Documentos de Académico
Documentos de Profesional
Documentos de Cultura
PUBLISHED 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
CONTENTS
34
Features
Departments
34
38
42
46
51
Editorial ............................4
Washington Watchword ..........6
Press Time News ..................8
News of the Industry ............10
Aluminum Q&A ..................18
Brazing Q&A ......................20
Technology........................22
Product & Print Spotlight ......24
Coming Events....................54
Certification Schedule ..........60
Welding Workbook ..............62
Society News ....................65
Tech Topics ......................66
Errata D1.4:2011 ..............66
Interpretations A5.01, A5.26..66
Guide to AWS Services ........83
Personnel ........................84
Classifieds ........................91
Advertiser Index..................92
38
Welding Research Supplement
46
On the cover: A welder performs gas tungsten arc welding on stainless steel.
(Photo copyright of Linde Canada Limited.)
WELDING JOURNAL
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
AWS An American
Organization, with Global Reach
A recent Welding Journal editorial (see April 2013) by AWS Vice President Dave
Landon looked at the role of strategic planning as a means of ensuring the continuing
success of the Society. His message touched on the importance of international growth
for AWS, as well as expanding influence in all countries that rely on welding. In our bid
to be the worlds premier organization devoted to welding and allied joining and cutting
processes, we need to be aware of technology needs worldwide, as well as locally. While
AWS will continue to have a strong domestic focus, we also need to be an effective player in an increasingly global economy.
To this end, it is worth noting that a good deal of our recent expansion is international. AWS membership in other countries has developed very rapidly, with international members growing about 25% over the past three years. Our total member base
outside the United States now numbers nearly 14,000. It may surprise you to learn that
our second-largest membership country is India, with 2928 members.
The current location of AWS World Headquarters in Doral (Miami), Fla., suits this
trend well. During its early years, following formation in 1919, AWS was headquartered
in New York City. With board approval, AWS relocated to Miami some 40 years ago. We
have often been asked, Why Miami?, but this move has proven to be an effective location for AWS, as it centralizes travel and business dealings with other parts of the world.
As part of its growing presence in other countries, AWS is involved in many international
welding exhibitions, including partnerships in foreign shows that serve American exhibitors.
For example, AWS will be hosting a USA Exhibitor Pavilion at the quadrennial Essen
Welding Fair (Schweissen & Schneiden) in Germany this September, the worlds largest
show devoted exclusively to welding technologies (see story on page 46). AWS also sponsors
a USA Pavilion at the Beijing Essen Welding and Cutting Fair held each year in China. We
are represented at the Japan International Welding and Cutting Show and the Brazil
Welding Show, and we were present for the first time this year at the Weld Arabia show in
Dubai. AWS Weldmex, held annually in Mexico, has grown each year since we acquired that
show. Our U.S. FABTECH partners have contributed to this success by holding FABTECH
Mexico and Metalform Mexico at the same time and place. These co-located shows have
experienced strong and growing support from the Latin American market.
AWS will undertake an important new show venture in 2014 when it brings FABTECH
India into a partnership with the existing Weld India show in New Delhi, in cooperation with
the Indian Institute of Welding. Further, we recently commissioned P. K. Das as a special
contract representative for AWS interests in India and the Middle East.
Our publishing activities are also growing outside the United States. Since 2007, each
issue of the Indian Welding Journal has included an AWS Section with articles from our
own Welding Journal, and we regularly exchange editorial materials with Modern Welding
Technology, a magazine published in China. In addition, several AWS codes and standards have been translated into other languages, including publication of D1.1, Structural
Welding Code Steel, in Mandarin for the Chinese market.
To support our certification efforts internationally, we have more than doubled our
number of international agents since 2007, and the number of certification exams conducted outside the U.S. has grown accordingly.
We are also active in affairs of the International Institute of Welding, hosting the IIW
Annual Assembly last year in Denver, but also participating each year in IIW Assemblies
outside the United States. AWS staff and volunteers have
served in many leadership roles on IIW Commissions and
the IIW Board of Directors.
In summary, AWS is keenly aware of the need to be represented globally as part of its overall development strategy.
While we will continue to maintain a strong focus on the
interests of our domestic members, we must also remain
aware of the central role of welding technologies throughout
the world.
Ray Shook
AWS Executive Director
AUGUST 2013
Officers
President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
U. Aschemeier (Dist. 7), Miami Diver
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
R. E. Brenner (Dist. 10), CnD Industries, Inc.
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (At Large), Tri Tool, Inc.
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (Dist. 17), The Harris Products Group
W. A. Komlos (Dist. 20), ArcTech, LLC
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), NS Inspection and Consulting
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
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WASHINGTON
WATCHWORD
BY HUGH K. WEBSTER
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
AUGUST 2013
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PRESS TIME
NEWS
EWI Commits to National Accelerated Welder Training
EWI, Columbus, Ohio, is launching a program to train 25,000 welders in the United
States over the next three years. The Clinton Global Initiative Commitment to Action,
finalized on June 14 at the Clinton Global Initiative America Manufacturing Working
Group meeting in Chicago, Ill., is aimed at helping the shortage of skilled replacement
workers facing American companies as the economy improves.
EWI and its affiliate, RealWeld Systems, Inc., are set to introduce welder training
and credentialing advancements that will set a future standard. Utilizing the RealWeld
Trainer, a motion-capture system that tracks and measures a welders technique during live welding, they will develop badge credentials for industry-specific welding procedures based on the Mozilla Open Badges standard. These can be incorporated into an
existing welding instruction curriculum.
The American Welding Society, Weld-Ed, and The Manufacturing Institute have
joined the endeavor to help develop training standards and define a certification system. Once in place, the program will be implemented through a network of 200 community colleges, career centers, and training sites.
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NEWS OF THE
INDUSTRY
Friction Stir Welding Tools Will Help Build the Worlds Largest Rocket
Engineers at NASAs Michoud Assembly Facility, New Orleans,
La., are installing large tools to weld pieces of the core stage for
the Space Launch System (SLS). This new, heavy-lift rocket will
send humans to deep-space destinations, including an asteroid and
Mars.
One of the challenges that we face in building this large core
stage is to develop world-class tooling using modern manufacturing methods in an affordable way, while maintaining the scheduled first launch in 2017, said Tony Lavoie, manager of the Stages
Office at NASAs Marshall Space Flight Center, Huntsville, Ala.
Six welding tools will be used to handle assembly of the new
cryogenic core stage on SLS. Suppliers worked with NASA and
The Boeing Co. of Huntsville over the course of a year to design
and build the tools.
The circumferential dome weld tool will be used to perform
circumferential friction stir welds in producing dome assemblies
for the SLS core stage cryogenic tanks. The gore weld tool will
perform vertical conventional friction stir welds in producing gore
assemblies for the SLS core stage tanks. In addition, the circumferential dome weld and gore weld tools are for the enhanced ro- This artist illustration features the vertical weld center, a fricbotic weld tool used to make dome components for SLS. The ver- tion-stir-weld tool for wet and dry structures on the Space Launch
tical weld center, a friction-stir-weld tool for wet and dry struc- System core stage. (Image courtesy of NASA/MAF.)
tures on the SLS core stage, will weld barrel panels to produce
whole barrels for the two pressurized tanks, intertank, forward skirt, and aft engine section; it stands about three stories tall and
weighs 150 tons. The segmented ring tool will use a friction-stir-weld process to produce segmented support rings for the SLS core
stage.
Also, the vertical assembly center 170 ft tall and 78 ft wide will join domes, rings, and barrels to complete tanks or dry
structure assemblies. The tool will perform nondestructive examination on the completed welds. It is anticipated to be completed
in 2014.
Were already welding on the new tooling and are gathering information well need to start production welding, said Rick
Navarro, Boeing operations manager at Michoud. That old saying, measure twice, cut once, applies in spades when youre building a 5.5-million-pound rocket. We do a lot of testing, validating, and what we call qualifying welds that ensure we have all the information we need to build with 100% quality assurance.
AUGUST 2013
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skill levels cutting through a -in. metal plate while being timed.
The top three contestants received product prizes from Flame
Techs Dean Bridges, district sales manager, and Phil Montez,
sales/marketing specialist. Fifty-three participants competed in
the event. Also, the company and other manufacturers spoke to
students about career options and equipment choices.
