aws welding journal november 2013

From world-class football stadiums to award-winning airport terminals, ESAB has played a pivotal role in many impressive projects around the globe. See these stories come to life at FABTECH 2013.

Heres what else you can look forward to when ESAB comes to FABTECH.

ESAB Welding & Cutting Products / esabna.com

n Dont miss exciting demos of Heliarc for AC/DC GTAW (TIG) weldingn Be here for live demos with the Warrior multi-process welding machinen See live demos of PowerCut manual plasma cutting systemsn Check out new products and processes from Welding Automation and Cutting Systemsn Get a first look at Marathon Pac 2 engineered for productivity and ease of usen Have a look at our newest PPE, including the Warrior Tech welding helmet

To find out how our welding and cutting solutions can help with your next project, visit esabna.com/fabtech2013 and stop by booths N1449 and N1145 in the North Hall.

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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDINGAND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING

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3WELDING JOURNAL

CONTENTS40 Welding Ingenuity + Operational Changes = A Saved Business

See how a job shop on the brink of closing its doors turnedaround its fortunes to the point of prosperityK. Campbell

46 Controlling SMA Welding Fumes in the Mining IndustryResearch was conducted to find how best to protect weldersinvolved in hardfacing operations in the mining industryK. Sham and S. Liu

52 Alabama Center Preps Trainees for Shipbuilding JobsA resurgency in shipbuilding and a shortage of qualified welders sparked the state of Alabama to address the need for a skilled workforce with a new maritime training centerM. R. Johnsen

56 Tips for Purchasing Welding Consumables for Nuclear WorkHeres help in finding the right electrodes, wires, and fluxesto meet the requirements of ASME Section III of the Boiler and Pressure Vessel CodeW. J. Sperko

60 FABTECHCheck out all the events and technical presentations the show has to offer on the welding side

Welding Journal (ISSN 0043-2296) is publishedmonthly by the American Welding Society for$120.00 per year in the United States and posses-sions, $160 per year in foreign countries: $7.50per single issue for domestic AWS members and$10.00 per single issue for nonmembers and$14.00 single issue for international. AmericanWelding Society is located at 8669 NW 36th St., # 130, Miami, FL 33166-6672; telephone (305)443-9353. Periodicals postage paid in Miami, Fla.,and additional mailing offices. POSTMASTER: Sendaddress changes to Welding Journal, 8669 NW36th St., # 130, Miami, FL 33166-6672. CanadaPost: Publications Mail Agreement #40612608Canada Returns to be sent to Bleuchip Interna-tional, P.O. Box 25542, London, ON N6C 6B2,Canada.

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

DepartmentsEditorial ............................4Press Time News ..................6International Update ............10News of the Industry ............12Stainless Q&A ....................18RWMA Q&A ......................24Product & Print Spotlight ......28AWS Show Information..........60AWS Events at a Glance ........66AWS Professional Program ....67AWS Exhibit Highlights..........89Coming Events ..................164Certification Schedule ........166Welding Workbook ............168Society News....................169

Tech Topics ....................170Official Interpretations:

A5.11, D1.3, D1.8 ..........170Guide to AWS Services ......180

Personnel........................182Red Hots ........................184Logos ............................193Classifieds ......................197Advertiser Index ................198

313-s Estimation of Weld Joint Penetration under Varying GTAPoolsA front-side vision system was aided in determining jointpenetration by a neuro-fuzzy modelY. K. Liu et al.

322-s Contribution of Phosphorus and Sulfur on Hot CrackingSusceptibility for Extra-High-Purity 25Cr-35Ni StainlessSteelsIt was found that the addition of low levels of lanthanum to a high-purity stainless steel reduced hot cracking susceptibilityK. Saida et al.

332-s Microstructure Analysis of Brazed Sapphire to Inconel 600 Using Porous InterlayerExperimentation with a porous Cu/Ni composite interlayer was conducted to evaluate its effectiveness in producing a sound brazedjointT. Zaharinie et al.

337-s Simplified Mathematical Modeling of Implant LimitStress and Maximum HAZ HardnessTwo simplified models were developed to predict hydrogen- induced cracking in high-strength steel weldmentsA. Fotouh et al.

Features

Welding Research Supplement

40

46

52

November 2013 Volume 92 Number 11 AWS Web site www.aws.org

On the cover: The Chicago River is a picturesque waterway that winds throughdowntown Chicago. The Willis Tower, which at over 1,700 feet tall is one of theworlds tallest buildings, is pictured here in the background. Photo credit Todd Rosenberg.

November 2013_Layout 1 10/16/13 1:54 PM Page 3

EDITORIAL

When people hear the words trade show, it elicits different thoughts. Buying oppor-tunities. Networking. New technologies.

FABTECH offers the prospect of all three and more. Back in Chicago this year, Nov. 18 to 21, FABTECH North Americas largest met-

alforming, fabricating, welding, and finishing event offers attendees a unique experi-ence to meet with old friends and colleagues, and develop new relationships with ven-dors all under one roof.

Among the 1500 exhibiting companies and more than 35,000 attendees expected atthe show this month are countless relationships built over business deals, annual tradeshow visits, and day-to-day contact. FABTECH offers the opportunity to reconnect andbuild on those collaborations. And for those who are new to the show, theres the excite-ment of building the foundation for what it is hoped will become similarly long-termrelationships, all while soaking up the latest products and business solutions.

But its not just about attending FABTECH for the first time or even the 15th time.Its about the opportunity to share and learn.

Whether visiting on behalf of a small family-owned shop, a large manufacturing facil-ity, or a welding distributorship, FABTECH provides the opportunity see new technolo-gies at work. Even better, it allows attendees to discover the ways these technologies cantranslate into real-world solutions ones that help improve productivity, quality, andprofitability. Attendees can even make side-by-side comparisons between products toweigh out the various features and benefits of each, or participate in hands-on demosbefore determining the next step in their buying cycle.

Students who attend and fortunately there are many, signifying an ongoing inter-est in the fabrication, metalforming, welding, and finishing industries can also get afirsthand look at the leading technologies, giving them a competitive advantage whenentering into the workforce.

Beyond learning about new technologies on the show floor, there are also many otheravenues for attendees to increase their knowledge. This years show boasts more than100 education and training programs designed to expand attendees skill sets. These pro-grams, presented by leading industry professionals, cover topics from technologyadvancements and best practices to automation, job shop solutions, and more. In addi-tion to enhancing attendees businesses, these programs also offer the chance to networkwith peers or even find out what the competition is doing. And they are designed for awide variety of audiences, so most any member of a companys team can benefit.

But as anyone whos attended a trade show the size of FABTECH (theres 550,000net square feet to cover over the course of four days), theres always the need for somedowntime and socializing, too. For fun, consider participating in the contests and give-aways at the show, or attending one of many afterhours receptions or networking events,including happy-hour events hosted by exhibitors. Or for some laughs, look to the annu-al FABTECH Cocktails and Comedy event, featuring sketch and improv acts fromChicagos famed cabaret theater, The Second City, and more. After all, the show is asmuch about having fun as it is about networking, learning, and doing business.

So whether attending for half a day or the entire show, take advantage of the manyofferings at FABTECH. Reach out to old colleagues,network with new vendors, and invest the time to learnabout the many new technologies and solutions avail-able in the marketplace. Attendees can even plan outa show experience ahead of time. VisitFabtechexpo.com to download the FABTECH mobileapp or use the online show planner. See you inChicago!

NOVEMBER 20134

OfficersPresident Nancy C. Cole

NCC Engineering

Vice President Dean R. WilsonWell-Dean Enterprises

Vice President David J. LandonVermeer Mfg. Co.

Vice President David L. McQuaidD. L. McQuaid and Associates, Inc.

Treasurer Robert G. PaliJ. P. Nissen Co.

