2004 june - american welding society · products, superior serx 1¢ c and most value-added can now...

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• AWS Show

• Shipbuilding Using Hybrid Laser/GMAW

• Advice for Job Shops

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When Jeff Schnabel joined the Select-Arc team ,,t welding specialists, hc envisioned adding a new dimension to the company~ highly regarded flux cored and metal cored product lines. Today: the union of Jeff~ extensive hardsurfacing electrode knowledge and Select-Arc~s exceptional manufacturing expertise has rtwolution- ized the welding industu'.

How?

With the introduction of a

comprehensive group of hardsurlacmg elcclrodc,~. speclfitall) developed to improve yonr welding productivit,~: enhance performance and extend the lift- of COlrlponenls and machinery left incorporated his >cars of hardsurtacing experience with Selccl-Arc's dedicated reseatxh professionals to produce thc innovative Selecl Wear hardsurlacmg electrode products. +Fhesc new wires art" designed to t i l t e r and c×cccd VOLII

most demanding hardsndating c1¢~ twdc rcquirenlcnl,~

the many cuslolners who have dcp~'ndcd on _hehx l- Art~s qLlaJily clet trode products, superior serx 1¢ c and most value-added can now enjoy the signifitant bencfits of specifying Select-Arc hardsurt~wing electrodes. For more inh)rnlation on Select Wear electrodes, call leffat 1-800-341-5215 or visit our wcbsile al www.select-arc.com.

600 Enterprise Drive CO. Box 259

Fort Loramie, Ott 45845-0259 Phone: (937) 295-5215

Fax: (917) 295-5217 www.select-arc.com

Circle No. 59 on Reader Info-Card CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY

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Envision your increased productivity with our innovative weld solutions

Weld Moni tors • Adaptive Weld Controls • Torch Posit ioners Thru-Arc TM Tracking Systems • Sensors & Accessories

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Circle No. 73 on Reader Info-Card

4 5 4 4 S. Pinemont, Suite 2 0 0 • H ~ t o n , Texas 77041 phone: 7 1 3 . 4 6 2 . 2 1 1 f - fax: 7 1 3 . 4 6 2 . 2 5 0 3

webs~e: www.cweldtech.com ° emaih [email protected]

CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY

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CONTENTS,u.._.vo,.o.,.,uo,, Features 3 3 A L o o k a t t h e A W S W e l d i n g S h o w

Highlights of the products and activities at this year's Welding Show are featured A. Cullison et al.

3 9 L a s e r - H y b r i d W e l d i n g o f S h i p s A hybrid process that utilizes laser beam welding and gas metal arc welding offers advantages in welding structural steels for shipbuilding S. H e r b e r t

4 5 T i p s f o r J o b S h o p s Owners share their expertise on how to run a successful job shop M. R. Johnsen

5 0 T h e A m e r i c a n W e l d i n g S o c i e t y T u r n s 85 A look at the history of the American Welding Society through the pages of the Welding Journal A. Cullison

Welding Research Supplement 1 6 9 . - 8 T h r e e - D i m e n s i o n a l S i m u l a t i o n o f T r a n s i e n t

G M A W e l d P o o l w i t h F r e e S u r f a c e A 3-D transient thermo-fluid model was used to simulate bead-on-plate and T-joints Z. C a o e t al.

t 7 7 - S P l a s t i c i t y - B a s e d D i s t o r t i o n A n a l y s i s f o r F i l le t W e l d e d T h i n - P l a t e T - j o i n t s In this study, plasticity-based distortion analysis successfully predicted total angular distortion G. H. J u n g a n d C. L. Tsai

1 8 8 - S R e s i s t a n c e S p o t W e l d i n g o f A l u m i n u m A l l o y t o S tee l w i t h T r a n s i t i o n M a t e r i a l - - F r o m P r o c e s s t o P e r f o r m a n c e - - P a r t h E x p e r i m e n t a l S t u d y A cold-rolled steel was used as a transition material between aluminum and steel for these resistance spot welding experiments X. Sun et al.

A W S W e b site http:llwww.aws.org

Departments Washington Watchword .......... 4

Press-Time News ................ 6

Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

News of the Industry . . . . . . . . . . . . 10

Aluminum Q & A . . . . . . . . . . . . . . . . 14

Brazing Q & A . . . . . . . . . . . . . . . . . . . . 20

New Products . . . . . . . . . . . . . . . . . . . . 22

Welding Workbook . . . . . . . . . . . . . . 56

Coming Events . . . . . . . . . . . . . . . . . . 58

Navy Joining Center ............ 64

Society News .................... 65

Guide to AWS Services ........ 86

Conferences . . . . . . . . . . . . . . . . . . . . . . 88

New Literature . . . . . . . . . . . . . . . . . . go

Personnel . . . . . . . . . . . . . . . . . . . . . . . . 94

Company Profile ................ 96

Classifieds . . . . . . . . . . . . . . . . . . . . . . 110

Advertiser Index . . . . . . . . . . . . . . . . 112

Welding Journal (ISSN 0043-2296) is published monthly by the American Welding Society for $90.00 per year in the United States and posses- sions, $130 per year in foreign countries: $6.00 per single issue for AWS members and $8.00 per single issue for nonmembers. American Welding So- ciety is located at 550 NW LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. Periodi- cals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-6671.

Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or resale. Per- mission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright.

I W E L D I N G J O U R N A L m i c r o

IVASHINGTOh WATCHWORD 1

BY HUGH K. WEBSTER AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE

Administration Announces New Education and Training Initiatives

The Bush administration has announced a new plan to strengthen and modernize federal support for vocational and technical education and also promote skills training for students. The major components of the plan include the following:

• Redirect $1 billion in annual funding from the current Perkins Vocational Educational Program into a new secondary and technical educational program ("Sec Tech"), which will require participating schools to offer at least three years of math and science as part of their vocational educational curricula.

• Establish a new public-private partnership to provide $100 million in grants to low-income students to study math or science in colleges and universities.

• Expand the National Assessment of Educational Progress program, which generally measures reading and math skills, to include additional grades.

Congress Adopts Standards Liability Legislation

The U.S. House of Representatives and the Senate have both approved virtually identical legislation that would provide protection to standards-development organizations from liability under federal antitrust laws. Under current law, a company may challenge standards as being anticompetitive if the company believes that the standards impose unreasonable or arbitrary requirements that the company's product cannot meet, thereby preventing the company's product from being sold in the marketplace. Standards-developing organizations can face charges of antitrust conspiracy and monop- olization and can be subject to treble damages in the event of an adverse verdict. This new legislation would mandate that a standards organization be permitted to submit evidence of any pro- competitive or other positive benefits of a particular standard, and, more important, would preclude the recovery of treble damages.

In order to take advantage of these protections, standards organizations would be required to disclose their standards activities to the federal government via a mechanism similar to the National Cooperative Research and Production Act.

SBA Proposes to Revise Size Standards

The U.S. Small Business Administration (SBA) is proposing a modification to its small business size standards by defining "size" in most instances in terms of the number of employees. Currently, the SBA size standards can be based on a variety of factors, including the number of employees, receipts, financial assets, or generating capacity. This approach, which has 37 different size levels applicable to more than 1100 industries, has been criticized as being overly complex and often causing unfair outcomes with respect to which businesses and which industries are classified as "small businesses."

Manufacturing Position Finally Filled After months of delay and one large misstep, the newly created

position of Assistant Secretary of Manufacturing and Services within the Department of Commerce has finally been filled with the appointment of Albert Frink, a small business owner from Cal- ifornia. Frink is actually the second choice for this post. The individual initially named was forced to withdraw after it was discovered that he had outsourced much of his business to China. Some

alarm within the manufacturing community has also been expressed over the recent addition of the words "and Services" to the position that was originally just "Assistant Secretary of Manufactur- ing." There has been lingering concern regarding an idea floated - - though not endorsed - - by the Office of Management and Bud- get that certain services, such as the fast food industry, could be recharacterized as manufacturing.

Key appointments have also been made to the Manufacturing Council, the newly created advisory committee that will operate under the auspices of the Department of Commerce.

OSHA Voluntary Compliance Programs Seem to Be Working

A recent report by the U.S. General Accounting Office (GAO) concludes that the voluntary compliance programs implemented by the Occupational Safety and Health Administration (OSHA) "appear to have yielded many positive outcomes" and "show prom- ising results."

Because it can inspect only a fraction of the seven million U.S. work sites each year in its efforts to ensure safe and healthful working conditions, OSHA has increasingly supplemented enforcement with "voluntary compliance strategies" to reach more employers and utilize its resources most effectively. Using a mix of strategies designed to reach different types of employers, OSHA has implemented four voluntary programs, including those that recognize employers with exemplary safety and health practices and programs designed to address serious hazards in workplaces. The emphasis on voluntary compliance also represents a policy shift from prior years in which OSHA focused chiefly on enforcement, creating a largely antagonistic relationship with the business community.

To support all of its voluntary compliance strategies, OSHA has increased the proportion of resources dedicated to them from about 20% of its total budget in fiscal year 1996 to about 28% in 2003. OSHA also plans to expand its voluntary compliance programs in the future. However, while the GAO report is very positive, it does recommend that a more comprehensive study be undertaken before the voluntary compliance programs are expanded.

No More H-1 B Visas for FY 2004 U.S. Citizenship and Immigration Services (formerly the Im-

migration and Naturalization Service) has announced that it has received enough H-1B petitions to meet this year's Congression- ally mandated cap of 65,000 new workers, and will no longer accept any new H-1B petitions.

The H-1B program has been controversial. Many in the business community maintain that the program is necessary in order to obtain sufficient skilled labor, and they have consistently urged Congress to increase the number of available visas. The cap has been as high as 195,000. But unions have argued that the program is simply a way for employers to hire foreigners at low wages, to the detriment of qualified U.S. workers. Of course, after the attacks of September 11, 2001, concerns about tightening immigration rules generally have also impacted H-1B visas.

It should be noted that petitions for new H-1B employment are not subject to the annual cap if the foreign worker will be employed at an institution of higher education or a related or affiliated nonprofit entity, or at a nonprofit research organization or a govern- mental research organization. 41,

Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail [email protected]; FAX (202) 835-0243.

B E I B JUNE 2004

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THE WELDING EXPERTS

The Lincoln Electric Company Cleveland, Ohio U.S.A.

216-q81-8100

www.lincolnelectric.com Circle No. 48 on Reader info-Card

Congratulat ions to AWS on its 85 'h Anniversary.

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)RESS TIM£

Search Is Underway for WW II Plane Builders The MAPS Air Museum in North Canton, Ohio, has been conducting a search for

surviving members of the 35,000-strong workforce who built 4000 Corsair fighter planes at the Goodyear Aircraft plant in Akron during World War II. The museum and Goodyear want to honor the classic plane's mechanics, builders, designers, and pilots at a "Corsair Homecoming" to take place on the evening of June 18, preceding the Defenders of Free- dom Air Show at Akron Fulton Municipal Airport . The air-show will feature FG-1D and F-2G Corsairs in flight, as well as many other aircraft. Members of the Corsair family should call museum director Joe Chevraux at (330) 896-6332.

"We have never really honored their accomplishments and thanked them for their service to the nation," Chevraux said. Corsairs were instrumental in helping the Allies gain air supremacy in the Pacific theater.

Philly Shipyard Starts Another Container Vessel Kvaerner Philadelphia Shipyard, which is currently in production of two container

vessels, has begun product ion of yet another. The new vessel will be the fourth to be constructed at the shipyard, and should be completed in early 2006.

Michigan Automation Development Agency to Open Headquarters

A consortium of manufacturing development interests has broken ground on a headquarters at a technology park in Troy, Mich. Southeast Michigan's regional manufacturing development agency, called "Automation Alley," will use its new center to showcase and incubate emerging manufacturing technologies to increase employment in the eight- county region surrounding Detroit.

Strategic Alliance to Serve Nuclear Industry Welding electrode and wire manufacturer Techalloy Corp., Balt imore, Md., has

formed an alliance with newly formed nexARC Inc., Millville, Pa., to distribute stainless steel and nickel-alloy filler metals to the nuclear power industry. Techalioy is a division of the world's largest steelmaker, Arcelor.

Lincoln Plant Earns ISO 14001 Certification The Lincoln Electric Co.'s welding equipment plant in Euclid, Ohio, has been certi-

fied to ISO 14001, an international standard for environmental management systems and procedures. The company's electrode plant in Mentor, Ohio, previously received the certification. Lincoln says it is now the first U.S. manufacturer in the arc welding industry to achieve this certification for its environmental practices.

Multiquip Expands to Vietnam Welding machine maker Multiquip, Carson, Calif., has opened a dealership in Hanoi,

Vietnam, primarily to serve the construction industry there. It plans another dealership in Ho Chi Minh City later this year. Multiquip has expanded to more than 50 countries since the 1990s. In March, it opened a sales site in India.

Coachmen Selects Site for New RV Factory Coachmen Industries will hire and train 100 new employees later this year at a new

147,000 sq-ft facility near Middlebury, Ind., adjacent to a plant it acquired in March for production of travel trailers and "fifth wheel" recreational vehicles. The newest facility will manufacture RVs with the "Coleman" brand, to be introduced in the fall.

E,-1B JUNE 2004 I

WELI I I Publisher Andrew Cullison

Editorial Editor/Editorial Director Andrew Cullison

Senior Editor Mary Ruth Johnsen News Editor Ross Hancock

Associate Editor Howard M. Woodward Peer Review Coordinator Doreen Kubish

Publisher Emeritus Jeff Weber

Graphics and Production Production Editor Zaida Chavez

Advertising National Sales Director Rob Saltzstein

Advertising Sales Representative Lea Garrigan Advertising Production Frank Wilson

Subscriptions Leidy Brigman [email protected]~

Amer ican Welding Society

550 NW LeJeune Rd., Miami, FL 33126 (305) 443-9353 or (800) 443-9353

Publications, Expositions, Marketing Committee G. O. Wilcox, Chairman

Thermadyne Industries J. D. Weber, Secretary

American Welding Society R. L. Am, WELDtech International T. A. Barry, Miller Electric Mfg. Co.

T. C. Conard, ABICOR Binzel D. L. Doench, Hobart Brothers Co. J. R. Franklin, Sellstrom Mfg. Co.

N. R. Helton, Pandjiris, Inc. G. M. Nally, Consultant

R. G. Pall, J. P. Nissen Co. J. E Saenger, Jr., Edison Weldinglnstitute

R. D. Smith, The Lincoln Elecaic Co. D. Trees, John Deere & Co.

B. Damkr0ger, Ex Off, Sandia National Laboratories J. Greet, Ex Off, Moraine Valley College

D. C. Klingman, Ex Off, The Lincoln Electric Co. D. J. Landon, Ex Off, Vermeer Mfg. Co. E. D. Levert, Ex Off, Lockheed Martin E. C. Lipphardt, Ex Off., Consultant J. G. Postle, Ex Off, Postle Industries

R. W. Shook, Ex Off, American Welding Society R. Tabemik, The Lincoln Electric Company

Copyright © 2004 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

MEMBER

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DITORIAI

The Future Looks Good This month marks the s tar t of my year as your p res iden t and I would like to

begin by thanking you for bestowing on me this privilege and honor. I have many plans for this year. First and foremost, I 'm interested in activities dealing with the educat ion of the future members of our welding profession.

Let me share a vision of the future with you. You've heard all kinds of g loom and doom commen t s and p red ic t ions about today ' s s tudents . I 've heard them, too. They ' re wrong. As a professor at Moraine Valley Community College in Palos Hills, I!1., I get the oppor tuni ty to see many young people who are joining our industry. They ' re smart, they ' re eager, and they ' re willing to work hard. Because of them, the future not only looks good, it looks great.

Le t me give you an example . Mike Pelegr ino is a s t ra igh t -A g radua te of my welding program. He s ta r ted t ra ining as a chef in the cul inary arts p rogram before switching to welding. After graduation, he went to work building cranes. Mar- r ied and the fa the r of th ree l i t t le girls, Mike took a pay cut when he jo ined the apprent iceship program of the Pipefit ters Union Local 597, but he wanted to improve his skills. He became a j o u rn ey ma n the o ther day, receiving four awards, including Apprent ice of the Year, at his graduation.

People are always asking you to suppor t educa t ion , but then don ' t give you specifics as to what you can do. I 've got some suggestions for how you can help.

• Contact the administrators of your school system and vocat ional schools to stress the importance of the welding programs. Let them know good jobs are ava i lab le for the graduates of those programs. Even though we get s tudents of the caliber I 've told you about, and despite the fact that welding professionals can earn high wages, school adminis t ra tors and guidance counselors are not in welding's camp. If you were to call and ask for informat ion about a welding program, most l ikely they 'd try to d i rec t you away f rom welding to ano the r curr iculum. Most ly it 's because they don ' t unders tand welding. I think of them as " technical illiterates"; they think "technical" educat ion only means computers.

• Donate supplies such as scrap metal. Welding programs are expensive classes to run. The welding schools need carbon steel, stainless steel, and aluminum, both in plate form and pipe.

• Donate equipment. Which employee will be p roduc t ive the soones t? One who has learned on ant iquated equipment or one who knows how to opera te the m o d e m equipment you've got in your shop?

• Give your time. Join a school 's advisory commit tee . This will let you play a role in what type of worker your local school will turn out.

• Hire a teacher as a consul tant . We've all heard that old saying, "Them that can, do. Them that can't , teach." Frankly, I hate that one because it just isn't true. The reality is that you can' t teach something if you don ' t know how to do it in the first place. Hir ing a welding teacher as a consul tant shows that person you have respect for his or her ability and, since educators are usually underpaid , the extra money just might allow that person to remain in the teaching profession.

I hope I 've given you some ideas of what you can do to help, but be assured that the Amer ican Welding Society will be doing its par t as well. For instance, the Nat iona l Science Founda t ion recent ly awarded a $70,000 grant for the crea t ion of a Nat ional Center for Excellence in Welding. Grant part icipants are the Amer - ican Welding Society, Loraine Communi ty College in Elyria, Ohio, and The Ohio State University, Columbus. The center will provide a central location for the collection and distr ibution of educat ion curricula and materials, will provide in-serv-

ice t ra in ing for weld ing faculty, will p resen t an annual conference on weld ing for educa tors , and d i s semina te needed materials to welding educators.

I realize that in some ways I 'm preaching to the choir, that you all realize the importance of high-quality welding education. However, if we're to keep the future of our industry looking great, the work must begin with us.

James E. Greer A WS President

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AmoricanWeldl Socl0tv Founded in t 919 to Advance the Science, Teclmology and Application of Welding '

Officers President James E. Greet

Moraine Valley Community College

Vice President Damian J. Kotecki The Lincoln Electric Co.

Vice President Gerald D. Uttrachi WA Technology, LLC

Vice President Gene E. Lawson ESAB Welding & Cutting Products

Treasurer Earl C. Lipphardt Consultant

Executive Director Ray W. Shook American Welding Society

Directors T. R. Alberts (Dist. 4), New River Community College

B. Albrecht (At Large), Miller Electric Mfg. Co.

A. J. Badeaux, Sr. (Dist. 3), Charles Cty. Career& Tech. Center

K. S. Baucher (Dist. 22), Technicon Engineering Services, Inc.

M. D. Bell (At Large), Preventive Metallurgy

L. J. Bennett (Dist. 21),Allan Hancock College

J. C. Bruskotter (Dist. 9), Production Management Industries

C. E Burg (Dist. 16),Ames Laboratory IPRT

N. M. Carlson (Dist. 20), INEEL

H. R. Castner (At Large), Edison Welding Institute

N. A. Chapman (Dist. 6), Entergy Nuclear Northeast

S. C. Chapple (At Large), Consultant

N. C. Cole (At Large),NCC Engineering

L. P. Connor (Dist. 5), Consultant

J. R. Franklin (At Large), Sellstrom Mfg. Co.

J. D. Heikkinen (Dist. 15), Spartan Sauna Heaters, Inc.

W. E. Honey (Dist. 8),AnchorResearch Corp.

J. L. Hunter (Dist. 13), Mitsubishi Motor M[g. of America, Inc.

M. D. Kersey (Dist. 12), The Lincoln Electric Co.

E. D. Levert (Past President),Lockheed Martin Missiles & Fire Control

V. Y. Matthews (Dist. 10), The Lincoln Electric Co.

J. L. Mendoza (Dist. 18), City Public Service

T. M. Mustaleski (Past President), BWXT Y-12, LLC

R. L. Norris (Dist. 1), Merriam Graves Corp.

T. C. Parker (Dist. 14),MillerElectricM[g. Co.

O. P. Reich (Dist. 17), Texas State Technical College at Waco

E. Siradakis (Dist. l l ),Airgas Great Lakes

K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Se~

R. J. Tabernik (Dist. 7), The Lincoln Electric Co.

P. E Zammit (Dist. 19), Brooklyn Iron Works, Inc.

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VEWS OF THE INDUSTRY J

Praxair Announces Partnership to Commercialize Tandem Process; Acquires Dallas Firm

Praxair Distribution, Inc., Danbury, Conn., has agreed to market a tandem arc welding process developed by Cloos Robotic Welding, based in Schaumburg, II1., with a parent company in Germany. The high-capacity process uses two in-line welding wires in a V-shaped configuration to achieve high deposition rates and travel speeds. "The new process has been installed now at a number of customer locations where it has proved ideal for robotic applications and adaptable to any robot cell configuration," a Praxair official said.

In separate news, Praxair Distribution, Inc., has purchased United Welding Specialties of Dallas, Tex., a division of Union In- dustrial Gas. The unit will become part of Praxair's Gulf States Di- vision headquartered in Austin, and will serve welding businesses in the Dallas-Ft. Worth market. United Welding is the seventh pack- aged business Praxair has acquired in the past three years.

Study Predicts Worldwide Aluminum Shortage

A survey by Merrill Lynch predicts that a shortage of aluminum ore will lead to bottlenecks in aluminum production in 2004 and 2005, leading to higher prices. Due to China's growing

consumption of the metal, demand will outstrip supply until 2006, when the supply of bauxite from new mining operations will catch up and surpass the forecasted demand.

Dust Collectors, Power Tools Take Road Trips

A fleet of 15 trailer-mounted dust-collection systems from Farr Air Pollution Control, Jonesboro, Ark., is traveling the country to provide on-site demonstrations and training. The "Gold Series" model collectors are optimized for removing fine parti- cles and fumes from metalworking facilities.

Meanwhile, a 53-foot trailer dubbed the "Red Zone Experi- ence" has been launched by Milwaukee Electric Tool Corp., Brookfield, Wis. The vehicle is equipped with pop-out sides for tool demonstrations, as well as an onboard multimedia theater. Destinations include vo-tech schools, union training centers, job sites, and trade shows nationwide.

Oilfield Business Endows Welding Scholarship

A $10,000 welding scholarship has been established at South Plains College, Levelland, Tex., by Worley Welding Works, an area company serving the oil industry. The scholarship is named

- - c o n t i n u e d o n p a g e 12

VIANUFACTURERS OF C O R E D W E L D I N G WIRE A N D ST ICK ELECTRODE~

We have been told that we are the best-kept secret in the welding industry. In an effort to correct this situation we advise that:

WE MA Stainless

410NiMo FC 502 FC 505 FC E2553 FC E2209 FC E630 FC 904L FC

Cast Iron 3 3 % Ni 5 5 % Ni 9 9 % Ni

Cobalt

6 12 21

2101

AISI 4 1 3 0 4 1 4 0 4 3 4 0

Nickel ENiCrFe-2 ENiCrFe-3 EniCrCoMo-1 ERNiCrMo-3 ERNiCr-3

THE ABOVE ARE JUST A FEW OF THE CORED WIRES THAT WE MAKE. FOR MORE INFORMATION CALL:


i [ ~ ! JUNE 2004 I i

"CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY"

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Hod gson Custom Rolling Inc. services a wide variety of industries in the ENERGY SECTORS of hydro, petro chemical, atomic, gas, oil, wind, etc. in addition to those in heavy manufacturing; steel, pulp & paper, mining, marine, forestry, etc. Hodgson's commitment to providing customers superior products and personalized professional service has earned itself a reputation for excellence, making the name HODGSON synonymous with

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Hodgson Custom Rolling Inc. is one of North America's largest plate rolling, forming, section • rolling and fabricating companies.

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PLATE ROLLING & FLATTENING Hodgson Custom Rolling specializes in the rolling and flattening of heavy plate up to 7" thick and up to 12 feet wide. Cylinders and segments can be rolled to diameters ranging from 10" to over 20 feet. Products made include ASME pressure vessel sections. Crane Hoist Drums, thick walled pipe, etc.

PRESS BRAKE FORMING & HOT FORMING Hodgson Custom Rolling's brake department processes all types of steel sections and plate up to 14" thick• Developed shapes such as cones, trapezoids, parabolas, reducers (round to round, square to round) etc.

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- - continued from page 10

in memory of O. M. "Rube" Morris, a retired oil field welder who died last December and who had been an inspiration to the founder of Worley Welding Works and many other young welders in west Texas.

Energy Firms Request Federal Help on New Nuclear Plants

A group of nine of companies in the nuclear industry have formed a consortium called NuStart Energy Development LLC that has asked the U.S. Department of Energy to share funding to develop designs and an application for a new generation of commercial nuclear reactors. The consortium includes Westing- house, GE, TVA, and Duke Energy. Under a federal program called Nuclear Power 2010, the government can provide a dollar-for-dollar match for approximately $400 million to be invested by the consortium over seven years to develop designs and fil- ings to the Nuclear Regulatory Commission.

Boeing Gets Order for Carbon-Fiber Jetliners

Boeing Co. received an order worth as much as $6 billion from All Nippon Airways for 50 7E7 Dreamliner jets. The new, fuel-efficient planes, to be delivered starting in 2008, will be the first commercial airliner to be made mostly of carbon-fiber composite materials, which are lighter and stronger than aluminum. Boeing projects that it can sell as many as 3500 of the new jets. About 35% of the aircraft's structure will be built by Japanese companies.

Caterpillar Expanding in China

Construction equipment maker Caterpillar has formed a leas- ing entity in Beijing to support sales of products made at the t e n facilities it operates in China. Caterpillar is also establishing a parts distribution center in China to serve its dealers and customers there. "We intend to be an industry leader in China by 2010," said Stu Levenick, the company's group president.

Alcan Opens Auto Component Plant

Aluminum supplier Alcan has opened a plant near Detroit in Novi, Mich., to produce lightweight structural parts for automak- ers. Production of structural subsystems such as instrument panel supports, engine cradles, and bumper beam assemblies will begin this summer. A sister plant in Saguenay, Quebec, will open later this year.

Best Place to Work in Federal Government Is NASA

The Partnership for Public Service and the American Univer- sity Institute for the Study of Public Policy Implementation ranked data on 100,000 federal workers and found that young people, mi- norities, and women rated NASA the best employer in government.

Fire Trucks Setting Sales Records

Oshkosh Truck Corp.'s firefighting apparatus subsidiary, Pierce Manufacturing, Bradenton, Fla., has reported three consecutive months of record sales for its Contender fire trucks. De- mand in the industry is being driven by military base purchases,


E P i JUNE 2004 I I


wildfire prevention, and increased spending of homeland security funds by municipal fire departments.

Metalforming Awards Announced

The Precision Metalforming Association, Cleveland, Ohio, has presented its annual Awards of Excellence to Spartanburg Steel Products, Spartanburg, S.C.; Stamco Industries, Euclid, Ohio; Kreider Corp., Springfield, Ohio; E & E Mfg. Co., Ply- mouth, Mich.; Dickey-Grabler Co., Cleveland, Ohio; and Penn United Technology, Cabot, Pa.

New Cutting Process Uses Nitrogen

A company has introduced Nitrojet, a new cutting process that uses a jet of liquid nitrogen as an alternative to water jet cutting in the auto and aviation industries. The technology was developed by NitroCision, Idaho Falls, Idaho, to clean reusable booster rockets for NASA, and it was discovered that the process cuts metal cleanly. Because it cuts with inert nitrogen instead of pressurized water, the process leaves no liquid waste, and can be used with materials that are sensitive to moisture.

Market for Material-Analyzing Tools to Approach $32 Billion

A study by Business Communication Company, Norwalk, Conn., predicts that the market for materials testing and characterization instruments will reach nearly $32 billion by 2009. The market is currently at $21.8 billion in annual sales. Chromatog-

raphy is the fastest-growing subsegment. Microscopy, radiogra- phy, and testing instruments (ultrasound, eddy current, liquid penetration, etc.) are also strong contributors to the growth of the industry.

3M Acquires Safety Products Company Hornell

The Swedish manufacturer of personal protective equipment for the welding industry, Hornell International, has been acquired by 3M, St. Paul, Minn. Hornell is known for its Speedglas autodarkening helmets and its Adflo respiratory equipment. Based in Gagnef, Sweden, Hornell employs 215 people.

Hypertherm Extends Warranties on Plasma Cutting Machines

Hypertherm, Inc., Hanover, N.H., has upgraded its warranties to existing owners of Powermax 190c, 380, and 600 models of plasma cutting machines purchased after 2001 to three years, bringing their coverage up to the level offered on its newest models.

World's Smallest Ruler Produced at MIT

Nanotechnology scientists at MIT have created the "Nanoruler," a device that can be used in manufacturing to accurately measure distances as small as a few hundred billionths of a meter apart. The device can make measurements on surfaces

- - c o n t i n u e d on page 29


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I WELDING JOURNAL m ~ m

4LUMINU~

Q : I have fabricated some fairly complex steel structures that have, on occasion, presented problems with distortion. I am now considering moving to a luminum as a replacement material for some of these structures. My questions are, what amount of distortion can I expect to see with aluminum? And how can I minimize it?

A: We need to consider the principal reasons for distortion in any arc welded structure, and some of the characteristics of aluminum specifically. Welding distortion can be defined as "the nonuniform expansion and contraction of weld metal and adjacent base metal during the heating and cooling cycle of the welding process." Distortion is a consideration when arc welding all materials, and the principles behind this reaction are fundamentally the same.

If we evenly heat an unrestrained piece of metal in a furnace to a prescribed temperature and then allow it to cool to its original temperature, it will first expand (to a degree based on its coefficient of expansion), and then contract as cooled to its original size. If we apply this kind of uniform heating and cooling to an unre-

BY TONY ANDERSON

strained structure, the heating and cooling process should promote no distortion of the structure. Unfortunately, when arc welding, we are usually applying nonuniform localized heating to the structure that we are welding. This heating is limited to the area of the weld and its close vicinity. Also, the heating and cooling are conducted under varying amounts of restraint during the welding process. The part of the welded component outside of the weld area that is not heated, or is heated to a much lower temperature, acts as a restraint on the portion that is heated to the higher temperatures and undergoes higher expansion. The nonuniform heating, resulting in nonuniform expansion and contraction, along with weld metal and base metal shrinkage, and the partial restraint from the less affected parts of the structure are the primary causes of thermal distortion problems that occur in welding.

Theoretically, when welding aluminum, as compared to carbon steels, the effects of some of the main contributing factors for distort ion may be somewhat increased. Aluminum has high thermal conductivity, a proper ty that may affect

distortion and can substantially affect weldability. The thermal conductivity of aluminum is around five times that of low- carbon steel. Aluminum also has high solidification shrinkage, around 6% by volume, and a high coefficient of thermal expansion. When we arc weld aluminum, we apply high localized heating to the material in and around the weld area. There is a direct relationship between the amount of temperature change and the change in dimension of a material when heated. This change is based on the coefficient of expansion. This is the measure of the linear increase per unit length based on the change in temperature of the material . Aluminum has one of the highest coefficient of expansion ratios, and changes dimension almost twice as much as steel for the same temperature change. However, it is not uncommon to apply higher material thickness to a comparable aluminum structure when compared to steel. This is a design considerat ion that may be used to provide the necessary rigidity and/or required strength. Because aluminum is approximately one-third the weight of steel, we could, in fact, double the origi-

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nal design thickness for our aluminum structure and still have only two-thirds the weight. The significance of such an increase in material thickness would be a substantial reduction in the potential for distortion.

Q: What methods can be employed to reduce distort ion?

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tlx: The methods used for the control of distortion when welding aluminum are the same as other materials. However, depending on material thickness and structure design, we may need to give greater consideration to the following:

1) Probably the most common cause of excessive distortion is from overwelding. In order to reduce distortion, we should try to keep the heating and shrinkage forces to a minimum. We should design the weldment to contain only the amount of welding necessary to fulfill its service requirements. The correct sizing of fillet welds to match the service requirement of the joint can help reduce distortion. We should not produce fillet welds that are larger than specified on engineering drawings. We should provide welders with fillet weld gauges so they are able to measure their welds to ensure that they are not producing welds that are much larger than that specified. With butt joints, we should control edge preparat ion, fitup, and excessive weld buildup on the surface, in order to minimize the amount of weld metal deposited, and thereby reduce heating and shrinkage.

2) When welding thicker material , a double-V-groove joint requires about half the weld metal of a single-V-groove joint, and is an effective method of reducing distortion. Changing to a J-groove or a U- groove preparat ion can also assist by reducing weld metal requirements in the joint.

3) We may consider the use of inter- mit tent fillet welds, where possible. We can often maintain adequate strength requirements and reduce the volume of welding by 70% by using intermittent fillet welds instead of continuous welding, if the design allows.

4) Balance welding around and position welds near the neutral axis of the welded structure. The neutral axis is the center of gravity of the cross section of the part. Plac- ing similarly sized welds on either side of this natural centerline can balance one shrinkage force against another. Placing the weld close to the neutral axis of the structure may reduce distortion by providing less leverage for shrinkage stresses to move the structure out of alignment.

5) Reduce the number of weld beads, if possible. Fewer passes with a large electrode are preferable to many passes with a small electrode. The additional applications

Fig. 1 - - Distortion of welded aluminum wheel The various colors indicate the different degrees of distortion throughout the welded structure, from dark blue, which shows little if any distortion, to red, which indicates maximum distortion within the structure.

of heat can cause more angular distortion in multipass single-sided fillet welds and multipass single-V-groove welds.

6) Carefully select the welding process to be used. Use a process that can provide the highest welding speeds and is able to make the weld in the least amount of weld passes. Make use of automated welding, whenever possible, as these techniques are often capable of deposit ing accurate amounts of weld metal at extremely high

Fig. 2 - - Predicted distortion. This is an illustration of an aluminum suspension frame. The purple dotted line indicates the original design dimensions (without distortion). The dark blue indicates little if any distortion. The pale blue, green, and yellow show varying degrees o f distortion to red, which indicates maximum distortion within the structure. (Pictures courtesy o f SYSWELD*, a product o f the ESI Group, www.esi-group.com. )

speeds. Fortunately, with modern arc welding processes, we are often able to use high welding speeds, which can help us control distortion.

7) Use welding sequences or backstep welding to minimize distortion. The back-

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step technique allows for the general welding progression to be in one direction, but enables us to deposit each smaller section of weld in the opposite direction. This provides us the ability to use prior welds as a locking effect for succes- sive weld deposits.

8) Whenever possible, weld from the center outward on a joint or structure. Wherever possible, alternate sides for suc- cessive passes on double-sided multipass welding. An even better method to control distortion is to weld both sides of a double-sided weld simultaneously.

9) Preset components so that they will move during welding to the desired shape or position after weld shrinkage. This is a method of using the shrinkage stresses to work for us during the manufacturing process. Through experimentation, we can determine the correct amount of offset required to compensate for weld shrinkage. We then need only to control the size of the weld in order to produce consistently aligned welded components.

10) Consider the use of restraints such as clamps, jigs and fixtures, and back to back assembly. Locking the weldment in place with clamps fixed to a solid base- plate to hold the weldment in position and prevent movement during welding is a

common method of combating distortion. Another method is to place two weldments back-to-back and clamp them tightly together. The welding is completed on both assemblies and allowed to cool before the clamps are removed. Pre-bending can be combined with this technique by inserting spacers at suitable positions between the assemblies before clamping and welding.

11) Consider the use of aluminum extrusions. Aluminum can be easily acquired in standard and customized extruded configurations. Many manufacturers are taking advantage of extruded aluminum sections to reduce the amount of welding in their fabricated components. Extruded aluminum offers a perfect opportunity to reduce welding (potential for distortion), assist with assembly, and often improve aesthetics.

One method of understanding and planning for distortion prevention is the use of specialized computer software - - Figs. 1, 2. Computer software has been developed as a tool to understand and predict distortions caused by the welding processes. This software is presented as being able to predict residual stresses and distortions after welding, thus allowing welding engineers the opportunity to optimize their process (weld sequence and/or clamping condition).

Many complex aluminum structures are welded every day without excessive distortion problems. This is often achieved through the combined effort of designers and manufacturers. The designers need to carefully consider options that are available to help reduce the amount of welding within the structure, and also to position those welds that are necessary in areas that least promote distortion. The manufacturer needs to develop, employ, and control the necessary equipment (welding process, fixturing, etc.) and techniques (welding sequences and balancing methods) to reduce the effects of the welding process that promote distortion. •

TONYANDERSON is Technical Director of AlcoTec Wire Corp., Traverse City, Mich. He is Chairman of the Aluminum Association Technical Advisory Committee on Welding and Joining; Chairman of the A WS Committee for D IO. 7 Gas Shielded Arc Welding of Aluminum Pipe; Chairman of the A WS B8.14 Committee for Automotive and Light Truck Components - - Aluminum; Chairman of the AWS D3.7 Guide for Aluminum Hull Welding; and Vice Chairman of the AWS Committee for D1.2 Structural Welding Code - - Aluminum. Questions may be sent to Mr. Anderson c/o Welding Journal, 550 N W LeJeune Rd., Miami, FL 33126 or via e-mail at [email protected].

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~RAZING Q & A J aYR. L. P sLEE

Q: When brazing 304L stainless steel, we see the brazing filler metal eating holes into the stainless in some of the assemblies. We do not understand what is causing this. We would like to know what is happening and why.

A: You are encountering what is te rmed erosion. In testing conducted years ago, we divided the erosion mechanism into three divisions:

1) Solid-state diffusion, where the melting point depressant in the filler metal diffuses into the base metal. With the nickel-based filler metals, this was primarily the diffusion of boron into the base metal.

2) Solution, when there is a large amount of nickel-based filler metal, such as a large fillet, enough boron would dif- fuse into the base metal to lower its melting point, and some of the base metal would become liquid and mix with the filler metal. After solidification, the only way to determine whether the base metal had dissolved into the filler metal is to section, polish, and etch. This will reveal the

Fig. 1 - - Puzzling even for the experts are the curious round-bottomed corrosion grooves radiating from the central brazed joint. The grooves were stained for clarity. This specimen is about ¾ in. wide.

amount of solution that had occurred. 3) Erosion is the final stage. This oc-

curs when the fillet and melted base metal flow away from their original locations, leaving a thinned base-metal section, or a

ii. :L

hole, in the base metal. This visible thin- ning, a hole, or streaks where filler metal ran down a part, or where the filler metal was sucked into the joint leaving a thinned area or hole, etc., is termed erosion.

I~Jl JUNE 2004


I "CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY"

The furnace cycle is sometimes very important in preventing erosion.

Consider an assembly consisting of thin tubing to be brazed onto a heavy fitting. A large quantity of filler metal must be placed against the tubing at the joint. When the assembly is heated rapidly to the brazing temperature, the tube will come to heat first and the filler metal will melt, while the heavy fitting lags in coming to brazing temperature. This condition, where the hot tube and molten filler metal are in contact for an extended time, promotes interaction between the molten filler metal and the tube. When the heavy fitting finally comes to the brazing temperature and capillary action sucks the filler metal into the joint, an eroded area will usually be seen on the tube above the joint.

The solution to this problem is to hold the furnace tempera ture down to about 50°F below the solidus of the brazing filler metal. The hold time should be long enough to allow the heavy fitting to reach the same temperature as the tube. Then the furnace temperature can be raised to the brazing temperature , permitt ing the filler metal to melt and flow directly into the joint with only a small fillet remain- ing. This method minimizes the interaction between the filler metal and tube, thus preventing erosion.

There is some concern that erosion will occur in the brazed joint. This will not occur, as it takes a large excess of brazing filler metal to dissolve the base metal and, if flowing away, to cause erosion. By holding the parts at the brazing temperature, we can produce diffusion in the brazed joint to strengthen the joint and increase the remelt temperature. This is a benefi- cial reaction.

Solution and erosion are controllable, and should not occur with the proper application of filler metal and the proper furnace cycle.

I liken this problem to my welding days. If the welder was continuing to undercut during welding, we blamed the welder because he or she did not know how to control the process. Similarly if we know how to control the brazing process, erosion should not occur.

There is a very obscure type of erosion that we very seldom encounter. This is surface erosion caused by the filler metal running out of the joint and across the surface of the base metal, producing a spreading or tree-like effect - - Fig. 1. The branches get progressively smaller as they spread out. This example is a copper-t in-bronze base metal brazed with BAg-8 brazing filler metal at about 1500°F (815°C). A ~A- in. (3.2-mm) diameter filler metal wire was placed at the step and the joint is 90 deg to the plane of the picture. The branch- ing ran both ways from the joint.

We are still trying to find out what is

the driving force that makes the branch- ing continue to flow. One would think it would pick up enough base metal to freeze off and not continue to flow, but it continues. Micros indicate they are shallow round-bot tom erosion grooves. We are still looking for the answer to this one. If you have some ideas on what causes this effect please share them with me.0

R. L. PEASLEE is l/ice President Emeritus,

Wall Colmonoy Corp., Madison Heights, Mich.

This article is based on a column prepared for

the A WS Detroit Brazing and Soldering

Division's newsletter. Readers may send ques-

tions to Mr. Peaslee c/o Welding Journal, 550

NIT" LeJeune Rd., Miami, FL 33126; or e-mail

to [email protected].

o

0

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106

The Orbiweld 12 Micro Weld Head can weld stainless steel fittings with stubs as short as 0.25 in. (6.35 mm). The water- cooled weld head features an integral control panel on its handle. It can be used for tubes from 3 to 12.7 mm diameter.

Orbimatic GmbH 107 RO. Box 416, Welbeck Way, Peterborough, PE7 3FT, U.K.

Multiprocess Inverter Handles Power Fluctuations

The 80-1b XMT 350 multiprocess in-

ECONOMICALLY PRICED TU~ G,~ fEN GRINDER

SAFETY: Enclosed diamond wheel grinding area

WELD QUALITY: 20 Ra finish improves tungsten life, starting & arc stability

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Circle No. 33 on Reader Info-Card J WELDING JOURNAL 11,'4.,"!1

Less handling, easier positioning, faster and cleaner welds.

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Q¢ ,,, Atlas Pipemate and Idler Roils >

• Unit with idler rolls supports balanced Z < loads up to 1000 lb. "" • Rotates pipe and tube up to 17" dia. I- =o • Portable, low profile for shop or field

• Dual speed 0 to 30 in/rain or 0 to 60 z in/min o • High frequency filter prevents <~ interference with GTA welding

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Atlas Rotary Table PosiUoners

* Three models: 9" table, 100 lb. capacity, 10" tilt table, 200 lb. capacity 14" table, 500 lb. capacity

• Heavy duty grounding circuit for stick electrode, MIG or TIG welding

• Low profile for bench mounting • Foot switch for feathering speed and

on/off control • Front panel speed and rotation controls

Other handling and welding aids...Atlas Pipe Supports, Atlas Roller Stands, Atlas Pipe Dol l i es

~ ATLAS WELDING ACCESSORIES, INC. Troy, MI 48099

8 0 0 - 9 6 2 - 9 3 5 3 --~:J WWW: allasweld.com E-Mail: [email protected]


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Automatically create WPQRs, PQRs, and WPSs in accordance with AWS D1.1 with the highest level of Code-Checking available in welding software today!

Create Welding Procedures and Maintain Welders with just ONE program/

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l i , .b l l JUNE 2004 [

verter automatically adjusts to primary power fluctuations between 190 and 630 V, reducing out-of-spec welding parameters and shutdowns due to dirty power. In addition, power costs and current limitations at construction sites can be improved due to the unit's 87.24% electrical efficiency at 400 A.

Miller Electric Mfg. Co. P.O. Box 100, Lithonia, GA 30058

108

Pneumatic Tool Light Powered by Compressed Air

The Air Light"at taches to any pneumatic tool and uses compressed air to generate an adjustable light beam to illumi- nate work surfaces.

Viking Air Tools, Inc. 28188 N. Bal lard Dr., Lake Forest, IL 60045

109

Laser Beam Mirrors Provide High Reflectance

The company's laser turning mirrors and phase retardation reflectors provide less than 2% absorption and scatter losses in 25- to 200-W industrial laser systems.

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The mirrors are made from molybdenum or silicon and are available in diameters from 0.5 to 3 in.

Laser Research Optics 120 Corliss St., Providence, RI 02904

110

Laser Welding Machine Designed for Aluminum

The LW300AL laser welding machine is capable of seam welds up to 40 mm/s

with weld penetra t ion of 600 [tm in aluminum alloys. The machine combines with the company's A Series Nd:YAG lasers to provide real-time power feedback, power ramping, and pulse shaping capabilities.

Unitek Miyachi Corp. 1820 S. Myrtle Ave., Monrovia, CA 91016

111

Lumber Crayons Suitable for Marking Metal

Pro-EX T M smear-resistant lumber crayons are available in ten bright colors.

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Earthmoving Ground engaging

Mining Shredding Crushing Pulverizing Forging Drilling

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WELDING JOURNAL i , ' 4 r l

The clay-based markers provide long-last- ing service on metal, wood, and masonry.

LA-CO Markal 112 1201 Pra t t Blvd., Elk Grove Village, IL 6000%$746

Portable Fume Extractor Weighs 40 Ib

The company's Portable Welding Fume Extractor removes toxic metallic

fumes from welding areas. The HEPA- equipped l15-V unit handles an air volume of 350 ft3/min through its 6-in.-diameter, 58-in.-long flex arm.

Sentry Air Systems 6999 W. Little York, P-l , Houston, TX 77092

113

Modular Fixturing Handles Prototypes

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Kick your cutting efficiency into high gear with the new 3D Link Plasma Bevel Cutter from Koike Aronson. The 3D Link makes a clean, bevel cut in one pass-no more labor wasted on cleanup, no more time wasted on second passes. The 3D Link even does contour cutting. Give us a call to find out how the new 3D Link Plasma Bevel cutter can increase your productivity.

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KOIKE ARONSOH, INC.

RANSOME

ARCADE, NYUSA 800-252-5232 HOUSTON, TX 800-868-06H0 www.koike.com

Congratulations to AWS on its 85'" Anniversary.


IP~:ll JUNE 2004

The Demmeler modular fixturing system includes a wide range of components to fixture parts for short runs or prototypes. Engineering changes can be made quickly, and duplicate fixtures can be prepared in 20 minutes.

Bluco Corp. 114 509 Weston Ridge Dr., Naperville, IL 60563

Dear Readers:

The Welding Journal encourages an exchange of ideas through letters to the editor. Please send your letters to the Welding Journal Dept., 550 NW LeJeune Rd., Miami, FL 33126. You can also reach us by FAX at (305) 443-7404 or by sending an e-mail to Ross Hancock at [email protected].

ARE YOU UP TO STANDARD? www.aws.orglcatalogs

CLICK FOR CODE SECRETS www.aws.org/catalogs

NEWS OF THE INDUSTRY

- - cont inued f rom page 13

wider than a foot. "That ' s the equivalent of shooting a target the size of a nickel in Manhattan all the way from San Francisco," said Dr. Carl G. Chen, one of the device's creators.

Report Says World Needs 250 New LNG Tankers

A report by an international shipping consultant says that world demand for liquified natural gas will require an average of 15 new LNG tankers per year through 2020. The report by U.K.-based Ocean Shipping Consultants sets the price tag at more than $29 billion. There are about 160 LNG tankers in service now, with 59 vessels on order.

Company Buys Its Welding Supplier

Edson International, New Bedford, Mass., a manufacturer of marine products, has acquired Quality Welding, Inc., the supplier that fabricated some of Edson's products, such as davit mounting systems and radar mounts.

China Is Fastest-Growing Auto Market

According to the Paris-based International Organization of Automobile Manufac- turers, China is the world's fastest-growing automobile market, and is already the second largest in Asia, after Japan. In 2003, the country produced about 4.4 million vehicles, ranking seventh in the world, and is growing at an annual rate of 25%.

- - cont inued on page 30


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WELDING JOURNAL me~l l

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Incidentally, China leads the world in auto deaths, with about 300 traffic fatali- ties per day, a rate attributed to bad roads and the increase in novice car owners.

Saudis Willing to Invest in New U.S. Refineries

Saudi Arabia ' s oil minister All bin Ibrahim AI-Naimi told a conference on global energy security that his country is willing to invest in two new U.S. refineries in order to reduce bottlenecks in production and distribution of oil products to the U.S. market. He said that there is no shortage of crude oil in the market, and that the rise in U.S. fuel prices is due to speculation, refinery bottlenecks, and environmental regulations.

Safety Alert for Self-Lighting Torches

Thermadyne has announced an inspection and screening program for some of its hand torch products. A small percentage of the torches may leak under certain conditions, the company said. Owners of the following models should contact Ther- madyne at (800) 688-9326 for instructions: 0386-0855 Nevax Hand Torch; 0386-1276 Turbo-Lite CTL-44 (Cigweld); 0387-0465 Firepower SMP-41; 0486-0010 Turbo Hand Torch; 0486-0012 Turbo Model 44 Hand Torch; 0387-0463 Firepower SMP- 31; 0387-0464 SMPK-31; 0426-4001 SK- 7000; 0386-1286 Turbolite TL-44 NL (w/o lock button); 0386-1293 TX504 Extreme; 0386-1294 TXC504 Torch Kit; 0386-1295 TXK504; 0386-1299 TX500 ProPak; and 0386-1297 TX503 Extreme.

Honda Adds Auto Assembly Line in Alabama

Honda has added a second assembly line to its Lincoln, Ala., plant, which has been producing Odyssey minivans, for the production of Pilot sport utility vehicles. The plant employs more than 3300 workers and expects to employ about 1000 more when the new product ion line reaches full production next year.

Electric Boat Gets New Navy Contracts

General Dynamics' Electric Boat Di- vision has received an order from the U.S. Navy to convert the USS M i c h i g a n and the USS F l o r i d a to accommodate tactical strike and special-operat ions support. Four other subs are already in the process of conversion by Electric Boat at two naval shipyards.

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CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY Circle No. 5 on Reader Info-Card B e y o n d t h e S t a n d a r d ' "

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\ AWS Welding Show

The newest welding equipment, consumables, and accessories; latest technological information; and top-notch welders

were all featured at this year's Welding Show BY ANDREW CULLISON, ROSS HANCOCK, AND MARY RUTH JOHNSEN

1

: First-class welders displaying their skills, world-renowned ex- p~rts sharing their knowledge, the newest advances in welding technology and equipment - - this year's Welding Show had it all. Following are just some of the highlights.

Annual Meeting

In a spirited fashion, President-Elect James Greer told attendees at the AWS Annual Business Meeting that education will be his focus for the coming year of his presidency. "Some say that students were better when we were growing up," he said. "I don't share that idea. I think the dedication of young people today is just as strong as it has ever been."