A Greenbrier welder at the companys new Concarril Mexico facility (Plant #2) finishes a side sheet weld using flux cored arc welding on a covered hopper railcar, which will be used to transport frac
sand for horizontal drilling.
WELDING JOURNAL
13
SGS, acting as client representatives on integrity digs, will be performing on-site inspections in Wisconsin.
Mandatory regular monitoring and inspection programs redflag pipeline features requiring visual inspection to determine
the need for repair or other action. Integrity digs involve excavating a section of buried pipe for cleaning and examination. Defects are repaired, the pipe recoated, and reburied. In some cases,
old pipe sections are cut and replaced with new welded pipe.
Gentec is a total solution provider for your welding, cutting, and gas control needs.
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AUGUST 2013
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Dean Wilson (left), AWS president-elect, presented an appreciation certificate to Edward R. Stanley, founder of Stanco Manufacturing, in honor of the companys 25th anniversary.
The event, celebrated with a luncheon at its manufacturing facility, included distinguished guests, retirees/current employees,
friends, industry associates, and local officials.
Edward R. Stanley, who started the business in 1988 and is
current president/COO, was honored with a presentation by Dean
Wilson, Well-Dean Enterprises and American Welding Society
(AWS) president-elect. Craig Loos, ORS Nasco, spoke of his
companys association with Stanco from day one, being its first
customer, and building a cohesive relationship.
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WELDING JOURNAL
15
ABB Robotics hosted more than 1000 people during its annual
Technology Day held May 15 at the companys U.S. headquarters and training center in Auburn Hills, Mich. The 55,000-sqft exhibit floor included more than 40 live robot-related demos
and 45 small-group, topic-specific seminars.
L.B. Foster Co., Pittsburgh, Pa., has completed delivering approximately 2600 tons of 36-in.-diameter steel pipe to Balfour
Beatty Infrastructure, Inc., for use as lateral shoring struts in
excavating San Franciscos new Transbay Transit Center.
SME, Dearborn, Mich., is integrating events, publishing, membership, the Tooling U-SME online training division, and SME
Education Foundation around a mission to inspire, prepare,
and support its stakeholders in advancing manufacturing. It
will also refer to itself by its monogram and has a new logo.
First Coast Technical College, an AWS member, recently announced the applied welding technology program is returning
to its main campus in St. Augustine, Fla., with classes scheduled to begin August 19 for adults and high school students.
Industry Notes
Through the Boy Scouts of America (BSA), 4422 Welding Merit
Badges were earned from March to December 2012. According to BSA, this number is huge because it was achieved during the first 10 months of the badges launch. It also expects
the number of welding badges distributed this year to double
based on Jamboree exposure and work being done with Lincoln Electric.
16
AUGUST 2013
/ The VR 5000 Case feeder is compact, sturdy and portable making it ideal for welding on rail
vehicle construction. Its light weight (22 pounds) and comes with a Bayonet connector which
protects it from strain when pulling on the hosepack (up to 225 feet). Synergic and manual,
water or gas-cooled models. To see the VR5000 Case feeder in action visit
www.youtube.com/FroniusWelding and search VR 5000.
To learn more visit www.fronius-usa.com
ALUMINUM
Q&A
BY TONY ANDERSON
Fig. 1 This chart shows the effect of varying heat inputs on the tensile strength of 6061T6. As can be seen, as the heat input is increased, the tensile strength of the base material
decreases. The 5083 base material has been added to show how the 5xxx series, nonheattreatable alloys are far less affected by the heat of the welding operation.
have on more than one occasion found
incorrect testing procedures to be the
cause of illogical test results. If the mechanical testing was performed by a reputable testing facility, it would be
extremely unlikely that this is your
problem.
18
AUGUST 2013
in the HAZ, and you increased the preheat temperature from 300 to 400F.
These two statements strongly suggest
that the reason for your weld test failures
is associated with overheating the base
material during the welding operation.
Preheating
Preheating this type of material (heattreatable aluminum) is best avoided;
there should be no necessity to preheat
3
8-in.-thick base material, other than to
remove moisture, which is achievable at
a temperature a little over 100F. The
300 and 400F preheating temperatures
that you have been using are seriously excessive and for that matter, outside of the
code requirements.
The American Welding Societys
D1.2, Structural Welding Code Aluminum, specifies the following under its
requirements for preheat and interpass
temperatures: When welding the heattreatable aluminum alloys or the 5000 series aluminum magnesium alloys containing more than 3% magnesium, the
preheat and interpass temperature shall
not exceed 250F. Holding time at this
temperature shall not exceed 15 min.
Summary
If a weld made in an aluminum heattreatable alloy meets the requirements
for guided bend testing, and gives the appearance of being relatively free of discontinuities, yet has insufficient tensile
strength to pass transverse tension tests,
the most obvious reason for its low
strength would be overheating of the
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Suggestions
Following are some suggestions on
how you may improve your tension test
results and hopefully qualify your welding procedures.
First, remove the excessive preheat
temperature; it should be perfectly acceptable to weld these test samples without any preheat. My suggestion would be
to use a preheat temperature of 150F
maximum, applied primarily to remove
moisture immediately prior to welding.
Second, carefully monitor your interpass temperature; do not continue welding a subsequent weld pass until the weld
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WELDING JOURNAL
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BRAZING
Q&A
Q: We need assistance to design and
manufacture a structure for cryogenic
work that will be immersed in liquid nitrogen with the upper tubing staying at
ambient temperature. The application of
low-weight metals is very desirable but
the bottom plate or cup should be made
from copper as the metal with the best
thermal conductivity. The cylinder can be
made of aluminum, titanium, or magnesium alloys. As any combination of these
metals with copper is not weldable, we
have to join the cylinder, the bottom, and
tubing by brazing or soldering. But we
cannot find any data about the mechanical behavior of brazed joints of dissimilar metals at cryogenic thermal cycling.
How should we select a filler metal or solder for this job? What would be the best
material combinations to provide reliable work for at least 2000 hours?
20
AUGUST 2013
BY ALEXANDER E. SHAPIRO
Fig. 1 Shrinkage porosity at the interface of copper and P81 brazing filler metal
after cycling in liquid nitrogen.
Fig. 2 Fillet microstructure after soldering A356 aluminum cast alloy with Sn20Zn solder. A After soldering; B
after one cycle of cryogenic cooling.
References
1. Faith, C., Gould, E., McNeal, A.,
Alexandrov, B., and Shapiro, A. 2009.
Evaluation of brazed and soldered joints
after thermal cycling in liquid nitrogen.
Proc. of 4th Int. Brazing and Soldering
Conference. AWS, Orlando. pp. 176180.
2. Lulay, K. E., Khan, K., and Chaaya,
D. 2002. The effect of cryogenic treatment on 7075 aluminum alloy. J. Materials Engineering and Performance 11(5):
479480.
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WELDING JOURNAL
21
TECHNOLOGY
BY BRAD MUTSCHLER AND DALE KEIL
AUGUST 2013
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centering three-jaw chuck that allows for fast setup. When moving from one weld joint to the next, the entire unit can be hoisted
via overhead crane and positioned on the next joint to be welded.
Mechanized circumferential welding also offers cost savings
through weld quality, consistency, and higher deposition rates.
On locomotives, the wheel truck assembly is a primary example of where circumferential welding machines are used. Located
on the wheel trucks are two large pins on the chassis that support the wheel trucks. For this welding application, the chassis is
positioned so that the pins are located in the vertical position
and the weld joint then becomes a simple, flat, downhill weld.
The pins are approximately 10 in. in diameter at the top and
roughly 30 in. in length with a base measurement of 3 ft. The base
plate where they are welded is typically 1.5-in.-thick steel and
must be completely filled with weld material Figs. 2, 3. To complete the weld, the welding machine is attached to the pin using
the three-jaw chuck that supports the entire machine. The machine operator must manually position the welding gun using vertical and horizontal racking systems before proceeding with the
weld. Typically, each weld joint takes multiple passes to fill and
is generally 6070% faster with the circumferential welding machine than with traditional welding methods. Once welding is
complete, the operator lifts the machine and positions it over the
next kingpin assembly to be welded and repeats the process. Since
the system is self-aligning, setup is fast and the operator is welding the next one very quickly.
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WELDING JOURNAL
23
The N400 Series gas hose reel improves the efficiency and safety of welding operations on railroads. Featuring a
narrow frame and compact mounting
base, it is useful for limited space environments. The model features two swivel
joint inlets and two outlet risers to handle
1
4- or 38-in. oxygen/gas dual welding hoses
in lengths of up to 100 ft.
