The individuals organization shall have shown an ongoing commitment to the industry, as
evidenced by support of participation of its employees in industry activities.
Leadership of or within an organization that has made a substantial contribution to training and
vocational education in the welding industry. The individuals organization shall have shown an
ongoing commitment to the industry, as evidenced by support of participation of its employees in
industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this
issue of the Welding Journal. The deadline for submission is July 1, 2013. The committee looks
forward to receiving these nominations for 2014 consideration.
Sincerely,
Lee Kvidahl
Chair, Counselor Selection Committee
Base Copy: 02
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II. RULES
A.
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PAGE 1
02
CLASS OF 2014
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V.
HOME ADDRESS____________________________________________________________________________________________________
CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________
PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________
TITLE/POSITION____________________________________________________________________________________________________
BUSINESS ADDRESS________________________________________________________________________________________________
CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________
ACADEMIC BACKGROUND, AS APPLICABLE:
INSTITUTION______________________________________________________________________________________________________
MAJOR & MINOR__________________________________________________________________________________________________
DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________
LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________
SIGNIFICANT WORK EXPERIENCE:
POSITION____________________________________________________________________________YEARS_______________________
SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE
SELECTED AS AN AWS COUNSELOR ACCOMPANY THE NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY
BE INCORPORATED WITHIN THE CITATION CERTIFICATE.
**MOST IMPORTANT**
The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All information and support material provided by the candidates Counselor Proposer, Nominating Members and peers are considered.
SUBMITTED BY:
PROPOSER_______________________________________________
AWS Member No.___________________
The proposer will serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include a
detailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the candidate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition
to the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.
PAGE 2
COMPANY/CITY/STATE_____________________________________________________________________________________________
BLIND PERF
POSITION____________________________________________________________________________YEARS_______________________
COMPANY/CITY/STATE_____________________________________________________________________________________________
02
CLASSIFIEDS
CAREER
OPPORTUNITIES
Welding Engineering
Technology Faculty
(9 mos. Full-Time, Tenure Track)
Teach undergraduate-level lecture and
laboratory course work in a process
oriented, hands-on A.A.S. and B.S.
degree program. Required: Bachelor of
Science in Welding Engineering, Welding
Engineering Technology, or a closely
related field. Two (2) years of welding related experience in a welding application,
design, educational, procedure or research
environment. Candidates must demonstrate proficiency in GMAW, SMAW, GTAW,
OFW, OFC, PAC, SAW, FCAW and RSW.
Additional requirements include knowledge
of pipe welding and experience in welding
graphics, welding fabrication, destructive
and nondestructive weldment evaluation,
mechanical testing, and computer applications. The successful candidate will have
a Masters degree by the time of appointment or will be required to obtain such a
degree within four (4) years of hiring. For
a complete posting or to apply, access the
electronic applicant system by logging on
to http://employment.ferris.edu. Ferris
State University is sincerely committed to
being a truly diverse institution and actively
seeks applications from women, minorities,
and other underrepresented groups.
An Equal Opportunity/Affirmative Action
employer.
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184
Our products are made in the USA
CERTIFICATION
& TRAINING
2013
CWI PREPARATORY
MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1-Ton thru 60-Ton
EQUIPMENT FOR
SALE OR RENT
40 HOUR COURSE
GET READY FAST PACED COURSE!
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
WELDING JOURNAL
95
ADVERTISER
INDEX
ALM Materials Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
www.almmh.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 544-5438
ArcOne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
www.Arc1Weldsafe.com . . . . . . . . . . . . . . . . . . . . . .(800) 223-4685
Midalloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
www.midalloy.com . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 776-3300
Red-D-Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
www.reddarc.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(866) 733-3272
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
www.cor-met.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
www.us.trumpf.com . . . . . . . . . . . . . . . . . . . . . . .web contact only
Gedik Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
www.gedikwelding.com . . . . . . . . . . . . . . . . . . .+90 216 378 50 00
96
MAY 2013
ABSTRACT
Through aging treatments at 873 to 1023 K, sigma- () phase embrittlement in Type
316FR stainless steel weld metal was predicted at service-exposure temperatures (773823
K) of a fast breeder reactor (FBR) based on a kinetic approach to -phase precipitation.
Microstructural examination by scanning and transmission electron microscopies (SEM
and TEM) revealed that the dominant precipitated phases were and chi (), nucleated at
-ferrite/austenite () interfaces or in the interior of the -ferrite grains, thereby consuming
the -ferrite during isothermal holds at each aging temperature. The total amount of precipitated phases during isothermal aging sigmoidally increased as a function of the aging
time. The kinetics of the appearance of these intermetallic phases could be expressed approximately by a Johnson-Mehl type equation. Based on the determined kinetic equation,
the precipitation behavior of intermetallic phases and the degradation of impact toughness
at 773 and 823 K could be successfully predicted.
Introduction
Recently, societys most important mission and goal is to secure an effective energy source that will contribute to a
reduction in global warming and replacement of the fossil fuels that are gradually
running short worldwide. Among various
possible energy sources, one that is increasingly coming into the spotlight is nuclear power generation, due to its merits
of providing a stable and efficient energy
supply system despite its known liabilities
of dangerous radioactivity and nuclear
waste concerns. Among the diverse types
of nuclear power generation, the fast
breeder reactor (FBR, using fast neutrons
that breed Pu-239 from U-238) is well
known as the most advanced thanks to its
superior fuel economy. Thus, much research has been performed in Japan on
the metallurgical behavior, as well as the
structural properties, of materials for the
Japanese prototype fast breeder reactor
E. J. CHUN, H. BABA, K. TERASHIMA, and
K. SAIDA are with Division of Materials and
Manufacturing Science, Graduate School of Engineering, Osaka University, Osaka, Japan.
K. NISHIMOTO is with Department of the Application of Nuclear Technology, Fukui University
of Technology, Fukui, Japan.
KEYWORDS
Embrittlement
Type 316FR
Weld Metal
Sigma Phase
Kinetics
cialization of future FBRs in Japan can become a reality, discovering the effects of
the sodium environment and the relatively
high operating temperature on the repair
weldability of components made of
austenitic stainless steel (Types 304, 316,
and 321), the alloy usually chosen due to
its superior corrosion resistance, ductility,
strength, formability, and weldability
(Refs. 6, 7), are very significant issues. Furthermore, an advanced 316FR stainless
steel structural material, which has improved creep fatigue behavior over other
austenitic stainless steels, and which possesses a higher phase stability during high
temperature at longer exposure times by
using the concept of solid-solution hardening with low-carbon and medium nitrogen as compared to conventional
austenitic stainless steel, is likely to be
used for the next generation of commercial FBRs in Japan. However, to the best
of the authors knowledge, research on
these issues has not been reported to date.
A particular result of the high-temperature operation of a FBR is the need
for weld repairs to the various main components in the nuclear plant. Such problems arise because welds have poorer
quality than the base metals due to solute
segregation or microstructural inhomogeneity (to avoid hot cracking, the weld
metal for austenitic stainless steel is often
intentionally rendered inhomogeneous
by introducing some amount of ferrite
as a result of the rapid solidification rate
during the welding process). These issues
promote the transformation of intermetallic phases, which affect various mechanical and chemical properties (Ref. 8).
