aws welding journal october 2014
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The joining of ESAB and Victor
brings together five heavy hitters.
Now all the welding and cutting
solutions you need are available
from one company ESAB.
Visit us at booths C2444, C2454, and C2466 at FABTECH 2014.
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7/21/2019 AWS Welding Journal October 2014
2/265UBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
October 2014
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44 Pairing Galvanized Steel with Metal-Cored Wire Selecting a metal-cored welding wire designed to
weld zinc-coated steel will help take some of thechallenges away in welding this material
A. DArcy
48 Changes Are Coming to Hazard Communication Manufacturers, distributors, and users of welding
electrodes need to prepare for new recommendations in the Globally Harmonized System of hazard
communication
52 Meeting the Demand for Welding Engineers The history, current status, and future direction of
The Ohio State Universitys welding engineeringprogram are profiled D. Phillips, A. Benatar, and
J. C. Lippold
OCTOBER 2014 / WELDING JOURNAL 3
CONTENTS
369-s Mechanical Behavior of Titanium-Clad SteelWelded Joints
Titanium-clad steel was welded with differentinterlayer materials and then tested for hardness,
ductility, and shear strength
J. E. Ramirez
379-s Flux-Assisted Gas Tungsten Arc and Laser Weldingof Titanium with Cryolite-Containing Fluxes: Arc
Spectroscopy and Corrosion Resistance Studies
Autogenous welding and welding with a solid wire andnewly developed tubular wires were compared forjoining commercially pure titanium
T. AlSabti et al.
388-s Learning Human Welder Movement in Pipe GTAW: A Virtualized Welding Approach
Experiments were conducted to transfer human welding intelligence into the control system of a robot
Y. K. Liu et al.
399-s Microstructural Characteristics and MechanicalProperties of Fiber Laser Welded-Brazed Mg
Alloy-Stainless Steel Joint
The influence of heat input on the microstructure andmechanical properties of a dissimilar joint welded witha laser-brazing process was investigatedC. W. Tan et al.
WELDING RESEARCH SUPPLEMENT
October 2014 Volume 93 Number 10
FEATURES
44
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6 Editorial
10 Washington Watchword
12 Press Time News
14 International Update
18 News of the Industry
28 Business Briefs30 Letters to the Editor
32 Aluminum Q&A
34 Brazing Q&A
36 Product & Print Spotlight62 AWS Show Information
67 AWS Events at a Glance
72 AWS Professional Program
90 AWS Exhibit Highlights
168 Coming Events
170 Certification Schedule172 Welding Workbook
175 Society News
181 Tech Topics190 Guide to AWS Services
192 Personnel
197 Red Hots208 Logos
212 Classifieds
214 Advertiser Index
WELDING JOURNAL / OCTOBER 20144
DEPARTMENTS
Welding Journal (ISSN 0043-2296) is published monthly by theAmerican Welding Society for $120.00 per year in the UnitedStates and possessions, $160 per year in foreign countries: $7.50per single issue for domestic AWS members and $10.00 per sin-gle issue for nonmembers and $14.00 single issue for interna-
tional. American Welding Society is located at 8669 NW 36th St.,# 130, Miami, FL 33166-6672; telephone (305) 443-9353. Period-icals postage paid in Miami, Fla., and additional mailing offices.POSTMASTER: Send address changes to Welding Journal, 8669NW 36th St., # 130, Miami, FL 33166-6672. Canada Post: Publi-cations Mail Agreement #40612608 Canada Returns to be sentto Bleuchip International, P.O. Box 25542, London, ON N6C 6B2,Canada.
Readers of Welding Journalmay make copies of articles for per-sonal, archival, educational or research purposes, and which arenot for sale or resale. Permission is granted to quote from arti-cles, provided customary acknowledgment of authors andsources is made. Starred (*) items excluded from copyright.
Copyright 2014 by American Welding Society in both printed
and electronic formats. The Society is not responsible for anystatement made or opinion expressed herein. Data and informa-tion developed by the authors of specific articles are for informa-tional purposes only and are not intended for use without inde-pendent, substantiating investigation on the part of potentialusers.
OfficersPresident Dean R. WilsonWelldean Enterprises
Vice President David J. LandonVermeer Mfg. Co.
Vice President David L. McQuaidD. L. McQuaid and Associates, Inc.
Vice President John R. BrayAffiliated Machinery, Inc.
Treasurer Robert G. PaliJ. P. Nissen Co.
Executive Director Ray W. ShookAmerican Welding Society
Directors
U. Aschemeier (Dist. 7), Miami DiverR. E. Brenner (Dist. 10), CnD Industries, Inc.D. J. Burgess (Dist. 8), University of TennesseeN. C. Cole (Past President), NCC EngineeringG. Fairbanks (Dist. 9), Fairbanks Inspection &Testing Services
T. A. Ferri (Dist. 1), Victor TechnologiesK. Fogleman (Dist. 16), ConsultantP. H. Gorman (Dist. 20), Sandia National LaboratoriesS. A. Harris (Dist. 4), Altec IndustriesK. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (At Large), The Harris Products GroupJ. Knapp (Dist. 17), Gas and SupplyT. J. Lienert (At Large), Los Alamos National LaboratoryD. E. Lynnes (Dist. 15), Lynnes Welding TrainingC. Matricardi (Dist. 5), Welding Solutions, Inc.S. P. Moran (At Large), Weir American HydroK. A. Phy (Dist. 6), K. A. Phy Services, Inc.W. R. Polanin (At Large), Illinois Central CollegeW. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State CollegeD. J. Roland (Dist. 12), Airgas USA, LLC,North-Central Region
R. W. Roth (At Large), RoMan Manufacturing, Inc.
R. Madden, HyperthermD. Marquard, IBEDA Superflash
J. F. Saenger Jr., ConsultantS. Smith, Weld-Aid ProductsD. Wilson, Welldean EnterprisesN. C. Cole, Ex Off., NCC EngineeringJ. N. DuPont, Ex Off., Lehigh UniversityL. G. Kvidahl, Ex Off., Northrop Grumman Ship SystemsD. J. Landon, Ex Off., Vermeer Mfg.S. P. Moran, Ex Off., Weir American HydroE. 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
N. Saminich (Dist. 21), NS Inspection and ConsultingK. E. Shatell (Dist. 22), Pacific Gas & Electric Co.T. A. Siewert (At Large), NIST (ret.)
J. Stoll (Dist. 18), Bohler Welding Group U.S.H. W. Thompson (Dist. 2), UL, Inc.R. P. Wilcox (Dist. 11), Ford Motor Co.
J. A. Willard (Dist. 13), Kankakee Community CollegeM. R. Wiswesser (Dist. 3), Welder Training& Testing Institute
WELDING JOURNALPublisher Andrew Cullison
EditorialEditorial Director Andrew CullisonEditor Mary Ruth JohnsenAssociate Editor Howard M. WoodwardAssociate Editor Kristin CampbellEditorial Asst./Peer Review Coordinator Melissa GomezPublisher Emeritus Jeff Weber
Design and ProductionProduction Manager Zaida ChavezSenior Production Coordinator Brenda FloresManager of International Periodicals andElectronic Media Carlos Guzman
AdvertisingNational Sales Director Rob SaltzsteinSenior Advertising Sales Executive Sandra JorgensenSenior Advertising Sales Executive Annette DelagrangeManager of Sales Operations Lea PanecaSenior Advertising Production Manager Frank Wilson
SubscriptionsSubscriptions Representative Tabetha [email protected]
American Welding Society8669 NW 36 St., # 130, Miami, FL 33166-6672(305) 443-9353 or (800) 443-9353
Publications, Expositions, MarketingCommitteeD. L. Doench, Chair, Hobart Brothers Co.S. Bartholomew, Vice Chair, ESAB Welding & Cutting Prod.J. D. Weber, Secretary, American Welding SocietyD. Brown, Weiler BrushT. Coco, Victor Technologies InternationalC. Coffey, Lincoln Electric
L. Davis, ORS NascoD. DeCorte, RoMan Mfg.S. Fyffe, Astaras, Inc.D. Levin, Airgas
On the cover: Atlanta Skyline as seen from Piedmont
Park in Midtown. Copyright 2007, Kevin C. Rose,
AtlantaPhotos.com.