The MAP Mix Provectus, originally designed for producing modified atmosphere packaging gas mixtures in the food
processing industry, has been reconfigured to accept argon. This makes it useful for delivering gas mixtures in a wider
range of applications, including welding.
The product uses a new operating principle to produce a compact and versatile
system. It blends argon in addition to
other gases, including carbon dioxide, oxygen, and nitrogen, for producing multiple
welding mixtures in proportion and at
exact flow rates.
The American Welding Society has released a new video titled Women in
Welding. The nine-min-long video explores some of the exciting career opportunities available to women who decide to
invest their time in the study of welding.
Such career options include welding instructor, certified welding inspector, weld
process specialist, welding technician, and
company president. The video can be
viewed at the following link: www.youtube.
com/watch?v=vHtHOumts7k. More information can be found online at
www.careersinwelding.com.
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point and single-sided protection, it features a low-profile design for quick machine integration. With a built-in automatic range detection of 10 m, the light
curtain is able to determine the distance
to the sender. It offers an IP 67 industrial
design and operating temperature down
to 30C. It is available in heights from
300 to 2100 mm with 14 and 30 mm resolutions and can be used in machine building, consumer goods, and storage/conveyor applications.
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RESISTANCE
WELDING SCHOOL
To
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g to www.fabtechexpo.com
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32
AUGUST 2013
34
AUGUST 2013
the most challenging welding applications. Optimized gas blends address specific application problems that will ultimately increase productivity and save
costs.
With the advances in todays technology and depending on the type of material to be joined galvanized steel,
stainless steel, or aluminum manufacturers have the ability to use enhanced,
more efficient blends for specific
By reducing arc instability and spatter, fume levels were reduced, as were
potential burns to welders. Adding the
blends into the welding processes also
helped reduce postweld cleanup and reduced the cost for welding gas.
WELDING JOURNAL
35
Welding Aluminum
Mixed Gas Development
COMPLETE
Visit Us
At Essen!
In Hall 6.0
A104
A1
Productivity
36
AUGUST 2013
Fig. 1 Joseph Boardman (left), Amtrak president and CEO, poses with Michael Cahill,
president of Siemens U.S. Rail Systems division, outside of an ACS64 locomotive.
WELDING JOURNAL
39
Fabrication Details,
Including Welding Work
As of press time, Siemens was in the
process of moving from the welding and
training that occurred in Germany for the
first few car shells to its Sacramento,
Calif., plant where that process is transitioning for remaining production.
Beginning this month, the car shells
will be welded in Sacramento. Its initial
team includes eight welders who are now
starting to work on the cars after having
been trained in Germany. The company
expects the team may be expanded based
on scheduling needs.
The welders are mainly performing
gas metal arc, shielded metal arc, and gas
tungsten arc welding (limited welds) with
construction materials and metal used
being A588B/A606 or equivalent.
As partially displayed in Fig. 3, the
Fronius USA, LLC equipment purchased
for this locomotive project included ten
TransSteel 3500 systems for compact
steel welding and 9 TPS3200 welding machines with VR4000 wire feeders for
pulse welding stainless steel.
40
AUGUST 2013
Speed Capabilities,
Power Elements
The new locomotives will operate on
northeast regional trains at speeds up to
125 mph on the Northeast Corridor
(NEC) along the Washington/New York/
Boston route and Keystone Service trains
at speeds up to 110 mph on the Keystone
Corridor from Philadelphia to Harrisburg, Pa.
All long-distance trains operating
on the NEC will be powered by these
locomotives.
Additionally, the ACS-64 will have a
peak of 8600 hp with good acceleration
capabilities to achieve revenue service
speeds of 125 mph pulling up to 18 Amfleet coach cars, while simultaneously
providing up to 1000 kVA of head-end
power for auxiliary train equipment such
as interior lights, electrical outlets, and
air-conditioning/heating.
The locomotive is based on Siemens
newest platform, the Vectron. Dual auxiliary inverters provide redundancy to ensure heating and cooling, and lighting
and door systems remain in service
should one inverter fail.
EnergyEfficient Features
The locomotives are not only designed for easier maintenance but to improve energy efficiency by using a regenerative braking system. It will feed energy back into the power grid to enhance
Smart Technology
Specifics
The microprocessor system installed
in the locomotive allows for self-diagnosing technical issues. The on-board computer system can notify the engineer and
operator of any maintenance issues and
take self-corrective action to maintain
operation.
Safety Factors
The Amtrak-specific design meets the
latest Federal Railroad Administration
safety requirements, including crash energy management components like frontend strength and a crumple zone for collision with large objects, in addition to
an enhanced safety cage, push back couplers, and anticlimber functionality.
The ACS-64 enhanced design allows
for more efficient maintenance as well to
ensure locomotives are returned to service as quickly as possible.
Testing Efforts
The first three locomotives will undergo a comprehensive testing program
Job Creation
Aspects
We are committed
to connecting people,
communities, and jobs.
This project does all
three, said Karen
Hedlund, Deputy Federal Railroad Administrator.
Investing in manufacturing, these 70
new locomotives are creating and preserving jobs in 60 cities across the country while meeting the growing demand
Conclusion
As part of the Amtrak Fleet Strategy
Plan to modernize and expand its equipment, the units will replace electric locomotives that have 25 and 35 service years,
plus average mileage of more than 3.5
million miles traveled (with some approaching 4.5 million miles).
So just think about it the next time
you travel by train in the northeast region, you could be riding in style thanks
to one of these new ACS-64 locomotives.
The benefits offered, including reliability, efficiency, mobility, and economic
growth, are significant. Also, the high
power, regenerative braking, key safety
points, efficient maintenance, smart
technology, and redundancy features
these hold are worthwhile.
WELDING JOURNAL
41
NO-Doped Shielding
Gases Benefit
Stainless Steel Welding
Ozone
Ozone emissions when welding were
recognized as an occupational hazard in
the mid 1980s (Ref. 5). At low levels (0.1
ppm), a sensation of dryness and irritation in nose and throat is felt after a short
period. At higher levels (0.11 ppm),
ozone can cause nasal congestion, chest
pain, and headache, as well as loss of
breath. A great deal of research has been
conducted regarding ozone emission
rates (Ref. 6), which vary by process and
welded material. Ozone is formed when
ultraviolet (UV) radiation emitted by the
arc comes into contact with oxygen at the
boundary between shielding gas and at-
BY J. BERKMANNS
J. BERKMANNS
(joachim.berkmanns@linde.com), PhD,
is the national technical manager for
Linde Canada Limited.
Photos copyright of Linde Canada Limited.
43
Hexavalent Chromium
Another occupational hazard, especially when welding stainless steel, is exposure to hexavalent chromium (CrVI).
Chromium in the amount of 1218% is
commonly used as an alloying element in
stainless steels to achieve corrosion resistance. Chromium can be oxidized to
different degrees, meaning it can produce compounds with one, two, or three
oxygen atoms. Chromium combined with
three oxygen atoms is called hexavalent
chromium and is a known carcinogen.
In the previous section, it was pointed
out that ozone is a strong oxidizing agent.
Consequently, the question arises as to
whether lower levels of ozone in the
vicinity of the arc coincide with lower levels of hexavalent chromium when welding stainless steels. If so, NO-doped
shielding gases may lower the emissions
of hexavalent chromium by lowering the
ozone levels. In Ref. 10, welding fumes
were exposed to concentrations of oxygen up to 100% and two different concentrations of ozone. While none of the
oxygen concentrations appeared to increase the Cr VI/total Cr ratio significantly, ozone concentrations of 10 and
30 ppm did.
In the following, publications that
have reported on ozone and hexavalent
44
AUGUST 2013
Chemical
Oxidizing Reagent
Helium
Argon
Carbon Dioxide
Oxygen (atomic)
Oxygen (molecular)
Nitric Oxide
Ionization
Energy [eV]
24.58
15.75
13.77
13.6
12.06
9.26
Ozone
Oxygen
Oxidizing
Potential [V]
2.07
1.23
Conclusion
Several studies have been referenced
that report on CrVI formation as a function of oxygen presence in the vicinity of
the arc. The presented literature is only
a small cross section of the total welding
research so the reader is invited to study
additional material. Also, the mechanisms for CrVI formation are complex and
new findings become available often.