Executive Director Ray W. ShookAmerican Welding Society

DirectorsT. Anderson (At Large), ITW Global Welding Tech. Center

U. Aschemeier (Dist. 7), Miami Diver

J. R. Bray (Dist. 18), Affiliated Machinery, Inc.

R. E. Brenner (Dist. 10), CnD Industries, Inc.

G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services

T. A. Ferri (Dist. 1), Victor Technologies

D. A. Flood (At Large), Tri Tool, Inc.

S. A. Harris (Dist. 4), Altec Industries

K. L. Johnson (Dist. 19), Vigor Shipyards

J. Jones (Dist. 17), The Harris Products Group

W. A. Komlos (Dist. 20), ArcTech, LLC

T. J. Lienert (At Large), Los Alamos National Laboratory

J. Livesay (Dist. 8), Tennessee Technology Center

M. J. Lucas Jr. (At Large), Belcan Engineering

D. E. Lynnes (Dist. 15), Lynnes Welding Training

C. Matricardi (Dist. 5), Welding Solutions, Inc.

J. L. Mendoza (Past President), Lone Star Welding

S. P. Moran (At Large), Weir American Hydro

K. A. Phy (Dist. 6), KA Phy Services, Inc.

W. A. Rice (Past President), OKI Bering

R. L. Richwine (Dist. 14), Ivy Tech State College

D. J. Roland (Dist. 12), Marinette Marine Corp.

N. Saminich (Dist. 21), NS Inspection and Consulting

K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.

T. A. Siewert (At Large), NIST (ret.)

H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.

R. P. Wilcox (Dist. 11), ACH Co.

J. A. Willard (Dist. 13), Kankakee Community College

M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute

D. Wright (Dist. 16), Zephyr Products, Inc.

Founded in 1919 to Advance the Science,Technology and Application of Welding

Enjoy the FABTECHExperience

Debbie DoenchChair, AWS Publications, Expositions, MarketingCommittee (PEMCO)

Editorial November 2013_Layout 1 10/15/13 4:09 PM Page 4

For Info go to www.aws.org/ad-indexSee us at FABTECH booth #N625

MATHEY DEARMAN_FP_TEMP 10/10/13 5:06 PM Page 5

PRESS TIMENEWS

Arcet Equipment and Machine & Welding Supply Merge

The businesses of Arcet Equipment Co., Richmond, Va., and Machine & WeldingSupply Co., Dunn, N.C., have merged. They will initially operate as wholly owned sub-sidiaries of a new entity known as Arc3 Gases, Inc., as a 50/50 merger.

Parker Dillard and Emmett Aldredge Jr. will serve as co-chairmen of the board ofdirectors of Arc3 Gases. In addition, Emmett Aldredge III will serve as co-president ofthe company with Parker Dillard. The executive team includes Andy Ellen as chief fi-nancial officer and Christopher Aldredge as chief operating officer. Ray Dillard hasbeen named Arcets general manager, and Jeff Johnson has been named general man-ager of Machine & Welding Supply.

The two multigeneration family businesses will operate a total of 46 retail locationsin North Carolina, South Carolina, and Virginia as well as a beverage CO2 business serv-ing the eastern U.S. from Delaware to Florida.

ESAB Sponsors the University of Toronto Baja Team

ESAB Welding & Cutting Products,Florence, S.C., is sponsoring the Univer-sity of Toronto Baja Team in the Baja So-ciety of Automotive Engineers (SAE) col-legiate design competition. The contest,conducted regionally throughout NorthAmerica, begins June 2014 in Peoria, Ill.ESAB will donate welding equipment,consumables, and personal protection ac-cessories as they compete to design andbuild a rugged, off-road vehicle.

Every year, more than 100 universityteams participate in Baja SAE competi-tions across North America. As part ofthese, student members must function asa team to design, build, test, promote,

and race a vehicle to meet dynamic elements, including acceleration, hill climb, maneu-verability, suspension, traction, and endurance. The competitions provide students theopportunity to complete a challenging project that involves planning and manufacturingtasks required to introduce a new product to the consumer industrial market. The win-ning design must be fast, robust, comfortable, safe, and easy to manufacture.

JGM Welding & Fabricating Services Expands

JGM Welding & Fabricating Services, a structural steel fabricator, will expand opera-tions and lease a 75,000-sq-ft facility in Valley Township, Chester County, Pa. The project isexpected to generate a capital investment in excess of $2.5 million in infrastructure im-provement, equipment, and employee training costs.

JGMs addition of 44 new jobs is the second jobs announcement in Chester Countythis year with the resulting total job creation projected to be more than 130 for the county,said Governor Tom Corbett.

The company also received a funding offer from the Department of Community andEconomic Development, including a $125,000 Pennsylvania First Program grant, $44,000in Job Creation Tax Credits, and $19,800 Guaranteed Free Training grant to be used fortraining its new workforce at the project site.

Madison-Kipp Corp. Celebrates 115 Years in Operation

Madison-Kipp Corp., Madison, Wis., a manufacturer of aluminum die cast componentsand subassemblies for the transportation, industrial, lawn and garden, and leisure-end mar-kets, is celebrating its 115th year of operations. The company will also mark the 110th yearof continuous operations at its current east side location.

MKCs first year of operations occurred in 1898, said Tony Koblinski, companypresident and CEO. At that time, less than a dozen employees showed up for work. Inthe decades since as the 20th century passed and the 21st century began more than25,000 dedicated MKC workers have met our customers need for essential precisionmetal components.

NOVEMBER 20136MEMBER

Publisher Andrew Cullison

Publisher Emeritus Jeff Weber

EditorialEditorial Director Andrew Cullison

Editor Mary Ruth JohnsenAssociate Editor Howard M. Woodward

Associate Editor Kristin CampbellEditorial Asst./Peer Review Coordinator Melissa Gomez

Design and ProductionProduction Manager Zaida Chavez

Senior Production Coordinator Brenda FloresManager of International Periodicals and

Electronic Media Carlos Guzman

AdvertisingNational Sales Director Rob Saltzstein

Advertising Sales Representative Lea PanecaAdvertising Sales Representative Sandra Jorgensen

Senior Advertising Production Manager Frank Wilson

SubscriptionsSubscriptions Representative Tabetha Moore

[email protected]

American Welding Society8669 NW 36 St., # 130, Miami, FL 33166-6672

(305) 443-9353 or (800) 443-9353

Publications, Expositions, Marketing CommitteeD. L. Doench, ChairHobart Brothers Co.

S. Bartholomew, Vice ChairESAB Welding & Cutting Prod.

J. D. Weber, SecretaryAmerican Welding SocietyD. Brown, Weiler Brush

T. Coco, Victor Technologies InternationalL. Davis, ORS Nasco

D. DeCorte, RoMan Mfg.J. R. Franklin, Sellstrom Mfg. Co.

F. H. Kasnick, PraxairD. Levin, Airgas

E. C. Lipphardt, ConsultantR. Madden, Hypertherm

D. Marquard, IBEDA SuperflashJ. F. Saenger Jr., ConsultantS. Smith, Weld-Aid Products

D. Wilson, Well-Dean EnterprisesN. C. Cole, Ex Off., NCC Engineering

J. N. DuPont, Ex Off., Lehigh UniversityL. G. Kvidahl, Ex Off., Northrop Grumman Ship Systems

D. J. Landon, Ex Off., Vermeer Mfg.S. P. Moran, Ex Off., Weir American Hydro

E. Norman, Ex Off., Southwest Area Career CenterR. G. Pali, Ex Off., J. P. Nissen Co.

N. Scotchmer, Ex Off., Huys IndustriesR. W. Shook, Ex Off., American Welding Society

Copyright 2013 by American Welding Society in both printed and elec-tronic formats. The Society is not responsible for any statement made oropinion expressed herein. Data and information developed by the authorsof specific articles are for informational purposes only and are not in-tended for use without independent, substantiating investigation on thepart of potential users.

