aws_wj_201401

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

January 2014

CA

RB

ON

ST

EE

LL

OW

AL

LO

YST

AIN

LE

SS S

TE

EL

NIC

KE

L A

LL

OY

SH

AR

DSU

RFA

CIN

G

T H E S T A N D A R D O F E X C E L L E N C E I N :

Hardsurfacing Tubular Electrodes

Select-Arc, Inc. delivers a broad

range of hardsurfacing electrode

products designed to handle

a wide variety of challenging

welding applications. From rock

crushing hammers and rolls to

wear plates, earthmoving bucket

lips to fan blades, mine car wheels

to dredge components and

many more Select-Arc provides

the right hardsurfacing wire to

meet your specic requirements.

Select-Arc hardsurfacing

electrodes:

U Reduce operations costs by reclaiming worn components

U Extend component life by utilizing more wear-resistant

alloys

U Decrease machinery downtime by increasing component life

And, of course, Select-Arc

hardsurfacing electrodes are

backed by the nest in value-

added support and our

renowned customer service.

For more information on

Select-Arcs entire line of superior

hardsurfacing electrodes, call us

at 1-800-341-5215 or visit our

website at www.select-arc.com.

Select-Arc, Inc. delivers a br

range of hardsurfacing electr

products designed to handle


welding applications. Fr

AR

BO

N S

TE

EL

c, Inc. delivers a broad

dsurfacing electrode

oducts designed to handle


welding applications. Fr ock

welding applications. Fr

crushing hammers and r



to dredge components and

many more Select-Ar

the right hardsurfacing wir

meet your specic r

CA

LL

OY

AR

BO

N S

TE

EL

welding applications. From rock

crushing hammers and rolls to



edge components and

e Select-Arc provides

dsurfacing wire to

meet your specic requirements.

Select-Arc hardsurfacing

electrodes:

U Reduce operations costs by reclaiming wor

U Extend component life by utilizing mor

alloys

U Decrease machiner

LO

W

NL

ESS

AL

LO

ST

EE

L

dsurfacing

Reduce operations costs by

eclaiming worn components

Extend component life by

utilizing more wear-resistant

ease machinery downtime

Decrease machiner

by increasing component life

And, of course, Select-Ar

hardsurfacing electr



renowned customer ser


TA

ST

AI

AL

LO

YN

LE

SS

S

ease machinery downtime

easing component life

And, of course, Select-Arc

dsurfacing electrodes are



enowned customer service.

e information on


Select-Arcs entir

hardsurfacing electr

at 1-800-341-5215

website at www

NIC

KE

L

e information on

s entire line of superior

dsurfacing electrodes, call us

1-800-341-5215 or visit our

w.w.select-arc.com.

For Info, go to www.aws.org/ad-index

Call us at 800-782-2110 for a free quote on yournext Girder Building job.

www.greinerindustries.com

Building heavy and complex girders is a specialtyat Greiner. Were able to build girders:

Up to 12 feet deep

Up to 150 feet long

Up to 140 tons

Our Girder Welder Gantry utilizes a 5/32-inch diameter single or tandem submerged arc welding process. This signicantlyreduces our labor and your cost.

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

(AISC Certied for Major SteelBridge Fabrication)

Greiners job shop services includesgirder building. Really big girders.


3WELDING JOURNAL

CONTENTS38 Spot Welding Different Sheet Metal Grades and Gauges

Ways to improve the cross-tension strength of spot welds inhigh-strength steel are examinedE. Biro et al.

44 FABTECH 2013Experience the highlights of this largest-ever exhibitionA. Cullison et al.

52 What Is the Best Method for Preheating 4130?Three different methods of preheating are compared andevaluatedJ. Walker et al.

58 In-Line Inspection of Resistance Spot Welds for Sheet MetalAssemblyA real-time ultrasonic monitoring system is used to trackexpulsion events, electrode life, and quality problemsR. Gr. Maev et al.

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 ..............8News of the Industry ............10Business Briefs ..................14Stainless Q&A ....................20RWMA Q&A ......................22Product & Print Spotlight ......28Coming Events....................64Certification Schedule ..........68Conferences ......................70Welding Workbook ..............72Society News ....................75

Tech Topics ......................77Guide to AWS Services ........95

Personnel ........................96Classifieds ......................102Advertiser Index ................104

1-s Visualization of Gas Flows in Welding Arcs by theSchlieren Measuring TechniqueOptical analysis of gas flow is simplified with the SchlierenmethodE. Siewert et al.

6-s Wettability by Liquid Metals, Metalization, and Brazingof Barium Titanate CeramicsA detailed investigation is conducted on the wettability, adhesion,and interaction of perovskite-type ceramicsT. V. Sydorenko et al.

15-s Characterization of High-Strength Weld Metal Containing Mg-Bearing InclusionsA novel flux cored electrode formulation produces a tensilestrength of 825 MPa without the addition of titanium or theformation of acicular ferriteA. P. Gerlich et al.

23-s Weldability of Niobium-Containing High-Strength Steelfor PipelinesThe investigation of high-strength Nb-containing steels reveals anabsence of HAZ cold crackingI. I. Frantov et al.

Features

Welding Research Supplement

52

44

38

January 2014 Volume 93 Number 1 AWS website www.aws.org

EDITORIAL

The focus of my presidency is continuous improvement through innovation.Innovation comes in many forms and can be experienced through inventive, revolution-ary, trial-and-error, borrowed, and even subtle changes that are difficult to notice butresult in continuous improvement.

Look to the birth of the American aircraft industry for a good example of trial-and-error innovation. During World War I, President Woodrow Wilson promised to produce8000 American fighter planes, but there wasnt a single American-made engine that hadenough power.

This challenge was on par with the Manhattan Project and the race to the Moon. Itwould be called the Liberty aircraft engine, and most of the young Detroit auto facto-ries cooperated to build it. In doing so, their innovations would establish Americas placeas a world leader in manufacturing.

Many welding puzzles had to be solved for the Liberty aircraft engine to be produced inlarge numbers. The joining of intake and exhaust elbow fittings to piston cylinders was animmense challenge. Early welding engineers struggled with dangerous backfiring from thewelding torches through the gas lines. The oxyfuel process was unsuccessful and a processof manual arc welding, rigged to a servo-controlled motor to feed the electrode also provedunsuccessful. Finally, they tried the resistance welding process, building a complex fixturefor flash welding the elbows to the cylinder. The result was a resounding success.

By wars end, 18 months later, more than 20,000 Liberty engines were produced athalf the cost of European aircraft engines. American ingenuity and the future of weldingwere both validated, and the aircraft helped bring the war to a quick end.

At my company, Wilson Industries, we borrowed technology that led to an inventiveinnovation: the see-through welding curtain.

In 1968, a welder working behind a canvas welding screen had a heart attack andremained there, unnoticed, for hours. This tragedy led to a movement to bring visibilityinto the welding booth.

At the time we were developing the Wilson Spectra curtain, NASA was developingnew chemical coatings used to filter light for satellite camera lenses, based on their stud-ies of the sharp eyes of eagles. A major breakthrough was achieved by incorporating theNASA lens coating technology into sheet vinyl, allowing us to develop the Spectra cur-tain, which has been honored as a NASA spin-off product.

Today, every part of our lives is influenced by welding, and AWS influences every partof welding. AWS is currently developing online training, mobile apps, a skills certifica-tion system featuring stackable credentials and digital badges, recognition of a MasterWelder status, and an extensive video library.

AWS has opened the door to lifelong professional development of all welding per-sonnel via American Welding Online (AWO). AWO focuses on the science, economics,and higher knowledge skills from which welders and others can benefit. We are on theverge of creating the most empowered welding workforce in history through our devo-tion to innovation.

Our Society is a partner in the Manufacturing Institutes Skill Certification System.Soon, AWS will document, archive, and validate the career achievements of welding pro-fessionals on all levels with secure online transcripts, a national certification registry, newID cards, and a certified welder passport.