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Have you ever considered where else you
might find all the products and services fea-tured at the FABTECH show? The simpleanswer is nowhere. Set for November1113 at the Georgia World Congress Cen-ter in Atlanta, FABTECH has developed intoa truly amazing focal point for everythingabout metalworking, including a weldingpresence that amounts to well over a thirdof the total show space. This yearsFABTECH is the second-largest in the ten-year period since the AWS Welding Showmerged with it, and the welding/cuttingspace sold is currently 48% greater than it
was the last time it was in Atlanta, in 2010.We expect some 27,000 attendees on handto view the products of 1400 exhibitingcompanies that will occupy more than550,000 sq ft of floor space.
In addition, there will be more than 100educational sessions to help you make themost of the broad array of metalworkingtechnology on display. AWS-sponsored ses-sions include programs on best practicesand new commercial developments in weld-ing and thermal spray, the Professional Pro-gram focusing on the latest in weldingresearch, the RWMA Resistance WeldingSchool, and more. Our show partners willoffer sessions on cutting, finishing, formingand fabricating, job shop solutions, automa-tion and robotics, stamping, and tube andpipe. A live demonstration area in Hall Awill include a special thermal spray demo,the AWS U.S. Invitational Weld Trials, and arobotic arc welding competition. FABTECHIndustry Night at the new College FootballHall of Fame will take place Wednesday,Nov. 12, at 5:30 p.m. Keynote speakers will
include luminaries from Walmart andGoogle, and ex-Pittsburgh SteelersSuperbowl Champion halfback Rocky Bleier. Whats the reason for the unprecedentedsuccess of FABTECH? The many reasons in-clude the continuing economic recovery, thestrong metal manufacturing and construc-tion markets in the Southeast (andelsewhere), the wide package of exhibitorsin one show, and continually growing inter-national interest. Although not as strong aswe would like, the economy is definitelygrowing, with the number of jobs
increasing. At the same time, U.S. manufac-turing is growing apace. Its an ideal
environment for both show exhibitors and
attendees, a situation that will definitelybenefit all parties involved. The importance of product exhibitions,generally, is not limited to the UnitedStates. Over recent years, we have seen sig-nificant and sustained growth in our annual
AWS Weldmex show in Mexico, held inalliance with FABTECH Mexico and Metal-form Mexico. We have also seen stronginterest in our FABTECH Canada exhibitionand the other shows in which we participatein Brazil, Germany, Japan, China, India, andmany other locations. The point here is that
it is abundantly clear, and particularly in arecovering economy, that face-to-face showsstill have a great relevance. The continuing success of the strongestshows, like FABTECH, is easy tounderstand. It results from a combinationof creating a showplace for the latesttechnology, plus an environment where po-tential buyers can view and watchdemonstrations of the latest equipment re-lated to their manufacturing and construc-tion operations. Combine this withtechnology-related education offeringsand you have an unbeatable, cant missmix of everything the consumer needs toknow. Of course, as show planners, we haventaccomplished all this ourselves. AWS greatlyvalues the skill and devotion demonstratedby its FABTECH partners: SME, the Fabrica-tors and Manufacturers Association, Inter-national (FMA), the Precision Metalforming
Association (PMA), and the ChemicalCoaters Association International (CCAI).
AWS and all of its partner associations con-
tinually strive to bring a more comprehen-sive and valuable show to both theexhibitors and all of the attendees, who aremutually dependent on each other toproduce a great exhibition.
Come join us this year at the FABTECHshow in Atlanta. We promise we will make itworthwhile for you from a businessstandpoint, as well as thoroughlyinteresting and enjoyable. For moreinformation on FABTECH, please visit ourwebsite at www.aws.org. This issue of theWelding Journal also features a comprehen-
sive preview of FABTECH 2014. We lookforward to seeing you there.
EDITORIAL
FABTECH A Show Like No Other
WELDING JOURNAL / OCTOBER 20146
Ray Shook
Executive Director,
American WeldingSociety
It is abundantly
clear, and particu-larly in a recover-
ing economy, that
face-to-face shows
still have a great
relevance.
WJ
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Manufacturing Universities Bill Introduced
The bipartisan Manufacturing Universities Act of 2014has been introduced in the U.S. Senate. This legislationwould establish a program within the Commerce Depart-ments National Institute of Standards and Technology(NIST) charged with designating 25 schools as Manufactur-
ing Universities. Designated schools would receive $5 mil-lion per year for four years to meet specific goals, includingfocusing engineering programs on manufacturing, buildingnew partnerships with manufacturing firms, growing train-ing opportunities, and fostering manufacturing entrepre-neurship. The program would be overseen by the director ofNIST, in coordination with the secretaries of Defense andEnergy, and the director of the National Science Foundation,among others. The intent is to provide incentives to betteralign educational offerings with the needs of modern manu-facturers. The incentives would be used to revamp theuniversities engineering programs to focus on manufactur-ing engineering and curricula specifically related to targeted
industries.
OSHA Updates Proposed PublicRecordkeeping Regulation
In late 2013, the Occupational Safety and Health Admin-istration (OSHA) proposed to expand its annual injury andillness reporting requirements by mandating that employerssubmit their reports on workplace injuries and illnesses toOSHA electronically. This information would then be includ-ed in a searchable online database. This represented a signif-icant change in the law, since presently employer-specificdata are not readily available to the public or even to em-ployees of a particular firm. This latter approach is believedto encourage accurate reporting of injuries and illnesses. Infact, OSHA is now concerned that these new proposed regu-lations may cause employers to underreport injuries and ill-nesses due to the increased visibility.
Therefore, OSHA has now proposed to expand the pro-posed rule by: requiring that employers inform their employees oftheir right to report injuries and illnesses; requiring that any injury and illness reporting require-
ments established by the employer be reasonable and notunduly burdensome; prohibiting employers from taking adverse actionagainst employees for reporting injuries and illnesses. These new requirements were published in the FederalRegister on August 14.
Export Control Reform Efforts Continue
The Departments of State and Commerce have publishedadditional regulations to continue efforts to streamline U.S.
export controls on certain military items by shifting less-sensitive equipment, parts, and components from U.S. Mu-nitions List to the less-sensitive Commerce Control List. These steps are part of the federal Export Control Re-form Initiative which is designed to enhance competitive-ness by overhauling the Cold War-era system of regulationsdesigned in part to update Cold War-era regulation of ex-
ports of controlled technologies. With these latest regula-tions, 15 of the 21 categories on the Munitions List havebeen successfully revised under the initiative. Work contin-ues on the remaining categories and other efforts to mod-ernize and harmonize the export control regulations.
Bill Introduced to Enhance Buy AmericaPolicy in Infrastructure Projects
The Invest in American Jobs Act, introduced in the U.S.Senate, is intended to improve Buy America preferences for
federal infrastructure programs. Specifically, this legislationwould improve Buy America preferences for federal highway,public transportation, rail grants, rail loans, Amtrak, andthe Federal Aviation Administration to maximize the use ofdomestic steel, iron, and manufactured goods in infrastruc-ture projects;
prevent segmentation of projects to circumvent BuyAmerica standards; apply enhanced provisions to projects sponsored by se-lect agencies, including Department of Transportation, theEconomic Development Administration, and the FederalEmergency Management Agency.
Available Federal R&D Data Expanded
A federal government website providing access to govern-ment information, www.data.gov, has been expanded to in-clude data on more than 700 Federal R&D facilities that maybe utilized to research, prototype, and test new technologiesin manufacturing and other industries. These facilities, op-erated by agencies including DOE, NASA, and NIH, repre-sent more than $5 billion dollars of taxpayer investment.Further expansion in the future is expected to include more
comprehensive data on other R&D assets, including federal-ly funded intellectual property.