By providing welding equipment and additionalaccessories, ESAB will support the Universityof Toronto Baja Team.

PTN November 2013_Layout 1 10/15/13 4:45 PM Page 6

For Info go to www.aws.org/ad-index See us at FABTECH booth #N1849

CM INDUSTRIES_FP_TEMP 10/10/13 4:26 PM Page 7

IT TAKES TEAMWORKTO WIN

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Our distributors are a key part of our professional sales team. We back them with EXCLUSIVE SALES TERRITORIES, our exceptional products and promotional support efforts. Territories are still available for full service welding distributors. Contact us today if you are interested in joining our team.

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INTERNATIONALUPDATE

Gallery Exhibits Welded Pieces by Bob Dylan

Halcyon Gallery, Mayfair, London, is presenting an exhibitionof new works by musician and artist Bob Dylan from November16 to January 25. Building on the success of his first museum

exhibition in Chemnitz, Germany, in 2007 and several subse-quent exhibitions, this show, titled Mood Swings, will feature ironworks by Dylan, alongside original works on canvas and signedlimited editions, all of which will be for sale.

Seven iron gates, welded out of vintage iron and other metalparts, created by Dylan in his studio will be featured in the exhi-bition and will be displayed publicly for the first time. Thesegates and other objects are the outcome of the artists lifelongfascination with welding and metalwork.

Thomas Riley Building Reopens after$60-Million Renovation

The Thomas Riley building, originally opened in 1952 at SAITPolytechnic, Calgary, Alberta, Canada, recently reopened to stu-dents with 162,000 sq ft of renovated learning space. The class-rooms and labs in the building have been upgraded to enhancethe learning experience for students in the schools ofConstruction and Manufacturing and Automation. Updatedspaces include a home lab that can accomodate the constructionof two 1200-sq-ft homes simultaneously and a brand-new mill-wright and natural gas compression lab.

Students are our top priority, and we wanted the new spacesin Thomas Riley to be designed to enhance the curriculum andensure our students are highly trained for their current andfuture employers, said Scott MacPherson, dean of the School of

800-835-9999 www.weilercorp.com 2013 Weiler Corporation. All Rights Reserved.

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The Mood Swings exhibit will showcase ironworks by artist and singerBob Dylan. (Image credit: Bob Dylan, 2013 John Shearer.)

For info go to www.aws.org/ad-index

NOVEMBER 201310

Intl Updates Nov[1]_Layout 1 10/15/13 4:07 PM Page 10

Construction at SAIT Polytechnic. The $60-million renovationhas added 40 years to the life of the building and is focused main-ly on improving the student learning experience classrooms,labs, and study space and giving it the same interior look andfeel as the other new buildings on campus.

Continuous Welded Rail in Oman Will Mean Smoother Rides

The Sultanate of Omans government recently opted for con-tinuous weld rail (CWR) to allow for the operation of higher-speed and heavier trains across the national rail network.

Although more expensive than traditional rail tracks, CWRtracks eliminate rail joints, which are essentially small gaps left atrail ends to make allowances for metal expansion. The rails arewelded together at a site to make lengths of several kilometers.Jointless tracks are less subject to wear and last longer than joint-ed tracks. The result will be a smoother, continuous surface forthe trains to roll along.

Oman is implementing a nonelectrified double-track networkthat will be integrated with the GCC Rail Project. Italferr, anItalian engineering consultancy firm, is underaking the prelimi-nary design of the national rail project. The 1394-mile networkcomprises nine segments, the first of which is due to be awardeda contract for construction before the end of 2014.

11WELDING JOURNAL

Renovations to SAIT Polytechnics Thomas Riley building includedupdates to classrooms and labs.

New continuous welded rail in Oman will ensure smoother, noclickety-clack train rides.


Intl Updates Nov[1]_Layout 1 10/15/13 4:07 PM Page 11

NOVEMBER 201312

NEWS OF THEINDUSTRY

Miller Electric Donates Equipment Worth$1 Million to Ferris State

Miller Electric Mfg. Co., Appleton, Wis., has donated morethan $1 million in robotic welding equipment and simulation soft-ware to the Welding Engineering Technology program at FerrisState University (FSU), Big Rapids, Mich. This includes threecomplete robotic welding cells that Miller and members of theprogram worked together to design modular bases for and install

in the welding lab. Installation was completed in August.The robotic welding cell donations mark the start of a rotat-

ing donation program organized by Miller and FSU. Every threeyears, the company will update the robotic welding cells with newequipment, ensuring students stay on top of these technologiesand gain the hands-on experience needed to be competitive asthey enter the workforce.

In addition, Miller worked with FSU staff to offer training toinstructors on the new equipment.

This donation was the result of a long-term partnership be-tween our organizations 20-plus years and it supports thevision we have for our program and our students, said Jeff Hard-esty, associate professor and program coordinator at FSU.

Vera Anderson: The Story of a WWIIWorld Champion Welder

A recent article by Mary Perez of The Sun Herald, the news-paper covering the Mississippi Gulf Coast, paid tribute to VeraAnderson, the Worlds Champion Welder, who died Aug. 29at the age of 90.

She earned the title during World War II while working at In-galls Shipbuilding in Pascagoula, Miss. Anderson was 19 whenshe competed against other female welding champions. In 1944,she won the first Womens National Welding Championship, re-ceiving $350 in war bonds and a trip to the White House.

I was invited to have tea with Mrs. Roosevelt. She talkedabout what a contribution the women were making to the war ef-fort, Anderson later said.

Bowling Green Assembly Plant Gets $131 Million Technology InvestmentGeneral Motors (GM) $131 million technology investment at the Bowling Green Assembly Plant in Kentucky such as the

first production use of a GM-patented process allowing aluminum to be spot welded to aluminum is resulting in the strongestand most precisely built Corvette in its six-decade history.

New technologies enable more accurate and efficiently produced subassemblies, such as the frame and components attached toit. Laser-based, three-dimensional inspection systems verify overall assembly tolerances targeted to be 25% tighter than the previ-ous-generation Corvette.

Approximately $52 million of the investment wentto a new body shop that manufactures the cars light-weight aluminum frame in-house for the first time.This is not only the foundation for the cars greaterdriving capabilities, but also the platform on whichthe 2014 Corvette Stingray is more precisely con-structed. It is 99 lb lighter and 57% stiffer than theprevious-generation frame.

In addition, it is the most complex frame design inthe cars history, featuring main rails composed of fivecustomized aluminum segments, including aluminumextrusions at each end, a center main rail section, andhollow-cast nodes at the suspension interface points.

There are 439 aluminum resistance spot welds onthe Corvette Stingray coupe. GMs new resistancespot welding process uses a patented multi-ringdomed electrode. Also, laser welding is used in theframes tunnel subassembly to attach sheet aluminumcloseout panels to the tunnel structure. Laser-basedvision inspection for quality assurance includes Per-ceptron-supplied tools to monitor critical points onevery Corvette body that comes down the line.

A 2014 Chevrolet Corvette Stingray frame makes its way down the compositeline in the new, $52 million body shop at General Motors Bowling Green As-sembly Plant. (Photo by AJ Mast for Chevrolet.)

FSU junior student Charles Adams gets hands-on experience withone of the robots donated by Miller Electric.

continued on page 15

NI November 2013_Layout 1 10/14/13 3:44 PM Page 12

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15WELDING JOURNAL

When she became the Gulf Coast Welding Champion, thatbrought a challenge from Vancouver Yard of Kaisers Shipbuild-ing Co., which claimed the West Coast Champion, Hermina Strmiska. She won that challenge on May 28, 1943. Then MooreDry Dock and Shipbuilding Co., Oakland, Cal., claimed the pre-vious contestant was not the West Coast Champion. On Jan. 24,1944, Anderson kept her crown by outwelding Edna Slocum.