He related how one of his welding students at Moraine Val- ley Community College finished in the top of his class, got a lu- crative job welding cranes, but then decided to improve himself even more by entering an apprentice program. Even though he had a family to support, he took a pay cut because he was dedicated to this improvement. When time came for graduation, he received the top four awards of the apprentice program. He now

A N D R E W CULLISON ([email protected]) is Publisher~Editor, ROSS HANCOCK ([email protected]) is News Editor, and M A R Y RUTH JOHNSEN ([email protected]) is Senior Editor o f the Welding JournaL

has a $35/hour welding job and is doing fine. Greer, a native of Chicago, enthusiastically welcomed the at-

tendees to his hometown, noting its industrial heart with steel mills and power plants rimming the shores of Lake Michigan and commenting on the area's strong union workforce.

Adams Lecture

Harry Bhadeshia was honored to present the Comfort A. Adams Lecture oh the Reliability of Weld Microstructure and Property Calculations. Bhadeshia is a professor of physical metallurgy in the Department of Materials Science and Metallurgy at the University of Cambridge, U.K.

He prefaced his talk by noting that the "study of steel has been my life for 30 years." Then he raised the basic question of his topic, whether we need many experiments to determine the characteristics of a new alloy when it is welded or can we rely on just calculations? The answer he concluded is "yes" and "no."

There are many factors that can aid in the calculations such as the time-temperature transformation diagram and carbon content. Carbon seems to have its greatest impact when concentra- tions are very small. Acicular and Widmanstatten ferrite growth can be calculated with knowledge of the cooling curve, and the strength of steel is fairly easy to calculate, but Charpy impact and fatigue strengths are complex functions that are difficult to prop-

I WELDING JOURNAL W,c~!

erly calculate. Here, experiments are important, but the information gained can be extrapolated to make calculations.

He noted that the University of Cambridge has a library of calculations on various alloys, and a grand plan to expand it entails industry providing the experimental data and the university providing the calculations. For those interested in accessing the site, the address is www.msm.com.ac.uk/phase-trans.

P l u m m e r Lecture

Byron May, manager, Repair Process & Materials Engineering, United Airlines, delivered this year 's Plummer Memorial Education Lecture titled "Welder Training: What We Can Learn from the Cockpit."

United Airl ines ' Maintenance and Engineering Division, which is headquartered at its base in San Francisco, Calif., performs very little t radit ional joining, May said. About 90% is buildup of worn geometr ies and crack repairs. "Welding saves (the airline) millions of dollars every year."

Pilot training incorporates a " tremendous understanding of human performance" and the way pilots are t rained has applicat ion to other types of training, he said.

The following are the hallmarks of how United Airlines' pilots are trained:

1) Training is built on a foundation of lessons learned.

2) There are high professional expectations.

3) Procedural deviations are rou- tinely analyzed to reduce the probabil- ity of reoccurrence.

4) It is very candid. It addresses difficult subjects that may introduce risk.

Similarities between welding and pi- loting, May said, are that both require strict adherence to procedure, not following procedure can have catastrophic results, and both are becoming more automated but still rely heavily on human performance. One big difference is the time from deviation to consequence is much shorter for a pilot.

The air l ine 's welder training program mimics that for training its pilots, he said. Welder training includes a difficult United Airlines' designed written and practical test for initial qualification, a two to four week indoctrination program that varies depending on where the welder will work, and required recurrent training.

The basic philosophy of both pilot and welder training at United is "train to proficiency."

~ f i m JUNE 2004 I

NewYorkerWins First-Ever AWS Professional Welder Competition

Andrew Miller had always wanted to go to the AWS Welding Show, but until this year circumstances somehow just never seemed to allow it. Some years the Show was located too far from his home in Rochester, N.Y.; other times the dates weren't convenient. This year, however, "work wouldn't pay for it, but I felt compelled to come," Miller said. So he took a week's vacation and, ac- companied by his sister, drove to Chicago.

It turned out to be a good move, because besides registering for the Show, Miller had signed up for the American Welding Soci- ety's first-ever Professional Welder Compe- tition. He outscored 146 other welders to take first place in the event, winning $2500 and a Sellstrom "Titans with Attitude" autodarkening welding helmet.

While not one of the official judges, Pres- ident-Elect Jim Greer, a Senior Certified Welding Inspector, said he had also examined all the welds and was impressed with their quality. "I have never seen so many good welders all in one place before," Greer said during the April 8th ceremony in which he announced the winners.

The top ten welding competitors (listed in order) were Andrew Miller, Rochester, N.Y.; Rick Prince, Farrington, Ill.; Ryan N. Rummel, Thorndale, Tex.; Michael J. Casper, Lincoln, Ill.; Steven J. Dipolito, Cranesville, Pa.; Amanda J. Scheffier, Belleville, Mich.; Michael A. Pelegrino, Or- land Park, Ill.; Michael Rose, Jonesboro, Ark.; David M. Balog, Lansing, Ill.; and Robert J. Carhart, Chicago, Ill.

Prince and Rummel received $1000 and $500, respectively. Each of the top ten welders received an AWS duffel bag and all participants received an official AWS Pro- fessional Welders Competition T-shirt.

Each contestant had to create a multipass horizontal fillet weld using shielded metal arc welding on low-carbon steel. The object of the contest was to produce a high- quality ~ x 7 in. weld with a visible tie-in (start-stop) on the final pass. The weld had to be done in the 2F position within a time limit of seven minutes. A panel of Certified Welding Inspectors evaluated the weldments based on speed, weld length, and weld quality.

After hearing his name announced, Miller, a First-Class Welder for Rochester Gas & Electric, said, "It feels unbelievable. I had no clue it would be me. I had just hoped to hear my name in the top ten." As far as his thoughts on the contest, "I knew there would be a lot of good welders here. I tried to keep (the weld) clean and symmetrical the best that I could and tried not to worry about the time."

Miller felt it was a fair test. While the

Four of the top ten finishers during the awards' ceremony. From left to right, Michael Rose (eighth), Amanda Scheffler (sixth), Ryan Rummel (third), Andrew Miller (first).

weld itself was simple enough for most welders to perform, the time restriction added considerably to the difficulty and to the welders' tension levels, he said.

Sixth-place finisher Amanda Scheffier was called the competit ion's calmest contestant. Scheffier, a student at Washtenaw Community College and a member of Pip- efitters Union Local 190, described the contest as "a lot of fun."

"It was pretty difficult," said third-place winner Ryan Rummel, who was attending the Show along with his instructors and fel- z low welding students from Texas State Tec '~ nical College, Waco. Rummel also wel(ls professionally for a construction company. "I just tried to relax. I weld better in a r,;- laxed position." ',

Eighth-place finisher Michael Ro~e agreed that the pressure of competi t ion made the weld more difficult to produce. A welder for about 30 years, Rose currently works for Nucor-Yamato Steel in Blythevitle, Ark. Rose entered the competition because he wanted to see how he'd measure up to the other welders.

Many of the other contestants signed up for the same reason. "I read about the contest in the Welding Journal," explained Chris Borkowski, a welder for SSD Control Tech- nology in South Bend, Ind. '~knd I thought, ' I 'm not that bad a welder.' I wanted to see how I compared."

Joe Eppy's reasons for entering were twofold. He had won the AWS Peoria Sec- tion's welding contest about a year ago and wanted to see how he 'd do on a national level. A boilermaker by trade and member of Local 60 in Morton, Ill., Eppy also wanted to represent his union.

Producing the weld "was tough with the amount of time given," he said. ' ~ ~-in. weld with a ~6 rod is kind of tough."

Product Highlights

High-Power Inverter. Lincoln Electric introduced its Power Wave AC/DC 1000 at the Show. Rated at 1000 A for AC or DC, it is the highest capacity inverter available for submerged arc welding on the market - - Fig. 1. This machine is intended for high production applications as a stand-alone or as a modular system operating multiple arcs. Two machines in parallel can produce up to 2000 A at 100% duty cycle. Because of its high-amperage capabilities, this inverter technology is now being evaluated for pipe mill applications, an area where inverters previously did not have the capabilities to perform adequately. It should also excel in multiple-arc cladding applications. Lincoln Electric Co., Cleveland, Ohio, (216)383- 2667: www. lincolnelectric.com.

Fig. 1 - - The introduction o/a IO00-A inverter for submerged arc welding opens new application possibilities.

Fig. 2 --Axccss tcclmolog~ ~:Wands to 300- A machines.

Improved Control for Gas Metal Arc. Considered the next generation of inverters for Miller Electric, the Axcess 300 series was added to the already introduced Axcess 450 series - - Fig. 2. The machines are software driven, and the Axcess technology increases operating response rate to speeds faster than previous technology. This allows it to sense arc fluctuations or unstable conditions at high speed and make corrections at equally high speed. This increased response rate is effective for all the different modes of transfer with the gas metal arc process. The software allows many waveform adjustments to be made. The Axcess and Auto-Axcess 300 machines have a capacity of a 60% duty cycle at 300 A/32 V. Miller Electric Mfg. Co., Appleton, Wis., (800) 462-4553, www. millerwelds, com.

Keep Hoses Out of the Way. Your acetylene hoses can be stored in a neat and compact fashion with retractable hose reels from Rapid Reel. The hose attaches to an all-brass, ball-bearing swivel, and a drag system on the brake prevents the hose from unraveling when you stop pulling. The reels come in four different

sizes from 50- to 300-ft capacity. There are mounting brackets for attaching reels to walls, trucks, or pedestals. Also available are tubular two- or four-wheeled carts and cylinder hand trucks with attached reels. A standard 50-ft-capacity reel begins at $170 and progresses to $430 depending on hose capacity, mounting method, and type of wheeled carrier. The company also makes similar reels for air, water, and high-pressure hoses. Reel Quick, Inc., Lincoln, Neb., (866) 523-2363, www. rapidreel, com.

Fig. 3 Rclr, cl,h/c how reels kctT~ llw workplace unchtttered and safe.

Remote Heat Treating. Superheat FGH (Fig. 4) offers a mobile heat treating unit for field and hard-to-reach locations. It's relatively compact and maneu- verable. The unit is self contained, offering 100 kW of power. 12 zones of control with a chart for each zone, and remote op-

Educator Honored for Enhancing Image of Welding One of the largest entourages to attend the show was that of

welding instructor Juan Martinez, who brought eight of his students as well as his entire family from Boise, Idaho. Martinez was on hand to receive the Image of Welding Award for the educator category. This award was established last year by the AWS Welding Equipment Manufacturers Committee (WEMCO) to recognize individuals and organizations that have excelled in promoting the image of welding in their communities.

Martinez led a community art project that brought together at-risk students from a variety of socioeconomic backgrounds. His inspirational leadership transformed the students into welding advocates and proud fabricators of a beautiful bridge arch.

Welding educator Juan Martinez, joined by a group of his students who traveled from Idaho, accepts the Image of Welding Award in the educator category from A W S President Tom Mustaleski.

Martinez stood with his students as he delivered an emotional acceptance speech.

"I feel blessed to be a witness to what I think is a miracle of nature," he said. "I have seen some amazing transformations in

the young men and women who have come with me today. Not just in welding skills, but in true growth as human beings. These young people will some- day inherit our world of welding. We must find ways to reach out to all young men and women, not only in the interest of future welding advocates, but also in the interest of assisting this positive transformation."

Nominations for the 2005 Image of Welding Awards are now being accepted. For more information, contact Amy Nathan at [email protected].

WELDING JOURNAL ~ l . ' !

eration from an authorized PC. The vital information from each heat treating application is archived on the unit's software. Welding machines can opera te from its 220-V outlets. This mobile heat-treating rig is available for purchase, rent, or lease. Superheat FGH Services, Inc., Mokena, IlL, (800) 454-4760, www.superheatfgh.com.

Water-Cooled GMAW Gun. Tregaskiss showed its 400-A water-cooled Tough Gun, which features a lightweight ergonomic handle. It comes with the cool- operat ing contact tip system, which can utilize air-cooled consumables. The new design allows operators to invert the gooseneck to allow activation with the thumb. Tregaskiss, Windsor, Ont., (519) 737-6966, www.tregaskiss.com.

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Fig. 4 - - This mobih" /teat treating unit goes where it's needed.

Lower-Cost Oxyfuel Torches. Victor showed its Cutskill oxyfuel gas cutting and welding torches, which are priced 20% lower than its premium line. The torches feature built-in flashback arrestors, and various fuel gases can be handled just by changing the tip. Victor Equipment, St. Louis, Mo., (636) 728-3000, www.thermadyne.com/vec.

Fixturing for Just about Everything. Recommended for short-run production or prototypes, the Demmeler modular fixturing system by Bluco Corp. adapts to many different applications - - Fig. 5. The tables come in various sizes and with fixturing components such as blocks, angles, bar stops, and clamps, many different configurations can be fixtured. Multiple ta-

Famous Weld Designer Tells of His Experiences 2

Omer Blodgett has developed a world-renowned reputat ion as an expert in weld design that is cost-efficient and follows sound engineering principles, yet is simple in execution. Long an employee of Lincoln Electric Co., he has trained thousands in weld design through his "Essential Elements of Steel Weldment De- sign for Manufactured Products" course. His book Design of Weld- ments and Design of Welded Structures has served as a textbook for many structural engineers, and the numerous technical articles he has published have established his authority and knowledge in the design of welds.

The AWS Show served as a perfect forum to meet and learn more of the man. Duane Miller, manager, Welding Technol- ogy Center, and also an expert weld designer, took time to interview Blodgett.

A native of Duluth, Minn., Blodgett has been associated with welding for more than seven decades starting when he first learned to weld from his father at the age of ten.

His father repai red boilers on the barges that plied the waterways of Min- nesota, but when that business dwindled he set up his own welding business in Du- Welding legend Omer luth. Omer worked in the family business and at the age of 20, he got his first experience climbing steel when he was called upon to make a structural repair on a bridge. "I got good at it, and really enjoyed it." he said.

'Tve always had a thirst for knowledge," he said. "I read whatever I could get my hands on. I found a little magazine called Weld- ing Digest, and I used to wear it out just reading it," he continued.

He attended Duluth Community College, operated at the time by the University of Minnesota, for a two-year engineering program. He joined the AWS in 1938 as a student member for $2.50 a year, but the real turning point in his life came in 1939 when he attended a three-day seminar on welding sponsored by the Uni- versity of Minnesota.

"There were people from U.S. Steel, Lincoln Electric, and professors from the university," he said. "After that I was en- thused to get back into school, and I would do just about anything to get there." His finances were meager, but he overcame many hardships to finally earn a degree in metallurgy.

When he graduated in 1941, World War II had already begun

Blodgett.

and his first job was training welders for the shipyards that began to materialize for the war effort. The Duluth area ended up with six, and he was active at Globe Shipbuilding. "Normally Duluth might have five or six welders, but it eventually ended up with about 2000," he said. "We started with absolutely nothing," he continued. "There was a six-month wait for electrodes and new welding machines might take a year." At the beginning of the war there was still some controversy as to whether to go to all-welded

vessels or remain with riveting. Welding won out because a welded vessel was not only 20% lighter than a riveted one, but it took less time to train a good welder than a good riveter. Welding was also more economical.

Through the war years, he worked on oceangoing tugs, frigates, and cargo ships. It was also during these years that Blodgett became familiar with a rudimentary method of dye penetrant testing, and began empirical research on electrodes, examin- ing their heat input characteristics and the impact on weld ductility. He published his first technical article in the Welding Jour- nal in 1942.

Blodgett started working for Lincoln Electric in 1945. After spending time on

the sales force - - "sales is excellent training" - - Blodgett moved to corporate headquarters in Cleveland and, in 1956, he started conducting design seminars. Originally the course was for a week and the charge was $50. He still conducts those seminars, but on a scaled-down schedule. Over the years, he estimates 10,000 engineers have taken his course.

During the years of teaching the seminar, a number of "Blod- gett sayings" have materialized. Some of the more noted ones are "Welding is not a fastener; don't be afraid to accept change; don' t design with your heart; codes always lag industry; and no shear, no ductility."

"I love to work problems," said Blodgett, and that love is what keeps him going. Although 87 years old, he is still active in the welding community. Over the breadth of such a career he has received many honors and accolades, including being a member of the first class of AWS Fellows. Although appreciative of all, the one he is most proud of is the naming of the Welding Engineer Chair at LeTourneau University in his honor.

JUNE 2004 ]

Fig. 5 - - Modular fixturing table is designed to hold many different configurations.

bles can be attached together and angles can be used as outriggers for oversized components. Company personnel will assist with initial setup for your applications. Bluco Corp., Naperville, Ill., (866) 372- 5826, www.bluco.com.

Flexible Track System. ESAB showed its Rail trak FW1000, a programmable, flexible track system for welding and thermal cutting. A remote control pendant controls up to five programs, and the opera tor can use its tacti le-shaped buttons to control voltage and current without lifting a helmet. The system is capable of welding a weave pattern up to 30 mm wide in a horizontal or vertical direction. ESAB also showed its Sabre SXE three-axes gantry cutting system, which uses digital AC drives with brushless motors and a new gearbox design. The machine can handle multiple cutting stations using water jet, oxyfuel, plasma, or laser cutting processes, as well as drilling, marking, and scribing. ESAB, Hanover, Pa., (800) 934-9353, www. esab. com.

Laser Cutting Heads. Hypertherm introduced its first laser beam cutting products, its FAST Laser plate cutting heads. The product cuts up to 25-mm plate faster by directing a high-pressure assist gas along the beam path through a special nozzle. The company demonstra ted the new laser technology in a system priced at about $50,000, incorporating its Mariner CNC controller, which uses optical pierce- sensing and a fiber-optic system to moni- tor the cutting head and optimize cutting speed. Hypertherm, Hanover, N.H., (603) 643-3441, www.hypertherm.com.

Hybrid welding head. Abicor Binzel showed its Highyag hybrid welding head, which combines laser and GMAW processes in the same device, leading to increased tolerances and speeds in seam welding. The company also showed its GMAW Push Pull welding guns. Abicor Binzel, Frederick, Md., (301) 846-4196, www.abicor.com.

Stud Weld Controller. The Studmatic 400-, 600-, and 800-A solid-state stud weld controllers convert any DC welding mach- ing to a stud welding machine - - Fig. 6. The devices offer a way to perform stud welding with the need for a dedicated stud welding machine. The devices connect to the output terminals of any DC power source that can provide an open-circuit voltage greater than 35 volts and is capable of supplying 100 watts. The machines measure the current and control the du- ration of the pulse to properly weld the stud. The compact machines include solid- state semiconductors to eliminate the use of mechanical contactors, which have a

Fig. 6 - - The compact Studmatic J?om Arcon Welding converts any DC welding machine to a stud welding machine.

more limited life span and higher maintenance requirements. The machines list for approximately $2000. According to the company, shipyards are among the firms expressing interest in the compact machines because of applications in which they need to join a few studs as well as perform shielded metal arc or other welding processes. Arcon Welding, Salisbury, Md., (410) 572-6000, www.arconweld.com.

Radial Bristle Discs. Intended as a replacement for wire wheels, Scotch-Brite radial bristle discs and brushes are made of a tough polymer embedded with the company's Cubitron TM abrasive grains - - Fig. 7. They can be used to clean metal prior to welding or for weld finishing. The discs and brushes come in a wide variety of sizes from ~, in. in diameter up to 8 in.,

Fig. 7 - - 3M's Scotch-Brite discs are intended as a replacement for wire wheels.

Engineer Reports on World Trade

Center Recovery Operations

The leader of the 300-member engineering team directing search and demolit ion efforts at the World Trade Center complex spoke to a large group of show attendees. Manny Velivakis, president of LZA Technology, was en- listed by New York authorit ies in the days after 9/11 to provide engineering assessments of search-and-rescue activities, the stability of 31 adjacent buildings, and plans for the demolition of acres of ruins. Velivakis directed the construction of the ramp to "the pit," which was welded from structural steel salvaged from toppled buildings. His efforts helped prevent any major in- juries among recovery workers, who removed 120,000 truckloads of debris, even as the site continued to burn for six weeks.

and can be used in industries ranging from jewelrymaking to automotive repair to metal fabrication. The discs are ~A2 in. wide and can be used alone or paired with several others for use on whatever width area the applicat ion requires. The discs and brushes are solvent free and contain no wire filaments that can be thrown off during operat ion. The products are flexible enough to penet ra te irregular surfaces, offering a consistent finish even on complex parts. 3M Abrasive Systems Division, St. Paul Minn., (866) 279-1235, www.3m.com/abrasives.

Antispatter System. This product works well for any application in which spatter is a problem. Spatter Shield is a patented liquid and in-line dispensing system that helps to significantly reduce spatter adhesion and buildup during gas metal arc welding. The system includes a special probe and reusable canister containing the Spat ter Shield fluid. The system is mounted along the shielding gas line between the solenoid and the gas nozzle. When in operation, the shielding gas and pressure turn the fluid into a fine mist that is transported to the weld nozzle where it inhibits spatter adhesion during welding. It can be used with automatic and semiautomatic gas metal arc welding. The probe is available in four different formats so that the system can be tailored to specific welding applications. It helps extend the life of the nozzle and contact tip and saves time and money with regard to weld cleaning and finishing. It works with all metals except aluminum and with all weld-

l WELDING JOURNAL i¢]r4H

There is , o s,l~stitttte fi~r e.~pcriencing the Show moves to Dallas.

ing wire types and gas mixtures. The initial cost is $239 for the probe and $79 for the canister plus the cost for the liquid, which is available in three bulk sizes. Spat- ter Shield o f North America, Markham, Ont., Canada, (905) 948-8119, www.spat- tershieldna, com.

Large Autodarkening Filter. ArcOne's new Xtreme autodarkening welding filter features 12.6 square inches of viewing area

Fig. 8 - - Arc'One is Xoeme aatothtrkening welding .filter features a 12.6-in. 2 viewing area.

- - Fig. 8. It is believed to be the largest autodarkening filter on the market today. In comparison, the company's next largest autodarkening filter features 7.3 square inches of viewing area. The filter comes

I~t : !1 JUNE 2004 ] I

A WS Welding Show in petwon. Ne~7 spring the

in two versions: a fixed shade 10.5 and a variable shade 9-12. Both types also offer a grinding mode that keeps the filter from flickering during grinding. The filter features four independent sensors located in all four quadrants of the filter. The solar- powered filter also offers a lithium battery backup power supply. The water- and

One qf the contestants i , the fi,:s't-ever A WS Professional Welder Competition works on his weld.

dust-resistant filter is available in two helmet styles, the narrow design Vision@ and the Eagle®, which offers full head, neck, and ear coverage. In the standard black helmet, the fixed shade filter lists for $249.99 and the variable shade filter lists for $299.99.ArcOne, Taunton, Mass., (800) 223-4685, www.arclweldsafe.com.

• Al l -Dig i ta l CV G M A W Power Source . Panasonic has made the move to all-digital circuitry with its new GBII 350-A constant voltage GMAW power source - - Fig. 9. The circuitry incorporates a 32-bit RISC processor, which operates at a speed about 3000% faster than the 16-bit processors of previous models. The machine incorporates two different databases to optimize arc characterist ics for semiautomatic and fully automatic welding. Unlike a robot, welders cannot maintain a perfectly uniform contact t ip-to- work distance or uniform travel speed; the manual database adjusts for such differ- ences. Other features include newly designed encoder feedback circuits to control wire feed speed and a new arc starting system that prevents wire meltback. The system lists for about $6000. Pana- sonic Factory Automation, Elgin, II1., (888)726-9353. www.panasonic.com.

Fig. 9 - - The GBII 350 incorporates two databases for separate control of arc characteristics depending on whether the machine is being used for semiautomatic or fully automatic welding.

Look Ahead to N e x t Y e a r

The AWS Welding Show will head south to the Dallas Convention Center next year. Mark April 26-28, 2005, on your calendar as the dates when you'll get the opportunity to learn about all of the new developments in welding.

Laser-Hybrid Welding of Ships Following tests at a German facility, a European group is conducting shipyard trials

BY STAUFER HERBERT

. . . . aser beam welding shows great potential in the welding l ~ of structural steels, due to its high welding speed, low dis-

tortion, and easy automation. Using hybrid gas metal _ arc/laser welding, an increased ability to bridge a root

opening, as well as a significant increase in speed when welding a wide root opening, may have advantages. Both laser beam welding and arc welding have long been used for industrial production, and permit a wide spectrum of uses in the field of materials joining technology.

Each of these processes has its specific areas of application, as determined by the physical processes of the energy transport to the workpiece and by the energy flows that can be obtained. The energy is transmitted from the laser beam source to the material for processing by means of high-energy infrared coherent radiation, using a fiber-optic cable or mirrors. The arc transmits the heat needed for welding by means of a high electric current flowing to the workpiece via an arc column. The laser radiation leads to a very narrow heat-affected zone with a large ratio of welding depth to joint width (deep-weld effect). The gap bridging ability of the laser welding process is very low, due to its small focus diameter, but on the other hand, it can reach very high welding speeds. The arc welding process has a much lower en-

ergy density, but causes a bigger focal spot on the surface of the workpiece and is characterized by a slower speed of processing.

By merging both these processes, useful synergies can be achieved. Ultimately, this makes it possible to achieve both quality advantages and production engineering benefits, as well as improved cost efficiency. The merged process offers interesting and economically attractive applications in the shipbuilding industry, not least because higher tolerances are permitted on the weldments, higher joining rates are possible, and very good mechanical/technological values can be achieved.

DR. STAUFER HERBERTis with Fronius International GmbH, Wels, Austria. Fig. 1 - - Schematic representation of laser/GMA welding.

WELDING JOURNAL m¢t~m

LASER t / G r e a t welding depth v' High welding speed v' Low thermal load v' High tensile strength

AR( v' Low-cost em v ~ Joint-bridgin v s Addition of fi v' Microstructu

influenced

LASER HYBRID V' Higher process stabilty v p Higher welding speed t / G o o d flowing of weld edges v' Large joint volume v' Good metalurgical properties

Fig. 2 - - Synergies of coupling the two processes.

It has been known how to combine laser light and the arc into an amalga- mated welding process since the 1970s; but for a long time thereafter, no further development work was undertaken. Re- cently, researchers have turned their at- tent ion to this topic and a t tempted to unite the advantages of the arc with those of the laser in a hybrid weld process. Whereas in the early days, laser sources still had to prove their suitability for industrial use, nowadays they are standard equipment in many manufacturing enterprises.

The combination of laser beam welding with another weld process is referred to as a "hybrid" welding process. This means that a laser beam and an arc act simultaneously in one welding zone, and influence and support one another.

An objective of the studies was to learn how far the process characteristics could lead to enhanced welding possibilities. One typical field for applying the CO 2- laser/gas metal arc welding (GMAW) hybrid process is shipbuilding. The possibilities in this field are demonstrated and discussed in this article.

C o n s i d e r a t i o n s of the Laser B e a m We ld ing Process

Laser beam welding requires not only high laser power but also a high-quality

beam in order to obtain the desired "deep- weld effect." The resulting beam can be exploited either to obtain a smaller focus d iameter or a larger focal distance. The energy per unit length E s is on a very low level, and so the distortion and the effort for leveling are remarkably reduced. As in advanced automated arc welding, offiine programming, joint tracking, and adaptive welding control are necessary when welding large workpieces with a laser.

A maximum root opening of approximately 0.1 to 0.2 mm may be accepted without welding wire addition, whereas a wider clearance requires some added material. Therefore, welding wire addition is generally used in shipbuilding for improv- ing the joint-bridging ability up to 0.4 mm. For an industrial application, a 12-kW CO 2 laser is used. The laser light is transmitted to the workpiece via mirrors. The laser beam is projected onto the workpiece by a focusing module with a focal distance of 300 mm. Also, a lamped- pumped YAG laser with 4 kW on the workpiece and a 7-kW fiber laser were used for this investigation.

Laser -Hybr id Process

For welding metallic workpieces, the laser beam is focused at intensities of above 10 ~ W/cm 2. When the laser beam

Process: Submerged arc Laser hybrid Laser + filler Speed: 100% 300% 150% Thickness: < 12 mm < 15 mm < 15 mm Joint clearance: 2 -5 mm 0-1 mm 0-0,4 mm Distortion: < 1.5 mm/m < 0.2 mm/m < 0.1 mm/m Metallurgy: Not critical Not critical Critical Fatigue: Good Excellent Critical

Fig. 3 - - Comparison of laser-hybrid welding to alternative processes (Ref 1).

hits the surface of the material , it heats the spot to vaporization temperature, and a vapor cavity is formed in the weld metal due to the escaping metal vapor. The dis- tinguishing feature of the root opening is its high depth-to-width ratio. The energy- flow density of the freely burning arc is slightly above 10' W/cm 2. Figure 1 illustrates the basic principle, especially the metal transfer of hybrid welding. The laser beam depicted here feeds heat to the weld metal in the top part of the joint, in addition to the heat from the arc. Unlike a se- quential configuration, where two separate weld processes act in succession, hybrid welding may be viewed as a combination of both weld processes acting simultaneously in the same process zone. Depending on which arc or laser process is used, and on the process parameters , the processes will influence one another to a different extent and in different ways.

Thanks to the combination of the laser process and the are process, there is also an increase in both the weld penetrat ion depth and the welding speed (as compared to ei ther of the processes used on its own). The metal vapor escaping from the vapor cavity retroacts upon the arc plasma. Absorption of the laser radiation in the processing plasma remains negligible. Depending on what ratio of the two power inputs is chosen, the character of the overall process may be determined to a greater or smaller degree by either the laser or the arc.

Absorpt ion of the laser radiat ion is substantially influenced by the temperature of the workpiece surface. After the vaporizat ion temperature has been reached, the vapor cavity is formed, with the result that nearly all the radiation energy can be input into the workpiece. The energy required for this is thus determined by the temperature-dependent absorption and by the amount of energy lost by con- duction into the rest of the workpiece. In laser /GMA welding, vaporization takes place not only from the surface of the workpiece but also from the welding wire, meaning that there is more metal vapor available, which in turn facilitates the input of the laser radiation. This also prevents process dropout.

One precondit ion for implementing hybrid welding in the shipbuilding industry is a sufficient gap bridging ability. That is the reason the investigation was aimed at a maximum gap bridging ability. A variable root opening leads to the necessity for adjusting several process parameters. Higher tolerances concerning the root opening of the groove require an adjustment of the laser power. Furthermore, the welding speed or the wire speed has to be adjusted to the actual groove volume, which varies with the included angle and the root opening.

Imloll JUNE 2004 I

Experimental Investigation and Comparison of Laser Hybrid Welding to Other Processes

Investigation with a CO 2 Laser

The high quantum efficiency of a CO 2 laser (which enables efficiency factors up to 20%), relatively simple technical possibilities of implementation, and scalabil- ity are the reasons that it is the most im- por tant laser in industrial material machining. Carbon dioxide lasers are characterized by high power output and are offered commercially in capacities up to 50 kW.

With a CO 2 laser (12 kW) from Trumpf Laser Technology and Fronius TPS 5000 digital power source equipment, the following results are given from Meyer Werft - - Fig. 3. The working area on this laboratory setup is 4.5 x 13 m. Within the uti- lized clamping device, it was possible to weld samples with the geometry of 2000 x 300 mm. The material used was the shipbuilding steel Grade A, with the usual pr imer (Lindokote Shopprimer) . The welding tests were carried out with a butt joint and fillet joint preparation, in the 1G and 2F positions and without backing support.

First, welds in butt joints with a material thickness of 15 mm were investigated. Submerged arc, laser hybrid, and laser with welding wire processes were compared to each other. The submerged arc welding process allows a gap bridging ability from 2 to 5 mm up to a thickness of 12 mm. With the laser hybrid process, it is possible to reach a gap bridging ability of up to 1 mm in a material thickness of up to 15 mm, but the welding speed is three times faster than submerged arc welding and two times faster than laser with welding wire. With the laser plus welding wire process, it is possible to reach a gap bridging ability of up to 0.4 mm and a material thickness of up to 15 mm.

Four different material thicknesses of 5, 8, 12, and 15 mm were investigated to evaluate the maximum welding speed at maximum root opening. The influence of the shielding gases helium and argon on the laser/arc welding process was studied. Predominantly He-fract ion in shielding gas is necessary for welding with high- power CO 2 lasers.

In shipbuilding, the laser /GMAW hybrid process is applied using gantries in the Meyer Shipyard in Papenburg, Ger- many. Here, in prefabrication, decks are manufactured fully automatically by means of technology developed by the shipyard. Because of the quality of this welding method, it is possible to manufacture 20 x 20 m sections without turning over the panel. There are two butt joint welding stations installed in the prefabri-

cation area. A plate thickness of up to 15 mm can be welded by a welding speed of up to 3.0 m/min. Further on, two fillet welding stations are installed. Stiffeners up to a length of 20 m and a thickness of up to 12 mm for decks and walls a r e welded.

Before welding, the joints were prepared with a milling machine to reach a high accuracy of the parts.

Fig. 4 - - Welding system and macrosection of a fillet weld at Meyer Werft (Ref 1).

Investigation with the Fiber Laser

Significant numbers of high-power fiber lasers up to 10 kW are now being installed in the materials processing market by IPG Photonics, which has its headquarters and factory in Oxford, Mass., and two other manufacturing plants in Eu- rope.

The heart of the company's technology is propr ie tary active fibers and a patented pumping technique that allows the utilization of broad area mult imode diodes rather than diode bars. This leads to a very high diode lifetime of operation. A device may be made from coils of ytterbium-doped multiclad fiber with an emis- sion wavelength of 1.07 to 1.08 microns. Alternately, it may be thulium-doped with a wavelength of 1.8 to 2.0 microns or erbium-doped with a wavelength of 1.54 to 1.56 microns The diode pump energy is delivered to the active medium via multimode fibers that are spliced to the multiclad coil. The laser cavity is created directly in the active fiber. The laser emis- sion exits the fiber laser through a passive single-mode fiber, typically with a core diameter of 6 microns. The resulting laser beam is essentially diffraction limited and, when outfi t ted with an integral collima- tor, produces a beam that is extremely parallel. For example, the 100-W single- mode fiber laser has a full angle diver- gence of 0.13 milliradians at half angle when collimated to 5 mm diameter.

The maximum power from an industrial single-mode IPG fiber laser module is currently 200 W. Higher powers are produced using multiple modules. The emis- sions from lasers are collected using a proprietary beam combiner, resulting in a single high-quality beam. For example, a 1- kW unit would be made up of 10 individual fiber lasers integrated into a common cabinet. Although the beam is no longer single-mode, the resulting M 2 of 7-10 is better than high-power solid-state lasers. The beam from a 7-kW fiber laser can be delivered via a 300-micron fiber. Differ-

ent output beam profiles, including a near rectangular shape, can be produced.

The ytterbium fiber laser has a wall- plug efficiency of 16 to 20%. Erbium and thulium fiber lasers demonstra te lower wall-plug efficiency but are still more efficient than typical YAG lasers. There are certain applications where these wave- lengths are the best choice. The unit is being developed because of industry demand for a laser with the performance of Nd:YAG and eye safety better than CO 2.

The company's single-mode CW systems can be modulated to 50,000 Hz with pulse durat ions as short as 10 microsec- onds. Three superpulsed versions with pulse durations as short as 1 nanosecond or pulse energies up to 1 millijoule in a 100-ns pulse and multimode CW versions from 300 W to 10 kW are now available.

F i b e r laser technology offers several benefits to the industrial user. The footprint of a 4-kW fiber laser unit is 0.5 m 2 vs. 11 m 2 for a conventional lamp-pumped Nd:YAG, and there is no requirement for a chiller. They are essentially maintenance-free during their entire lifetime because there is no need to replace flash lamps or diodes. The high electrical efficiency greatly reduces operat ing costs. Better beam quality allows the user to produce spot diameters substantially smaller than conventional lasers, producing high fluence and/or longer working distances (1 kW can be focused to 50 microns with a 4-in. lens). The cost for fiber laser technology, up to 1 kW output power, is below or comparable to lamp-pumped YAG lasers. At this time, the acquisition cost of a fiber laser greater than 1 kW is higher. However, when all factors - - floor space, chillers, maintenance, and so o n - - are ac- counted for, these lasers should be more cost-effective than equivalent power rod- type Nd:YAG lasers. During the last six months, several mult i-kW fiber lasers have been in beta environments in Euro- pean factories. These lasers have operated flawlessly on a multiple-shift basis, demonstrat ing their reliabili ty and pro-

WELDING JOURNAL ~ l i m

Fig. 5 - - Schematic representation of a tractor for long linear butt joint welds.

viding performance data only possible with much larger lasers. A 2-kW beta unit has been lap welding 1.2-mm-thick, zinc- coated automotive steel at 5 m/min. The quality and performance is comparable to a 4-kW lamp-pumped rod-type Nd:YAG laser. A 2-kW fiber laser with a 300- micron final fiber d iameter cuts 4-mm- thick coated steel at a rate of 10 m/min, with clean sharp edges. The maximum cutting speed attained is 16 m/min. (Ref. 5).

Investigations of coupling a 7-kW fiber laser with an arc process shows that it is possible to weld unalloyed and high- alloyed steels with a thickness up to 8 mm at the laser hybrid laboratory at the R&D department at Fronius-Wels.

Investigation with a Lamp-Pumped Solid- State Laser with 4 kW on the Workpiece

Due to the available Nd:YAG laser outputs of more than 4 kW and the simple operation of such systems, the technical facilities for the application were investigated. In all applications and investigations looked into, CO 2 and/or neodymium-added yt tr ium-aluminum- garnet (Nd:YAG) lasers have been used. Unfavorable are the plasma shielding, due to the wavelength of 10.6 p.m, and the elaborate beam guidance via an inelastic system of mirrors, which makes a mobile applicat ion with a CO 2 laser practically impossible.

Robotic or mobile concepts are enabled mostly by use of Nd:YAG lasers. In the last decade, this type of solid-state laser gained dramatically in industrial importance. Due to its wavelength of 1.06 ktm, the laser beam can be led by means of a flexible optical fiber even across large distances of more than 70 m, which allows three-dimensional welding jobs using robots. The effect of plasma shielding does not exist, so that for the gas-shielded welding process, the optimal gases can be used for arc stability, drop separation, spatter- free material junction, and protective effect. By means of laser system manage-

ment, several processing stations can access one laser source. Thus, power-on time and also costs themselves can be optimized.

High-power sources of Nd:YAG lasers have been established on the market for only a short time, so that the price is relatively high ($/kW) compared with CO 2 laser sources. In comparison, power output is lower, with capacity ranges up to 6 kW. In Japan, trials with a 10-kW class laser have been executed. One cannot overlook the danger of reflected irradia- tion, which even at some meters' distance endangers the unprotected eye.

The European "DockLaser" project aims to increase productivity, flexibility, quality, and working conditions by developing laser processing techniques and equipment for the final assembly area in shipbuilding and repair. These areas are characterized by low-productivity welding techniques with a high heat input, which leads to weld distortions and destruction of already applied painted and outfit ted components. The project defines cases, requirements, and goals for laser processing in a dock area, to develop welding/cutting processes and equipment. Work safety and approval are the focus of one work package. Close-to-reali ty tests and prototype production at the end user sites will help to est imate the benefits and to achieve applicability under practical conditions.

The three main application areas are

• welding of long linear fillet welds with a tractor system

• tack welding with a mechanical system

• manually guided welding/cutting for outfitting.

The DockLaser will commence with a Requirements Definition Phase, containing a detailed survey of shipyard requirements and existing technical solutions, as well as approval and work safety aspects. In the subsequent Development Phase, solutions for the three application areas will be created. Work Package 2 will focus on process development under laboratory conditions, Work Package 3 will develop the components of the equipment following the concepts described before, Work Package 4 will integrate and test the equipment in the laboratories, and Work Package 5 will put emphasis on approval and work safety. The final Evaluation Phase will shift the stage of actions to end user sites, where the equipment will be tested and evaluated under practical conditions. Each end user is primari ly in charge of one applicat ion area. Work Package 7 will focus on dissemination with an industrial user group as the main tool.

Work Package 8 covers the technical and administrative management of this chal- lenging project.

The work will be performed by a highly skilled consortium comprised of 12 part- ners from five European Union countries, one associated country, and one candidate state. The consortium includes five SMEs and is highly complementary, involving three end users, four welding in- stitutes, one major classification society, and four equipment manufacturers. The group provides complementary and con- siderable experience in laser processing techniques. Practical feedback and dissemination are provided by an industrial user group. Project management is performed on the basis of long-term experience in international R&D.

A large disadvantage of a gantry system is its directional dependence and high

Fig. 6 - - Fillet joint, welded from both sides. Thickness: 8 mm; Nd:YA G laser; power: 4.2 k14~ welding speed: 2 m/min (Ref. 4).

weight. A given approximate arrangement must be kept with respect to the joint direction. A welding system with a six-axes robot is limited to a maximum welding length of 2 m.

The final solution for all these problems is the development of a mobile tractor, carrying the laser hybrid welding head. Changes of or ientat ion can occur manually. The area of operations needed is very small, compared to a gantry system. As a result of the reduced move- ments of the optics, the optical f iber of the laser beam is protected from mechanical strain. Adjustments for the process are only necessary at the welding power source, because the characteristics of gas- shielded arc welding are not optimal for the hybrid process. It is possible to very precisely adjust the joint tracking system, the laser beam, and the torch. By using a special laser optic, a fillet joint can also be welded with a modified tractor. To protect the optical fiber against reflections from the processing zone, the axes of the laser beam can be bent up to a couple of degrees, pushing in the direction of welding. The welding result was thereby nearly uninfluenced.

ml,,.i JUNE 2004 [

Conclusion

Laser /GMA welding is a wholly new technology that offers synergies for wide fields of application in shipbuilding, especially where it is not possible or financially viable to achieve the component tolerances that are required for laser beam welding. The much wider range of application and the high capability of the combined process can lead to enhanced com- petitiveness in terms of reduced invest- ment outlays, shorter fabrication times, lower manufacturing costs, and higher productivity. The big advantage of laser hybrid welding is the lower distortion and reduced rework after welding.

The present investigation shows the applicability of high power CO2, YAG, or fiber laser /GMAW laser hybrid process for welding different plate thicknesses. The advantages of hybrid welding - - the good gap bridging ability and the low energy per unit length - - are discussed.

Compared to welding with the laser

with welding wire process, the laser hybrid process increases the welding speed up to two times. The maximum gap bridging ability with the laser hybrid welding process is up to 1 mm, with a material thickness up to 15 mm. •

References

1. Roland, E, and Lembeck, H. 2001. Laser Beam Welding in Shipbuilding-- Experience and Perspectives at Meyer Shipyard. 7th International Aachen Welding Conference.

2. Roland, E 1996. Trends, Problems and Ex- periences with Laser Welding in Shipbuilding. Proceedings IIW Shipbuilding Seminar, Odensee, Denmark.

3. Kristensen, K. 2001. Laser Welding in Shipbuilding--A Challenge to Research and De- velopment for More than a Decade. 7th Interna- tional Aachen Welding Conference.

4. DockLaser: Entwicklung mobiler Laser- schweiflgerdte. Erstes Treffen der Nutzergruppe des EU-Projektes DockLaser. Presseerklarung, Hamburg, 27.11.2003.

5. Shiner, Bill. 2003. High-power fiber lasers impact material processing. Industrial Laser So- lutions. Feb.

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Ava i l ab l e at ymJr I~cal we ld ing supp ly s tore

Circle No. 55 on Reader Info-Oard

WELDING JOURNAL E k I

//

m The better the welder, the better the toy. With the fastest swi tching speed in the wor ld, Jackson EQC Auto-Darkening f i l ters and helmets take the tedium out of your trade - and raise your welds to a whole new level. You are no longer at the mercy of a passive hood. Our fami ly of electronic lenses let you see everything clearly before, dur ing and after the arc, g iv ing you complete control of the process. Because there is less strain on your eyes - and no need to f l ip your hood up and down - the qual i ty of your work stays consistent f rom first weld to last.

Whether it's stick, mig or tig, a Jackson EQC lens lets the serious welder work in almost any application. And Jackson EQC Auto-Darkening fi lters are the only ones made right here in the USA. Speed, accuracy and control. Get it all under one hood. Now, that's a helluva toy.

Call 1-800-253-7281 or go onl ine at www. jacksonproducts .com to f ind a d is t r ibutor near you.

F a s t . S m a r t . M a d e i n A m e r i c a .

Jackson Products, Inc. 801 Corporate Centre Drive, Suite 300 St. Charles, MO 63304

, m c m o ~ u M ~ m M L m t l W ~


/

BY MARY RUTH JOHNSEN

Job shop owners

relate experiences

that just might help

you run your

company more

successfully

Sometimes, when it comes to running a job shop, the welding is the easy part. Especially when compared to the myriad other things it takes to run a business - - finding clients, hiring and training employees, making sure there's enough work to keep those workers busy but not so much work they're overwhelmed, collecting fees, just to name a few.

On the premise that it's usually best to talk with someone who's "been there, done that," the Welding Journal asked three job shop owners and the manufac-

turing director at a medium-sized fabrication facility to share their experiences regarding what it takes to operate a successful job shop.

All Metals Welding Andre M. Lopez started All Metals

Welding, San Francisco, Calif., in Apri l 1989. Although the company does some new fabrication, it specializes in repair welding. Lopez employs one other welder

and operates two mobile welding rigs plus a shop. The majority of the work is done in the field - - Figs. 1-3.

Lopez got interested in setting up his business while working in a refinery and watching the mobile welding units that came in to service it. In the beginning, he figured he'd specialize in pipe work. While he still works on a lot of pipe, the company is called upon to repair a wide range of items. About 80% of the work is on low- carbon steel, about 15% on aluminum, and 5% on stainless steel.

MARY RUTH JOHNSEN (mjohnsen@ aws.org) is Senior Editor of the Welding Journal.

WELDING JOURNAL m l . l l

Fig. 3 - - A - - A truck needing a repair weld; B - - the completed repair weld.

Fig. 4 - - The Hirschfeld Welding shop and mobile unit.

Fig. 5 - - Hirschfeld prefers working in the shop because it contains all the tools and equipment he needs for a job.

Fig. 6 - - Hirschfeld said his work has benefit ted f rom the purchase o f this Weldsale platen because it helps keep everything true.

The toughest parts of operat ing the company are "repairing something where I have no idea what (the material) is" on the welding side and "paperwork" on the business side. "Gett ing people to pay. I don ' t do big jobs, so I 'm collecting from four or five people in a day."

Lopez said the most fun he's had since opening the business was between 1998 and 2000. "We had a building boom in San Francisco," he recalled. "No one had seen anything like that since the Gold Rush days. There were no welders around. I did everything C.O.D. I can' t wait for those good times again."

For Lopez, the most gratifying aspects of owning his company are having control over his schedule so that he can spend more time with his wife and two children, and possessing a skill that not many people have.

' ~ lot of guys say they hate their job but I still get a kick out of making a perfect weld," he said. "I like being able to do something that not too many people can do. There are not a lot of welders out there. If you look in the phone book there may be 50 pages of plumbers and half a page of welders. It makes you feel special."

Lopez's suggestions for someone con-

sidering opening a job shop include the following: * You have to be able to weld very well.

He recommends spending time in a couple of trades before opening your own shop so you can get the necessary experience.

Spend some money on advertising. Lopez found his business increased once he began running an ad in the telephone directory. Advertising might not be as important for someone in a small town, he said, but in a large city such as San Francisco you need something to draw attention to your company.

Be sure to use all the modern business technology, such as cell phones, fax machines, answering machines, and e-mail. "People need to be able to reach you." Cell phones have been especially helpful, he said, because if he's away from the shop, clients can choose whether to leave a message or speak to him directly over his cell phone. Lopez recently began using e-mail. "I hate computers like we all used to hate answering machines," he said, "but it 's something I have to do now. People

want to send me photos of jobs, etc. It 's how people communicate now."

Buy new equipment, if possible. "I started out getting everything used," he recalled. "That was a bad decision. You can't break down in the middle of a job. It may be hard to buy new because you don't have a lot of money in the beginning, but it's better in the long run." Along with that, Lopez recommends buying well-known brands that are easier to find parts for and to have repaired. "Don ' t buy the great new thing that's kind of weird," he said. "If something wears out, how will you get it repaired?"

Show up when you say you will. "Peo- ple like it when you show up and get very irr i tated if they're kept waiting," Lopez said. The same goes for completing a job on time.

Hirschfeld Welding Owner/opera tor Jud H. Hirschfeld

started Hirschfeld Welding in Pagedale, Mo., a St. Louis suburb, in 1983. A side- line at first, he turned to it full time in

mI.~m JUNE 2004 I

1985, after quitting his job at Anheuser-Busch, a step he describes as the "best move I ever made." He operates a 3000-sq-ft shop plus a mobile unit - - Fig. 4. "I consider this a job shop, meaning many different projects roll through here each month, ' he said. "A lot of repair, modifications, short- run fabrications. I do not specialize. If I can handle your job. I will quote it. If not, I will tell you right up front and we can part friends."

Hirschfeld splits his til between the shop and the bunch of accounts that c . . . . . . . . . . . . . . come out to their site," he said, "and I enjoy servicing those, but I 'm not going to drive to your house and weld your mail- box anymore." These days he prefers working in the shop because then he has everything at hand he needs to do a job - - Fig. 5.

Although he's employed several workers in the past and felt he had good workers, nowadays "I work for myself, by myself." He prefers it that way because he was never comfortable being responsible fo someone else's paycheck.

Even though he's been in business more than 20 years, Hirschfeld said, "I 'm not a business person by any stretch. I like steel work, always have, always will, but I 'm not a great businessman." Despite his self-dep- recating statements, Hirschfeld offers the following advice to those considering opening a similar type of business. • "First, don't get involved in any type of

venture if you do not truly love the work.

• "Second, always do the slickest job you can. Your tenth grade metal shop teacher wasn't telling you to file off all the sharps because he didn ' t want to get cut. He had you do that so you would learn to pay attention to detail. Underpromise, overdeliver.

• "Third, never get greedy, it isn't worth it. I have picked up some nice accounts simply because somebody decided to cut a corner for an extra dollar.

• "Fourth, always pay attention to the little red flag (in your mind). It is almost always right, and if a job looks like trouble, run the guy off."

Hirschfeld warns newcomers that they'll end up spending much more time than they may want to on the business side

Fig. 8 - - Rows of completed dome supports. Temcor huilds geode.~ic domes und other clean span structures.

of the operat ion. For instance, just like Lopez, dealing with poor paying customers occupies quite a bit of Hirschfeld's time. Getting people to pay is one of the toughest parts of running this type of business, he said. In addition, if you want to start a job shop because you think working for yourself means you can do whatever you want, Hirschfeld said, forget it. "People think being the boss is a great thing. They think they'll never have to answer to anyone, but in reality you switch from having one boss to where everyone is your boss."

With regard to equipment, Hirschfeld said the item he feels has paid for itself several times over is a welding platen - - Fig. 6. "The platen is the greatest money I ever spent. Buy a big one and purchase tooling as you need it. The platen is just a great tool. It allows very accurate, clean, professional-looking work, done quickly and efficiently. I can' t think of anything that I 've gotten more use out of. I could kick myself for hemming and hawing around before buying it."

Leitner Fabrikation Corp. Although Lei tner Fabrikat ion Corp.

does a small amount of field erection, all welding is done in its l l ,000-sq-f t shop (Fig. 7), said Hans Leitner, company president. Leitner started his job shop in Buf- falo, N.Y., in 2000. Employment peaked at seven workers, now there are three employees.