WASHINGTON WATCHWORD
WELDING JOURNAL / OCTOBER 201410
HUGH K. WEBSTER, AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania
Ave. NW, Washington, DC 20006; e-mail [email protected]; FAX (202) 835-0243.
WJ
BY HUGH K. WEBSTER
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For Info, go to www.aws.org/ad-index See us at FABTECH booth C3045
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Swift Academy Offers Welders Chance to Learn
Aluminum Welding while Earning a Salary
Swift Academy recently opened its School of Welding totrain and qualify experienced aluminum welders. Opened by Swiftships, Morgan City, La., which con-structs small-to-medium sized watercraft built of steel, alu-minum, and fiberglass, the welding academy is a 6 to 8 weekcourse where potential company welders will be trained tomeet American Bureau of Shipping and United States CoastGuard regulations. Upon entering the course, students will receive a salarybased on their skill level. Lawrence Alleman, a senior certi-fied fitter/welder, and Terry Gilmore, a senior quality assur-
ance inspector, serve as instructors. Curriculum includes gasmetal arc welding of aluminum. After completing the academy and qualification exam,students will join the companys team. Opportunities exist for individuals who have completed atwo-year welding course and welders who have a fewmonths to a year of aluminum welding experience. Interested candidates may apply in person at Swiftships,LLC, 1105 Levee Road, Morgan City, La. The first classes be-gan on August 18, but future chances will take place for par-ticipating in this six-person-per-class experience. We are always looking for people; some people get certi-fied in just a few weeks and spots open up, said Morgan
Rhoades, Swiftships marketing and public relations repre-sentative. People should apply as soon as possible as we arelooking to hire aluminum welders. Its a strong need in ourmarket.
Hypertherm Announces Succession Plans
Hypertherm, Hanover, N.H., a supplier of plasma, laser,and waterjet cutting systems, has recently announced staffchanges to take effect Jan. 1, 2015. The current president, Evan Smith, will assume the roleof CEO from founder Dick Couch, who will retain the posi-
tions of executive chairman of the board and trustee of thecompanys stock ownership plan. Smith has served in a suc-cession of business management and executive roles sincejoining Hypertherm 22 years ago.
In addition, Jenny Levy, director of corporate social re-sponsibility, will assume the role of vice president, corporatesocial responsibility, from Barbara Couch, who will retainher roles as board director and chair of its corporate social
responsibility committee. Levy joined Hypertherm in 2004,holding positions in sales and marketing before beingnamed director of environmental stewardship in 2010.
Airgas Opens New North Dakota Location
for Servicing Bakken Shale Oil Region
Airgas, Inc., Radnor, Pa., has opened a new location inDickinson, N.Dak., enhancing its local product and servicecapabilities for users in the Bakken shale oil region. This oilformation is positioned in western North Dakota and east-ern Montana, plus extends into Canada.
Our comprehensive product and service offering is tai-lored to meet the unique needs of customers in the energyindustry, particularly in oilfield logistics and operations,well completions and production, and pipeline constructionand maintenance, as well as customers involved in the fabri-cation of metal components and structures that are a criticalpart of the energy sector value chain, said Airgas Presidentand CEO Michael L. Molinini.
Patrick Henry Community College to Upgrade
Welding Technologies
Welding virtually and robotically are two new technolo-
gies coming to the welding shop at Patrick Henry Communi-ty College, Martinsville, Va. A report prepared for the Commonwealth Center for Ad-vanced Manufacturing by the Boston Consulting Group re-sulted in a Centers of Excellence grant, which will help fundcosts for the colleges welding upgrades. A proposal that includes Patrick Henry, Danville Commu-nity College, New College Institute, and the Institute for Ad-vanced Learning and Research outlines Patrick Henry as thelead provider in welding training. It also includes virtual androbotic welding equipment to total $230,000, with addition-al costs for faculty training at $20,000 and a renovation ofthe colleges existing welding lab at $100,000. Dr. Angeline Godwin, Patrick Henrys president, addedthe grant has been awarded but funds are yet to be dis-persed. She anticipates funding this fall.
PRESS TIME NEWS
WELDING JOURNAL / OCTOBER 201412
WJ
Welding student Brady Bray tacks together test plates.
Evan Smith Jenny Levy
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For Info, go to www.aws.org/ad-index
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Canadian College Receives Funding for
Additional Training Spaces
Northern Lights College (NLC), Dawson Creek, BritishColumbia (B.C.), Canada, recently announced it will receive
funding for anadditional 75 training
spaces to increase ac-cess and help reducewait lists for tradescritical to the liquefiednatural gas (LNG) in-dustry and in-demandtrades, as part of B.CsSkills for JobsBlueprint.
The allocation ispart of the $6.8million recentlyannounced to create1424 foundation andapprenticeship seats
at 14 public postsecondary institutions through British Co-lumbia. NCL will receive a total of $438,000 including$226,000 for the additional training spaces and $212,000 inoperating and minor equipment funding such as tools,safety gear, and rods and gas for welding to support deliveryprograms. The 75 spaces will include 32 electricalapprenticeship, 16 welder foundation, and 27 welderapprenticeship seats. This generous funding provided by the Ministry of Ad-vanced Education will allow Northern Lights College to pro-
vide more of the high-demand trades training that isrequired by the growing labor demand in northeast BritishColumbia, said Laurie Rancourt, NLC president. Thegovernment announced an initial $6.6 million for criticaltrades seats as part of B.C.s Skills for Jobs Blueprint. Onemillion job openings are expected in B.C. by 2022, with 43%requiring college education or apprenticeship training.
Fine Tubes Contracted for Egina and
Solar Orbiter Projects
Fine Tubes, Plymouth, Devon, UK, a manufacturer ofprecision tubes forcritical applications,announced that ithas been awarded amajor order by FMCTechnologies for thesupply of advancedtubing for Total Up-stream Nigeria Lim-iteds offshore Eginaproject.
Located 150 kmoff the coast of Nige-
ria at a depth of1750 m, the Eginaoil field is estimated
to reach a peak production rate of 150,000 barrels per dayand covers an area of around 500 m2. FMC Technologies isproviding Total Upstream Nigeria all the subsea productionsystems, and Fine Tubes will supply FMC with significantvolumes of seamless instrumentation tubing for the control,hydraulic, and injection lines required for the subsea mani-folds.
In related news, Fine Tubes has also been selected to sup-ply tubing for the chemical propulsion system of the SolarOrbiter project, a European Space Agency project that willinvestigate how the sun creates and controls theheliosphere. Contracted by OHB Sweden, Fine Tubes will bemanufacturing Grade 2 titanium tubing. The challenging environment in which these tubes mustoperate necessitates traditional manufacturing processes beimproved to meet the demanding technical requirements,said Paul Mallet, aerospace business development manager,Fine Tubes. At Fine Tubes, we are proud of our flexibility inadapting to new specification requirements and of our rolein enabling such exciting projects to take place.
Pilot Welding Academy to Train 30 in
Specialized Welding Fields
Dr. StephenFarry, Employmentand Learning minis-ter in the NorthernIreland Executive, re-cently announced anew pilot weldingacademy to address
specialist weldingneeds for Harlandand Wolff, Belfast,Northern Ireland, anindustrial companyspecializing in ship-building andoffshoreconstruction. Theproject is supportedby the Departmentfor Employment andLearnings Skills Solutions Service with training delivered byBelfast Metropolitan College and Northern RegionalCollege. The initiative will be aimed at unemployed people with abackground in welding to provide training in modern tech-niques. The program will ensure that one of Northern Ire-lands most well known employers will be able to access ahigh-quality, high-caliber, and highly skilled pool ofwelders, said Farry. Looking forward, this improves theoverall skillset in our workforce significantly and will help toensure that other Northern Ireland employers can also drawon this expertise and help them to remain competitive in ademanding global economy.
The program, which will select the best 30 candidatesfrom those who pass a trade test, will last approximately sixto eight weeks.
NTERNATIONAL UPDATE
WELDING JOURNAL / OCTOBER 201414
WJ
NLC is receiving funding to add 37
electrical apprenticeship, 16 welder
foundation, and 27 welder appren-
ticeship spaces.