In announcing the winner of this contest, NBC announced Iwas Champion Woman Welder of the World, Anderson said.

Her story part of the National History Project alongwith her picture, history, and welding trophy are on display inthe military museum at Camp Shelby, Hattiesburg, Miss.

Obama Administration Announces$474.5 Million in Skills Training Grants

U.S. Secretary of Labor Thomas E. Perez recently revealed$474.5 million in grants to community colleges and universitiesaround the country for developing as well as expanding trainingprograms with local employers. Listed below are a few of theawardees.

In Michigan, Macomb Community College leads a consor-tium where the total award amount is nearly $25 million. TheMichigan Coalition for Advanced Manufacturing will focus onCNC machining, welding/fabrication, multiskilled technicians,and production operations.

In Tennessee, Pellissippi State Community College heads a

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Vera Anderson raises her welding torch after being named WorldsChampion Welder in a 1944 competition. (Photo courtesy of Hunt-ington Ingalls Industries.)

continued from page 12

NEWS OF THE INDUSTRY


NOVEMBER 201316

consortium for which the total award amount is nearly $13 mil-lion. The Southeastern Economic and Education LeadershipConsortium implements a partnership in support of developingeducational/career pathways tied to national industry stan-dards/credentials in welding, machining, and manufacturing.

In Wyoming, the Northern Wyoming Community College Dis-trict has been awarded nearly $2.8 million. It is working with ex-isting Trade Adjustment Assistance Community College and Ca-reer Training-funded programs to develop training curriculumthat lead to credentials for machinists, and award one-year cer-tificates and two-year associates degrees in machine tool tech-nology and welding technology.

Minnesota Welding Firm Creates Jobs

WFSI, Inc., Sauk Rapids, Minn., a contract welding shop serv-ing the oil and gas, energy, and military markets, plans to expandits operations and add 32 new positions. This was made possiblewith a $200,000 loan to increase its welding and manufacturingbusiness, according to the Minnesota Department of Employ-ment and Economic Development.

This funding will help us at WFSI acquire major pieces ofequipment, said WFSI CFO Allan Beyer.

Currently, the company employs about 45 people at its facil-ity and plans to fill the additional positions over the next twoyears. It recently relocated from a 14,000 to a 145,000-sq-ft facil-ity that will allow production of larger products such as pressurevessels.

Employment for welders in Central Minnesota is on the up-swing as manufacturing activity in the area rebounds from theGreat Recession, added Commissioner Katie Clark Sieben.

NexAir Debuts Advanced Welding& Cutting Demonstration Lab

NexAir, a large distributor of atmospheric gases and weldingsupplies, recently debuted its Advanced Welding & CuttingDemonstration Lab in Memphis, Tenn. A facility for weldingequipment demonstration and training use, it is outfitted withnew welding equipment and will be used to train employees andcustomers. Also, it will be utilized locally by schools with studentsinterested in the welding profession.

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Highlights include a PerformArcTM pre-engineered roboticwork cell, Retro Systems CNC plasma cutting table, and micro-bulk gas system with two mixers for blending welding gas mix-tures. Customers may also bring product specifications of theirown to see how the labs equipment can work for them. All equip-ment and accessories demonstrated are products sold by nexAir.

The lab is led by Sales Engineer Samantha Noland, an Amer-ican Welding Society member, who is a welding and roboticstrainer and provides automation sales and support.

Arapahoe County Approves Permit forOil and Gas Pipeline

The Arapahoe County Board of County Commissioners inLittleton, Colo., have unanimously approved a land-use permitallowing construction of part of a pipeline to transport naturalgas liquids from Weld County, Colo., to Texas.

Front Range Pipeline, LLC, a partnership with Anadarko Pe-troleum, Enterprise Products Partners, and Denver-based DCPMidstream, has received approval for constructing the 435-milepipeline across Weld, Elbert, and El Paso Counties.

The pipeline is 16 in. in diameter and will carry an average of150,000 barrels of liquid per day, but can accommodate up to230,000 barrels daily. The expected completion date is sometimewithin the fourth quarter of this year.

Industry Notes

Chicago Bridge and Iron will contribute $100,000 to CentralPiedmont Community College to support welding and nonde-structive exam facilities at its Harper Campus, Charlotte, N.C.

Advance Welding, West Springfield, Mass., an AWS Support-ing Company Member, is celebrating its 35th anniversary. Thecompany is Nadcap accredited with merit for fusion and re-sistance welding, plus brazing; ISO9001/AS9100 certified; andis a certified FAA Repair Station.

Quality Marine Alaska, Kodiak, was recently featured in theAlaskan Steel Men series, which follows the adventures of a teamof extreme heavy-metal welders on the Discovery Channel.

Victor TechnologiesTM, St. Louis, Mo., is positioning Twecoas its single brand for specialty welding products/arc acces-sories. Starting with the Tweco Fabricator 3-in-1 welding ma-chines, and continuing throughout the Thermal Arc productline, all welding products will transition.

Shasta College, Redding, Calif., has expanded its cooperativeprogram with local businesses by working with Sierra PacificIndustries to train students in practical welding technologyapplications. They are constructing projects that will be putinto use by the company at its local wood products facilities.

GEs Measurement and Control business is expanding its port-folio of inspection technologies through a new agreement withThermo Fisher Scientific. The company will sell three ofThermos products in the positive material identification area.

Hobart Institute of Welding Technology, Troy, Ohio, has beennamed a Military Friendly School for 2014 by Victory MediaInc., the media entity for military personnel transitioning tocivilian life.

The Independent Welding Distributors Cooperative recentlyannounced the addition of Holston Gases, Knoxville, Tenn., alarge independent supplier of many gases, to its membership.

Ten soldiers from Joint Base Lewis-McChord in Washingtongraduated from its first Heating, Ventilation, Air Condition-ing and Refrigeration, Veterans In Piping Welding Program.

Abbott Welding Supply, Olean, N.Y., has purchased Lind Weld-ing Supply, Jamestown, N.Y., allowing it to provide an ex-panded selection of gases, welding supplies, and products.

17WELDING JOURNAL

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STAINLESSQ&A BY DAMIAN J. KOTECKI

Q: I have been using the ArcWorks soft-ware from Lincoln Electric to calculateFerrite Numbers for austenitic stainlesssteel weld metals. However, my old com-puter, with the Microsoft Windows XPoperating system, is being replaced andthe new computer, with a newer version ofWindows, does not support the old soft-ware. What can I do?

A: I have had similar questions a numberof times over the past several years. Myown desktop computer, with WindowsXP, continued to live long after I con-verted to laptops, solely for Ferrite Num-ber (FN) calculations with ArcWorks.However, last year, that desktop died andwent to a landfill. Before I offer a solu-tion, I think it might be of interest to de-scribe the history of computerized calcu-lations of FNs based on earlier diagrams,the WRC-1992 Diagram, and its forerun-ner, the WRC-1988 Diagram. For some,

this will be a sojourn down memory lane.Computerized calculations of ferrite

content of nominally austenitic stainlesssteel weld metals actually predate theWRC-1988 Diagram. In 1984, LarryClark, then an electrical engineer em-ployed by Combustion Engineering inChattanooga, Tenn., wrote a computerprogram for the Apple II-c in the BASIClanguage, that calculated ferrite percents(Schaeffler Diagram), FNs (DeLong Dia-gram), and made graphical displays of theresults. Clark used the graphical presen-tation of the published Schaeffler and De-Long Diagrams to estimate equations forthe iso-ferrite lines, and since these linesare neither parallel nor uniformly spaced,his program had to use two-point meas-urements to develop an equation for eachiso-ferrite line, then interpolate betweenthe lines. In 1984, Clark demonstrated hisprogram at a meeting of the Welding Re-search Council (WRC) Subcommittee on

Welding Stainless Steel. The Subcommit-tee recommended WRC distribute ormarket the program. In 1990, Clark leftCombustion Engineering for McKeeFoods near Chattanooga, where he worksto this day.