However, at this time the absence of
strong oxidizers in the vicinity of the arc
when welding stainless steel correlates to
a decrease in the emissions of harmful
CrVI. Ozone is a particularly strong oxidizing agent and its presence was investigated and directly relates to the presence
of CrVI. This indicates that NO-doped
shielding gases not only offer a way to reduce ozone emissions but also Cr VI formation when welding stainless steel all
while providing improved arc stabilization and heat input. As for the reduction
in CrVI formation, more research is
needed and the use of a NO-doped shielding gas should only be viewed as one step
toward creating a better weld environment. The correct use of suitable personal
protective gear and effective fume extraction are always recommended.
References
1. ANSI/AWS 5.10-94, Recommended
Practices for Shielding Gases for Welding
and Plasma Arc Cutting. Miami, Fla.:
American Welding Society.
2. GMAW Welding Guide. Cleveland,
Ohio: The Lincoln Electric Co.
3. Guidelines for Gas Metal Arc Welding. Appleton, Wis.: Miller Electric Mfg.
Co.
4. Guidelines for Gas Tungsten Arc
Welding. Appleton, Wis.: Miller Electric
Mfg. Co.
5. Zens, D. E., et al. 1986. Safety and
health in welding An evaluation of respiratory protection. Welding Journal
65(9): 57.
6. Ozone in welding and related procedures. Literature report from Berufsgenossenschaft Metal Nord (BHM),
2002.
7. Facts about: Ozone reduction with
MISON shielding gases. AGA Gas.
8. Emission of UV radiation during
arc welding. Institute for Occupational
Safety and Health of the German Social
Accident Insurance (IFA), 2011.
9. Lindstroem, J. 1988. Adding NO to
argon or argon/helium mixtures does the
trick. INALCO Conf.
10. Madden, M. G. 1987. Hexavalent
chromium in aerosols evolved during a
high temperature metallurgical process.
PhD thesis, University of Bradford.
11. Eagar, T. W., et al. 1998. Study of
chromium in gas metal arc welding fume.
Proceedings of ASM-AWS Trends in Welding Research Conference.
12. Dennis, J., et al. 2002. Control of
occupational exposure to hexavalent
chromium and ozone in tubular wire arcwelding processes by replacement of
potassium by lithium or addition of zinc.
Ann. Occup. Hyg. 46(1): 3342.
13. Dennis, J., et al. 2002. Control of
exposure to hexavalent chromium and
ozone in gas metal arc welding of stainless steel by use of secondary shield gas.
Ann. Occup. Hyg. 46(1): 4348.
14. Keane, M., et al. 2009. Hexavalent
chromium content in stainless steel welding fumes is dependent on the welding
process and the shielding gas. J. Environ.
Monit. 11: 418424.
15. Matusiak, J., and Wycislik, A.
2010. The influence of technological conditions on the emissions of welding fume
due to welding of stainless steel. Metalurgua 49(4): 307311.
The Modular Drive System is the only American made travel carriage.
For info go to www.aws.org/ad-index
WELDING JOURNAL
45
Fig. 1 A view of the Messe Essen Place of Events, venue for the 2013 Essen Trade Show.
46
AUGUST 2013
BY HOWARD M. WOODWARD
HOWARD M. WOODWARD
(woodward@aws.org) is associate
editor of the Welding Journal.
Thermal Spraying to Be
Featured
There will be a number of innovative
exhibits at the fair promoting equipment,
installations, and materials for brazing,
soldering, heat treatment, and especially
thermal spraying demonstrated by the 13
member companies of the German Association of Thermal Sprayers comprised
of nine German companies, three Swiss,
and one Dutch company. Featured will
be thermal spraying torches, coating systems for agriculture, the textile industry,
automotive sector, and laser optics for
spraying torches in addition to the associated powder nozzles and feeders. Visit
the 2200-sq-ft exhibition at Booth A120
in Hall 5 where specialists will demonstrate how thermal spraying can protect
metals, ceramics, plastics, textiles, wood,
glass, and turnkey installations for surfacing. Also, they will demonstrate a
cross section of applications for the manufacture of turbine blades, sealing rings,
printing rolls, and other products.
47
Fig. 3 Essen, Germany, site of the Schweissen & Schneiden 2013 International Trade Fair and 66th IIW Annual Meeting.
48
AUGUST 2013
ters, restaurants, and conference facilities. Another attraction for locals and
tourists alike is the Baldenevsee, a large
water reservoir where one can stroll
along the boardwalk past numerous
cafs, restaurants, and beer gardens.
PlasmaCAM
Polymet Corp.
Postle Industries, Inc.
Pro Spot International
Selectrode Industries, Inc.
Sellstrom Mfg. Co.
Special Metals Welding Products Co.
Strong Hand Tools
Sumner Mfg. Co., Inc.
United States Welding Corp.
Uniweld Products, Inc.
Weld Engineering Co.
Weld-Aid Products
Weldcraft Products
WELDING WIRES
MIG Welding Wires ! TIG Welding Rods ! Submerged Arc Welding
Wires ! Mild Steel Welding Wires ! High Temperature & Creep Resistant
Welding Wires ! Flux Cored Wire ! Aluminium Wire ! Bronze Wire !
Copper Zinc Tin Alloyed Wires ! Oxyfuel Gas Welding Rods
STICK ELECTRODES
Stainless Steel Electrodes ! Cast Iron Electrodes ! Hard Facing
Electrodes ! Pipe Welding Electrodes ! High Strength Cryogenic
Electrodes ! High Temperature & Creep Resistant Electrodes !
Corrosion Resistant Electrodes ! Heat Resistant Electrodes ! Nickel
Base Electrodes
SUBMERGED ARC WELDING FLUX
Aluminate Rutile Fluxes ! Aluminate Basic Fluxes ! Fluorid Basic Fluxes !
Manganese Silicate and Calcium Silicate Fluxes
WELDING MACHINES
MIG/MAG & RECTIFIERS ! INVERTER ! TIG ! AC/DC TIG ! DC TIG !
Pulsed MIG/MAG ! Synergic MIG/MAG ! AC/MIG-MAG ! Submerged
Welding Machines ! Air Plasma Cutting ! Welding Generators
WELDING JOURNAL
49
BY DON SADLER
Keys to Collecting
Experienced owners of welding businesses say there are several keys to collecting payment from customers. The
first is covering all your bases before you
start the job with regard to getting contracts and purchase orders completed
and signed by all parties.
This is very important without the
right signed paperwork, youre dead in
the water when it comes to collecting,
said Gilly Burrion, COO of Florida Gas
Welding Supply, Hollywood, Fla. The
company once had to sue a major customer to collect money owed and was
able to settle with them out of court. Having all the signed paperwork in order was
a big part of reaching a positive settlement, Burrion recalled.
We usually create a letter of intent
that describes the scope of the project
before proceeding to set up the job,
added Massa. Most jobs are actually
done through the contractors contract,
and then we attach our letter of intent to
this as an addendum so its clear what our
obligation is.
Wyatt Swaim, CEO of WJS Consulting, Gueda Springs, Kan., echoed this
point about clarifying your specific responsibilities: Be very clear up front and
in writing about the specific job youre
performing. Communicate every detail
of your responsibilities in the purchase
order or contract.
51
Collecting Down
Payments
Of course, the more money you can
collect from customers up front, the less
youll have to collect after the job is finished. All the experienced welding business owners said they collect a 50% deposit up front when they can, especially
if they have to lay out money for materials and supplies. Its nearly impossible
to get full payment up front, but if I can
get half, thats usually pretty good, said
Rolla.
Massa said he has one employee dedicated to handling billing and collections.
I call her my little pit bull. But there are
still times when I have to call customers
about late payments, and I dont have a
problem with this.
Swaim also said he calls customers
when late payments hit the 90 day mark.
But this is sometimes awkward because
my relationship is with a technical per-
Collections Tips
Here are five tips from experienced welding business owners
for collecting payment after a job is complete:
1. Create an accounts receivable aging report. This will tell you
which accounts are past due and how late they are so you know
where to concentrate your collection efforts. It will track the payment status of all of your customers by time period (such as 030
days, 3060 days, etc.) and amounts due.
2. Act quickly. The chances of collecting payment drop quickly
over time: from 74% after 90 days to about 50% after six months
and just 23% after one year, according to data from the Commercial Collection Agency Association. Call or e-mail customers as
soon as the payment is past due to inquire about its status. If youre
friendly and nonthreatening, this will often get the problem resolved
quickly.