"We are a small job shop that will tackle any job that fits into our facility," Lei tner said. "We have made bridge expansion joints to eight tons, automotive testing equipment per government specs,

to welding items down to 0.006 in. thick." The most gratifying aspect of the busi-

ness? "Seeing our customers ' satisfaction," Lei tner said. "Taking a concept from a drawing or sketch to reality is a great feeling. Using our God-given talent is really the best part of it all."

The most difficult aspect? Lei tner echoes Hirschfeld's and Lopez 's senti- ments, "Finding customers willing to pay according to stated terms. Being a small company requires getting paid on time."

Lei tner 's advice on solving the problem is "you just keep hounding them." And, while acknowledging it's easier said than done, "Find customers who will pay in 30 days and hold them to it. If they won't, don't do any more work for them."

Following are Leitner's other tips: • Diversify. "Specialize in one area,

but don ' t discount other avenues within the framework of your talents." Lei tner learned the value of diversification the hard way. He went into business for himself because the company he had been working for closed. His first and primary customer was one he took over from his former company. The customer mostly needed him to work on bridge expansion joints, but that work dried up following the terrorist attacks on September 11, 2001, because the states and federal government were pouring money into security rather than roadwork. "I haven't done a bridge expansion joint for anyone for about one and a half years," Leitner said. If he were to start again, he would not wait to diversify.

• "Within your means, modernize your equipment and operations for more accurate and quality-driven production.

I WELDING JOURNAL l ~ m

CREATING THE PERFECT WELD ENVIRONMENT

PURGING UNITS

PIPE ALIGN CLAMPS

TIG GRINDERS

OXYGEN INDICATORS (PPM)

DISSOLVING PURGE PAPER

Tel:(800) 665-6655 Fax:(604) 946-5340 E-mail: [email protected]

www.intercononline.com

Look for equipment that can do more than one thing." Instead of buying three different machines that can each do one job, look for one machine that can do all three things, Lei tner advises.

• Spend some time researching your options before incurring large business ex- penses. For instance, workers' compensation insurance is a necessary, but costly, expense, and most insurance companies require their fees paid up front. Leitner found he could avoid a large outlay of cash and still get the coverage he needed going through a payroll company and paying weekly.

Fig. 9 - - Jeff Caughron working on some dome supports. Tem- cor's welding operations are mostly GMA W and G TA W of aluminum components, with some GMA W of steel and stainless steel

Temcor Leland A. Sanders is the director of

manufacturing at Temcor, a leading manufacturer of clean span (meaning no truss- ing in the roofing systems) architectural and environmental enclosures made primarily of aluminum - - Fig. 8. The company began designing, manufacturing, and erecting geodesic domes and other clean span roofing systems in 1964 in Torrance, Calif., then relocated to Carson, Calif., in the 1980s. In 2001, the manufacturing department relocated to Rincon, Ga., about a half hour north of Savannah, and the corporate office moved to Gardena, Calif. It employs approximately 115 people.

Temcor's manufacturing operations include computer numerically control led machinery for routing sheet metal components and milling gusset plates and structural extrusions; and programmable logic computer-controlled machinery for punching and shearing structural extrusions and abrasive cutting aluminum, steel, and stainless steel plates. It also operates one of the largest brake presses in the Southeast at 30 feet long and 400-ton capacity. Gas metal arc and gas tungsten arc welding of aluminum structural and nonstructural components with some GMAW of steel and stainless steel components make up most of the company's welding operations - - Fig. 9.

"The most difficult issues facing Tem- cor manufacturing are hiring and retain- ing a qualified workforce," Sanders said. "The workforce in the Georgia Depart - ment of Labor Savannah Metropol i tan

Service Area has been determined to be so underdeveloped that had Daimler- Chrysler decided to open a Mercedes Sprinter Van assembly plant in Pooler, Ga., the state Economic Development au- thorities would have had to import most of the proposed 3300 jobs to staff the plant."

To ensure the company has the man- power it needs, Sanders and other personnel are active in all aspects of workforce development. He works closely with the U.S. Depar tment of Labor, the area boards of education, and the area secondary schools and postsecondary technical schools. The company employs a number of high school students under the Geor- gia Youth Apprenticeship program, a program recognized and certified by the U.S. Department of Labor.

No mat ter what size your business, Sanders advises you become involved in your community. "Be involved in the educational facilities in your area," he said. "Be involved in the educat ional entit ies of the community you set up in. Grow your own employees out of those institutions."

His other advice: "If I were planning to start up a business of my own or if I were to relocate the manufacturing facility again, I would first ensure that a developed workforce existed that supported my needs. I would also ramp up the workload slowly in a startup company to allow the employees to become familiar with the product and processes to make the product. If I were relocating a facility, I would ramp down the sales effort to reduce the workload at the new facility to a level that would allow me to achieve the same results in employee understanding."4

i f : i JUNE 2004

PTR-Precision Technologies, Inc.

120 Post Road Enfield, CT 06082-5625 Precision

Technologies

State-of-the-Art Products t

State-of-the-Art Process t

Electron Beam Welding Have you looked at Electron Beam Welding lately??

PTR, the world leader in Electron Beam Welding, has for over 40 years maintained the EB welding process at the cutting edge of joining technologies. Many well-recognized intemational companies that are known as the pioneers in pushing the envelope of technology are working with us today to achieve ambitious goals for advancing the state- of-the-art of their products using superior EB welding techniques developed by PTR.

PTR not only offers state-of-the-art production equipment and complete processing lines, but offers the same state-of-the-art capability in its modern EB job shop for contract welding and process development.

PTR can help keep your EB welder fine tuned - just contact our service and spare parts departments for assistance. If you have problems with labor qualifications due to turnover, we provide standard training classes for machine operators, engineering, and maintenance people, or we can tailor a program to your specific needs.

D o n ' t fall beh ind - C o n t a c t us T O D A Y Telephone 860-741-2281 Telefax 860-745-7932

[email protected] www.ptreb.com



"%..

,AW 5 ANNIVERSA,1Ry

I li

1919

1949

/11 ?

L

Y

: : i

I ~ I I i l JUNE 2004

ANDREW CULL1SON ([email protected]) is Publisher~Editor of the Welding Journal.

ings" and advertisements. Below is a journey through the ages.

News of the Society

In the January 1922 issue it was reported, "Mr. C. A. McCune, Chairman of the Membership Committee, who has recently returned from a business trip to the Pacific Coast, reports that the West is keenly interested in the American Weld- ing Society. The welding applications of the West and Pacific Coast differ from those of the East in relation to the industries but naturally the actual performance of the work, the necessity for properly training operators, establishing standard methods of welding procedure, etc., is the same all over the country.. . .Preliminary meetings were held in Denver, Portland, San Francisco, and Los Angeles, and Local Sections of the Society will be organized shortly in each of these cities."

In April 1925, a report from the Meet- ings and Papers Commit tee stated, "A novel feature has been proposed in connection with the fall and annual meetings, namely, to hold exhibits of welding apparatus and welded products. The merits and demeri ts of this feature were discussed, but no immediate action was taken, as it was felt that the decision should rest in the hands of the executive committee."

In the May 1930 Journal, it was noted, "By far the most successful Annual Meet- ing of the American Welding Society came to a close Friday afternoon, Apri l 25. There was a registered attendance of 225 at the technical sessions."

A report on the Journal from that meeting stated, "During the past year, the 12 issues of the Journal totalled 1255 pages as against 1300 the previous year. It will be recalled early in 1929 a reduction in number of pages of technical matter was made to offset a reduction in space taken by one large advertiser."

The war years brought many restrictions to everyday life and the AWS com- plied accordingly. In the July 1945 issue

of the Welding Journal under the heading Twenty Sixth Annual Meeting, it was stated, "Upon recommendat ion of the Convention Committee, the Board of Di- rectors at its meeting on June 28th approved plans for holding a convention-by- mail and confining the necessary business meeting, award of metals, and Director 's meeting to a one-day affair....the meeting will be arranged so as not to require more than fifty out-of-town members."

The 1950 issue has a notice that the Third Edition of the Welding Handbook is available. The list price is $12 in the United States and Canada and $13 else- where.

m ",.% n e w Welded Spoke Lin- welding! c o i n a n d F o r d W i r e Wheels. Elkonite welds Le t our e n g i n e . s s h o w a r c s~ong . H a r d copper you how Elkoni te can be a ~ various alloys fail a t used effectively in y o u r onbe but E ] k o n i t e dies field also---no obligation.

,,,+ E L K O N , lne. i~vlslon of p. R. Msllar./£ Co~ Int~ 3~0 Madlson A ~ , N. Y. C.

A 1929 ad promotes a new filler metal for welding the spokes on Ford and Lincoln wire wheels.

JOllRlqAt. OF T U J A. W. $. [ ~ l b~

CF~CO ARC WELDING HELMET ~ d~a ~k~ Fq.~ or ~ tb* wDrk ~ d x zbo door iua~ted ~r tim

*a,,~to. M work b ~ d o ~ l m l .I.I fm [ r~ ~ ~ampr d faUin I t~ ~b~s~ ~r'* ,y,. with ~ud.

W

Tk4, O"~l~rl+~ff ~ P~tabte i

Alia you AWAIm t~,t ~ k h . , ~ b. . , ,d. ,o ~ ~ mmmnl'elU,~ . o w ~ ~o;"~q , . ¢ . .

Electric Arc Cu~n| & W®l~ni~ Co.

Ads from the twenties include "comfortable" helmets and "the only really portable machine, "carried by two men. This stylish lineup of welding machines has an art deco look.

~"P,,i JUNE 2004

That same issue also suggested that those who plan to at tend the Annual Meeting at the Hotel Sherman in Chicago should book their reservations soon, noting "Eighty-two percent of the rooms in the Hotel Sherman are twin beds. There- fore, we suggest that individuals double up, wherever possible, as they will stand a much better chance of securing satisfac- tory accommodations....if confirmation of your reservation is not received within thirty days after mailing your application, please notify the hotel."

In July 1962, there was a notice that "The American Welding Society has announced the publication of its first book on friction welding. The process was developed in Russia and the AWS publication is a careful translation of the original

Russian text .... it is a profusely illustrated 128 page book."

In the same year 's September issue it was noted that "High voltage electron beam methods have been successfully applied to the fabrication of bi-metal turbine wheels....blades and rim of a nickel- based super alloy were welded to an A286 stainless steel turbine wheel disk....in destructive spin tests the weld burst at 91,600 rpm - - approximately three times the design requirements."

A preview of the upcoming Show in Cleveland appeared in the April 1975 issue. One of the planned evening activities was "Dining at the Racetrack. The club house of Cleveland's Northfield Park will provide the atmosphere for an outstanding dinner with an evening of harness rac-

ing highlighted by the running of the special AWS Trotting Classic." Listed under workshops was the topic "Key Factors Af- fecting the Economy of the Welding In- dustry and Metal Fabrication - - Present day material shortages, high labor costs, and lack of skilled workers should make this one highly popular."Also under that listing was "The Metric System: It's Here to S t a y - - It's all part of the effort to overcome the mighty mass of inertia that stands in the way of 'thinking metric. '"

or o u f o m a t i c weldin~ ~ ' a . n e w

principle

~'E~::K;~. " , 72°:."E~!.~2 ® West Ja a

Long before it became a "standard feature" on machines, automatic feed control was on the market, as this 1930's ad shows.

~ . ~ v a I'-- of ~ w h t ~ b.,i,+ ,-. -~gi.--,,-d ~,-,.,,dEE.

I c . A . P i o . 21v .T co. I I ~ 11400 H A R V A R D AVE. • CLEVELAND, O H I O I

EAST CHICAGO, IND.

The Champion Rivet Co. saw the "handwriting on the wall" and made the switch to welding electrodes. They just don't make advertisements like this anymore.

M I L B U R N

Irydrolen, city and other + Ranle from the mnallut jeweler's to~h to torchel capable of the heaviest weldlnli mad cuttir~.

I I q

COUBINKnoN CUTTING AND WELDING TORCH cuts and ~Idl~ c o m l l y with eq~l ~P~ci.mcy. Adopted by leadinll rmlr~ l~ n d Govm-nmlmt departmentL

PilP.q.qURE REGULA'I'Chq.q for control n d del~rer*+ of ~

ACI~YI.,,F..,NE ~ ' r o 0 ~ for weldh'~ cutting lind compremlnlg. C~mplete i n e t ~ 1 8 ~ S~ck e~ze8 to 500 pounds cspac/t~. Lm1~ . i za I~dlt/or ac~lene compremlnl plants.

T H E A L E X A N D E R M I L B U R N C O . 14.10-1428 W. B a l ~ r e St+ Bdt~mm~

VALUAm.E AmmC~S AVAn.Am~

This 1922 ad offers complete installation o f acetylene generators up to 500-pound capacity.

WELDING JOURNAL I I -~!

In the July 1983 WeMingJournal, a report on the AWS Show held in Philadelphia that year noted, "Robots for arc welding, spot welding, and cutting were shown in 31 exhibits, confirm- ing the trend toward automation is still on the increase." It was also stated that ' ~ peer review system was adopted for the Re- search Supplement starting with the January 1983 issue of the Journal. The academic community has long needed such a system and is fully supporting it."

A news item appeared in the August 1997Journal that stated that a cooperative effort among Fraunhofer, NedCar B.V., and Audi AG "has shown that laser beam welding can be used on aluminum with impressive results...a lightweight floor panel was welded together...this weld joint, with a length of more than 10 m, is a world record in laser beam welding of aluminum."

The January 2000 issue welcomed in the millennium with an article headed "Arc Welding Cited as a Top Construction In- novation of the Past 125 Years." This honor was bestowed on welding by the editors of ENR (Engineering News Record) in a retrospective salute to that publication's 125th anniversary. Welding was noted as one of those innovations that "brought better, faster and cheaper materials, equipment and processes to the job of creating the built environment." It was recognized that welding is universally accepted in the construction of high- rise buildings and long-span bridges, and the American Weld- ing Society has been providing the standards for welded steel construction for decades.

A journey back in time helps put into perspective our welding community as we move forward in the the 21st century. Often we find that while much has changed, much has also stayed the same.@

Proper Welding Accessorie and Increase Production

Select yours from this now G-E c a t a l o g - - - describes aad illustrates more than 100 items

H I S n e w ~*2-1m&e G-E cmmiog is ~ r ~ T d ~ a n a m~e llscing of prod~as--~ i~ s comH,~, u ~ n u c e ~ b~mk

Pl~[m~'ly illmmlrmJed d~m~so~t, il ~o~alns •

D ~ , d f~r quldc, ¢~7 re~e~-ace, ~i~ c~-

openno~ Fi l l b ~ o g sp~ili~nlons, p r ~ . , lad ~ r eros o( cem~e~em order I=~m~ks are ~ i m ~ e ~ L

Prope~ uc-we~ling accessories do

help ~ ~ produ~on b 7 providing I)~er ~orking ( ~ d l t i o ~ l au~ reducing the lost in m~kinll ~ l i ~ n o( C~l~ipmem.

F o r this mr*on. ~,ery o p e ~ . e'*e~y ~ p e ~ i w r u d [ o ~ . aho~ld ~ this

simply ~ k )our G-E ~u,~.welding disuiEmor o r E~'al G-E o~c"~ ~ G~.4~-2704~ o~ use c~po~ on o ~ pqe..

A 32-page catalog/~'atured a ,special section "wltich describes and illustrates a complete line of helmets and handshields, electrode holders, and protective cloth ingparticularly suited for women•"

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, d m ~ k d i y s ~ h o ~ ~ d ~ * f l ~ r ~ k * * *d dmb~ b,d~ i,~o ~ . u*~ , ,4,* d,* pmmD 6 ~ s aft. 11~ is M . ~ c l m "FROSTRODE" F ~ . • *FRO~TROOE" m~* *m ¢o~*~*¢~. ImJh~dwl ~ I ~ * * w~&-i,,bie t ~ ~ t lxm *m.E,l~m* C., ~ l , ~ l i.,,¢*lG,Eom

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FROSTRODE DIVISION

WELTRONIC CORPORATION 30CO E. 0, ,*~ Ck~vt,

I wonder if there are any Frostrode electrode refrigeration units still out there.

i m l ADVKN+IS lHG M

decrease y o u r outlay

W V ~ L t D ~ L . ~

~ ! MACHINES AND WELDING WIRE

The Wilson model lineup included "two-operator Type 400, Type 600 and Type 800 ampere units (one hour rating)."

J

VVelding the wc~rld

ST'A I N,L L

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SS

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NELDIN( WORKBOOK]

Flux Cored Arc Welding Basics Datasheet 2 5 7 a

The flux cored arc welding (FCAW) process uses an arc between a continuous filler metal electrode and the weld pool. The process is used with shielding from a flux contained within the tubular electrode, with or without additional shielding from an externally supplied gas, and without the application of pressure.

The tubular electrode is a filler metal composite consisting of a metal sheath and a core of various powdered materials manufactured in the form of wire. During welding, an extensive protective slag cover is produced on the face of the weld bead.

EX~klPJES OF CRO¢~ FCAW WITH SECTIONS OF FLUX FC~W WITH ~ I E I . D E D CORED ARC ~ GAS-SHIELDED ELECTROOE ELECll~OOE ELECTROOE

i i

ue

FLUX CORED / ELECTROOE

Fig. 1 - - Self-shielded and gas-shielded flux cored arc welding.

Fig. 2 - - Flux cored arc weld profile.

Flux cored arc welding is an efficient process readily adaptable to semiautomatic or automatic welding operat ions and capable of producing high- quality weld metal at a high deposit ion rate. Users of the process include manufacturers or builders of pressure vessels, submarines, aircraft carriers, earth moving equipment, and buildings and other structures.

The two major vari- ations of the FCAW process, the self- shielded and the gas- shielded versions, are

shown in Fig. 1. In the gas-shielded method, the shielding gas (CO 2 or a mixture of argon and CO2) protects the molten metal from the oxygen and nitrogen present in air by forming an envelope of gas around the arc and over the weld pool. Because air, along with the nitrogen it contains, is mostly excluded, little need exists for denitrification of the weld metal. However, some oxygen may be generated from the dissociation of CO2, which forms carbon monoxide and oxygen. The compositions of the electrodes are formulated to provide deoxidizers that combine with small amounts of oxygen in the gas shield.

Self-shielded flux cored arc welding is often the process of choice for field welding because it can tolerate stronger air currents than gas-shielded FCAW. The main reason for this distinction is that the high-temperature decomposition of some of the electrode core in- gredients provides some shielding. The vaporization of these in- gredients displaces air from the area immediately surrounding the arc. In addition, the wire contains a large proportion of scavengers (deoxidizers and denitrifiers) that combine with undesirable elements that might contaminate the weld pool. A slag cover protects the metal from the air surrounding the weld.

Advantages

The following benefits are offered by FCAW: • High-quality weld metal deposit • Excellent weld appearance • Welds many steels in a wide thickness range • High operating factor and easily mechanized • High deposi t ion rate (up to four times greater than SMAW

and high current density • Relatively high electrode deposit efficiency • Allows economical engineering of joint designs • Visible arc contributes to easy use • Requires less precleaning than GMAW • Often results in less distortion compared to SMAW • Exceptionally good fusion when used with shielding gas com-

pared to short-circuit gas metal arc welding • High tolerance for contaminants that may cause weld cracking • Resistance to underbead cracking • Self-shielding characteristic of electrodes eliminates the need

for flux handling and gas apparatus • Shelf-shielding tolerates windy condit ions in outdoor

applications An example of the good sidewall fusion, deep penetrat ion,

and smooth weld profile that can be obtained with gas-shielded FCAW is shown in Fig. 2.

Limitations

Compared to the shielded metal arc process, the major limitations of FCAW are the higher cost of equipment, relative complexity of equipment setup and control, and the restriction on operating distance from the electrode wire feeder. The process may generate large volumes of welding fumes and requires suitable exhaust equipment, except for field work. The need for removing slag between passes is an added labor cost; however, in most cases slag is easily removed and cleanup time is minimizedAI,

Excerpted from the WeMing Handbook, Vol. 2, ninth edition, Welding Processes, Part 1.

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¢OMIN~ E V E N T S I NOTE: A DIAMOND (*) DENOTES AN AWS-SPONSORED EVENT.

, 2004 International Conference on Aluminum Structural Design (INALCO 2004). June 2-4, The Lincoln Electric Co., Cleveland, Ohio. Cosponsored by The Lincoln Electric Co., American Welding Society, Aluminum Association, ASCE Structural Engineering Institute, Japanese Light Metal Welding and Construction Association, and Univ. Prof. Dr.-Ing. H. D. Kosteas, Light Metal Structures and Fatigue, Technical University of Munich. Contact randy.kissell@tgbpartnership, com.

26th Annual Industrial Ventilation Conferences. June 7-10, Las Vegas, Nev.; October 20-23, Birmingham, Ala. Sponsored by the University of Alabama at Birmingham, and University of Nevada at Las Vegas. For complete information, contact (205) 934-8994; www. eng. uab. edu/epd.

SME Annual Meeting. June 9-13, Hyatt Regency, Cincinnati, Ohio. This year's theme is Where Manufacturing Comes Together to Give You a Competitive Edge. Contact: Barbara Gaston, Society of Manufacturing Engineers, (313) 425-3065; [email protected].

Japan International Welding Show. July 14-17, Intex, Osaka International Trade Fair Ground, Osaka, Japan. Organized by The Japan Welding Engineering Society and Sanpo Publications, Inc. For details visit www.sanpo-pub, co.jp.

strengthen domestic manufacturing. Sponsored by the Robotics Industries Assoc. For details visit www.roboticsonline.com.

14th International Conference on Computer Technology in Weld- ing and Manufacturing. June 15-17, Sheffield Hallam Univer- sity, U.K. Contact: The Welding Institute, Ltd., Granta Park, Great Abington, Cambridge CB 16AL, U.K.; meetings@twi, co. uk.

14th Annual METALCON International Conference and Exhi- bition, October 20-22, Las Vegas Convention Center, Las Vegas, Nev. Sponsored by The Metal Construction Assn., (800) 537- 7765; www.metalcon.com.

Metalform-Mexico Exposition. November 9-11, Santa Fe Expo- sition Center, Mexico City. Sponsored by the Precision Metal- forming Association. Targeted at the metal stamping, fabricating, and assembly industries in Mexico. Contact Precision Met- alforming Assn., 6363 Oak Tree Blvd., Independence, OH 44131; (216) 901-8800; www.metalforming.com.

JOM-12, Twelfth International Conference on the Joining of Materials, and Fourth International Conference on Education in Welding. March 20-23, 2005, Helsingrr, Denmark. Contact Institute for the Joining of Metals, telephone: +45 48355458; e-mail: jom aws@post l O.tele.dk.

Robots 2004 Conference. June 9, 10. Ypsilanti Marriott at Eagle Crest Resort, Ypsilanti, Mich. Will examine how robotics can

Metalform 2005 Symposium. March 20-23, 2005, Donald E. Stephens Convention Center, Rosemont, Ill. Sponsored by the

Has the lack of a CWI b e c o m e

an obstacle to y o u r success? The Hobart Institute of Welding Technology can provide the professional training you need to pass the Certified Welding Inspector and Educator exams. While nearly all of our students pass with flying colors, those . , ~ who don't the first time can return within six months free of charge.* We're that confident!

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or visit us at www.welding.org for more information. Some restrictions apply; please contact us for details. © 2004 Hobart Institute of Welding Technology, Troy, OH, St. of Ohio Reg. No. 70-12-0064HT

"Congratulations AWS on 85 Years of Service"


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Precision Metalforming Association. Contact Precision Metal- forming Assn., 6363 Oak Tree Blvd., Independence, OH 44131; (216) 901-8800; www.metalforming.com.

Educational Opportunities ASME International m Section IX Seminars. June 7-9, Las Vegas, Nev.; October 4-6, Pittsburgh, Pa. A three-day seminar covers writing, qualifying welding procedures, and qualifying welders. Emphasis is on meeting Code requirements economically while providing useful direction to welders. Impact tested qualification and brazing are also covered. For information, visit www.asme.org/pro_dev.

Pipeline Process Solutions Seminars, July 13-15, repeated November 2-4, The Lincoln Electric Co., Cleveland, Ohio. For pipeline contractors and manufacturers. There is no charge for this seminar. For more information or to register, call (216) 383- 4718, www.lincolnelectric.com.

Blacksmithing Indiana State Fair. August 11-22, Indianapolis, Ind., McKenzie Career Center, Robert Dalrymple Blacksmithing Shop. Contact Ed Wyatt at [email protected]; (317) 576- 6420, ext. 303.

Welding Technology Workshop. July 1, Ball State University, Muncie, Ind. For everyone interested in welding. Fee $25. Contact Ed Wyatt at [email protected]; (317) 576-6420, ext. 303.

Fundamentals of Visual Inspection, July 7, September 8. Classes held at Hobart Institute of Welding Technology, Troy, Ohio. For further information and 2004 schedules, call (800) 332-9448 or e-mail [email protected]; www.welding.org.




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Welding for the Non-Welder, August 16, October 11. Classes held at Hobart Institute of Welding Technology, Troy, Ohio. For further information and 2004 schedules, call (800) 332-9448 or e-mail hiwt @welding. org; www. welding, org.

Boiler and Pressure Vessel Inspectors Training Courses and Seminars. Courses and seminars cover such topics as ASME Code Sections I, IV, V, VIII (Division 1), IX, and B31.1; Writing Welding Procedures; Repairing Pressure Relief Valves; Understanding How Boilers and Pressure Vessels Are Constructed and Inspected; and others. To obtain the 2004 schedule of training courses and seminars offered by the National Board of Boiler and Pressure Vessel Inspectors at its Training and Conference Center in Columbus, Ohio, contact: Richard McGuire, Manager of Training, (614) 888- 8320, e-maih [email protected]; www.nationalboard.org.

Welding Introduction for Robot Operators and Programmers. This one-week course is offered at the Troy, Ohio, facility, or presented at a corporate location tailored to specific needs. Contact Hobart Institute of Welding Technology, 400 Trade Square East, Troy, Ohio; 1-800-332-9448, ext. 5603; Web site: www.weMing.org.

Unitek Miyachi Corp. Training Services. Unitek Miyachi's Applications Lab offers personalized training services to customers desiring training on resistance and laser beam welding and laser marking. For information, contact (626) 303-5676 or e- mail [email protected]; www.unitekmiyachi.com.

CWI Preparatory and Visual Weld Inspection Courses. Classes presented in Pascagoula, Miss., Houston, Tex., Houma, La., and Sulphur, La. Course lengths range from 40 to 80 hours. Contact Real Educational Services, Inc., (800) 489-2890; or e-mail to [email protected].

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EPRI NDE Training Seminars. EPRI offers NDE technical skills training in Visual Examination, Ultrasonic Examination, ASME Section XI, and UT Operator Training. For information, contact Sherryl Stogner, (704) 547-6174, e-mail: sstogner @epri.com.

Victor 2004 Training Seminars. Victor Equipment Co. offers training programs for gas apparatus and service repair technicians, end users, and sales personnel. For the 2004 schedule, contact Aaron Flippen, (940) 381-1217; www.victorequip.com.

The Fabricators & Manufacturers Association, International (FMA), and the Tube and Pipe Association, International (TPA), Courses. For the course schedule, call (815) 399-8775; e-mail: [email protected]; www.fmametalfab.org.

Malcom Plastic Welding School. Offers a comprehensive two-day, hands-on course that leads to certification in accordance with the latest European DVS-approved plastic welding standards for hot gas and extrusion techniques. Contact: Sheila Carpenter, Administration, Malcom Hot Air Systems, 1676 E. Main Rd., Portsmouth, RI 02871, (888) 807-4030, FAX: (401) 682-1904, e-mail: [email protected]; www.plasticweldingtools.com.

Hellier NDT Courses. The 2004 schedule of courses in nondestructive testing is available from Hellier, 277 W. Main St., Ste. 2, Niantic, CT 06357, (860) 739-8950, FAX: (860) 739-6732.

How to Buy Gases 2004 Road Show Seminars. For buyers of specialty gases. Forty seminars are scheduled for 27 states nationwide through August. For schedule of dates, cities, and sign-up information, contact your local Airgas distributor or visit www.airgas.com.


As a leading manufacturer of precision pipe beveling and weld preparation ~ equipment, Tri Tool Inc. salutes the men and women of the AWS and | ~ joins with them in their support and dedication the welding industry.

You can depend on Tri Tool for the best portable machine tools, on-site machining services, equipment rentals and application assistance for your most demanding welding requirements, i ~ ~

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©2004 Sustaining Member, AWS


WELDING J O U R N A L l , l i m

E d u c a t i o n a l O p p o r t u n i t i e s

AWS 2 0 0 4 Schedule CWI /CWE Prep Courses and Exams

Exam application must be submitted six weeks before exam date. For exam information and an application, contact the AWS Certification Dept., (800) 443-9353, ext. 273. For exam prep course information, contact the AWS Education Dept., (800) 443- 9353, ext. 229.

City Exam Prep CWl/CWE Course Exam

Albuquerque, N.Mex.Aug. 1-6 Aug. 7 (API 1104 Clinic also offered)

Anchorage, Alaska Sept. 12-17 Sept. 18 (API 1104 Clinic also offered)

Atlanta, Ga. Oct. 24-29 Oct. 30 (API 1104 Clinic also offered)

Baltimore, Md. Oct. 31-Nov. 5 Nov. 6 (API 1104 Clinic also offered)

Baton Rouge, La. July 18-23 July 24 (API 1104 Clinic also offered)

Charlotte, N.C. Aug. 22-27 Aug. 28 (API 1104 Clinic also offered)

Chicago, I11. July 25-30 July 31 (API 1104 Clinic also offered)

Chicago, I11. Oct. 24-29 Oct. 30 (API 1104 Clinic also offered)

Columbus, Ohio Aug. 2--6 Aug. 7 (API 1104 Clinic also offered)

City Exam Prep CWI/CWE Course Exam

Corpus Christi, Tex. EXAM ONLY July 24 Corpus Christi, Tex. EXAM ONLY Sept. 18 Dallas, Tex.

Denver, Colo.

Denver, Colo.

Detroit, Mich.

Houston, Tex.

Sept. 26-Oct. 1 Oct. 2 (API 1104 Clinic also offered) July 11-16 July 17 (API 1104 Clinic also offered) Oct. 3-8 Oct. 9 (API 1104 Clinic also offered) Sept. 26-Oct. 1 Oct. 2 (API 1104 Clinic also offered) Aug. 2-7 No Test 9-Year Recertification Course

Houston, Tex.

Indianapolis, Ind.

Kansas City, Mo.

Los Angeles, Calif.

Aug. 15-20 Aug. 21 (API 1104 Clinic also offered) Aug. 15-20 Aug. 21 (API 1104 Clinic also offered) July 25-30 July 31 (API 1104 Clinic also offered) July 19-24 No Test 9-Year Recertification Course

Memphis, Tenn. Aug. 8-13 Aug. 14 (API 1104 Clinic also offered)

Miami, Fla. EXAM ONLY July 15 Miami, Fla. EXAM ONLY Aug. 19 Miami, Fla. EXAM ONLY Sept. 16 Miami, Fla. EXAM ONLY Oct. 14 Milwaukee, Wis.

Minneapolis, Minn.

New Orleans, La.

New Orleans, La.

Sept. 26-Oct. 1 Oct. 2 (API 1104 Clinic also offered) Sept. 19-24 Sept. 25 (API 1104 Clinic also offered) Sept. 12-17 Sept. 18 (API 1104 Clinic also offered) Sept. 13-18 No Test 9-Year Recertification Course

Orlando, Fla.

Philadelphia, Pa.

Philadelphia, Pa.

July 11-16 July 17 (API 1104 Clinic also offered) July 11-16 July 17 (API 1104 Clinic also offered) Aug. 9-14 No Test 9-Year Recertification Course

Phoenix, Ariz.

Pittsburgh, Pa.

Portland, Maine

Reno, Nev.

Oct. 3-8 Oct. 9 (API 1104 Clinic also offered) Oct. 17-22 Oct. 23 (API 1104 Clinic also offered) July 25-30 July 31 (API 1104 Clinic also offered) Oct. 31-Nov. 5 Nov. 6 (API 1104 Clinic also offered)

Rochester, N.Y. EXAM ONLY Aug. 21 Sacramento, Calif. Aug. 8-13 Aug. 14

(API 1104 Clinic also offered) Sacramento, Calif. Oct. 4--9 No Test

9-Year-Recertification Course Salt Lake City, Utah July 18-23 July 24

(API 1104 Clinic also offered) San Antonio, Tex. Oct. 17-22 Oct. 23

(API 1104 Clinic also offered) San Diego, Calif. Sept. 19-24 Sept. 25

(API 1104 Clinic also offered) Seattle, Wash. Sept. 19-24 Sept. 25

(API 1104 Clinic also offered) Tulsa, Okla. Oct. 17-22 Oct. 23

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I S O S O 0 1 REGISTERED CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY

YAVY JoININ~ CENTERJ A MANTECH CENTER OF EXCELLENCE OPERATED BY EWl 0

Fabrication Cell to Feature Robotic FSW Capability

In addition to the Navy Joining Cen- ter MANTECH Program, EWI has initiated two major programs to develop, demonstrate, and deploy advanced welding technology on a variety of new lightweight weapon systems for the Army.

The first program, "Materials Joining for Army Weapon Systems," is focused on supporting the Future Combat System, which is the Army's next-generation mul- tipurpose manned ground vehicle. This program supports ongoing activities at the Army Research Laboratory (ARL).

The second program, '~dvanced Weld- ing Technology Deployment Initiative," is focused on producing lightweight prototype structures to support work being performed at the Picatinny Arsenal.

The Army is developing a number of lightweight applications as part of its ongoing transformation process to permit more rapid deployment and better performance and sustainment. To reduce weight, the Army is incorporating a variety of low-density materials such as aluminum, titanium, and composites into advanced structural designs. Combining these materials to produce hybrid structures requires a number of advanced joining technologies including friction stir welding (FSW), hybrid gas metal arc/laser beam welding (GMAW/LBW), pulsed gas metal arc welding (GMAW-P) of titanium, adhesive bonding, and active brazing and soldering.

EWI is currently working with the Army to define performance requirements, joint designs, and to develop and apply new joining and inspection technologies.

To demonstrate the joining technology on full-scale test articles, EWI is procur- ing a flexible fabrication cell. The cell will be capable of performing several different types of joining processes, and will permit rapid tool design and setup. EWI will make extensive use of modular tooling, self-locating designs, and offline modeling and programming. The cell will include a large multiple-axis FSW machine with robotic welding capability.

The General Tool Company is manufacturing the FSW machine, which will be the largest gantry-type machine available in North America. It will feature a work-

The flexible fabrication cell will be capable of performing several different types of joining processes and permit rapid tool design and setup.

ing envelope of 10 x 10 x 16 ft (h x w x 1). The seven-axis machine will have the ability to work on surfaces that have complex curvatures. The Army Research Labora- tory provided EWI with a smaller five-axis laboratory FSW machine that is now in operation. This machine is being used to develop FSW procedures for aluminum and titanium alloys with thicknesses ranging from 0.060 to 1.0 in.

A specification is being prepared for the robotic welding portion of the flexible fabrication ceil. The robotic system will have multiprocess capability including GMAW, LBW, and hybrid GMAW/ LBW Other flexible fabrication cell features will include a heavy-duty rotary tilt table, tailstock, laser joint tracking, offline programming, and a portable coordinate measuring machine. The cell design will permit the Army to have secure real- time data acquisition and control of the equipment inside the flexible fabrication cell.

For more information about the flexible fabrication cell or the Navy Joining Center, contact Tim Trapp, Edison Weld- ing Institute, at (614) 688-5231.

What's Happening at NJC?

Dates: August 17-18, 2004 Workshop: University Welding Research Conference for Defense Applications Hosted by: Edison Welding Institute and Navy Joining Center, Columbus, Ohio Organized by: The Navy Joining Center Objective: To promote awareness of current materials-joining research activities to industry and Department of Defense and provide a forum for discussion of future research issues and needs.

For more information, contact Larry Brown, Edison Welding Institute, at (614) 688-5080; [email protected].

r ' L J C Operated by

S l M i

The Navy Joining Center 1250 Arthur E. Adams Dr. Columbus, OH 43221 Phone: (614) 688-5010 FAX: (614) 688-5001 e-mail: NJ C @ewL org www: http.'/Avw~.ewL otg Contact: Larry Brown

M.'~m JUNE 2004 I

AWS Celebrates Industry Achievers at Chicago Welding Show

Harshad Bhadeshia

Comfort A. A d a m s Lecture Award Harshad K. D. H. Bhadeshia is a pro-

fessor of physical metallurgy at the Uni- versity of Cambridge, where he received his Ph.D. He has been with the university since 1979 when he joined as a Sci- ence Research Fellow. He has held the positions of university demonstrator, university lecturer, reader in physical metallurgy, and Royal Society Lever- hume Trust Senior Fellow.

He specializes in the theory of solid- state transformations with emphasis on the prediction of microstructural development in complex metallic alloys, particularly for multicomponent steels as applied to engineering applications.

He was elected a Fellow of the Royal Society, the Institute of Physics, the In- stitute of Materials, and the Royal Academy of Engineering, and this year was awarded Consulting Professorship by Harbin Institute of Technology, China. He has received other honors from institutions in Brazil, Japan, India, and the United States.

Bhadeshia serves on the editorial boards of Material Transactions of JOM, Australasian Journal of Welding, and Ma-

terials Science & Technology. He is associate editor of Materials Science and En- gineering, editor of Science and Technol- ogy of Welding and Joining, and vice president of Industrial Trust.

Adams Memorial Membership Award

William F. Gale received his doctor- ate and postdoctoral research in materials science and metallurgy at the Uni- versity of Cambridge. In 1992, he joined the faculty of Auburn University, where he is currently a professor.

Gale was the editor-in-chief for the eighth edition of Smithells Metals Refer- ence Book, published in 2003. Gale's research interests include a variety of joining and coating processes, with a special emphasis on diffusion brazing. He has conducted research on a wide range of materials- related and cross- disciplinary topics.

His educational interests include William Gale joining, crystallogra- phy, microscopy, phase transformations, and other metallurgical topics. In recent years, he has placed special emphasis on cross-disciplinary, Web, and team-based education.

Tracy W. Nelson received his Ph.D. from The Ohio State University in welding engineering. He joined Brigham Young University in 1995 where he currently is director of the Center for Ad- vanced Joining of Materials. He teaches courses in materials science, manufacturing, and joining processes. Nelson's research focus over the past five years has been both fundamental and applied topics in friction stir welding, including process development, local texture evolution, and microstructural characterization in friction stir welded aluminum, steels, stainless steels, and nickel alloys.

Nelson has received the IIW Henry

Granjon Award, and the AWS Warren E Savage and Professor Masubuchi Awards. He presently serves on the AWS Handbook Committee, Chapter 4, and as an advisor to the D17 Com- mittee on Welding in the Aircraft and Aerospace Industries.

Howard E. Adkins Memorial Instructor Membership Award

Wanda Sue Benton graduated with honors in industrial technology from Florence-Darlington Technical College. She joined Southern Steel, Inc., in Dar- lington, S.C., where she worked as a welder, fitter, quality control inspector, supervisor, and project manager. Dur- ing this time, she taught evening welding classes at the college. In July 2000, she became a full-time welding instructor at the college where she was instrumental in developing a gas metal arc welding course exclusively for women.

Benton is active in her local AWS Section, and is a member of NAWIC, Women to Work. She is a certified NCCER trainer, an AWS Certified Welding Inspector, and an AWS Certi- fied Welding Educator.

Davis Rayborn, Jr., a Certified Welder and a Certified Educator, is on the faculty of Zachary High School in Zachary, La. His class projects include building a gazebo for the Zachary Historical District, an arched entrance for the local baseball park, band bleachers for the high school, and an outdoor classroom building. Davis Rayborn, Jr.

He worked as a welder on the Trans-Alaska Pipeline, and at Precision Industries, Inc., where he was responsible for fabrication and welding. Concurrently, he taught at the Local 198 Pipefitters' night school for 12 years.

I WELDING JOURNAL i,-!.,'!

Robert J. Conkling Memorial Award First Place - - High School Flatrock High School Flat Rock, Mich.

First Place - - Postsecondary Washtenaw Community College Ann Arbor, Mich.

A. F. Davis Silver Medal Award Machine Design

"Controlling Robotic Friction Stir Welding"

George E. Cook has earned a number of U.S. and foreign patents for welding power supplies, welding torches, automatic pipe welding systems, and through-the-arc sensing technology. He received the James E Lincoln Founda- tion Gold Medal Award, the Franklin- Jefferson Award, the Comfort A. Adams Lecture Award, Adams Memo- rial Membership Award, and a NASA Space Act Award, plus a number of NASA Certificates of Recognition for his many contributions to automated and robotic welding. He is a Fellow of the American Welding Society and the Institute of Electrical and Electronics Engineers.

Herschel B. Smartt has more than 35 years of experience in solidification microstructure development, aluminum casting and iron foundry technology, di- agnostics, sensing and control of gas metal arc and gas tungsten arc welding, and is currently doing basic research on intelligent machines.

Smartt is an editorial board member for the Journal of Science and Technol- ogy of Welding and Joining, and is a principal reviewer for technical papers published in the Welding Journal. He also chairs the AWS Welding Research and Development Committee.

Smartt has participated in thesis and dissertation committees at the Univer- sity of Idaho, Idaho State University, Massachusetts Institute of Technology, and Aalborg University. He was awarded the A. E Davis Silver Medal Award in the category of Machine De- sign in 1993, and elected a Fellow of the American Welding Society in 1997.

Jason E. Mitchell received his M.S. in mechanical engineering from Van- derbilt University. He was awarded an AWS fellowship from the Navy Joining Center to study friction stir welding. Mitchell is currently working as a research engineer in the Mechanical En- gineering department at Vanderbilt University.

Alvin M. Strauss is professor of mechanical engineering at Vanderbilt Uni- versity and is the director of the (NASA)

II,"[,'IB JUNE 2004

George Cook Herschel Smartt George Fairbanks William Bruce

Tennessee Space Grant Consortium. Strauss received his Ph.D. in theo-

retical and applied mechanics from West Virginia University. In addition to welding, he has research projects in space nuclear propulsion and the design of the next generation of small arms.

Reginald Crawford received his B.S. degree in mechanical engineering in 2000 from Tennessee State University. As an undergraduate student, he was recognized as a NASA Glenn Scholar, NASA Center for Automated Space and Science Scholar, and served as the USAF Detachment 790th Wing Com- mander.

Crawford was decorated as a U.S. Air Force Distinguished Graduate, Blue Chip (top tenth of all commissioned of- ricers), and inducted into the Detach- ment 790th Hall of Fame. He is currently enrolled as a graduate student at Vanderbilt University in the Depart- ment of Mechanical Engineering. He at- tends on an AWS fellowship working in the area of robotic friction stir welding. He plans to earn his Ph.D. at Vander- bilt University and continue his research in robotic friction stir welding.

Structural Design 34 Proposed S-N Curve for

Welded Ship Structures" Sung Won Kang received his Ph.D.

from Hiroshima University. He is currently a professor in the Department of Naval Architecture and Ocean Engi- neering at Pusan National University, where his research focus is welding and fatigue strength of ship and oceanic structures.

He is the current president of the Ko- rean Welding Society, and served as a vice president of the Society of Naval Architecture of Korea in 2003. He is a member of the Japan Welding Society, Kansai Society of Naval Architects, and West-Japan Society of Naval Architects.

W. S. Kim received his Ph.D. degree in naval architecture and ocean engineering from Pusan National Univer- sity, Korea. Kim joined Hyundai Heavy Industries Co., Ltd., in 1980, where he worked in the field of ship structure design and analysis. He is currently a sen-

ior engineer in the company's Hull Ini- tial Design Department.

Dalton E. Hamilton Memorial CWl of the Year Award

George D. Fairbanks, Jr., studied electromechanical mechanisms during his tour of duty in the U.S. Navy, 1966 -1970. He served the Louisiana State University's mechanical engineering department as a research technician and supervisor of student projects.

He worked for Scientific Testing Laboratories for 16 years as chief welding inspector, vice president and manager of the welding lab, and vice president and manager of welding-related research services. At Gonzales Industrial X-Ray he developed a program for screening personnel for the welding, pipefitting, and millwright trades.

In 2001, Fairbanks prepared a pro- posal for a federal grant to fund a certified welding educator project for instructors in the Louisiana colleges. The grant was awarded, and the program is now in operation. Fairbanks has served on the AWS D14C Committee on Earthmoving and Construction Equip- ment. He currently operates a private consulting company and participates in the AWS Baton Rouge Section.

W. H. Hobart Memorial Award "Effect of Welding Parameters and H2S Partial Pressure on the Susceptibility

of Welded HSLA Steels to Sulfide Stress Cracking"

William A. Bruce is a lead engineer in the materials section at Edison Weld- ing Institute. Before joining EWI in 1988, he was a senior engineer at Pan- handle Eastern Pipeline Co. He has been involved in pipeline welding research continuously since his graduation from The Ohio State University with a degree in welding engineering.

Bruce's areas of interests include repair welding, inspection techniques, and failure analysis. He has carried out numerous projects pertaining to welding repairs and modifications of in-service pipelines. He pioneered the use of lasers for mapping corrosion damage on ex- posed pipelines.

Bruce is an American Welding Soci- ety representative on the American Pc-

6, Gerald Frankel Gerhardus Koch

troleum Institute API 1104 Committee, is chair of the Maintenance Welding Subcommittee, and a member of the AWS D10 committee. He has received the Airco Award, and the Distinguished Researcher Award from Pipeline Re- search Council International . He is a Registered Professional Engineer and an IIW International Welding Engineer.

Gerald S. Frankel is a professor of materials science and engineering at The Ohio State University and director of the Fontana Corrosion Center. He received his Sc.D. degree in materials science and engineering from Massachu- setts Insti tute of Technology in 1985. Prior to joining OSU, Frankel was a postdoctor at the Swiss Federal Institute of Technology in Zurich, and a research staff member at the IBM T. J. Watson Research Center.

Frankel 's research is in the passiva- tion and localized corrosion of metals and alloys, and corrosion-inhibiting protective coatings.

He is chair of the Corrosion Division of the Electrochemical Society, vice chair of the NACE Research Commit- tee, and has chaired the 2000 Gordon Conference on Aqueous Corrosion. He is a member of the editorial board of the journal Corrosion.

Frankel, a Fellow of NACE Interna- tional, has received the Alexander von Humboldt Foundation Research Award for Senior U.S. Scientists, the H. H. Uhlig Educators Award from NACE, and the Harrison Faculty and Lumley Research Awards from OSU.

Gerhardus l-I. Koch received his Ph.D. in metallurgical engineering from the University of Illinois. He worked for Fokker Aircraft Industries and Battelle Memorial Insti tute before joining his present employer, CC Technologies, Dublin, Ohio, in 1990.

He has conducted projects related to corrosion and materials performance in the electric power, chemical process, oil production, and refinery industries. He recently completed a landmark study on the cost of corrosion in the Uni ted States, funded by the U.S. Congress.

Jose Ramirez Thomas Mustaleski Dietrich Roth Richard Dolby

Koch served as project manager on a recent two-year, multimillion-dollar project for a Middle East oil company to as- sess all field production equipment with respect to internal corrosion.

Koch has published numerous papers on corrosion control, and has authored or contributed to five books.

G. M. Omweg is with the Fontana Corrosion Center at The Ohio State University, Columbus, Ohio.

Jose E. Ramirez received his Ph.D. in metallurgical and materials engineering from Colorado School of Mines. Since 1999, he has worked for Edison Welding Institute where he researches welding of high-strength steel, corrosion- and heat-resistant alloys, stainless steels, and nickel-based alloys. He has extensive experience in welding and corrosion technologies. His areas of expertise include phase transformations of engineering materials; microstructure- property relationships of welded joints; and the weldability of ferrous and nonferrous materials in the heavy manufacturing, oil, and gas industries.

Ramirez has conducted studies on welding, materials, and corrosion for the oil and gas industries. He is a peer reviewer for Welding Journal, and is a member of several NACE International technical committees, where he is recognized as a corrosion specialist.

Honorary Membership Award Thomas Michael Mustaleski, Jr., re-

ceived his B.S. degree in metallurgical engineering from Rensselaer Polytech- nic Institute, followed by graduate studies at the University of Wisconsin and the University of Tennessee.

Since 1974, he has been employed at the Oak Ridge Y-12 Plant of BWXT- Y12 LLC, where he currently is a research staff member in the Develop- ment Division. Mustaleski 's work is in the areas of welding metallurgy, and process and procedure development. From 1980 to 1985, he served as group leader of the Joining Group. Previously, he was a senior welding engineer at the

A. O. Smith Corp., and electron beam welding applications engineer for Hamilton Standard Division of United Aircraft Corp.

Mustaleski has received several En- ergy Systems and DOE awards for quality improvements and technical achievements.

Mustaleski served as president of the American Welding Society (2003-2004), and is an AWS Distinguished Member and an AWS Fellow. He has received the District Meri tor ious Award and the William Irrgang Memorial Award. He served AWS as a director-at-large. He continues to serve as Section education chairman and as an AWS Foundat ion representative.

Dietrich K. Roth graduated from the State Engineering College in Darm- stadt, Germany, with a degree in electrical engineering. After graduation, he worked for Dr. Masing and Co. in the field of resistance welding controls and power factor correction systems.

In 1958, he came to the United States to work for Kirkhof Manufacturing as a design engineer, then progressed to chief engineer, resistance welding machines. For ten years he was a division manager for Kirkhof in its Transformer Division.

In 1980, he became president and co- founder of RoMan Manufacturing, Inc., a producer of resistance welding power s o u r c c s .

Roth served as chair of the Western Michigan Section and as a speaker at various AWS functions, including the Detroi t Sheet Metal Welding Confer- ence. He is a past member of the AWS National Finance Committee. He was also active in the RWMA where he chaired subcommittees and served as an instructor at the Emmett A. Craig Re- sistance Welding School.

In 1996, Roth received the Elihu Thomson Resistance Welding Award.

International Meritorious Certificate Award

Richard Dolby worked for The Weld- ing Institute, U.K., from 1965 until his re t i rement in 2003. Ear l ier he served

WELDING JOURNAL I I ~ m

Ernest Levert Ronald Pierce

with Alcan, GEC, BWRA, and two years of national service. He began his welding career working on the metallurgical aspects of heat-affected-zone toughness of pressure vessel steels, and then helped to lead TWI's pioneering studies into lamellar tearing.

Dolby subsequently became head of the Materials Department, associate director of research, then director of research and technology. He was appointed to the U.K. Technical Advisory Committee for Structural Integrity of Nuclear Plants, the Materials Board of the U.K. Defense Scientific Advisory Council, and various DTI committees, as well as the Council of the Institute of Materials, Minerals and Mining. He served as vice president of the IIW, chair of the IIW Technical Management Board, and chair of the IIW Research Strategy Group.

Dolby is a Fellow of the Royal Acad- emy of Engineering, The Welding Insti- tute, and the Institute of Materials, Min- erals and Mining. He received the Order of the British Empire, the TWI Brooker Medal, and the Bessemer Gold Medal. In 1997, he delivered the Hatfield Lec- ture, and last year, he received the IIW Arata Prize for contributions to the science of welding and joining.

Ernest D. Levert, Sr., served as AWS president (2002-2003), and currently serves on the AWS board of directors.