The American Welding Institute(AWI), founded in 1983 as the AmericanWelding Technology Application Center,attempted to carve out a niche for itselfwith a number of welding software offer-ings. Clarks original BASIC program ap-parently found its way to AWI. AWIsFERRITEPREDICTOR software as aconcept was reported in the July 1987Welding Journal. When the software wentcommercial in 1988, it offered calculationof ferrite percent according to the Scha-effler Diagram, and FN according to theDeLong Diagram.

Meanwhile, the WRC-1988 Diagramwas published under two covers (T. A.Siewert, C. N. McCowan, and D. L.

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Olson, 1988. Ferrite Number Predictionto 100 FN in Stainless Steel Weld Metal,Welding Journal, 67(12), 289-s to 298-s;and C. N. McCowan, T. A. Siewert, andD. L. Olson, 1989. Welding ResearchCouncil Bulletin 342, Stainless Steel WeldMetal: Prediction of Ferrite Content).McCowan did the work as part of his mas-ters degree studies at the ColoradoSchool of Mines in Golden, Colo., underthe tutelage of Siewert and Olson. Thework was supported by funds from theWRC, using data supplied from a numberof sources, mostly welding filler metalmanufacturers, with additional guidancefrom the WRC Subcommittee on Weld-ing Stainless Steels. Since completion ofhis MS studies, McCowan has been withthe National Institute of Standards andTechnology (NIST) in Boulder, Colo.

The February 1991 Welding Journal in-cluded an announcement that FER-RITEPREDICTOR was to be revised byAWI to include the WRC-1988 DiagramFN calculations. This didnt happen rightaway, and a small modification of theWRC-1988 Diagram that included cop-per in the nickel equivalent was pub-lished as the WRC-1992 Diagram. Thislatter Diagram was included in theASME Code in 1994 to replace the De-Long Diagram. Then a revision of FER-RITEPREDICTOR that included calcula-tion of FN by the WRC-1988 Diagramand the WRC-1992 Diagram, along withDeLong FN and Schaeffler percent fer-rite, was introduced by AWI in 1995. Un-fortunately, the software offerings werenot enough to keep AWI financially vi-able, and it ceased operations in 1997.

When AWI ceased operations, TheLincoln Electric Co., a major investor inAWI, picked up some of the AWI soft-ware, including FERRITEPREDICTOR,which was packaged within Lincolns ArcWorks software. In order for a per-sonal computer to run either the stand-alone AWI version of FERRITEPRE-DICTOR or that incorporated by Lincolnin ArcWorks, the computer had to exit theWindows operating system and run inDOS, which was supported by Windows98, 2000, and XP. But Windows Vistain 2006 changed the game exit to DOSwas not supported and it is not supportedby Windows 7 or 8. So I kept my olddesktop PC with Windows XP.

In the December 2000 Welding Jour-nal, martensite boundaries at three levelsof manganese were added to the WRC-1992 Diagram. These are quite useful inpredicting microstructures of dissimilarmetal joints and cladding over carbon orlow-alloy steel. Until now, I am not aware

19WELDING JOURNAL



that these boundaries are addressed inany computerized predictions of stainlesssteel weld metal microstructures. Subse-quently, John Vitek at Oak Ridge Na-tional Laboratory (ORNL) developed aneural network method of predicting FN,published in the January and February2003 Welding Journal. He eventually pub-lished it on a Web site supported byORNL, which also included Schaeffler,DeLong, WRC-1988, and WRC-1992 Di-agram calculations. That Web site ap-pears to be closed.

Now, for a solution. I developed anExcel spreadsheet that performs theWRC-1992 Diagram FN calculations. Todo so, I had to do as Clark did earlier withthe Schaeffler and DeLong Diagrams inhis BASIC program use the two-pointmethod of deriving an equation for eachiso-ferrite line on the diagram, then de-vise an interpolation method between thenon-parallel iso-ferrite lines. I thentested my spreadsheet predictionsagainst a large number of predictions Ihad accumulated using the ArcWorkssoftware. The results agree within a fewtenths of one FN. The differences seemrandom, up to 0.1 to 0.2 FN for nominallyaustenitic stainless steel weld metals, andup to about 0.7 FN for duplex stainlesssteel weld metals. The spreadsheet alsoincludes graphical displays of the results.An example of the graphical display ap-pears in my September 2013 StainlessQ&A column. I transmitted the spread-sheet to Gib Gratti, quality assurancemanager at Arcos Industries, who re-ported very similar results vs. the Arc-Works calculations. So, I am confidentthat the spreadsheet is sufficiently accu-rate for any prediction purpose. I offer itwithout charge to everyone. E-mail yourrequest to [email protected],and I will send the Excel spreadsheetpromptly.

NOVEMBER 201320

DAMIAN J. KOTECKI is president,Damian Kotecki Welding Consultants, Inc.He is treasurer of the IIW and a member ofthe A5D Subcommittee on Stainless SteelFiller Metals, D1K Subcommittee on Stain-less Steel Structural Welding; and WRCSubcommittee on Welding Stainless Steelsand Nickel-Base Alloys. He is a past chair ofthe A5 Committee on Filler Metals and Al-lied Materials, and served as AWS president(20052006). Send questions to [email protected], or mail to DamianKotecki, c/o Welding Journal Dept., 8669NW 36th St. # 130, Miami, FL 33166-6672.

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RWMAQ&A BY DONALD F. MAATZ JR.

Q: We are resistance spot welding ongalvanized coated parts and experienc-ing what we consider to be short elec-trode life. We start each production runwith welds that barely meet their size re-quirements but finish with expulsion sosevere we end up destroying the electrodeface. We are hesitant to change the weldschedule due to the small initial weld sizeand have instead focused on the currentstepper, to little effect. The water flow,electrode cap size, weld force, secondarycurrent, and weld time are all in line withRWMA guidelines. Any ideas would beappreciated.

A: Your question intrigues me. If it is as-sumed that all other aspects of your re-sistance spot welding (RSW) applicationare within acceptable industry norms,and that you are welding parts with acoating that is not too detrimental (theyall are to a certain extent) to the elec-trode caps, you may actually have a cur-rent stepper boost issue. However, as I

will illustrate, this boost issue may be ofa very different kind than you realize.But, before we move forward, the follow-

ing caveat must be understood: This dis-cussion is really relevant only for auto-motive-grade coated steel products, with

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RWMA Q&A November 2013_Layout 1 10/11/13 9:22 AM Page 24

the assumption that you are referring tohot-dipped galvanized parts for your ap-plication. I say this as other automotivegrade coatings (electro-galvanized, gal-vanneal, etc.) do exhibit this behavior buttypically to a lesser degree. The weldingof any other material substrate (stainless,etc.), or grade of galvanized coating (i.e.,commercial, military, etc.) on steel, fallsoutside of the realm of this articles ap-plicability. Again, please note that forthis discussion, all aspects of the RSWprocess are correct for the applicationbeing discussed. The important elementsof material weldability; part presenta-tion; weld gun capability, configuration,and condition; electrode alignment, cool-ing, stack-up ratio; plus the actual weldschedule itself, are suitable for the appli-cation. If this were not the case, we wouldnot be able to correctly evaluate the ap-plication for electrode wear and weldperformance over the course of a pro-duction run.