We are on a mission to approve community colleges nationwide as Accredited TestFacilities. This accreditation will enable schools to train and certify welders for the needsof their local industries, with transferable, stackable, nationally recognized AWS

credentials.The American Welding Society is devoted to

advancing the science, technology, and people of weld-ing, by providing for the lifelong professional develop-ment of welders, educators, welding engineers, andinspectors around the world. In doing so, AWS aims toimprove everyones safety, productivity, and careersatisfaction, by dedicating ourselves to continuousimprovement through innovation.

JANUARY 20144

OfficersPresident Dean R. Wilson

Welldean 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

DirectorsU. Aschemeier (Dist. 7), Miami Diver

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

D. J. Burgess (Dist. 8), University of Tennessee

N. C. Cole (Past President), NCC Engineering

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

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

P. H. Gorman (Dist. 20), Sandia National Laboratories

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

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

J. Jones (At Large), The Harris Products Group

J. Knapp (Dist. 17), Gas and Supply

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

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

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

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

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

W. R. Polanin (At Large), Illinois Central College

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

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

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

R. W. Roth (At Large), RoMan Manufacturing, Inc.

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

K. 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), Underwriters Laboratories, Inc.

R. P. Wilcox (Dist. 11), Ford Motor Co.

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

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

D. Wright (Dist. 16), Wright Welding Technologies

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

Improving through Innovation

Dean R. WilsonAWS President

PRESS TIMENEWS

Praxair to Fund Welding Scholarships throughAWS Program and SkillsUSA Competition

Praxair, Inc., Danbury, Conn., a leading industrial gases company, recently an-nounced the companys global giving program will fund more than $200,000 in schol-arships over the next five years for the American Welding Society (AWS) and Skill-sUSA. They will support education and hands-on training for student welders in theUnited States.

An applicant must be a minimum of 18 years old, at least a high school senior whowill be applying (or has applied) to a certificate welding program or to a college/uni-versity for a two- or four-year degree focused on welding. Information on additionalqualifications is available at www.aws.org/foundation.

Twenty-six awards will be made to students who reside/attend school in the areasin which the following AWS Sections are located: Chicago, Ill. (Section 002); Cleve-land, Ohio (Section 006); Dallas, Tex. (North Texas Section 053); Detroit, Mich. (Sec-tion 011); Fox Valley, Wis. (Section 074); Houston, Tex. (Section 022); Kansas City,Mo. (Section 016); Los Angeles, Calif. (Section 008); North Dakota (Northern PlainsSection 117); Portland, Ore. (Section 052); Salt Lake City, Utah (Utah Section 059);Tulsa, Okla. (Section 034); and North Carolina (Charlotte #140 and Triangle #151).

BMT to Support Welding Research Project for Shipbuilding

BMT Fleet Technology Ltd.s latest research project with the National Shipbuild-ing Research Program will evaluate recent advancements in Integrated Cold Elec-trode (ICE) welding technology. Jointly funded by industry and the U.S. Navy throughthe program, it will look at how this technology can improve productivity rates andreduce construction costs of both commercial and naval vessels.

As project lead, BMT will work with Huntington-Ingalls Industries; Newport NewsShipbuilding; Marinette Marine Corp.; ESAB; American Bureau of Shipping; NavalSurface Warfare Centre Carderock Division; and Defence R&D Canada.

Our main objectives for this project are to assess ICEs ability to enhance thewelding production rates, decrease distortion and costly rework, improve the proper-ties of welds in high-strength steels and therefore reduce costs, whilst increasing theintegrity of the ships structure, said Darren Begg, project manager at BMT FleetTechnology.

Northwest Florida State College Starts Welding ProgramNorthwest Florida State College, Niceville, Fla., has launched a new vocational

certificate program in welding technologies. It is funded by a federal Department ofLabor grant to meet the demand for high-skill, high-wage jobs in Northwest Florida.

Welding classes started in September. The program runs 12 months, divided intothree semesters, and consists of six courses covering shielded metal arc, gas metalarc, flux cored arc, and gas tungsten arc welding on plate/pipe. Welding instructorScottie Smith, an AWS Certified Welding Inspector and Certified Welding Educator,stated the program follows the National Center for Construction Education and Research curriculum.

Currently, the colleges welding lab is 2000 sq ft and features 15 welding boothscontaining Miller Electric multiprocess power sources and wire feeders, but the col-lege has plans to double the welding labs size. The program will receive a mobilewelding lab this month to facilitate industry training for local businesses as well.

Koike Aronson, Miller Electric Enter Strategic AgreementKoike Aronson, Inc./Ransome, Arcade, N.Y., and Miller Electric Manufacturing

Co., Appleton, Wis., have entered into a strategic partnership agreement. Koike willact as a distributor of certain Miller welding products throughout North and SouthAmerica, including Mexico and Central America. Also, Miller will act as a distributorof the Koike Aronson welding positioning equipment and portable welding and cut-ting equipment in the same areas. The Miller products covered by the agreement areequipment used in submerged arc and electroslag, automated gas metal arc, and au-tomated flux cored arc welding. The companies distributorships are nonexclusive.

JANUARY 20146MEMBER

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 2014 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.

INTERNATIONALUPDATE

Lincoln Electric Opens Automation Facility in Brazil

Lincoln Electric Co. recently opened its new Automation Cen-ter of Excellence in Brazil, a 5000-sq-m facility that includesdemonstration, integration, training, and office space. The newlybuilt facility, located in the city of Indaiatuba, features a traininglab with six robot systems, a station for orbital welding processdevelopment and system instruction, and eight additional demon-stration systems for robotic and mechanized applications. Twoclassrooms can accommodate up to 40 students.

Lincoln held a grand opening event, where a welcome was ex-tended by Indaiatuba Mayor Reinaldo Nogueira, who stressedthe importance of creating an environment for business to growand in which their employees could feel comfortable making theirhome. George Blankenship, president of Lincoln Electrics NorthAmerican operations, delivered the keynote presentation. Hesaid, Our responsibility to our customer must be more than justa provider of product. Their expectations of us are greater todaybecause they have escalated demands from their customer. Whenwe can improve their welding and fabrication procees, we be-come a partner rather than a vendor.

Leonardo Sabedot, business manager for the ASG-Brazilgroup, closed out the presentation. We are excited by the op-portunity that this facility represents, and look forward to forg-ing strong partnerships with the many customers in the region,he said.

Lincoln Electric has grown its automation offerings over thelast few years to include preengineered robotic systems, CNCplasma cutting equipment, fixturing and tooling, engineered linebuilds, robotic integration, laser systems, weld fume control, andfire prevention.

Stork Technical Invests in New Daughter Craft

Stork Technical Services, a global provider of managementservices for the oil and gas, chemical, and power sectors, recentlyannounced an investment of more than $3.2 million in its newdaughter craft, The Edradour. The craft, which will provide addi-tional operational support to meet the expanding needs of Storksdiving operations, has additional lifting capability for four-pointlifting, providing vessel crane launch and recovery capabilities,and increased generator capacity.

The Edradour complements the companys existing fleet, whichincludes daughter craft, The Aberlour, a mother vessel, The SIEMStork, and three dive intervention craft. The vessel has the samedesign specification as The Aberlour, which will allow both to beinterchangeable with the existing twin davit system.

We are very pleased to welcome The Edradour to our fleet.The shared design specification allows compatibility with our ex-isting launch and recovery system and will bring familiarizationto all our crews, resulting in a greater safety recovery and effi-ciency in our diving operations, said Roddy James, senior vicepresident of Stork Technical Subsea.

Kemppi and ABB Announce Robotic Welding Systems Collaboration

Kemppi Oy, a manufacturer of industrial arc welding equip-ment, and ABB Robotics, a supplier of industrial robots and mod-ular manufacturing systems, have established a collaboration todevelop fully equipped robotic welding packages. ABB indicatedthe technologically innovative welding packages would be de-signed as modular, cost-effective projects for companies to eas-ily install or upgrade into a robotic system. The joint businesscovers Europe, Asia, Africa, and South America.