He received his B.S. degree in welding engineering from The Ohio State University. He is employed as a senior staff manufacturing engineer for Lock- heed Martin Missiles and Fire Control in Dallas, Tex. He has led projects on the Patriot Advance Capability (PAC-3) Missile, Line-of-Sight Missile (LOSAT), Joint Strike Fighter (JSF-F22), Interna- tional Space Station, Army Tactical Mis- sile System (ATACMS), and the Multi- ple-Launch Rocket System (MLRS) Advanced Missile Programs.

Previously, Levert worked for Gen- eral Dynamics, Convair Div., as a welding engineer supporting the Atlas space vehicle, Tomahawk cruise missile, and ground-launched cruise missile programs. He is a registered Professional Engineer in the state of Texas.

Levert was a U.S. delegate and U.S.

IE.I:ll JUNE 2004 I

11 Thomas Eagar Patricio Mendez

representative to the IIW Commission IV Annual Assembly in 2001 and 2002. He was awarded Lockheed Martin's NOVA Award for Technical Expertise.

William Irrgang Memorial Award Ronald C. Pierce is chairman, presi-

dent, and CEO of Welding Engineering Supply Co., Inc., based in Prichard, Ala. He has been with the company as a major stockholder and corporate officer since 1966.

Pierce served as AWS president (1998-1999), and has served on the board of directors. He is an AWS Life Member, and has a long history of contributions to many AWS Section and national committees. Pierce has been a trustee of the AWS Foundation since 1990, and presently serves as its chair.

Pierce earned his degree in mechanical engineering at Purdue University in 1955. He is a registered Professional En- gineer in Alabama and Mississippi.

Pierce is currently chairman of the board of the Independent Welding Dis- tributors Cooperative, is a past member of the Welding Distributor editorial advisory board, and is presently affiliated with the Gases and Welding Distribu- tors Assn., Associated Builders and Contractors Assn. (serving as a board member 1990-2002), and Associated General Contractors. He also serves on the welding advisory boards of Bishop State Community College and North Baldwin Center for Technology. He has served on the advisory boards of Bryant Area Vocational Center and Jefferson Davis Community College. He holds memberships in ASME, Naval Archi- tects and Marine Engineers, and ASM International.

Charles H. Jennings Memorial Award

"Penetration and Defect Formation in High-Current Arc Welding"

Thomas W. Eagar received his Sc.D. degree from Massachusetts Institute of Technology. He worked for Bethlehem Steel Corp., Homer Research Labora- tories, then returned to MIT as a faculty member. There he rose through the ranks to his current position as Thomas Lord Professor of Materials Engineer- ing and Engineering Systems.

He served five years as head of the Department of Materials Science and Engineering. In 1984 and 1985, he was a liaison scientist with the Office of Naval Research - - Far East, in Tokyo.

Among his numerous citations are the Adams Memorial Membership Award, Charles H. Jennings Memorial Medal Award, AIME's Champion H. Mathewson Gold Medal, Warren E Sav- age Award, William Spraragen Memor- ial Award, William Irrgang Award, Sil- ver Quill Award, ASM International's Henry Marion Howe Medal, and the AIME's Henry Krumb Lecturer Award.

Eagar is a Fellow of AWS, ASM In- ternational, and AAAS. He received an Honorary Membership in AWS in 1999. He has delivered the Houdremont Lec- ture at the IIW and the AWS Comfort A. Adams Lecture. He was elected a member of the National Academy of Engineering. In 2003, he testified before Congress on manufacturing employment in the United States.

He serves on the National Research Council, Board of Manufacturing and Engineering Design, and is a former member of the National Materials Ad- visory Board. He is on the editorial board of Science and Technology of Weld- ing and Joining, and is a principal reviewer for the Welding Journal. He has published more than 200 papers and holds 13 patents.

Patricio F. Mendez is president of Semi-Solid Technologies, specializing in semi-solid processing of metals. He is an engineer in the division of mechanics and materials of Exponent, Inc., an engineering consulting firm; and a research affiliate at Massachusetts Insti- tute of Technology.

Mendez earned his Ph.D. from MIT in 1999 working with Thomas Eagar on scaling and order of magnitude modeling techniques for welding and other materials processes. His interest in welding was stimulated by working with Julian Szekely and Stan David at Oak Ridge National Laboratory. He was a research engineer for Techint/Tenaris, a pipe manufacturer for the oil industry. He holds six U.S patents.

Mendez has coauthored several publications, and in 2000 received the AWS Silver Quill Award.

James F. Lincoln Gold Medal Award "Evaluation of Necessary Delay before

Inspection for Hydrogen Cracks" Richard Pargeter joined the Materi-

als Department of The Welding Insti- tute in 1976 following graduation from the University of Cambridge. He currently serves as a consultant in the Ma- terials, Arcs and Surfacing Group. He is a member of the Institution of Met-

allurgists, and a Chartered Engineer. He is a Fellow of The Welding Institute, a European Welding Engineer, and a registered Welding Materials Engineer Group 1.

Pargeter's research and development projects have focused on ferritic steels, sour service, corrosion fatigue, hydrogen-induced cracking, weldability of high-strength steels, resistance welded and spiral welded pipe, and weld metal and heat-affected zone microstructures.

Pargeter has conducted failure investigations on pressure vessels, offshore pipelines and structures, mooring chains, and wire ropes. He serves on the BSI committees on testing of welds and corrosion of metals, and on IIW Sub- commissions I IA on the Metallurgy of Weld Metal and IXJ on Metallurgical Studies of Fused Metal.

McKay-Helm Award "Friction Stir Welding Studies

on Mild Steel" Bennett B. Grimmett received his

M.B.A. from Franklin University in 2002.

He worked as a senior engineer with Ashland Chemical Company, before joining Edison Welding Institute in 1999 as a senior research engineer. At EWI he developed NDE techniques and procedures for adhesive bonding, welding, composites, laminates, and solid-state joining technologies. His activities included code interpretations, design engineering for developing standards and test samples, training, qualification and certification of inspections personnel.

Thomas J. Lienert is a technical staff member at Los Alamos National Labo- ratory. He previously held positions at the University of South Carolina, Edi- son Welding Institute, and Sandia Na- tional Laboratories. Lienert holds M.S. and Ph.D. degrees in materials science and engineering from The Ohio State University. He is currently researching laser beam materials processing and friction, and friction stir welding.

He is a member of Tau Beta Pi and Alpha Sigma Mu engineering honor societies.

Lienert presently serves as chair for the Joining Critical Technology Sector for ASM International, and is a member of its technical programming board. He is also a member of the AWS C6 Committee on Friction Welding, and the D17J Subcommittee on Friction Stir Welding for Aerospace. He serves as a principal reviewer for the Welding Jour- nal and is a reviewer for Metallurgical and Materials Transactions.

Lienert has organized several sym- posiums for ASM International, TMS, and AWS. He has made 60 presenta-

tions at technical conferences, published 25 papers, and authored the chapter on Selection and Weldability of Alu- minum Metal-Matrix Composites in the Welding, Brazing and Soldering volume of ASM International 's Metals Hand- book series. He has received the AWS Charles H. Jennings Award.

William L. Stellwag, Jr., received his B.S. degree in welding engineering technology from Ferris State University.

He joined Edison Welding Institute in 1999, where he served as a research assistant, project engineer, and applications engineer. His work is focused on the friction stir welding process and its applications. He was the first to weld aluminum to tungsten and MA956 to itself using the magnetic pulse welding process. He completed a feasibility study in welding various alloys such as 321 stainless steel to itself, titanium to InconeF M, aluminum to steel, and a duplex 600 steel to itself. He is also profi- cient in welding various metals combinations using SMA, GMA, and GTA welding techniques.

Robert W. Warke received his M.S. degree in metallurgical and materials engineering at Illinois Institute of Tech- nology. Currently, he is assistant professor of welding and materials joining, School of Engineering and Engineering Technology at LeTourneau University.

While studying, he interned at the welding engineering and quality assurance departments at Electro-Motive Di- vision of General Motors and at NWI International. From 1987 to 1990, he was a materials staff engineer with Packer Engineering, Inc. There he performed failure analysis, metallurgical problem solving, and welding process and design consultations for a variety of industries. In 1990, he joined Case Cor- poration, Technology Center. From 1994 to 1999, he was with Edison Weld- ing Institute as a senior research engineer on the Engineering and Materials Technology Team. In 1999, he joined Southwest Research Institute as a senior research engineer in the Materials Engineering Department. There he maintained primary responsibility for failure analysis, and continued studies of flawed pipeline girth welds.

Warke is a member of ASM Interna- tional and has served on its Failure Analysis Committee since 1990. He has held various officer positions in ASM's Chicago Western Chapter, and is a past officer of the AWS East Texas Section and LeTourneau University Student Chapter.

Prof. Koichl Masubuchi Award Weiping Liu is currently a visiting re-

search scientist in the Materials Sci- ence and Engi- neering Depart- ment at Lehigh University. He received his Ph.D. in 1989 in welding engineering from Harbin Institute of Technology, China, Weiping Liu and completed postdoctoral work at the Technical Uni- versity of Berlin. In 1993, Liu joined the Dalian Railway Institute in China as associate professor, and was promoted to professor in 1996. He was a visiting scientist at Max Planck Institute for Met- als Research, and a visiting professor at the Joining and Welding Research In- stitute, Osaka University.

Liu has published 60 research papers in the areas of materials joining and laser beam processing. He has received several best paper awards at national and international conferences, the outstanding-achievement awards from the Chinese Ministry of Railways and the Liaoning provincial government of China, and various awards for outstanding research and teaching from DRI. Liu is a member of AWS, ASM Interna- tional, and the Chinese Welding Soci- ety. He served on the International Sci- entific Advisory Board for the AWS- ASM-sponsored International Brazing and Soldering Conference (2000).

Samuel Wylie Miller Memorial Medal Award

John W. Elmer received his Sc.D. in metallurgy from Massachusetts Insti- tute of Technology in 1988. He worked as a welding metallurgist at Lawrence Livermore National Laboratories (LLNL) for defense-related programs. He returned to LLNL, and is currently deputy program element leader for Stockpile Metallurgy and Joining, in the Materials Science and Technology Di- vision. He also serves as adjunct professor at Pennsylvania State University.

Elmer is the principal investigator for a DOE-Basic Energy Sciences program to study welding-induced phase transformations using synchrotron radiation.

He is a Fellow of the American Weld- ing Society and ASM International. He received the Professor Masubuchi-Shin- sho Corporation Award, William Spraragen Award, A. E Davis Silver Medal, and the Warren Savage Memo- rial Award. He serves as a member of numerous professional committees for AWS and ASM International, has published 80 articles and reports, and has been granted seven U.S. patents for his work in the field of welding. Elmer is

I WELDING JOURNAL l ~ l

Geoffrey Putnam Lee Kvidahl

renowned for his understanding of solidification and the kinetics of phase transformations during welding, and high-energy-density beam material in- teractions.

National Meritorious Award Geoffrey H. Putnam is a plasma arc

cutting torch designer with Thermal Dy- namics Corp. Previously, he owned and operated G. H. Putnam Welding and Fabrication in East Corinth, Vt., a welding and consulting business.

Putnam is an AWS Certified Weld- ing Inspector, and is certified by ASNT to ultrasonic and magnetic particle testing Level II. He has been an active member of the AWS Green and White Mountain Section for more than 20 years. He served from 1997 to 2003 on the AWS Board of Directors as District 1 Director. He continues to be active on the AWS Education Scholarship Com- mittee and at the local Section level.

Lee G. Kvidahl, a graduate of Stevens Institute of Technology, is the sector manager of welding engineering for Northrop Grumman Ship Systems. He is responsible for all welding engineering activities at the Pascagoula, Gulfport, New Orleans, and Tallulah, sites. Presently, these sites construct surface warships for the U.S. Navy and tankers for the U.S. oil markets.

Kvidahl was AWS president (1993- 1994), and served as District 9 director and chair of the Pascagoula Section. He has chaired the Executive, Role and Missions, Compensation, National Nominating, and Honorary-Meritori- ous Award Committees. He has served on the AWS Technical Activities, Tech- nical Papers, and Counselors Commit- tees, and several special study committees. Presently, he chairs the AWS Membership, Products Development, and Conference Committees, and is a member of several other AWS committees. He also serves as the vice chair of the AWS Foundation.

Kvidahl chairs the Steering Commit- tee for the Navy Joining Center, chairs the Welding Technology Panel for the National Shipbuilding Research program, and serves on the American Bu- reau of Shipping Welding and Materi-

Harvey Solomon

als Committee.

Jeffrey Thyssen

Robert L. Peaslee Brazing Award Ronald E. De Lair is a graduate of

Union College. He worked at General Electric Knolls Atomic Laboratory from 1969 to 1979 then moved to General Electric Global Research Center where he worked until he retired last year. Presently, he has a consulting service on novel testing.

De Lair is the holder of four U.S. patents and has authored 20 open literature publications. He is credited with developing an isothermal test facility for forging studies with a temperature capability of 1650°C, and a high-temperature (425°C) extensometer that can be used in BWR/PWR environments. His research interest was focused on stress corrosion and low cycle fatigue studies for nickel-based alloys and low-alloy steels, and brazing.

Harvey D. Solomon earned his doc- torate at the University of Pennsylvania. He has been employed at the General Electric Global Research Center since 1968. He is concurrently an adjunct associate professor at Union College, where he teaches courses on welding metallurgy, fatigue, and fracture.

Solomon has received the New York AIME Outstanding Scholarship in the Field of Metallurgy Award, ASTM's Viletla Award, IEEE-CHMT Prize Paper Award, Prof. Dr. Rene Wasser- man Award, and The Lincoln Gold Medal Award. He holds 15 U.S. patents. He has authored numerous publications, including a section on duplex stainless steels for Encyclopedia of Ma- terials Science and Technology, a section on weld solidification for Volume 6 of ASM's Metals Handbook, and book chapters on embrittlement of welds and fatigue in solders. His research interests have focused on metal fatigue, stainless and low-alloy steels, stress corrosion cracking, corrosion fatigue, welding, brazing, and soldering.

Jeffrey R. Thyssen is senior staff scientist in the Ceramic and Metallurgy Technologies Laboratory at the General Electric Company Global Research Center. Previously, Thyssen worked as

Byron May Joseph Kolasa, Jr.

a senior engineer in the material and process engineering group of GE Power Systems. He worked as chief metallurgist at Howmet Dover Castings, assistant vice president of metallurgical joining processes at Chromalloy Research and Technology, supervisor of welding development at AVCO-Lycoming, and a materials engineer at Sikorsky Air- craft. He has also been a joining technology consultant to several companies in the gas turbine industry.

Thyssen received his M.S. in materials engineering from Rensselaer Poly- technic Institute. He served on the AWS C6 Committee on Friction Welding. He has been granted two U.S. patents with three more applied for.

Plummer Memorial Educational L~"~u m Award

Byron May received an associate's degree in welding technology from the College of San Mateo. He joined The Scott Company as a welding engineer in its piping fabrication shop in Emeryville, Calif., where he was responsible for welded piping subassemblies for the chemical, power generation, and construction industries.

In 1983, May joined Dimetrics, Inc., where he implemented automated pipe, tube, and robotic gas tungsten arc and plasma arc welding systems on three continents. In 1989, he joined United Airlines where he implemented robotic plasma arc welding of turbine blades. Since then he has served as process engineer, JT8D fleet technical coordinator, and CFm56 fleet engineering manager. May is presently United's manager of repair, process and materials engineering.

He is a CWI and an advisor to the AWS D17 Committee on Welding in the Aircraft and Aerospace Industries.

Private Sector Instructor Membership Award

Joseph Kolasa, Jr., has served as a welding instructor at The Lincoln Elec- tric Company for ten years, where he has developed an educational program tailored to train the fabricators serving NASCAR.

Kolosa is well known in the racing industry. He provides trackside welding

IDI JUNE 2004 I

Jackie Morris John Hinrichs

services for NASCAR, INDY Racing Leagues and the Indy 500, National Hot Rod Association, Automobile Racing Club of America, Sports Car Club of America, and the International Hot Rod Association. He maintains a mobile welding garage at the major racing events to provide on-the-spot welding services for the teams.

Kolasa is active in the AWS Cleve- land Section, and gives presentations at other AWS Section meetings. He is an instructor for the United Association for Pipefitters where he teaches gas tungsten arc and shielded metal arc welding on pipe. He also conducts welder training classes for the Boiler- makers, IBEW Electrical Workers, and commercial in-plant assignments.

Jackie W. Morris received an A.A. degree in math and science from St. Johns River Jr. College, then continued his studies at Jacksonville University.

Morris joined Bender Shipbuilding & Repair Company where he is corporate quality assurance, warranty, and environmental manager. He developed and implemented the company's environmental and quality manuals to com- ply with ISO 9001 and 14001.

Morris is an AWS Senior Certified Welding Inspector and Certified Weld- ing Educator. He holds ASNT Level III in MP, LP, visual and optical, and ASNT ACCP Level III in MT and PT. He has performed classroom training, and has certified many employees to NDT Level II in MT, PT, VT, LT, and UT. He is active in the AWS, and has served as chairman of the Mobile Section, and as Dis- trict 9 deputy director.

Robotic and Automatic Arc Welding Award

John F. Hinrichs received his M.S. degree in metallurgical engineering from the University of Wisconsin. He is a registered Professional Engineer in the state of Wisconsin, a Certified Man- ufacturing Engineer, and a Fellow of the American Welding Society.

Hinrichs has been the owner of The Welding-Link since 1995. He is also the founder of the Friction Stir Link, Inc., specializing in developing the robotic friction stir welding process and robot

William DeLong John Brooks

software for welding aluminum. Previously affiliated with A.O. Smith

for 40 years, he served as director of manufacturing engineering at its Auto- motive Products Co.

Hinrichs holds 15 U.S. and three foreign patents on welding subjects. In 1989, he was the first American to be presented the Golden Robot Award at the International Symposium of Indus- trial Robots. He served as an AWS Di- rector-at-Large, and chair of the Safety and Health, and the Technical Papers committees.

Safety and Health Award William T. DeLong served as AWS

president (1981-1982) and has been a member of the Society for 56 years. Prior to his retirement, he was vice president of corporate development at Tele- dyne McKay.

He has been active in industry affairs, participating in the International Insti- tute of Welding and the Welding Re- search Council, and has published widely in industry journals. He is a past chair of the AWS A5 Committee on Filler Metals and Allied Materials, and the Technical Activities Committee.

DeLong, the holder of 15 patents, has received the Comfort A. Adams Lecture Award, R. D. Thomas Memor- ial Award, National Meritorious Award and Honorary Membership Award.

DeLong has served on the AWS Safety and Health Committee and its subcommittees, the Project Committee on Ni and Cr6, and the Task Group on Health Hazards. He was also a member of the NEMA Task Group to develop OSHA Material Safety Data Sheets and product warning labels.

Warren F. Savage Memorial Award "WeM Solidification and Cracking Be- havior of Free-Machining Stainless Steel"

John A. Brooks received his Ph.D. in materials science from Carnegie Mel- lon University.

For the past 33 years he has held positions in research, management, and consulting at Sandia National Labora- tories. His early research focused on weld microstructure and property relationships, environmental effects on weldments, and weld cracking mecha-

nisms. This work lead to the development of alloys with improved weldability and hydrogen compatibil- ity. Brook's later work has concentrated on modeling of weld solidifica-

Joseph Michael tion and cracking, and microstructure

development with special emphasis on stainless steel alloys. He serves as a peer reviewer of technical papers for publication in the WeMingJournal, and serves on the editorial board of Science and Technology of Welding and Joining. He is a Fellow of ASM International, and was named a Fellow of AWS in 1997.

Thomas J. Headley received his Ph.D. degree in materials science and engineering from the University of Florida. In 1974, he joined Sandia Na- tional Laboratories where he is a Dis- tinguished Member of the Technical Staff in the Materials Characterization Department. His principal area of expertise is in transmission electron microscopy (TEM) of advanced materials and components.

His current interests include the application of TEM analysis to ceramics synthesis, nanoparticle synthesis and structure, active metal brazing, welding microstructures, and LIGA fabrication of microsystem components.

AWS has awarded him the Warren E Savage Memorial and the Robert L. Peaslee Brazing Awards.

Joseph R. Michael received his Ph.D. degree at Lehigh University. He is a member of the technical staff in the Materials Characterization Department of Sandia National Laboratories. He is primarily interested in the application of advanced characterization techniques to the study of materials. His recent research interests involve the application of electron backscatter diffraction and focused ion beam techniques to materials science. Prior to joining Sandia, Michael was a senior research engineer at the Bethlehem Steel Homer Research Laboratory, where he was involved in the physical metallurgy of new HSLA steels with improved properties.

Michael has served as the president of the Microbeam Analysis Society. He has received the McKay-Helm Award from AWS, Burton Medal from Mi- croscopy Society of America, the K. E J. Heinrich Award from Microbeam Analysis Society, and the ASM Gross- man Award. In 1998, he received an R&D 100 Award. Michael has published more than 100 papers in the areas ofma-

l WELDING JOURNAL l~Ai l

Charles Robino David Matlock

terials science and the application of materials characterization techniques.

Charles V. Robino received his Ph.D. in materials science and engineering from Lehigh University. From 1988 to 2002, he was Principal Member of the technical staff at Sandia National Lab- oratories, and was promoted to Distin- guished Member of the technical staff in 2002.

His research includes fabrication and service weldability, solidification, and phase transformations. He also performs materials selection, weld reliability, and weld processing studies relating to Department of Energy programs in the defense and energy sectors. He has authored or coauthored over 130 papers in the areas of welding, solidification, kinetics, and heat treatment.

Robino, an AWS Fellow, has received the Koichi Masubuchi/Shinsho Corporation Award, William Spraragen Award, McKay-Helm Award, the First Place Poster Award for the Professional Division, and the ISS/AISI Meritorious Award. In 2001, he received the A. E Davis Silver Medal.

Silver Quill Editorial Achievement Award

Maureen Byko is managing editor of JOM, a technical journal published for subscribers and to members of The Min- erals, Metals, and Materials Society (TMS). Byko has worked for TMS since 2000. Earlier, she was a newspaper reporter and editor for 15 years, most recently at the Pittsburgh Tribune-Review. As a reporter, she received the Pennsyl- vania Newspaper Publishers' Associa- tion Keystone Press Award for Public Service/Investigative Reporting.

William Spraragen Memorial Award David K. Matlock received his Ph.D.

degree in materials science and engineering from Stanford University. Mat- lock is the Armco Foundation Fogarty Professor in the Department of Metal- lurgical and Materials Engineering at Colorado School of Mines. He also serves as director of the Advanced Steel Processing and Products Research Cen- ter, an industry-university cooperative research center at CSM. He joined the

B'~'~ll JUNE 2004 ]

David Howden Herbert Cable, Sr.

faculty in 1972, and is currently involved in teaching and research, primarily as related to the mechanical properties of materials.

Matlock is a Fellow of AWS and ASM International, and a member of the National Academy of Engineering. He has received the McKay-Helm Award, Adams Memorial Membership Award, Charles H. Jennings Memorial Award, and the William Spraragen Memorial Membership Award.

Ryan W. Rathbun received his M.S. in metallurgical and materials engineering from the Colorado School of Mines in 2002. His research focused on the effects of spot welding on the fatigue properties of newly developed grades of high-strength sheet steels.

Rathbun is currently employed as materials engineer within the Technol- ogy Group of QuesTek Innovations. His responsibilities include alloy development, heat treatment simulation, development, and product commercialization.

John G. Speer received his Ph.D. in physical metallurgy from the University of Oxford. He was affiliated with Beth- lehem Steel's Homer Research Labora- tories from 1983 to 1997, where he was involved in product research, customer and operations support, and research management.

In 1997, he joined the Colorado School of Mines as a professor in the Department of Metallurgical and Ma- terials Engineering where he teaches metallurgy and performs research with the Advanced Steel Processing and Products Research Center.

Speer is a Fellow of ASM Interna- tional, an Iron and Steel Society professor, and chairman of the Ferrous Met- als Committee of SAE. His specialties are physical metallurgy, solid-state phase transformations, and steel product development.

R. D. Thomas Memorial Award David G. Howden is an associate pro-

fessor in the Department of Welding Engineering at The Ohio State Univer- sity, where he is concerned with the technology of joining methods, weld-

ing/brazing metallurgy, process applications, filler metal development and safety and health. He earned his undergraduate and Ph.D. degrees at the Uni- versity of Birmingham, England.

In 1963, Howden joined the Centro Tecnico de Aeronautica in Brazil where he performed metallurgical research and teaching duties. He then joined the Department of Energy, Mines and Re- sources, Ottawa, Canada, to pursue investigations into welding metallurgy. Arriving in the United States in 1967, he took the position of associate manager of the Materials Joining Technol- ogy Section at Battelle Columbus Lab- oratories, where he performed and managed contract research programs relating to welding, joining, manufacturing, and fabrication for industry and government agencies.

In 1977, he joined the faculty of The Ohio State University, Department of Welding Engineering, where he teaches and conducts research primarily in the area of high-strength steel weldability, hydrogen effects in welding, fracture toughness studies, and filler metal development.

Howden is a member of the AWS, Welding Research Council of the Engi- neering Foundation, ASM Interna- tional, and the American Council of the International Institute of Welding, where he is presently the U.S. Delegate to Commission VII, Authorization and Qualification. He served as AWS president (1994-1995), and served on the board of directors for many years. He has also served on many committees.

He has received the Lincoln Gold Medal Award, and the Oxigenio do Brasil Award from the Associacao Brasileira de Metais.

He authored two AWS books, Weld- ing Safety and Health, and Welding Struc- tural Design.

Elihu Thomson Resistance Welding Award

Robert Paul Matteson received his B.S. degree in electrical engineering from Georgia Tech in 1964. That same year he joined Taylor-Winfield as an electrical engineer. Currently he is director of technology, product development, and labs.

Matteson has authored several technical papers published in the Welding Journal and other periodicals. He has been an active member of RWMA since 1967, served on its board and technical subcommittees, and served as an instructor at the RWMA welding school.

George E. Willis Award Herbert E. Cable, Sr., graduated

from Washington and Jefferson College in 1954. After two years in the U.S.

Army Transportation Corps, he joined Weld Tooling Corp. He succeeded his father as president in 1972, and was succeeded by his son in 1993.

Cable, an Honorary and Life Mem- ber of AWS, was active in the Pittsburgh Section, is a past chair of the C-4 Corn-

mittee on Oxyfuel Gas Welding and Cut- ting, chair of the Manufacturers Com- mittee, director-at-large, member of the Finance, Marketing, and Welding Jour- nal Committees, and has been a member of AWS since 1957. Cable is a past chair of the Pittsburgh District Export

Council. He was a director of the St. Clair Health Corp., chairman of St. Clair Management Resources, Inc., and is CEO of Weld Tooling Corp., Bug-O Sys- tems International, Cypress Welding Equipment, Inc., Kayto, Inc., and vice chair of Fein Power Tools, Inc. *

Support ing Companies Well Engineering 1180 E. Big Beaver Troy, MI 43083

Educational Institutions Gulf University Bldg. No. 1964, Rd. 4363, Block 743 Sanad, Bahrain Kingdom

Manufacturing Technology Institute 512 Falconer St. Jamestown, NY 14701

Professional Career Academy 9521 Valparaiso Ct. Indianapolis, IN 46268

Whittier Vo-Tech High School 115 Amesbury Line Rd. Haverhill, MA 01830

Distributor Members CONTECH Str. Democratiei M. 101, B1.1, Ap. 7 Ploiesti 2000, Romania

Affiliate Companies Allied Welding Services Int'l Corp. RO. Box 22148, Grande Prairie, Alberta, T8V 6X1, Canada

AMC, Inc. 2011 Hwy. 79 N EO. Box 3419 Camden, AR 71711

Brothers 4164 3 Mile Rd. Bay City, MI 48706

Case Welding & Fabrication 235 N Angola Rd. Coldwater, MI 49036

Equipos y Accesorios Industriales S.A. de C.V. San Pedro Sula, Cortes, Honduras

Friction Forge & Cutting, LLC 4111 Technology Dr. South Bend, IN 46628

Member As of Grades 5 1 t / 0 4

Sustaining Companies ...................... 410 Supporting Companies* .................... 202 Educational Institutions .................... 328 Affiliate Companies .......................... 232 Welding Distributor Companies ........ 50

Total Corporate Members .. 1,222

* During March 2003, the Society initiated the Welding Distributor Company membership categor)z Those Supporting Company members identified as welding distributors were at that time upgraded to this new corporate member category.

Individual Members .................... 42,840 Student & Transitional Members..4,552

Total Members .............. 47 ,392

Herbert's Welding, Inc. 6747 Hwy. 64 Bloomfield, NM 87413

Industrial & Crane Services, Inc. 6500 Shortcut Rd. Moss Point, MS 39563

Mustang Metal & Supply 1107 Delano Houston, TX 77003

NASA Glenn Research Center Bldg. 50-4, 21000 Brookpark Rd. Cleveland, OH 44135

Pal-Con Ltd. EO. Box 718, 125 W Hwy. 171 Godley, TX 76044

RCR Fabrication, Inc. 523 Centennial St. Santa Cruz, CA 95060

Syn-Ergomachines Pvt. Ltd. B-49 Devasandra Industrial Estate Whitefield Rd. Bangalore 560-048, India

R/D Tech designs and manufactures eddy current and ultrasound test systems for manual and automated inspections in nondestructive testing. Its broad field of activity includes hydroelectric, fossil, and nuclear power plants, oil refineries, pipelines, aerospace and automobile industries, and all companies that produce homogeneous and composite metal structures.

Precitec is a global company providing customer-specific solutions to industrial applications utilizing precise mechanical, optical, and electronic components and systems, designed for materials processing using CO 2 and Nd'Yag lasers. Precitec products are highly innovative and protected by more than 100 patents. Its comprehensive range of products includes robust distance control and positioning systems with relavant software and axis drives, as well as beam-delivery components for laser beam cutting and welding.

Kaynak Teknigi produces coated electrodes and gas metal arc and submerged arc welding wires. It also markets and sells Lincoln Electric brand consumables, machines, and welding equipment.

D I S B A N D E D SECTION NOTICE On April 4, 2004, after due consid-

eration of the recommendation by Dis- tricts Council, the AWS Board of Direc- tors approved the disbandment of the Eastern Carolinas Section, District 4.

l WELDING JOURNAL i ' / t l l

Listed are the people participating in the 2003-2004 Member-Get-A-Mem- ber Campaign. For campaign rules and a prize list, see page 83. For more information, call the Membership Dept.(800) 443-9353, ext. 480.

Winner's Circle A W S M e m b e r s w h o h a v e s p o n s o r e d

2 0 o r m o r e n e w i n d i v i d u a l m e m b e r s , p e r

year, s i n c e J u n e I, 1999. ( ) D e n o t e s t he

n u m b e r o f t i m e s t he m e m b e r h a s e a r n e d

W i n n e r ' s Circ le s tatus .

J. Compton, S a n F e r n a n d o Valley (4) E.H. Ezell, M o b i l e (2) J. Merzthal, Peru (2) B.A. Mikeska, H o u s t o n (1) R.L Peaslee, Det ro i t (1) W.L. Shreve, F o x Valley (1) G. Taylor, P a s c a g o u l a (2) S. McGill, N o r t h e a s t Tennessee (1) T. Weaver, J o h n s t o w n / A l t o o n a (1) G. Woomer, J o h n s t o w n / A l t o o n a (1) R. Wray, N e b r a s k a (1)

President's Guild A W S m e m b e r s w h o s p o n s o r e d 2 0 o r

m o r e n e w i n d i v i d u a l m e m b e r s b e t w e e n

J u n e 1, 2003 , a n d M a y 31, 2004.

President's Roundtable M e m b e r s w h o s p o n s o r e d 1 1 - 1 9 n e w

i n d i v i d u a l m e m b e r s b e t w e e n J u n e 1, 2003 ,

a n d M a y 31, 2004.

R. Purvis, S a c r a m e n t o - - 14 P. Evans, C h i c a g o - - 12 T. Hart, M o b i l e - - 12 G. Taylor, P a s c a g o u l a - - 12

President's Club A W S M e m b e r s s p o n s o r i n g 6 - 1 0 n e w

i n d i v i d u a l m e m b e r s b e t w e e n J u n e 1, 2 00 3,

a n d M a y 31, 2004 .

K. Baucher, F r e s n o - - 10 C. Daily, P u g e t S o u n d - - 9

J. Powell, Triangle - - 9

W. Drake, Jr., O z a r k - - 8

E Walker, O z a r k - - 7

J. Compton, S a n F e r n a n d o Valley - - 6

President's Honor Roll A W S m e m b e r s s p o n s o r i n g 2 - 5 n e w in-

d i v i d u a l m e m b e r s b e t w e e n J u n e 1, 2003 ,

a n d M a y 31, 2004 .

R. Fontenot, O k l a h o m a Ci ty - - 5

D. St.-Laurent, N o r t h e r n A l b e r t a - - 5

B. Suckow, N o r t h e r n P l a i n s - - 5

C. Wesley, N o r t h w e s t e r n Pa. - - 5

D. Wright, K a n s a s Ci ty - - 5

S. Abarca, I l l ino i s Valley - - 4

C. Dynes, K e r n - - 4

J. Smith, C o h t m b u s - - 4

C. Boulden, N o r t h Texas - - 3

K. Campbell, L . A . / I n l a n d E m p i r e - - 3

J. Cantlin, S o u t h e r n C o l o r a d o - - 3

C. Chilton, O z a r k - - 3

R. Culbert, L . A . / I n l a n d E m p i r e - - 3

B. Franklin, M o b i l e - - 3

J. Greer, C h i c a g o - - 3 S. Jamaluddin, L o n g I s l a n d - - 3

R. Norris, M a i n e - - 3

H. Shore, Tulsa - - 3

T. Nichols, West Tennes see - - 3

G. Ullman, L a k e s h o r e - - 3

C. Casey, A r i z o n a - - 2

S. Colton, A r i z o n a - - 2

A. DeMarco, N e w O r l e a n s - - 2

E. Duplantis, S a n A n t o n i o - - 2

S. Henson, S p o k a n e - - 2

R. Holman, Flor ida S p a c e C o a s t - - 2

R. Johnson, Detroit - - 2 P. Krishnasamy, I n d i a - - 2

T. Lettich, S a c r e m e n t o - - 2

S. Luis, Jr., C a l i f C e n t r a l C o a s t - - 2

G. Mulee, R o c h e s t e r - - 2

J. O'Neal, O z a r k - - 2

R. Painter, H o l s t o n Valley - - 2

S. Schrecengost, Pi t t sburgh - - 2

T. Shirk, T i d e w a t e r - 2

R. Stobaugh, Jr., C a r o l i n a - - 2

R. Warner, U t a h - - 2

M. Wilkes, M a h o n i n g Valley - - 2

R. Wright, S o u t h e r n C o l o r a d o - - 2

Student Sponsors M e m b e r s w h o s p o n s o r e d 3 o r m o r e

n e w s t u d e n t m e m b e r s b e t w e e n J u n e 1,

2003, a n d M a y 31, 2004.

D. Scott, Peoria - - 67 G. Euliano, N o r t h w e s t e r n Pa. - - 42 R. Olson, S i o u x l a n d - - 36 R. Norris, M a i n e - - 35 W. Kielhorn, E a s t Texas - - 34 H. Jackson, L . A . / I n l a n d E m p i r e - - 31 M. Pointer, Sierra N e v e d a - - 27 C. Donnell, N o r t h w e s t O h i o - - 26 E Mong, P i t t s b u r g h - - 26 J. Sullivan, M o b i l e - - 26 T. Buchanan, M i d - O h i o Valley - - 25 D. Hatfield, Tulsa - - 24 S. Sivinski, M a i n e - - 24 M. Arand, L o u i s v i l l e - - 23 C. Overfelt, S o u t h w e s t Virginia - - 23 M. Wilkes, M a h o n i n g Valley - - 23 D. Combs, S a n t a Clara Valley - - 22 D. Ketler, W i l l i a m e t t e Valley - - 21 E Juckem, M a d i s o n - B e l o i t - - 20 D. Kowalski, Pi t t sburgh - - 20 S. Robeson, C u m b e r l a n d Valley - - 20 C. Daily, P u g e t S o u n d - - 19 L. Davis, N e w O r l e a n s - - 19 E Wernet, L e h i g h Valley - - 19 J. Carey, B o s t o n - - 18 B. Chesney, G m ~ & White M o u n t a i m - - 17 T. Baldwin, A r r o w h e a d - - 16

J. Daugherty, L o u i s v i l l e - - 16 R. Durham, C i n c i n n a t i - - 16 A. Reis, Pi t t sburgh - - 16 J. Hepburn, J o h n s t o n - A l t o o n a - - 15 D. Roskiewich, P h i l a d e l p h i a - - 15 M. Anderson, I n d i a n a - - 14 W Harris, Pascagoula- 13 T Strickland, A r i z o n a - - 13 K. Ellis, C e n t r a l P e n n s y l v a n i a - - 12 A. Badeaux, W a s h i n g t o n D.C. - - 12 W. Galvery, L o n g B c h . / O r a n g e Cty. - - 12 J. Miller, S a n D i e g o - - 12 J. Smith, Jr., M o b i l e - - 12 P. Walker, O z a r k - - 12 D. Weeks, S o u t h w e s t Virginia - - 12 J. Boyer, L a n c a s t e r - - 11

R. Tupta, Jr., M i l w a u k e e - - 11 R. Williams, O z a r k - - 11

D. Vranich, N o r t h F l o r i d a - - 11

M. Koehler, M i l w a u k e e - - 10 J. Pelster, S o u t h e a s t N e b r a s k a - - 10 A. Vidick, W y o m i n g - 10 G. Gammill, N o r t h e a s t Mis s i s s ipp i - - 9

W. Johnson, P o r t l a n d - - 9

J. Mendoza, S a n A n t o n i o - - 8

J. Morash, B o s t o n - - 8

R. Rux, W y o m i n g - - 8

J. Swoyer, L e h i g h Valley - - 8

S. Colton, A r i z o n a - - 7

J. Compton, S a n F e r n a n d o Valley - - 7

A. Dommer, K e r n - - 7

R. Gallagher, Jr., L e h i g h Valley - - 7

C. Kipp, L e h i g h Valley - - 7

W. Howell, S a b i n e - - 6

M. Tryon, Utah - - 6

D. Zabel, S o u t h e a s t N e b r a s k a - - 6

J. Carney, Western M i c h i g a n - - 5

T. Kienbaum, C o l o r a d o - - 5

J. Livesay, N a s h v i l l e - - 5

A. Mattox, L e x i n g t o n - - 5

S. MacKenzie, N o r t h e r n M i c h i g a n - - 5

W Miller, N e w Jersey - - 5

R. Richwine, I n d i a n a - - 5

S. Williams, C e n t r a l A r k a n s a s - - 5

J. Ciaramitaro, North Central Flo~4a - - 4

R. Douglas-Wells, A t l a n t a - - 4

E Henry, L . A . / l n l a n d E m p i r e - - 4

W. Menegus, L e h i g h Valley - - 4

A. Ochoa, S a n F r a n c i s c o - - 4

J. Olivarez, Jr., P u g e t S o u n d - - 4

H. Riviere, S o u t h F l o r i d a - - 4

D. Smith, N i a g a r a Fron t i e r - - 4

W. Wilson, N e w O r l e a n s - - 4

C. Bridwetl, O z a r k - - 3

T. Bur, N o r t h e r n M i c h i g a n - - 3

R. Chase, L . A . / I n l a n d E m p i r e - - 3

J. Crosby, A t l a n t a - - 3

R. Grays, K e r n - - 3 R. Hilty, P i t t s b u r g h - - 3

S. Hoff, S a n g a m o n Valley - - 3

R. Huston, O l y m p i c - - 3

C. Jones, H o u s t o n - - 3

R. Ledford, Jr., B i r r n i n g h a m - - 3

S. Luis, Jr., Cahfomia Central C o a s t - - 3

H. McRae, N e w York - - 3

G. Moreno, L o n g B c h . / O r a n g e Cry. - - 3

T. Shirk, T i d e w a t e r - - 3

M. Tait, L . A . / I n l a n d E m p i r e - - 3 •

~,&m JUNE 2004 I

I

Brent lrvine (right) holds his Big Dig, speaker plaque presented to him by Jim Devine, chair, ASNT Boston Chapter.

DISTRICT 1 Director: Russ Norris Phone: (603) 4 3 3 - 0 8 5 5

BOSTON APRIL 13 Speaker: Brent Irvine, public affairs specialist Affiliation: Massachusetts Turnpike Authority Topic: The Big Dig public works project Activity: This was a joint meeting with members of the local chapter of ASNT, hosted by them at The Chateau Restau- rant in Norwood, Mass.

CENTRAL MASS./R.I. FEBRUARY 14 Speakers: Dave Bergman, owner; Ronald Pond, race car builder Affiliation: McKenna Performance Topic: The skills needed to build a race car from scratch Activity: The program was held at the McKenna Performance shop at the speedway in Seekonk, Mass.

DISTRICT 2 Director: Kenneth R. Stockton Phone: (732) 7 8 7 - 0 8 0 5

NEW JERSEY APRIL 20 Speaker: Margaret O'Meara, president

Dave Bergman (left) accepts a speaker certificate from Paul Mendez, vice chair of the Central Massachusetts~Rhode Is- land Section, in February.

Affiliation: O'Meara Financial Group Topic: Managing your money Activity: The program was held at EAf- faire Restaurant in Mountainside, N.J.

NEW YORK FEBRUARY 9 Speaker: William Dotson, manager Affiliation: The Lincoln Electric Co. Topic: Future impact of automation on U.S. manufacturing industry Activity: The program was held at Buck- ley's Restaurant in Brooklyn, N.Y.

DISTRICT 3 Director: Alan J. Badeaux, Sr. Phone: (301) 934-9061

YORK CENTRAL PENNSYLVANIA MARCH 4 Activity: AWS President Thomas Mustaleski met with students at the York County School of Technology's welding department. This school uses the AWS SENSE teaching program. Mustaleski discussed electron beam welding.

APRIL 1 Speaker: Francis Butkns, owner Affiliation: Welding & Thermal Tech- nologies, Inc. Topic: Thermal spray coatings Activity: This York Central Pennsylva- nia Section program was held at Four

Speaker Margaret O'Meara chats with Vince Murray at the New Jersey Section program. April 20.

William Dotson (left) accepts a speaker gift from Vice Chair Bob Waite at the New York Section program in February.

George Bottenfield (left), York Central Pennsylvania Section chair, presents Francis Butkus with a speaker gift at the April i meeting.

WELDING JOURNAL B ' $ ' !

A WS President Tom Mustaleski (wearing a necktie) is shown with welding students during his visit to the York Central Pennsylvania Section.

Mike Bunnell (right) accepts the Past Chairman's Appreciation Award from York Central Pennsylvania Section Chair George Bottenfield in April.

Speaker Jimmy Singley (left) is shown with Terry Williams at the North Central Florida program in February.

Shown at the February South Carolina Section program are (from left) Gale Mole, chair, and speaker Steve Gillard.

Speaker John Letki (left) is shown with Gale Mole, South Carolina Section chair, at the March meeting.

IB~r.ll JUNE 2004 I

Welding students and Rochester Section members are shown during the Students' Night program held March 30.

Points Sheraton. Past Chair Mike Bun- nell presented current Chair George Bottenfield the Chairman Appreciation Award.

DISTRICT 4 Director: Ted Alberts Phone: (540) 674-3600, ext. 4314

NORTHEASTERN CAROLINA MARCH 25 Speaker: Roy Lanier, welding teacher Affiliation: Pitt Community College Topic: Planning for the future Activity: The meeting was held at Pitt Community College in Greenville, N.C. For Section information and meeting plans, contact Roy Lanier at (252) 321- 4285.

DISTRICT 5 Director: Leonard P. Connor Phone: (954) 9 8 1 - 3 9 7 7

NORTH CENTRAL FLORIDA FEBRUARY 10 Speaker: Jimmy Singley, sales manager Affiliation: ESAB Welding & Cutting Products Topic: Oxyfuel safety Activity: Following the presentation, the

Section toured the Florida Department of Transportation maintenance yard in Gainesville, Fla. Guides for the tour included DOT staff Bruce Strickland, Michael Adams, Terry Williams, Wal- ter Hall, and Eddie Thompson.

SOUTH CAROLINA FEBRUARY 19 Speaker: Steve Gillard, district representative Affiliation: Victor Equipment Co. Topic: Safety with compressed gases and welding/cutting equipment Activity: The program was held at Air Star, Inc., in North Charleston, S.C.

MARCH 18 Speaker: John Letld, welding engineer Affiliation: Crenlo, LLC Topic: Special welding applications used by aerospace, automotive, U.S. Dept. of Defense, and automation Activity: The program was held at Shoney's in North Charleston, S.C.

DISTRICT 6 Director: Neal A. Chapman Phone: (315) 3 4 9 - 6 9 6 0

ROCHESTER MARCH 30 Activity: The Section hosted its Stu- dents' Night program featuring hands- on displays of welding equipment and

inverter power supplies provided by local distributors. The students were invited to apply for scholarships, and ad- vised about welding-related job opportunities in the area.

DISTRICT 7 Director: Robert J. Tabernik Phone: (614) 4 8 8 - 7 9 1 3

COLUMBUS APRIL 15 Speaker: Paul Denny Affiliation: Edison Welding Institute Topic: The latest and greatest in lasers Activity: The program was held at Da Vinci's Restaurant in Columbus, Ohio.

PITTSBURGH MARCH 25 Speakers: Mike Oertter, certified diver; and Mike Boorean, PowerPoint instructor Affiliation: Seneca College Topic: The skills and requirements needed to be a certified SCUBA diver

MARCH Activity: Dale Glavin guided welding students from Pittsburgh's South Vo- Tech High School on a tour of Local #449 Steamfitters apprenticeship training center. The students received a wealth of information on the benefits of becoming a steamfitter welder, including salary expectations, benefits, and pension plans.

DISTRICT 8 Director: Wallace E. Honey Phone: (256) 3 3 2 - 3 3 6 6

CHATTANOOGA MARCH 16 Activity: The Section toured Valmont Industries in Jasper, Ga., to study its oxyfuel and plasma arc cutting and welding operations. The facility manufactures steel poles used for the power utility, transportation, and communication industries.

MARCH 29 Activity: The Chattanooga Section hosted a tour for local welding students to the Dave Hamilton Tennessee Valley Railroad Museum in Chattanooga, Tenn. More than 200 students from Hamilton and surrounding counties rode the steam-powered train and toured the facilities.

Jerry Van Meter (left), Columbus Section vice chair, presents a speaker gift to Paul Denny at the April program.

Mike Boorean (left), Pittsburgh Section secretary, is shown with speaker Mike Oertter at the March program.

Pittsburgh South Vo-Tech High School welding students are shown outside the Local #449 Steamfitters facility they toured in March.

NORTHEAST MISSISSIPPI AFRIL 15 Activity: The Section toured the Nissan manufacturing plant in Canton, Miss. Rohbin Shull, Chairman Steven Leach, and Dr. Berry coordinated the event.

WESTERN NORTH CAROLINA MARCH 18 Activity: The Section officers met to plan for initiating a Section newsletter with supporting advertisers, and make plans for attending the District 8 conference. The meeting was held at the BMW plant in Spartanburg, S.C.

Speaker Mike Elliott (left) is shown with Paul Herbert, secretary, at the New Or- leans Section program in March.

DISTRICT 9 Director: John Bruskotter Phone: (504) 3 6 3 - 5 9 0 0

NEW ORLEANS MARCH 16 Speaker: Mike Eiliott, sales rep Affiliation: Industrial Welding Supply Topic: Stud welding Activity: The Section hosted its Stu- dents' Night for 97 attendees at Indus- trial Welding Supply in Harvey, La.

DISTRICT 10 Director: Victor Y. Matthews Phone: (216) 3 8 3 - 2 6 3 8

CCCTC Student Chapter MARCH Activity: The Mahoning Valley Section hosted a program for its Student Chap- ter at Columbiana County Career and Technical Center (CCCTC) at the school in Lisbon, Ohio.

I WELDING JOURNAL Blrni

Shown at the March New Orleans Section program arc (from left) Tony DeMarco, and New Orleans Pipe Trades welding students Hank Guhon, Terrance Brown, Theron Moses, and Chad Dubea

Student Chapter members from Cohtmbiana County Career and Technical Center pose in March at a program arranged for them by the Mahoning Valley Section.

Shown at the Detroit Section program arc (from left) Heath Drone, Nick Perry, and Matt Albright, the winners of the Michi- gan Area Sections' Traveling Cup. The trophy is presented to the winners of the annual Quiz the Expel:ts event.

Fox Valley sharpshooter Rick Duba lines up a shot during the Section's sporting clay shoot in March.

DISTRICT 1 1 Director: Eftihios Siradakis Phone: (989) 8 9 4 - 4 1 0 1

DETROIT APRIL 19 Activity: The Section hosted its annual Quiz the Experts event, won for the second year in a row by the team from the Ferris State University Student Chap- ter. The runners-up were teams from the Detroit, Central Michigan, and Western Michigan Sections. The FSU team members were Heath Drone, Nick Perry, and Matt Albright.

NORTHWEST OHIO MARCH 22 Speakers: Larry Blake, Richard West Topic: Touch-start GTA welding Activity: Blake and West demonstrated the proper techniques for connecting air-cooled GTAW torches and how to use them. Everyone had the opportunity to weld using the equipment. The program was held at Owens Commu- nity College.

APRIL 8 Speaker: Dennis Klingman, director of technical training Affiliation: The Lincoln Electric Co. Topic: The materials and processes used

Di: la JUNE 2004 I

Scot Forbes informed the students about career opportunities in the welding inspection field at the Fox Valley Section program in April.

to fabricate racing and off-road vehicles Activity: Klingman cited the fabrication requirements for each of the 18 specialty vehicles on display. This North- west Ohio Section meeting was held at Owens Community College.

DISTRICT 12 Director: Michael D. Kersey Phone: (262) 6 5 0 - 9 3 6 4

FOX VALLEY MARCH 27 Activity: The Section hosted its spring sporting clay shoot outing at Hunters Park in Brillion, Wis.

APRIL 7 Activity: Twenty-five Fox Valley Section members traveled to Chicago for the AWS Welding Show.

APRIL 13 Activity: The Section hosted its Stu- dents Night program at Fox Valley Tech- nical College in Appleton, Wis. The speakers were Scan Moran and Dennis Tiedt from Miller Electric Mfg. Co.; Kory'russ, Seaview Diving Contractors; Dave Hoffman, FVTC; Michael Kersey, The Lincoln Electric Co.; and Scot Forbes from TechAid.

DISTRICT 13 Director: Jesse L. Hunter Phone: (309) 3 5 9 - 8 3 5 8

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BLACKHAWK MARCH 13 Activity: The Section held its awards presentation program in Rockford, Ill.

J.A.K. MARCH 6 Activity: The Section held its awards program in Kankakee, I11.

PEORIA MARCH 18 Activity: The Section hosted its second annual welding contest, held at the Illi- nois Central College welding shop. The top winners in the College/Apprentice class were Chris Sieg, Todd Short, 3~ler Kocher, and William Scott. High School class winners were Kris Weiss, Corey Dawson, Curtis Postin, and Jeremy Vance. Curt Rippey, Section chair, served as the program coordinator. Robert Swegle, training coordinator, represented the Mid-Central Illinois Regional Council of Carpenters-JATC.