Dr. Stephen Farry (left) with RobertJ. Cooper, chief executive, Harlandand Wolff, announcing the new pilotwelding academy. (Photo courtesy ofNorthern Ireland Executives Face-book page.)
Fine Tubes will supply tubing for the
chemical propulsion system of the
Solar Orbiter project, which will fly to
within 45 million km of the sun and
image the solar poles for the firsttime.
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Piping Professionals Union, Washtenaw
Community College Sign 15-Year
Contract Extension
During a recent ceremony celebrating the 25-year part-nership between the United Association of Plumbers, Pipe-fitters, Sprinklerfitters, Welders, and HVACR Technicians(UA) and Washtenaw Community College (WCC), Ann Ar-bor, Mich., the parties signed a 15-year contract extension.
Attendees included UA General President William P. Hite,UA Director of Training Chris Haslinger, and WCC PresidentRose Bellanca. We have asked everyone to join us as we celebrate thesigning of our new agreement with WCCan agreementthat will allow our annual Instructor Training Program tocontinue here for the next 15 years, Haslinger said.
Every summer, instructors from across North America aswell as Australia come to the college to pursue certificationas instructors of UA apprentices and journeymen. The pro-gram benefits the Ann Arbor and Ypsilanti metro area bybringing revenue into the community. The UA maintains a full-time, year-round presence atWCC with full-time staff through its Great Lakes RegionalTraining Center. Members of its local unions from all acrossthe United States come there for training throughout theyear. This facility includes classroom and auditorium spacealong with hands-on labs and workshops. We are also here to celebrate the installation of a newmicroturbine project done jointly between our two organiza-
tions, Haslinger said at the event. GEM Energy, Walbrige, Ohio, recently designed and builtthe colleges first combined cooling, heating, and power sys-tem, plus donated another microturbine to train future en-ergy professionals at the Great Lakes facility. In addition,the company donated a Capstone C30 microturbine for theUAs training program at the college. Our partnership with Washtenaw Community College
NEWS OF THE INDUSTRY
For more than six decades, the United Association has been
training instructors to pass on the skills of piping trades to
generations of journeymen and women.
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has been one of the most successful relationships in the his-tory of the UA, Hite concluded. When we made our deci-sion to relocate our program here 25 years ago, none of uscould have known just how well it would work out...we ap-preciate your support and we look forward to our continuedstrong and enduring partnership.
Two STEM Education Efforts Announced
Lockheed Martin has donated $200,000 to Project Lead
the Way for implementing its science, technology, engineer-ing, and math (STEM) curriculum in all of the 26 elemen-tary schools in Alabamas Huntsville City School System.The grant makes Huntsville City Schools the largest schooldistrict in Alabama that has implemented this project in allof its elementary, middle, and high schools. In addition, more than 52 elementary school teachers inthe 26 elementary schools attended this projects profes-sional development training earlier this summer.
The first phase of Praxair, Inc.s Skills Pipeline programwill provide more than $300,000 to train 100 new weldersin an accelerated one-year curriculum in Louisiana. Funded by Praxairs Global Giving Program, and conduct-ed in cooperation with the Louisiana Community and Tech-nical College System, it will be offered through the BatonRouge, Delgado, and SOWELA Technical Community Col-leges. The program also provides funding for new instruc-torships and professional development opportunities for ex-isting welders. The state of Louisiana has more than $60 billion in newplant construction slated to begin by 2016 and the need for
skilled welding professionals is urgent, said LouisianaHouse Speaker Chuck Kleckley. The scholarships will provide students access to an accel-erated AWS SENSE curriculum and career-readiness contentfrom Praxair.
Gullco Celebrates 60 Years in Operation
On July 14, Gullco International Ltd. (www.gullco.com)celebrated its 60th anniversary. The company has come a
The companys booth is shown during SCHWEISSEN & SCHNEI-
DEN at Messe Essen held in Germany last year. This represented
its 15th time exhibiting at the international show thats held
every four years.
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long way from its small beginnings in Ontario, Canada. Still family owned, it has grown from employing six peo-ple to more than 100 men and women in more than eightcountries with customers in more than 80 countries. Featur-ing a background in research and development, Gullco con-tinues to produce welding and cutting automation systems.The company has also expanded into a global business andwill continue to pursue its goals of providing North Ameri-can-made quality automation systems.
Eastern Florida State College and NASAPartner for Welding Training
Eastern Florida State College (EFSC), Cocoa, Fla., andNASA Rocket U have partnered to provide Kennedy SpaceCenter engineers with a one-week comprehensive weldingtechnology training workshop. Ken Cox, associate professor of welding technology at thecollege, and Tom Merry, welding technology lab specialist,guided the students. Instruction included basic weldingtechniques; metallurgy fundamentals; shielded metal arc,gas tungsten arc, and gas metal arc welding applications;plus grinding functions. Rocket U was developed to help civil service and contrac-tor engineers expand their skill set in flight systems engi-neering and learn to better manage design programs. Theinsight into welding techniques allows engineers to commu-nicate more effectively with front-line welders. To date, EFSC Corporate Services and NASA Rocket Uhave facilitated three workshops covering classroom theory
and hands-on lab exercises for more than 45 professionals.The most recent session took place this summer, and they
hope to conduct future sessions.
ABB Completes New Construction andFacilities Renovation in Wisconsin
The ribbon cuttings at both ABBs new office facility onDiscovery Parkway, Wauwatosa, Wis., and the office/manu-
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facturing site on Glendale Ave., New Berlin, Wis., markedcompletion of the buildings. Construction and renovationbegan in April 2013 and nearly all of the 725 employees whowork at the ABB Southeastern Wisconsin sites were present. The white, three-story building at the Discovery site fea-tures ABB logos on all four sides and sits on the highestpromontory in Wauwatosa, noted Aaron Aleithe, generalmanager and vice president of drives and controls. Huntzinger, the general contractor who built the new fa-
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continued from page 20
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NEWS OF THE INDUSTRY
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cility, logged 50,000 h of construction with zero lost-timeaccidents, according to Aleithe. Additionally, at both facilities, a wrap of fenestrationaround the buildings allows sunlight to reach interior spaces. The building at Discovery Parkway is Silver LEED certi-fied, contains ABB drives/controls throughout the HVACsystem, and features acoustic tile that creates a quiet workenvironment. At Glendale Blvd., renovations included ex-panding capacity on the manufacturing floor; adding newoffices and conference rooms; plus increasing the trainingrooms. ABB engineers also designed a Class 100 Clean Oper-ating HVAC Room.
Joliet Junior Colleges Welding ProgramPrepares Students to Fill Welder Jobs
Thanks to funding from a Trade Adjustment AssistanceCommunity College and Career Training Grant, Joliet Jun-ior College, Joliet, Ill., received in 2012, the programs facili-ties and equipment underwent upgrades and expansionslast year. It received the grant as one of 21 Illinois communi-ty colleges in an education consortium, the Illinois Network
for Advanced Manufacturing. Today, the program features 18 individual weldingbooths, doubling previous capacity; includes booths forpracticing oxyfuel and gas tungsten arc welding; has a newventilation system and an upgraded 110-V electrical system;plus the grant allowed purchase of virtual welding machines. Our welding lab is now a utopia learning environment
for our students, said Industrial Welding Technology In-structor Greg Foster. They are absolutely learning the vari-ety of skills they will need to achieve a good welding career. In addition, starting this fall, the program will offer six
new specialized welding certificates of completion. Studentscan earn these while simultaneously pursuing the industrialwelding technology AAS degree. The program also changedto a full academic 16-week schedule. Interest in welding has grown, and from spring 2013 to2014, enrollment grew 100%. We had 258 students inspring 2014, said Foster. Students are starting to realize
The welding lab at Joliet Junior College has been expanded and
upgraded. Pictured is 2014 welding graduate Dawana Griffin.