Kemppi equipment will be featured at all certified ABB Ro-botics welding lab locations, where customers will be able to con-duct robotic welding trials on the latest equipment.

Pema to Supply Two Robotic ProfileProcessing Lines

Pemamek, a manufacturer of automated welding and produc-tion systems, has received another contract to supplement

Through an agreement between the two companies, Kemppi Oywelding equipment will be paired with ABB robots such as in thisFlexArc robotic welding cell.

JANUARY 20148

The Edradour, which represents a more than $3.2 million invest-ment, will provide additional operational support of Storks divingoperations. continued on page 100

NEWS OF THEINDUSTRY

GE Researchers Experiment with 3DPainting to Build Up and Repair Parts

GE researchers recently announced they are using a processcalled cold spray where metal powders are sprayed at high ve-locities to build a part or add material to repair an existing part.

Also known as 3D painting, cold spray demonstrates a blendof materials, process, and product function that can in the im-mediate future transform repair processes for industrial andaircraft components such as rotors, blades, shafts, propellers, andgear boxes. Future benefits include extended product lifespan andreduced manufacturing time along with material costs.

To view a demonstration, visit the following link:www.youtube.com/watch?v=NXGOZ5ns3Zo&feature=youtu.be.

Northwest Pipe Co.s Tubular ProductsGroup Earns Largest Project in Its History

Northwest Pipe Co., Vancouver, Wash., will provide about 400miles of 1234-in. line pipe for the Double H Pipeline project totransport crude oil from Dore, N.Dak., to Guernsey, Wyo.

The ability for Northwest Pipe Co. to participate on projectslike Double H is the result of $35 million of investments that havebeen made in our Atchison [Kansas] facility over the last severalyears. These investments have allowed us to continue to expandour product offering both in wall thickness and strength level on line pipe up to 16 in. in diameter, said Scott Montross, company CEO.

Apple Secures Patent for New FSW MethodThe U.S. Patent and Trademark Office has published a series

of 41 newly granted patents for Apple, Inc., Cupertino, Calif. Included is an invention relating to friction stir welding (FSW).

U.S. Patent 8,556,156 dynamic adjustment of FSW processparameters based on weld temperature lists the inventor asShravan Bharadwaj, San Jose, Calif., with the assignee as Apple,Inc. The abstract states that a method for FSW is provided, andit may include beginning an operation by directing a rotatingFSW tool along a joint between two parts; a temperature of theresulting weld may be measured; a controller may adjust processparameters associated with this process to decrease a differencebetween weld desired and measured temperatures; desired tem-perature may correspond to a temperature at which parts areplasticized; and process parameters may include rotational speedof the FSW tool, feed rate, axial force along the FSW tool length,and tilt angle of the FSW tool.

Sheet Metal Work Gets Efficiency BoostThrough New Technology

After receiving feedback from members, the InternationalTraining Institute (ITI), Fairfax, Va., put a new web-based

Greater Waco Advanced Manufacturing Academy Awarded $2.2 Million GrantThe Waco Independent School District, Waco, Tex., has been awarded a $2.2

million grant from the U.S. Department of Education to further enhance theGreater Waco Advanced Manufacturing Academy. The school opened its doorsin August and is now teaching welding skills to students from Waco and the sur-rounding area.

The grant is part of the federal governments $89.8 million in Magnet SchoolAssistance Program grants featuring a goal to promote courses within magnetschools that will strengthen knowledge of academic subjects and attainment oftangible vocational skills.

Our vision for the Greater Waco Advanced Manufacturing Academy is to pre-pare Waco area students for productive employment, success in postsecondaryeducation, or both, said Waco Independent School District Superintendent Dr.Bonny Cain. Right now, we know that many of our local manufacturing busi-nesses need welders, so were trying to meet that demand.

The school district plans to use the grant awarded to the academy for purchas-ing additional equipment and consumables, provide professional developmentstaff and students, plus expand the schools curriculum.

JANUARY 201410

Welding is taught at the Greater Waco AdvancedManufacturing Academy, and this substantialgrant will be used in many ways, including topurchase extra equipment and consumables.

GE researchers are developing new ways to repair and build upparts using a process called cold spray. Here, GE Materials Engi-neer Leo Ajdelsztajn prepares a test in one of the companys spraybooths.

11WELDING JOURNAL

e-reader into development. With the launch of this method ofviewing texts and class assignments, apprentices and journey per-sons in courses can see their books from any device with an In-ternet browser. The option is also useful for individuals on thego or those who dont have a home computer or an iPad.

On the Windows-based e-reader, students can print pagesfrom texts; with the iPad application, they can store books on thedevice from the application; on the web-based e-reader, savingand printing functionality is limited to specific versions; and amobile version of the web-based e-reader is available as well.

According to David Collins, software development managerfor ITI, the general look and feel of the website will allow foreasier navigation. About a year ago, we started traveling aroundthe county taking original photos to update nearly all the im-

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


The International Training Institute has launched a web-based e-reader and new website (shown above) at www.sheetmetal-iti.org.

JANUARY 201412

agery on the site, so the members will be able to really see them-selves in the new design, Collins added.

ASM International Celebrates 100 Years

ASM International, Materials Park, Ohio, commemorated its100th anniversary with a gala on Oct. 27 in Montreal, Quebec,Canada. Nearly 400 guests, including members, past presidents,dignitaries, and partners from around the world, came together.

For more than 100 years, in large part because of volunteer

commitment and involvement, ASM has remained relevant andfocused in materials science. The gala was a wonderful way toexpress our gratitude for a century of greatness, said ThomPassek, ASM managing director.

Founded in 1913, ASM began as the Steel Treaters Club inDetroit, Mich., with fewer than 20 members. Today, it has morethan 30,000 members and 80 worldwide chapters.

Along with historical tributes of the organizations past and alook to the future, the event featured a keynote speech by Dr.Peter Diamandis, chair and CEO of the X Prize Foundation.

Industry Notes The Bhler Welding Group, Vienna, will become an integrated

part of the voestalpine Group, a steel-based technology andcapital goods group with about 500 group companies and lo-cations in more than 50 countries and on five continents. Itsname now also changes to voestalpine Bhler Welding.

Miller Electric Mfg. Co., Appleton, Wis., has consolidated thegas tungsten arc torch and accessory lines from Weldcraft underits brand. The only change will be the addition of the Millername on products, labels, and packaging. Torch bodies havealso transitioned from red to black (excluding Redhead series).

A $95,000 grant from the U.S. Department of Energy will allowAiken Technical College, Graniteville, S.C., to purchase an or-bital welding machine and Bevelmaster beveling machine foruse in both advanced manufacturing and nuclear training.

One Bad Weld Could Cost You Million$

Fol low us on Facebook, Twi t ter & YouTube

Our Customers Receive these Benets at NO Additional Cost:

Recognized as Construction Industrys Highest Training Requirements

Ironworker Qualied Welding Certications meet AWS D1.1 Structural Code & AWS D1.5 Bridge Code Standards

Complete Welder Portability

110 Classroom/Hands-on Hours Minimum

Performance Veried by AWS Certied Welding Inspectors

State-of-the-Art Training Materials

Easy Online Verication

Network of over 150 Training Centers in the USA & Canada

Certied by the U.S. Department of Labor

w w w . i r o n w o r k e r s . o r g | 8 0 0 . 5 4 5 . 4 9 2 1 | w w w . i m p a c t - n e t . o r g

Over 3,000 Contractors & Over 100,000 Ironworkers

Can You Afford NOT to Hire Us?


Pictured at the gala for ASM Internationals 100th anniversary,from left, is ASM President (20132014) Ravi Ravindran and theevenings emcee, Dave Kelly, a Canadian radio/TV personality.

continued on page 100

BUSINESSBRIEFS

Recent Acquisitions

At FABTECH 2013, Lincoln Electric Holdings, Inc., Cleve-land, Ohio, announced the company acquired an ownership in-terest in Burlington Automation Corp., Hamilton, Ontario,Canada, a designer and manufacturer of 3D robotic plasma cut-ting systems. Rob Tyler serves as its president. In addition, thecompany has entered into a definitive agreement to acquire Robo-lution GmbH, based outside of Frankfurt, Germany, a Europeanprovider of robotic arc welding systems. Wolfgang Koenig is itsmanaging director.