Therefore, in anticipation of the need for
welding repairs to FBRs, the study and
prediction of the aging behavior of the
weld metal is an absolutely necessary
prerequisite.
Consequently, as a first research step
toward developing a process for weld repairs in the newly developed 316FR stainWELDING JOURNAL 133-s
WELDING RESEARCH
WELDING RESEARCH
AF
solidification
mode, solidifying as
primary austenite (),
which is generally regarded as having a
pronounced high-temperature
cracking
susceptibility.
Materials and
Experimental Procedures
Materials
Aging Treatment of Weld Metal
Type
316FR
Type
316L
Cr
Ni
Mo
Si
Mn
Al
Fe
0.0085
0.0009
0.023
17.56
12.02
2.15
0.44
0.79
0.088
0.011
0.007
Bal.
0.0150
0.0040
0.031
17.28
12.11
2.04
0.70
0.92
0.024
Bal.
1000
1127
1532
1
1
1
1
5
5
5
5
10
10
10
10
50
50
50
50
100
100
100
100
394
500
500
526
Details of the machining and the dimensions of welding specimen are indicated in Fig. 1. Smaller Charpy impact test
specimens of size 55 10 3 mm were
machined from welded plate as also indicated in Fig. 1. The aging treatment for
Charpy impact test specimens was heating
at 1023 K for 0, 0.5, 1, and 10 h to differentiate ferrite decomposition behavior,
while the tests themselves were conducted
on the as-welded and aged samples at
room temperature according to JIS Z
2242, Method for Charpy pendulum impact
test of metallic materials. Four specimens
were tested for each aging time and their
average taken as the absorbed impact energy value. After the impact test, the fractured surfaces of the specimens were
observed using SEM.
Fig. 4 TEM micrographs and diffraction patterns of intermetallic phases ( and phases).
1.2 106
2.9 106
3.0 105
1.8 104
k0 (/s)
Q (kJ/mol)
0.320
2.1 109
258
WELDING RESEARCH
The content of ferrite in the aswelded and aged specimens was measured
using the magnetic induction method
(Feritscope) in the central area of the
bead surface. To clarify microstructural
changes caused by the aging treatments,
specimens were observed by scanning
electron microscopy (SEM) equipped with
electron backscatter diffraction (EBSD)
under an acceleration voltage of 20 kV
after electrolytic etching with a 10% aqueous solution of KOH using an applied voltage of 100 mV. The specimens were also
observed by transmission microscopy
(TEM) under an acceleration voltage of
200 kV after jet polishing with a solution
of perchloric acid (5%) and acetic acid
(95%), using an applied voltage of 50 V.
Fig. 5 Backscattered electron micrographs of SEM and EBSD micrographs of the weld metal after
aging at 873 K for 100 h.
WELDING RESEARCH
where fi is the initial amount of the -ferrite prior to aging and ff is final amount
of the -ferrite after aging. Based on this
relationship, Fig. 6 shows the change in
the decomposed -ferrite fraction as a
function of the aging temperatures and
holding times. The fraction of the intermetallic phases increased sigmoidally
with an increase in the aging time at any
aging temperature, and approached the
saturation point for long-term aging at
973 and 1023 K.
Kinetic Equation for the -Ferrite
Decomposition
267
262
283
296
y=k t
(2)
dy
m
= k n t n 1 (1 y )
dt
(3)
Fig. 10 Change of impact toughness as a function of the amount of decomposed -ferrite (aging
at 1023 K).
tion results, showing a sigmoidal relationship between operating time and the decomposed fraction of -ferrite. There was
a large difference in the decomposition
behavior between operating temperatures
of 773 and 823 K. Specifically, it took 15
months to reach 50% -ferrite decomposition at 773 K, but it took only 1 month at
an operating temperature of 823 K to arrive at the same point. In other words, a
50 K difference in the operating temperature caused about a 15 times faster decomposition rate. The decomposed
fraction of ferrite at other points on the
aging time curve is also listed in Table 5.
According to these predictions, about
90% of the -ferrite will have decomposed
after only 5 years of operation of a FBR at
823 K, while about 66% of the -ferrite
will have decomposed at an operating
temperature of 773 K. Furthermore, after
50 years of FBR operation, in Type 316FR
weld metal, -ferrite will be completely
decomposed at 823 K. Consequently, the
operating temperature of the FBR should
be closely considered from the viewpoint
of -ferrite decomposition behavior, because it could seriously affect not only various mechanical and chemical properties
during service, but also the weldability of
any required repairs.
y = 1 exp ( kt )
y
n
= ( kt )
1 y
(4)
(5)
The applicability of these kinetic equations can be confirmed by parabolic, Johnson-Mehl (log ln (1/1y) = n log t+n
log k) and Austin-Rickett (log (y/(1y) =
n log t+n log k) plots.
Figure 7 shows the results of applying
the three kinds of kinetic approaches.
There was a good linear relationship between the aging time and the fraction of
decomposed -ferrite in the Type 316FR
weld metal in the Johnson-Mehl plot regardless of aging temperature, while the
other plots failed to adequately describe
the -ferrite decomposition behavior. In
particular, the Austin-Rickett plot deviated from a linear relationship in the final
stages of precipitation, and the parabolic
plot showed also totally nonlinear behavior at every aging temperature. In other
words, -ferrite decomposition behavior
during aging of Type 316FR weld metal
was best described by the Johnson-Mehl
kinetic equation.
To predict the decomposition behavior
during long-term service exposure of a
FBR, the remaining constants in the Johnson-Mehl equation (n and k) need to be
determined. These values were found
from a simple regression analysis of the
Q
k = k0 exp
RT
(6)
where k0 is the frequency factor; Q is the
activation energy; T is the temperature;
and R is the gas constant.
Equation 6 can be transformed into the
following to describe an Arrhenius plot:
ln k =
Q1
+ 1nk0
RT
(7)
Figure 8 shows the Arrhenius plot,
showing a simple linear relationship between the reciprocal temperature and the
logarithm of k, allowing the determination
of the activation energy for the decomposition of -ferrite and the k0 constant.
All the parameters determined in this
way are shown in Table 3. The fitting constant n was independent of the aging temperature, but the precipitation rate
constant k increased as a function of aging
temperature.
Literature report (Ref. 23) of the activation energy for diffusion of the main alloying elements present within the
-ferrite is shown in Table 4. Their similar
activation energies suggest that the decomposition of -ferrite in this study
would be strongly influenced by the diffusion of these alloying elements.
Prediction of -Ferrite Decomposition at
Service-Exposure Temperatures of a FBR
WELDING RESEARCH
Fig. 11 SEM fractographs after Charpy impact tests as a function of decomposed fraction of -ferrite Fig. 12 Predicted results of the absorbed impact
(aging at 1023 K).
energy during long-term operation of a FBR.