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that there is a very bright future in welding. Graduate Dawana Griffin, 27, said the program preparedher well for a welding career and she is grateful to have hadprofessors who challenged her along with coursework de-signed to provide real-world experiences. She graduated inMay 2014 with an associates degree in industrial weldingtechnology, and a certificate of achievement in welding andmetal fabrication. he first female African-American gradu-ate of the colleges welding program said she would love to
see more women and minorities pursue careers in the trades.
Industry Notes
Te Texas Comptrollers Office has approved a $336,090grant to fund equipment for Weatherford Colleges weld-ing program. Te Jobs and Education for Texas grant pro-gram supports high-demand career and technical educationprograms in exas public community colleges. Te followingwill be purchased: another welding simulator; machines forrobotic welding, milling, and sanding; plasma beds.
Rolled Alloys, Houston, ex., has expanded processing ca-pabilities at its 80,000-sq-ft service center. A new BehringerHBM-540 complements existing bar saws, a new rackingsystem, and expanded inventory/grades. Also, the compa-nys division in Los Angeles, Calif., has achieved AS9120Acertication on Quality Management System Requirementsfor Aviation, Space and Defense Suppliers.
Sciaky, Inc., Chicago, Ill., has received a purchase orderfrom a major aerospace parts maker to provide an electronbeam additive manufacturing system that will help savetime and cost on producing large, high-value metal parts.
Te welding department at Manatee Technical Insti-tute, Bradenton, Fla., has earnedAWS Accredited Test Fa-cility status. Companies in the region who need weldersqualied to meet contract requirements can now do so local-ly. Also,Air Products Plant Manager Mark Evans recentlyvisited and brought two checks totaling $3000 representingprogram support for 2014. Te school has been trainingwelders for the company for about a year. Tis money will beused to fund scholarships to students with nancial need topurchase required welding gear.
MISTRAS Group, Inc., Princeton Junction, N.J., wasawarded a multiyear contract for providing eet radiography
services to Southern Nuclear. It includes, but is not limit-ed to, balance of plant, ow accelerated corrosion programs,in-service, and vendor location inspection services.
ESAB Welding & Cutting Products, Florence, S.C., hasachieved ISO 9001, ISO 14001, and OHSAS 18001 recerti-cation for its quality, environmental, and occupationalhealth and safety management systems. Tis triple distinc-tion covers all ESAB activities, people, and units worldwide.
Washington State Community College, Marietta, Ohio,has built a new welding lab and developed a new weldingprogram to meet local shale and industry demands. Te one-year welding certicate includes shielded metal arc, gas met-al arc, gas tungsten arc, and plate/pipe welding as well assetup techniques. Earning AWS certications will also be
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available to students. Josh Horner, a member of Boiler-makers 667, is the welding instructor.
United Performance Metals has increased nickel plateproduct inventory and added processing capabilities, includ-ing a plate shear and high-denition plasma table, at itsHouston, ex., facility.
Viva Motorsports, El Paso, ex., will be using the new
FroniusAccuPocket portable welding machine for mobile
repairs throughout the remainder of the 2014 race season.Additional equipment will also be on hand to support therace crew. Te #55 Chevrolet displayed the Fronius logo be-ginning with the Aarons 312 at alladega Superspeedway.
Administration, staff, and supporters at Mayland Com-munity College recently gathered to cut a ribbon dedicat-ing the Glenn and Carol Arthur Welding Lab at its AveryLearning Center in Newland, N.C. A new feature there is awelding simulator purchased with support by a grant fromthe Piedmont Natural Gas Foundation.
o customize a Clean Air fume extraction gun, Bernard,Beecher, Ill., offers an online congurator atBernardWelds.com/CongureMyGun. Trough a step-by-step process, usersmay choose each component. When complete, a specic partnumber and summary are provided.
Fischer Technology, Inc., Windsor, Conn., has achievedaccreditation to ISO/IEC 17025:2005 by theAmerican As-
sociation of Accreditation Laboratories. It can offer ISO17025 certications for lm thickness instruments andstandards for eddy current, magnetic induction, X-ray uo-rescence, coulometric, and beta backscatter applications;electrical conductivity instruments and standards for eddycurrent comparison; ferrite number instruments and stan-dards; and nanoindentation instruments/standards.
Te new Highland Community College Western Cen-
ter, Baileyville, Kan., has received notice it was awarded
funding through a grant from the federal Perkins ReserveFund to establish the Industrial Welding Program. Tosefunds are being used to acquire welding equipment. Also,the center is part of the Kansas AO-K grant program in theHighland Technical Center, Atchison, Kan., and weldingis one of the focus technical programs in that grant.
E. H. Wachs has moved its Houston sales, service, andrental location to 3414 Lilac Unit E in Pasadena, ex. Itscloser for industrial users in the oil/gas market and rener-ies in the shipping channel in the area. Tis facility sells,services, and rents equipment for pipe cutting/beveling.
Earlier this year,Airgas Nor Pac hosted its annual salesmanagement meeting at the Kahneeta Resort in WarmSprings, Ore., where more than 100 company sales man-agers and support persons met to review the previous yearsresults and attend workshops. Representatives from Bug-OSystems, one of 12 invitation-only guests at the two-dayevent, showcased products at its booth and trailer.
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North American Robotics MarketPosts Its Best Quarter
The North American robotics industry is off to its fasteststart ever in 2014, according to new statistics from the Ro-botic Industries Association (RIA), Ann Arbor, Mich. A record 14,135 robots, valued at $788 million, were or-
dered from North American robotics companies in the firsthalf of 2014. This represents an increase of 30% in unitsand 16% in revenue vs. the same period in 2013. The second quarter of 2014 was also the main driver ofthe markets record first half with 8197 robots valued at$450 million sold to North American customers. Since 2010, the robotics market in North America hasgrown an average of 26% per year. Simultaneously, the U.S.unemployment rate has fallen. Manufacturing jobs are nowreturning to the United States because of automation as well. While we often hear that robots are job killers, just theopposite is true, said Jeff Burnstein, president of RIA. Ro-bots save and create jobs.
Element Opens $5 Million Oil and GasMaterials Technology Center
Element Materials Technology has recently opened anOil and Gas Materials Technology Center in Houston, Tex.Representing the companys largest ever single site invest-ment in capabilities, this lab represents a total investmentin excess of $5 million. Officially launched by Elements President and CEO,Charles Noall, an event was attended by many clients includ-ing Baker Hughes, BP, Exxon Mobil, Chevron, Serimax, andTechnip. Vallourecs North American Managing Director,Skip Herald, also gave a keynote speech. The center features fracture mechanics and engineeringcritical assessment, nondestructive examination (NDE), andcorrosion testing across many metal alloys, thermoplastics,composites, and elastomers. Located on a 5.3-acre campus adjacent to the Houstonenergy corridor, the sites testing facilities, technology, and
design offer extended capabilities. In addition, a new poly-mers facility has been developed in collaboration with theState of Texas Governors Office and Emerging TechnologyFund promoting collaboration with Texas A&M University.
Encompassing a main facility of 40,000-sq-ft housing, allcore testing capabilities plus an expanded 15,000-sq-ft facil-ity for onsite NDE, the center delivers a 50% increase intesting capacity over Elements previous lab in the city. Itsstaffed by 95 personnel and new equipment includes electri-cal discharge machining, water jets, four servohydraulic ma-chines for fracture mechanics, and a high-pressure, high-
temperature lab for sweet and sour exposures to metal/polymeric materials.
Aerojet Rocketdyne Awarded Defense Contract
Aerojet Rocketdyne, Sacramento, Calif., has been award-ed a contract by Wright-Patterson Air Force Base throughthe Defense Production Act Title III Office for large-scale ad-ditive manufacturing development and demonstration. The company and its subcontractors will design and de-velop larger scale parts to be converted from conventionalmanufacturing to additive manufacturing (3D printing). We have developed and successfully demonstrated addi-
tive-manufactured hardware over the last four years but themachines have been limited in size to 10-inch cubes, saidSteve Bouley, vice president of Space Launch Systems at
Aerojet Rocketdyne. These next-generation systems areabout six times larger, enabling more options for our rocketengine components. Also, the company will demonstrate three different alloyswith these larger additive manufacturing machines to in-clude nickel, copper, and aluminum alloys. Parts rangingfrom large ducts to heat exchangers are planned to bedemonstrated in full scale.