To help answer your question, we mustfirst understand what would occur if wewere spot welding and did not have a cur-rent stepper boost feature on our weldcontrol. As each weld is made, the act ofapplying the scheduled weld time andsecondary current, combined with the ap-plication of the needed weld force, phys-ically degrades the condition of the elec-trode contact face. Some in the industryrefer to this as mushrooming. This degra-dation may be subtle and barely notice-able even after many welds, or it may bedramatic, occurring very quickly in theproduction run. As an example, when theRSW process is used on bare steel andthe parts are free of dirt and lightlycoated with a known benign oil, it maybe possible to make many thousands ofwelds before the electrode caps are nolonger able to produce a weld of accept-able quality. On the other hand, I haveseen coatings that acted so aggressivelyas a wear agent that the electrode capswere essentially ruined and requiredmaintenance after less than a few dozenwelds. The most common electrodemaintenance activity involves renewingthe contact face geometry either by dress-ing the electrode cap, or replacing it.

The current stepper is a feature of theweld control and was created as a meansto help increase the number of welds be-tween electrode maintenance cycles. Itaccomplishes this by adjusting the sec-ondary current in a programmed mannerso that the current density (amps/unitarea) remains relatively consistent as theelectrode cap contact face area increaseswith every weld. The early weld controls

25WELDING JOURNAL

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only permitted the addition of current atdiscrete intervals, and a plot of their pro-file over time looked like a set of steps,hence the name. A more modern weldcontrol permits a customized profile plot(e.g., boost of 1 amp/weld). However, de-spite the fact the profile is a sloped lineand no longer looks like a set of stairs,the name has stuck. As an aside, therehas been movement at the OEM levelaway from utilizing the boost feature ofcurrent steppers and strictly using themas a counter to trigger a maintenance ac-tivity. This no-boost, dress early, dressoften philosophy has merit but reallyneeds to be the subject of a separate discussion.

An examination of your applicationreveals you may be dealing with atleast for the first portion of your produc-tion run a large variance with yourelectrode contact face resistance. I saythis based on your statement that thewelds initially were almost unacceptablysmall at the start of a production run butgrew so hot over time that expulsion en-sued. This is a phenomenon that we haveseen frequently and have illustrated withan additional data point in a weld lobeplot (see Fig. 1 and also the March 2012RWMA Q&A for more details on weldlobes). What is unique about this partic-ular weld lobe plot is that it details thesecondary current value when a new setof electrodes produces a weld that meetsthe requirements of minimum weld size(MWS). However, once the electrodeshad been conditioned (Ref. 1), the sec-ondary current required to achieve aweld at MWS (I-Min) was substantiallylower. Additionally, the new electrodeMWS current is only slightly lower thanthe conditioned electrode expulsion cur-rent (I-Max). From a production stand-point, this represents a real problem asthe electrodes are exhibiting a very dy-namic break-in behavior due to variancewith their contact face resistance.

The situation detailed in our exampleweld lobe is a result of the electrode capsurface contact resistance changing rap-idly over the initial 30100 welds of theirlife cycle. Once the weld-to-weld vari-ability of the surface contact resistancehas been greatly reduced, the effect ofelectrode face geometry (see the May2009 RWMA Q&A for more details onelectrode geometry) becomes the domi-nant driving force for the weld lobe re-sults. A potential fallout from this dy-namic behavior is that the published re-sults for this weld lobe would be of min-imal value unless they were confirmed by

a Weld Lobe Point Verification. TheWeld Lobe Point Verification test vali-dates a specific set of welding parame-ters as to its ability to consistently pro-duce welds of acceptable quality. The testis conducted by establishing the weldpoint within the lobe that is to be vali-dated. For typical automotive grade ma-terials, the validation point is usually5001000 A beneath the expulsion cur-rent for a given weld time and utilizeselectrodes configured to mimic a produc-tion environment (i.e., out of the boxwithout conditioning or stabilization).The welding portion of the validationconsists of a series of peel coupons (typ-ically 30 or more) at the desired valida-tion point. All peeled test welds shouldbe greater than minimum weld size, andideally exhibit no expulsion.

One possible solution to your issue isto employ a negative stepper boost pro-file Fig. 2. As detailed in the example,this type of boost profile permits the uti-lization of a higher initial starting sec-ondary current with new electrode capsthat quickly fades back to a baseline valuemore suitable for conditioned electrodecaps. Once the electrode caps begin toexhibit normal wear, a positive value ofboost can be programmed, thus prolong-ing the time between electrode mainte-nance cycles. While it will take a bit ofexperimentation on your part, you shouldfind that your RSW process will be morerobust and cost effective by employingthis alternative boost strategy.

The RSW process can be very robust,even on coated materials. However, inorder to achieve that robustness there

are many variables that must be consid-ered, addressed if they are out of com-pliance, documented for reference, and,finally, maintained for the life cycle ofthe part.

Acknowledgment

I would like to thank James W. Dolfi,former AWS Detroit Section, D8D andAuto/Steel Partnership (ASP) JoiningCommittee chairman, for his invaluableperspective on the welding of coated materials.

References

1. AWS D8.9:2012, Test Methods forEvaluating the Resistance Spot WeldingBehavior of Automotive Sheet Steel Mate-rials. Miami, Fla.: American Welding Society.

NOVEMBER 201326

DONALD F. MAATZ JR. is a laboratorymanager, RoMan Engineering Services. Heis past chairman of the AWS Detroit Sec-tion, serves on the D8D and D8.9 Auto-motive Welding committees, is an advisorto the C1 Resistance Welding Committee,is an AWS CWI, and is vice chairman ofthe Certified Resistance Welding Techni-cian working group. He is a graduate ofThe Ohio State University with a BS inWelding Engineering. This article wouldnot have been possible were it not for theassistance from members of the RoManteam. Send your comments/questions toMaatz at [email protected], or toDonald F. Maatz Jr., c/o Welding Journal,8669 NW 36 St., #130, Miami, FL 33166.

Fig. 2 A resistance spot weld current stepper boost profile.


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P and P November 2013_Layout 1 10/15/13 8:31 AM Page 28

29WELDING JOURNAL

ing. It cleans, contains, and filters washwater, removing contaminants for recy-cling or proper discharge to drain. Bene-fits include the GripStart on/off system;1500 to 2900 lb/in.2 of cleaning power; lowprofile; nonskid, flat surface; manufac-tured to length and width requirements,the design allows for a multitude of padsizes; forklift ports for moving the rackand filtration unit; and overspray walls invarying heights. Also, the product featuresthe RTS 500 washwater water treatmentsystem.

Riveerwww.riveer.com(269) 637-1997

Laser Machine OffersExpanded Workspace

The Optiplex CO2 laser cutting systemcomes in a 6- 12-ft format. The 4020model can process materials ranging fromthe thinnest gauge steel to 1-in.-thick mildsteel with a workpiece weight capacity ofup to 3527 lb. It also uses the companysautomated AO|5 setup and features Pre-View Control with a 15-in. touch screen.The graphical interface visualizes the cut-ting path and automatically determinesprocess conditions, including the requiredlens, nozzle, feed rate, and laser outputfor different materials and thicknesses.The system features are complementedby a 4000-W, Type 10 resonator.

Mazak Optonics Corp.www.mazakoptonics.com(847) 252-4500

Brochure ShowcasesMetalworking Products

The companys Equipment for the Met-alworking Industry brochure highlights

products designed to improve productiv-ity and efficiency in day-to-day metal-working operations. The brochure show-cases the companys selection of metal-working products, including magna rolls,vibratory feeders and conveyors, magneticdrum separators, and grate magnets. Eachproduct is outlined with a brief synopsisand the application it serves. The four-page, full-color brochure is available on-line and in hard copy format, by request.

Eriezwww.eriez.com(888) 300-3743

WANT TO LANDA JOB AFTERGRADUATION?Employers want commercial divers that are internationally certified.

CDA

TECHN

IC AL INSTITUTE CDA Technical Institutes Commercial Diver Program offers the

internationally recognized DCBC Unrestricted Surface Supplied Divers Certification.