WELDING RESEARCH
Table 5 Predicted Results of the Decomposed Fraction of -Ferrite at Some Major Time
Points in Fig. 9
Decomposed Fraction of Ferrite
Operating time (years)
5
10
30
50
773 K
0.66
0.74
0.85
0.89
823 K
0.90
0.95
0.98
0.99
Conclusions
In this study, the precipitation behavior and changes in impact toughness during actual operation of FBR was predicted
for Type 316FR stainless steel weld metal,
based on the kinetics of -ferrite decomposition. The main conclusions of this
work can be summarized as follows:
1) Type 316FR stainless steel weld
metal contained approximately 3% (FN <
3) of -ferrite formed in the AF solidification mode. Intermetallic - and - phases
were precipitated inside -ferrite during
aging treatments at 823, 873, 923, and
1023 K, consuming the -ferrite (i.e., fraction of decomposed -ferrite = fraction of
precipitated intermetallic phases). As the
aging temperature and isothermal hold
time increased, the amount of intermetallic phases increased sigmoidally.
2) The decomposition of -ferrite was
examined by three types of kinetic approaches the parabolic law, Austin-Rickett, and Johnson-Mehl equations. Among
these kinetic approaches, the decomposition behavior was best described by the
Johnson-Mehl type equation. The kinetic
parameters in the Johnson-Mehl type equation were determined to be n = 0.320, Q =
258 kJ/mol, and k0 = 2.1 109/s, regardless
of the aging temperature.
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
NUCu-140 is a recently developed steel that relies on nano-scale Cu-rich precipitates to achieve yield strength levels in excess of 825 MPa (120 ksi). In order for
NUCu-140 to be utilized as a structural material, a comprehensive welding strategy
must be developed. Since NUCu-140 is a precipitation-strengthened material, this
strategy must include a detailed understanding of the precipitate evolution that occurs in the heat-affected zone (HAZ) as a result of welding thermal cycles. A combination of dilatometry, HAZ simulations, and mechanical testing are presented to determine the mechanical properties that develop in the HAZ of NUCu-140. MatCalc
kinetic simulations and Russell-Brown strengthening calculations were conducted to
model the observed precipitate and mechanical property trends. The microhardness
and tensile testing results reveal that local softening is expected in the HAZ of NUCu140 welds. MatCalc simulations show that a combination of partial dissolution, full
dissolution, and re-precipitation of the Cu-rich precipitates is expected to occur in the
various HAZ regions. The predicted precipitate parameters are used as input to the
Russell-Brown strengthening model to estimate the changes in strength expected due
to changes in precipitate features. The measured and predicted strength levels exhibit
very good quantitative agreement for the low-heat-input simulations and reasonable
qualitative agreement for the high-heat-input weld simulations.
Introduction
Copper precipitation-strengthened
materials such as high-strength, low-alloy
(HSLA) 80 and 100 have been used extensively in naval and structural applications due to their excellent combination of
strength and toughness. As a result of the
ever increasing need to minimize cost, it is
desirable to develop a HSLA variant that
can achieve even higher yield strength levJ. D. FARREN is with Naval Surface Warfare
Center Carderock Division, West Bethesda, Md.
A. H. HUNTER and D. N. SEIDMAN are with
Dept. of Materials Science and Engineering,
Northwestern University, Evanston, Ill. J. N.
DUPONT (jnd1@lehigh.edu) is with Dept. of
Materials Science and Engineering, Lehigh University, Bethlehem, Pa. C. V. ROBINO is with Sandia National Laboratories, Albuquerque, N.Mex.
E. KOZESCHNIK is with Dept. of Materials Science and Technology, Vienna University of Technology, Vienna, Austria.
els [ 825 MPa (120 ksi)], while maintaining suitable toughness. Recent research
conducted at Northwestern University has
produced a candidate structural material
that achieves yield strength levels in excess
of 825 MPa while retaining toughness levels that would exceed the requirements for
most naval and structural applications
(Refs. 19). NUCu-140 is a copper precipitation-strengthened steel that is composed of a nominally ferritic microstructure with nano-scale Cu-rich precipitates
that strengthen the material, and NbC
precipitates that limit the austenite grain
growth. The use of NUCu-140 can offer
KEYWORDS
High-Strength Steels
Fracture
Weld Process Simulation
ite grain growth. The intercritical, finegrained, and coarse-grained HAZ regions
all experience transformation to austenite
during the weld thermal cycle. Therefore,
both the microstructural and precipitate
evolution needs to be investigated to understand the mechanical properties in
these regions.
A preliminary investigation of the microstructural evolution and mechanical
properties in NUCu-140 gas metal arc
welds (GMAW) and gas tungsten arc
welds (GTAW) was recently conducted
(Ref. 12). Microhardness traces revealed
that a locally softened HAZ region
formed as a result of the fusion welding
process. Average precipitate radius
(<R>), number density (Nv), and volume
fraction measurements () conducted
using local electrode atom probe (LEAP)
tomography confirmed that the observed
decrease in microhardness occurred as a
result of the precipitate evolution that occurs in the HAZ. Figure 1 shows a summary of the results. The base metal region
shows the initial precipitate parameters
that develop as a result of the solution and
aging thermal treatment. The region labeled HAZ 1 experienced a peak temperature of ~ 675C and exhibits a reduction
in <R> and while showing a concomitant increase in Nv. This results from partial dissolution of the precipitates on heating, followed by re-precipitation of new
and smaller Cu-rich precipitates during
cooling. The region labeled HAZ 2 experienced a peak temperature of ~910C
and exhibits a further decrease of the
<R> and with an even greater increase
in Nv. It was determined that full precipitate dissolution occurs in HAZ 2 on heating, followed by re-precipitation on cooling. The fusion zone also undergoes full
dissolution of the Cu-rich precipitates on
heating but exhibits only minimal
re-precipitation during the cooling portion of the weld cycle. Therefore, the fusion zone exhibits the lowest <R>, Nv,
and of any weld region. The overall
trends in <R>, Nv, are consistent with
the observed local softening that occurs in
the HAZ as a result of the fusion welding
process. The current research focuses on a
more detailed investigation of the mechanical properties of each of the four critical regions of the HAZ using simulated
HAZ samples.
Experimental Procedure
The chemical composition of the
NUCu-140 steel investigated in this study
was measured using inductively coupled
plasma-optical emission spectroscopy
(ICP-OES) and the results are shown in
Table 1. The composition of NUCu-140 is
similar to HSLA-100 Comp II, with
slightly increased C and Al levels and
slightly decreased Cr and Mo levels. The
Al content is relatively high compared to
traditional structural steels, but Al has
been shown to segregate to the interface
of the Cu-rich precipitates in NUCu-140
and is believed to limit the coarsening kinetics during aging (Ref. 3). The NUCu-
NUCu-140
Al
C
Cu
Fe
Mn
Nb
Ni
P
S
Si
0.65
0.04
1.35
Bal.