Manufacturing Skill Standards Council WinsNational Program Workforce Award
Under its Talented Workforce Initiative, the Great LakesManufacturing Council recently announced the Manufactur-ing Skill Standards Council was selected as the Best U.S. Na-tional Program for workforce development. An awards cere-mony took place during the annual Big M conference at theCobo Convention Center in Detroit, Mich. The council created this initiative to identify the mostimaginative and effective solutions for building the regionspool of manufacturing talent.
Recent Acquisitions
Sparton Corp., Schaumburg, Ill., announced its whollyowned subsidiary, Sparton eMT, LLC, has acquiredElectronic Manufacturing Technology, LLC, Irvine, Calif., a$25 million revenue business, in an all-cash transaction.
Linde LLC, Murray Hill, N.J., has signed a contract to sup-ply liquid oxygen, nitrogen, and argon to Conroe WeldingSupply, Inc., an independent distributor in Conroe, Tex.
Durable Mecco, Worcester, Mass., a manufacturer of indus-trial marking equipment, has acquired the steel stamp divi-sion of Stamp-Rite Supersine, Inc., Lansing, Mich.
BUSINESS BRIEFS
WELDING JOURNAL / OCTOBER 201428
WJ
At Elements new facility, situated on a 5.3-acre campus adjacent
to the Houston energy corridor, fracture mechanics and engineer-
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Arc Plasma ResearchGarners Interest
This letter is in reference to the paper pub-
lished in the Welding Research Supplement
titled Separation of Arc Plasma and Cur-
rent in Electrical Arc An Initial Study, by
S. J. Chen, F. Jiang, Y. S. Lu, and Y. M. Zhang
in the Welding JournalsJuly 2014 maga-
zine (pages 253-s to 261-s).
I enjoyed reading this interestingand well-written article. It remindedme of work that was published in theWelding Journal and Welding Handbookback in the 1960s. The Welding Handbook, Chapter 53,Plasma Welding, Fifth Edition, page53.3, Fig. 53.1, clearly shows a non-transferred arc with separated arcplasma. The Sixth Edition of the hand-
book, Chapter 54, plasma arc welding,Fig. 54.4, shows a redrawn version ofthat Fig. 53.1. The redrawn figure stillshows a separated arc plasma. In the Welding Handbook, SeventhEdition, Vol. 2, Chapter 9, Fig. 9.4, theoriginal Fig. 53.1 was once again re-drawn. This time it was incorrectly re-
drawn and has been incorrect eversince. It shows the plasma portion ofthe system originating from the face
of the constricting nozzle instead offrom the electrode as in the originalFig. 53.1. This error should be cor-rected in the next Welding Handbookedition. The 1966 Welding Journal, Vol. 45,No. 11, pages 899908, by E. F. Gor-man, G. M. Skinner, and D. M. Yenni,
Plasma Needle Arc for Very Low Cur-rent Work, shows a correctly drawnstylized version of the same Fig. 53.1.
An article reprint by Linde clearlyshows a nontransferred separatedplasma see Fig. 1. Perhaps the authors of this excellent2014 article will find my commentaryhelpful in their future investigations.
August F. Manz, AWS Fellow
LETTERS TO THE EDITOR
WELDING JOURNAL / OCTOBER 201430
Fig. 1 Schematic diagram showing major differences in gas tungsten arc, transferred
plasma arc, and nontransferred plasma arc processes.
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1. Which of the following American
landmarks, built in 1884, has an alu-minum pyramid cap on its top?A Lincoln MemorialB Washington MonumentC Jefferson MemorialD Benjamin Franklin Memorial
2. In what year was the filler metalAlloy 4043A registered with the Alu-minum Association?A There is no such aluminum fillermetal alloy.
B 1954C 1976D 1981
3. Which of the following alu-
minum alloys has been cooled froman elevated temperature shapingprocess (not cold worked after cool-ing) and naturally aged to a substan-tially stable condition?
A 6463-T1B 6063-T2C 6351-T4D 6063-T5E 6061-T6
4. In accordance with the require-
ments of AWS D1.2/D1.2M:2008,Structural Welding Code
Aluminum, what is the bending
diameter to be used for base Alloys7005 and 2219 when conducting aguided bend test?
A 6tB 8tC 10t + 18 in.D It is different for each alloy.
5. In accordance with the require-ments of AWS D1.2/D1.2M:2008,Structural Welding Code Aluminum,what is the minimum tensile strengthrequired when conducting a reducedsection tension test on Alclad 3003-H112 tube 12 in. thick?
A 11 ksiB 14 ksiC 15 ksiD 13 ksi
6. Which of the listed aluminumfiller metal classifications would bethe most appropriate to weld a 5052base metal that is going to be used ina service environment with a sus-tained elevated temperature of250F?
A ER5356B ER4043C ER5556D ER5183
7. What would be the most appro-priate aluminum filler metal to weld a6061-T6 base metal that 1) is going tobe clear coat anodized after welding,2) is required to be a good colormatch with the base metal after an-odizing, and 3) will be going into aservice environment with a sustainedelevated temperature of 270F?
A ER5356
B ER4043C ER6061D ER5554
8. What is the minimum ultimatetensile strength of 7075-T651 plate in12 in. thickness as specified in the Alu-minum AssociationsAluminum Stan-dards and Data 2013?
A 78 ksiB 82 ksiC 94 ksi
D 100 ksi
ALUMINUM Q&A
WELDING JOURNAL / OCTOBER 201432
Q: Last year, in my October column, there was a short quiz on aluminumwelding issues. It was very well received lots of people participated, manypositive comments came through, and prizes were won. So, I have put to-gether another quiz providing readers an opportunity to once more test theirknowledge of aluminum and aluminum welding technology. To enter, e-mail me at [email protected] by October 25 andlist the question numbers along with the letter of your answers. All respon-dents with the correct answers will be eligible for prizes. There is only onecorrect answer to each question. Out of the accurate entries received, 10 will be randomly selected to win asigned copy of the AWS publication, Welding Aluminum Questions and An-swers (2nd edition), along with their choice of a golf shirt (in small, medium,large, XL, 2XL, and 3XL) or a leather welding jacket (in small, medium, large,XL, 2XL, 3XL, 4XL, and 5XL) Fig. 1. In addition, to make the process easier if you win, provide your name,mailing address, clothing choice (golf shirt or leather welding jacket), and sizein your e-mail. The answers to these questions will be published in the December 2014Aluminum Q&A column along with the names of the winners. Best of luck!
BY TONY ANDERSON
Fig. 1 All 10 winners will receive a signed copy of Welding Aluminum Questions and
Answersplus their choice of a golf shirt or a leather welding jacket.
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9. What is the typical ultimate ten-sile strength of 7075-T651 plate at75F and 320F, respectively, as spec-ified in the Aluminum AssociationsAluminum Standards and Data 2013?
A 70 and 65 ksiB 73 and 60 ksiC 83 and 102 ksiD 75 and 55 ksi
10. In accordance with the require-ments of AWS D1.2/D1.2M:2008,Structural Welding Code Alu-
minum, temporary backing made ofcopper shall not be used ifA It is more than 1 in. wide.B The weld joint has a 132-in. open-ing or larger.C It is less than 99.97% purecopper.D The weld joint has a root opening
less than1
32 in.
11. In accordance with the require-ments of AWS D1.2/D1.2M:2008,Structural Welding Code Alu-
minum, the use of antispatter com-pound is prohibited unlessA It is hydrogen free.B It is applied more than 1 in. awayfrom the welded joint.C Approved by the engineer.D Specified by the welding
inspector.
12. Gas tungsten arc welding directcurrent electrode negative with purehelium shielding gas is seldom used toweld aluminum, but when it is used,welds would typically have which ofthe following characteristics?A Good cleaning actionB Deep and narrow penetration butno cleaning actionC Very low heat inputD Shallow and wide penetration forvery thin sheet welding.