3. Consider offering a payment plan. If the customer is having
cash flow problems, you might consider negotiating a payment plan
52
AUGUST 2013
for the past-due amount. It should specify that consecutive payments of a certain amount will be made over a certain number of
months ideally, the debt will be paid in full within six months.
Formalize the agreement in writing and have it signed by both
parties.
4. Send a past-due letter. If these steps dont yield results, you
may have to get a little more serious. A past-due letter should be
sent via certified mail, clearly explaining the delinquent status of
the account. For example: This letter is to follow up on phone messages and e-mails regarding the past-due status of invoice #ABC.
Please remit payment at once, or contact us if you have any questions about the invoice.
5. Get help from a professional. If a past-due letter gets no response, you might consider turning the account over to a collection
agency. But this may threaten your future relationship with the
customer, so weigh the value of the relationship against the amount
of money owed to decide whether to go this route or simply write
off the debt.
COMING
EVENTS
ASM Heat Treating Society Conf. and Expo. Sept. 1618. Indiana
Convention Center, Indianapolis, Ind. www.asminternational.org/
content/Events/heattreat/.
9th Annual Northeast Shingo Prize Conf. Sept. 24, 25. The Resort & Conference Center at Hyannis, Hyannis, Mass.
www.neshingoprize.org.
C315/350
Manual
Cold Saw
Simple
hinge-type
construction
Ideal for
prototype and
low volume work
Two-speed spindle
(30 & 60 rpm)
Heavy-duty drive
3.5 hp TEFC motor
Sliding double vise assembly for precision,
burr-free cutting
Totally enclosed transmission
6700 Quality Way
Portage, MI 49002
269-321-8860
Fax: 269-321-8890
www.kmtsaw.com
54
AUGUST 2013
WJS1235
COMING EVENTS
continued from page 54
30Oct. 3. The International Centre, 6900 Airport Rd., Mississauga, Canada. Society of Manufacturing Engineers. (888) 3227333, ext. 4426; www.cmts.ca.
Brazil Welding Show 2013. Oct. 14. So Paulo, Brazil. Sponsored
by DVS, German Welding Society. www.brazil-welding-show.com/.
National Manufacturing Day. Oct. 4. Events held nationwide.
Sponsored by Fabricators & Manufacturers Assn. To find events
planned near you, visit www.mfgday.com for interactive map.
ICALEO Intl Congress on Applications of Lasers & ElectroOptics. Oct. 610, Hyatt Regency Miami Resort, Miami, Fla.
www.lia.org/conferences/icaleo.
The Intl WorkBoat Show. Oct. 911, Morial Convention Center,
New Orleans, La. www.workboatshow.com.
WESTEC. Oct. 1517. Los Angeles Convention Center, Los Angeles, Calif. The Society of Manufacturing Engineers. (800) 7334763; www.westeconline.com.
12th Inalco Intl Aluminum Conf. Oct. 21, 22, Palais des Congrs
de Montral, Montreal, Que., Canada. www.inalco2013.com.
WELDING JOURNAL
57
Educational Opportunities
Aluminum Welding Technology School. Oct. 13, AlcoTec,
Traverse City, Mich. For brochure and to register, visit
www.alcotec.com/us/en/education/Training-Alcotec.cfm.
Brazing School Fundamentals to Advanced Concepts. Oct.
2224 (Greenville, S.C.); Nov. 1921 (Simsbury, Conn.).
www.kaybrazing.com/seminars.htm; dan@kaybrazing.com; (860)
651-5595.
CWI Preparation Courses. Aug. 1923, Nov. 1115. D1.1
Endorsement: Aug. 23, Nov. 15; D1.5 Endorsement: Aug. 16; API
Endorsement: Nov. 8. All courses and endorsements held at
Welder Training & Testing Institute, 1144 N. Graham St.,
Allentown, Pa. www.wtti.com; (610) 820-9551, ext. 204.
Fundamentals of Welding Engineering. Aug. 59, EWI,
Columbus, Ohio. www.ewi.org/events; education@ewi.org.
Grounding and Electrical Protection Courses. Aug. 15, 16,
Chantilly, Va.; Oct. 17, 18, Albuquerque, N.Mex. Lyncole XIT
Grounding, www.lyncole.com/courses; education@lyncole.com.
Industrial Ventilation Training Programs. Oct. 1416,
Birmingham, Ala.; March 1719, 2014, Las Vegas, Nev. For electronic copy of the brochure e-mail rdeckhoff@gmail.com. The
Deep South Center for Occupational Health & Safety.
Introduction to Friction Stir Welding. Nov. 6, EWI, Columbus,
Ohio. www.ewi.org/events; education@ewi.org.
Laser Vision Seminars. Aug. 28, 29; Oct. 2, 3; Nov. 6, 7; Dec. 4,
5. Servo-Robot, Inc. www.servorobot.com.
Environmental Online Webinars. Free, online, real-time seminars conducted by industry experts. For topics and schedule, visit
www.augustmack.com.
ASM Intl Courses. Numerous classes on welding, corrosion, failure analysis, metallography, heat treating, etc., presented in
Materials Park, Ohio, online, webinars, on-site, videos, and
DVDs; www.asminternational.org, search for courses.
Automotive Body in White Training for Skilled Trades and
Engineers. Orion, Mich. A five-day course covers operations,
troubleshooting, error recovery programs, and safety procedures
for automotive lines and integrated cells. Applied Mfg.
Technologies; (248) 409-2000; www.appliedmfg.com.
58
AUGUST 2013
CERTIFICATION
SCHEDULE
EXAM DATE
Sept. 21
Sept. 21
Sept. 21
Sept. 21
Sept. 21
Sept. 28
Sept. 28
Sept. 28
Oct. 5
Oct. 12
Oct. 12
Oct. 12
Oct. 12
Oct. 17
Oct. 19
Oct. 19
Oct. 19
Oct. 26
Oct. 26
Oct. 26
Oct. 26
Nov. 2
Nov. 2
Nov. 9
Nov. 16
Nov. 16
Nov. 16
Nov. 16
Nov. 21
Dec. 5
Dec. 14
Dec. 14
Dec. 14
Dec. 14
Dec. 14
EXAM DATE
Sept. 28
Oct. 19
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the
seminar/exam or exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept.
to confirm your course status before making travel plans. For information on AWS seminars and certification programs, or to register online, visit www.aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars. Apply
early to avoid paying the $250 Fast Track fee.
60
AUGUST 2013
Join together.
Meet over 1,000 exhibitors and experts from all over the world.
Discover innovative solutions in joining, cutting and surfacing.
Take advantage of the opportunities in the industrys hot spot.
Join your industry in Essen!
WELDING
WORKBOOK
Datasheet 342
Units
Argon
Helium
Hydrogen(1)
Carbon Dioxide
Nitrogen
Oxygen
Density(2)
lb/ft3
[kg/m3]
0.103
[1.656]
0.0103
[0.1656]
0.0052
[0.0834]
0.114
[1.833]
0.0725
[1.1605]
0.0828
[1.326]
Liquid Density(3)
lb/ft3
[kg/m3]
86.98
[1394]
7.803
[125]
4.28
[68.6]
63.3(4)
[1014]
50.9
[808.8]
51.22
[820.5]
Heat of Vaporization(5)
Btu/lb
[KJ/kg]
69.7
[162.0]
8.77
[20.4]
192.7
[448.2]
119.3(6)
[276.8]
85.6
[149.1]
91.7
[213.0]
F
[C]
302.6
[185.9]
452.0
[268.9]
423.0
[252.7]
109.3
[78.5]
320.4
[195.8]
297.3
[183.0]
Btu/h ft F
[watt/m K]
0.0094
[0.0153]
0.0886
[0.1532]
0.1008
[0.175]
0.0093
[0.0162]
0.0147
[0.0254]
0.0149
[0.0258]
eV
15.7
24.5
13.5
14.4
14.5
13.2
39.94
4.003
2.016
44.01
28.013
31.99
Boiling Point(7)
Thermal Conductivity(8)
Ionization Potential
Molecular Weight
Notes:
(1) Flammable limits of hydrogen: in air, 4.174.2% (vol); in O2, 4.793.9% (vol). (2) At 70F [21C] and 1 atm. (3) At boiling point. (4) Saturated liquid at 1.7F [16.8C]. (5) All at boiling point except CO2. (6) Liquid CO2 at 300 lb/in.2 [2.07 MPa] and 1.7F [16.8C]. (7) All at 1 atm except CO2 at
sublimation point. (8) All at 32F [0C] except CO2 at 77F [25C].