0.47
0.07
2.75
0.009
0.002
0.47
WELDING RESEARCH
Fig. 2 Dilatometry results for NUCu-140 heated at 1, 10, 100, and 1000C/s.
Table 2 Summary of the Precipitate Evolution Predicted Using MatCalc Kinetic Simulation
Software
Sample
WELDING RESEARCH
Fig. 3 Summary of the thermal cycles predicted using SOAR for the following samples: A
Low heat input (1.5 J/m); B high heat input
(3.75 J/m).
Peak
Temperature
(C)
MatCalc
Radius
(nm)
MatCalc
Number Density
(m3)
MatCalc
Phase
Fraction
150
675
800
900
1350
675
800
900
1350
4.25
1.11
0.56
0.54
0.46
0.96
0.60
0.60
0.60
2.53 1022
1.10 1023
5.86 1024
5.95 1024
7.51 1024
1.24 1023
5.19 1024
5.17 1024
5.19 1024
0.0099
0.0064
0.0042
0.0041
0.0030
0.0068
0.0051
0.0051
0.0051
a 1000C/s heating rate. The Ac3 temperature exhibits a much narrower range,
824 to 839C, indicating that the ferriteto-austenite transformation finish temperature is not as dependent on heating
rate as the ferrite-to-austenite transformation start temperature. The transformation start temperatures increase directly with the heating rate since the
ferrite to austenite transformation is diffusion controlled. Increased heating rates
provide less time for diffusion to occur,
which causes a concomitant delay in the
transformation start temperatures. These
results were used to select peak temperatures to simulate the four critical regions
of the HAZ. A peak temperature of 675C
was selected for the subcritical HAZ region since it is below the Ac1 temperature
over the entire range of heating rates investigated. An 800C peak temperature
was selected for the intercritical HAZ region since it falls inside the Ac1 and Ac3
range for all four dilatometry curves. A
900C peak temperature was selected for
the fine-grained austenite region since
900C minimally exceeds the maximum
measured Ac3 temperature of 839C. Finally, a 1350C peak temperature was selected for the coarse-grained austenite
HAZ region since 1350C significantly exceeds the Ac3 temperature but is still
below the melting temperature of the
alloy.
The Smartweld Optimization and
Analysis Routine (SOAR) software (Ref.
13) was used to determine thermal cycles
associated with the various peak temperatures identified previously. An 85% transfer efficiency, representative of the
GMAW process, was assumed in the calculations (Ref. 14). Weld thermal cycles
for each peak temperature were estimated
for both a low (1.5 kJ/mm) and a high (3.75
kJ/mm) heat input to determine the effect
of heat input on HAZ mechanical properties. The weld thermal cycles associated
with the 675, 800, 900, and 1350C peak
temperatures are shown in Fig. 3A, B for
Fig. 6 Microhardness data collected from NUCu-140 base metal and simulated
HAZ samples.
WELDING RESEARCH
WELDING RESEARCH
properties is observed in the LH1350 sample, which agrees with the observed microhardness trends. These strength trends
are consistent with the observed microhardness results discussed previously. The
elongation values only range from 18 to
21% across the base metal and all four
simulated HAZ samples, with the ductility
decreasing in the 675 and 800C samples.
This observation is unexpected since the
675 and 800C samples have decreased
strength levels compared to the base
metal, which would typically lead to higher
ductility. However, it must be noted that
the specimen gauge length contains
NUCu-140 material that was heated to a
range of different peak temperatures during the Gleeble thermal cycle. The uniformly heated region in the simulated
HAZ sample is shorter than the specimen
gauge length and so the elongation results
represent some average elongation behavior of each peak temperature/microstructural region. As a result, the elongation
value reported for each condition is actually a composite measurement and the resulting trends are insignificant. Nearly
identical trends in yield strength and tensile strength are observed for the high
heat input sample matrix.
Figure 8 shows the Charpy impact values for both the low and high heat input
samples tested at 40C. The Charpy impact energy generally increases relative to
the base metal value for the 675, 800, and
900C peak temperature samples. This is
consistent with the microhardness and
yield strength results, since a decrease in
strength/hardness typically produces an
increase in toughness. The high heat input
1350C peak temperature sample exhibits
only a very slight reduction in impact
toughness relative to the base metal, while
the impact toughness of the low heat input
sample is higher than that of the base
metal. The difference in impact toughness
between the LH1350 and HH1350 samples can be attributed to the prior austenite grain size in each region. The LH1350
sample has a prior austenite grain size of
32 m while the HH1350 sample has a
prior austenite grain size of 42 m. The reduced prior austenite grain size and corresponding increase in grain boundary
area in the low heat input sample results
in a concomitant increase in the impact
toughness. It is interesting to note that all
regions of the HAZ exhibit relatively good
impact toughness relative to the base
metal, regardless of the location or heat
input.
In order to better understand the observed mechanical property trends, the expected precipitate evolution in the base
Table 3 Calculated Precipitate Parameters and Measured and Predicted Strength Change for LH800, LH900, HH800, and HH900 Samples
Base Metal
LH800
LH900
HH800
HH900
Average
Precipitate
Radius
<R> (nm)
4.25
0.56
0.55
0.60
0.60
Precipitate
Volume
Fraction
0.0099
0.0042
0.0041
0.0051
0.0051
Interprecipitate
Spacing L
(nm)
Predicted
Strength
Change (MPa)
Measured
Strength
Change (MPa)
75.5
15.1
15.0
15.0
14.9
162
185
52
53
165
183
176
176
2
Gb E
= 0.8 1 P
L E2
M
when sin1
E
E
50 deg
2
Gb E P
=
1 2
L E
M
when sin1
E
E
50 deg
r
log
E
M
log
R
r
L=
1.77r
(2)
E log
E
(1)
+
log
R
r
R
(3)
(4)
where G is the shear modulus of the matrix (77 GPa); b is the Burgers vector (0.25
nm); L is the interprecipitate spacing
(Equation 4 ); EP is the dislocation energy
in the precipitate; EM is the dislocation energy in the matrix; EP is the dislocation
WELDING JOURNAL 145-s
WELDING RESEARCH
Fig. 10 Measured vs. predicted strength change of 800 and 900C simulated HAZ
samples using MatCalc as input to the Russell-Brown model.
WELDING RESEARCH
Conclusions
Microstructural evolution and mechanical properties of simulated heataffected zones in NUCu-140 steel was investigated via light optical microscopy,
dilatometry, Gleeble HAZ simulations,
mechanical testing, and modeling tech-
The authors gratefully acknowledge financial support of this research by the Office of Naval Research through Grant
Number N00014-07-1-0331 and useful discussions with the program manager, Dr.
William Mullins, of the Office of Naval
Research.
References
1. Isheim, D., and Seidman, D. N. 2004. Surface and Interface Analysis 36: 569.
2. Isheim, D., Gagliano, M. S., Fine, M. E.,
and Seidman, D. N. 2006. Acta Materialia 54:
841.
3. Kolli, R. P., and Seidman, D. N. 2007. Microscopy and Microanalysis 13: 272.
4. Gagliano, M. S., and Fine, M. E. 2004.
Metallurgical and Materials Transactions A 35A:
2323.