TONY ANDERSON is director of aluminum
technology, ITW Welding North America. Heis a Fellow of the British Welding Institute
(TWI), a Registered Chartered Engineer withthe British Engineering Council, and holds
numerous positions on AWS technical com-mittees. He is chairman of the Aluminum As-
sociation Technical Advisory Committee for
Welding and author of the book Welding
Aluminum Questions and Answers currently
available from the AWS. Questions may be
sent to Mr. Anderson c/o Welding Journal,8669 NW 36th St., #130, Miami, FL 33166-
6672; [email protected].
WJ
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A: Most brazing shops will occasional-ly be given rush jobs by their good cus-tomers and they do the best they canto comply; however, no brazer wants torisk losing a good customer by deliver-ing a poor-quality product. Lets suppose your vacuum brazingfurnace has just completed a series ofcycles that has left it contaminated.You were preparing to take the furnace
out of service for the next day or twofor maintenance including hand clean-ing, vacuuming, a high-temperatureburn-out cycle, etc, then a customershows up with a hot job that must bedone right away.
The customers assembly consists ofsome components made from 316L
stainless steel and others from atitanium alloy. These base met-als should be brazed in a thor-oughly clean and leak-tight fur-nace. What to do? Should you attempt to brazethe assembly in the dirty furnace
and risk an unsatisfactory brazeor just tell the customer you can-not do the rush job that day? Ipropose you enclose the assem-bly inside of a protective boxbefore placing it into the dirtyfurnace to ensure it will brazewell. Boxing an assembly prior tothe brazing run is a simple tech-nique that more shops shoulduse. Heres how to do it. Prior tobrazing, place the parts inside of a foil
box that is easily constructed by handspecifically for those parts. The foil boxshields the parts so they effectivelybraze inside their own pristine mini-furnace chamber. The foil box is usual-ly used only once, for a particular as-sembly for one furnace run. In my brazing shops, we kept rolls
of titanium foil and stainless foil onhand just for this purpose. The titani-
um foil may be either pure titaniumor a titanium alloy both types workwell. Similarly, the stainless steel foilmay be made from any one of anumber of different alloys. A regulargrade stainless steel foil works well.Using a low-carbon L-grade foil is notnecessary.
RAZING Q&A
WELDING JOURNAL / OCTOBER 201434
BY DAN KAY
Q: What should we do when acustomer has a critical hot jobthat he wants brazed immediatelyand cannot wait for us to properlyclean the furnace and run the nec-essary leak checks? How can wemake a good braze when the fur-nace isnt ready?
PIPE WELDERS... PURGE PROBLEMS?INTERPURGE... IS YOUR SOLUTION!
QUICK & ACCURATEPIPE ALIGNMENT
PURGE MONITORS(OXYGEN TO 1PPM)
PURGE 2-3 MINUTES!DAMS FOR ALL SIZES
ASSORTED PURGEKITS AVAILABLE
PERFECT PURGING = HIGH QUALITY WELDS
WHY SETTLE FOR THIS?
316L Stainless w/ Argon Purge @ 250ppm Oxygen Level
WHEN YOU CAN HAVE THIS!
316L Stainless w/ Argon Purge @ 12ppm Oxygen Level
NOTE: 1% Oxygenin Atmosphere is 2,094.6 ppm!
Fig. 1 Making the base of the box to hold com-
ponents for brazing.
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When a customer gave us a verysensitive part that needed to be brazedright away, we did not delay brazingthat component until after the furnacewas cleaned. Instead, we placed the
component on some thin, clean alumi-na-ceramic sheet, which we thenplaced on top of some thin titanium orstainless steel foil. We then cut someshort slits in the foil to allow the foil tobe folded up to form a box around thecomponent taking care the compo-nent did not touch any of the foil. Fig-
ure 1 illustrates how this isdone.
Once two walls are fold-ed up, then the side wallscan be folded up into placeand the extra foil lengthfolded around the box toensure there are no openseams to the outside.
Everything is merely bentover, crimped, etc., usingpliers, metal shears, andother standard tools, sothat the box can be madequickly and easily by handright there in the shop.
The walls of the boxformed in this manner
should be tall enough so that the sidesof the box are higher than the top ofthe part to be brazed. Then, take an-other piece of the metal foil to make a
loosely fitting cover which is simplylaid on top of the box. Fold the edgesof the cover down so that there is ab-solutely no line-of-sight into the box.Figure 2 illustrates how this is done.Note: use thinner foils to make theseboxes, they are much easier to workwith. Keep the foils clean and stored
where they will stay clean and not oxi-dize. Always handle the foils with cleangloves and use clean tools to constructthe box and for placing the compo-nents inside it.
During the brazing cycle, the out-side of the box serves as a getter. Itcatches the outgas products in the larg-er furnace chamber atmosphere that
would normally condense onto or coatthe parts being brazed. But the foil boxcan quite effectively prevent those con-taminants from reaching the assemblyprotected inside. When the cycle isover and the box is removed from thefurnace, the outside of the box may ap-pear very dark and discolored. Howev-er, when the lid is carefully removed,the components inside the box shouldbe pristine clean and nicely brazed.
OCTOBER 2014 / WELDING JOURNAL 35
DAN KAY ([email protected]),
is an advisor to the C3 Committee on Brazingand Soldering. Kay has contributed to the 5th
edition of AWS Brazing Handbook. He has
more than 40 years of experience in the in-
dustry, and operates his own brazing training
and consulting business.
Post your questions for use in this column
on the Brazing Forum section of the BSMC
website www.brazingandsoldering.com.
WJ
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Fig. 2 Placing the cover onto the box to protect boxed
contents.
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Work Wear SportsReflective Trim
A line of flame-resistant (FR), en-hanced visibility uniforms features re-flective trim to improve worker safetyin many industries, including welding,manufacturing, petroleum refining,and electric or gas utility. The workwear assortment also protects workersfrom arc flash, flash fire, combustibledust, or molten metal while offeringgreater visibility in low-light condi-tions. The line consists of pants, shirts,coveralls, and jackets in UltraSoft andGlenGuard FR fabric options.
G&K Services, Inc.www.gkservices.com(800) 452-2737
Machine Cuts Pipes, FlatPlate Profiles
The Multi-Profile Cutting Machinecan be configured to cut many profileshapes. It offers three basic flexiblemachine configurations to cut pipes,box sections, or profiles from bar flatstock. In addition, the product can beprogrammed using the companysmanual data input and/or ProCADsoftware. The companys ProGRAMsoftware provides a direct link fromindependent workstations to the cut-
ting machine, which in turn providesbasic programming of end cuts tocomplete part design and program-ming of all necessary machine cuts.
HGG Profiling Equipmentwww.hgg-group.com(330) 461-6855
Arc Process EnablesMore Efficient Welding
Four arc variants for the TPS/iGMAW platform have been intro-duced. The characteristics for LSC
RODUCT & PRINT SPOTLIGHT
WELDING JOURNAL / OCTOBER 201436
P.O. BOX 218 STEVENSVILLE, MICHIGAN 49127PHONE: 269/465-5750 FAX: 269/465-6385
E-mail: [email protected]
Website: www.galgage.comVisa & Mastercard Accepted
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custom gages manufactured
request.
legged fillet
Measures
sizesplus
CAMBRIDGE
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Angle of
Excess
Depth
Depth
Fillet W
new, improved Auto Weld Size
gage youcan meet specification
forbutt andfillet type welds.
Redesigned gage is pocketsize,
easyto use and has thumb screw
adjustment replacing old, hard
to operate rivet. Automatically
shown convexity and concavity
sizes have been predetermined
in accordance with American
Welding Society D1.1
GAGE/CALCULA OR
CA . NO. 9
Replaces all other sets of gages
fillet welds
15 differentweld
plus throat thickeness
CAMBRIDGETYPE GAG
4
of Preparation
Excess Weld Metal
of Undercut
of Pitting
Weld Throat Size
HI-LO WELDING
CAT. NO. 1
Forinternal misalign in
.. .