Victor Technologies, St. Louis, Mo., has acquired Gas-ArcGroup Ltd., a privately held manufacturer of gas control equip-ment in the United Kingdom, for approximately $40 million incash, subject to post-closing adjustments. Its portfolio includesbranded gas control products that meet specialty gas applicationrequirements as well as cutting and welding equipment for theindustrial, laboratory, and medical gas control markets. In addi-tion, Gas-Arc will continue to operate under its own name.

Reliance Steel & Aluminum Co., Los Angeles, Calif., recentlyannounced that, through its wholly owned subsidiary AmericanMetals Corp., the company has acquired all of the capital stockof Haskins Steel Co., Inc., Spokane, Wash. Founded in 1955,Haskins processes and distributes carbon steel and aluminumproducts of various shapes/sizes. In-house processing capabili-ties include shearing, sawing, burning, and forming. Haskins willoperate as a wholly owned subsidiary of American Metals Corp.,and current management will also remain in place.

Antelope Oil Tool & Manufacturing Co., LLC, Mineral Wells,Tex., has acquired WearSox, L.P., Houston, Tex. Founded in 2004,WearSox is a developer of thermal spray-on casing centralizers

and stop collars, as well as stabilizers for the deep water/offshoresegment of the oil and gas industry. WearSoxs patent-protectedprocess allows for shapes to be built directly onto casing withoutaffecting the casings metallurgical properties. George Ribble,Antelopes CEO, will oversee the combined business.

Airgas, Inc., Radnor, Pa., has completed acquiring the assetsand operations of The Encompass Gas Group, Rockford, Ill.,one of the largest privately owned suppliers of industrial, med-ical, and specialty gases/related hardgoods in the United States,with eleven locations and more than 130 associates in Illinois,Wisconsin, and Iowa.

Automation International, Inc., Danville, Ill., has acquiredHess Industries Rim and Wheel Intellectual Property. Hess In-dustries was located in Niles, Mich., and ceased operations inJune 2012. The purchase aligns with the companys role as aprovider in the design and manufacture of automated wheel pro-duction equipment, including welding, metal forming, assembly,and spinning.

Keen Compressed Gas Co., Wilmington, Del., has acquiredthe assets of Urie & Blanton Welding Supply Co., including allassets associated with the industrial gas and welding supply busi-ness. Urie covered New Castle County, Del.; southeastern Penn-sylvania; the Philadelphia area; some of South Jersey; and hadtwo retail locations that Keen will take over.

Mistras Group, Inc., Princeton Junction, N.J., has acquiredCarmagen Engineering, Inc., a professional engineering consult-ing and technical training services provider serving the hydrocar-bon processing and other energy-related industries. Since 1986,Carmagen has provided services focused on the oil and gas in-dustry that includes plant operations support; turnaround plan-ning/execution programs; and technical training.

JANUARY 201414

Ford Adds Jobs, Invests Millions in Buffalo Stamping Plant

Ford Motor Co. will invest $150 million and add approxi-mately 350 new jobs at its Buffalo Stamping Plant in NewYork.

The venture is for more than 25 new subassemblies, in-cluding hoods, doors, and fenders; more than 500 new diesand a new blanking line; as well as equipment upgrades andrefurbishing to support future product programs. The plantwill also add a third shift to its press room.

These additional jobs are the direct result of the dedi-cated effort our United Automobile Workers (UAW) mem-bers display every day at facilities all across the country, andserve as another reminder of the resilience of Americanworkers and our nations manufacturing sector, said JimmySettles, UAW vice president and director of the NationalFord Department.

Ford Motor Co. will invest $150 million and add approximately 350new jobs at its Buffalo Stamping Plant. (Photo courtesy of Ford.)

Friends and Colleagues:

I want to encourage you to submit nomination packages for those individuals whom you feelhave a history of accomplishments and contributions to our profession consistent with the standardsset by the existing Fellows. In particular, I would make a special request that you look to the mostsenior members of your Section or District in considering members for nomination. In many cases,the colleagues and peers of these individuals who are the most familiar with their contributions, andwho would normally nominate the candidate, are no longer with us. I want to be sure that we takethe extra effort required to make sure that those truly worthy are not overlooked because no obviousindividual was available to start the nomination process.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWSheadquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issueof the Welding Journal. Please remember, we all benefit in the honoring of those who have mademajor contributions to our chosen profession and livelihood. The deadline for submission is July 1,2014. The Committee looks forward to receiving numerous Fellow nominations for 2015consideration.

Sincerely,

Thomas M. MustaleskiChair, AWS Fellows Selection Committee

(please type or print in black ink)

FELLOW NOMINATION FORM

DATE_________________NAME OF CANDIDATE________________________________________________________________________

AWS MEMBER NO.___________________________YEARS OF AWS MEMBERSHIP____________________________________________

HOME ADDRESS____________________________________________________________________________________________________

CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________

PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________

TITLE/POSITION____________________________________________________________________________________________________

BUSINESS ADDRESS________________________________________________________________________________________________

CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION______________________________________________________________________________________________________

MAJOR & MINOR__________________________________________________________________________________________________

DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________

LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE_____________________________________________________________________________________________

POSITION____________________________________________________________________________YEARS_______________________


POSITION____________________________________________________________________________YEARS_______________________

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BESELECTED AS AN AWS FELLOW ACCOMPANY NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE IN-CORPORATED WITHIN THE CITATION CERTIFICATE.

SEE GUIDELINES ON REVERSE SIDESUBMITTED BY: PROPOSER_______________________________________________AWS Member No.___________________

Print Name___________________________________The Proposer will serve as the contact if the Selection Committee requires further information. Signatures on this nominating form, orsupporting letters from each nominator, are required from four AWS members in addition to the Proposer. Signatures may be acquiredby photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package shouldbe submitted.

NOMINATING MEMBER:___________________________________NOMINATING MEMBER:___________________________________Print Name___________________________________ Print Name___________________________________

AWS Member No.______________ AWS Member No.______________

NOMINATING MEMBER:___________________________________NOMINATING MEMBER:___________________________________Print Name___________________________________ Print Name___________________________________

AWS Member No.______________ AWS Member No.______________

CLASS OF 201

SUBMISSION DEADLINE July 1, 2014

5

Fellow Description

DEFINITION AND HISTORYThe American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for

distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professionalstature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of theindividual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by:

Sustained service and performance in the advancement of welding science and technology Publication of papers, articles and books which enhance knowledge of welding Innovative development of welding technology Society and chapter contributions Professional recognition

RULES1. Candidates shall have 10 years of membership in AWS2. Candidates shall be nominated by any five members of the Society3. Nominations shall be submitted on the official form available from AWS Headquarters4. Nominations must be submitted to AWS Headquarters no later than July 1 of the year prior to that in

which the award is to be presented5. Nominations will remain valid for three years6. All information on nominees will be held in strict confidence7. No more than two posthumous Fellows may be elected each year

NUMBER OF FELLOWSMaximum of 10 Fellows selected each year.

AWS Fellow Application Guidelines

Nomination packages for AWS Fellow should clearly demonstrate the candidates outstanding contributions to the advance-ment of welding science and technology. In order for the Fellows Selection Committee to fairly assess the candidates qualifica-tions, the nomination package must list and clearly describe the candidates specific technical accomplishments, how they con-tributed to the advancement of welding technology, and that these contributions were sustained. Essential in demonstrating thecandidates impact are the following (in approximate order of importance).

1. Description of significant technical advancements. This should be a brief summary of the candidates mostsignificant contributions to the advancement of welding science and technology.

2. Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited in (1). Where possible, papers and articles should be designated as to whether they were published inpeer-reviewed journals.

3. Inventions and patents.4. Professional recognition including awards and honors from AWS and other professional societies.5. Meaningful participation in technical committees. Indicate the number of years served on these committees and

any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.).6. Contributions to handbooks and standards.7. Presentations made at technical conferences and section meetings.8. Consultancy particularly as it impacts technology advancement.9. Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology.

10. Participation on organizing committees for technical programming.11. Advocacy support of the society and its technical advancement through institutional, political or other means.

Note: Application packages that do not support the candidate using the metrics listed abovewill have a very low probability of success.

Supporting LettersLetters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These

letters should address the metrics listed above and provide personal insight into the contributions and stature of thecandidate. Letters of support that simply endorse the candidate will have little impact on the selection process.

Return completed Fellow nomination package to:

Wendy S. ReeveAmerican Welding SocietySenior ManagerAward Programs and Administrative Support

Telephone: 800-443-9353, extension 293

SUBMISSION DEADLINE: July 1, 201

8669 Doral Blvd., #130

4

Miami, FL 33166

Just About the Only Type of Positioner We Dont Make.

Just About the Only Type of Positioner We Dont Make.

Koike Aronson, Inc./Ransome Arcade, NY USA 800-252-5232

www.koike.com

HT SeriesHead Tailstock

TR SeriesTurning Rolls

HD SeriesGear DrivenPositioner

Locust I & IIWelding Head Manipulators

Koike Aronson positioning equipment cant tee up your 392-dimple favorite, but we have you covered nearly everywhere

else from 100 lbs. to 4 million lbs., at any angle. Koike Aronson/Ransome can help you weld just about any type of piece more profitably. Call us to find out

how we can make your welding operation more efficient.

Follow us on


STAINLESSQ&A BY DAMIAN J. KOTECKI

A: There is some logic in the welders sug-gestion. Locally heating the fitting andtank shell will reduce the yield strength ofthese materials, making them easier tobend. But things are not so simple. As-suming that the fitting and tank are really304, not 304L, sensitization needs to betaken into account. Welding the fitting tothe tank shell will already have somewhatsensitized the fitting and tank shell. Soboth could be damaged by intergranular

corrosion, depending upon the severity ofthe corrosive environment inside and out-side the tank. See the November 2007Stainless Q&A column for details of sen-sitization and intergranular corrosion.

Local heating, improperly applied, canseverely sensitize the tank shell and fit-ting. The sensitization temperature rangefor welding is generally considered to be900 to 1600F (480 to 870C). But local-ized heating is a much slower process so

that the minimum sensitization tempera-ture can be reduced to 840F (400C). Ifthat temperature is exceeded anywhereduring local heating, there must be a tran-sition in temperature to the cold tankshell so there will be a considerable regionof the tank shell that will be sensitized.Water quenching cannot prevent that andmay cause distortion, which could makethe pipe alignment problem worse, notbetter. I have to assume that the extent ofsensitization you already have is accept-able, but local heating above 840F islikely to make it much worse.

If the extent of sensitization alreadypresent due to welding is acceptable andyou dont want to make matters worse,then local heating needs to be limited to apeak temperature anywhere in the tankshell and fitting to about 750F (400C) toprovide some margin of safety. Some sig-nificant reduction of yield strength occurswhen 304 is heated, which would be help-ful in your proposed bending operation. I

AT FABTECH 2014Atlanta Nov. 11-13, 2014

Submission deadline: Mar. 29, 2014

The AWS Professional Program is an annual three-day program of sessions on technical topics featuring the most recent welding research and best practices

in manufacturing and construction from around the world.

Submit your Professional Program abstract online by March 28 athttp://awo.aws.org/professional-program-abstract-form

or contact Martica Ventura at (800) 443-9353 ext 224 ([email protected])

AWS PROFESSIONAL PROGRAM ABSTRACT SUBMITTAL

JANUARY 201420

Q: We welded the flange of a 304 stainless steel pipe fitting(female threads), after hammering the flange to approximatelyfit the tank curvature, to the cylindrical surface of a 304 tank.Unfortunately, the fitting was not aligned correctly, so the pipeinserted into the fitting does not take off from the tank in thecorrect direction. The welder suggested that we could locallyheat the fitting and the tank, then thread a pipe into the fittingand bend the fitting and tank shell slightly to get the correctdirection for the pipe. Is this a good idea?

expect that the stainless steel shell isquite a bit thicker than the fitting, and theshells cylindrical shape will give it con-siderable stiffness, so most or all of theyielding will have to be in the flange ofthe fitting. The AK Steel online Data Bul-letin provides typical yield strength of 304as a function of temperature, as shown inTable 1. Also included in Table 1 are thereduction factors (ratio of elevated-tem-perature yield strength to room-temper-ature yield strength), from the AISC De-sign Guide 30: Structural Stainless Steel, tobe applied to the design of stainless steelconstruction. The two sources providesimilar information.

Local heating with a torch would bevery risky in this case because of thetemptation to direct the heat on the sur-face for a while, then withdraw the torchand test the surface temperature with atemperature-indicating crayon. You can

easily exceed the suggested temperaturelimit before you realize it. I suggest youuse electric strip heaters for the heating,and use thermocouples or an optical py-rometer to measure temperature contin-uously to be sure that 750F is not ex-ceeded.

Table 1 indicates that the yieldstrength of 304 stainless steel at 750F islikely to be about one-half of that at roomtemperature. So there will be some helpin your attempt to realign the fitting. But,because the flange diameter is greaterthan the pipe diameter, there will also bea tendency for the pipe to bend more eas-ily than the flange, even if the pipe is keptcold. I suggest you put a sleeve (a larger-diameter pipe that just fits over the neckof the fitting) to stiffen your lever armwhen trying to bend the flange of the fitting.

In summary, your welders idea is not

a bad idea, but its execution is not with-out risk. If you follow the guidelinesherein, I think you can be successful,though I would not guarantee it.

21WELDING JOURNAL

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 chairof the A5 Committee on Filler Metals andAllied Materials, and served as AWS presi-dent (20052006). Send questions todamian@ damiankotecki.com, or mail toDamian Kotecki, c/o Welding JournalDept., 8669 NW 36th St. # 130, Miami, FL33166-6672.

Table 1 Effect of Temperature on 304 Stainless Steel Yield Strength

Temperature, F (C) 68 (20) 200 (93) 400 (204) 600 (316) 750 (399) 800 (427)AK Steel Typical YS, ksi (MPa) 36 (241) 23 (159) 20 (134) 17 (114)AISC Reduction Factor 1.00 0.80 0.65 0.59 0.55 0.54


RWMAQ&A BY TOM SNOW

Q: One of our resistance welding ma-chine operators recently lost part of hisfinger when it was crushed between theelectrodes of the machine. How can weprotect our operators from similar in-juries in the future?

A: Forging forces ranging from severalhundred to several thousand pounds arerequired to properly resistance weld metaltogether, so resistance spot and projec-tion welding machines can be dangerousif care is not taken to protect theoperator.

For example, a welding machine oper-ating at 600 lb of forging force with anelectrode contact area of in. will pro-duce more than 12,000 lb of force persquare inch on a finger or anything elsecaught between them.

Having witnessed an operator crush hisfinger while on a factory tour years ago, Icertainly share your desire to avoid thisunfortunate situation in the future.

While not necessarily simple, the safestway to ensure operator safety on a resist-ance welding machine is to tool the ma-chine to hold and clamp the part, whichavoids the need for an operator to posi-

tion and hold the part during the process Fig. 1.

In a welding machine with proper tool-ing and guards, the operator manuallyloads the parts and then completely clearsout of the welding/pinch point area beforethe machine closes the tips.

That being said, it is not always possi-ble to accomplish. Following are outlinedsome other ideas that can help ensure op-erator safety.

You did not specify whether the ma-chine involved in the accident was a rockerarm-type spot welding machine or a ver-tical action press-type machine, so en-hancing the safety of both is addressed.