5. Isheim, D., Kolli, R. P., Fine, M. E., and
Seidman, D. N. 2006. Scripta Materialia 55: 35.
6. Kolli, R. P., and Seidman, D. N. 2008. Acta
Materialia 56: 2073.
7. Kolli, R. P., Wojes, R. M., Zaucha, S., and
Seidman, D. N. 2008. International Journal for
Materials Research (formerly Zeitschrift fur Metallkunde) 99: 513.
8. Kolli, R. P., and Seidman, D. N. 2011. International Journal for Materials Research (formerly Zeitschrift fur Metallkunde).
9. Leister, B. M., and DuPont, J. N. 2012.
Fracture toughness of simulated heat-affected
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
Preliminary investigations of the microstructure and fracture behavior of ultrasonicassisted brazing of CP titanium to itself and to AISI 304 stainless steel was conducted,
using an aluminum-based filler. Test joints were processed at a temperature of 670C
and with a holding time of 3 min, followed by ultrasonic vibrations for 6 s. The resultant
joints were characterized in order to determine the brittle intermetallic compound
(IMC) in the interfacial layer. The shear strength of the joints was tested as well. The preliminary experimental results showed that sound joints with good wetting quality, without pores and cracks can be achieved. Intermetallic Ti-Al phases were detected at the
titanium/aluminum-based filler metal in both similar and dissimilar joints. Both joints
fractured after shear strength tests in the area containing this intermetallic compound.
The titanium/titanium joints achieved a higher shear strength of 64 MPa. Meanwhile, the
titanium/stainless steel joint obtained 46 MPa.
Introduction
Titanium and its alloys exhibit a unique
combination of mechanical and physical
properties as well as corrosion resistance,
which make them desirable for several industrial sectors such as power generation,
chemical processing, aerospace, and medical applications. On the other hand, steel
and steel alloys represent the most important and widely used materials in industrial
applications. Gradually, composite structures of dissimilar metals were accepted in
national defense and civil industrial fields,
such as aeronautics and astronautics, and
energy and electric power industries.
Composite components of titanium alloy
and steel can take advantage of these two
materials simultaneously. A partial replacement of steel components with titanium alloys will become an important way
to reduce the mass of spacecrafts (Refs.
13).
Titanium belongs to a family of metals
called reactive metals that have a strong
affinity for oxygen. At room temperature,
titanium reacts with oxygen to form titanium dioxide. This passive, impervious
coating resists further interactions with the
surrounding atmosphere, and gives titanium its famous corrosion resistance. The
A. ELREFAEY, L. WOJARSKI (lukas.wojarski@udo.edu), J. PFEIFFER, and W. TILLMANN are with the Institute of Materials Engineering, TU Dortman, Dortman, Germany.
KEYWORDS
Titanium
Stainless Steel
Brazing
Ultrasonic
Joint Microstructure
Shear Strength
Experimental Work
The base metals used in this work were
2-mm-thick commercially pure titanium
(CP Ti) Grade 2 and 2-mm-thick
austenitic stainless steel AISI 304. The
chemical compositions of the base metals
are presented in Table 1. The stainless
steel plate was cut into 25 25 mm chips,
Brazing of Titanium/Al-2.5Mg-0.3Cr/
Titanium Joint
CP Ti
AISI 304
Wt-%
C
Fe
Ti
Cr
Ni
Si
0.02
0.06
0.03
Bal.
Bal.
17.88
8.52
0.31
0.009
0.03
0.01
0.25
1
2
3
4
5
6
7
98.76
99.61
0.37
74.60
61.46
68.70
68.63
1.24
0.39
97.35
21.99
36.58
30.12
29.96
2.17
2.41
1.87
1.18
1.30
0.11
0.09
0.11
1
2
3
4
5
6
7
8
5.55
6.33
97.09
92.51
69.35
69.97
66.70
61.06
91.36
90.71
2.51
6.24
27.53
26.42
23.75
32.09
2.96
2.85
0.40
1.25
3.04
3.49
9.48
6.83
0.13
0.10
0.08
0.12
0.07
0.02
WELDING RESEARCH
WELDING RESEARCH
Al
22.93
73.98
19.28
83.91
63.98
86.73
80.31
0.47
2.71
Mg
6.00
3.58
3.85
4.91
3.58
0.65
0.20
Cr
0.36
0.67
1.15
1.31
0.67
5.51
3.19
19.20
Fe
0.43
0.32
0.82
7.17
0.32
5.26
13.58
68.73
Ni
0.09
0.06
0.08
0.76
0.06
2.31
1.28
7.77
Si
1.20
1.10
1.20
1.22
formation of the hard and brittle Ti3Al intermetallic compound. The fracture morphology of the joints after the shear test is
presented in Fig. 7A. Chemical analyses of
the corresponding fracture area (Table 3)
showed a high probability of a Ti3Al phase
at the surface of the aluminum-based filler
metal Areas 5 and 6 in Fig. 7B, and the
titanium base metal as well, Areas 7 and 8
in Fig. 7C. This implies that the Ti3Al intermetallic compound is the most harmful
phase in the joint. Aluminum-based filler
metal is shown in the fracture surface by
the Areas 1 and 2, while the titanium base
metal is presented by the Areas 3 and 4.
The fractography of these fracture surfaces basically showed cleavages in addition to tearing regions. The fracture
direction took the same direction as in the
shear test.
Brazing of Titanium/Al-2.5Mg-0.3Cr/
Stainless Steel Joint
Fig. 7 Fracture morphology of the titanium/titanium joint. A General view of the fracture surface;
B close-up view at the surface of aluminum-based filler; C close-up view at the surface of titanium
base metal.
percentages of titanium caused the formation of Ti3Al phase only at the interface
since titanium has limited solubility in
molten aluminum. On the other hand,
iron has a high solubility in molten aluminum and is easily dissolved at the
molten stage (Refs. 29, 30). During cooling, iron has a very low solubility in the
solid state and is therefore present mostly
as a coarse intermetallic phase in the
brazed zone.
The hardness distribution in the joint is
shown in Fig. 10. In contrast to the titanium/titanium joint, the hardness of the
brazed area showed the highest values.
The brazed area close to the stainless steel
side showed the peak hardness in respect
to other areas in the brazed zone. It was
also noted that the stainless steel showed a
higher average hardness than titanium.
The average shear strength of the joints
achieved 46 MPa with a standard deviation
of 3.1 MPa. The strength was lower than
the titanium/titanium joint, since an Al-Fe
intermetallic compound was detected in
the brazed area in addition to Al-Ti. Addi-
Al
85.69
84.52
75.57
56.55
53.49
61.01
Mg
6.16
3.30
6.91
18.45
16.77
7.55
Cr
0.79
0.59
0.82
0.53
0.78
0.12
Ni
0.25
0.31
0.52
Fe
1.13
3.70
4.66
1.95
2.19
WELDING RESEARCH
Fig. 8 SEM microstructure features of the titanium/stainless steel joint. A General view of the cross
section; B close-up view at the titanium/aluminum-based filler metal interfacial area; C close-up
view at the stainless steel/aluminum-based filler metal interfacial area.