Excerpted from AWS C5.10/C5.10M: 2003, Recommended Practices for Shielding Gases for Welding and Cutting.
62
AUGUST 2013
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share what you like about the industry.
industry.
An Open Letter T
To
o The W
Welding
elding Industry
As everyone should be aware,
suffering
from a lack
our industry is suf
ffering
f
of young entrants into the welding
industry
industry.. This is evident in all facets
of our industry
industry,, from hands-on
welding to the many business
Jim Horvath
disciplines related to welding.
The barrier to entry into our industry is low
low,, with welding
programs readily available through vocational schools
as well as many distributors throughout the country
country,,
we are still not seeing the level of new recruits that we
would expect.
At the request of WEMCO
WEMCO,, the American We
Welding
eld
elding
Society has been tasked with providing volunteers with a
presentation that promotes our industry to students and
young professionals pursuing a career in welding. This
presentation can be shared with junior colleges, teacher
PTA
associations, PT
TA mee
meetings, guidance counselors, and
any other groups that have some influence over career
choices of our younger generation.
Youre
Y
oure
o
probably asking
as
yourself at this point, Whats
Whats
dif
different
ffferent about this p
program that hasn
hasntt been done
before?
before? We
Well,
ell, the ans
answer is YOU
YOU!!
We
e ask that you speak
s
from your heart about your
industry..
job and share what you like about the industry
Shine""
The key to success of the ""Weld
Weld and Shine
program is to get as many members of the welding
community in front of these groups as possible. The
effort
Your
our
ef
ffort
f on your part
p is minimal. Y
o role will
wil be to show
the presentation, engage the audience in questions, and
provide information about your career in the welding
industry.. Whatever your position may be, whether sales,
industry
marketing, hands-on welding, counter sales, etc., we
hope you will share with these groups the many
opportunities available in welding.
In conjunction with developing the presentation, the
American Welding
We
elding
eld
Society is asking you to join our
Speakers
Speaker
s Bureau. The list of speakers will be available
to the aforementioned groups. Y
You
ou
o will not be asked to
community.. If youre not
travel any distance outside your community
available for a presentation, we understand, but hope
you can participate as other opportunities arise. Please
industry,,
join me in giving some of your time back to our industry
which has provided us with the opportunity to raise
families, send our children to college, and enjoy the
benefits of employment.
To
T
o learn more about
ab
bout the Weld
We
eld and Shine Program,
please contact the WEMCO Management Specialist
Ms. Keila DeMoraes 305.443.9353 ext. 444 or via email kdemoraes@aws.org
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
Shown at the D. Fred Bovie Library ribbon-cutting ceremony are (from left) Sam Gentry, Gerald Uttrachi, Lou Bovie, and Ray Shook. Inset: The D. Fred Bovie Library wall plaque.
WELDING JOURNAL
65
Tech Topics
Errata: D1.4/D1.4M:2011
Structural Welding Code
Reinforcing Steel
Page 40, Figure 6.5 (c), the 8 in the formula should read B.
Correct the formula to read:
LMIN = 2L1 + 16D + B
Official Interpretation
AWS A5.26/A5.26M-97
Specification for Carbon and Low-Alloy
Steel Electrodes for Electrogas Welding
AWS Log: A5.26/A5.26M-97-I01
Inquiry: If a manufacturer of self-shielded
electrogas electrodes does not manufacture a 0.120-in. (3.0-mm) wire, then can
they classify their electrode based on the
use of a 332-in. (2.4-mm) size (if that is the
closest size produced) using their recommended procedure appropriate for that
size, which could require use of a beveled
joint?
Response: Yes
Official Interpretation
AWS A5.01M/A5.01:2008
(ISO 14344:2002 MOD)
Procurement Guidelines for Consumables
Welding and Allied Processes
Flux and Gas Shielded
Electrical Welding Processes
Inquiry: Is analysis of weld metal chemical composition sufficient to satisfy that
all wet mixes within the lot are equivalent
per AWS A5.01 controlled chemical
composition?
Response: No.
AUGUST 2013
Shown are several International Thermal Spray Association members and guests during their tour of the Snow Basin Resort, home of the
2002 Olympic Winter Games.
The International Thermal Spray Association (ITSA), a Standing Committee
of the American Welding Society, held its
annual membership meeting and technical program June 68 in Ogden, Utah.
A professional industrial association,
ITSA is dedicated to expanding the use
of thermal spray technologies for the benefit of industry and society. The Association is closely interwoven with the history
of thermal spray development in this
hemisphere. Founded in 1948, and once
A complete list of ITSA member companies, their products and services, and
their representatives can be reviewed at
www.thermalspray.org.
Mark your calendar:
Nov. 1820, 2013: Visit the Thermal
Spray Pavilion and Conference to be held
during FABTECH in Chicago, Ill.
April 2426, 2014: The next ITSA annual meeting will be held in Savannah,
Ga.
67
Winners Circle
Sponsored 20 or more Individual Members per year since June 1, 1999. The superscript denotes the number of times the status
was achieved if more than once.
E. Ezell, Mobile11
J. Compton, San Fernando Valley7
J. Merzthal, Peru2
G. Taylor, Pascagoula2
L. Taylor, Pascagoula2
B. Chin, Auburn
S. Esders, Detroit
M. Haggard, Inland Empire
M. Karagoulis, Detroit
S. McGill, NE Tennessee
B. Mikeska, Houston
M. Pelegrino, Chicago
W. Shreve, Fox Valley
T. Weaver, Johnstown/Altoona
G. Woomer, Johnstown/Altoona
R. Wray, Nebraska
Presidents Guild
Sponsored 20+ new Individual Members
M. Pelegrino, Chicago 36
E. Ezell, Mobile 32
Presidents Roundtable
Sponsored 919 new Individual Members
R. Fulmer, Twin Tiers 10
W. Blamire, Atlanta 9
A. Tous, Costa Rica 9
P. Strother, New Orleans 9
Presidents Club
Sponsored 38 new Individual Members
D. Galiher, Detroit 7
W. Komlos, Utah 7
J. Smith, San Antonio 6
C. Becker, Northwest 5
R. Thacker Jr., Oklahoma City 5
L. Webb, Lexington 4
D. Wright, Kansas City 4
T. Baber, San Fernando Valley 3
J. Bain, Mobile 3
A. Bernard, Sabine 3
J. Blubaugh, Detroit 3
P. Brown, New Orleans 3
D. Buster, Eastern Iowa 3
C. Daon, Israel Section 3
G. Gammill, NE Mississippi 3
B. Hackbarth, Milwaukee 3
S. Jaycox, Long Island 3
D. Jessop, Mahoning Valley 3
D. Saunders, Lakeshore 3
T. Sumerix, Dayton 3
J. Turcott, Rochester 3
A. Winkle, Kansas City 3
R. Wright, San Antonio 3
R. Zabel, SE Nebraska 3
68
AUGUST 2013
Affiliate Companies
21st Management Corp.
PO Box 9206, Paducah, KY 42002
Accutech Mfg., Inc.
13109 Los Nietos Rd.
Santa Fe Springs, CA 90670
Acutech, LLC
3816 Hwy. 40, Columbia Falls, MT 59912
Bombay Amusement Ride P Ltd.
303 Cliff Tower 3rd Cross Ln.
Lokhandwala Andheri (W)
Mumbai Maharashtra 400053, India
Hero Protective Alloys, Inc.
400 Watt Dr., Fairfield, CA 94534
Kasal Engineering Services, Ltd.
2 Court 4 Junction off Ogunu Rd.
POB 2076, Delta State, Warri, Nigeria
Quinlan ISD
401 East Richmond, Quinlan, TX 75474
Supporting Companies
Elgin Sweeper
1300 W. Bartlett Rd., Elgin, IL 60120
Northeast Welding
302 Reservoir, North Attleboro, MA 02760
Educational Institutions
Community College of Denver
6221 Downing St. (rear building)
Denver, CO 80216
69
AUGUST 2013
District conferences bring Section leaders together annually to share their experiences and
renew relationships. Shown are District 18 Section leaders at the 2011 conference.