Rocker Arm Spot Welding Machine

These machines are typically used toweld sheet metal parts that are held withboth hands while the operator manipu-lates the part in the throat of the machineto access all the weld locations.

Initiation of the machine should bewith a shrouded foot switch, and a pinchpoint warning sign should be prominentlydisplayed Fig. 2. In addition, the oper-

ator should be instructed verbally and inwriting to keep his hands away from the tips.

Although using both hands to hold thepart usually ensures that the operatorsfingers are not in the pinch point area,management can augment safety by se-lecting the right machine for the job andsetting it up properly.

A simple way to reduce the potentialfor a spot welding machine pinch point in-jury is to position the machines electrodetips so close together (typically about a -in. gap) that a finger cannot get betweenthe tips prior to the weld stroke.

To overcome clearance problemscaused by such a short working stroke, anoptional feature for the welding machinecalled an adjustable and retractable strokeair cylinder can make it much easier toload bulkier parts, such as those withflanges or lips, into the welding machinesthroat prior to welding.

When using retraction, the operatortypically steps on a separate shrouded footswitch to activate the adjustable retrac-tion stroke, also called high lift, whichgives the operator extra clearance to loadthe part in the throat prior to reverting toa minimal stroke for welding.

JANUARY 201422

continued on page 25

WE

BUIL

D

IndustryThe biggest, toughest shovels on the planet. Moving tons of earth in a single scoop. With key components built by Al and the team of welders at Weldall Mfg., Inc.Together, we build industry.

The Power of Blue

MillerWelds.com/webuild


25WELDING JOURNAL

However, if an operator is not prop-erly trained in the operation of a retrac-tion feature, or if its not properly ad-justed, additional pinch point dangers canresult when the machine comes out ofretraction.

OSHA requires guarding against pinchpoint injury to be passive. This means thatthere can be no way to defeat the protec-tion system and that safety of the weldingmachine cannot be dependent upon op-erator adjustments. Since the gap betweenelectrodes can vary depending on thesetup, at present the only way to meet thisOSHA requirement is by use of a systemcalled Soft Touch.

Press-Type Resistance WeldingMachines

A vertical-action press-type spot weld-ing machine can be operated much like a

rocker arm and initiation with a shroudedfoot switch is generally acceptable if bothhands are used to hold the part beingwelded Fig. 3.

Again, using the Soft Touch systemand/or reducing the gap between the tips

to in. are recommended, as are ad-justable and retractable stroke weldingmachine cylinders to make loading andunloading easier.

Hand-loading projection welded nutsor weld studs exposes the operator to

Fig. 1 A growing trend is to completelyguard the pinch point of a resistance weld-ing machine. In addition to a physical en-closure, this vertical-action pedestal-typespot welding machine includes a light cur-tain to ensure that the operators hands areoutside the pinch point area after loadingthe assembly to be welded into a toolingnest. When the operator initiates the ma-chine with a foot switch, a door automati-cally closes the opening in the enclosure andshields the operator from weld flash.

Fig. 2 A A rocker-arm spot welding machine with a prominently displayed pinchpoint warning sign; B a close-up view of a warning sign.


continued from page 22

A B

pinch point injury every time a part iswelded, since the gap between electrodesmust be greater than in. to clear thepart. One solution is to place the nuts orstuds on the part prior to placing the partbetween the electrodes. The part can thenbe supported by a table and the weldingmachine initiated by use of dual hand but-tons installed with an anti-tie-down safetycircuit. If this method is not practical, useof the Soft Touch system will provide therequired protection.

Another highly recommended solutionis to use an automated bowl feeder andplacement mechanism to load the nuts orstuds being welded.

Projection welding machines with tool-ing mounted to T-slotted platens in thethroat of the machine are considered tobe much like a sheet metal stamping presswhen it comes to ensuring safety, since theparts being welded are typically loaded byhand into a locating fixture directly underthe ram in the pinch point.

Dual palm buttons connected to ananti-tie-down and anti-repeat circuit havelong been the standard initiation meansfor projection welding machines, and op-tical-touch devices are rapidly replacingthe old-style palm buttons that requirephysical force to depress.

Guarding of the welders pinch pointwith wire mesh or Plexiglas is also moreprevalent than ever, and light curtains in-

stalled on the openingensure that the operatoris completely outside thework area when the ma-chine is initiated (seeFig. 1).

Zone scanners arealso now available thatsense if someone is in-side the guarded area.

Using a robot to re-place the operator andmanipulate a fixturedpart inside the throat ofa rocker arm or press-type resistance weldingmachine is also a goodway to enhance safety.

We applaud your de-sire to learn from this ac-cident and to help pro-tect your operators fromsimilar injuries in the fu-ture. It is also encourag-ing to see that a growing number of com-panies are becoming proactive by addingprotection systems to their spot weldingmachines before accidents occur.

As weve explained, there are numer-ous ways to enhance the safety of resist-ance welding machines, but proper oper-ator training, especially of new hires or temporary workers, should be top priority.

JANUARY 201426

The RWMAAnnual Meeting is a three-day event filled with unparalleled networking opportunities and enlightening presentations. Renowned economist Alan Beaulieu of the Institute for Trend Research (ITR) continues to be the keynote speaker for the meeting. Additional speakers will be announced. Non-members are welcome to attend! Registration opens mid-December. For more information please contact:

Keila DeMoraes at [email protected] or 800-443-9353, ext. 444

A STANDING COMMITTEE OFANDING COMMITTEE OFSTTAAA inoy Renaissance Resort & Golf Club, St. Petersburg, Fla.Vinoy Renaissance Resort & Golf Club, St. Petersburg, Fla.y

inoy Renaissance Resort & Golf Club, St. Petersburg, Fla.inoy Renaissance Resort & Golf Club, St. Petersburg, Fla.

The R

bCo

b

Alan Beaulieu of the Institute for presentations. Renowned economist WMAAnnual Meeting is a threRRW

oadening its use,bommitted to advanbro d i it

Alan Beaulieu of the Institute for WMAAnnual Meeting is a three-day event filled with unparalleled networking opportunities and enlightening

omoting its ecoesistance wencing r

, prg

ti it

rend Research (ITR) continues to be the TAlan Beaulieu of the Institute for WMAAnnual Meeting is a three-day event filled with unparalleled networking opportunities and enlightening

onomic benefits.elding technology, g g

i b fity,

rend Research (ITR) continues to be the WMAAnnual Meeting is a three-day event filled with unparalleled networking opportunities and enlightening

Registration opens mid-Decemberkeynote speaker for the meeting. presentations. Renowned economist

.Registration opens mid-DecemberAdditional speakers will be announced. Non-members are welcome to attend! keynote speaker for the meeting.

Alan Beaulieu of the Institute for presentations. Renowned economist Additional speakers will be announced. Non-members are welcome to attend!

Alan Beaulieu of the Institute for

Keila DeMoraes at [email protected] or 800-443-9353, ext. 444For more information please contact:

Additional speakers will be announced. Non-members are welcome to attend! rend Research (ITR) continues to be the TAlan Beaulieu of the Institute for


Additional speakers will be announced. Non-members are welcome to attend! rend Research (ITR) continues to be the


Fig. 3 Standard spot welding machines, both vertical actionand rocker arm types, can be operated safely if an operatorholds the parts with both hands outside the pinch point area.Safety can be enhanced by minimizing the opening between thetips and by a control feature called Soft Touch.

TOM SNOW is CEO of T. J. Snow Co.,Chattanooga, Tenn., a resistance weldingmachine manufacturer and a member ofthe Resistance Welding Manufacturing Al-liance (RWMA). Send your comments/questions to Tom at [email protected], or to Tom Snow, c/o WeldingJournal, 8669 NW 36th St., #130, Miami,FL 33166.