WELDING RESEARCH
Fig. 9 A Isothermal section in the Al-Fe-Cr ternary phase diagram at 600C; B the partial isothermal section at the aluminum-rich corner.
tionally, extra internal stresses are expected in this joint compared with the similar titanium joint. Surprisingly, Fig. 11
shows the joints failed mainly at the titanium/aluminum-based filler metal interface in spite of the thinner intermetallic
compound of this area, compared with the
area close to the stainless steel/aluminumbased filler metal, which showed thick and
different intermetallic compounds.
Fracture surface, corresponding to the
previous fracture pass, is shown in Fig.
12A and C for the stainless steel and titanium sides, respectively. Chemical analyses of different areas at the fracture
surface generally showed high aluminum
content in the stainless steel side (Table 5,
Areas 13). Meanwhile, at the titanium
side, the content of titanium increased significantly (Areas 46). The stoichiometric
composition of different areas did not confirm the occurrence of any Al-Ti intermetallic compound at the fracture surface
in contrast to the titanium/titanium joint.
152-s MAY 2013, VOL. 92
Figure 12B and D showed enlarged images of the stainless steel and titanium
sides, respectively. The microscope fractography of these fracture surfaces basically showed cleavage morphologies in
both sides of the joint with more tearing
regions in the stainless steel side of the
fracture and more flat areas and shearing
directions in the titanium side.
Conclusions
Ultrasonic-assisted brazing experiments of CP titanium to itself and to AISI
304 stainless steel were conducted using
an aluminum-based filler metal. The joints
were successfully brazed without voids,
cracks, or surface oxides disturbing the
wetting of the joint. The relationship between the mechanical properties of the
joints and the microstructure of the brazed
layers was examined. The results obtained
can be summarized as follows:
1) For the titanium/titanium joint, the
brazed area mainly consisted of solid solution aluminum with a Ti3Al intermetallic compound at the interfacial area.
During shear tests, the crack pass propagated at this intermetallic compound has
almost no ductility to withstand thermal
stresses. The average shear strength of
the joints was 64 MPa.
2) For the titanium/stainless steel
joint, Ti-Al intermetallic compounds
were formed at the titanium/aluminumbased filler metal interfacial area. Meanwhile, three-phase + (Al13Fe4) + (Al)
were formed at the stainless steel/aluminum-based filler metal interfacial area.
In spite of the high hardness of this area
in respect to the titanium/aluminumbased filler metal interfacial area, the
crack pass during shear tests was close to
the Ti-Al intermetallic compound. The
average shear strength of the joints was
46 MPa.
References
1. Boyer, R. 1996. An overview on the use
of titanium in the aerospace industry. Materials
Science and Engineering A 213(12): 103114.
2. Yuan, X. J., Sheng, G. M., and Qin, B.
2008. Impulse pressuring diffusion bonding of
titanium alloy to stainless steel. Materials Characterization 59(7): 930936.
3. Wang, T., Zhang, B., and Chen, G. 2010.
Electron beam welding of Ti-15-3 titanium alloy
to 304 stainless steel with copper interlayer
sheet. Transactions of Nonferrous Metals Society
of China 20(10): 18291934.
4. Luck, J., and Fulcer, J. 2007. Titanium
welding 101: Best GTA practices. Welding Journal 86(12): 2631.
5. Liu, L. M., Zhu, M. L., Pan, L. X., and
Wu, L. 2001. Studying of micro-bonding in diffusion welding joint for composite. Materials
Science and Engineering A 315 (12): 103107.
6. Shi, L., Yany, J., Han, Y., and Peng, B.
2011. Behaviors of oxide layer at interface between semi-solid filler metal and aluminum matrix composites during vibration. Journal of
Materials Science Technology 27(8): 746752.
7. Watanabe, T. 2000. Soldering of high
strength aluminum alloys with the aid of ultrasonic vibration. Proc. Int. Brazing & Soldering
Conf. pp. 523. Albuquerque, N.Mex.
8. Watanabe, T., Yanagiswa, A., Furkawa,
A., and Onuma, S. 1993. Soldering of Al-Mg
alloy with the aid of ultrasonic vibration. Quarterly Journal of Japan Welding Society 11(4):
484489.
9. Zhao, W. W., Yan, J. C., Yang, W., and
Yang, S. Q. 2008. Brazing of aluminium matrix
composites. Science and Technology of Welding
and Joining 13(1): 6669.
10. Xu, Z. W., Yan, J. C., Zhang, B. Y.,
Kong, X. L., and Yang, S. Q. 2006. Behaviors of
oxide film at the ultrasonic aided interaction interface of Zn-Al alloy and Al2O3p/6061Al composites in air. Materials Science and Engineering
A 415(12): 8086.
11. Ma, Z., Zhao, W., Yan, J., and Li, D.
2011. Interfacial reaction of intermetallic compounds of ultrasonic-assisted brazed joints between dissimilar alloys of Ti6Al4V and
Al4Cu1Mg. Ultrason Sonochemistry 18(5):
10621067.
WELDING RESEARCH
Fig. 12 Fracture morphology of the titanium/stainless steel joint. A General view of the fracture surface at the stainless steel side; B enlarged view at the fracture surface at the stainless steel side; C
general view of the fracture surface at the titanium side; D enlarged view at the fracture surface at the
titanium side.
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 154
ABSTRACT
WELDING RESEARCH
Introduction
Manual gas tungsten arc welding
(GTAW) is thought by many as an operation that requires the highest skills, yet is
commonly used in the industry, especially
for applications requiring assured weld
quality. A human welder can hear the
sounds of the arc, sense the reactive forces
from the torch, and observe the weld pool
surfaces. Using such feedback information, a welder can appraise the welding
process with respect to the desired state,
then intelligently adjust the welding parameters (e.g., current, welding speed, arc
length), and maintain appropriate torch
orientation and distance in an effort to
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, University of Kentucky, Lexington, Ky.
KEYWORDS
Human Welder Response
Joint Penetration Control
Intelligent Welding and
Control
Weld Pool Surface
Complete Joint Penetration
Gas Tungsten Arc Welding
(GTAW)
the welder is imprecise and can only reflect partial truths about the instant status
of the weld process. An automated welding control system requires both mechanistic methods for the welding phenomena that are physically well understood
and mathematically feasible for both sensors and control algorithms.
The theory of modeling for the human
controller dynamics has been extensively
studied since the 1940s. Great progress
was achieved in the 1960s and 1970s (Ref.
10), such as linear crossover model (Ref.
11) and the optimal control model (Ref.
12). The physical nature of a human operator indicates that the human controller is
naturally dynamic, stochastic, nonlinear,
and time varying. In this sense, nonlinear
methods were introduced to model the
human action neural networks, and
neuro-fuzzy or adaptive models (Refs.
1317).