DISTRICT 14 Director: Tully C, Parker Phone: (618) 6 6 7 - 7 7 4 4

DISTRICT 15 Director: J. D. Heikkinen Phone: (800) 2 4 9 - 2 7 7 4

ARROWHEAD MARCH 18 Activity: The Section members and local welding students toured Tri-Tech of Minnesota's fabrication shop in Mt. Iron, Minn. Mitchell Robertson, Tri- Tech CEO, lectured on the Descender M-50, the company's hydraulic lift used for servicing city manholes and sewer systems. Following the tour, the members dined at Adventurers Grill in Vir- ginia, Minn.

i Mitchell Robertson (right) conducted the Arrowhead Section members on a tour of Tri-Tech of Minnesota in March.

Dave HoJJman demonstrates robotic welding to attendees at the Fox Valley Student Night program in April

Blackhawk Section members are shown at their meeting in March.

J.A.K. Section members pose at the awards-presentation meeting in March.

Shown at the Peoria Section's second annual welding contest are (from left) William Scott, Roderick Eyers, Chris Sieg, and Robert Swegle.

WELDING JOURNAL m ' ~ l

Shown during the Arrowhead Section's tour of the Tri- Tech of Minnesota facilities are (from left) Joe Stauty, Bill Wiltse, District 15 Director Jack Heikkinen, Dan Edblon, speaker Mitchell Robertson, Adam Edblon, Jason Kotnik, Trevor Anderson, Tom Bald- win, and Darren Akkanen.

Shown at LeTourneau University's booth at the A WS Welding Show are (from left) Pro- fessor Robert Warke, Courtney McCollum, Jim Sullens, Milton Coker, Caleb Roepke, Stephen Stoll, Dale Jones, Jonathan Ridenour, Aaron Bliss, and John Harshaw.

Shown at the North Texas Section meeting are speaker Joseph Woehrle (left) and Chairman Kirk Jordan.

Michael Kessler (left) accepts the Tulsa Section's A WS cap as a speaker gift from Chairman Todd Fradd at the March meeting.

I : I ) IE JUNE 2004 I I

DISTRICT 16 Director: Char les F. Burg Phone: (515) 2 3 3 - 1 3 3 3

KANSAS CITY MARCH 16 Speaker: Bob Simmons Affiliation: The Lincoln Electric Co. Topic: Technology advances in welding machines

APRIL 3 Activity: The Kansas City Section hosted its spring seminar on weld doc- umentation, welding procedure specifications, welding procedure qualification records, and welder performance qualifications. Presenters were Dick Blaisdell, Barry Hamilton, Kevin John- ston, David MeKenzie, Sam Newhouse, Steve Sprague, Bob Worthington, and Dennis Wright. The training was held at Black & Veatch in Overland Park, Kans.

MID PLAINS MARCH 25 Speaker: Dean Kurth Affiliation: Small Business Administra- tion (SBA) Topic: How the SBA helps small businesses in west-central Nebraska Activity: The program was held at the

Sam Newhouse reviews weld documen- tation methodology with participants in the Kansas City Section's spring seminar.

Nebraska Machinery Co. plant in North Platte, Neb.

NEBRASKA MARCH 18 Speaker: Mike Vincent, steel department manager Affiliation: Kleinfelder Co. Topic: D1.3, Structural Welding Code - - Sheet Steel Activity: The Section discussed the details of the D1.3 Code regarding what inspectors look for in welding procedure qualifications, welder performance qualification, and fabrication inspections.

DISTRICT 17 Director: Oren P. Reich Phone: (254) 8 6 7 - 2 2 0 3

EAST TEXAS MARCH 25 Speaker: J. Jones, training specialist Affiliation: Victor Equipment Co. Topic: Setup and safe use of oxyfuel and gas equipment Activity: Jones included product demonstrations in his presentation for the 63 attendees. The program was held at Tyler Jr. College in Tyler, Tex.

LeTourneau University Student Chapter APRIL 6--8 Activity: Members of the East Texas Section's LeTourneau University Stu- dent Chapter, Longview, Tex., staffed the university's booth for three days at the AWS Welding Show in Chicago.

NORTH TEXAS MARCH 16 Speaker: Joseph Woehrle, field officer Affiliation: Texas Workers' Compensa- tion Commission, Ft. Worth, Tex. Topic: Occupational safety Activity: The meeting was held at Mer- cado Juarez Restaurant in Dallas, Tex.

TULSA MARCH 23 Speaker: Michael Kessler, associate professor, Dept. of Engineering Affiliation: University of Tulsa Topic: Self-healing polymers The program was held at the Tulsa Tech- nology Center in Tulsa, Okla.

DISTRICT 18 Director: John L. M e n d o z a Phone: (210) 8 6 0 - 2 5 9 2

CORPUS CHRISTI MARCH Activity: The Section held its officer installation and awards-presentation program. John Mendoza, District 18 director, presented a special district appreciation award to Tommy Campbell, and the Dalton E. Hamilton CWI of the Year Award to Raul Robles.

Shown at the Corpus Christi Section program in March are (from left) District 18 Di- rector John Mendoza, Tommy Campbell, David Savoy, and Raul Robles.

SABINE NOVEMBER 18, 2003 Speaker: Tony Mydland, QA manager Topic: Ethics in the workplace, and integrity of inspections Activity: Alton Wolf received his Silver Certificate for his 25 years of membership in the Society.

MARCH 16 Speakers: Chris Green, vice president; Keith Browning, sales manager Affiliation: Greson Technical Sales Topic: The lock ring system Activity: The Sabine Section's board met to approve the awarding of a fifth annual scholarship to be named in honor of longtime member Alton Wolf.

SAN ANTONIO APRIL 14 Speaker: Ron Haler, technical sales manager Affiliation: Thermadyne Industries Topic: Cutting GTA welding costs Activity: John Mendoza, District 18 director, presented the Educator of the year Award to Robert Medina.

NOTICE The Section picnic will be held Satur- day, August 14, at Braun Hall, in San Antonio, Tex.

Shown at the Corpus Christi Section program are (from left) John Mendoza, District 18 director; David Savoy, deputy District 18 director; Bridget Emery, Johnny Grimes, Misty Rails, John Rails, and Tommy Campbell.

(From left) Sabine Chair James Amy presents a speaker gift to Chris Green and Keith Browning at the March program.

Sabine Section Chair James A my (left) presents a speaker gift to Tony Mydland at the November program.

DISTRICT 19 Director: Phil Z a m m i t Phone: (509) 4 6 8 - 2 3 1 0 ext. 120

Robert Medina (right) accepts the Edu- cator of the Year Award from John Men- doza, District 18 director, at the San An- tonio Section program in April.

Alton Wolf (left) received his Silver Cer- tificate Award from Morris Weeks at the Sabine program in November.

I WELDING JOURNAL l:~n

Puget Sound LWTC Student Chapter members are (standing, from left) Andrew Cor- nelissen, Christian Fritz, Andy Winsberg, James Allen, Jon Kirwin, and Martin Chap- man. Welding instructors Don Marshall and Linelle Russ pose in front.

PUGET SOUND APRIL 1 Speaker: John A. Pursley, president Affiliation: Envision Topic: Gamma and X-ray imaging Activity: Chair Sid Capouilliez and Treasurer Shaven McDaniel announced a new scholarship fund had been established to honor Gary Diseth and the late Wally Urbick. The first check was awarded to student Danielle Slatinsky, secretary of the Lake Washington Tech- nical College (LWTC) Student Chap- ter.

DISTRICT 20 Director: Nancy M. Carlson Phone: (208) 5 2 6 - 6 3 0 2

DISTRICT 21 Director: Les Bennett Phone: (805) 3 4 8 - 1 8 3 0

DISTRICT 22 Director: Kent S. Baucher Phone: (559) 276 -9311

C7B Committee Has Reasons to Celebrate The American Welding Society's

C7B Subcommittee on Electron Beam Welding and Cutting convened April 4th at the Welding Show in Chicago to get down to business on its standards. The meeting was opened by Pat Hochanadel, the new subcommittee chairman. The occasion for the picture was the announcement that the Sub- committee had just published its revised edition of AWS C7.1M/C7.1:2004, Rec- ommended Practices for Electron Beam Welding.

This new standard is an enhanced 115-page document containing an expanded Practical Examples section and extended glossary in the Annex section. The document has been modified to include both metric and U.S. customary dimensions. The publication of this document, along with the reaffirmation last October of the Subcommittee's AWS C7.31999R, Process Specification for Electron Beam Welding, mark the completion of several years of subcommittee work.

Attending the program were Ken Zacharias, Hamilton Sundstand Space Systems; Gordon Gibbs, Sandia Na- tional Labs; Richard l-luber, AWS past president; Donald Powers, PTR Preci-

II :PII JUNE 2004 I

Shown (from left) at the C7B Subcommittee meeting are Ken Zacharias, Gordon Gibbs, Richard Huber, DonaM Powers, Ernest Levert, Tom Mustaleski, Pat Hochanadel, Todd Palmer, Ray Shook, Ken Lachenberg, Doug Kautz, and Harold Ellison.

sion Technologies; Ernest Levert, Lock- heed Martin Missile and Fire Control; Tom Mustaleski, BWXT Y-12 LLC; Pat l-lochanadel, Los Alamos National Lab; Todd Palmer, Lawrence Livermore Na- tional Lab; Ray Shook, AWS executive director; Kenn Lachenberg, Sciaky; Doug Kautz, Los Alamos National Lab; and Harold Ellison, AWS staff secre-

tary to the C7B Subcommittee. Copies of the Recommended Prac-

tices for Electron Beam Welding and the Process Specification for Electron Beam Welding are available from Global En- gineering Documents, 15 Inverness Way East, Englewood, CO 80112-5776; and online at www.globaLihs.com. ,

The 2003-2004 AWS Member-Get-A-Member Campaign* RECRUIT NEW MEMBERS... WIN GREAT PRIZES

A s imple way to give b a c k to your p rofess ion , s t rengthen AWS and win grea t pr izes is by par t ic ipa t ing in th-

2OO3-2OO4 M e m b e r - G e t - A - M e m b e r Campaign . By recru i t ing new m e m b e r s to AWS, y o u ' r e add ing to the r e s o u r c e s n e c e s s a r y to e x p a n d your benefi ts as an AWS Member . Plus, you b e c o m e par t of an exclusive g r o u p of AWS M e m b e r s who get involved. Year round , you' l l have the oppor tun i ty to recru i t new m e m b e r and be eligible to win speci,,d contes ts and prizes. Referra ls a re ou r mos t successfu l m e m b e r r ec ru i tmen t Our M e m b e r s k n o w f i rs t -hand how useful AWS M e m b e r s h i p is. Who bet ter than you to e n c o u r a g e someol

to join AWS?

-~,~,mf,~% 7 events every year. • Access to widely recognized AWS Certification

programs. • New Members can save nearly 90% off an AWS

publication. Choose from four of our most popular titles (see reverse).

• AWS Membership Certificate and Card.

• Members'-only discounts on auto insurance, car rentals, credit cards and more.

• Connection to career opportunities through AWS JobFind - at www.aws.org/jobfind

• The American Welder section of the WJ geared toward front-line welders.

• And much more!

GET INVOLVED TODAY, AND WIN! PRIZE CATEGORIES President's Honor Roll: Recruit 1-5 new Individual Members and receive a welding ball cap.

President's Club: Recruit 6-10 new Individual Members and receive an American Welder TM polo shirt.

Pres ident ' s Roundtable : Recruit 11-19 new Individual Members and receive an American Welder TM watch.

President's Guild: Recruit 20 or more new Individual Members and receive an American Welder TM watch, a one-year free AWS Membership, the "Shelton Ritter Member Proposer Award" Certificate and membership in the Winner's Circle.

Winner's Circle: All members who recruit 20 or more new Individual Members will receive annual recognition in the Welding Journal and vii] be honored at the AWS Welding Show.

SPECIAL PRIZES Participants will also be eligible to win prizes in spedalized categories. Prizes will be awarded at the close of the campaign (June 2004).

Sponsor of the Year: The individual who sponsors the greatest number of new Individual Members during the campaign will receive a plaque, a trip to the 2005 AWS Welding Show, and recognition at the AWS Awards Luncheon at the AWS Welding Show.

Student Sponsor Prize: AWS Members who sponsor two or more Student Members will receive a welding ball cap.

The AWS Member who sponsors the most Student Members wii] receive a free, one-year AWS Membership and an American Welder TM polo shirt.

International Sponsor Prize: Any member residing outside the United States, Canada and Mexico who sponsors the most new Individual Members will recei,~ a complimentary AWS Membership renewal.

*The 2003.2004 MGM Campaign runs from June 1, 2003 to May 31, 2004. Prizes are auorded at the close of the campaign.

LUCK OF THE DRAW For every new member you sponsor, your name is entered into a quarterly drawing. The more new members you sponsor, the greater your chances of winning. Prizes will be awarded in November 2003, as well as in February and June 2004. Prizes Include: • American Welder TM T-shirt • one-page, blackN;hite ad in the Welding Journal • Complimentary AWS Membership renewal • American Welder TM polo shirt • American Welder TM baseball cap

SUPER SECTION CHALLENGE The AWS Section in each District that achieves the highest net percentage increase in new Individual Members before the June 2004 deadline ~ill receive special recognition in the F/eldingjournal.

The AWS Sections with the highest numerical increase and greatest net percentage increase in new Individual Members will each receive the Neitzel Membership Award.

American Welding Society ~ e ~ ; ' ~ t a m ~

Visit our website http://www.aws.org

All AWS technical committee meetings are open to the public. Persons wishing to attend a meeting should contact the staff secretary of the committee as listed below at AWS, 550 N.W. LeJeune Rd., Miami, FL 33126; telephone (305) 443-9353.

June 2-3, B2F Subcommittee on Plastic Welding Qualifications. Rancho Mirage, Calif. General meeting. Staff contact: S.P. Hedrick, ext. 305.

June 16, Safety and Health Committee. Columbus, Ohio. General meeting. Staff Contact: S. R Hedrick, ext. 305.

June 25, Committee on Personnel and Facil- ities Qualification. Columbus, Ohio. Gen- eral meeting. Staff Contact: S. P. Hedrick, ext. 305.

ISO Draft Standards for Public Review Copies of the following draft international standards are available for review and com- ment from ANSI, 25 W 43rd St., 4th Floor, New York, NY 10036; (212) 642-4900.

ISO/DIS 22827-1, Acceptance Tests .for Nd: YAG Laser Beam Welding Machines - - Ma- chines with Optical Fibre Delivery - - Part 1: Laser Assembly

ISO/DIS 22827-2, Acceptance Tests .for Nd: YA G Laser Beam Welding Machines - - Ma- chines with Optical Fibre Delivery - - Part 2: Moving Mechanism

Revised Standard Approved by ANSI B5.17:2004, Specification for the Qualifica- tion of Welding Fabricators. Approval date: March 23, 2004.

Standards for PINS Development work has begun on the fol-

lowing new or revised standards. Directly and materially affected individuals are invited to contribute to the development of such standards. Contact the Staff Engineer listed with the document. Participation on AWS Technical Committees and Subcommittees is open to all persons.

B2.1 - 1-016-94, Standard Welding Procedure Specification (WPS) ]br Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2), 1/8 through l- 1/2 in. Thick, E7018, As- WeMed or PWHT. This standard describes the method of welding carbon steel to carbon steel using the SMAW process. Stakehold- ers: Engineering contractors, purchasers, and fabricators of welded products. Reaf- f irmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-1-017-94, Standard Welding Procedure Specification (WPS) for Shielded Metal Arc Welding of Carbon Steel (M-1/P-I/S-I, Groups 1 or2), 1/8 through 1-1/2 in. Thick, E6010, As- Welded or PWHT Condition. This standard describes the method of welding carbon steel to carbon steel using the SMAW process. Stakeholders: Engineering contractors, purchasers, and fabricators of welded products. Reaff irmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-1-018-94, Standard Welding Procedure Specification (HIPS).for Self-Shielded Flux Cored Arc Welding of Carbon Steel (M-1/P- I/S-l, Groups 1 or 2), 1/8 through 1-1/2 in. Thick, E71T-8, As-Welded Condition. This standard describes the method of welding carbon steel to carbon steel using the FCAW, self-shielded welding processes. Stakehold- ers: Engineering contractors, purchasers, and fabricators of welded products. Reaffirmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-1-019-94, Standard Welding Procedure Specification (WPS) for CO 2 Shielded Flux Cored Arc Welding of Carbon Steel (M-I/P- 1/S-1, Groups 1 or 2), l/8 through 1-1/2 in. Thick, E7OT-I and E7IT-I, As-Welded Condi- tion. This standard describes the method of welding carbon steel to carbon steel using the FCAW, CO 2 gas-shielded processes. Stake- holders: Engineering contractors, purchasers, and fabricators of welded products. Reaffirmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-1-020-94, Standard Welding Procedure Specification (WPS).for 75% A/25% CO 2 Shielded Flux Cored Arc Welding of Carbon Steel (M-I/P-I/S-I, Groups 1 or2), 1~8through 1-l/2 in. Thick, E7OT-1 and E71T-1, As-Welded or PWHT Condition. This standard describes the method of welding carbon steel to carbon steel using the FCAW, Ar-CO 2 gas- shielded processes. Stakeholders: Engineer- ing contractors, purchasers, and fabricators of welded products. Reaffirmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-1-021-94, Standard Welding Procedure Specification (HIPS) for Gas Tungsten Arc" Welding of Carbon Steel (M- 1/P- 1 / S- 1, Groups 1 or 2), 1/8 through 1-1/2 inch Thick, ER70S- 2 and E7018, as-Welded or PWHT Condition. This standard describes the method of welding carbon steel to carbon steel using the GTA followed by SMA welding processes. Stake- holders: purchasers of welded products, fabricators, of welded products, and engineering contractors. Reaffirmed standard. Engi- neer: Richard McGinnis, ext. 471

B2.1-1-022-94, Standard Welding Procedure Specification (WPS) for ShieMed Metal Arc Welding of Carbon Steel (M-1/P-HS-1, Groups l or 2), 1/8 through 1-1/2 inch Thick, E6010 (Vertical Uphill), followed by E7018, As- Welded or PWHT Condition. This standard describes the method of welding carbon steel to carbon steel using the SMA welding process. Stakeholders: Purchasers and fabricators of welded products, and engineering contractors. Reaffirmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-8-023-94, Standard Welding Procedure Specification (WPS) for Shielded Metal Arc' Welding of Austenitic Stainless Steel (M-8/P- 8/S-8, Group 1), As-Welded Condition. This standard describes the method of welding stainless steel to stainless steel using the SMA welding processes. Stakeholders: Purchasers of and fabricators of welded products, and engineering contractors. Reaff irmed standard. Engineer: Richard McGinnis, ext. 471

B2.1-1-026-94, Standard Welding Procedure Specification (WPS).for Shielded Metal Arc WeMing of Carbon Steel (M-lIP-I/S-I, Groups 1 or2), 1~8through 1-1/2in. Thick, E6010 (Ver- tical Downhill)followed by E7018 As-Welded Condition. This standard describes the method of welding carbon steel to carbon steel using the SMA welding process. Stake- holders: Purchasers and fabricators of welded products, and engineering contractors. Reaff irmed standard. Engineer: Richard McGinnis, ext. 471

D3.6M:200X, Specification for Underwater Welding. This specification covers underwater welding in both dry and wet environments. Operations required at the surface related to and in support of underwater welding are within the scope of this document, but welding above the surface is not. All provisions of this document apply equally to new construction and to modification and repair of existing structures underwater. Stakehold- ers: marine construction and repair. Revised standard. Engineer: Brian McGrath, ext. 311

D3.7:2004, Guide for Ahtminum Hull Weld- ing. This guide provides information on proven processes, techniques, and procedures for welding aluminum hulls and related ship structures. The information presented applies chiefly to the welding of aluminum hulls that are over 30 ft (9 m) in length and made of sheet and plate 1/8 in. (3.2 ram) thick and greater. Thin-gauge aluminum welding usually requires specific procedures in the areas of fixturing, welding sequence, and other techniques for distortion control that are not necessarily applicable to thick plates. Similarly, the choice of welding process or applicable process conditions, or both, also differs according to thickness. Stakeholders: aluminum vessel construction companies and subcontaractors. Revised standard. Engi- neer: Brian McGrath, ext. 311. •

WELDING JOURNAL I ! : ] .1 l

Guide to AWS Services 550 NW LeJeune Rd., Miami, FL 33126

Phone (800) 443-9353; (888) WELDING; FAX (305) 443-7559 Internet: www.aws.org

Phone extensions appear in parentheses.

AWS PRESIDENT James E. Greer ............. ~oro~img@aoLcom Moraine Valley Community College 248 Circlegate Rd., New Lenox, IL 60451

ADMINISTRATION Executive Director Ray W. Shook.. [email protected] ............ (210)

DeJ~uty Executive Directors JelTrey R. Hufsey .. [email protected] ....(264)

John J. [email protected] ..(235)

CFO/Deputy Executive Director Frank R. Tsrafa.. [email protected] .......... (252)

Corporate Director of Quality Management Systems Linda K. Henderson.. [email protected] (298)

Executive Assistant for Board Services and IIW Gricelda Manalich.. [email protected] _(294)

HUMAN RESOURCES Director LuIsa Hernsndez.. [email protected] .......... (266)

DATABASE ADMINISTRATION Corporate Director Jim Lankford. . jiml @aws.org .................. (214)

INTERNATIONAL INSTITUTE OF WELDING [email protected] ...................... (319)

Provides liaison activities involving other professional societies and standards organizattons, nationally and internationally.

GOVERNMENT LIAISON SERVICES Hugh K. Webster ......... [email protected] Webster, Chamberlain & Bean Washington, D.C. (202) 466-2976; FAX (202) 835-0243

Identifies funding sources for welding education, research, and development. Momtors leg- islative and regulatory issues of importance to the industry.

BRAZING AND SOLDERING MANUFACTURERS' COMMITTEE Jeff Weber.. [email protected] .................. (246)

WELDING EQUIPMENT MANUFACTURERS' COMMITTEE Mary Ellen Mills.. [email protected] ...... (444)

WELDING INDUSTRY NETWORK (WIN) Mary Ellen Mills.. [email protected] ...... (444)

CONVENTION & EXPOSITIONS Exhibiting Information .................. (242, 295)

Associate Executive Director/Sales Director Jeff Weber.. [email protected] .................. (246)

Director of Convention & Expositions John Ospina. . [email protected] .............. (462)

Organizes the annual AWS Welding Show and Convention. Regulates space assignments, registration materials, and other Expo activities.

PUBLICATION SERVICES Department Information ........................ (275)

ManagingDirector Andrew uuIIIson., [email protected]......(249)

Welding Journal Publisher/Editor Andrew Cullison.. [email protected]......(249)

National Sales Director Rob Saltzstein.. [email protected] .............. (243)

Welding Handbook Welding Handbook Editor Annette O'Brlen.. [email protected] ...... (303)

Publishes the Society's monthly magazine, Welding Journal, which provides information on the state of the welding industry, its technology, and Society activities. Publishes Inspection Trends, the Welding Handbook, and books on general welding subjects.

MARKETING Corporate Director Bob Bishopric.. [email protected] .............. (213)

Plans and coordinates marketing of AWS products and services.

Marketing C o m m u n i c a t i o n s Senior Manager George Leposky.. [email protected] ....(416)

Manager Amy Nathan.. [email protected] .............. (308)

Market ing R e s e a r c h i D e v e l o p m e n t Mana~n~ Director Debran u. Weir.. [email protected] ............ (482)

Proposes new products and services. Re- searches effectiveness of existing programs.

MEMBER SERVICES Department Information ........................ (480)

Associate Executive Director Cassie R. Burrall.. [email protected] ....(253)

Director Rhends A. Mayo.. [email protected] ...... (260)

Serves as a liaison between Section members and AWS headquarters. Informs members about AWS benefits and activities.

EDUCATIONAL PRODUCT DEVELOPMENT Director Christopher Pollock.. [email protected](219)

Information on education products, projects, and programs. Responsible for the S.E.N.S.E. program for welding education, and dissemination of training andeducation information on the Web.

CONFERENCES & SEMINARS Director Giselle I. Hufsey.. [email protected] ........ (278)

Responsible for conferences, exhibitions, and seminars on topics ranging from the basics to the leading edge of technology. Organizes CWl, SCW1, and other seminars for preparation for certification.

CERTIFICATION OPERATIONS Managin~ Director Wenoy ~. Reeve.. [email protected] ........ (293)

Director Terry Perez.. [email protected] .................. (470)

Information and application materials on certi- fying welders, inspectors, and educators..(273)

INTERNATIONAL BUSINESS DEVELOPMENT Director Walter Herrera.. [email protected] ............ (475)

AWS AWARDS, FELLOWS, and COUNSELORS Managin~ Director Wenoy ~. Reeve., [email protected] ........ (293)

Coordinates AWS awards and AWS Fellow and Counselor nominees.

TECHNICAL SERVICES Department Information ........................ (340)

ManagingDirector AndrewH. Davis.. [email protected] ....(466) International Standards Activities, American Council of the International Institute of Weld- ing (IIW)

Director, National Standards Activities Peter Howe.. [email protected] .............. (309) Machinery & Equipment Welding, Robotic & Automatic Welding, Computerization of Weld- ing Information.

Manager, Safety and Health Stephen P. Heddck.. [email protected] (305) Metric Practice, Personnel & Facilities Quahfi- cation, Safety & Health, Joining of Plastics & Composites, ASC Committee on Safety, Plas- tic Welding Qualification

Engineers Harold R Ellison.. [email protected].....(299) Welding in Sanitary Applications, Automotwe Welding, Resistance Welding, High-Energy Beam Welding, Aircraft and Aerospace, Oxy- fuel Gas Welding & Cutting. John L. Gayler.. [email protected] ........ (472) Structural Welding, Welding Iron Castings Rakesh Gupta.. [email protected] .......... (301) Filler Metals & Allied Materials, International Filler Metals, Instrumentation for Welding.

CDYnthla Jenney .. [email protected]....(304) efinitions & Symbols, Brazing & Soldering , Braz-

ing Filler Metals & Fluxes, Technical Editing.

Richard McGinnis.. [email protected] (471) Procedure & Performance Qualification, Rail- road Welding, Mechanical Testing of Welds, Methods of Inspection.

Brian McGrsth. [email protected]......(471) Thermal Spraying, Arc Welding& Cutting, Welding in Marine Construction, Piping & Tub- ing, Friction Welding, Joining Metals & Alloys, Titanium and Zirconium Filler Metals.

Official interpretations o f A WS standards may be obtained only' by' sending a request in writing to the Managing Director, Technical Services. Oral Ot~oinions on A WS standards may be rendered.

wever, such opinions represent only the personal opinions o f the particular individuals giving them. These indivtduals do not speak on be- ha l f o f A WS, nor do these oral opinions consti- tute official or unofficial opinions or interpretations o f A WS. In addition, oral opinions are in- formal and should not be used as a substitute for an official interpretation.

Technical Publications Senior Manager, Rosalinda O'Neill.. [email protected] ..(451)

AWS publishes over 200 technical standards and publications widely used in the welding industry.

WEB SITE ADMINISTRATION DireCtor Keith Thompson.. [email protected] ........ (414)

! : [ , ! JUNE 2004

Only Sustaining Members, Members, Honorary Members , Life Members , or Ret i red Members who have been members for a period of at least three years shall be eligible for elect ion as a Direc- tor or National Officer.

It is the duty of the National Nominat- ing Committee to nominate candidates for national office. The committee shall hold an open meeting, preferably at the Annual Meeting, at which members may appear to present and discuss the eligibility of all candidates.

To be considered a candidate for positions of President, Vice President, Trea- surer, or Director-at-Large, the following qualifications and conditions apply:

President: To be eligible to hold the office of President , an individual must have served as a Vice Pres ident for at least one year.

Vice President: To be eligible to hold the office of Vice President, an individual must have served at least one year as a Director, o ther than Executive Di- rector and Secretary.

Treasurer: To be eligible to hold the office of Treasurer , an individual must be a member of the Society, o ther than

a Student Member , must be frequent ly available to the Nat ional Office, and should be of executive status in business or industry with experience in financial affairs.

Director-at-Large: To be eligible for election as a Director-at-Large, an individual shall previously have held office as Chairman of a Section; as Chairman or Vice Chairman of a standing, technical or special commit tee of the Society; or as District Director.

In te res ted par t ies are to send a let- ter stating which par t icular office they are seeking, including a s ta tement of qualifications, their willingness and ability to serve if nomina ted and elected, and 20 copies of their biographical sketch.

This mater ia l should be sent to Ernes t D. Levert , Chai rman, Nat ional Nomina t ing Commi t t ee , Amer ican Welding Society, 550 NW LeJeune Rd., Miami, FL 33126.

The next mee t ing of the Nat ional Nomina t ing Commi t t ee is current ly scheduled for Apri l 2005. The term of office for candidates nomina ted at this meeting will commence June 1, 2006. •

TeleWeld FAX: (305) 443-5951

Publications Sales/Orders Global Engineering Documents (800) 854-7179 or (303) 397-7956, or online at: www.global.ihs.com.

Reprints O r d e r qual i ty c u s t o m repr in t s f r o m Claud ia S tachowiak , Fos t eRepr in t s , (866) 879-9144, ext. 121, o r e - m a i l at: sales @fostereprints. com.

AWS Mission Statement

The mission o f the American Welding Society is to provide quality products and services to its members and the

industry that will advance the science, technology, and application o f materials

joining throughout the world.

It is the intent of the American Weld- ing Society to build AWS to the highest quality standards possible. The Society welcomes your suggestions. Please contact any of the staff listed on the previous page or AWS President James E. Greer, Moraine Valley Community College, 248 Circlegate Rd., New Lenox, IL 60451.

The Honorary-Meritorious Awards Committee makes recommendations for the nominees presented for Honorary Membership, National Meritorious Certificate, William Irrgang Memorial, and the George E. Willis Awards. These awards are presented during the AWS Exposition and Convention held each spring. The deadline for submissions is July 1 prior to the year of awards presentations. Send candidate materials to John J. McLaughlin, Secretary, honorary-Meritorious Awards Committee, 550 NW LeJeune Rd., Miami, FL 33126. A description of the awards follow.

National Meritorious Cert i f icate Award: This award is given in recognition of the candidate's counsel, loyalty, and de- votion to the affairs of the Society, assistance in promoting cordial relations with industry and other organizations, and for the contribution of time and effort on be- half of the Society.

Will iam Irrgang Memorial Award: This award is administered by the American Welding Society and sponsored by The Lin- coln Electric Co. to honor the late William Irrgang. It is awarded each year to the individual who has done the most to enhance the American Welding Society's goal of advancing the science and technology of welding over the past five-year period.

George E. Willis Award: This award is administered by the American Welding Society and sponsored by The Lincoln Electric Co. to honor George E. Willis. It is awarded each year to an individual for promoting the advancement of welding internationally by fostering cooperative participation in areas such as technology transfer, standards rationalization, and promotion of industrial goodwill.

International Meritorious Cert i f i - Award: This award is given in recog-

nition of the candidate's significant contributions to the worldwide welding industry. This award should reflect "Service to the International Welding Community" in the broadest terms. The awardee is not required to be a member of the American Welding Society. Multiple awards can be given per year as the situation dictates. The award consists of a certificate to be presented at the award's luncheon or at another time as appropriate in conjunction with the AWS President's travel itinerary, and, if appropriate, a one-year membership in the American Welding Society.

Honorary Membership Award: An Honorary Member shall be a person of ac- knowledged eminence in the welding profession, or who is accredited with exceptional accomplishments in the development of the welding art, upon whom the American Welding Society sees fit to confer an honorary distinction. An Honorary Member shall have full rights of membership. •

AWS Foundation, Inc.

550 NW LeJeune Rd., Miami, FL 33126 (305) 445-6628; (800) 443-9353 ext. 293

e-mail: [email protected] general information

(800) 443-9353, ext. 689

Chairman, Board of Trustees Ronald C. Pierce

Executive Director Ray W. Shook

Director Wendy S. Reeve

The AWS Foundation is a not-for-profit corporation established to provide support for educational and scientific endeavors of the American Welding Society. Information on gift-giving programs is available upon request.

WELDING JOURNAL m : ] r j

CONFERENCES

Welding in the Defense Industry Conference July 13-14

Orlando, Florida Grosvenor Resort in the Walt Disney World Resort

Leading defense industry experts share results on overcoming weldability obstacles of aluminum, titanium, and stainless steels on an

array of applications.

Engineers wanting to use aluminum, titanium, and/or stainless steels because of their excellent mechanical properties, but who are struggling to achieve the cost economy of high-volume production, need to attend this conference.

With new available alloys and ingenious use of existing welding processes - - including friction stir welding, electron beam welding, laser beam welding, and new hybrid processes, such as flux-assisted gas tungsten arc welding - - engineers from Top 100 defense contractors will share the results of weldability development on applications that can be transferred quickly to commercial manufacturing and fabrication.

To review the program and presenters, go to www.aws.org/ conferences~defense~

Friction Stir Welding Conference August 10-11


Discover the ability to join materials that are difficult to fusion weld.

No consumables. NO fumes. Low distortion, even in long welds. Excellent mechanical properties as proven by fatigue, tensile, and bend tests. No porosity. No spatter. Low shrinkage. Can operate in all positions. Energy efficient.

Sound too good to be true? There are a few challenges with friction stir welding. Over two intense days, find out how these final stumbling blocks are being resolved.

To review the program and presenters, go to www.aws.org/ conferences/frictionstir/

Overcoming the Problems of Dissimilar Metal Welding

September 14-15 New Orleans, Louisiana

The Monteleone

Get the material properties you need by using highly versatile joining processes. Experts explain how to exploit • explosion welding • friction stir welding • magnetic pulse welding • adhesive bonding

• ultrasonic welding • laser welding • brazing • and diffusion welding

Here's a walk through the decision-making process, and its challenges, for developing a system for welding and inspecting dissimilar metals that provides consistent quality and productivity.

To review the program and presenters, go to www.aws.org/ conferences~dissimilar~

The Fifth Weld Cracking Conference February 15-16, 2005


Brought back by popular demand, the Fifth Weld Cracking Conference will once again provide useful information to keep the welding engineer out of trouble, specifically cracking trouble. The old and the new will be presented. The old represents all the things you should know about weld cracking and were afraid to ask, while the new represents some of the newer technologies that can be used to keep the problem at arm's length. The elements of hot and cold cracking, weld repair, lamellar tearing, and stress corrosion cracking will all be covered. Toughness testing and heat treating will also be discussed. As in past conferences, there will be time for questions from the audience and knowledgeable speakers will be on hand to provide the answers. Be prepared to take many notes.

AWS D1.1 Code Week September 20-24, San Francisco, Calif.

October 11-15, Philadelphia, Pa. November 0-12, Atlanta, Ga.

The AWS DI.1 Code Week is designed to provide an in- depth look at AWS DI.1/DI . IM: 2004, Structural Welding Code - - Steel.

• Day 1 - - DI.1 Road Map • Day 2 - - Design of Welded Connections • Day 3 - - Qualifications • Day 4 - - Fabrication • Day 5 - - Inspection

Register for the full week and receive your complimentary copy of AWS DI.1/DI . IM: 2004, Structural Welding Code - - Steel. For more information, contact the AWS Conferences and Seminars Business Unit at (800) 443-9353 ext. 223, or visit our Web site at www.aws, org.

For further information, contact Conferences, American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126. Telephone: (800) 443-9353 ext. 449 or (305) 443-9353 ext. 449; FAX: (305) 648-1655. Visit the Conference Depar tment home page, www.aws.org, for upcoming conferences and registration information.

E: ] ; ! JUNE 2004 I

~i~ii~i i~ii ~!~ ~i. ;i ~ ii~/ ~ . . . . . . . ~ • L

rhe secret to a better ;un Changer in a word. F eliability.

A more reliable locking mechanism. 7,000 pounds of locking force guarantees that signals pass flawlessly, even with heaw accelerations and payloads.

A more reliable fail-safe. A patented "springless" mechar fail-safe is guaranteed to work, even with loss of air pressure

A more reliable primary power module. Patented angled surfaces resist weld spatter. Non-touchable contacts improve safety. - ...................

I

ATI announces the new standard in Welding Gun Changer reliability. With patented advances in the locking mechanism, failsafe and power module, the QC-200 may be the most reliable gun changer ever built. This, along with its wide range of customizable modules, may explain why we sell more of them than anyone else.

• Patented "springless" mechanical fail-safe is guaranteed to work, even with loss of air pressure

• The power module's patented angled surfaces resist weld splatter • 7,000 pounds of locking force guarantees that signals pass flawlessly,

even under extreme conditions

The QC-200 Welding Gun Changer. Another reliable solution from ATI.


A k T " INDUSTRIAL BB AUTOMATION

ISO 9001 Registered

Engineered Products for Robot/c Productivity

www.at i - ia .com/weld /


YEH L I T E R A T U R E ] FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMAtiON CARD.

Pipe Cutting/Beveling Machines Pictured

A 55-page, full-color catalog pictures the company's complete lines of pipe cutting and beveling machines and accessories. The machines include saddle, mag-

netic, chain, band, and cold-cutting types using oxyfuel and plasma arc cutting systems. A full-page chart presents details on commercial pipe sizes and wall thicknesses.

115 MAGIO

Construction Safety Text Released

Construction Safety Management and Engineering is a reference text for safety practitioners, project engineers, workers, and students. Topics include preconstruc- tion tasks, key components of the safety process, construction safety management, legal aspects, and technical construction issues. Technical issues addressed are crane safety, electrical hazards, fall protection, health issues during demolition operations, hygiene issues, and safety during excavation, shoring, and trenching. The book is $99.95, $89.95 for members of the American Society of Safety Engi- neers (ASSE). To order, contact ASSE at (847) 699-2929; or visit w~.asse.org.

Catalog Displays Protective Clothing

Mathey Dearman, Inc. 4344 S. Maybelle Ave., Tulsa, OK 74107

B Disposable clothing, boots, protective

eyewear, hearing protection, first-aid supplies, respiratory protection, ergonomic products, and numerous other safety- related products are illustrated in a 48- page, full-color catalog. A two-page

! r .... I The new Tubemaster brings the benefits of digital technology ~ to the orbital welding customer: unparalleled accuracy,

i repeatabilily, and re|iability. Designed "from scratch", the Model 514 is only half the size and weight of the previous

~-!~: ~ model, with an increased 200 amp output.

Efiminates the Programming "Learning Curve" AutoProgram and AutoTack self-generate procedures and tacking routines.

M A G N A T E C H 514 TUBEMASTER

~ v u LI sm ,~1,~102 cai~,d 08/18/=0e~ 01,01

Use AutoProgrom to Create New Weld Program?

M A G l U A T E C H O R B I T A L W S I . D I N Q 8 Y S T S M 8

i~I~Im JUNE 2004

Ye~ Weld Number 007 !~,ad Model C35 OD 01.500 Wall Thickness 00.049 Malerial SS

www.magnatech-lp.com

Circle No. 49 on Reader Info-Card "CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY"

I

spread displays the company's extensive line of industrial gloves.

Magid Glove & Safety Mfg. Co. 2060 N. Kolmar Ave., Chicago, IL 60639-3483

116

Industrial Part Lifters Described in Brochure

SERIES PHL

A brochure describes the company's Series PHL heavy lifters for automated, high-load part lifting applications. In- cluded are full-color photographs, detailed engineering drawings, and parts lists. One page illustrates an assortment of clamps for use in automated fabrication and welding environments.

PHD, Inc. 117 P.O. Box 9070, Fort Wayne, IN 46899

Plasma Arc Cutting Machines Pictured

The company's CutmasterT~81 air plasma arc cutting system is displayed in a four-page, full-color brochure. Included are details on all features and specifications of the 1Torch TM plasma torch and a

new quick-disconnect feature. The systems are designed for cutting aluminum, stainless steel, and mild steel.

Thermal Dynamics Corp. 118 Ste. 300, 16052 Swingley Ridge Rd., St. Louis, MO 63017

Flux Recovery Vacs Detailed in Flyer

The company's Mighty-Mac-5000X- MILL heavy-duty flux-recovery vacuum and dust collector is featured in a one-

page, full-color flyer. The equipment is pictured in several configurations with technical data, and optional accessories.

Weld Engineering Co., Inc. 34 Fruit St., Shrewsbury, MA 01545

119

Free Weld Purging Guide Offered

The new 20-page edition of the Guide to Weld Purging, published by Huntingdon Fusion Techniques, comprehensively cov-


WELDING JOURNAL ~ ] i ==

World leader in plasma cutting technology.., now laser too!

] J . B m

ffl

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35 years of delivering breakthroughs in productivity and precision to high-temperature metal cutting.

Hypertherm, Inc. Etna Road, PO Box 5010 Hanover, NH 03755 USA 603-643-3441 x 1273 Tel 603-643-5352 Fax

www.hypertherm.com


ers this technical field. It offers explana- tions of terms and advice on all aspects of weld purging. The guide, offered free of charge, is designed for use in any organization involved in welding stainless steel, nickel alloys, nickel chrome, duplex, or titanium materials.

Capsa Vox Ltd. 120 Stockwell House, Kidwelly Carms SAI7 4TW, U.K.

Digital Welding Equipment Pictured

The company's Nextweld TM line of dig- itally controlled Power Wave® welding systems and communications protocols are illustrated and described in a 12-page, full- color brochure. Presented are the systems' simplified wiring, flexibility, process controls, and production monitoring innovations. Compared in detail are the communications protocols ArcLink'", De- viceNet", and Ethernet'".

The Lincoln Electric Co. 22801 St. Clair Ave., Cleveland, OH 44117-1199

121

Numerous Pneumatic Tools Featured in Catalog

The table of contents matches tools to applications, and the quick-reference

Circle No. 53 on Reader Info-Card "CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY" ~ P ~ i JUNE 2004

Displayed are the P-Wee®, Pro-Lite®, Pro-Plus®, and Pro-Wave® lines of power supplies designed for use in SMA, GTA, and GMA welding applications. The output current types, amp ranges, and other details are presented in chart form to describe each of the machines.

Thermal Arc, Inc. 123 Ste. 300, 16052 Swingley Ridge Rd., St. Louis,MO 63017

Specialty Abrasive Products Displayed

charts aid in the selection of the right tools for the job in this 94-page color catalog. The company's complete line of Top Cat® pneumatic tools is featured, including vertical grinders, pile cutters and sanders, die grinders, right-angle grinders, bench grinders, scalers, chipping hammers, air saws, air drills, and power supply motors.

T. C. Service Co. 122 38285 Pelion Rd., Willoughby, OH 44094

Next-Generation Inverter Power Supplies Featured

Nine lightweight inverter power supplies are featured in a full-color brochure.

Five specialty abrasive products, designed to cut, grind, blend, and finish stainless, aluminum, tool and mild steels, and exotic alloys, are presented in a 26- page catalog. Detailed are the Sigma Green wheels for stainless and aluminum, carbide burrs, MX Plus-mounted points, and high-speed Type 1 grinding wheels.

Rex-Cut Products, Inc. 124 960 Airport Rd., P.O. Box 2109, Fall River, MA 02722


PRECISION, RIGIDITY, and TORQUE... The RD Series Gearhead

provides high-end

performance for positioning

requirements with:

• Zero backlash

• Hol low shaft option

• Integrated support bearings

• Large thrust and moment capacity

• Mounts to any motor

Index Tables Robotics

Positioners

Nabtesco former ly Tei j in Seik i

o I- Nobtesco Precision USA, Inc

31731 Northwestern Hwy. Suite 113E O Farmington Hills, MI 48334

.~ Ph. 248-538-9165 Fax. 248-538-9170

rr www.nabtesco-prec is ion .com

O ? Circle No. 52 on Reader Info-Card

WELDING JOURNAL I t i < I

PERSONNEL

Chemetall Oakite Announces D. C. Ball and CEO Awards

Chemetall Oakite, Berkeley Heights, N.J., presented its annual D. C. Ball Award to Karen M. Sohl, corporate training manager. The award is presented annually to an employee who exemplifies the goals of the organization. The award is named for David Ball, one of the company's founders.

The company's North American CEO Awards were presented in April to three outstanding employees for exemplary contributions to the company. Named were Tim McCune, Charlotte, N.C., for achieving record-high sales, and Karen Sohl and Ron Aseenzo who shared the award for outstanding achievements by support personnel.

CFO Appointed at Rexarc

Galen Woodhouse was appointed

M e m b e r Mi lestone

Baeslack Named Dean at OSU William A. Baeslack III, was appointed dean of the College of Engineering at The

Ohio State University, Columbus, Ohio, effective July 1, 2004. Baeslack served as an OSU faculty member from 1982 until 1999 when he left to be-

come a professor and dean of the School of Engineering at Rensselaer Polytechnic Insti- tute, Troy, N.Y.

Baeslack is renowned for his expertise as an administrator and as an expert in joining advanced materials, including titanium, aluminum, and nickel-based alloys, inter- metallics, and metal-matrix composites.

Baeslack is a Fellow of the American Welding Society, ASM International, and The Welding Institute.

chief financial officer at Rexarc Interna- tional, Inc., West Alexandria, Ohio. Woodhouse previously served nine years as president and chief financial officer at Fed Holdings, Inc.

EWl Fills Two Key Posts

Edison Welding Institute, Columbus, Ohio, named Grant Wilson as medical/mi- croelectronics market leader, and Frank

Grant Wilson Frank Jacob

A U T O M A T E D M A N U F A C T U R I N G SYSTEMS

Designing, building and supporting Robotic, CNC and PLC equipment for the last 21 years.

G T A - G M A - P T A - H o t W i r e www.arcspecialties.com [email protected]

7775 Little York, Houston, TX 77016 Phone: 713-631-7575


Ez~! JUNE 2004 I

Fax: 713-356-0844 "CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY"

E. Jakob, program manager in the Techni- cal Division. Prior to joining EWI, Wilson worked at Battelle Memorial Institute in product development and market research. Jakob previously worked for Battelle as a commercialization manager.

New Accounts Manager at Great Lakes Air

Steven C. Nagle has joined Great Lakes Air Systems, Clawson, Mich., as account manager for the Michigan and On- tario area. Nagle brings to the company eleven years of experience in the industrial and construction industry.

New Product Manager at ESAB

Jack Minser was named a business product manager for gas apparatus at ESAB, Florence, S.C. Minser previously held management posit ions at Victor Equipment for the past 25 years.

Obituaries

Robert L. Apps

Robert (Bob) L. Apps, 75, died Febru- ary 2 in Bedford, U.K. A renowned inven-

tor and welding pioneer, he earned his Ph.D. in industrial metallurgy from Birm- ingham University.

Dr. Apps became directly involved in the development of hyperbaric welding, which was critically important in the North Sea oil excavation projects of the sixties and seventies. He was a visiting professor in welding for the Indian and Brazilian governments. For many years he chaired JOM, the Denmark-based International Institute for the Joining of Materials.

He served as a member of the Profes- sional Board of The Welding Institute, served on its Educat ion and Training Committee, and as a mentor and assessor to many persons qualifying for Chartered Engineer via the mature candidate route.

Dr. Apps, a Fellow of TWI and the In- stitute of Materials, was awarded the Brooker Medal in 1986.

Joseph Caprarola, Jr.

Joseph Caprarola, Jr., 73, a Life Mem- ber of AWS, died March 9, in New Ox- ford, Pa.

He was vice president of marketing for ESAB in Hanover, Pa., retiring in 1994. Earlier he had served as vice president of research and development at Alloy Rods, and held various positions of responsibility at Airco Welding Products, where he started in 1954.

Mr. Caprarola was an active member in the National Electrical Manufacturers' Association, served as an AWS Director- a t -Large and was a past member of the AWS Board of Directors. He was chosen as an AWS Counselor and as chairman of the board of the Hanover Chamber of Commerce 1987-1989, and sat on the board of directors for the Hart Center in New Oxford. He also volunteered as a sto- rytel ler for the e lementary schools in Hanover, and was a member of the Knights of Columbus in Basking Ridge, N.J.

Mr. Caprarola served in the U.S. Army Corps of Engineers during the Korean conflict. His fifty-year career in the welding industry contributed greatly to the advancement of welding.

Mr. Caprarola is survived by his wife, Joan, a daughter, three sons, one brother, one sister, and ten grandchildren.

Change of Address? Moving?

Make sure delivery of your Welding Journal is not interrupted. Contact the Membership Depar tment with your new address information - - (800) 443- 9353, ext. 480; [email protected].

Call for Papers

The American Welding Society announces a Call for Papers for the 2005 Professional Program to be held as part of Welding Show 2005 on April 26-28, 2005 in Dallas, Texas.

Submissions should fall in one of the following three categories and will be accepted only in a specific format. Individuals interested in participating should contact Dorcas Troche, Manager, Conferences & Seminars via email at [email protected] for specific details. Deadline for submission of paper is Friday, July 30, 2004.

Technical/Research Oriented • New science or research • Selection based on technical merit • Emphasis is on previously unpublished work in science or engineering relevant to welding, joining and allied processes. • Preference will be given to submittals with clearly communicated benefit to the welding industry

Applied Technolocjy • New or unique applications • Selection based on technical merit • Emphasis is on previously unpublished work that applies known principles of joining science or engineering in unique ways • Preference will be given to submittals with clearly communicated benefit to the welding industry.

Education • Welding education at all levels • Emphasis is on education/training methods and their successes • Papers should address overall relevance to the welding industry

WELDING JOURNAL I~]~'!1

~wsANN~ C O M P A N Y P R O F I L E S

1655 EImwood Ave. Building #7 1~19_zoo4 Cranston, RI 02910; (401) 461-4140; I I

Abicor Binzel Corp, F o u n d e d 1945

ABICOR Binzel Corp. is the world leader and one of the largest U.S. providers of automatic, semiautomatic and robotic MIG and TIG air- and water-cooled welding guns and robotic peripheral equipment used primarily in metal fabrication industries. The company's global footprint encompasses 30 subsidiaries strategically located in most major industrial markets.

See our ad on IBC

650 Research Dr., Ste. 110 Frederick, MD 21703 (800) 542-4867 FAX: (301) 846-4497 Website: www.abicorusa.com

Acorn Iron & Supply Co., Inc. Founded 1910

Acorn Iron & Supply Co., Inc., has provided Acorn Platens, stands and acces- sory tooling to the welding industry for 94 years. Acorn Platens are used as welding platens, bending blocks, surface plates, layout tables, setup blocks, assembly platens, floor plates, and leveling blocks.

See our ad on page 58

915 N. Delaware Ave., Philadelphia, PA 19123; (215) 922-7070; Fax: (215) 922-2522; E-mail: [email protected] Website: www.acorniron.com

AElectronic F o u n d e d 1983

AElectronic Bonding Inc. (A.B.I.) was established in 1983 to invent, design, engineer and manufacture the Lightning Welding Systems. These include micro welding machines for pulsed arc, stored energy resistance and fusion percussion metal bonding applications. We specialize in welding systems to bond similar and dissimilar metals of all types.

See our ad on p a g e 24

Fax: (401) 461-5250; E-mail: abi11655 @aol.com; Website: www.abiusa.net

American Technical Publication F o u n d e d 1898

Since 1898, our company has been a leader in quality technical training materials. We are vitally interested in quality training materials for today's students and workers. The primary purpose of our training materials is to provide trade information to help build the skills required for employment and advancement in a trade.