CAD/CAM Software BoostsSheet Metal Cutting

Radan 2014 incorporates 3D workflowimprovements and safety measures to pre-vent tipping on flat-bed lasers, along withadvances in common cutting on punchesand support for cluster/asymmetric wheeltools. Simulation and time calculationhave also been improved. In addition, thesoftware adopts the same common cuttingstrategy for punch presses as that used forprofiling machines; allows common cutnests to be created automatically; and tag-ging for common cut parts has been en-hanced. The nest project workflow pro-vides graphical/interactive help when nec-essary, informing a user when a part is notclosed, tooling is out of date, or what im-provements are needed.

Vero Software Limitedwww.verosoftware.com(440) 552-9743

Cutting Tip Guide IncludesGas Fuel Comparison Chart

The companys new Cutting Tip Guideis a quick-reference guide for its gas ap-paratus equipment. The pocket guide pro-vides comprehensive operating data, in-

cluding gas pressure, gas consumption,and other key parameters required toquickly and easily identify the proper cut-ting tip for any manual or machine cut-ting application. Also included is a fuel-gas comparison chart as well as cutting tipand welding head/tip cross-referencecharts. It is available in print or digital format.

ESAB Welding & Cutting Productswww.esabna.com(800) 372-2123

Mobile Work Table HandlesMany Applications

The Mobile Work Table XL has a 5000-lb distributed weight capacity and can ac-commodate a variety of plant operations,including moving supplies and equipmentthroughout a facility, moving parts and as-semblies between workstations, use as aworkstation for a shipping department,use as a mobile work table for wrappingboxed parts on pallets for shipping, as amaintenance department mobile worktable, and as an automotive parts table forrebuilding parts and assemblies. It fea-

tures all-welded steel construction, a largetop work surface, a fixed bottom shelf forstorage with a raised lip-edge design onthree sides to retain parts, and a formed-down bottom lip for easy cleaning.

Ohio Laserwww.ohiolaser.com(614) 873-7030

Diamond Wheels EnableFast Cutting Speeds

Pearl Xtreme diamond wheels are de-signed to cut metal, stainless steel, and avariety of ferrous metals with less odorand debris. Engineered with a high con-centration of diamonds and a strong bond,the wheels feature fast cutting speeds andthe need to change wheels frequently isreduced. The shape of the wheel does notchange over time, keeping the size of thewheel consistent from the first to last cut.Sizes available are 4, 5, 6, 7, 9, 12, and14 in.

Pearl Abrasive Co.www.pearlabrasive.com(800) 969-5561

Brochure Features DustCollector Specifications

The companys full-color brochureshowcases its line of dust collectors. Pho-tos and illustrations show how the dustcollectors protect workers from smoke,fumes, and other pollutants in metalwork-

PRODUCT & PRINTSPOTLIGHT

Mounted Points Designed for Safer Sheet Metal Fabrication

The companys mounted points for stain-less steel edge-breaking include a nonwovencotton fiber type that leaves a smooth finishand a rubber version that produces a finer fin-ish. Both are self dressing to the workpieceand help make it safer for workers who han-dle stainless steel sheet metal. They also in-clude the A54GFX cotton fiber type. Avail-able in a 1 2 in. size for this application, theyare also offered in several other sizes.

Rex-Cut Abrasiveswww.rexcut.com(800) 225-8182

JANUARY 201428

29WELDING JOURNAL

ing, plastics, painting, powders, and othermanufacturing industries. The brochurealso contains detailed specifications to de-termine the correct configuration for ap-plications, including welding, grinding,painting, sanding, cutting, finishing, andmore. This brochure may be downloadedat the website shown.

Micro Air Clean Air Systemswww.microaironline.com(866) 566-4276

Magnetic Travel CarriageOffers 25-lb Pull Capacity

The K-BUG 4000, a digital, magnetictravel carriage, produces continuous orintermittent fillet welds while traveling ona vertical wall. The constant travel speedproduces high-quality, uniform welds.Programming of travel pattern and weldcontrol eliminates excessive depositionand reduces defects. The guide wheelstrack the workpiece to provide preciseweld placement and have a pull capacityof 25 lb.

Bug-O Systemswww.bugo.com(800) 245-3186

Fixturing Devices Suitedfor Tack Welding

The companys Radiusmagnetic fix-turing tools can be used to position steelfor tack welding or other pre- or postweldoperations. They also are suited for cut-ting and grinding applications. Three dif-ferent models, all compact and light-weight, intended for various materialthicknesses or applications, are available.The company is also offering a manualhand lifter designed for small steel partlifting and sheet dragging. The hand lifterdoes not require batteries or electricity.

The Lincoln Electric Co.www.lincolnelectric.com(888) 355-3213

Corporate Video HighlightsWaterjet Technology

The manufacturer of waterjet systemshas produced a new corporate video fea-turing a behind-the-scenes look inside itsmanufacturing facility in St. Michael,Minn. The video includes an overview ofthe companys capabilities and products aswell as testimonials from customers. Thevideo explains how water is pressurized upto 90,000 lb/in.2 to create a stream that cancut precise parts from virtually any mate-rial, from huge steel parts to intricate stoneinlays. Also highlighted is how customersare using waterjet technology to solve man-ufacturing challenges. The video is nowshowing on the companys YouTube chan-nel at www.youtube.com/jetedgewaterjets.

Jet Edge, Inc.www.jetedge.com(800) 538-3343


Collection Arm ProvidesSource-Point Dust Removal

The E-Z Arm High Flow series ofcontaminant extractor arms providessource-point collection as well as removalof dusts, powders, fumes, smoke, odors,and other contaminants. Capable of han-dling air flow rates up to 1500 ft3/min, itsdesign delivers an energy consumptionlevel of 0.35 kW/h at 800 ft3/min. The high-capacity air flow volume with the low en-ergy consumption level is made possibleby the companys patented pawl-and-sprocket, friction-release, external armsupport system. The extractor arm has a6.75-in. diameter and is available in 7-, 10-, and 14-ft lengths.

Airflow Systems, Inc.www.airflowsystems.com(800) 818-6185

Refractometer DeterminesCoolant Concentration

The companys automatic temperaturecompensating refractometer allows plantoperators to quickly determine the con-centration of metalworking coolants andcleaners, heat-treating fluids, water-basedhydraulic fluids, and plating baths. Thedevice is portable and requires no batter-ies. Its large scale is available in tworanges, 010 and 032 Brix. These fluidrecycling instruments are designed formost metalworking operations, includingcutting, grinding, and synthetic machin-ing fluids; plating, acid, and cleaner baths;water-based hydraulic fluids; die lubri-cants; and chromating systems.

Eriez HydroFlowwww.eriez.com(888) 300-3743

Mobile App Allows Usersto Share Auto RestorationPhotos

The company has introduced its new,free mobile app for iPhone and Androidsmartphones. The app provides instant ac-cess to the companys video library, techlibrary, blog, live chat, social media, andin-app coupons. The Car Cam feature al-lows users to submit pictures of their proj-ect, cars that were spotted at a car show,

JANUARY 201430


or shots of products in action. The appprovides a convenient way to get informa-tion to solve problems that are encoun-tered while working in the garage. TheiPhone version of this mobile app is avail-able at the Apple iTunes store, and theAndroid version is available on GooglePlay.

Eastwood Co.www.eastwood.com(800) 343-9353

Laser System QuicklyCuts Aluminum, Brass

The Sigma XY fiber laser cutting sys-tem enables high-speed cutting of thinmetals using a rigid linear drive, gantry-based motion system. The fiber laser tech-nology offers high-resolution cutting, withoptical spot sizes down to 10 microns, andhigh linear-speed cutting made possiblethrough high pulse repetition rates. Fea-tures include up to 500 W of availablelaser power for a range of materials, in-cluding aluminum, steels, and brass. Thelaser system is available with many op-tions, including class 1 or 4 operation, sev-eral cutting box styles, fume exhaust, parthold-down tooling, focus control sensing,

programmable gas pressure, high-pres-sure cutting heads, 4- or 8-in. travel Z-stage axes of motion, and a control pendant.