Start your career training in an internationally recognized Commercial Diving and Underwater Welding program.

Financial aid available for those who qualifyApproved for Veterans Benefits For more information about graduation rates, the median debt of students who completed the program and other important information, visit www.cda.edu.

UTUTETTEE

CDA Techni

echnical Institutes

Start your career training in an internatio

in

Commercial Diver Progr internationally recognized DCBC Unr

Surface Supplied Dive

nally recognized Commercial Diving and Unde

r

ogram offers theecognized DCBC Unrestricted

rs Certificatio

nd Underwater Welding program.

n.

Financial aid available for those who qualifyApproved for For more information about graduation rates,median debt of students who completed the program and other important information,

inancial aid available for those who qualifyoved for Veterans Benefits

or more information about graduation rates,median debt of students who completed the program and other important information, visit www

inancial aid available for those who qualify

or more information about graduation rates, the median debt of students who completed the program

visit www.cda.edu.



Power Supply AllowsIncreased Data Storage

The Orbitig 240 is a GTAW powersupply and control system that offers usersa lightweight, portable, welding powersupply capable of executing a vast arrayof applications. The system provides a PC-controlled segmented schedule genera-tion method for accurate, flexible param-eter control of the welding process. Thenew design features increased data stor-age, allowing technicians to input multi-ple schedules, as well as record parame-

ters during the welding application. Thepower supply and control system is suitedfor tube joining, small bore pipe, heat ex-changer, and process pipe applications.

Liburdi Dimetricswww.liburdi.com(704) 230-2516

Program Enables EffectiveEyewear Management

The Honeywell Eyelation program, anautomated system that features on-site,Web-enabled, touchscreen kiosks, allowsend-users 24/7 access for fitting, selecting,and ordering prescription eyewear. Pro-viding employees with the prescriptionsafety eyewear that delivers the perform-ance, style, fit, and comfort they require,it eliminates paperwork, manages payrolldeduction automatically, and saves time.The software-based program offers em-ployees more than 65 styles of prescrip-tion frames.

Honeywell Safety Productswww.honeywellsafety.com(800) 446-1802

Software Helps ManageAccounts Receivables

FG Receivables Manager is an onlineaccounts receivable management soft-ware. It gives business owners transpar-ent control of their customer accountsthroughout all stages of a credit sale andallows them to take appropriate actions

NOVEMBER 201330

Carestream NDTs Digital Products are made right here in the USA. We design, test and manufacture them in the same plant every day with pride.

The HPX-1 also won the award for Product Differentiation Excellence*, how many other NDT CR systems can say the same? Its rugged enough to handle the rigors of our industry and designed to minimize damage to the imaging plates by reading them phosphor side up, unlike some of our competitors.

And, while were talking about the competition, the next time youre looking for a CR system make sure to ask them

about service. If you ever need it on an HPX-1 under warranty well send you a free loaner within 24 hours while yours is being repaired to ensure you can keep working.

At Carestream its all about performance, both for our products and the people who support them. Were proud to manufacture in America and to build one of the best products in the industry. Let us show you the difference.

Built with Pride.

FLEXIBLE. RELIABLE. POWERFUL. DIGITAL.*Frost & Sullivan 2012 Best Practices Awards

Built with Pride.

unlike some of our competitors.by reading them phosphor side up,minimize damage to the imaging platesthe rigors of our industry and designed tothe same? Its rugged enough to handlemany other NDT CR systems can sayProduct Differentiation Excellence*The HPX-1 also won the award for

plant every day with pride.test and manufacture them in the samemade right here in the USA. We design,Carestream NDTs Digital Products are

Let us show you the difference.

one of the best products in the industry.manufacture in America and to buildwho support them. Were proud toboth for our products and the peopleAt Carestream its all about performance,

working.keep is being repaired to ensure you canfree loaner within 24 hours while yoursHPX-1 under warranty well send you aabout service. If you ever need it on an

by reading them phosphor side up,minimize damage to the imaging platesthe rigors of our industry and designed tothe same? Its rugged enough to handlemany other NDT CR systems can say

, howProduct Differentiation Excellence*The HPX-1 also won the award for

test and manufacture them in the samemade right here in the USA. We design,Carestream NDTs Digital Products are

Let us show you the difference.

one of the best products in the industry.manufacture in America and to buildwho support them. Were proud toboth for our products and the peopleAt Carestream its all about performance,

is being repaired to ensure you canfree loaner within 24 hours while yoursHPX-1 under warranty well send you aabout service. If you ever need it on an

ndt.carestream.com

2013 Carestream, Inc. Rochester, N.Y. 14608

Carestream NDT

for a CR system make sure to ask themcompetition, the next time youre lookingAnd, while were talking about the

unlike some of our competitors.

dsarwes Aacticr12 Best Pan 20ost & Sullivr*F

for a CR system make sure to ask themcompetition, the next time youre lookingAnd, while were talking about the

unlike some of our competitors.

FLEXIBLE. RELIABLE. PO

AL.WERFUL. DIGITTAFLEXIBLE. RELIABLE. PO

continued on page 33For info go to www.aws.org/ad-index


1-800-263-2547

Email [email protected] 1-905-356-6025

www.hcrsteel.com

For all of your rolling, formingand bending needs, please call

1-800-263-2547

Email [email protected] 1-905-356-6025

www.hcrsteel.com

For all of your rolling, formingand bending needs, please call

North Americas largestPlate Rolling, BrakeForming and StructuralRolling facility deliverscost effective solutions.We serve a wide range of industries including energy,transportation, architectural, construction, mining, metals, and agricultural as well as OEMs across North America.

11 thick11 thick

3.5 thick x200 in length x40 inside diameter


hodgson_FP_TEMP 10/11/13 4:36 PM Page 31

A More EfficientSurface

To more efficiently crush rock, mining engineers partnered with Sulzer for the answer.

Without a wear-resistant coating, r

ToTo more efficiSulzer for the

esistant coating, rock crusher t

iently crush rock, min answer.

ock crusher teeth can wear out in a matt

ing engineers partner

eeth can wear out in a matter of a few

red with

Meet us at:

Without a wear-resistant coating, rdays. So when mining engineers askreduce their maintcladding solution using a thick deposit on all eThe result? Those rstay in service substantially longer

esistant coating, rock crusher tdays. So when mining engineers asked us to help them decreduce their maintenance costs, we got right t

cladding solution using a MetcoClad system and a thick deposit on all exposed surfaces of the t

esult? Those rock crushers never worked so harvice substantially longer.

ock crusher teeth can wear out in a matto help them decrease their downtime and

enance costs, we got right t Too work. Together, we developed a laser em and a MetcoClad material t

faces of the teeth with a hardness better than 1500 HV300. ed so hard! They crush more efficiently and

eeth can wear out in a matter of a few ease their downtime and

, we developed a laser erial to create a

er than 1500 HV300. e efficiently and

November Chicago IL, U

www

Meet us at:Fabtech 2013

November 18 21Chicago IL, U.S.A.

Booth N404

w.sulzer.comFor Info go to www.aws.org/ad-index

sulzer metco_FP_TEMP 10/10/13 4:44 PM Page 32

to get paid faster. The real-time softwarealso reduces the amount of time spentgathering and sorting critical informationon outstanding accounts.

Funding Gateswww.fundinggates.com(888) 370-6026

Web Site Highlights ColdSaw Cutting Process

The company recently launched a re-designed Web site, which showcases stain-

less steel, Prodec, and aluminum plateproducts with photos, properties, and ap-plications. The site also highlights thecompanys precision cold saw cuttingprocess.

Plus Ten Stainlesswww.plustenstainless.com(707) 745-4625

Calculator Identifies SavingOpportunities

The SnapShot bandsawing calcula-tor is a data-driven Microsoft Excel tool

that identifies and measures the impactof improved productivity and perform-ance on day-to-day bandsawing opera-tions and their effect on profitability. Thecalculator guides manufacturers throughthe individual cost components of theirsawing operation. For categories with in-direct value, this tool allows customers tomeasure their value on soft costs. It ulti-mately identifies opportunities for signif-icant time and cost savings.