1155 W 175th St., Homewood, IL 60430-4600; (800) 323-3471 Fax: (708) 957-1101; E-mail: service @ americantech.net; Website: www.go2atp.com

American Torch Tip Co. Founded 1940

ATTC makes over 16,000 replacement parts for more than 112 plasma, laser, MIG, TIG, oxyfuel and multi-use systems using welding and cutting machines and torches. The company sells to more than 45 countries and has warehousing in Canada and England.


6212 29th St. East, Bradenton, FL 34203; (941) 753-7557; Fax: (941) 753-6917; E-mail: attc @ ate.net

A. O. Safety Co. Founded 1833

A.O. Safety is part of the Aearo family of brands. Aearo manufactures respirators, hard hats, faceshields, fall protection, and safety eyewear under the A.O. Safety brand, and hearing protection under the E-A-R® and Peltor~ brands. Its products are sold worldwide for a variety of industrial applications including manufacturing, auto- body painting and refinishing, welding, construction, and other potentially haz- ardous enviroments. Aearo is also a leading supplier of safety equipment for consumer markets in the U.S. and

itZ.IN JUNE 2004 I

Europe. Nine manufacturing locations worldwide are ISO 9000 certified, as is the automated global distribution center in Indianapolis, Indiana.


90 Mechanic St., South Bridge, MA 01550; (508)764-5720; Fax (508) 764-5268; E-mail: tracy_macmillan @ aearo.com

ArcOne Company Founded 1992

ArcOne has pioneered a wide variety of autodarkening welding helmets, inverter power sources, and NIOSH approved PAPR and SAR respiratory and safety products. Every product that ArcOne develops is carefully controlled at its modern facility located in Taunton, Mass. At ArcOne we are committed to providing superior products and services to promote safety, productivity, quality improvement and overall work place performance.

See our ad on pages 16,1 7,18

ArcOne Div. of A.C.E. Intl. 85 Independence Drive Taunton, MA 02780; (800) 223-4685; Fax: (508) 884-9666; E-mail: customerservice @ aceintl.com Website: www.arclweldsafe.com

ARC Specialties, Inc. Founded 1983

ARC Specialties designs and builds automated manufacturing systems, robots and custom equipment with emphasis on weld joining, overlay, cladding, cutting, forming, and many other applications. ARC has been the supplier of choice for engineering services, process development, systems integration, service, parts, and training. ARC has installed and supported systems around the world. The combination of experience, reputation, equipment functionality and leading edge technology makes ARC Specialties a leader in a competitive marketplace.


7775 Little York, Houston, TX 77016 (713) 631-7575 Fax (713) 356-0844 E-mail: dan @ arcspecialties.com Website: www.arcspecialties.com

- - continued on page 98

Since 1919, we've established the standards that guide welding, .j. •

Doesn't it make sense to let us guide you to getting certified?

SIGN UP FOR THE AWS CWl OR eWE SEMINARS, AND PREP WITH THE EXPERTS. We offer five and a half days of intensive seminars that help prepare you to pass the AWS certification tests• Our experienced teachers help you learn the material you need to

know fast, and show you how to use and understand the latest standards. AWS seminars

are an excellent value, saving you time and literally hundreds of dollars, by supplying you

with many of the books you need FREE. Seminar topics include D1.1 Code, API 1104 Code,

Welding Inspection and Technology, and Visual Inspection, followed by the certification

exam at the end of the week. By grouping the preparation with the test, you can attend

AWS seminars with less time off from the job and less travel expense.

When it comes to preparing for an exam that proves you're one of the best, then take it

from the people who know it best--AWS.

FIND THE AWS SEMINAR NEAREST YOU.

LOCATION SEMINAR EXAM LOCATION SEMINAR EXAM DATES DATES DATES DATES

MIAMI, FL (EXAM ONLY) 6/17/2004 MEMPHIS, TN 8/8-13 MIAMI, FL (EXAM ONLY) 7/15/2004 MIAMI, FL (EXAM ONLY) DENVER, CO 7/11-16 7/17/2004 INDIANAPOLIS, IN 8/15-20 PHILADELPHIA, PA 7/11-16 7/17/2004 HOUSTON, TX 8/15-20 ORLANDO, FL 7/11-16 7/17/2004 ROCHESTER, NY (EXAM ONLY) CORPUS CHRISTI, TX (EXAM ONLY) 7/24/2004 CHARLOTTE, NC 8/22-27 BATON ROUGE, LA 7/18-23 7/24/2004 MIAMI, FL (EXAM ONLY) SALT LAKE CITY, UT 7/18-23 7/24/2004 ANCHORAGE, AK 9/12-17 KANSAS CITY, MO 7/25-30 7/31/2004 NEW ORLEANS, LA 9/12-17 CHICAGO, IL 7/25-30 7/31/2004 CORPUS CHRISTI, TX (EXAM ONLY) PORTLAND, ME 7/25-30 7/31/2004 MINNEAPOLIS, MN 9/19-24 ALBUQUERQUE, NM 8/1-6 8/7/2004 SEATI'LE, WA 9119-24 COLUMBUS, OH (AT NOBPV=) 8/2-6 8/7/2004 SAN DIEGO, CA 9/19-24 SACRAMENTO, CA 8/8-13 8/14/2004

8/14/2004 8/19/2004 8/21/2004 8/21/2004 8/21/2004 8/28/2004 9/16/2004 9/18/2004 9/18/2004 9/18/2004 9/25/2004 9/25/2004 9/25/2004

For more information, call 1-800-443-9353, Ext. 449

~ American Welding Society Founded in 1919 to Advance t ' ~ h ~ Techno logy and App l i ca t i on o f Weld ing•

To become an AWS member, call 800-443-9353, ext. 480, or visit our website at http://www.aws.org Circle No. 12 on Reader Info-Card

1

, ~ ANNIVEIR~A~

191 _

I |

C O M P A N Y P R O F I L E S - - continued from page 96 changers, multiaxis force/torque sens-

Atlas Welding Accessories, Inc. F o u n d e d 1393

From the original Dual tool Tomahawk, patented in 1939, the company today manufactures 28 models of weld cleaning hammers, and proprietary products including welding positioners, pipe stands, and the Pipemate. Products are sold through welding distributors nationally. Our 400-page distributor catalog offers 7,000 welding and safety items.

S e e o u r a d d on p a g e 2 6

501 Stephenson Highway, Troy, MI 48099; (248) 588-4666; Fax: (248) 588-2706

Al l F o u n d e d in 1989

Since 1989, ATI engineers have been developing cost-effective, state-of-the- art products and solutions to improve robotic productivity. ATI is a leading developer of robotic/automatic tool

ing systems, compliance devices, robotic crash protection devices, robotic rotary joints, and robotic/CNC deburring tools. Visit our Website for more information, including down- Ioadable 2D drawings and 3D models of ATI products.

S e e o u r a d on p a g e 8 9

Pinnacle Park, 1031 Goodworth Dr. Apex, NC 27539; (919) 772-0115 Fax: (919) 772-8259; E-mail: info @ati-ia.com; Website: www.ati-ia.com

Avesta Welding Products, Inc. F o u n d e d in 1975

Avesta Welding Products, Inc., an Outokumpu Group Company, offers a full range of stainless steel, duplex, and nickel alloys welding materials including covered electrodes, flux cored products, solid wire, welding strip, pickling chemicals, and fluxes. All are backed by the finest technical support and are available though a wide distribution network.

S e e o u r a d o n p a g e 5 5

3176 Abbott Rd., Orchard Park, NY 14127; (800) 441-7343; Website: www.outokumpu.com/stainless/N DA

Bluco Corporation F o u n d e d in 1990

Is a leading supplier of modular fixturing for welding in North America. Fixture short runs, prototypes, spares, and specials from more than 140 standard, off-the-shelf fixturing components and 13 table sizes. Build a fixture in less than 4 hours the first time; repeat the setup in less then 20 minutes.

S e e o u r a d o n p a g e 2 4

509 Weston Ridge Dr., Naperville, IL 60563; (800)535-0135; Fax: (630) 637-1847; Website: www.bluco.com

Bug-O Systems F o u n d e d / n 1948

BUG-O Systems Inc., a division of Weld Tooling Corporation,is a manufacturer of a modular systems of drives, carriages, rails and attachments designed to auto- mate welding guns, cutting torches and other hand held tools.

S e e o u r a d on p a g e 14

3001 W. Carson St., Pittsburgh, PA 15204; 800-245-3186 ext.42; Website: www.bugo.com

- - continued on page 100

Designer and Manufacturers fWeld Guns, Transguns and CylinSers

TG Systems offers a complete line of weld guns ranging from cable guns to AC and MFDC transguns. They are used in portable, robotic and pedestal applications, with existing sizes fl'om 1 "x 3" to 43" x 25". TG Systems will provide a custom design to meet your specific needs or you can select from our library of existing designs. TG Systems is an ISO 9001-2000 registered company, whose dedication to the customer is exemplified by the quality of our products, our drive to reduce leadtime, and our continuous efforts to reduce costs. We have combined years of experience with the latest technologies in manufacturing, modular design and systems operations to better serve you.

TG S y s t e m s , LLC M E M B E R

ISO CERTIFICATE NUMBER 16650-QMS-1864

851 47th Street SW, Suite D • Grand Rapids, MI 49509 Tel 616/257-8700 • Fax 616/257-8734 Web www.tg-systems.com

The wldeM army of product. All wel l -e~red and csrefully made of

WELDING ELECTRODE TIPS . , . , - Straight, bent, swivel, cap-type, high- ~ ~ ~'~ ~'~ i pressure, nut and stud, etc. ~j

f f TIP HOLDERS Straight and offset (ejector and non-ejector),ll ~ " ~ / platen-mounted, cylinder-mounted, fast- follow-up and paddle-type.

MUL PUE we,-,NG 11 RWM Adapters and holders to hold 2 or 3 tips . ~ . k,"~ " ; ' " L . ~ , for increased production rates. ~ * J~' II Pr,~il

Forgings, castings, bar stock; ~ finished or unfinished. ~

T U F F A L O Y P R O D U C T S , INC. ISO CERTIFICATE NUMBER 16649-QMS-1860

Customer Services & Manufacturing Facility: 601 High Tech Court, Greer, SC 29650 • Tel 800-521-3722 or 864-879-0763 • Fax 864-877-2212 ° Web www.tuffaloy.com

~I :m JUNE 2004 Circle No. 66 on Reader Info-Card

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~ American Welding Society ~ 1 9 to Advance t'~he Science'~-~ Technology and Appl icat ion of Welding.

To b e c o m e an A W S m e m b e r , call 800,854,7179 or visit our w e b s i t e a t h t tp : / /www.aws ,o rg

A# ANNWE~t~A ~

1919 --2004

It C O M P A N Y P R O F I L E S

--continued from page 98 extreme heat environments. Our patented products address $25 billion in heat driven productivity losses; increasing productivity, comfort and safety for personnel in high heat environments.

CK Worldwide Inc. Founded in 1967


For 37 years, CK Worldwide has advanced the design of TIG torches and accessories more than any other TIG manufacturer. Improved torch designs include the Flex-Loc and Trim-Line series. Wedge collets and Gas Saver improve parts life and reduce shield gas costs. CK offers the largest selection of TIG torches and accessories in the world.


3501 "C" St. NE, P.O. Box 1636, Auburn, WA 98002; (800) 426-0877; Fax: (800) 327-5038

Climatech Safety, Inc. Founded in 1995

ClimaTech has been a leading manufacturer of patented, wearable, personal A/C; products that are light, thin, comfortable and designed for use in

115 Windmill Point Rd., White Stone, VA 22578; (800) 266-5440 or (804) 436-0089; Fax: (804) 436-0178 Website: www.climatechsafety.com

College of Oceaneering Founded 1967

The College of Oceaneering is a professional diving school dedicated to providing the commercial diving industry with the finest caliber of entry-level graduates who are prepared to begin their journey to a rewarding career. The cur- riculum includes three specialties: underwater welding, nondestructive testing, and advanced dive medicine.


272 Fries Avenue, Wilmington, CA 90744; (310) 834-2501 Fax: (310) 834-7132

Commercial Diving Academy (CDA) F o u n d e d in 1995

CDA is an outstanding training facility located in Jacksonville, FL. In addition to air/mix gas training, the Academy offers advanced specialty training in underwater welding/burning, Non- destructive testing Levels I &ll and dive medical technician to name a few. All programs meet or exceed the ACDE/ANSl standards for commercial diver certification. Dormitory style housing and a meal plan are available.


8137 N. Main St. Jacksonville, FL 32208; (888) 974-2232; (904) 766-7736; Fax: (904) 766-7764 Website: www.Com mercialDivingAcademy.com

Computer Engineering Founded 1986

For more than 18 years, CEI has provided software for the welding and pressure vessel industries. Our welding software complies with AWS D1.1 and/or ASME Section IX, and employs the highest level of Code-checking available on the market today. In addition to our industry leading welding software, we have engineering calculation programs for designing pressure vessels in accordance with Section VIII Division 1, and software for form sub- mittal in compliance with the ASME and National Board.


P.O. Box 1657, Blue Springs, MO 64016; 800-473-1976; Fax: 816-228-0680 E-mail: sales @computereng.com Website: www.computereng.com

Computer Weld Technology F o u n d e d in 1988

The primary business of Computer Weld Technology, Inc., is providing solutions to industry for automating, controlling, and monitoring welding processes. These solutions manifest themselves in the form of products designed and manufactured by CWT and technological assistance provided to our customers as a result of extensive research and development.

II[0IoI JUNE 2004 Circle No. 69 on Reader Info-Card

"CONGRATULATIONS TO AWS ON ITS 85TH ANNIVERSARY" - - c o n t i n u e d o n p a g e 1 0 2

W e l d i n g in t h D e f e n s e i n 6 u

C o n f e r J

TWO DAYS OF BREAKTHROUGH WELDING INFORMATION FROM LEADING DEFENSE INDUSTRY EXPERTS

~,..- .~." .~ ~.~ ---- ~,~..~.~

AT THE WELDING IN THE DEFENSE INDUSTRY CONFERENCE, you will:

• Benefit from hearing about major U.S. Defense-budgeted welding breakthroughs

• Gain knowledge on getting economical weldability from titanium, aluminum and stainless steels

• Hear how processes like GMAW-Pulsed, friction stir spot welding, laser beam welding and electron beam welding are being used effectively, even on high- volume production.

July 13-14, 2004 Orlando, Florida

Valuable insights from defense industry experts you won't want to miss!

To register call: 1-800-443-9353, Ext. 312 or go online: http://www, aws,org, click on "Conferences" < • American Welding Society

F o u n d e d in 1 9 1 9 t o A d v a n c e t h e Sc ience, T e c h n o l o g y a n d A p p l i c a t i o n o f W e l d i n g .


To become an AWS member, call 800.854.7179 or visit our website at http://www.aws.org

© American Welding Society 2004 CNF1063

C O M P A N Y P R O F I L E S ~ ' ~ J d ~ 8 ~ DE-STA-CO

1919 - - 2 0 0 4 - - continued from page 100 F o u n d e d 1915

i t ¸ See our ad on p a g e 1

4544 S. Pinemont Dr., Ste. 200 Houston, TX 77041 U.S.A. (713) 462-2118; Fax: (713) 462-2503 Email: sales @cweldtech.com Website: www.cweldtech.co

COR-MET, Inc. Founded in 1972

See our ad on pages 10,102

12500 E. Grand River, Brighton, MI 48116; (800) 848-2719; Fax: (810) 227-9266.

DE-STA-CO Industries, a Dover Company, is a world leader in clamping, gripping, transfer, and robotic tooling solutions for workplace automation needs. The customer base covers a wide range of industries. DE-STA-CO Industries, vision brings customers superior innovation, engineering, customer support and value-added services to advance their manufacturing improvements, and sustains DE-STA- CO Industries as a leader. Visit our website.


2121 Cole St., Birmingham, MI 48009; (248) 594-5600; Fax: (800) 682-9686; Website: www.destaco.com

C-Spec Founded 1985

Since 1985, C-spec's industry-standard WeldOffice software greatly sim- plifies the creation and management of welding procedures, and of welder data for thousands of users worldwide. C-spec's software and its legendary customer service are supported by welding industry leaders and code committee members.

See our a d on p a g e 59

P. O. Box 27604, Concord, CA 94527 (888) 673-9777; Fax: (925) 930-8223 E-mail: [email protected] Website: www.cspec.com

Diamond Ground Products Founded in1992

Diamond Ground Products specializes in GTAW and plasma arc welding electrodes. Their tungsten grinders are well known for precision and ease of use. Other offerings include raw tungsten and preground electrodes CNC ground to customer specifications. Applications for the electrodes include manual, automatic, orbital and robotic TIG and plasma arc welding.


2550 Azurite Cir., Newbury Park, CA 91320; (805)498-3837; Fax: (805) 498-9347; E-mail: sales @ DiamondGround.com Website: diamondground.com

COR-MET S P E C I A L T Y C O R E D W I R E

A N D C O A T E D E L E C T R O D E S

®

(810) 227-3251 www.cor-met.com

FAX: (810) 227-9266

lil0P, i l JUNE 2004


Divers Academy International F o u n d e d in 1977

See our p a g e on p a g e 62

2500 Broadway, Camden, NJ 08104, (800) 238-3483; Fax: (856) 541-4355; Website: www.diversacademy.com.

ESAB Welding & Cutting Products Founded 1904

Started in 1904 by Oscar Kjeilberg when he submitted a hand-written patent for a covered electrode, ESAB has always blazed new trails with new products, processes, and innovative solutions for welding and cutting. Today, as ESAB celebrates its 100th anniversary, it is still an industry leader, and one of the world's largest produc- ers of equipment and filler metals.

See our ad on OBC

411 S. Ebenezer Rd., Florence, SC 29501; (800) ESAB-123; Website: www.esabna.com

Gedik Welding Inc. F o u n d e d in 1963

GEDIK Welding has been the leader in the welding sector in Turkey since 1963. GEDIK produces numerous welding electrodes, welding MIG wires, TIG rods, SAW wires. GEDIK holds ISO 9001 and supplies mainly to the companies in the USA and Europe under private labels.


Ankara Caddesi No. 28, Seyhli - Pendik 34913, Istanbul - Turkey Tel: 90 (216) 378 50 00; Fax: 90 (216) 378 7936; E-mail: [email protected] Website: www.gedik.com.tr

Hobart Institute of Welding Technology F o u n d e d in 1930

Our staff of seasoned professionals offers you advanced training in all major welding processes. Services include 1- to 36 -week skill-development courses for the beginners, as well as certifica- tions and/or technical training for welders looking to advance their skills.

--continued on page 104

Exhibiting at the AWS Welding Show 2005 is the most cost-effective way to gain broad exposure in a short time. As an AWS exhibitor, you will have the opportunity to meet those buyers who need your products. The AWS Welding Show has more to offer than any other show in the metal-fabricating and construction industries.

Big benefits for exhibitors before, during, and after the Show.

• Advance multi-media ad and direct mail campaign promoting the Show.

• Local newspaper and media coverage.

• Listing in the official Show Program and Buyers' Guide distributed at the Show.

• Use of the AWS Press Room.

• Discounts on freight, car rentals, and room rates, as well as free shuttle buses from AWS-sponsored hotels to the Show.

• On-site staff to assist you during the Show and to help provide a hassle-free exit at the end.

• AWS website, which is used as a year-round tool by manufacturers, distributors and end-users looking for products and services.

• A targeted demographic attendee list will be available from Show management.

• Our marketing staff will be available for consultation on lead follow-up and tracking.

To participate in any of the pavilions or for more infonnaU~, please contact our Welding Show Exhibit Sales office at: 1-84)0-443-9353, ext. 295 or 242.

V V E I . D I N G

S H O W 2 0 0 5 April 26-28, Dallas, Texas D A L L A S C O N V E N T I O N C E N T E R

Circle No. 16 on Reader Info-Card © American Welding Society 2004 CON-1070

~V~3 ANN~/ER~4~,

1919 -2(30

C O M P A N Y P R O F I L E S - - continued from page 102

Customized training for your corporate welding needs is available on- or off-site. A wide selection of world-class welding training and educational materials are available for training or reference use.


400 Trade Square E., Troy, OH 45373; (800) 332-9448; Fax: 937- 332-5200.

Hodgson Custom Rolling inc.

Hodgson specializes in heavy plate rolling, thick plate forming, and manufacturing of heavy steel plate and plate products with 85,000 sq. ft. under roof and ASME certified, whether a single prototype, or multiple units, component parts for pressure vessels or heavy industrial applications, from cylinders, rings, truncated cones, to structural forms including the stringers for spiral staircases, HODGSON CUSTOM ROLLING INC. can help solve your plate problems.


5580 Kalar Rd., Niagara Falls, On., Canada L2H 3L1: (905) 356-8132 Fax: (905) 356-6025; E-mail: hodson @ hodgson.on.ca; Website: www.hodgsoncustomrolling.com

Hornell, Inc, F o u n d e d 1981

Hornell is a world leading manufacturer of autodarkening welding lenses. Over 1,500,000 Speedglas lenses have been sold worldwide. Speedglas helmets, lenses, and state-of-the-art respiratory systems can be found in virtually every industry.


2374 Edison Blvd., Twinsburg, OH 44087; (800) 628-9218 or (330) 425-8880; Fax: (330) 425-4576

Hypertherm, Inc. F o u n d e d 1968,

Hypertherm has been a leader in

plasma arc cutting equipment and service. Now, with its entry into the laser-plate cutting market, it expands its technology leadership commitment. By continually delivering breakthrough advances in metal-cutting productivity and precision --f irst in plasma, now also in l a s e r - it reaffirms and extends its position as the world's leading supplier of advanced high-temperature metal cutting technology.


Etna Rd., P.O. Box 5010, Hanover, NH 03755 USA; (603) 643-3441; (800) 643-0030; Fax: (603) 643-5352 E-mail: info@ hypertherm.com

Intercon Enterprises Inc. Founded 1977

Intercon Enterprises Inc. is a leading supplier of TIG pipe welding accessories including purging equipment, dissolving purge paper and tape, tungsten electrode grinders, oxgyen indicators, pipe alignment clamps, and chains as well as aluminum, and fibre- backed tapes. For over 25 years Intercon has been supplying the welding industry with quality products

ATTEHTiOH DISTRIBUTORS,.. Receive TWO FREE Publications!

PLUS GET MAXIMUM EXPOSURE ° INCREASED BUSINESS ° UHMATCHED SAVIHGS

• Jefferson's Welding Encyclopedia (CT)-ROM only) Choose from these four • Welding Metallurgy

award-winning publications! • Welding Handbook (9th Ed., Vol. 1) • Design and Planning Manual for Cost-Effective Welding

Increase your customer base by becoming an AWS Welding Distributor Member. Receive a spot on the AWS Distributor Locator Map - companies and individuals will be able to find your distributorship fast and easy, and you can even add a link to take them straight to your website. In addition, AWS Welding Distributor Members receive access to a variety of networking opportunities, business development tools and service discounts you won't find anywhere else.

American Welding Society Weldin Distribut Me% er

For more information, call the Membership Department today at: (800) 443-9353, ext. 480, or (305) 443-9353, ext. 480 Visit us on-line at www.aws.org/distributor

i l o ~ i JUNE 2004 I


such as the Intercon weld-on hinges, JOKISCH antispatters and the TIGRIP line of plate clamps and lifting tackle.


1125 Fir Ave., Blaine WA 98230 (800) 665-6655; Fax: (604) 946-5340 Email: sales @ intercononline.com Web Site: www.intercononline.com

IWE - Consulting Inc. See our ad on p a g e 24

352 NW 152nd Ln., Pembroke Pines, FL. 33028; (954) 432-2655; E-mail: [email protected]; Website: iweconsulting.com

Jackson Products Founded 1932

Jackson has been a pioneer in the development of safety products for the welding industry and continues to be a leader in the marketplace. All Jackson products are tested in conjunction with one another for superior performance

C O M P A N Y P R O F I L E S and protection. This drive for excel- ~/d'/dl~/fh~'

1919 -2004 lence can be seen across the board - in all Jackson, Jackson Safety and Huntsman products.


801 Corporate Center Dr., Suite 300, St. Charles, MO 63304; (800) 253- 7281 Website: www.jacksonproducts.com

Johnson Mfg. Co. Founded 1909

Johnson Manufacturing Co., has played a key role in the development of safer solders and fluxes for over 95 years. Johnson's soldering fluid was safer then, as now because it contains no free acid. Johnson's exclusive vacuum casting process eliminates inclu- sions and oxidation from Johnson's solders. IA-423 ternary eutectic, tin/silver/copper solder is the ideal replacement for companies who are switching away from leaded solders. Our recent purchase of L. B. Allen Corp. fluxes has enabled us to provide even more "soldering solutions" than ever before.


114 Lost Grove Rd., Princeton, Iowa 52768; (563)289-5123; Fax: (563) 289-3825; E-mail: johnsonmfg @ aol.com Website: www.johnsonmfg.com

Kennametal Inc. Founded in 1938

Kennametal Inc. is a world-renowned manufacturer of premium-quality metal- cutting construction, and mining tools and related wear products. Our hardfacing rods, with their superior physical and chemical uniformity, high carbon content, uniform granule distribution, and high level of carbide particle depostion, extend a part's service life, while significantly reducing replacement downtime and labor.


347 N.Taylor St., Fallon, NV 89406; (800) 443-4862 or (775) 428-6286; Fax: (775) 428-6298

C O M P A N Y P R O F I L E S " - - r ' O J ~ 22801 St. Clair Ave., Cleveland, OH

1919--2004 44117-1199; (216) 481-8100;

Pl Koike Aronson, Inc./Ransome

F o u n d e d in 1918

Koike Aronson designs and manufactures one of the world's broadest selections of welding positioners, plasma and thermal cutting products for the metalworking industry. Our lines of proven performers also includes portable and gas apparatus equipment, and the Koike Aronson- Ransome line of welding machines, all serviced by the craftsmen who build them.

See ou r ad on p a g e 28

635 W. Main St., P.O. Box 307 Arcade, NY, 800-252-5232; Fax: (585) 492-2400; Email: [email protected]

La-Co Industries Inc. F o u n d e d 1934

La-Co's mission is to actively listen to our customers and meet or exceed their expectations by providing the highest quality performance products for marking, sealing, joining and other chemical specialty applications. La-Co aims to be enviromentally responsible in the design and manufacture of its products, and to promote the growth and well-being of its employees.

Fax: (216) 486-1751; Email: info @ lincolnelectric.com Web site: www.lincolnelectric.co

Magnatech Limited Partnership F o u n d e d 1946

Magnatech designs and manufactures systems for orbital welding of pipe, tube, and for tubesheet seal welding applications. Magnatech has years of experience in providing tools to increase productivity and quality in the pipe and tube welding industries.


6 Kripes Rd., P. O. Box 260, East Granby, CT 06026; (860) 653-2573; Fax: (860) 653-0486

Magnetic Products and Services, Inc. F o u n d e d 1964

Paul Nippes, EE., and his team of engineers specialize in building products to accurately measure and control magnetism. Whether the application is pipeline, construction or industry, stabi- lizing magnetic fields will improve welding performance, speed up production lines and produce quality results. MPS also offers consulting services from their engineers fondly referred to as 'The Gaussbusters'.

See our a d on p a g e 12

1201 Pratt Blvd., Elk Grove Village, IL 60007-5746; (847) 956-7600; Fax: (847) 956-9885

The Lincoln Electric Company F o u n d e d 1895

The Lincoln Electric Co. is a world leader in the design, development and manufacture of arc welding products, robotic arc welding systems, plasma and oxyfuel cutting equipment. With more than 100 years in the industry, Lincoln Electric has built a reputation for providing quality products and cutting-edge technologies. Technical representatives are available globally to provide innovative solutions.



2135 Highway 35, Holmdel, NJ 07733 (732) 264-6651; Fax: 732-264-6876 Website: www.gaussbusters.com

Mannings USA, Inc. F o u n d e d 1989

Specializing in on-site heat treating utilizing the induction, combustion, and resistance methods, Mannings personnel can handle any project, large or small anywhere in the world. We also manufacture and rent a wide range of portable equipment that can be used to satisfy the majority of your heat treatment requirements.

See ou r ad on p a g e 93

200 Richards Ave., Dover, NJ 07801 (800) 447-4473; Fax: (973) 537-1576 Website: www.manningsusa.com

li lT,1 JUNE 2004 I

MK Products F o u n d e d 1966

MK Products is the original inventor of Cobramatic~ push-pull wire feed technology and is recognized worldwide as a leader in aluminum welding systems. MK Products also manufactures Aircrafter TM tabletop rotary positioners and MK Orbital TM Tube welding systems for sanitary, high-pressure and ultrahigh purity applications.


16882 Armstrong Ave., Irvine, CA 92606; (800) 787-9707; Fax: (800) 373-3329; Website: www.mkproducts.com

Nabtesco Precision USA F o u n d e d in 1944

Nabtesco leads the precision gear industry by providing high performance cycloidal gear reducers, hollow shaft gear heads and single-axis serve-actu- ators and controllers. Our precision equipment provides large torque, high- ratio and significant shock-load capabilities with extreme precision and very low backlash--Ideal for rotary tables and headstock/tailstock applications.


31731 Northwestern Hwy., Suite 113E, Farmington Hills, MI 48334; (248) 538-9165; Website: www.nabtesco-precision.com

Obara Corporation F o u n d e d 1956

Obara Corporation manufactures and supplies a complete range of resistance welding products that are widely used at automobile manufacturing plants worldwide and have won a reputation for their superior quality. We have sales and manufacturing facilities in Japan, China, Korea, Malaysia, Thailand, India, Australia, England, Mexico, and USA.


11478 Timken St., Warren MI, 48089; (586) 755-1250; Fax: (586) 755-6790; Cell: (586) 419-6965 E-mail: James.Jones @ obarausa.com

- - c o n t i n u e d o n p a g e 1 0 8

I

. t

Every year, more than 25,000 students begin an education that could lead to a successful career in welding. As a welder. As an engineer. As a scientist. As a teacher. Or one of hundreds of other rewarding professions in welding. The problem is, we need twice as many.

The American Welding Society Foundation has helped thousands of students who otherwise would be unable to afford a welding education. We are proud of the fact that we help hundreds of welding students annually by providing them with funding towards their education. In fact, we are the only industry foundation set up specifically, to further educations and in so doing, create the careers that sustain and grow our industry.

We get these funds from your contributions. So if you don't contribute, then we will not be able to expand our work and our students' educations. And there is so much work to be done.

If you would like to make a scholarship contribution, or even set up your own Section Named Scholarship, contact your Section or Vicki Pinsky at AWS Foundation, by phone at 1-800-443-9353, ext. 212 or by email at [email protected].

Thank you for your continued support. Foundation____ , Inc__ . Building Welding's Future through Education

Circle No. 17 on Reader Info-Card ©American Welding Society 2003 FDN1015

,&Ws ANNIVEF~

191980~

I L , Fork-Levator Inc. Founded 1984

Fork-Levator Inc. has been supplying OSA-LATOR® indexing tables for high- cycle robotic welding across North America for more than a decade. These orbital gear-driven tables offer capacities from 1,000 to 10,000 lb. and provide fast indexing, smooth rotation, high repeatability, and precise positioning. A new headstock/tailstock model now available.


P.O. Box 279, Niagara Falls, NY 14304-0279; (716) 285-0685 Fax: (716) 694-6903

Porta-Vise/ehester Industries LLC Founded 2 0 0 2

The Porta-ViseT is a revolutionary new concept in clamping technology. The exclusive feature of the Porta-Vise is a nonrotating shaft and pad for precision placement without deflection. What this really means is that the Porta-Vise works on the same principle as a vise or a press but with the added conven- ience of mobility. It is available in drop forged steel or aircraft-quality aluminum in sizes ranging from 3 to 12 inches.


P.O.Box 52, Chester, NH 03036; (877) 312-9601; Fax: (877) 378-1319 Email: jnardozza @ porta-vise.com; Website: www.porta-vise.com

Postle Industries F o u n d e d 1969

Postle offers a complete range of welding alloys for hardfacing, forging die repair, specialized fabrications and repair welding. Products include iron- based alloys, chromium, tungsten and complex carbide hardfacing products, cobalt and nickel-base-alloys, and custom product development. Available as metal and flux cored wires, welding electrodes and spray powders.


P.O. Box 42037, Cleveland, OH 44142 (216) 265-9000; Fax: (216) 265-9030 Website: www.postle.com

C O M P A N Y P R O F I L E S - - continued from page 106 Process Welding Systems, Inc.

Founded 1993

Since 1993, Process Welding Systems has been designing and manufacturing turnkey plasma arc and TIG welding systems. We are experts in welding exotic materials and small intricate parts. The equipment can ensure repeatable results, reduce welding costs, reduce the need for higher operator skill levels, and lower reject rates.


72 Buchanan St., LaVergne, TN 37086; (615)793-7020, Fax: (615) 793-7557; E-mail: prowetdl @gte.net Website: pwsweld.com

PTR-Precision Technologies, Inc. F o u n d e d 1959

Over the past 45 years, PTR-Precision Technologies and its predecessors Hamilton Standard & Leybold-Heraeus have been leaders in the field of electron beam welding. PTR has uti- lized this wealth of experience to provide its customers with state-of-the-art solutions to their equipment and joining problems. This allows PTR to offer users of the EBW process a full line of system manufacturing, contract welding, customer support/training and engineering assistance services.


120 Post Rd., Enfield, CT 06082-5625 (860) 741-2281; Fax: (860) 745-7932 Website: www.ptreb.com

Select-Arc, Inc. Founded 1996

The Select-Arc family of high-quallity welding wire has grown to encompass a complete line of carbon steel, low- alloy and stainless steel electrodes in both metal cored and flux cored versions. Select-Arc has also introduced a Iline of premium Select Wear hardsurfacing electrode products.

See our a d on IFC 600 Enterprise Dr., Fort Loramie, OH 45845-0259; (800) 341-5215; Fax: (937) 295-5217

Special Metals Welding Products F o u n d e d in 1922

Special Metals Welding Products is a world's leading developer and manufacturer of nickel-based welding consumables for joining nickel alloys, high-performance steels, cast irons and dissimilar metals, as well as over- laying on steel for corrosion or erosion protection. Products are sold under the internationally recognized brand names such as Inconel, Monel, Inco-Flux, and Inco-Weld.


1401 Burris Rd., Newton, NC 28658; (800) 624-3411or (828) 465-0352; Fax: (828) 464-8993 E-mail: [email protected] Website: www.specialmetalswelding.com

Thermadyne Industries, Inc. Founded in 1988

Thermadyne's founding date masks the extraordinary depth of experience found within its family market leading companies. Names like Victor, Tweco /Arcair, Stoody, Thermal Dynamics, Thermal Arc, C&G Systems and TurboTorch have led the metalworking industries for decades and together represent over 400 years of problem- solving expertise. Thermadyne has the products you need and the brands you can trust for any welding or cutting application.

See our ad on pages 7, 9

16052 Swingley Ridge Road, Suite 300, St. Louis, MO 63017, (636) 728-3177; Webiste: www.thermadyne.com

Tregaskiss Ltd. F o u n d e d in 1968

Tregaskiss, manufacturer of Tough Gun and TGX welding products, is an industry leader in the development and manufacturing of semi-automatic, automatic, and robotic MIG welding guns and consumables. All Tregaskiss products are marketed through distribution channels. Tregaskiss' primary markets include automotive, shipbuilding

(marine equipment), farm equipment, and container manufacturing, recreational vehicles, truck trailer manufacture, agricultural fencing.

See our ad on pages 23,24,25

2570 North Talbot Rd., Windsor ON

i1~I:!1 JUNE 2004

NOR 1L0; Canada (800) 787-6966 Customer Service: USA (800) 618- 6966; Website: www.toughgun.com

Tri Tool Inc, Founded 1972

Tri Tool designs and manufactures rugged and reliable portable equipment for precision weld prep and in-place machining to companies around the world. Along with a wide range of standard products, Tri Tool offers cost-saving alternatives with equipment rentals, maintains a staff of on-site service technicians, provides training, repairs, special engineering, and custom manufacturing.


3806 Security Park Drive, Rancho Cordova, CA 95742; (800) 345-5015, (916)351-0144; Fax: (916) 351-0372; E-mail: b.atkinson @tritool.com Website: www.tritool.com

Triangle Engineering, Inc. Founded 1960

A family-owned and operated business dedicated to serving the welding community with weld test coupons, destructive test equipment, weld engineering and material testing services. Triangle is your one stop shop to develop the WPS, supply certified materials and testing of weld procedure & performance qualifications. A long time AWS Sustaining Member, and QC-4 certified,Triangle Engineering is committed to meeting your needs.


6 Industrial Way, West Hanover, MA 02339; (781) 878-1500; Fax: (781) 878-2547; Website: www.trieng.com

Tuffaloy Products, Inc. Founded 1937

Tuffaloy offers a complete line of resistance welding products. ISO certified, we engineer and build the highest quality tips, caps, shanks, electrodes, adapters, holders, nut and stud, multi- tip, gauges, complete systems, and accessories. Our catalog and website offer a complete guide to our products.

C O M P A N Y P R O F I L E S , . . . . ,

See our ad on page 98 c ~ t @ ~ f l h

601 High Tech Ct., Greer, SC 29650; (864) 879-0763; Fax: (864) 877-2212; Website: www.tuffaloy.com

Uniweld Products Founded 1949

Uniweld Products, a U.S. manufacturing company, has grown and expanded into one of the major players in the welding and alloys markets. Uniweld's new and larger headquarters houses some of the latest state-of-the-art manufacturing equipment. The product line includes U.S. made welding apparatus, accessories, pressure gauges and alloys. Uniweld operates and maintains warehouses in Las Vegas, Nevada and in Houston, Texas. It has offices in Canada, South America, the Middle East and Singapore.


2850 Ravenswood Rd., Ft. Lauderdale, FL 33312; (954) 584-2000; Fax: (954) 587-0109; Website: www.uniweld.com

Weld Aid Founded 1958

Weld Aid has been a welding industry leader in spatter protection products for almost 50 years. It's Nozzle Kleen product line protects nozzles, tips, and dif- fusers. The Weld-Kleen line protects parts, fixtures, and tooling. The Lube- Matic line cleans and lubricates welding wire. The company also is noted for its rust protection product Brite Zinc that zinc shields metals from the corrosive effects of moisture.


14650 Dequindre, Detroit, MI 48212 (313) 883-6977; Fax: (313) 883-4930 Website: www.weldaid.com

Weld Hugger, LLC

F o u n d e d 2 0 0 0

Weld Hugger manufactures a unique cover gas distribution system for reducing discoloration in GTA Welding and TIG trailing shield and back-side cover gas applications. The system's 316L stainless steel nozzles are extremely efficient gas dis

tributors that create an inert gas cloud over, or behind, the weld pool. The nozzles' thin, flat profile facilitates getting cover gas into tight situations and allows it to be bent to conform to the shape of the part being welded.


7201 W. Oakland St., Chandler, AZ 85226; (877) 935-3447, (480) 940-7654, Fax: (480) 940-9366; Website: www.weldhugger.com

ZRO Founded in 1908

ZRC is an international leader in zinc coating technology for the protection of iron and steel. ZRC is widely used to prevent rust and rust creepage in place of hot-dip galvanizing. ZRC is excellent for long-term protection of structural steel, waste and water facilities, power plants, transmission towers and anten- nae, steel decking, facility maintenance, and bridges.


145 Enterprise Dr., Marshfield, MA 02050; (781) 319-0400; Fax: (781) 328-1504; Website: www.zrcworldwide.com

Genstar Technologies Co., Inc. Founded in North Amer ica in 1950


4525 Edison Ave., Chino, CA 91710 (909) 606-2726, Fax: (909) 606-6485, Email: sales @ genstartech.com Website: www.genstartech.com

Tee Torch Co. Inc. Founded 1955


P.O. Box 1870, San Marcos, CA 92079; (760) 747-3700; Website: www.tectorch.com

Centerline Windsor Limited Founded 1964


415 Morton Dr., Windsor, On. Canada N9J 3T8; (519) 734-8464; Website: www.cntrline.com

WELDING JOURNAL mim~ll

:LASSIFIED$

WANTED

Welding Alloy Sales Reps

Vulcan Systems is seeking professionals for the next level of profitability. Unique opportunity to build and secure your future. Protect your profits and income.

Contact Christopher Biggar (800) 642-9885

WELDING ENGINEER American Railcar Industries (ARI), the highest quality railcar builder in the U.S., is seeking a Welding Engineer for our Marmaduke, Arkansas, tank car manufacturing facility. The ideal candidate will have some welding engineering experience in a railcar manufacturing setting, and will have experience managing a facility's welding procedures and materials and equipment used in the manufacturing of tanker railcars. In addition, the ideal candidate will have experience in managing the training of welders and the administration of welder and procedure qualifications. You are encouraged to apply even if you do not meet the ideal requirements. ARI offers a competitive salary and complete benefits package including 401K plan. If you are interested in this opportunity, please send your resume with salary requirements to: Mr. Dean Inman, Human Resources, American Railcar Industries, Inc., 7755 Hwy 34 E., Marmaduke, AR 72443 - Or call: 870-597-2224 or email:dinman @ americanrailcar.com

ARI is an equal opportunity employer.

l i i l 0 1 JUNE 2004

CON EDISON Must have a rain. of 2 yrs of welding experience including, reading and understanding welding procedures; qualification with ASME B31.1, AP11104 Codes using shielded metal arc welding and/or gas tungsten arc welding; and fabricating piping from layouts, blueprints and mechanical drawings; must demonstrate skill in welding of pressure piping, oxygen/I acetylene cutting of steel plates and piping, ! brazing and soldering. Must possess burning license and fireguard, and obtain and main- tan asbestos hand er certif cate. Must be able to perform heavy manual labor and work in power plant environment. Must be medically approved to wear a respirator. Please send your resume to: opportuni- [email protected], or by mail to: Con Edison, Recruitment, Room 2215-S, 4 Irving Place, New York, NY 10003. Please use Job Code: WP2081

I

BUSINESS FOR SALE

Established 1983. Make small stored energy welding equipment. Pulse arc, spot resistance and fusion percussion mini stud welder. International markets through distributors, reps and direct sales. Miniature tech joining of similar and dissimilar metals for medical, dental, optical, jewel- ry, crafts, appliance, auto, aircraft, and electronics industries. Very strong gross profit @84%, before tax earnings @26% and after tax profits of 15%. Strictly confidential, please write:

Business 4 Sale PO Box 893

E. Greenwich, RI 02818

WANTED

Independent Sales Reps

To demonstrate welding alloys to end users.

-Consumable market -Repeat Customers -Complements Industrial Rep's

present line(s) of products.

Very unique opportunity,

Contact Christopher Biggar (800) 642-9885

CERTIFICATION & TRAINING

CWl PREPARATORY Guarantee - Pass or Repeat FREE!

@AT-FRI COURSE (7 DAYS) EXTRA INSTRUCTION TO GET A HEAD START Pascagoula, MS Aug. 14-20 Oct. 9-15

Houma, LA Sep. 11-17 Nov. 6-12 Houston, TX Jul. 10-16 Sulphur, LA Aug. 21-27

MON-FRI COURSE (5 DAYS} GET READY - FAST-PACED COURSEI

Pascagoula, MS Aug. 16-20 Oct. 11-15 Houma, I_A Sep. 13-17 Nov. 8-12

Houston, TX Jul. 12-16 Sulphur, LA Aug. 23-27

2 WEEK COURSE (10 DAYS} MORE HANDS-ON/PRACTICAL APPLICATIONS

Pascagoula, MS Aug. 9-20 Oct. 4-15 Houma, LA Sep. 7-17

(Test follows on Saturday st same facility)

TRAINING FOR RECERTIFICATION:

APPLICATIONS OF VISUAL WELDING INSPECTION

Hands-on training for real work situations

RT FILM INTERPRETATION

Level II training using real welds

WELDING PROCEDURES

Learn code requirements to write/audit

ADVANCED VISUAL INSPECTION

For experienced inspectors & engineers

M'r/PT/U'r/RT LEVEL I & II Classroom training per ASNT SNT-TC-1A

For our entire class schedule, call or e-mail 1-800-489-2890 or

info@ realeducational.com r

I W E L D 479O R i~ r Road CJnclnnaU, Ohio 45233 1,513-941-4411 1-513-,467-3585 Fa~ www, we ld~us .com

/ JSl I INC .

w w w . w e l d p l u s . c o m E-maih [email protected] 800-288-9414 Jack, Pete, Paul or Dennis Fax: 513-467-3585

JUST IN! Jetline LWC-144, 12 ft. & LWX-96 Precision 8 ft. Longitudinal Seam Welders!! TOTAL of 20 Seamers in Stock!! Come & Look!!

New "2004" Pandjiris 1500 Ib, 3000 Ib & 4500 Ib Positioners!! Call for "SPECIAL SALE PRICING"

OVER 40 "NEW 2004" POSITIONERS in STOCK!!!

Well Over 100 Positioners Up to 350 Tons!! Head/Tailstocks, Turntables up to 60 tons. Manipulators up to 14'x 14', Travel Cars, Longitudinal Seamers from 12" to 26 ft., Turning rolls up to 400 Tons, Circular Weld Systems, Welding Lathes, Arc Machines & other Orbital Welders.

WELDING RELATED MACHINERY IS OUR ONLY BUSINESS If Your Business Does Weld Fabricating--YOU NEED TO VISIT US!!!

TALK TO US!!m"WE KNOW WELDING"

m m m m m m m r ' - - - - -" USED : : ~ PLATENS

Re-Ground Tops | J FOB: Shipping Point * Call for Details | | Weldsale Company (215) 739-7474 | | www.weldsale.com j

W e Buy & Sel l Surp lus Welding Rod & Wire All types, sizes & Quantities

Carl us f irs#

800-523-2791 PA: 610-825-1250

FAX: 610-825-1553

robots4welding . c o m

Toll free: t-800-762-6862

ATTENTION! Welding Equipment Sales Personnel. We pay you for finding us good used

welding systems, seamers, positioners, manipulators, turning rolls, etc.

We will buy your customers' trade-ins.

WELD PLUS, INC. 1-800-288-9414

We buy and sell WELDING RODS & WIRE

*'ALL TYPES ** ALL SIZES ** All . QUANTITIES

Excess Welding Alloys, Inc. A division of Weld Wire Company Inc.

800-523-1266 FAX 610-265-7806 www.weldwire.net

FOR SALE

S u r p l u s m a n u f a c t u r i n g equ ip - ment to ex t rude coat ings on arc e lec t rodes and braz ing rods for p ro to t ype or sma l l p roduc t i on . Q u a l i t y e q u i p m e n t m a d e by Oer l i kon in exce l len t cond i t ion . Capab le of mak ing 3/64" to 3/8" (1.2 mm to 10 mm) d i a m e t e r and 9" to 40" (.23 M to 1 M) long.