Although nonlinear methods typically
improve the prediction performance to
some extent, it is still very appealing to use
linear models due to their convenience for
analysis and design. Instead of taking real
industrial processes, most of the literature
in this area took certain benchmarks as
control objects, such as the pendulum, joystick, etc. Besides, those developed models tend to be too complex to understand
and difficult to apply to the practical control systems.
In our first study on human welder responses (Refs. 18, 19), dynamic models of
a novice human welders behavior were
developed. The studied behavior of the
welder is focused on the adjustment of
welding current in response to the observed three-dimensional (3D) weld pool
surface during the complete-joint-penetration process. The weld pool geometry is
used as the sensory feedback information
since it is believed to provide valuable insights into the welding process state.
Important information such as weld
defects and penetration are contained in
the surface deformation of the weld pool
in the GTAW process (Refs. 20, 21). The
Fig. 1 Demonstration of a manual control system of the GTAW process. It is not a typical manual
GTAW process. The human welder only adjusts the welding current based on his observation of the 3D
weld pool surface. The pipe rotates during the experiment while the torch, imaging plane, laser, and camera are stationary.
geometry of the weld pool has been studied (Refs. 2226) as a means of monitoring and controlling the weld joint penetration. A vision-based sensing system has
been developed to simultaneously measure the 3D weld pool surface and record
the responses the human welder made to
the surface. A dynamic model that correlates the welder responses (model outputs) to the characteristic parameters
(model inputs) of the 3D weld pool surface has been established.
This paper is the first of this kind addressing implementation of the human
welder response model as a controller in
the automated GTAW process. In particular, this study focuses on how this model
controls the current to achieve consistent
complete joint penetration under different welding parameters. The backside
weld bead width is used as a measurement
for the penetration state. The effectiveness and robustness of the model-based
control are evaluated and verified in this
paper.
Modeling of the human welder response is briefly reviewed in the next section. In the experimental system and
methods section, a vision-based sensing
system is detailed as well as the experiment method for implementation of the
model. The results of the model-based
control is presented and analyzed in the
human welder response model control
section. The human welder response
model is further improved in the improvement of the human welder response
model section. The robustness of the control using the improved model is then analyzed in the results and analysis of robustness experiments section. The
conclusion is then given.
Arc length/mm
[2, 5]
Monitoring Parameters
Project angle/deg
35.5
Camera Parameters
Shutter speed/ms
4
Frame rate/fps
30
WELDING RESEARCH
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WELDING RESEARCH
D
Fig. 2 Results of image processing and threedimensional reconstruction. A Captured image
using the sensing system; B resultant dots in the
captured image using image processing. The asterisk in the figure is the reference dot matching the
dot at the 10th row and 10th column in the projected laser dot matrix. C Projected dots on the
3D weld pool surface; D interpolated 3D weld
pool surface; E weld pool boundary and the projected dots in oxy plane. The pentagrams are the reflected laser dots, and the stars are the boundary
dots of the weld pool. The blue curve is a fitted 2D
weld pool boundary in literature (Ref. 28).
E
Human Welder Response Model
Principle of Human Welders Behavior
The 3D weld pool surface being observed by the human welder is also simultaneously measured by a vision system.
The system includes the low-power, 20mW illumination laser generator at a
wavelength of 685 nm with variable focus,
a 1919 dot matrix structured light pattern (Lasiris SNF-519X (0.77)-685-20) attached to the head of the laser, an imaging
plane made by a piece of glass attached by
a sheet of paper, and a camera (Point Grey
Flea 3). The laser projects the 19 19 dot
matrix on the melting region. Part of the
dot matrix projected inside the weld pool
is reflected by the specular weld pool surface. Then a reflection pattern of the dot
matrix is intercepted by the imaging plane.
Because of the plasma impact, the surface
of the weld pool is depressed and distorted
in GTAW. Therefore, no matter which
shape (concave or convex) the weld pool
presents, the alignment of the reflected
laser dot matrix is distorted by the deformed specular weld pool surface. The
distortion of the reflected dot matrix is determined by the shape of the threedimensional weld pool surface and contains the 3D geometry information about
the weld pool surface. The camera captures the images of the reflected laser dot
matrix from the imaging plane. A computer connected to the camera processes
the images and reconstructs the 3D weld
pool surface in real time (Ref. 27).
Taking Fig. 2A, an acquired image in the
imaging plane, as an example, the results
of image processing and reconstruction
are shown in Fig. 2BE. The time for the
image capturing, processing, and weld
pool reconstruction is about 30 ms, which
is fast enough for monitoring the weld
pool dynamics in GTAW.
Human Welder Response Model
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 157
WELDING RESEARCH
Fig. 3 Weld pool boundary and parameters. A 2D boundary; B longitudinal intercepted area.
50, 54
3
Fig. 4 Demonstration of experimental setup. The sensing system for the experiment is identical with that
in Fig. 1. A computer connected to the camera is used for image processing, weld pool reconstruction,
characterization, and to calculate the current output using the human welder response model.
54
2, 3, 4, 5
x = ay b (1 y ) , (a > 0, 1 b > 0)
r
(1)
(2)
w = w L = 2 aL
r
1 + b 1 + b
Figure 3B shows the longitudinal intercepted area of the weld pool in oxy plane.
The convexity is defined as the intercepted
area divided by the length of the weld pool.
Modeling the human welder response
is then to correlate his adjustment Ik as
a function of the characteristic parameters in different instants around instant
k. This can be done using the standard
least squares algorithm. To obtain this
optimal model, F-test (Ref. 31) has also
been used to determine the instant range
that needs to be included in the model
for each of the characteristic parameters.
As a result, the following model was obtained (Refs. 18, 19):
0.4725 I
k 1
+ 0.1366I
= 0.6097L
2.2283L
+ 1.6137 L
1.2675 W
+0.0930 W
0.6088 W
k 3
k 5
k 5
+ 30.3658C
67.6373C
k 4
k 3
k 5
k 2
k 3
+ 1.7667 W
k 4
k 6
+ 19.6357C
+ 18.7761C
k 4
k 6
(3)
where Ikj is the current adjustment at instant kj with a 0.5-s sampling period. It
can be found the human welder adjusts
the current based on the previous current
adjustments and weld pool surfaces. That
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 158
WELDING RESEARCH
Fig. 5 Results from experiment with initial current of 50 A. A The current and voltage; B the backside weld bead width; C the backside weld
bead (the unit of x and y axis is pixel).
Fig. 6 Results from experiment with initial current of 54 A. A The current and voltage; B the backside weld bead width; C the backside weld
bead (the unit of x and y axis is pixel).
Fig. 7 Diagram of control system of the human welder response model with additional low-pass filter.
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 159
Fig. 8 Current and voltage of the experiments. A Initial current of 50 A; B initial current of 54 A; C initial current of 58 A; D initial current of 62 A.