SECTIONNEWS
Shown at the District 2 conference are (from left) Bob Waite, Jesse Provler, Thomas Colasanto III, Dominick Colasanto, Tom Gartland,
Brian Cassidy, Paul Lenox, Terry Perez, Eric Dolan, Dist. 2 Director Harland Thompson, Bill Mowbray, Gus Manz, Frank Srogota, Mike
Chomin, Sal Russomanno, Ken Stockton, and Ken Temme.
District 1
District 2
District 2 Conference
JUNE 1
Activity: Harland Thompson, Dist. 2 director, conducted the meeting in Scotch
Plains, N.J. Attending were Bob Waite,
Jesse Provler, Thomas Colasanto III, Dominick Colasanto, Tom Gartland, Brian
Cassidy, Paul Lenox, Eric Dolan, Bill
Mowbray, Gus Manz, Frank Srogota,
Mike Chomin, Sal Russomanno, Ken
Stockton, Ken Temme, and Terry Perez,
AWS representative.
NEW YORK
MAY 13
Speaker: Bob Waite, P.E.
Affiliation: Waite Welding Metallurgy
Topic: Welding inspection using D1.1 and
AISC codes
Activity: Treasurer Alan Zibitt received an
award in appreciation for his services.
Shown at the New York Section program are (from left) Dist. 2 Director Harland Thompson, speaker Bob Waite, Treasurer Alan Zibitt, and Chair Dominick Colasanto.
WELDING JOURNAL
71
Shown at the District 5 conference are from left (seated) David Ennis, Al Sedory, Jennifer Skyles, and Frank Rose; (standing) Odell Haselden,
Gale Mole, Bill Myers, Doug Yates, Ray Monson, Gilly Burrion, Kevin Rawlins, and Carl Matricardi, District 5 director.
Shown at the Philadelphia Section meeting are (from left) Dominick Colasanto, Chair Bill
Mowbray, Salvatore Russomanno, Mike Chomin, Frank Srogota, and Ken Temme.
Dan Moldovan (right) is shown with Allen
Quigg, Reading Section treasurer.
LANCASTER
JUNE 5
Activity: The board held a planning meeting in Lancaster, Pa.
READING
JUNE 1
Activity: The Sections board members
met for its end of the year meeting. Participating were Chair Bill Mowbray, Salvatore Russomanno, Mike Chomin, Frank
Srogota, and Ken Temme. Also attending
were Dist. 2 Director Harland Thompson,
Terry Perez, AWS director of Certification,
and Dominick Colasanto, chairman of the
New York Section.
APRIL 17
Activity: Mike Wiswesser, Dist. 3 director,
presented the District Meritorious Award
to Merilyn McLaughlin and an award to
Tracy Davenport for his services as chairman. Treasurer Allen Quigg presented a
Section scholarship to Dan Moldovan who
also won the first-place trophy in the thirdlevel category at the recent welding contest. Other contestants recognized included Skyler Becker, Diego Jimenez, Levi
Bucher, Nate Miller, Evan Hostetter, Jordan Makison, Dylan Weaver, Dylan Sheha,
Kegan Landis, Alex Barlow, and Zachery
Dougherty. The meeting was held at Dutch
Way Restaurant in Myerstown, Pa.
District 3
District 4
Shown at the Reading Section program are the third-level welding contestants (from left)
Levi Bucher, Dan Moldovan, Skyler Becker, and Diego Jimenez.
PHILADELPHIA
AUGUST 2013
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
District 5 Conference
JUNE 7, 8
Activity: The meeting was held at AWS
World Headquarters in Miami. Attending
were District 5 Director Carl Matricardi,
David Ennis, Al Sedory, Jennifer Skyles,
Frank Rose, Odell Haselden, Gale Mole,
Bill Myers, Doug Yates, Ray Monson, Gilly
Burrion, and Kevin Rawlins.
Shown at the Florida West Coast program are (from left) Randy Kelley, Alan Shissler, Harold
Delegado, and Lianna Smith.
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
Shown at the Niagara Frontier Section event are (from left) Ron Stahura, Fred Schmidt,
John Sullivan, Jeff Klapper, Howard Johns, and Tom Matecki.
NIAGARA FRONTIER
MAY 30
Activity: The Section held its past chairmens dinner at Dominics Little River
Grille in Niagara Falls, N.Y. Honored were
past chairs Ron Stahura, Fred Schmidt,
John Sullivan, Jeff Klapper, Howard
Johns, and Tom Matecki.
District 7
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
Master chefs (from left) Paul Huffman, Samuel Scripnic, Marty Dominy, Jason West, and
Richard Daffron were kept busy at the Chattanooga Sections 60th annual fish fry.
CHATTANOOGA
MAY 17
Activity: The Section held its 60th annual
hush puppy and catfish fry fund-raising
event at Alstom Power in Chattanooga,
73
Dray Sweeton (left) receives a welding scholarship from Robin Dykes, Chattanooga Section education chair.
District 9 officers and guests are shown at the annual conference in June.
NASHVILLE
District 9 Conference
APRIL 25
Speaker: D. Joshua Burgess, Northeast
Tennessee Section chair
Affiliation: University of Tennessee
Topic: Welding metallurgy
Activity: The Section conducted its scholarship awards presentations at World Testing in Mt. Juliet, Tenn. District 8 Director
Joe Livesay presented the Section-sponsored $1000 Roy Petty Memorial Scholarship to Jordan West. Eleven other students
received $500 scholarships.
JUNE 68
Activity: District 9 officers and guests met
at Rips on the Lake in Madisonville, La.,
for a special event followed by the conference on June 8 at the Maritime Museum.
Special guests at the conference included
John Bruskotter, a past AWS president;
John Bray and J. Jones, directors of District 18 and 17, respectively; and Mary
Ruth Johnsen, AWS staff representative.
MOBILE
NORTHEAST TENNESSEE
D. Joshua Burgess, District 8 deputy director, discussed welding metallurgy at the
Nashville Section program.
APRIL 9
Speaker: Nancy Cole, AWS president
Affiliation: NCC Engineering
Topic: Careers for women in welding
Activity: D. Joshua Burgess received an
award for his distinguished services as
chairman. Paul Pipkin received the Section Meritorious Award and the Silver
Member Certificate to recognize his 25
years of service to the Society. Chris Hayes
and Don Combs received Section Meritorious Awards. Special guests included Zhili
Feng, group leader at ORNL; Kurt Sickafus, head, University of Tennessee Materials Science Engineering Dept.; Tom
Mustaleski, an AWS past president; and
District 8 Director Joe Livesay.
District 9
ACADIANA
AUGUST 2013
MAY 28
Speaker: Wendell Dietz
Affiliation: Miller Electric Mfg. Co.
Topic: Welding aluminum
Activity: The Section members and welding students convened at Acadiana Technical College welding lab in New Iberia,
La. Following the presentation, attendees
welded aluminum using the gas metal arc
process.
APRIL 29, 30
Activity: The Section supported three students, Eric Roblee, Steve Goulet, and
Ronald Castleberry, to participate in the
SkillsUSA regional welding competition
held in Pensacola, Fla., and their trip to
the national welding competition.
MAY 16
Speaker: George Fairbanks, Dist. 9 director
Affiliation: Fairbanks Inspection & Testing Services, LLC
Topic: Inspection and repair welding of
large castings in the sugar mill industry
Activity: Incoming Chair Michael Zoghby
presented Johnny Dedeaux an award for
his services as chair. Michael Zoghby received the Section Meritorious Award, Jim
Sullivan the Public Sector Educator
Award, and Cleveland Rhodes Jr. received
the District and Section CWI of the Year
Awards. Ronald Castleberry received an
autodarkening welding helmet as a reward
for the welding student attending the most
meetings during the year. The event was
held at The Original Oyster House in
Spanish Fort, Ala.
District 10
Shown at the Drake Well Section meeting are (from left) Joseph Crate, Robert Fugate, Colin Young, Travis Crate, Dan Bubenhiem, Ward
Kiser, Eric Speer, Nate McNett, and Rolf Laemmer.
Paul Pipkin receives his Silver Member Certificate from Nancy Cole, AWS president, at
the Northeast Tennessee Section program.
DRAKE WELL
MAY 14
Activity: The Section hosted a meeting at
The Commons at Franklin, Pa., to discuss
the recent District 10 conference and view
the video of the ribbon-cutting at the AWS
headquarters building. Attending were
Travis Crate, Joseph Crate, Robert Fugate, Colin Young, Dan Bubenhiem, Ward
Kiser, Eric Speer, Nate McNett, and Rolf
Laemmer.