For Information: Contact Richard Donovan

PH: 800-521-3060 FAX: 586-296-6771

EM: [email protected]

FOR SALE - FOR RENT

Welding Positioners

Headstock Tailstock

Tank Turning Rolls

Manipulators, Subarc

Welding Machines

800-218-9620 713-943-8032

www, mitrowskiwelding.com sales @ mit rowskiwelding .com

I I

Quality-Checked" Used Equipment

www.red-d-arc.corn

An Excellent Selection of Used Welding and Positioning Equipment for Sale

1-800-245-3660 ~ , . ~ 7 c e Centers Across North A m e r i c a j

I Used-Robots I .~:)-I Webuyand sell '~z~ I l-STT-4usedrobots

WELDING JOURNAL 111

4DVERTISEI; INDEX]

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A v e s t a W e l d i n g P r o d u c t s .. . . . . . . . . . . . . . . www.outokumpu.com/stainless/nad. .55

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A W S C o n v e n t i o n S a l e s .. . . . . . . . . . . . . . . . . w w w . a w s . o r g .. . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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A W S M e m b e r S e r v i c e s .. . . . . . . . . . . . . . . . . w w w . a w s . o r g ... . . . . . . . . . . . 19, 104, 105

A W S T e c h n i c a l S e r v i c e s . . . . . . . . . . . . . . . . . . w w w . a w s . o r g .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9

B l u c o C o r p o r a t i o n .. . . . . . . . . . . . . . . . . . . . . . . . . w w w . b l u c o . c o m .. . . . . . . . . . . . . . . . . . . . . . . . . 2 4

B U G - O S y s t e m s , I n c . . . . . . . . . . . . . . . . . . . . . . . w w w . b u g o - c o m ... . . . . . . . . . . . . . . . . . . . . . . . . . 14

C e n t e r l i n e L t d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . c n t r l i n e . c o m ... . . . . . . . . . . . . . . . . . . . R I

C K W o r l d w i d e , l n c . . . . . . . . . . . . . . . . . . . . . . . . . w w w . c k w o r l d w i d e . c o m .... . . . . . . . . . . 4 3

C i i m a T e c h .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w c l i m a t e c h s a f e t y . c o m .... . . . . . . . 2 2

C o l l e g e o f O c e a n e e r i n g .. . . . . . . . . . . . . . . . . w w w . c o o . e d u .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

C o m m e r c i a l D i v i n g A c a d e m y ........ www.commercialdivingacademy.com . .29

C o m p u t e r E n g i n e e r i n g , I n c . . . . . . . . . . . w w w . c o m p u t e r e n g . c o m .... . . . . . . . . . . 2 6

C o m p u t e r W e l d T e c h n o l o g y , I n c . . . w w w . c w e l d t e c h . c o m ... . . . . . . . . . . . . . . . . . . . 1

C o r - M e t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . c o r . m e t . c o m .... . . . . . . . . . . 10, 102

C - S p e c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d o f f i c e . c o m .. . . . . . . . . . . . . . . . . 5 9

D E - S T A . C O I n d u s t r i e s . . . . . . . . . . . . . . . . . . w w w . d e s t a c o . c o m ... . . . . . . . . . . . . . . . . . . . 5 9

D i a m o n d G r o u n d P r o d u c t s , I n c . . . w w w . d i a m o n d g r o u n d . c o m ..... . . . 2 5

D i v e r s A c a d e m y I n t e r n a t i o n a l ...... w w w . d i v e r s a c a d e m y . c o m ... . . . . . . . 62

E S A B W e l d i n g & C u t t i n g P r o d . . . . . w w w . e s a b n a . c o m .. . . . . . . . . . . . . . . . . . . O B C

G e d i k W e l d i n g , I n c . . . . . . . . . . . . . . . . . . . . . . . . . w w w . g e d i k . c o m . t r . . . . . . . . . . . . . . . . . . . . . . 2 0

G e n s t a r T e c h n o l o g i e s Co . , I n c . . . . . . . w w w . g e n s t a r t e c h . c o m ... . . . . . . . . . . . . . 61

H o b a r t I n s t . o f W e l d i n g T e c h . . . . . . . . . w w w . w e | d i n g . o r g .. . . . . . . . . . . . . . . . . . . . . . . 5 8

H o d g s o n C u s t o m R o l l i n g , I n c . . . . . . . w w w . h o d g s o n c u s t o m r o l l i n g . c o m 11

H o r n e l l , I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . h o r n e l l . c o m .. . . . . . . . . . . . . . . . . . . . . . . 21

H y p e r t h e r m , I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . h y p e r t h e r m . c o m ... . . . . . . . . . . . . . 92

l n t e r c o n E n t e r p r i s e s , I n c . . . . . . . . . . . . . . . w w w . i n t e r c o n o n l i n e . c o m ... . . . . . . . 4 8

I W E C o n s u l t i n g , I n c . . . . . . . . . . . . . . . . . . . . . . . w w w . i w e c o n s u l t i n g . c o m ... . . . . . . . . . 2 4

J a c k s o n P r o d u c t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w j a c k s o n p r o d u c t s . c o m ..... . . . 4 4

J o h n s o n M a n u f a c t u r i n g .. . . . . . . . . . . . . . . w w w . j o h n s o n m f g . c o m ... . . . . . . . . . . . . . 5 9

K e n n a m e t a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . k e n n a m e t a l . c o m ... . . . . . . . . . . . . . 63

K o i k e A r o n s o n , I n c . . . . . . . . . . . . . . . . . . . . . . . . . w w w . k o i k e . c o m .. . . . . . . . . . . . . . . . . . . . . . . . . 2 8

L a c o M a r k a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . l a c o . c o m ... . . . . . . . . . . . . . . . . . . . . . . . . . 12

L i n c o l n E l e c t r i c C o . . . . . . . . . . . . . . . . . . . . . . . . . w w w . l i n c o l n e l e c t r i c . c o m .... . . . . . . . . . . 5

M a g n a t e c h L i m i t e d P a r t n e r s h i p . . w w w . m a g n a t e c h - l p . c o m .... . . . . . . . . 9 0

M a g n e t i c P r o d u c t s & S e r v i c e s ...... w w w . g a u s s b u s t e r s . c o m . . . . . . . . . . . . . 60

M a n n i n g s U S A ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . m a n n i n g s u s a . c o m ... . . . . . . . . . 9 3

M K P r o d u c t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . m k p r o d u c t s . c o m .... . . . . . . . . . . . . 3 0

N a b t e s c o P r e c i s i o n . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . n a b t e s c o - p r e c i s i o n . c o m . . . 9 3

O b a r a C o r p o r a t i o n U S A ... . . . . . . . . . . . . . w w w . o b a r a u s a . c o m ... . . . . . . . . . . . . . . . . . 9 2

O s a - L a t o r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . o s a l a t o r . c o m ... . . . . . . . . . . . . . . . . . . . 15

P o r t a - V i s e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . p o r t a - v i s e . c o m ... . . . . . . . . . . . . . . . 4 3

P o s t l e I n d u s t r i e s , I n c . . . . . . . . . . . . . . . . . . . . . w w w . p o s t l e . c o m .. . . . . . . . . . . . . . . . . . . . . . . . . 2 7

P r o c e s s W e l d i n g S y s t e m s , l n c . . . . . . . w w w . p w s w e l d . c o m ... . . . . . . . . . . . . . . . . . . . 6 0

P T R . P r e c i s i o n T e c h n o l o g i e s , I n c . . . w w w . p t r e b . c o m .. . . . . . . . . . . . . . . . . . . . . . . . . 4 9

S e l e c t A r c , I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . s e l e c t - a r c . c o m .... . . . . . . . . . . . . I F C

S p e c i a l M e t a l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . s p e c i a l m e t a l s w e l d i n g . c o m . .31

T e c T o r c h Co . , I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . t e c t o r c h . c o m ... . . . . . . . . . . . . . . . . . . . 91

T h e r m a l A r c / T h e r m a d y n e ... . . . . . . . . . . . w w w . t h e r m a l a r c . c o m .. . . . . . . . . . . . . . . . . 7

T h e r m a l D y n a m i c s / T h e r m a d y n e . . w w w . t h e r m a l - d y n a m i c s . c o m ...... 9

T r e g a s k i s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . t o u g h g u n . c o m ..... . . . 23 , 25, 2 7

Tr i Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w w w . t r i t o o l . c o m ... . . . . . . . . . . . . . 61

T r i a n g l e E n g i n e e r i n g .. . . . . . . . . . . . . . . . . . . . . w w w . t r i e n g . c o m ... . . . . . . . . . . . . . . . . . . . . . . . 6 0

T u f f a l o y P r o d u c t s I n c . . . . . . . . . . . . . . . . . . . . . w w w . t u f f a l o y . c o m ... . . . . . . . . . . . . . . . . . . . . . 98

U n i w e i d .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . u n i w e l d . c o m ... . . . . . . . . . . . . . . . . . . . 5 7

W e l d A i d .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d a i d . c o m ... . . . . . . . . . . . . . . . . . . . 2 9

W e l d H u g g e r , L . L . C .. . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d h u g g e r . c o m ... . . . . . . . . . . . . .30

Z R C W o r l d w i d e .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . z r c w o r l d w i d e . c o m / w j ...... 100

I F C -- I n s i d e F r o n t C o v e r

I B C = I n s i d e B a c k C o v e r

O B C = O u t s i d e B a c k C o v e r

R I = R e a d e r I n f o r m a t i o n C a r d

AWS JobFind

B I P i JUNE 2004

WELDING RESEARCH SUPPLEMENT TO THE WELDING JOURNAL, JUNE 2004 [~X7 i~ (~

Sponsored by the American Welding Society and the Welding Research Council

Three-Dimensional Simulation of Transient GMA Weld Pool with Free Surface

A 3-D transient thermo-fluid model with free surface can analyze droplet flow effects on weld pool formation and weld bead profile

such as finger-like penetration and weld toe radius

ABSTRACT. A 3-D transient numerical model was developed for simulation of gas metal arc (GMA) weld pools with free surface and droplet impact effects. This effort predicted a moving GMA weld pool by considering not only the heat transfer and fluid flow driven by surface tension gradient, electromagnetic force, buoyancy, and arc pressure, but also detailed information about droplet flow effects on a weld pool, its solidification, and weld bead shape. Due to its unique capacity in simulation of free surface, this model can be applied to various welded joints. In the present study, the model was used to simulate both bead- on-plate and T-joints with different welding positions. The simulated weld bead geometries were in good agreement with experimental measurements.

Introduction

There has been growing recognition of the fact that convection in the weld pool is one of the dominant phenomena contributing to the weld pool formation (Refs. 1--4). The fluid flow inside the weld pool affects the heat transfer in the weld pool, the uniformity of weld composition, and the final weld bead profile. Furthermore, the thermal cycles experienced by the heat-affected zone during a welding operation determine solid-state transformations, thereby influencing the microstructure. In addition, weld bead profile is one of the critical factors in the specification for welded joint design, since it has a direct influence on welded structure stresses, weld joint strength, and fatigue life. Therefore, it is crucial to establish an accurate thermo-fluid model to simulate the entire welding thermal and fluid processes to obtain the desired weld bead profile and thermal history for structurally

Z. CAO is with the Center for Welded Structures Research, Battelle Memorial Institute, Cohtm- bus, Ohio. Z. YANG and L. X. CHEN are with the Technical Center, Caterpillar Inc., Peoria, IIL

BY Z. CAO, Z. YANG, AND X. L. CHEN

sound and high-performance welded joint design.

The gas metal arc welding process is one of the most commonly used joining methods because of its high productivity and process robustness. During GMA welding, weld metal is deposited into a weld pool from an electrode as a droplet stream. The metal transfer mechanisms play an important role in determining the resulting heat and fluid flow characteristics and final weld profile. The heat content and impact force of droplets tend to induce a series of physical, chemical, and metallurgical changes in the weld pool. Therefore, it is difficult to simulate the GMA welding process, mainly due to the droplet impact and the large flow and temperature gradients associated with this process. A better understanding of droplet impact effects on weld heat transfer and fluid flow is critical to determine welding procedures and to predict weld bead profiles.

To date, most investigations of fluid flow in weld pools have concentrated on the gas tungsten arc (GTA) welding processes, without including the complexity of metal transfer across the plasma (Refs. 5-12). Unfortunately, little work has been done in the area of fluid flow and heat transfer in GMA weld pools, due to its complexity. For instance, in Tsao's 2-D GMA weld pool model (Ref. 13), droplet heat was considered, but a fiat weld pool

KEYWORDS

Gas Metal Arc Welding Modeling Weld Pool Fluid Flow Heat Transfer Free Surface Droplet T-Joint Fillet Weld

surface was assumed. Weld pool surface deformation was incorporated in Kim's 3-D GMA weld pool solution (Ref. 14), while the effect of droplets was ignored. In another paper by Kim (Ref. 15), the droplet effect was taken into account. It was assumed that the molten droplet is transferred to the weld pool surface with distributed velocities of the Gaussian type. In Ohring's paper (Ref. 16), a 3-D transient GMA weld pool model was established by incorporating droplet and moving arc effects. However, the droplet influence was simulated by using a liquid column acting directly under the welding arc center with a constant impact speed. Apparently this kind of liquid column is very different from the individual droplets, unless these droplets transfer into the weld pool at an infinitely fast frequency. Recently, Davies (Ref. 17) proposed an investigation of the interaction of molten droplets with a liquid weld pool surface, but the model considered a 2-D stationary arc and did not incorporate arc travel effects. Yang and DebRoy (Ref. 18) considered the effect of droplets on GMA weld pool formation by incorporating a cylindrical volumetric heat source in the weld pool. The dimensions of the cylindrical volumetric heat source were calculated using parameters such as the drop size, shape, velocity, and frequency. Although their model demonstrated its capability to predict some essential features of GMA weld profile, such as finger penetration, the model was based on a fixed flat surface and cannot predict the metal reinforcement from GMA welding. In the author's recent paper (Ref. 19), a 3-D quasi-steady state model was proposed to describe fluid flow and heat transfer in a fully penetrated GMA weld pool. Droplet heat content, impact force, arc pressure, and pool surface deformation were considered. How- ever, droplets were treated purely as a heat and momentum problem, and droplet effects on the fluid flow field in the weld pool were neglected.

WELDING JOURNAL li[.-f¢l~l

It should be pointed out that all the aforementioned studies were focused on bead on plate, and no 3-D transient computational fluid dynamics (CFD) models considering individual droplet impact and T-joints were reported for GMAW. In this study, a 3-D transient weld pool model was developed to study the fluid flow and heat transfer in the GMA welding process with consideration of individual droplets with high speed and high temperature. Both bead-on-plate and T-fillet joints at different positions were investigated, and experimental measurements were performed to validate the model.

Model Definition and Formulation

In order to simplify the mathematical model, the following assumptions have been adopted: 1) the flow is Newtonian and laminar, and compressibility is only included through the buoyancy term and the Boussinesq approximation; 2) physical properties, as listed in Table 1, are constant with temperature; and 3) the arc is regarded as a spatially distributed source of heat, current, and pressure flux.

Governing Equations

The coordinate system (x, y, z) is shown in Fig. 1. The workpiece bottom surface is used to define the x-y plane and the torch travels along the x-axis. A three-dimensional transient model is used to analyze the heat transfer and fluid flow for the GMA welding process. The computation domain is established to include the interaction of metal droplets with the weld pool. A moving arc and a fixed coordinate system are adopted for solving the transient problem. The metal droplets were generated as source term in the computation domain. It is assumed that spherical droplets at a certain height transfer into the weld pool. The droplets carry mass, momentum, and thermal energy, and pe- riodically impinge into the weld pool. The initial temperature of the droplet is assumed to be constant. The droplet is also given an initial transfer speed, together with a horizontal speed with the welding torch. Once a droplet reaches the weld pool surface, the droplet interacts with the weld pool by transferring mass, momentum, and energy (Ref. 20). The values for droplet size (Rd), velocity (Vd) , and its transfer frequency (Fd) are given in the appendix.

The heat transfer and fluid flow were calculated by numerical solution of the equations of conservation of mass, momentum, and energy in three-dimensional form. The governing equations are given as Equations 1-3. The mathematical equations provided in this section are

Table 1 - - P a r a m e t e r s Used in Calcu la t ion

K 32.3 (solid) W/m K 26.9 (liquid) W/m K

Cp 732 J/kg K p 6900 kg/m 3

I a 5 x 10 -3 kg/m s lao 1.26 x 10 -6 H/m y 1 N/m YT -0.2 x 10 .3 N/m K 13 1.0 X 10 .4 K -1 T v 2900 K T l 1798 K T s 1768 K h c 100 W/m 2 K Lf 2.77 x 105 J/kg L e 7.34 x 106 J/kg L 1.27 cm t~q 0.4 cm Gj 0.2 cm u o 0.5 cm/s I 210 A V 30 V V d 50 cm/s F d 400 drops/s R d 0.05 cm

valid for whole computat ion domain, which includes droplet, weld pool, and base material.

The value and physical meaning of each variable are listed in the appendix.

Mass continuity equation:

v.#=0 (1)

Momentum equation:

017" +(17 .V)p=l (vp+gV21? + Fh) Ot p (2)

Energy equation:

1 [Oh +(I / V)h I = V.(KVT) ~ L ~ "

where (3)

h = C p . T + f . L

I O, i fT <T,

f ( T ) = l T I_~.~,. i f T , < T < T l

L1, i fT > Tt (4)

The body force is calculated using the electromagnetic and buoyancy forces:

- + - ~ -4.

(5) The electromagnetic force in the pre-

Table 2 - - E x p e r i m e n t a l Condi t ions

Material A36 steel Thickness 1.27 cm Wire stickout 2.2 cm Wire diameter 0.132 cm Wire feed rate 13.76 cm/s Welding current 280 A Welding voltage 30 V Welding speed 0.5 cm/s

sent work is calculated based on Tsao's analytical solutions (Ref. 13).

Arc pressure is determined using the following formula (Ref. 21):

P , , ~ ( x , Y ) = ~ e x p ( - ~ 2 . 1 J " J J (6)

It should be pointed out that the are pressure in Equation 6 is adopted from the GTA welding process due to the lack of an arc pressure expression for GMA welding.

Boundary Conditions

The boundary conditions for temperature distribution and fluid flow are described below:

a) Weld pool top surface

K OT _ q l V I x2 + y2 ) 0n 2rt62q exp , 2~'q 2 )

T 4 4

,7,

- 0 G = _ p o ~ +_~ - p + z g 3~-

0V~ 0T la an = ~'r a~-

(8)

b) Bottom surface

0n U = V = W = 0 (9)

c) Front surface

T = T u = v = w = O (10)

d) Rear and side surfaces

On u - - v = w = 0 (11)

l i i r ldt~"] J U N E 2 0 0 4

WELDING RESEARCH

: y !

arc w e ~

travel direction -- electrode /

Fig. 1 - - Schematic sketch o f GMA welding.

Numerical Method

The developed weld thermo-fluid model in this research used a software package, F L O W - 3 D (Ref. 22), as the solver of the heat transfer and fluid flow in the weld pool. The selected solver has the capability of modeling fluid flow with free surface, which is a must to predict non-fiat weld bead shape. A unique technique called the FAVOR (fractional-area-volume-obstacle-representation) method is used to define general geometric regions within the rectangular grid. Its free griding feature el iminates the tedious tasks of generating body-fitted or finite-element grids. Furthermore, this feature makes it possible to simulate the dynamic weld pool with free surface within a reasonable computation time frame. The flow region is subdivided into a mesh of fixed rectangular cells. With each cell, there are associated local average values of all dependent variables. All variables are located at the centers of the cells except for velocities, which are located at the cell faces (staggered grid arrangement) . Curved weld surfaces (both molten and solidified) and other geometry features are embedded in the mesh by defining the fractional face areas and fractional volumes of the cells that are open to flow (Ref. 23). To construct discrete numerical approxima- tions to the governing equations, control volumes are defined surrounding each dependent variable location.

R e s u l t a n d D i s c u s s i o n

A 3-D transient weld pool dynamics model is constructed to simulate the GMA welding process. The governing equations, including continuity, momentum, and energy equations, are discretized using the control volume method. The regular rectangle meshes are used in the whole domain. Convection, radiation, and

T e m p e r a t u r e (C) and vector (vmax=54.2cm/s) z s 304 $83 862 1141 1410 1700

|

01tl

0 . 0 ' , . 3 ' 1 ~ '

~ U 3 5

2 1 Z 8 J x

Fig. 2 - - Temperature and fluid flow field at longitudinal cross section at different moments for the bead- on-plate case.

evaporation are incorporated as thermal boundary conditions. Both droplet travel speed and arc pressure are involved to determine fluid flow field and free surfaces. Furthermore, latent heat of fusion and evaporation are considered in the model.

Three cases were analyzed in the study, which include bead-on-plate, horizontal- vertical T-joint, and T-joint with 45 degrees. The welding parameters used in experiments are given in Table 2. Other parameters and constants for simulation have been listed in Table 1.

Bead on Plate

The calculated temperature distribution and fluid flow field at different sections and at different moments for the bead-on-plate case are displayed in Figs. 2-4. The dark color at the middle indicates above-melting temperature, and the small arrows inside the weld pool represent molten material flow direction and magnitude. It can be seen that the weld pool penetra t ion is developed gradually as welding time increases. As droplets enter the weld pool, both deep pool surface de- pression under the arc and high elevation away from the arc are clearly observed. The deposit material forms big weld rein-

forcement behind the welding torch. In the longitudinal central cross sec-

tion in Fig. 2, the three figures on the left side show tempera ture and fluid flow fields, and the three figures on the right show enlarged local views of their coun- terparts from the left side. It is seen that the weld pool depth does not change much after three seconds, which means the majority of penetration happens in the first three seconds, since the high-speed droplets penetrate the pool so quickly that this kind of penetration reaches equilibra- tion after three seconds between the pool and droplets. As for fluid flow inside the weld pool, Fig. 2 (left side) shows a complex flow pattern in the weld pool. There exist two flow loops at the longitudinal cross section at all three moments. The big radially inward flow loop is dominated by the high-speed droplets and electromagnetic force. This is the driving force for GMA to form a deeply penetrated weld. The small radially outward flow loop behind the former one is driven by the surface tension gradient, and it makes the weld pool longer.

In order to capture the temperature and fluid flow features at the top view, re- suits at the two cross sections (.4-14 is z = 1.25 cm for the left three figures, and B - B

WELDING JOURNAL li lrAil~l

-0 32

-D ~6

~6D

Temperature (C) and vector (vmax=9. I cm/s)

?~ ]D4 ~ ~ H4t :420 1700 I S 2 - -, - I-~ r ~

B B

s e c ~

Q 32

3Z

-1 5D

:°

B=B

Fig. 3 - - Temperature and fluid f low field at z = 1.25 cm cross section at different moments for the bead- on-plate case.

Temperature (C) and vector (----*7.28cm/s)

2.4

-0 312 0 32 0"0-1160 -0 96 -0 32 0 32 0 96 i 60

- 0 3~2 I 0 312 I 0 9 J,

Fig. 4 - - Temperature and fluid f low field at transverse cross section at different moments for the bead- on-plate case.

is z = 1.29 cm for the right three figures) are plotted in Fig. 3. Since the plate thickness is 1.27 cm, only weld reinforcement is sectioned at B - B . From the top view, the weld pool is elliptical at the beginning, and then it gradually becomes a teardrop shape, due to the small radially outward flow loop mentioned at the longitudinal cross section. Also, it is because the part of the weld pool behind the torch still holds higher than melting temperature, and the part of the weld pool directly under the torch is continuously heated. This type of teardrop-shaped weld pool was observed by Kou (Ref. 24) for high heat input and high travel speed. Also, it can be seen that there are two small flow loops behind the arc near the weld interface. They are caused by the strong backward flow, and are contributing to enlarging the weld width.

From the transverse cross section in Fig.4, it is found that the deepest penetration occurs at the section when the arc reaches the surface. Reinforcement forms after the arc passes. Fluid at the cross section when t = 2.5 s flows downward at the center driven by droplet flow, and flows outward driven by the surface tension gradient. This trend can be observed more clearly at the cross section when t = 3.1 s. Deep inside the pool, there are two downward flow loops, which produced deep and finger-like penetrat ions. Near the pool surface, there are two outward flow loops, which generated wide pool width.

Figure 5 shows the 3-D temperature distr ibution of the bead-on-plate case. The half model is displayed because of its symmetrical features. It can be seen that the splatter of droplets is severe at the beginning, and the situation of splatter is improved as time increases. The weld bead is formed uniformly along the welding direction, and the weld bead shape can be observed. Under the given GMA welding condition, it can be observed that the droplet impact force, surface tension gradient force, and electromagnetic force are the predominant factors in determining weld pool penetration and fluid flow velocity and pattern. Weld penetration is primarily determined by the droplet impact force, while weld width is determined by surface tension gradient force. To justify this statement, we also did a simulation for another case with much lower droplet velocity (5 cm/s). The penetrations assuming two different metal droplet velocities are compared in Fig. 6. It is observed that the penetration from normal droplet velocity (50 cm/s), which was selected based on the data in literature, is significantly higher than that from assumed low droplet velocity (5 cm/s). As is shown later in Fig. 13A, the predicted weld penetration using 50- cm/s droplet velocity is comparable with

mt~,~1 JUNE 2004

= I l,Nfl

"I NI~6

Temperature (C) and vector (vmax=54cm/s)

304 583 862 1141 1420

,,~L ,['

1700

Fig. 5 - - Three-dimensional temperature distribution for the bead-on-plate case.

Fig. 6 - - Comparison o f calculuted penetration assuming different metal droplet velocities: A - - 50 cm/s; B - - 5 cm/s.

the experimental results. In contrast, the predicted penetra t ion using 5-cm/s droplet velocity is much lower than the actual penetration. Thus, it is clear that weld penetration is primarily determined by the metal droplet impact force. Compared to metal droplet impact force, the effect of electromagnetic force on weld penetration is much less under the investigated (3MA welding condition. The finger-like penetration that occurs in GMA welding is caused by the combinat ion of the droplet impact force, surface tension gradient, and electromagnetic force.

Horizontal-Vertical T-Joint

With a T-joint, unlike the bead-on- plate cases, there are both horizontal and vertical plates, and the arc torch has a 45- deg angle with respect to the horizon. In order to compare the joint type effects, all the calculation parameters used are the same as in the bead-on-plate case.

The calculated temperature distribution and fluid flow field at transverse cross sections and at different moments are displayed in Fig. 7. The arc center is located at the cross section when t = 2.5 s. As shown in Fig. 7A, finger-like penetration still occurs for this case, due to the combination of droplet impact force and electromagnetic force. The maximum velocity at this moment is 5.39 cm/s, which is a little larger than the specified velocity of a metal droplet. When the arc moves away from this location, as shown in Fig. 7B, the maximum velocity decreased to 0.729 cm/s. This is because surface tension gradient force at this moment is dominant at this location. Thus, the fluid near the pool surface flows from the center outward. In addition, more fluid is formed near the horizontal plate due to gravity. As a result, the leg length of the weld on the horizontal side is larger than that on the vertical

2~ T e m p e r a t u r e (C)

v e c t o r ( ~ 54 c m , s )

~03 I ]62 1141 1420 1700

II ~ :1~:~

v e c t o r ( - , - 7 .3 c m s )

.0[ oo

a n

Fig. 7 - - Temperature and fluid flow field at transverse cross section at different moments for the horizontal T-fillet case.

side. The predicted final weld bead shape after solidification is shown in Fig. 7C.

The calculated temperature distribution and fluid flow field at longitudinal cross sections and at different moments are displayed in Fig. 8. Since the longitudinal cross section is taken near the vertical plate surface, the weld reinforcement is naturally higher at this view. In the weld pool, there are two same-sized flow loops

overlapping each other. The top loop, driven by surface tension gradient, flows outward at the pool surface; and the bottom loop, driven by droplet impact and electromagnetic force, flows downward deep inside the pool.

The three-dimensional tempera ture distribution is shown in Fig. 9. It can be observed that there is severe spatter at the beginning of the weld, and some spatter is

W E L D I N G J O U R N A L lilr~l~..'ll

Temperature (C) and vector (vmax=l 7.3cm/s)

2S 301 6113 862 1141 1420

0n,0 J 0~ '

1 1

0 .0

0.0

2 Z

1700

I

14 21 28 3~

0 % ' o + ' 1 1 ' 2t ' 2 6 ' 3~ x

Fig. 8 - - Temperature and fluid flow field at longitudinal cross section at different moments for the horizontal T-fillet case.

25 304 $83 862 1141 142B

Temperature (C) I!~:: %

vec tor ('---* 160 cm/s) vector (-'-*'50 cm/s)

Fig. 10 - - Temperature and fluid flow fieM at transverse cross section at different moments for the 45- deg T-joint case.

- |

-I

Fig. 9 - - Three-dimensional temperature distribution for the horizontal T-fillet case.

located on the side of the weld on the horizontal plate. However, the situation is improved when time increases. Also, the weld bead shape can be observed clearly.

T-Joint with 45 Degrees

In this case, the horizontal-vertical T- joint structure from the last case is rotated 45 deg around the x-axis, so that the weld torch is located at the vertical position and it has the same angles (45 deg) to the two plates. The calculated temperature distribution and fluid flow field at longitudinal and transverse cross sections and at different moments are displayed in Figs. 10 and 11, respectively. There is much splatter in the torch travel direction, and less splatter along the side of the weld, which is due to its special joint position.

Figure 11 shows that both the weld surface and the transition between weld and plate are very smooth. Obviously, this is more desirable than those of the horizontal-vertical T-joint from the fatigue point of view. Finger-like penetration occurs again for this case, due to the high-speed droplet flow (which increases the penetration) and the two outward flow loops be- side the weld center (which increase the weld width).

From Fig.11, the weld reinforcement is also higher at this view than that in the bead-on-plate case in Fig. 2. However, the fluid flow patterns at these longitudinal cross sections are similar to those in the bead-on-plate case in Fig. 2, except that the flow loop driven by droplet impact and electromagnetic force is much bigger than that in Fig. 2. The three-dimensional temperature distribution is shown in Fig. 12. Only half of the model is plotted, due to the symmetrical features of the structure. Again, the weld bead shape can be observed clearly from this view. Some splat-

lilr~l$.'] JUNE 2004 I

WELDING RESEARCH

vector ( ~ 52 era/s)

vector ( ----------~55 era/s)

26

Fig. 11 - - Temperature and fluid f low field at longitudinal cross section at different moments for the 45- deg T-joint case.

Cah • W l u u z - i . . ~ ~111

• depth-0.39 cm (a) • depth-0.41 cm

cn'~ Calet ~.3 cm • wid T4 cm • d e p

(b)

Fig. 13 - -Weld profile comparison between calculation and measurement for: A - - bead-on-plate; B - - 4 5-deg T-fillet weM.

Fig. 12 - - Three-dimensional temperature distribution for the 45-deg T-joint case.

ter can be seen, but it is less severe than the horizotal-vertical case in Fig. 9 and, especially, the weld bead shape is better.

V a l i d a t i o n

To validate the modeling results, GMA welding experiments were carried out for both bead-on-plate and T-fillet welds. The test conditions are listed in Table 2. Com- parisons between the calculated and actual weld bead shape for both bead-on- plate and T-fillet welds are shown in Fig. 13. It can be seen that the predicted weld width and depth are close to the experimental ones in both cases. In the bead-on- plate case, the predicted width and depth are 0.124 cm and 0.039 cm, and the mea- sured width and depth are 0.129 cm and 0.041 cm. Also, the finger-like penetration is captured from the prediction, and its penetrat ion shape matches the experimental one well. In the T-fillet weld case, the concave weld bead shape was well predicted from simulation. As shown in Fig. 13B, the predicted penetration and weld toe radius are comparable with the actual weld geometry.

C o n c l u d i n g R e m a r k s

A 3-D transient thermo-fluid model with free surface was developed to simulate the heat transfer and fluid flow in the GMA weld pool. This work represents the first effort to explicitly simulate the interaction of a metal droplet with the weld pool using the free surface model. The model has been used to analyze the heat transfer and fluid flow pattern for different types of welded joints, including bead- on-plate and T-fillet joints. The predicted weld bead shapes were compared with the experimental results. The results here in-

I WELDING JOURNAL lilr~l.'l~.'l

dicate the significant promise to use a 3-D t rans ien t f ree-surface weld thermo-f lu id model to design a desired weld bead shape for a h igh-per formance welded joint. T he following conclusions can be m a d e f rom the present work:

• The 3-D t rans ient f ree-surface model can simulate the details for weld pool format ion dur ing the G M A welding process. This includes mel t ing of base mater ia l , in- t e r a c t i o n of the me ta l d r op l e t wi th the weld pool, weld pool sol idif icat ion, and final weld bead shape.

• The flow pa t t em in the G M A welding process can be well predicted by considering the combined forces from metal droplet impact, surface tension gradient , electro- magnet ic force, arc pressure, and gravity. Among all of the forces, the metal droplet impact is the primary force responsible for penetrat ion, which in combinat ion with the outward flow on the pool surface driven by tens ion gradient force, causes the f inger penet ra t ion in G M A welds.

• The 3-D free-surface model is capable of s imulat ing hea t t ransfe r and fluid flow in var ious types of welds. T h e de- tai led features for G M A welds, such as fin- ge r p e n e t r a t i o n , r e i n f o r c e m e n t due to wire deposi t ion, and weld toe, can be mod- eled. G o o d ag reemen t was observed between the predic ted and actual welds.

Acknowledgments

The authors would like to thank Dr. E W. Brust and Dr. E Dong of Battelle for their support and suggestions. This paper was prepared with the support of U.S. Department of Energy (DOE) Award Number DE-FC07-01ID14242. However, any opinions, findings, conclusions, or recommendations expressed herein are those of the authors and do not necessarily re- fleet the views of DOE.

References

1. Oper, G. M., and Szekely, J. 1984. Heat and fluid flow phenomena in weld pools. Jour- nal of Fluid Mechanics 147:53-79.

2. Chan, C., Mazumder, J., and Chan, M. M. 1984. A two-dimensional transient model for convection in laser melted pools. Metallurgical Transactions 15A:2175-2184.

3. Kou, S., and Wang, Y. H. 1986. Computer simulation of convection in moving arc weld pools. Metallurgical Transactions 17A:2271-2277.

4. Zacharia, T., et al. 1989. Three-dimensional transient model arc welding process. Metallurgical Transactions 20B:645-659.

5. Heiple, C. R., and Roper, J. R. 1982. Mechanism for minor element effects on GTA fusion zone geometry. Welding Journal 60(8): 143-s to 145-s.

6. Thompson, M. E., and Szekely, J. 1989. The transient behavior of weld pools with a deformed free surface. International Journal of Heat & Mass Transfer 32(6): 1007-1019.

7. Choo, R. T. C., and Szekely, J. 1990. Mod- eling of high-current arc with emphasis on free

surface phenomena in the weld pool. Welding Journal 69(9): 223-s to 233-s.

8. Tsai, M. C., and Kou, S. 1989. Marangoni convection in weld pools with a free surface. In- ternational Journal of Numerical Methods in Fluid 9:1503-1516.

9. Kim, S. D., and Na, S. J. 1992. Effect of weld pool deformation on weld penetration in stationary gas tungsten arc welding. Welding Journal 71(5): 179-s to 193-s.

10. Zhang, Y. M., Cao, Z. N., and Kovace- vic, R. 1995. Numerical analysis of fully penetrated weld pools in GTA welding. Proc. Instn. Mech. Engrs., Part C: Journal of Mechanical En- gineering Science 210:187-195.

11. Kovacevic, R., Cao, Z. N., and Zhang, Y. M. 1996. Role of welding parameters in determining the geometrical appearance of weld pool.ASME Transactions Journal of Engineering Materials and Technology 118(10): 589-596.

12. Cao, Z. N., Zhang, Y. M., and Kovace- vic, R. 1998. Numerical dynamics analysis of moving GTA weld pool. ASME Transactions Journal of Manufacturing Science and Engineer- ing 120(2): 173-178.

13. Tsao, K. C., and Wu, C. S. 1988. Fluid flow and heat transfer in GMA weld pool. Weld- ing Journal 67(3): 70-s to 75-s.

14. Kim, S. -D., and Na, S. -J. 1995. A study on the effect of constant tube-to-workpiece distance on weld pool shape in gas metal arc welding. Welding Journal 74(5): 141-s to 152-s.

15. Kim, S. -D., and Na, S. -J. 1994. A study on the three-dimensional analysis of heat and fluid and flow in gas metal arc welding using boundary-fitted coordinates. ASME Transac- tions Journal of Engineering for Industry 116(2): 78-85.

16. Davies, M. H., Wahab, M., and Painter, M. J. 2000. Investigation of the interaction of a molten droplet with a liquid weld pool surface: A computational and experimental approach Welding Journal 79(1): 18-s to 23-s.

17. Ohring, S., and Lugt, H. J. 2000. Nu- merical simulation of a time-dependent 3-D GMA weld pool due to a moving arc. Welding Journal 78(12): 416-s to 424-s.

18. Yang, Z., and DebRoy, T. 1999. Model- ing macro- and microstructures of gas-metal- arc welded HSLA-100 steel. Metallurgical and Material Trans. 30B: 483-488.

19. Cao, Z., and Dong, P. 1998. Modeling of GMA weld pools with consideration of droplet impact. ASME Journal of Engineering Materials and Technology 120(10): 313-319.

20. Wang, Y., and Tsai, H. L. 2001. Effects of surface active elements on weld pool fluid flow and weld penetration in gas metal arc welding. Metallurgical and Material Trans. 32B:501-515.

21. Tsai, N. S. and Eagar, T. W 1985. Distri- bution of the heat and current fluxes in gas tungsten arcs. Metallurgical Transactions 16B:841-846

22. FLOW-3D User's Manual, Excellence in Flow Modeling Software. Version 7.7. Flow Sci- ence, Inc.

23. Hirt, C. W., and Sicilian, J. M. 1985. A porosity technique for definition of obstacles in rectangular cell meshes. Proc. Fourth Interna- tional Conf. Ship Hydro. Washington, D.C.: Na- tional Academy of Science.

24. Kou, S., and Le, Y. 1988. Welding parameters and grain structure of weld metal - - A thermal dynamic consideration. Metall. Trans. 19A:1075-1083.

Appendix

Nomenclature

c, f Fh

hc I ] K

Le L n

p P~,~ qe~'ap

r

R T T~ rm r~ TI 1", u o u

v

v~ tion

V, v

w

x,y,z ~t ~to P Pa

Y

t3

% aj £

,[

magnetic induction vector, tesla specific heat, J/kgK frequency of droplet transfer, 1/s component of body force, N gravitational acceleration vector, m/s" convection coefficient, W/m-'K welding current, A current density vector, A/m: thermal conductivity, W/mK l a t e n t h e a t o f f u s i o n

latent heat of evaporation thickness normal unit vector to outer pool surface pressure, N/m-" arc pressure, N/re" heat loss from evaporation, W/m 2 radial distance, m radius of surface curvature, m temperature, K ambient temperature, K melting temperature, K boiling point liquidus temperature solidus temperature welding speed, m/s x-direction velocity, m/s arc voltage, V velocity vector, m/s velocity component in surface tangential direc-

droplet transfer velocity, m/s velocity component in surface normal direction y-direction velocity, m/s z-direction velocity, m/s coordinates, m viscosity, kg/ms magnetic permeability, H/m density, kg/m 3 droplet density, kg/m 3 coefficient of volume expansion, 1/K surface tension, N/m surface tension temp. coefficient, N/mK arc efficiency Stefan-Boltzmann constant, 5.67 x 10 -8 W/m2K ' arc heat flux distribution parameter arc current flux distribution parameter surface emittance, 0.8 the tangential direction of the pool surface

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|lrX,"~.,.~ JUNE 2004

Plasticity-Based Distortion Analysis for Fillet Welded Thin-Plate T-Joints

A new relationship between cumulative plastic strains and angular distortion was found

BY G. H. dUNG AND C. L. TSAI

ABSTRACT. The procedure of plasticity- based distortion analysis (PDA) for directly mapping cumulative plastic strains into elastic models using equivalent thermal strains was developed and applied to the investigation of the characteristic relationship between cumulative plastic strains and angular distortion in fillet welded thin-plate T-joints. Plasticity- based distortion analysis successfully predicted the total angular distortion with an accuracy of 97% compared with angular distortion obtained from the elastic- plastic analysis, demonstrating the validity of the unique relationship between cumulative plastic strains and distortions and the applicability of linear elastic models in welding-induced-distortion analysis. The PDA procedure also provided the quantitative relationship between six cumulative plastic strain components and angular distortion of fillet welded T-joints. Transverse cumulative plastic strain-inducing transverse shrinkage generated bend-down angular distortion, which was different from what has been understood. Vertical and longitudinal cumulative plastic strains produced bend-down and slight bend-up angular distortion, respectively. The major bend-up angular distortion was induced byxy-plane shear cumulative plastic strain, which has not been considered as a cause of angular distortion in fillet welded T-joints. Other shear components were not related to angular distortion.

Introduction

From a mechanical viewpoint, distortions and residual stresses induced in structures after welding can be regarded as the resultant of incompatible strains consisting of thermal strains, plastic strains, creep strains, and others. In this study, it is assumed that only plastic strains exist as the incompatible strain after weld-

G. H. JUNG is with the Edison Welding Institute, Columbus, Ohio. C. L. TSAI is with Industrial, Welding and Systems Engineering at The Ohio State University, Columbus, Ohio.

ing, because creep would not be expected due to fast cooling, and no thermal strains are expected after completion of cooling. Therefore, understanding the cumulative plastic strain distribution after welding can be regarded as a linchpin of residual stress and distortion analysis.

Ueda and his coworkers (Refs. 1--4) defined the characteristic distribution of inherent strains, and applied it to predict residual stresses induced by welding. Based on experimental, theoretical, and numerical studies, they defined inherent strain distributions using a trapezoid curve pattern, and predicted residual stresses by performing the elastic analysis, in which equivalent distributed loads replaced inherent strains. Others (Refs. 5-7) applied this method to predict welding-induced distortion. This inherent strain approach was based on the assumption that residual stresses and distortions being analyzed should be uniquely predicted by the specifically selected component of inherent strains. For example, if longitudinal inherent strain were used in the prediction of longitudinal residual stress or distortion, other inherent strain components should not affect longitudinal residual stress or distortion, or their effect should be small enough to be negligible. There- fore, it is critical to understand the relationship between cumulative plastic strains and distortions/residual stresses in the application of the inherent strain approach.

In terms of angular distortion, it has been believed that angular distortion is in-

KEYWORDS

Plasticity-Based Distortion Numerical Analysis Finite Element Model Fillet Welds Weld Process Simulation

duced by transverse cumulative plastic strain, which is distributed nonuniformly through the thickness of a plate. This statement may be true in the case of welded butt joints, but Han (Ref. 8) found that angular distortion in butt joints resulted not only from transverse cumulative plastic strain, but also from a longitudinal component, according to his observation of the evolution of angular distortion and cumulative plastic strains. On the other hand, for fillet welded T- joints, which have more complex geometric configurations than welded butt joints, only a few studies (Refs. 3, 9, 10) have been performed to figure out the angular distortion mechanism using numerical and experimental analyses. They explained the angular distortion mechanism using the change of the location of the shrinkage source. It seems those researchers believed the gradient of transverse shrinkage resulted in angular distortion in fillet welded joints like welded butt joints. For the application of the inherent strain approach to T-joints, Yuan and Ueda (Ref. 4) used it to predict longitudinal residual stress in T-joints and I-beam cross-section joints, but no further research on the prediction of angular distortion ofT-joints has been done. Some diffi- culties or misunderstandings may restrict the application of the inherent strain approach to the prediction of angular distortion in fillet welded T-joints.

As mentioned above, it is critical to postulate the characteristic relationship between cumulative plastic strains and angular distortion in order to provide better quantitative understanding of the angular distortion mechanism. In this study, a new approach analyzing the relationship between cumulative plastic strains and angular distortion in fillet welded T-joints, dubbed "plasticity-based distortion analysis," is proposed and applied to the investigation of the relationship between cumulative plastic strains and angular distortion in fillet welded thin-plate T- joints.

WELDING JOURNAL lilrX~,.1

Thermo Elastk-Ph~tie Analysb ] - aeatTransferAnalysis l ' I Element I - E l a s l i © - P h l s l i e A l a l l l y s i s I I rood=, I

+ • . [ Residual Slresses I I ~ - - ~ [ Cumuhllive PIllsli+ Strains J . i I I u++,,+ [

Thermo Elastic Analysis /

~ ~ [ Tom~..,-.J ~ , _ ~

, E+:,

.... oj + = + - N / I

Fig. 1 - - Procedure o f plasticiry-based distortion analysis (PDA ).

The Procedure of Plasticity- Based Distortion Analysis

Plasticity-based distortion analysis (PDA) is a numerical procedure to predict welding-induced distortion by direct mapping characteristic cumulative plastic strains into elastic models, instead of applying equivalent forces and moments. One of the advantages of this approach is to incorporate all cumulative plastic strain components in predicting distortion, and investigate the relationship between each cumulative plastic strain and a distortion type of concern. Especially for fillet welded T-joints, which are complex in geometric configuration, PDA becomes a more powerful tool.

General Procedure of PDA

Figure 1 shows the flow chart of PDA consisted of three parts:

Part 1: Thermal-elastic-plastic analysis (EPA), determining the characteristic cumulative plastic strain distributions of all six components and distortions.

Part 2: Elastic analysis, calculating individual distortions corresponding to the mapped individual cumulative plastic strains. Repeat six times with all components of cumulative plastic strains in the case of a 3-D model, and four times for a generalized plane strain model.

Part 3: Post-processing, obtaining the total distortion by adding individual distortions induced by each cumulative plastic strain component.

In Part 1, PDA requires the appropriate distributions of all cumulative plastic components from the thermal-elastic-plastic analysis for the given welding condition. It was assumed that the present thermal- elastic-plastic analysis with an initial finite element model would predict the reasonable distortion pattern, and the change of the number of nodes and elements would not significantly affect the characteristic distribution pattern of cumulative plastic strains.

Part 2 is an elastic analysis. Each cumulative plastic strain distribution obtained from the thermal-elastic-plastic analysis was mapped into elastic models using the equivalent incompatible strain fields, such as thermal strains. Thermal strains can be dependent on temperature or field variables. In this study, temperature and the corresponding thermal expansion coefficient were used to generate thermal strains. For the 3-D model, six components of cumulative plastic strains were mapped one by one into six elastic

k2 = 5,000 N / m m ~ " l ~ N/mm

~ ~ Node 31 K" mm x 1 mm I kl = lO,O00N/mm

Fig. 2 - - Simple 2-D FE model.

o / 0.012

i Applied Plastic Strain 00o8 , Using Temperature

\ J Thermal Strain

+ -' l Distance ,, r ' P; I 14 2 mm

-0.004 r [ ' I ' I ' [ ' I 0 0.4 0.8 1.2 1.6 2

Distance (ram)

Fig. 3 - - Characteristics of thermal strain in second-order elements.

models using corresponding temperature fields, and six individual distortions were determined from the six elastic analyses.

In Part 3, the relationship between cumulative plastic strains and distortion can be explained with quantitative measure, and the accuracy of the PDA procedure can be checked. Each individual distortion represents the contribution of each cumulative plastic strain to total distortion. The total distortion can be calculated by adding six individual distortions, comparing the total distortion with the distortion obtained from the thermal-elastic-plastic analysis in order to check the accuracy of the PDA procedure. If the accuracy does not satisfy the required accuracy in terms of the engineering application, Parts 1, 2, and 3 should be repeated with the remeshed finite element model until the accuracy is acceptable. At this point, it is assumed that the accuracy is mainly dependent upon the mesh pattern.

iilr4:l~ JUNE 2004

, , W E L D I N G R E S E A R C H Mapping Method

After completing heating and cooling, six components of cumulative plastic strains exist as incompatible strains and result in distortion. The equivalent thermal strains induced by thermal expansion, plastic strains, or other field variables causing straining of materials may be considered as incompatible strains. In this study, the equivalent thermal strains were used as incompatible strains replacing the effect of cumulative plastic strains.

Using anistropic thermal expansion coefficients and corresponding temperature fields, each cumulative plastic strain component can be mapped independently into six elastic models. For example, transverse cumulative plastic strain, E<',(x.y.~l, can be mapped by using the temperature field calculated by Equation 1.

, oo/x,y,z )-

0 ~ = c o n s t a l l t , ~ y = 0~,~ = 0 ~ . = (Ixz = OCy z = 0 (1)

where 0 is temperature and cc is anistropic thermal expansion coefficients. Other temperature fields associated with other cumulative plastic strain components c a n be obtained in the same way using Equa- tion 1.

In order to obtain corresponding temperature fields, a FORTRAN program was developed to retrieve all cumulative plastic strains (averaged at nodes) over all nodes from the thermal-elastic-plastic analysis, and the program saved them into a data file. Using the data file containing cumulative plastic strain values at all nodes, corresponding temperature values at all nodes were calculated using a user- subroutine "UTEMP" and Equation 1 (Refs. 11, 12).

Six cumulative plastic strains can also be simultaneously mapped into an elastic model using the equivalent thermal strains depending upon six field variables. These equivalent thermal strains can be calculated by user-subroutines "UFIELD" and "UEXPAN" using Equa- tion 2 (Ref.11).

where,

F,l(x,y,z)=~e~(x'Y'Z): FieldVariables (2)

This simultaneous mapping method was used to demonstrate the validity of the addition procedure to obtain the total distortion and the unique relationship be-

Table 1 - - Comparison of Results from EPA and PDA

Type of Mapped Stress (MPa) Displacement (mm) Analysis Component S~ Syy Szz Mises U x Uy

EPA 5.86 -5.36 17.73 20.00 -2.928E-04 5.359E-04

PDA Z~exr 4.61 0.46 1.52 3.73 -2.305E-04 -4.598E-05 PDA Ee p . -1.20 -7.41 -2.58 5.65 5 .997E-05 7.412E-04 PDA Ye~ 2.45 1.59 18.79 16.00 -1.223E-04 -1.593E~)4 PDA Sum 5.86 -5.36 17.73 -2.928E-04 5.359E-04

Table 2 - - Comparison of Results from PDA and Simultaneous Mapping Analysis

Case Mapped Stress (MPa) Displacement (mm) Component

Sxx Syy Szz Mises U x Uy

1 Z~ P 4.61 0.46 1.52 3.73 -2.305E-04 -4.598E-05 Eeeyy -1.20 -7.41 -2.58 5 .65 5 .997E-05 7.412E-04 Sum 3.41 -6.95 -1.06 -1.705E-04 6.952E-04

EaPxr + ZcPyy 3.41 -6.95 -1.06 -1.705E-04 6.952E-04 ZCPxx 4.61 0.46 1.52 3.73 -2.305E-04 -4.598E-05 E~ezz 2.45 1.59 18.79 16 .00 -1.223E-04 -1.593E~)4 Sum 7.06 2.05 20.31 -3.528E-04 -2.053E-04

ZEe~r + Eeezz 7.06 2.05 20.31 -3.528E-04 -2.053E-04 Ee P 4.61 0.46 1.52 3.73 -2.305E-04 4.598E~35 ~-~Pzz -1.20 -7.41 -2.58 5 .65 5 .997E-05 7.412E-04 Sum 3.41 -6.95 -1.06 -1.705E-04 6.952E--04

ZeP. + ZePzz 3.41 -6.95 -1.06 -1.705E-04 6.952E-04 Y~c~ 4.61 0.46 1.52 3.73 -2.305E-04 -4.598E--05 Ec e -1.20 -7.41 -2.58 5 .65 5 .997E-05 7.412E-04 ZeFz~ -1.20 -7.41 -2.58 5 .65 5 .997E-05 7.412E-04 Sum 5.86 -5.36 17.73 -2.928E-04 5.359E-04

ZcPxx +.Zeeyy + ZEPzz 5.86 -5.36 17.73 -2.928E-04 5.359Eq34

PDA: Sum. Simultaneous mapping analysis: ,Ta G +,Y.aPyy, .Zc% +,Ta P , Z~eyy +,Zaezz,,Zeexr+,~eyy+ Eeezz

tween cumulative plastic strains and distortions.

Accuracy of PDA Procedure

As a final step of PDA, the total distortion induced by all cumulative plastic strains is obtained by adding individual distortions calculated from six independent elastic analyses:

6

a;,o,; =Ea, ' = ' (3)

where 8;7~' is the total distortion, and 8~ is individual distortion with only ith component of cumulative plastic strains. The ac-

c u r a c y of the PDA procedure can be determined by comparing distortions from the elastic-plastic analysis with the total distortion obtained from the PDA using Equation 3.

Error = ~ x 100(%)

(4)

Table 3 - - Material Constants for Kinematic Nonl inear Hardening

Temperature Yield C O y (A°C) Strength (MPa)

(MPa)

21 145 3714 27 70 145 2800 27

225 84 1300 27 325 45 600 27 400 15 10 27 470 5 1 27 595 5 1 27

This accuracy of the PDA procedure may be affected by some factors, such as nonlinearity of material and mapping ac- c u r a c y .

One factor is nonlinearity of material, which does not allow linear supposition if the effect of nonlinearity is dominant. Ma- terial nonlinearity comes from plastic de-

I WELDING JOURNAL lilr~]~"1

. :i/ i)il;i i ii:!::iiii!ii ii!i!iiiiii ,!!iii ii iiii!i! : i ii '̧ " , ' ' " : i L :

Y

100 m t=3.2 mm

lOOmm ~ ~ lOOmm

Fig. 4 - - Symmetric-half finite element model for the T-joint.

i ! 8

. lCOoo -

e o o o -

g '

.

u i 4ooo-

2ooo-

o -

. . . . 1 / o o 0.14 ,~i

i o.12

1 I ~ , , . , . , 0 ~ . . , , . :

°°'-L .Z . . . I . ,.

0.04 - J I ' I ' I ' o ~oco 2OOO

Temperatum(.C)

I 3000

Fig. 5 - - Temperature-dependent thermal material properties o f magnesium alloy, A Z 91 C.

0.OOO3

i

O.OOO2 A C

l

~ o.Oool, =

' I ' I ' I ' I I 4OO ooo 1200 1600 2000

Tempe~tum ( 'C)

Fig. 6 - - Temperature-dependent natural convection (film) coefficients.

~~ i ~ [: X: Transverse Y: Vertical

', ~ Z: Longitudinal / : ! ' I

, .-/ Y ' . . . . . . . . . .

~ _~_2-~ . . . . . . . . . . . o x ...... ,

Fig. 7 - - Definition o f a moving coordinate system (x,y, 4) in the T-joint.

formation and temperature dependency in a welding situation. In the PDA, material nonlinearity due to temperature dependency does not exist anymore, because temperature is constant (room temperature) after completing welding. Nonlin- earity due to plastic deformation can also be negligible because the PDA is somewhat elastic, reloading analysis up to the final plastic deformation after welding.

In order to demonstrate the effect of material nonlinearity on the PDA accuracy, a 2-D simple plain strain model is used as shown in Fig. 2. For this analysis, cumulative plastic strains are perfectly mapped because they are uniformly distr ibuted. Elastic modulus, yield stress, Poisson's ratio, and thermal expansion coefficient are 30E3 MPa, 20 MPa, 0.3, and 1.0E-5, respectively. They are constant during heating and cooling. No strain hardening occurs during plastic deforma-

tion. The uniform temperature is applied on an element, increasing linearly to 1000°C from 0°C, and decreasing to 0°C. Three-axial stress state is generated by using different spring constants, k l = 1.0E5 (N/ram) and k2 = 0.50E5 (N/ram). The obtained cumulative plastic strains are -0.3643E-03, 0.9504E-03, -0.5861E-03, and 0.0 in the x, y, z, and xy directions, respectively. All components of stresses and displacements in an element at Node 3 are listed in Table 1. Each cumulative plastic strain was mapped into an elastic model one by one. Stresses and displacements obtained from the PDA are listed and compared in Table 1. In the case with the uniform cumulative plastic strain distribution, the PDA calculates the exact stresses and displacements. Therefore, material nonlinearity may not affect the accuracy of the PDA.