Simonds Internationalwww.simondsinternational.com(800) 343-1616

Welding Helmets OfferCustom Airbrushing

The Tagged and Imposter series aretwo additions to the companys ExtremeFace Protector welding helmets. TheTagged series is custom airbrushed byhand; offers an adjustable 4/913 auto-darkening filter (ADF) integrated into a180-deg viewing lens; and features grindmode, sensitivity, and delay controls. TheImposter series can be custom airbrushedby the customer; comes in two models, theChameleon with a fixed 3/10 ADF inte-grated into its patented 180-deg passivewelding lens and Du Mi with a 2 4 ad-

33WELDING JOURNAL

continued from page 30

PRODUCT & PRINTSPOTLIGHT

Gentec is a total solution provider for your welding, cutting, and gas control needs. JIHGFEHGDHCBCA@FAHF?>==A;HC@FAHF4AFIF@DBE;4EFCBB8@3F2>IFAB9GF;@F8B8;E9AB8FAHF@BI1;E;C:FF6;A0FBC:;CBBI;C:F9C8F@>DDHIA3

/BC@A9IF. BE0CH=H:;B@F-HGD9C

justable 4/913 ADF with grind mode andsensitivity delay controls integrated intothe 180-deg welding lens; and offers aviewing area of more than 23 in..

Save Phacewww.savephace.com(866) 783-3223

Weld Inspection CartProvides Easy Portability

The companys weld inspection cart al-lows easy access to all body panel weldsfor integrity testing. The carts can be tai-lored to hold workpieces of any shape.Components such as fenders, hoods, anddoors can be mounted to the carts with

mechanical clamps. A pivot feature thenallows the operator to adjust the compo-nent up, down, or over for convenient ac-cess to either the front or back of the work-piece, making it easier to do visual weldinspection and physical weld integrity testing.

Bilsing Automation North Americawww.bilsing-automation.com(586) 463-0686

NOVEMBER 201334

For info go to www.aws.org/ad-indexSee us at FABTECH booth #N1949

Belt Sander Reaches into Areas of Small Access

The 300B is an air-drivenbelt sander for metal grinding,sanding, deburring, and polish-ing. It is useful for applicationsfrom foundry finishing to sheetmetal fabrication. The sandercan drive a belt abrasive up to5700 surface ft/min with a frontexhaust directly on the belt forcooling. It performs materialremoval or fine finishing with areach into areas of small access.

T. C. Service Co.www.tcservice.com(800) 321-6876


Call us at 800-782-2110 for a free quote on yournext Metal Rolling job.

www.greinerindustries.com

Give it to us straight, and well handle the curves Plate Forming: 2,750-ton Press Brake with 40' long bed

Plate Rolling: Up to 4-3/4" thick by 12' wide carbon steel

I-Beam Rolling: Up to 44" the hard way and any size the easy way

Pipe Rolling: Up to 24" in diameter with 2wall thickness Tube Rolling: Up to 30" square

Channel Rolling: Up to 36" the easy way and 24" the hard way

Angle Rolling: Up to 12" by 12"

Tees: Any size

Solid Bar Rolling: Up to 14" square and up to 16" round

Flat Bar Rolling: Up to 40" by 7" the easy way and 20" by 6" the hard way

Structural Steel Fabrication Steel Plate & Sheet Metal Fabrication Miscellaneous Metals Machining Rolling & Forming Services Cutting Services Industrial Coatings Industrial & Electrical Contracting Crane Rental & Trucking Services Heat-Bending Services

(AISC Certied for Major SteelBridge Fabrication)

W40x593# I-beam being rolled to a 100-ft. radius.

Greiners job shop arsenal now includes the worlds largest steel rolling capacity.

Our Roundo R-16S Angle Rolling Machine is only the second machinewith this technology and capacity in the world, and the only one inthe United States. It can roll any beam size either the easy way or thehard way. It can roll a W40-in. by 211-lb. beam to a radius less than100 ft. with almost no distortion. Plus, roll up to 24-in.-OD pipe with2-in. wall thickness.


GREINER_FP_TEMP 10/10/13 4:30 PM Page 35

voestalpine. The three brands provide the deepest portfolio of ller metal solutions and the most competent technical

As a world leading provider of ller metals voestalpine Bhler W

Metallurgical know-how for the best welding results.


As a world leading provider of ller metals voestalpine Bhler W



elding is now an integrated unit of the steel producer As a world leading provider of ller metals voestalpine Bhler W



elding is now an integrated unit of the steel producer


elding is now an integrated unit of the steel producer

support in the market for Joint W


elding Bhler W

.voestalpine.com/weldingwww

elding, Repair & Maintenance and Brazing applications.support in the market for Joint W


elding UTP Maintenance

.voestalpine.com/welding

elding, Repair & Maintenance and Brazing applications.


Fontargen Brazing

elding, Repair & Maintenance and Brazing applications.

voestalpine. The three brands provide the deepest portfolio of ller metal solutions and the most competent technical voestalpine. The three brands provide the deepest portfolio of ller metal solutions and the most competent technical

bohler 1_FP_TEMP 10/14/13 1:21 PM Page 36

Visit us at booth N867 at FABTECH in Chicago

from November 18th-21st, 2013

Visit us at booth N867 at

Visit us at booth N867 at

from No

t us from No

, 2013 st-21th

ovember 18

at booth N867 at ABTFFAbooth N

ovemb , 2013

hicago C in

ABTECH


bohler 1_FP_TEMP 10/14/13 1:22 PM Page 37

The voestalpine Group

The voestalpine Group is an employee owned steel-based technology and capital goods group that operates worldwide. With 500 group companies and locations in more than 50 countries and on all 5 continents, the Group has been listed on the Vienna Stock Exchange since 1995. With its top-quality products, the Group is one of the leading partners to the automotive and consumer goods industries in Europe and to the oil and gas industries worldwide. The voestalpine Group is also the world market leader in turnout technology, special rails, tool steel, and special sections. In the business year 2012/13, the voestalpine Group reported revenue of more than EUR 11.5 billion and an operating result (EBITDA) of EUR 1.45 billion. It staffs roughly 46,400 employees worldwide.

voestalpine Bhler Welding

voestalpine Bhler Welding (formerly Bhler Welding Group) operates 40 branch locations in 28 countries around the globe. It services its customers in more than 150 countries either directly or via a network of over 1,000 carefully selected distribution partners. Its more than 2,200 experts inform you which ller materials best meet your needs and provide in-depth technical advice for custom-tailored solutions with regard to industrial welding and brazing applications. Its 11 pro-duction sites offer a total production capacity of more than 130,000 tons of welding and brazing consumables.

Welding know-how joins steel with customer focus

Like no other enterprise, voestalpine Bhler Welding joins

welding expertise with steel expertise. Customers benet

from comprehensive welding and steel know-how from one

source that generates complete welding solutions tailored

to the customers specic performance criteria and base

materials, as well as from a partner offering extremely high

economic stability and technological competence.

The new name and corporate design constitute only the

nal touch in an overarching internal process in which the

entire enterprise has committed itself to absolute customer

focus. Its predominant philosophy is to deliver always the

best possible solution to its industry customers however

challenging a task may be: safely, fast, and by building on

the worldwide availability of its products and consulting

services.

Focused on three business units and three brands

voestalpine Bhler Welding bundles its competence into

three strong brands. Here, customers will nd a focused

range of products and a pool of experts for their special

challenges. The brands at a glance:

Bhler Welding Creating lasting connections is the most important part of

the welding process. Designed for join

aws welding journal november 2013

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