Miyachi Unitekwww.miyachiunitek.com(626) 303-5676

Document Guides InstallingGas Transfer Connectors

A new version of the companys Instal-lation Procedures Document LP-105 hasbeen recently issued. The comprehensiveinstallation guide complements the Dis-

31WELDING JOURNAL

COR-MET, INC.12500 Grand River Rd.

Brighton, MI 48116PH: 800-848-2719FAX: 810-227-9266

[email protected]

Manufacturing Flux Cored

Welding WireCobaltNickel

HardfaceStainless

Alloy SteelTool Steel

MaintenanceForge Alloys

Custom Alloys

WE ARE

GAS SA

FETY

EXPERT

S

Superash Compressed Gas Equipment / IBEDA Inc. ##-' +-/()! //+++$,-*!()-$"/(!($,-*!()-$"

Toll Free: 1-888-327-7306

SAVE MONEY GET BETTER RESULTS SuperFlash 2-Gas Adjustable Mixer Provides customized mixed gases for

welding machines and other operations Available for all popular 2-gas mixtures Fully adjustable, less than 1Ft3

in size, and very low maintenance

Call us or visit www.oxyfuelsafety.com to see how much money you can save vs. buying pre-mixed gases!

Mixer model 0801-4410 for Ar/CO2

100%

Made in the USA

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

tributor Installation Training Course andis an essential tool for using the companysproducts. The guide covers carbon steel,stainless steel, and CuNi pipe fittings. Italso includes tube (OD) fitting installa-tions for stainless steel and copper nickelrange. The LP-105 is a necessary resourcefor learning the procedures needed to be-come a trained installer for the company,and a reference tool for installers want-

ing to stay up-to-date on the latest instal-lation procedures. To order a copy, visitthe website listed.

Lokring Technology LLCwww.lokring.com(800) 876-2323

JANUARY 201432

WORK SMART

Model 200 Positioner

Model 1200 Pipemate

RTRTRAMSKROW

TK

RTRTAMS

TT

Your research sent to more than 68,000 American Welding Society members Your published paper posted on the AWS Web site for FREE access worldwide (www.aws.org/w/a/research/index.html) The most recent Impact Factor of 1.00 No page charges Your paper printed in full color Electronic submission and tracking through Editorial Manager (www.editorialmanager.com/wj) Every research paper published in the Welding Journal since 1970 available FREE on the AWS website (www.aws.org/wj/supplement/supplement-index.html)

Publish Your Research in the

and Youll Get

By far, the most people, at the least cost, will be exposed to your research when you publish in the world-respected

Welding Journal



By far, the most peoplto your research when you publish in the world-respected

, the most people, at the least cost, will be exposed to your research when you publish in the world-respected

Welding Journal

, at the least cost, will be exposed to your research when you publish in the world-respected


Submit a New ProductsItem for Consideration

If your company has a new welding,fabricating, or manufacturing productreadily available, the details requiredto be considered for possible publica-tion in the Welding Journal are as follows:

Press release with the productsname, important features, and specificindustries its aimed for.

High-resolution jpg or tiff photo (266or more dpi).

Please e-mail submissions to Asso-ciate Editor Kristin Campbell [email protected].

Metallurgical know-how for the best welding results.

As a world leading provider of ller metals voestalpine Bhler

is now an integrated unit of the steel producer voestalpine. The three

brands provide the deepest portfolio of ller metal solutions and the

most competent technical support in the market for Joint W

Repair & Maintenance and Brazing applications.


As a world leading provider of ller metals voestalpine Bhler



most competent technical support in the market for Joint W



As a world leading provider of ller metals voestalpine Bhler Welding



most competent technical support in the market for Joint Welding,


Join the highest level of welding performance

www.voestalpine.com/welding

Bhler W elding



.voestalpine.com/welding

UTP Maintenance elding


Fontargen Brazing



Friends and Colleagues:

The American Welding Society established the honor of Counselor to recognize individualmembers for a career of distinguished organizational leadership that has enhanced the image andimpact of the welding industry. Election as a Counselor shall be based on an individuals career ofoutstanding accomplishment.

To be eligible for appointment, an individual shall have demonstrated his or her leadership in thewelding industry by one or more of the following:

Leadership of or within an organization that has made a substantial contribution to the weldingindustry. The individuals organization shall have shown an ongoing commitment to the industry, asevidenced by support of participation of its employees in industry activities.

Leadership of or within an organization that has made a substantial contribution to training andvocational education in the welding industry. The individuals organization shall have shown anongoing commitment to the industry, as evidenced by support of participation of its employee inindustry activities.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWSheadquarters in Miami, or simply follow the instructions on the Counselor nomination form in thisissue of the Welding Journal. The deadline for submission is July 1, 2014. The committee looksforward to receiving these nominations for 2015 consideration.

Sincerely,

Lee KvidahlChair, Counselor Selection Committee


COUNSELOR NOMINATION FORM



HOME ADDRESS____________________________________________________________________________________________________



TITLE/POSITION____________________________________________________________________________________________________



ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION______________________________________________________________________________________________________

MAJOR & MINOR__________________________________________________________________________________________________

DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________

LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________

SIGNIFICANT WORK EXPERIENCE:


POSITION____________________________________________________________________________YEARS_______________________


POSITION____________________________________________________________________________YEARS_______________________

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BESELECTED AS AN AWS COUNSELOR ACCOMPANY THE NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAYBE INCORPORATED WITHIN THE CITATION CERTIFICATE.

**MOST IMPORTANT**The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All in-

formation and support material provided by the candidates Counselor Proposer, Nominating Members and peers are considered.

SUBMITTED BY: PROPOSER_______________________________________________AWS Member No.___________________The proposer will serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include adetailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the can-didate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in additionto the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the sig-natures are secured, the total package should be submitted.

NOMINATING MEMBER:___________________________________Print Name___________________________________AWS Member No.______________




CLASS OF 201

SUBMISSION DEADLINE JULY 1, 2014

5

Nomination of AWS Counselor

I. HISTORY AND BACKGROUNDIn 1999, the American Welding Society established the honor of Counselor to recognize indi-

vidual members for a career of distinguished organizational leadership that has enhanced theimage and impact of the welding industry. Election as a Counselor shall be based on anindividuals career of outstanding accomplishment.

To be eligible for appointment, an individual shall have demonstrated his or her leadership inthe welding industry by one or more of the following:

Leadership of or within an organization that has made a substantial contribution to the welding industry. (The individuals organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employeesin industry activities such as AWS, IIW, WRC, SkillsUSA, NEMA, NSRP SP7 or other similar groups.)

Leadership of or within an organization that has made substantial contribution to trainingand vocational education in the welding industry. (The individuals organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities such as AWS, IIW, WRC, SkillsUSA, NEMA,NSRP SP7 or other similar groups.)

II. RULESA. Candidates for Counselor shall have at least 10 years of membership in AWS.B. Each candidate for Counselor shall be nominated by at least five members of

the Society.C. Nominations shall be submitted on the official form available from AWS

headquarters.D. Nominations must be submitted to AWS headquarters no later than July 1

of the year prior to that in which the award is to be presented.E. Nominations shall remain valid for three years.F. All information on nominees will be held in strict confidence.G. Candidates who have been elected as Fellows of AWS shall not be eligible for

election as Counselors. Candidates may not be nominated for both of these awards at the same time.

III. NUMBER OF COUNSELORS TO BE SELECTEDMaximum of 10 Counselors selected each year.

Return completed Counselor nomination package to:

Wendy S. ReeveAmerican Welding SocietySenior ManagerAward Programs and Administrative Support

Telephone: 800-443-9353, extension 293

SUBMISSION DEADLINE: July 1, 201

8669 Doral Blvd., #130

4

Miami, FL 33166


COUNSELOR NOMINATION FORM



HOME ADDRESS____________________________________________________________________________________________________



TITLE/POSITION____________________________________________________________________________________________________



ACADEMIC BACKGROUND, AS APPLICAB

aws_wj_201401

Documents