Accurate
GAGES
in pipe
Fillet W
Fillet W
Outside
.W.T. ..S.TYPE GAGE
Measures .010 inch deep
undercut
CA . NO. 7
TOLERANCES +.0005 inches
American Welding Society
Structural Welding Code D1.1,
Undercutshall be no more than
.010 inches (.25mm) deep when
the weld is transverse to the
primary stressin thepart that is
undercut.
used to measure fillet or groove
welds in skewedmembers at 90O
Handy compilation ofmath -
ematical relationships between leg
length, throats, skew anglesand
inspection dimensions.
Weld Throat Size
Weld Length
Outside Misalignment
.P.O. BOX 218 STEVENSVILLE, MICHIGANPHONE: 269/465-5750 FAX: 269/465-6385
E-mail: [email protected]
Website: www.galgage.comVisa & Mastercard
Forinternal misalign in
welds in addition to6
cal, required measurements.
Patent No. 3,869,801
Accepted
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CA NO. 8
ALL EDGES DEBURRED
ALL LETTERS AND CHARACTERS
LASER ETCHED
HANDY POCKET CASE
The G.A.L. Fillet Weld gage allows
fast, accurate measurement of 11
fillet weld sizes:1/8, 3/16, 1/4, 5/16,
3/8,7/16, 1/2,5/8,3/4, 7/8,and 1
inch. Includes metric equivalents.
Determine eitherconcave or convex
weld sizes.
in pipe
other cr it -
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Accepted
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continued on page 39
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Root ensuring good root formationand a high deposition rate with re-duced energy input plus LSC Uni-versal suited to welding fillet welds,corner welds, lap joints, filling and
capping runs, and brazing supple-ment a new algorithm as well as fea-ture reduced spatter with greater arcstability. The penetration stabilizerkeeps the fusion penetration constantduring electrode extension fluctua-tions with the help of the wire feedspeed control. Arc length and dynamiccorrections have also been enhanced.To enable using longer hosepacks, ad-ditional hardware reduces the influ-ence of increased inductance in the
welding circuit. Pictured is the crosssection of a joint root welded with LSCRoot with the penetration stabilizerdisabled.
Fronius International GmbHwww.fronius.com(877) 376-6487
Gun Offers PreciseWire Feeding
The Frontpull 7 welding gun, whichfeatures a close-to-process drive unitlocated at the gun neck, feeds weldingwires of steel, aluminum, or other al-loy material with a diameter from 0.8to 1.6 mm. The four-roll drive gun,with an output of 90 W, keeps a tool
center point with an accuracy of 0.2mm. Changing is done via the stan-dard bayonet system.
SKS North Americawww.sks-welding.com(248) 519-5079
Redesigned Site OffersSafety Training Courses
The company has launched a newwebsite designed to make it easy tofind hands-on industrial skills trainingcourses and resources. The site pro-vides training courses and informationto assist industry professionals in de-veloping safe and skilled industrialemployees. The new web design alsofeatures the latest news and white pa-pers on industry trends, videos withtips and examples of training that stu-
dents receive, an advanced search thatallows users to find training courses bylocation, type, and date, plus socialnetworks and feeds.
NTT Trainingwww.nttinc.com(800) 922-2820
MORE THAN WELDING.METAL JOINING, SAFETY & EFFICIENCY
www.binzel-abicor.com
T E C H N O L O G Y F O R T H E W E L D E R S W O R L D .
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continued from page 36
PRODUCT & PRINTSPOTLIGHT
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Pipe Purging Systems PreventOverinflation
HotPurgeTM pipe purging systemsare for use at up to 572F for 24 h.Based on the companys QuickPurgeII design, they are adapted foruse at high temperatures. This systemis available for pipe internal diameters
from 4 to 96 in. Each is made to sizeand has a tolerance of 12 in. Featuresinclude a central large collar thatmakes it easier to reach the lower oxy-
gen levels faster; four pull handles at-tached to each dam secured withKevlar thread; and PurgeGate, a
patented invention that allows usersto connect the system to any source ofcompressed inert gas and turn it on towhatever flow/pressure they want, toprevent overinflation.
Huntingdon Fusion Techniques
www.huntingdonfusion.com
44 (0) 1554 836 836
Free Plans Available forWelding Projects
The company is now offering freeDIY welding project ideas and plans onits website. The plans, available in in-stant downloads, come with detailedinstructions for many useful and funprojects. Many offer instructions onwhere to purchase supplies, what toolsare necessary, and how to modify theprojects plans to fit individual needs.
Examples of free DIY plans includesoap-box go kart, garage workbenchtable, 90-deg jig, coffee table, trailerdolly, welding table, and campfire grillstand.
DIY Welding Plans
www.diyweldingplans.com
(888) 964-0813
GTAW Torch Includes WaterCooling Jacket
Micro Torch, the companys small-est GTAW torch, includes three differ-ent angled heads, making it useful for
tightly spaced applications. The torchfeatures a clear Pyrex nozzle, lowprofile torch body, and water cooling
See us at FABTECH booth C1016
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jacket that lets the torch reach itshighest amperage possible, even with a332-in. tungsten electrode. The torch isavailable in 70-A gas-cooled or 140-Awater-cooled models, each with 45-,90-, and 180-deg heads. A kit is includ-ed with each torch that contains thethree interchangeable heads, threepresharpened tungstens and a tung-sten stick-out gauge, two Pyrex noz-zles, and one aluminum nozzle.
CK Worldwide, Inc.www.ckworldwide.com(800) 426-0877
App Allows Sharing of WeldingCalculations
The Welding Calculatorapp includesheat input, energy density, and powerratio calculation; IPM and RPM conver-sions; pulse conversions; averages, vol-
umes, fractions, and deposition rates.The app, available for Android and iOSdevices, allows users to save or sharecalculations using the mobile operatingsystem sharing capabilities. English ormetric units can be selected.
Arc Machines, Inc.www.arcmachines.com(818) 896-9556
Cutting Table Removes
Slag Automatically
The Klean Sweep, a self-cleaningcutting table that removes slag and
scrap automatically during cutting op-erations, eliminating production inter-ruptions and reducing labor costs, canbe used with various laser, oxyfuel,and plasma cutting machines. Avail-able with cutting widths ranging from5 to 24 ft, the tables exhaust channelducts for fume extraction can be inter-nal or external depending on theapplication.
Koike Aronson, Inc./Ransomewww.koike.com(800) 252-5232
Manual Band Saw Features2-hp Motor
The companys Model H275 manu-al band saw cuts tubes, pipes, lightstructural shapes, and small solids upto 10 in. at 90 deg. The saw has a vari-able-speed blade from 65 to 320ft/min and can accurately miter up to
60 deg to the right. Operations includemanual sawframe raise, manual vise,hydraulic/solenoid-powered downfeed,and status indicators for power on,
OCTOBER 2014 / WELDING JOURNAL 41
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correct blade tension, broken blade,and bandwheel cover open. The toolfeatures a 2-hp totally enclosed, fan-
cooled motor, 24-V controls, bimetalblade with shutoff for broken blade orlow tension, blade-drive load monitor,and full coolant system.
Kalamazoo Machine Toolwww.kmtsaw.com(269) 321-8860
Courseware Presents CommonArc Welding Processes
The companys new release of Com-mon Arc Welding Processes, a trainingtool for industry and educational facil-ities that want to offer an introductionto welding without hands-on trainingapplications, includes two DVDs and
an instructor guide. Topics include acourse overview, safety topics, and anintroduction to shielded metal arc, gasmetal arc, flux cored arc, and gas tung-sten arc welding. It also provides infor-mation about consumables for the var-ious arc welding processes.
Hobart Institute of Welding Technologywww.welding.org(800) 332-9448
Carrying Strap Helps Welders
Safely Move Cylinders
The JugLugger carrying straphelps welders carry propane cylindersand torches on the job site and up lad-ders. The strap lets welders free their