1
0
54
havior, in each experiment of the study, specific welding conditions (welding conditions
and parameters that are not changed/adjusted on purpose in each particular experiment including welding speed, arc length,
etc.) and an initial current are first applied
for the weld pool to grow freely to complete
joint penetration. Then the welding process
is manually switched to control mode, i.e.,
the human welder response model starts to
adjust the current for consistent complete
joint penetration.
Experiments
2
2
3
58
3
[0, 5]
54
Experimental Approach
WELDING RESEARCH
Zhang and Zhang Supplement May 2013_Layout 1 4/17/13 3:53 PM Page 160
WELDING RESEARCH
D
Fig. 9 The backside appearance of the weld bead. A Initial current of 50 Fig. 10 The backside width of weld beads with a different initial current.
A; B initial current of 54 A; C initial current of 58 A; D initial current
of 62 A.
With specific welding conditions and initial current, the welding process is able to
reach to complete joint penetration. Yet,
the dimension of the weld pool at complete joint penetration in each experiment
is expected to be different. Then the experiment is manually switched to control
mode, that is, to apply the human welder
response model to control the process.
Specifically, the model adjusts the welding
current based on the geometry of the 3D
weld pool surface such that the adjusted
welding current controls the process to obtain a desired penetration that is evaluated
by the backside weld bead width. After
each experiment, the width of the obtained backside weld bead is measured to
verify the effectiveness of the human
welder response model-based control.
The experimental parameters used
here are listed in Table 1. The pipe used in
this study is 4-in. nom. stainless T304/304L Schedule 5.
The initial current is in 50, 62 A, the arc
length varies within 2, 5 mm, and the joint
opening changes from 0 to 5 mm. The rotation speed of the pipe, i.e., the welding
speed and up-down motion of the torch
are controlled by the computer to achieve
the required welding speed and arc length.
The effectiveness and robustness of the
human welder response model-based control will be evaluated against those welding parameter variations in this paper.
As mentioned before, a welder esti160-s MAY 2013, VOL. 92
Fig. 11 Current and voltage from arc length robustness experiments. A Arc length of 2 mm; B arc length of 3 mm; C arc length of 4 mm; D arc
length of 5 mm.
be determined as shown by the red vertical line in the middle of Fig. 5C.
By the start position of the model control, each of the weld beads in the two experiments is divided into two zones as
shown in Figs. 5C and 6C. In zone A, the
backside bead width is determined by the
welding conditions used and initial current. In the first experiment, the initial
current is 50 A. The average width of the
backside bead in this zone, shown in Fig.
5B, is about 1.7 mm. With a greater initial
current (54 A) in the second experiment,
the average width becomes 3.2 mm in zone
A as can be seen in Fig. 6B. In zone B, the
human welder response model starts to
control the process for a desired and consistent penetration. Despite the fluctuation, the average width for the first experiment, shown in Fig. 5B as about 4.8 mm,
and that in the second experiment, shown
in Fig. 6B as about 4.7 mm, are considered
WELDING JOURNAL 161-s
WELDING RESEARCH
Zhang and Zhang Supplement May 2013_Layout 1 4/17/13 10:27 AM Page 161
Zhang and Zhang Supplement May 2013_Layout 1 4/17/13 3:51 PM Page 162
tem and methods section, the model represents the average performance of a
welder with limited skill. As a result, it
shows in the human welder response
model control section that the model is
not able to adjust the current accurately
enough to reduce the oscillation although
a comparatively consistent penetration is
obtained. It is known that a skilled welder
can avoid the current ripple with smooth
current adjustment. In this sense, to
smooth the models adjustment is to filter
out the high-frequency part of the calculated current adjustment, i.e., to neutralize the dynamics associated with the overreaction in the response model. A simple
method is to adapt a digital low-pass filter
after the model in the control system as
shown in Fig. 7.
The low-pass filter used in this study
can be written in Equation 4.
WELDING RESEARCH
Fig. 12 The backside weld beads from arc length robustness experiments. A Arc length of 2 mm;
B arc length of 3 mm; C arc length of 4 mm; D arc length of 5 mm.
the same.
It can be found there are current fluctuations during the control period in both
experiments, shown in Figs. 5A and 6A.
That means the model is able to adjust the
current quickly but not skilled enough to
reduce the current ripples. That leads to
noticeable oscillations of the backside
bead width, which are clearly shown in
Figs. 5B, C and 6B, C. The current fluctuates between 64 and 55 A in the first experiment, and 64 and 54 A in the second.
Correspondingly, the backside bead width
changes from about 5.8 to 3.5 mm in the
first experiment, and 5.2 to 3.7 mm in the
second experiment.
The fluctuation of the current adjusted
by the model is understandable since the
model is developed using the data from
the behavior of a novice welder with limited skills. The reason for using an unskilled welder is that the authors intend to
study and follow the development of
welder skills and responses. It is a common
welding scenario that an unskilled welder
cannot predict the process quickly and accurately so that he/she would frequently
overreact or underreact to the welding
process. A seasoned welder can easily
where Ik and Ik1 are the filtered current adjustment at time instant k and k1,
respectively, and Ik is the current adjustment calculated by the welder response
model at time instant k. Coefficient controls the frequency bandwidth of the filter.
A greater gives a wider bandwidth. In
this study, is selected to be 0.5.
Since the filter blocks high-frequency
components in the current output, its
function would be pronounced during the
transition period. However, when the current approaches its steady state, the highfrequency components become insignificant. The steady-state value of the current
for a particular experiment is not affected
by the filter. Moreover, since the current
adjustment is smoothed by the filter, the
current ripple is expected to be minimized. The backside weld bead width is
expected to be more consistent. The transiting period also should be reduced significantly. In this sense, adapting a lowpass filter to the human welder response
model makes the model function like a
more skilled welder.
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 163
WELDING RESEARCH
Fig. 13 The backside width of weld beads from arc length robustness experiments.
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 164
WELDING RESEARCH
ing through the welding process. Even a
constant welding input might cause the
backside bead width varies within a small
range. It is possible that the difference of
the weld pool dimension generated by the
current varying from 59.5 to 61.5 A is unperceivable to the human welder response
model. In this sense, despite the different
backside width obtained at the beginning
of those experiments, because of different
initial current, a consistent penetration
with only a 0.3-mm width variation is
achieved using the model-based control.
Robustness with Respect to Arc Length
Zhang and Zhang Supplement May 2013_Layout 1 4/17/13 3:52 PM Page 165
Conclusion
This paper addresses implementing
the human welder response model to adjust the welding current in reply to the
characteristic parameters of the 3D weld
C
Fig. 16 The backside appearance of the weld beads from root opening robustness experiments. A 0
nominal root opening; B 2-mm nominal root opening; C nominal root opening increases from 0 to
5 mm (0.21 in.).
WELDING RESEARCH
Zhang and Zhang Supplement May 2013_Layout 1 4/16/13 2:55 PM Page 166
Fig. 17 The backside width of weld beads from root opening robustness experiments.
WELDING RESEARCH
Lea Paneca
lea@aws.org
(800) 443-9353, ext. 220
Sandra Jorgensen
sjorgensen@aws.org
(800) 443-9353, ext. 254
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