In order to demonstrate the unique re-

lationship between cumulative plastics and distortion, the simultaneous mapping analysis was performed under the combined cumulative plastic strains. Table 2 shows that the final stresses and displacements obtained from the simultaneous mapping analysis are equal to those calculated by the PDA, which satisfies the linear superposition requirement described in Equation 5. Therefore, it can be said that each individual displacement (distortion) and stress can be uniquely determined by the associated cumulative plastic strain.

tY_, J L e + L e + L e = 1 xx 2 yy 3 zz

( 5 )

il:Iel~.~ JUNE 2004

2oo

8

Ioo

/ f

f i r

o ; I i o l 02

Equivalent Plastic Strain

21 ¢c1

rs ¢-c)

22s t ' c )

,too ( 'q

drS - pc.) I

03 04

Fig. 8 - - Maximum peak temperature map in the T-joint. Fig. 9 - - Temperature-dependent nonlinear kinematic strain-hardening model of magnesium alloy.

0.42

i ~ o.4.

J 03S -

°.~ 4

O,34 I

socoo - - - Elastic Modulus ' . . . . . Poisson's Ratio • • . . . . . . . . . .

/¢

!~ 40¢¢030000-- •••// If•I• i :1 i •

2o0 Temperature (,C) 4O0 6OO

002

I 0018 ~

g i i ~ 2E-005-

t

o

3E-005

!

2E-005 - -

' ! 1 400 800 1200 1600 2000

T s m p l R t u r ~ ' C |

Fig. 10 - - Temperature-dependent elastic modulus and Poisson's ratio of magnesium alloy.

Fig. 11 - - Temperature-dependent CTE and corresponding thermal strain o f magnesium alloy.

Geometric nonlinearity does not exist in this study because the small deformation theory is used in both the EPA and the PDA.

Mapping accuracy may also affect the accuracy of the PDA procedure. If cumulative plastic strains were not precisely mapped, individual and total angular distortions calculated from the PDA would not be correct. Mapping accuracy is strongly dependent upon the number of elements/nodes and the order of shape function of element. Figure 3 shows the applied cumulative plastic strain using temperature and the calculated thermal strain within two second-order elements in which thermal strain is linear. It shows that unless cumulative plastic strains are distributed uniformly or linearly within an element, mapping error is unavoidable, even though second-order elements are used. The averaged cumulative plastic strains at nodes may also result in error when the significant discontinuity of cu-

mulative plastic strains at integration points between adjacent elements is present. In order to reduce the error induced by mapping, a finer meshed model with second-order elements is recommended.

In this study, it is assumed that the acceptable error range of the PDA procedure was 0% to 10% in view of the engineering application. Since most error comes from the mapping, the finite element model used in the EPA and the PDA should be updated until the required accuracy is achieved.

Numerical 3-D Thermal-Elast ic- Plastic Analysis

In thermal-elastic-plastic analysis, the effects of more complex behaviors in welding, such as metallurgical transformation, stress and strain relaxation at the melting temperature, filler metal deposition, etc., were not considered in this analysis. Without considering these ef-

fects, the present thermal-elastic-plastic analysis predicted the reasonable angular distortion of an aluminum T-joint compared with the published experimental re- suits (Ref. 12). Therefore, it can be assumed that the present analysis procedure provides the reasonable baseline information, such as the characteristic distribution patterns of cumulative plastic strains and the corresponding angular distortion in fillet welded T-joints.

Two fillet welds running simultaneously at two sides constructed a T-joint. Welding parameters of gas metal arc welding were voltage of 13 V, current of 110 A, and weld speed of 10 mm/s for 3.2-ram- thick magnesium alloy (AZ91 C) plates (Ref. 13). ABAQUS 5.8-14 was used in the following thermal-elastic-plastic analysis.

Thermal Analysis

Quadrat ic brick elements with 20 nodes were used. The total numbers of el-

WELDING JOURNAL i l : l l~ ' ]

Fig. 12 - - Deformed shape of the T-joint after welding.

Table 4 - - Comparison of the Averaged Displacements Obtained from EPA, PDA, and Simultaneous Mapping Analysis for a T-Joint

Type of Analysis Displacement (mm) U x Uy U z

EPA -2.090E-01 1.042E+00 1.328E-01

PDA Z~ex,¢ -1.694E-01 -1.143E+00 1.028E-01 Zeeyy 1.202E-02 -7.656E-01 5.590E-04 Z~ezz -2.263E-04 8.392E-02 5.364E-03 T.ePay -4.991E-02 2.805 E + O0 1.088 E-03 Z~Pxz -3.316E-04 9.435 E-03 1.627E-01 Zeeyz -4.742E--04 1.995E-02 -1.399E--01

SUM -2.084E-01 1.009E+00 1.327E-01

Simultaneous Mapping -2.084E-01 1.009E+00 1.327E-01

ements and nodes used were 6100 and 30068, respectively. Figure 4 shows a symmetric-half finite element model used in the thermal analysis for the fillet welded T-joint, with a flange of 100 x 200 x 3.2 mm, and a web erected on the flange plate of 100 x 100 x 3.2 mm.

Figure 5 shows the temperature- dependent thermal-material properties of AZ91 C (Ref. 14). Latent heat, solidus temperature, and liquidus temperature are 3.73E5 J/(kg'°C), 470°C, and 595°C, respectively. Natural convection bound- aries shown in Fig. 6 were described on the entire free surfaces of the joint except for a symmetric plane.

A user-subroutine in ABAQUS, "DFLUX" (Ref. 11), was written to incorporate the effect of the moving heat defined by the double ellipsoidal distribution (Ref. 15), the moving coordinate, and the coordinate transformation using Equa- tions 6 and 7.

> O, q(x,y,¢)

6 3~ : r lV l ( 3x~ 3y2 3¢2 / - abc/x~fx exp a2 b2 2

Cf

[Front region] (6)

¢<0 , q(x,y,~)

6~/~hrlVl ( 3xZ 3yZ 3,2 / - abchlrx/~ exp • a2 b2 1

C b

[Rear region] (7)

where r I is arc efficiency, V is voltage, I is current, (xy,~) are moving coordinates (see Fig. 7). Parameters in Equations 6 and 7 for fillet welded T-joints with 3.2 mm of weld leg in fillet welds (Ref. 16) are

a = b = 3. 2. sin(45)

c / = a, c b = 2a

2c: 2c~ r : - , r~-

ct +c b c: +c~

In order to predict distortion patterns induced by welding, it is critical to obtain the reasonable temperature evolution without the significant loss of accuracy. For fillet welded joints, heat input calibration was carried out by matching the boundary of the molten pool with the pre- designed fillet size. In order to obtain the boundary of the molten pool, a user- subroutine, "UVARM" (Ref. 11), was developed to calculate the maximum peak temperature over all nodes. Figure 8 shows a map of the maximum peak temperature after welding calculated by UVARM. For the given welding conditions and finite element meshes, arc efficiency 01) was 0.6, which includes the effects of the arc efficiency itself, as well as the heat loss during scanning heat distribution onto the discrete finite elements.

Elastic-Plastic Mechanical Analysis

The main purpose of the elastic-plastic mechanical analysis is to obtain the characteristic cumulative plastic strain distribution patterns and the associated angular distortion for fillet welded thin-plate T- joints. In the elastic-plastic mechanical analysis, the same finite element model used in the thermal analysis was used. The temperature evolution was retrieved from the thermal analysis.

In the thermal-elastic-plastic analysis, it has been known that the most difficult part is to obtain the appropriate material properties at the elevated temperature. Especially for special and rare alloys, it is

very hard to find the material database applicable at the elevated temperature. For the magnesium alloy AZ91 C, only a few material properties at the elevated temperature are available from metals hand- books. Dependency of elastic modulus, yield strength, and tensile strength on temperature may give a significant impact on cumulative plastic strains and distortion patterns.

In this study, temperature dependency of mechanical material properties of AZ91 C were taken from that of other applicable magnesium alloys at elevated temperatures (Ref. 17). Figures 9, 10, and 11 show mechanical properties depending on temperature. It was assumed that thermal strain over melting temperature was constant. Thermal expansion coefficients associated with this were modified as shown in Fig. 11. Nonlinear kinematic strain hardening proposed by Chabochi (Refs. 11, 18) was used to consider the effect of a cyclic loading (heating and cooling), as shown in Fig. 9. Back-stress evolution is used to define the kinematic strain hardening model, which is

(8)

where Co is a material constant represent- ing initial kinematic hardening modulus; 7 is a material constant determining the rate at which the kinematic hardening modulus decreases with increasing plastic deformation; and ~pt is equivalent plastic strain. These material constants are listed in Table 3.

The top edge of the web plate, Y = 100 mm in Fig. 4, was fixed during welding and cooling. Symmetric boundary conditions were applied in the YZ plane a tX = 0 mm.

il:P.B.-! JUNE 2004 I

WELDING RESEARCH

PE, PEll (Ave. Crit.: 75%)

+6.865e-02 ~ +2.000e-03

+1.333e-03 +6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -2.253e-01

(A) ZeP

PE, PE22 (Ave. Crit.: 75%)

+2.267e-01 I +2.000e-03 +1.333e-03

+6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -6.844e-02

(B) ~P


+3.081e-02 I +2.000e-03

+1.333e-03 +6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -1.258e-02


+4.498e-01 I +2.000e-03

+1.333e-03 +6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -4.188e-02

(c) (D) ~e


+2.598e-01 ~ +2.000e-03

+1.333e-03 +6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -6.523e-02

(E) E e l 2

Fig. 13 - - Cumulative plastic strain maps in the T-joint.

Y

L z x


+1.453e-01 ~ +2.000e-03

+4.333e-03 +6.667e-04 +5.821e-ll -6o667e-04 -1.333e-03 -2.000e-03 -2.105e-01

(F)

WELDING JOURNAL il:gll=l

WELDING RESEARCH

THE, THEll (Ave. Crit.: 75%)

+6.044e-02 I +2.000e-03

+1.333e-03 +6.667e-04 +5.821e-11 -6.667e-04 -1.333e-03 -2.000e-03 -1.734e-01

THE, THE22 (Ave. Crlt.: 75%)

+1.768e-01 I +2.000e-03 +1.333e-03

+6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -5.391e-02

(A) y_.ethx~ (B) Xethyy

THE, THE33 (Ave. Crit.: 75%)

+3.021e-02 I +2.000e-03 +1.333e-03

+6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -9.814e-03

(C) ,~,Ethzz


+3.367e-01 I +2.000e-03 +1.333e-03

+6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -5.504e-02

(D) ,~,ho '


+2.243e-01 I +2.000e-03 +1.333e-03

+6.667e-04 +5.821e-ll -6.667e-04 -1.333e-03 -2.000e-03 -5.307e-02

(E) ~ t h z

Fig. 14 - - Equivalent thermal strain maps in the T-joint.

Y

L z x


+1.053e-01 I +2.000e-03 +1.333e-03

+6.667e-04 +5.~1e-ll -6.667e-04 -1.333e-03 -2.000e-03 -L387e-01

(F) X~,%

li1[:.~!$.~ JUNE 2004

W E L D I N G RESEARCH 0.04 -~ ~ Plastic straln-xx component ]

Equivalent thermal strain- xx component ]

0..,%

.0.08 i j fill -0.12

-0.16 I ~ I ' I ' I 0 t0 20 30

Olstanco (mm)

. . . . , 1 0.15 t ~ Equivalent thermal straln-yycomponent /

O.OS

-0.05 I -- - - I I 0 10 20 30

Distance (ram)

0.002 Plastic strein-zz component Equ ve ant thenne stra n- zz component

! ~ -0.002 --~

F /

I .0.006 [

/ /

i I I 10 20 30

Distance (ram)

(c)

Fig. 15 - - Comparison o f cumulative plastic strains and equivalent thermal strains.

0.3

0.2

_c

m o.1

-0,1

Plastic strain-xy component Equivalent thermal strain-xy component

L

t I I 0 10 20 30

Distance (ram)

(D) E e ~

Results of Thermal-Elastic-Plastic Analysis

Figure 2 shows the deformed shape after welding and cooling. Significant bend-up angular distortion is observed. Angular distortion can be interpreted by displacement in the Y-direction. The maximum angular distortion along the free edge of the flange plate is 8 = 1.05 mm at its mid-span o fZ = 50 mm. It is shown that angular distort ion at the weld stop is smaller than at the weld start.

Six components of cumulative plastic strains are plotted in Fig. 13 with the same color contour spectrum. The range of the color spectrum is the same for all contour plots: maximum band = +0.002 - max.; minimum band = min. - -0.002. It has been reported that the transverse cumula-

tive plastic strain shown in Fig. 13A is mainly related to angular distortion when it has the gradient through the plate thickness (Refs. 10, 19). The longitudinal component has been realized as a main source related to longitudinal bending and buckling. To date, three shear components shown in Fig. 13 D - F have not been highlighted in any distortion analysis.

Results of Plasticity-Based Distortion Analysis (PDA)

Cumulative plastic strains obtained from the thermal-elastic-plastic analysis were mapped into elastic models with elastic modulus, 4.3E04 (MPa), and Poisson's ratio, 0.35, at room temperature using the equivalent thermal strains. Figure 14 shows the equivalent thermal strain contours

mapped into elastic models. Four components of cumulative plastic strains and equivalent thermal strains on the top surface of the flange plate at Z = 50 mm are plotted and compared in detail, as shown in Fig. 15. Even though there are some differ- ences in magnitude of cumulative plastic strains and equivalent thermal strains near the weld region, the general distribution patterns are very close to each other.

Six deformed shapes related to each cumulative plastic strain were obtained and plotted in Fig. 16. What was expected and previously believed based on the observation of welded butt joints was that transverse cumulative plastic strain, Z ~ , would cause bend-up angular distortion. However, as shown in Fig. 16A, PDA shows that transverse cumulative plastic strain results in bend-down angular dis-

WELDING JOURNAL ii:l,'l~"]

r e=

. . . . . . . : : ! ! ! ! I I I

r e= "Y-~Pz

: : : : : : : : ! ! ! . . . . . . - - I I ~ i ~ i i i i

Fig. 16 - - Deformed shapes associated with each cumulative plastic strain.

tortion. Vertical cumulative plastic strain, ~ ; , also generates bend-down angular

distortion. A slight bend-up angular distortion is produced by longitudinal cumulative plastic strain, E , : , which may be mainly related to longitudinal bending and buckling.

All three of the above-mentioned components are nominal components that have been taken into consideration in the distortion analysis. However, the other three shear cumulative plastic strain com-

ponents have never been highlighted in the distortion analysis. As shown in Fig. 16D, xy-plane shear cumulative plastic strain, E~: , produces the most bend-up angular distortion. Figure 16E and F shows that the other shear cumulative plastic strains are not related to angular distortion.

In order to clearly show the contribution of each cumulative plastic strain to the total angular distortion, the averaged individual and total angular distortions

from PDA and the angular distortion from the elastic-plastic analysis along the free edge line of the flange plate (X= 100 mm, I,'--3.2 mm in Fig. 4), were plotted using a bar chart, as shown in Fig. 17. It shows clearly the relationship between cumulative plastic strains and angular distortion quantitatively: • Transverse and vertical cumulative plas-

tic strains result in bend-down angular distortion.

• Longitudinal and xy-plane shear cumulative plastic strains generate bend-up angular distortion.

• Most bend-up angular distortion is induced by xy-plane shear cumulative plastic strain.

• Angular distortion induced by other shear cumulative plastic strains is small enough to be negligible. Therefore, without considering the ef-

fect ofxy-plane shear and vertical cumulative plastic strains, the inherent strain model incorporating only transverse cumulative plastic strain may not predict the correct angular distortion pattern in fillet welded T-joints.

The accuracy of the PDA was evaluated. The averaged total angular distortion at the free edge of the flange plate (X= 100 mm, Y=3.2 mm in Fig. 4) is 1.01 mm and 1.04 mm in the PDA and the EPA, respectively, as shown in Fig. 17. Using Equation 4, the error is only 3.0%, which is acceptable.

The unique relationship between cumulative plastic strains and angular distortion on this T-joint was investigated by comparing the averaged three displacements at the free edge of the flange plate. Table 4 shows that the linear superposition and the unique relationship between cumulative plastic strains and distortions are valid even though the mapping error exists. This implies that the application of elastic models with material properties at room temperature and cumulative plastic strains (or equivalent forces and moments) is valid in engineering applications.

Conclusions

From the PDA for fillet welded, thin- plate T-joints, the following results were obtained. • The relationship between cumulative

plastic strains and angular distortion is unique.

• Plasticity-based distortion analysis (PDA) was proved to be an effective tool to investigate the relationship between cumulative plastic strains and angular distortion.

• New knowledge about the angular distortion mechanism for fillet welded T- joints obtained from the PDA was addressed:

li!:I.'-D."] JUNE 2004

WELDING RESEARCH

3 ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i l j

t ° ] > <

-2 I

PDA

Elastic-plastic analysis ( E P A )

Bm - I

......................................................................... i

8 ~

' I ' I ' I ' I ' I Components

Fig. 17-- Averaged angular distortions calculated by EPA and PDA.

1) xy-plane shear cumulative plastic strain produces most bend-up angular distortion, and other shear components are not related with angular distortion.

2) Transverse and vertical cumulative plastic strains result in bend-down angular distortion.

3) Longitudinal cumulative plastic strain produces a slight bend-up angular distortion.

• It was demonstrated that the application of an elastic model using material properties at room temperature and cumulative plastic strains (or equivalent forces and moments) is valid in the distortion analysis.

• In the case of using the inherent strain model in prediction of angular dis-

tortion in T-joints, the right angular distortion pattern cannot be obtained by transforming only transverse cumulative plastic strain into equivalent forces and moments. The effect of transverse, vertical, longitudinal, and xy-plane shear cumulative plastic strains should be employed in calculation of equivalent forces and moments.

References

1. Ueda, Y., Fukuda, K., and Tanigawa, M. 1979. New measuring method of three dimensional residual stresses based on theory of inherent strain. Trans. of JWRl 8(2): 249-256.

2. Ueda, Y., and Yuan, M. G. 1993. Prediction of residual stresses in butt welded plates using inherent strains. Trans. of the ASME, Journal of Engineering Materials and Technology 115(10): 417-423.

3. Ma, N. X., Ueda, Y., Murakawa, H., and Maeda, H. 1995. FEM analysis of 3-D welding residual stresses and angular distortion in T- type fillet welds. Trans. of JWR124(2): 115-122.

4. Yuan, M. G., and Ueda, Y. 1996. Predic- tion of residual stresses in welded T- and I-joints using inherent strains. Journal of Engineering Materials and Technology 118(4): 229-234.

5. Jang, C. D., Seo, S. I., and Ko, D. E. 1995. A study on the simulation of line heating process using a simplified thermal elasto-plastic analysis method. Journal of Ship Production 13(1).

6. Luo, Y., Murakawa, H., and Ueda, Y. 1997. Prediction of welding deformation and residual stress by elastic FEM based on inher-

ent strain (Report I) - Mechanism of inherent strain production. Trans. of JWRl 26(2): 49-57.

7. Son, K. J., Yang, Y. S., and Beom, H. G. 2000. Analysis of angular distortion in weldments using laminated plate theory. Science and Technology of Welding and Joining 5(4): 245-249.

8. Han, M. S. 2002. Fundamental studies on welding-induced distortion in thin plate. Ph.D. dissertation. The Ohio State University, Columbus, Ohio.

9. Kirillov, V. A. 1960. Angular distortions when welding massive members. BWRA-WeM- ing Production.

10. Ohata, M., Toda, Y., Toyoda, M., and Takeno, S. 1999. Control of welding distortion in fillet welds of aluminum alloy thin plates. Welding International 13(12): 967-976.

ll.ABAQUS User's Manual. 1998. HKS Co. 12. Jung, G. H. 2003. Plasticity-based dis-

tortion analysis for fillet welded thin plate T- joints. Ph.D. dissertation. The Ohio State Uni- versity, Columbus, Ohio.

13. ASM Handbook Vol. 6." Welding, Brazing, and Soldering. 2000. ASM International, Mate- rials Park, Ohio.

14. International Magnesium Association. Mg Database. http://www, intlmag.org.

15. Goldak, J., Charkravarti, A., and Bibby, M. 1984. New finite element model for welding heat sources. Metallurgical Trans. B 15B: 300-305.

16. Nguyen, N. T., Ohta, A., Matsuoka, K., Suzuki, N., and Maeda, Y. 1999. Analytical solutions for transient temperature of semi-infi- nite body subjected to 3-D moving heat sources. Welding Journal 78(8): 265-s to 274-s.

17. Metals Handbook 9th Ed. Vol. 2: Proper- ties and Selection: Nonferrous Alloys and Pure Metals. 1979. ASM. 553-595.

18. Chabochi, J. L. 1986. Time independent constitutive theories for cyclic plasticity. Inter- national Journal of Plasticity 2(2): 247-302.

19. Kim, Y. C., Chang, K. H., and Horikawa, K. 1998. Production mechanism of out-of-plane deformation in fillet welding. Trans. of JWRI 27(2): 107-113.

IIW Annual Assembly Convenes in Japan

The 57th Annual Assembly of the International Institute of Welding (IIW) will be hosted by the Japan Institute of Welding (JIW), at the Osaka International Convention Center, Osaka, Japan, July 11-16, 2004

The IIW is the global body in the science and application of joining technology providing networking and knowledge exchange. Its technical field encompasses the joining, cutting, and surface treatment of metallic and nonmetallic materials by such processes as welding, brazing, soldering, thermal cutting, thermal spraying, adhesive bonding, and microjoining and embraces allied fields including quality assurance, nondestructive testing, standardization, inspection, health and safety, education, training, qualification, design, and fabrication.

The United States will be represented by members of The American Council of the IIW, which is the United States' national committee for the IIW. As a comprehensive forum for professional cooperation through interaction with representatives of the other 41 member countries, the IIW provides a unique opportunity for sharing technological innovations and can be an important avenue for international trade.

For further information on the IIW and membership on The American Council, please contact Andrew Davis, Managing Director, Technical Services Division, at [email protected], (305) 443-9353, ext. 466; or Gricelda Manalich, IIW Coordinator, at [email protected], (305) 443-9353, ext. 294. Further information, including registration forms, can also be obtained from the IIW Secretariat in Paris, France, at www.iiw-iis.org.

WELDING JOURNAL liB]MS."]

Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material From Process to Performance

Part I: Experimental Study

Weld strength, failure mode, and fatigue life were compared with self-piercing rivets of the same dissimilar metals combination

BY X. SUN, E. V. STEPHENS, M. A. KHALEEL, H. SHAO, AND M. KIMCHI

ABSTRACT. This paper summarizes our work to date on resistance spot welding of aluminum alloy to steel, from process development to performance evaluation. Since aluminum alloys and steel cannot be readily fusion welded together due to their drastically different thermal physical properties, a cold-rolled clad material was introduced as a transition to aid the resistance welding process. The optimal welding parameters and electrode selections were established using experimental approaches.

The welded samples' mechanical behaviors were then evaluated using static and dynamic weld strength tests as well as cyclic fatigue tests. The weld strength, failure mode, and fatigue life were then compared with self-piercing rivets of the same dissimilar metals combination. Statistical analyses were also performed to analyze the effects of different failure modes on samples ' peak strength and energy absorption.

Introduction

It is envisioned by the automotive industry that the optimized vehicle design in terms of performance and cost can only be achieved by using different materials at different vehicle locations to utilize the materials' functionalities to the fullest extent. Today, steel and aluminum are the most important construction materials for the mass production of automotive structures. It is well known that metallurgical bonds between aluminum and steel are difficult to achieve with fusion welding because of the inherent discrepancies in electrical, thermal, and mechanical prop-

X. SUN is with Battelle Memorial Institute, Columbus, Ohio. E. V. STEPHENS and M. A. KHALEEL are with Pacific Northwest National Laboratory, Richland, Wash. H. SHAO and M. KIMCHI are with Edison Welding Institute, Columbus, Ohio.

erties between the two materials. For fusion welding processes such as direct resistance spot welding (RSW), little or n o

mutual solubility of aluminum and steel exists. The intermetallic compound that is formed between the two metals often results in cracking, brittleness, and susceptibility to corrosion.

The use of a transition material to fa- cilitate spot welding of aluminum to steel is a concept that has shown promise in the past (Refs. 1-2). Use of this transition in- sert allows for two separate weld nuggets to be formed in their respective aluminum/aluminum and steel/steel interfaces. Joining at the aluminum/steel interface is achieved by the cold-clad process (Ref. 1). Few previous studies exist on this subject matter, and almost all of these studies focus on nugget growth kinetics for the spot welds using experimental approaches. There is a lack of understanding on the performance of these spot welds, particularly in comparison with other joining methods such as self-piercing rivets.

The first purpose of this study was to examine the possibility of using an inter- mediate, transition material to spot weld aluminum alloy to steel for structural applications. The optimal welding parameters and electrode selections were established using an iterative experimental approach. Welded samples were then fabricated using the optimized welding para-

KEYWORDS

Spot Welding Dissimilar Metals Joining Aluminum Alloy Transition Material Aluminum-Clad Steel Nugget Growth Weld Strength Weld Dynamic Strength Weld Fatigue Strength

meters. The welded samples' mechanical behaviors were then comprehensively evaluated using static and dynamic weld strength tests as well as cyclic fatigue tests under different loading configurations. The weld strength, failure mode, and fatigue life were then compared with self- piercing rivets of the same two dissimilar metals combination.

Welding Process Development

Material Selections

The dissimilar metals investigated in this study were 1.4-mm SAE1008 mild steel sheet and 2-mm 5182-O aluminum alloy sheet. The transition material introduced was a cold rolled clad material of aluminum to steel. Cold rolled cladding is a process that combines deformation and surface coating. The energy necessary for the coating process is obtained almost exclusively from the deformation process. Compared to the competing processes of electro- or hot-dipped coatings, strips c a n

receive thick coating layers in a very short time. Because of low heat input, the formation of alloyed intermetallic layers can be suppressed at the interface of the clad materials. The metals are bonded together by extremely high pressure, which results in deformat ion at the interface (Ref. 1). The percentage of the coating is established by the thickness of the nonferrous metal strip related to the steel strip thickness.

Two total thicknesses of the transition materials were investigated in this study: 1.0 and 1.5 mm. The aluminum/steel ratios are 20/80 for the two thicknesses, meaning that the ratio of aluminum thickness vs. entire sheet thickness is 20%. The aluminum in the transition material is a 1050 alloy with low Si content and high aluminum purity. The steel in the transition material is an aluminum-free, low-carbon steel equivalent to SAE1006 steel. The

ll:~:~-'l JUNE 2004

Fig. 1 - - Cross section of the 1. O-mm-thick alumim~m-clad steel sheet: the thickness o f the aluminum layer is 0.2 mm and the thickness o f the steel layer is 0.8 mm.

Fig. 2 - - Cross section o f the 1.5-mm-thick aluminum-clad steel sheet: the thickness o f the aluminum layer is 0.3 mm, and the thickness o f the steel layer is 1.2 mm.

Fig. 3 - - A --Aluminum~steel interJbce of the 1. O-mm-thick aluminum-clad steel sheet, with no intermetallic compound obsen,ed; B - - ahmlinum/steel m- terrace of the 1.5-mm-thick aluminum-clad steel sheet, with no intermetallic compound observed.

cross sections of these two aluminum-clad steel sheets are shown in Figs. 1 and 2. In Fig. 1, the clad sheet is 1.0 mm thick, in which the thickness of the aluminum layer is 0.2 ram, and the thickness of the steel layer is 0.8 mm. In Fig. 2, the clad sheet total thickness is 1.5 mm, with the thickness of the aluminum layer being 0.3 mm and the thickness of the steel layer being 1.2 mm. The interface bond structures of the two aluminum-clad steel sheets are shown in Figs. 3A and 3B, respectively. It appears that aluminum and steel are solid- state bonded, with no intermetallic com- pounds observed.

It should be noted that the clad ratio of 20% was not optimized for our particular resistance spot welding application. Be- cause of the small amount of the transition material needed for this study, rolling of a clad strip with our desirable clad ratio was not economically feasible. The material with 20% clad ratio was adopted because

of the on-shelf availability of the material supplier.

Electrode Selections

Welding trials were conducted on a single-phase 100-kVA pedestal-type Taylor- Winfield resistance welding machine equipped with a Medar MedWeld 3000s constant voltage controller. A fast follow- up welding head was used. In the initial stage of electrode selections, 1-mm transition material and the following initial welding parameters were used: • Electrode force: 650 lb-f • Welding current: 13.6 kA with 74% heat • Welding time: 5 pulses of 7 cycles weld-

ing + 2 cycles holding The following two combinations of electrode pairs were investigated experimentally: • Combination No. 1 - - Both sides: 30-

deg truncated cone Class 2 electrodes

with 8-mm face diameter and 3-in. face radius

• Combination No. 2 - - Aluminum side: 30-deg truncated cone Class 2 electrode with 8-mm face diameter and 3- in. face radius; steel side: 30-deg truncated cone Class 2 electrode with 8-mm face diameter and flat faced. Combination No. 1 is the type of elec-

trode recommended by Ford Motor Com- pany for aluminum spot welding (Ref. 12). During our initial welding trials with electrode combination No. 1, frequent expulsion was observed. In addition, a ring of softened aluminum was observed being squeezed out from the nugget periphery and forming a collar of aluminum outside the nugget area on the aluminum/aluminum laying interface, which further ag- gravated the final sheet separation. Based on these observations, electrode combination No. 2 was chosen by machining out the radius portion of the electrode tip on

WELDING JOURNAL il;I~1-1

Transition material

AA5182-0

SAE 1008

transition mateda

AA5182-O

Fig. 4 - - Weld cross section at 4 cycles weld time: no melting observed. The Fig. 5 - - Weld cross section at 8 cycles weld time." initial melting observed. steel sheet separated from the transition sheet due to short weld time.

Fig. 6 - - Weld cross section at 12 cycles weld time (lst pulse). Fig. 7 - - Weld cross section for (lst pulse) + (4-cycle current on).

the steel side. Further welding trials with this pair of electrodes yielded better welds in terms of weld expulsion and sheet separation. Electrode combination No. 2 was then chosen for the rest of the study. Cou- pled electrical-thermal-mechanical finite element modeling procedures (Refs. 3-5) were also used in selecting the final electrode combinations. Those results will be discussed in Part II of our study.

Welding Parameter Selections

With the selected electrode combination, optimal welding parameters were determined by iterative welding trials. Both 1.0- and 1.5-mm transition materials were used. Peel and lap-shear tensile tests were used to provide a quick estimate of the weld quality. The results of the peel tests indicated that a weld button was easily achieved when peeling was conducted between the steel sheet and the transition material. However, it was extremely difficult to obtain a consistent full button pullout when peeling was conducted between the transition material and the aluminum sheet, even for the samples made with the same welding parameters. Since the peel

test results were inconsistent, lap-shear tensile tests were also used to evaluate the weld quality. It appeared that the welds with 1.5-mm transition material yielded higher tensile shear strength than the welds with 1.0-mm transit ion material. Therefore, 1.5-ram-thick transition material was selected to make the welded samples for further performance evaluations. After iterative welding trials, the following welding parameters were finalized for spot welding of 2-mm 5182-O to 1.4-mm SAE1008 with 1.5-mm-thick transit ion material: • Electrode on A1 side: 30-deg truncated

cone Class 2 electrode with 8-mm face diameter and 3-in. face radius

• Electrode on steel side: 30-deg truncated cone Class 2 electrode with 8-mm diameter, flat faced

• Electrode force: 1050 lb-f • Welding current: 13.6 kA with 97% heat • Welding schedule: 3 pulses of 12 cycles

welding + 3 cycles holding • Cooling water flow rate: 1.75 gal/min

Nugget Development Study

With the final welding parameters s e -

lected, weld nugget development studies were conducted experimentally to get an in-depth, fundamental understanding of the heat generation and nugget formation sequence of the weld. This was accom- plished by consecutively metallurgically cross-sectioning the weld for every four welding cycles. The resulting weld cross sections are shown in Figs. 4-12 with increasing weld times. The experimental nugget growth study was also accompa- nied by coupled finite element analysis on heat generat ion and nugget growth. In Part II of this study, we will use the experimental weld cross sections to compare with the finite element predictions.

Figure 4 shows the weld cross section at the end of the first four welding cycles. Melting has not occurred at this time and there are some degrees of material soft- ening at the aluminum/aluminum interface. In fact, the SAE1008 sheet separated from the transition material after the electrode was removed at the end of the hold cycle. At the end of the 8th cycle weld time, initial melting on the aluminum/aluminum interface starts to take place and heat has been rapidly conducted to the AA5182-O side - - Fig. 5. At the end of the

l i l ~ I ~ JUNE 2004

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:, W E L D I N G R E S E A R C H

Fig. 8 - - Weld cross section for ( ls t pulse) + (8-cycle current on). Fig. 9 - - Weld cross section for ( ls t pulse) + (2nd pulse).

Fig. 10 - - WeM cross section for ( ls t pulse) + (2nd pulse) + (4-cycle current on).

Fig. 11 - - WeM cross section Jbr ( ls t pulse) + (2nd pulse) + (8-cycle current on).

first welding pulse, shallow fusion zones can be observed on both the aluminum/aluminum interface and steel/steel interface as shown in Fig. 6. During the subsequent welding pulses, the width and depth of the fusion zones on the aluminum/aluminum side and steel/steel side continue to grow. At the end of the 3rd welding pulse, two distinct, well- developed fusion zones can be observed with some aluminum being pushed out on the aluminum/aluminum interface. The final nugget diameters on the aluminum side and the steel side are around 10.1 and 8.2 mm, respectively. It should be mentioned that the weld cross sections in Figs. 4-12 also show a slight degree of electrode misalignment during the welding process. The existence of electrode misalignment and the softened aluminum on the interface could be the reason for the one-sided material squeeze-out on the aluminum/aluminum interface as shown in Figs. 8-12.

Microstructure Evolution of the Aluminum/Steel Clad Interface during Welding

The microstructures of the aluminum/ steel interfaces at the end of the 1st, 2nd, and 3rd pulses are presented in Figs. 13-15. Pores and gaps were observed at the steel/aluminum interface and in the aluminum side of the transition sheets. The presence of the weld discontinuities along the aluminum/steel interface can be attributed to the following factors: First, shrinkage stresses. During welding, the aluminum adjacent to the aluminum/steel interface is the last area to solidify. Shrink- age stresses (from solidification) combined with constraint from the surrounding solid metal can result in cavitations, typically evidenced as pores (adjacent to the steel) and solidification cracks (gaps). Secondly, they could be hydrogen-related porosities. This is similar to the hydrogen porosities that occur in arc welds and alu-

minum resistance spot welds. Since the aluminum surface is hydroscopic, it ab- sorbs hydrogen from the atmosphere. During welding, this hydrogen is dissolved into the liquid metal. Upon solidification, the hydrogen is partitioned and therefore can form as gas or pores at the last area for aluminum to solidify.

Figures 13-15 also reveal the thicken- ing of the intermetallic compound layer at the aluminum/steel interface within the transition material as the weld time progressed. During the first two welding pulses, the thickness of the intermetallic compound layer increased from 0 to about 7 I.tm. The thickness of the intermetallic layer increased to about 8.5 lam after the third welding pulse.

Peel tests conducted between the aluminum sheet and transition sheet indicated that interfacial failure often occurred at the aluminum/steel interface within the transition material, rather than the interface between the aluminum sheet

WELDING JOURNAL li~]il~-ll

aluminu~

intermetall layer

steel

Fig. 12 - - Weld cross section for (lst pulse) + (2nd pulse) + (3rd pulse).

Fig. 13 - - Microstructure o f the aluminum/steel inter]ace Jbr the weld shown in Fig. 6, at the end o f the 1st welding pulse.

Fig. 14 - - Microstructure o f the aluminum~steel interface for the weld shown in Fig. 9, at the end o f the 2nd welding pulse.

Fig. 15 - - Microstructure o f the aluminum~steel interface for the weM shown in Fig. 12, at the end o f the 3rd welding pulse.

and the transition sheet. It is conceivable that the pores and gaps at the aluminum/steel interface could have provided the favorable fracture paths for peel test samples to fail at the interface. The presence of the brittle intermetallic compound layer at the aluminum/steel interface also contributes to such brittle interfacial failures. In general, the thicker the intermetallic layer, the more brittle the welds are and the less load and energy the welded sample will carry in the strength test. The effects of interracial fracture on the welded samples' performance will be addressed in the next section.

As an interesting comparison, Fig. 16 shows the cross section of a spot weld made between 1-mm AA5052 and 0.8-mm bare low-carbon steel without any transition material. A semielliptical weld nugget is formed in the top aluminum sheet, and there is evidence of fusion material in the

bottom steel sheet. However, a very thick layer of intermetallic compound formed on the faying interface with thickness around 65 tim. A recent study by Rathod and Kutsuna (Ref. 13) on joining of AA5052 and low-carbon steel concluded that with the increase of total thickness of the intermetallic layer, the amount of AI- rich intermetal l ic compound in it increases and the amount of Fe-rich intermetallic compound decreases. In addition, they also found that the amount of Al-rich brittle intermetallic compound on the interface drastically reduces the joint strength. Comparing the thickness of the intermetallic layers in Figs. 15 and 16, it is not difficult to conclude that the welds made with the transition material have a much thinner intermetall ic layer and therefore will have much higher strength than the welds made without the transition material.

We should point out again that the cladding ratio of the transition material used in this study was not optimized. It is conceivable that, with thicker aluminum in the transition layer, an even thinner intermetallic layer can be achieved on the aluminum/steel interface during the welding process. Moreover, with thicker aluminum in the clad material, it will be more difficult for the fracture path to go through the aluminum layer and reach the aluminum/steel interface. Therefore, it would be more difficult for interfacial fracture to occur at the aluminum/steel interface during strength tests.

Dissimilar RSW Performance Evaluations

With the established welding schedule, welded samples were made for tensile shear (also known as lap shear), cross ten-

lii~I,,.,l.,-'~ JUNE 2004

A A 5 0 5 2

B a r e l o w c a r b o n steel

Fig. 16 - - Cross section of l -ram A A 5 0 5 2 to 0 .8-mm bare low-carbon steel spot weld.

-Interfacial f racture at AI/Steel interface in interlayer

-Nugget pull-out on AI side Cross Tension

-Nugget pull-out on AI side Coach Peel

-Nugget pull-out on AI side

Fig. 1 7 - - Illustration o f different failure modes under different loading conditions.

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sion, and coach peel tests according to the coupon geometry developed in Ref. 6. Sta- tic, dynamic, and fatigue tests were then performed on the joint samples. In total, 30 quasi-static tests and ten dynamic tests were performed for each coupon configuration following the testing procedures described in Refs. 6 and 7.

Quasi-Static and Dynamic Performance Evaluations

For cross tension and coach peel samples, nugget pullout from the aluminum side was the consistent failure mode observed for both the static and dynamic samples tested - - Fig. 17. For lap shear samples, however, a combination of interfacial fracture and nugget pullout from the aluminum side was observed for both the static and dynamic tests. The interfacial fracture mostly occurred at the aluminum/steel interface within the transition material, consistent with the observa-

tions in the peel tests as discussed in the previous section.

In order to study the effects of different failure modes on the peak load and energy absorption of the statically loaded lap shear samples, statistical analyses similar to those performed in Ref. 7 were conducted. Figure 18 shows the Weibull plots of peak load distributions for interracial fracture and nugget pullout modes under static lap shear. It is clear that the modal- ity and the mean values of these two failure modes for the static lap shear samples are close to each other, with the mean peak load for the interracial fracture slightly lower than that for the nugget pullout. In other words, for this weld population, the samples' failure mode does not significantly influence their lap shear peak load. This observation is similar to the conclusions derived for aluminum spot welds in Ref. 7. However, the slope of the interracial fracture curve is lower than that of the nugget pullout curve in Fig. 18; this

is particularly true at low load levels. This observation indicates that the interracial fracture mode has larger strength varia- tion than the nugget pullout mode.

The statistical characteristics for the energy absorption of the two failure modes, as shown in Fig. 19, are drastically different. Energy absorption for nugget pullout mode fits perfectly on a Weibull paper, which indicates that it has a unique Weibull shape parameter and median value associated with this distribution. On the other hand, the energy absorption level for interracial fracture has a bi-modal distribution. The mean energy absorption of the interfacial fracture population is only 52% of the mean energy absorption of the nugget pullout population. This is mainly due to the fact that for interracial fracture mode, very little sheet bending takes place during the loading process. For nugget pullout mode, sheet bending caused by weld failure prolongs the total deformation of the failure event, resulting in increased total energy absorption.

W E L D I N G J O U R N A L l i l ~ i < l ~ l

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tension

Fig. 2 0 - - Comparison of peak load levels between dissimilar RSW and SPR. Fig. 21 - - Comparison of energy levels between dissimilar RSW and SPR.

RSW and SPR Comparison of 1008 / 5182-O (1.4 m m / 2.0 ram)

I.

Cw

10,0(10 100,000 1,000,000 10.000,000

Cycles to Fallnre, N r

Fig. 22 - - Fatigue life comparisons o f dissimilar R SW and dissimilar SPR.

pullout failure according to this prediction. However, as discussed earlier, both nugget pullout and interracial fracture were observed in our static lap-shear test - - Figs. 18, 19. The existence of pores and gaps on the aluminum/steel interface could have provided a favorable crack path and promoted interfacial fracture mode. Meanwhile, with many assumptions

It is very important to note that the failure mode of a spot welded sample is greatly influenced by its weld attributes and the geometric configurations of the sample itself. Different analytical-based formulations have been developed in the literature to ensure nugget pullout mode of failure (Refs. 8 and 9). For example, a bending moment-based analytical equation was derived in Ref. 8 to predict the failure mode of a shear-loaded weld sample. Weld size and sheet thickness together with the ratio of the base metal tensile strength to the weld metal shear strength were used to determine the failure mode of the sample. Based on this theory and the assumption that the shear strength of the aluminum weld metal is about 0.7 times the tensile strength of the base metal (Ref. 14), the critical weld diameter for bending-type failure is calculated to be 7.8 mm for our lap shear samples with 50-mm coupon width. Since the final weld diameter on the aluminum side was -10.1 mm, we should expect nugget

and simplifications employed in its derivation, the analytical prediction could have underestimated the critical weld diameter.

Comparison with Performance Data of Self-Piercing Rivets

Next, the static and dynamic performance data obtained for the dissimilar RSW population with transition material are compared with the performance data of the self-piercing rivet (SPR) population using the same two metal combinations: 2- mm AA5182-O (head side) to 1.4-mm SAE1008 (tail side). The dissimilar SPR population was fabricated by the Henrob Corporation with rivet head diameter of 7.5 mm, shank diameter of 5 mm, and length of 6.5 mm. A set of fabrication parameters was established for this SPR population and they are proprietary information of Henrob. The same coupon geometries as in the dissimilar RSW population (Ref. 6) were used for the dissimilar SPR population.

Overall, the static and dynamic strengths of the dissimilar RSW samples under lap shear and cross tension are comparable to those of the dissimilar SPR popu la t ion - - Fig. 20. Given the same material combinations, the strength levels for the RSW and SPR populations are primarily dependent on weld size, rivet geometry, and the corresponding failure modes. The failure modes for the lap shear and cross-tension SPR samples are all rivet head pullout from the AA5182-O side. Since the RSW populat ion has slightly larger weld diameter than the SPR population, it should offer slightly higher static lap-shear and cross-tension strength. This is consistent with the experimental strength comparison shown in Fig. 20. Under coach peel condition, however, the peak load of the SPR population is higher than the RSW population because failure occurred at the tail end (SAE1008) of the rivet.

Comparison of total energy absorption between dissimilar RSW and dissimilar SPR is shown in Fig. 21. The energy absorption level of RSW under lap shear is considerably lower than those of SPR. This is because of the very low energy absorption level associated with the interracial fracture mode of RSW. For SPR, on the other hand, all lap shear samples failed consistently in rivet head pullout mode. The energy absorption levels for RSW under cross-tension and coach peel loading conditions are slightly lower than those of SPR. Again, the energy absorption level for the RSW population can potentially be improved by using an optimized cladding ratio of the transit ion material to ensure nugget pullout failure during lap shear tests.

Comparisons of Fatigue Performance

Fatigue tests on lap shear, cross-

lii:~lE-1 JUNE 2004

tension, and coach peel samples of the dissimilar RSW population were carried out using tension-tension ratio of R = 0.1. The results are shown in Fig. 22 in comparisons with the fatigue test results of the dissimilar SPR population.

The fatigue strength of the dissimilar SPR populat ion is considerably higher than the RSW population. This observation is consistent with most of the reported data on fatigue strength comparisons between SPR and RSW (Ref. 10). The main reason for the superior fatigue behavior of rivets can be contributed to the fact that SPRs do not have the single-point crack tip (or notch tip) stress concentration effects as those in spot welds. In addition, the riveting process itself generates a com- pressive residual stress in the rivet periphery as opposed to the spot welding process, which generates yield-magnitude tensile residual stress at the weld periphery that is detrimental to the weld's fatigue performance (Refs. 5 and 11).

It should be pointed out again that the geometry of the weld sample makes a large contribution to the weld sample fatigue behavior. Figure 22 indicates that, for the same weld, the lap shear samples have the highest fatigue strength and the coach peel samples have the lowest fatigue strength. Many researchers have focused their efforts in addressing the coupon geometry effects using an equivalent stress intensity factor or structural stress approach (see, for example, Refs. 15 and 16). These approaches are very effective in comparing weld fatigue performance of sample populat ions made of different coupon configurations. The detailed fatigue performance comparisons for different joint populations using the equivalent stress intensity factor approach will be presented in a separate study.

Conclusions and Discussion

The objective of this research was to investigate whether spot welding between aluminum and steel can be achieved using a transition material. Experimental approaches were used in determining the optimal electrode combinations and welding parameters . Nugget formation process was then examined using consecutive metallurgical cross-sectioning. It was found that two distinct fusion zones formed during the spot welding process of aluminum to steel using a transition aluminum-clad steel strip. The nugget on the steel side is a regular, elliptical weld with dendritic grain structure inside the nugget region. The nugget on the aluminum side is the top half of the elliptical shape. Also, a thin, intermetall ic compound formed on the aluminum/steel clad interface due to the welding heat input.

Static, dynamic, and fatigue perfor- mances of these welds were then examined and compared with the self-piercing rivet population of the same dissimilar materials combination. It was found that the static and dynamic strength of the RSW samples are comparable to those of the strength of the self-piercing rivets under the same loading conditions. How- ever, because of different failure modes, the lap shear dissimilar RSW samples have a considerably lower energy absorption level than the dissimilar SPR samples. Fatigue strength comparison of the RSW population and the SPR population indicates that SPR populat ion has much higher fatigue resistance than the spot welds.

This study demonstrated the spot weldability of aluminum to steel with transition clad material and evaluated the structural performance of these welds. The corrosion-related performance evaluation for the dissimilar RSW populat ion is currently being pursued. It should be mentioned that the cladding ratio of the transition material used in this study was not optimized. With an optimized cladding ratio, it is conceivable that the weld static strength, failure mode, and energy absorption of the dissimilar RSW population can be further improved.

It should also be noted that the economic and production feasibilities of in- troducing such transition welds into automotive production need to be further studied and justified. First of all, spot welding using the transition material adds weight to the entire vehicle. Secondly, the relatively low yield of the cladding process would translate to the potential material cost increase for the automotive industry. Furthermore, the difference in thermal expansion coefficients of the two cladding materials would promote thermal distortion of the parts made of these materials. Nonetheless, the results of this study do suggest the potential application of aluminum clad steel as a load-bearing structural component as well as a material transition between the possible aluminum parts to the steel parts of the vehicle for optimized safety and weight reduction of a particular vehicle design.

Acknowledgments

Pacific Northwest National Laboratory is operated by Battelle for the U.S. De- partment of Energy under contract DE- AC06-76RL01830. This work was funded by the Dept. of Energy Office of Free- domCAR and Vehicle Technologies under the Automotive Lightweighting Materials Program managed by Dr. Joseph Carpen- ter. The USCAR program manager is James Quinn.

References

1. Johnson, J., Theile, R., and Kobeloer, N. 2000. Transition material- characteristics of aluminum-clad strip steels. Proceedings of the IX Sheet Metal Welding Conference, Detroit, Mich.

2. Chang, H. S., Johnson, G. E, Dickinson, D. W., and Tsai, C. L. 1999. Spot welding aluminum to steel - - Transition material inserts help to overcome incompatibility. Practical Welding Today, May/June.

3. Sun, X. 2001. Effect of projection height on projection collapse and nugget formation - - A finite element study. Welding Journal 80(9): 211-s to 216-s.

4. Sun, X. 2000. Modeling of projection welding processes using coupled finite element analyses. Welding Journal 79(9): 244-s to 251-s.

5. Sun, X., and Dong, E 2000 Analysis of aluminum resistance spot welding processes using coupled finite element procedures. Welding Journal 79(8): 215-s to 221-s.

6. Vela, E., Sun, X., Davies, R., and Khaleel, M. A. 2002. Lap shear coupon design sensitivity study for self-piercing rivets and resistance spot welds, PNNL technical report for USCAR No. 13943, April.

7. Sun, X., Vela, E., Khaleel, M. A., and Davies, R. 2002. Effect of failure modes on strength of aluminum resistance spot welds. PNNL technical report for USCAR, October.

8. Koenigsberger, E 1948. Design for Weld- ing in Mechanical Engineering.

9. VandenBossche, D. J. Ultimate strength and failure mode of spot welds in high strength steels. Society of Automotive Engineers, paper No. 770214.

10. Booth, G. S., Olivier, C. A., Westgate, S. A., Liebrecht, E, and Braunling, S. Self-piercing riveted joints and resistance spot welded joints in steel and aluminum, SAE paper No. 2000-01-2681.

11. Bae, D. H., Sohn, I. S., and Hong, J. K. 2003. Assessing the effects of residual stresses on the fatigue strength of spot welds. Welding Journal 82(1): 18-s to 22-s..

12. Ford Laboratory Test Method BA 113- 07: Welding Acceptance Test for Aluminum.

13. Rathod, M. J., and Kutsuna, M., 2004. Joining of aluminum Alloy 5052 and low-carbon steel by laser roll welding. Welding Journal 83(1): 16-s to 26-s.

14. Metals Handbook, Ninth Edition, Vol. 1, Properties and Selection: Irons and Steels. 1978. ASM International, Metals Park, Ohio.

15. Zhang, S. 2001. Fracture mechanics solutions to spot welds. International Journal of Fracture 112: 247-274.

16. Sheppard, S. D. 1995. Further refine- ment of a methodology for fatigue life estima- tion in resistance spot welds. ASTM STP 1292, Advances in Fatigue Lifetime Prediction Tech- niques. M. R. Mitchell and R.W. Landgraf, eds., pp. 265-282.

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