District 11
Robert P. Wilcox, director
(734) 721-8272
rmwilcox@wowway.com
WELDING JOURNAL
75
Shown are the participants in the Detroit Section-sponsored high school welding competition.
Shown at the Detroit Section past chairmens program are (from left) Mike Palko, Tom
Sparschu, Dick DuCharme, John McKensie, Glen Knight, John Bohr, Bernie Bastian, Don
Maatz, Mike Karagoulis, Jim Osborne, Amos Winsand, Ray Roberts, and Bob Wilcox, District 11 director.
CENTRAL MICHIGAN
JUNE 11
Activity: Chair Roy Bailiff and Scholarship
Chair Jeff Grossman presented a Section
scholarship to welding student Jenna R.
Lone in Lansing, Mich.
DETROIT
Shown at the Madison-Beloit Section event are (from left) Welding Instructor Mark Prosser,
Mike Miller, Derrick Hintzman, Trevor Rolette, and Alex Carpenter.
76
AUGUST 2013
MAY 17
Activity: The Section, headed by Glen
Knight, hosted a high school welding contest involving 41 students from nine area
schools. The contest included a written
exam and a welding skills project. Other
awards included welding machines and
St. Louis Section members are shown during their tour of Quality Testing Services.
various prizes. The top three contestants
received scholarships in the amounts of
$2500 to Brody Depa, $1500 to Michael
Waszkiewicz, and $1000 to Daniel
Dveweke. Additional awards included
welding machines and other prizes. The
event was held at Washtenaw Community
College in Ann Arbor, Mich.
JUNE 8
Activity: The Detroit Section held its annual past chairmens dinner and business
meeting at Skyline Club in Southfield,
Mich. Attending were Chair Mike Palko
and past Chairs Tom Sparschu, Dick
DuCharme, John McKensie, Glen Knight,
John Bohr, Bernie Bastian, Don Maatz,
Mike Karagoulis, Jim Osborne, Amos
Winsand, Ray Roberts, and Bob Wilcox,
District 11 director.
The Quality Testing Services presenters at the St. Louis Section tour are (from left) Andrew
Dickenson, Brandon Murrie, Nate Hardy, Steve Stutz, Heather Jacobs, D. J. Prohaska,
Melissa Rankin, Rick Kenloge, and Ken Koppen.
District 12
MADISON-BELOIT
APRIL 20
Activity: The Section members participated in the SkillsUSA welding competitions held at NWTC in Green Bay, Wis.
The winning Nebraska Section golf team members are (from left) Chair Chris Beaty, Tom
Pickrel, Paul Goodby, and Darren Stane.
District 13
District 14
District 13 Conference
ST. LOUIS
JUNE 7
Activity: The Chicago Section hosted the
District 13 annual conference at Grizzly
Jacks Resort in Utica, Ill., conducted by
District Director John Willard. The
speaker was AWS staff representative
Martica Ventura, director, operations, Education Services.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
WELDING JOURNAL
77
The Central Arkansas Section members are shown during their tour of Welspun Tubular in Little Rock.
Alaska Section members are (from left) Willi Davidson, Creighton Moore, presenter Charles Engblom, Craig Soto, Peter Macksey, Stephen
Foreman, Chair Rod London, Kelly Mann, Jeremy Calderon, Cole Mesick, Dennis Long, and Jack Simpson.
Don Schwemmer (far left) led the Idaho-Montana Section on a tour of AMET, Inc.
NEBRASKA
MAY 17
Activity: The Section held its golf outing
at Eagle Hills Golf Course in Omaha, Neb.
About $2000 was raised for the Sections
scholarship fund. Taking the team trophy
were Chair Chris Beaty (Metropolitan
C.C.), Tom Pickrel (Matheson Tri-Gas),
Paul Goodby (Olsson Associates), and
Darren Stane (Hobart Brothers).
District 17
J. Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
CENTRAL ARKANSAS
AUGUST 2013
MAY 21
Activity: The Section toured Welspun Tubular LLC in Little Rock, Ark., to study
the manufacture of spiral-welded pipe
using the HSAW process.
District 18
HOUSTON
MAY 15
Speaker: Curtis Dickinson, senior engineer
Affiliation: University of Ultrasonics
Topic: Inspecting welds using ultrasonic
phased array technology
Activity: Chair Justin Gordy greeted 145
attendees for the Sections last meeting of
the year. Barney Burks and Gary Holbrook
manned the sign-in desk.
District 19
ALASKA
MAY 22
Speaker: Charles Engblom, trainer
Affiliation: Ironworkers Local 751
Topic: Ironworkers apprentice program
Activity: Charles Engblom was elected incoming chair. Following his talk, Engblom
conducted the Section on a tour of Ironworkers Local 751 in Anchorage, Alaska.
BRITISH COLUMBIA
MAY 29
Speaker: Scott Stanley, technical sales representative
Affiliation: The Lincoln Electric Co.
Topic: Recording welding procedures by
connecting the machines to the Internet
Activity: The program was held in Delta,
B.C., for 25 attendees.
District 20
Participants in the SkillsUSA welding contest hosted by the AWCIWT Student Chapter are
shown in February.
District 20 Conference
JUNE 7
Activity: The Idaho-Montana Section
hosted the conference and the Wyoming
Section hosted the luncheon at Hilton
Garden Inn in Idaho Falls, Idaho. Rhenda
Kenny, director, AWS Member Services,
was the AWS staff representative.
IDAHO/MONTANA
JUNE 6
Activity: The Section toured the AMET,
Inc., facility near Rexburg, Idaho. Don
Schwemmer, CEO, conducted the program. Chair Paul Tremblay and Tevan
Boersma displayed the banner for the
newly rechartered BYU Student Chapter.
District 21
FEBRUARY 22
Activity: The Arizona Western College Institute of Welding Technology Student
Chapter hosted the Region I SkillsUSA
welding contest for college and high school
students in Yuma, Ariz.
MARCH 25
Activity: The Student Chapter hosted the
Arizona State SkillsUSA welding contest
held at Phoenix Convention Center
headed by Advisor Samuel Colton.
Tevan Boersma (left) and Chair Paul Tremblay are shown at the Idaho/Montana Section program.
WELDING JOURNAL
79
Shown in March at the Arizona State SkillsUSA welding contest are (from left) Advisor Samuel Colton, Daniel Herrera, Omar Macias,
Adrian Castillo, Trisha Haswood, Christopher Smart, Ricardo Aldan, Manuel Robles, James Veldhuis, Larry Lebsock, and Jason Trepanier.
APRIL 11
Activity: Student Chapter Advisor Samuel
Colton, President Adrian Castillo, and
Wanda Reid, Pipeline Grant staff member,
manned a table at the Arizona Western
College Sustainablity Fair promoting welding as a career choice.
MAY 1
Activity: The Student Chapter promoted
welding as a career to three groups of middle school students as part of the Somerton School District 11 Career Day event.
Participating were President Adrian
Castello, Vice President Christopher
Smart, Omar Marcias, Trisha Haswood,
Manuel Robles, Larry Lebsock, and
Wanda Reid, Pipeline Grant staff member.
CALIFORNIA CENTRAL
COAST
MARCH 15
Activity: The Section promoted welding at
the eighth annual Career Day program
held at Pioneer Valley High School in
Santa Maria, Calif.
MARCH 28
Activity: The California Central Coast Section promoted welding as a career at the
Career Day program held at Fesler Jr.
High School in Santa Maria, Calif., for
about 100 attendees.
80
AUGUST 2013
APRIL 12
Activity: The California Central Coast Section promoted welding as a career for the
7th and 8th grade students at the Career
Day program held at Judkins Middle
School in Pismo Beach, Calif.
APRIL 27
Activity: The California Central Coast Section, headed by Chair Stan Luis, participated in the Allan Hancock College high
school welding competition. The barbecue
lunch was provided by Praxair. The topscoring contestants included Eric Alvarez,
Kasey Millsap, Jose Guzman, Connor
Herrera, Jose Rodriguez, Devin Miller,
Pedro Asuncion, Cole Cargill, Will Jevne,
Cameron Wright, Victor Benitez, and
Daniel Herrera.
MAY 4
Activity: The California Central Coast Section participated in the Future Farmers of
America seventh annual state welding
competition held at Cresta College. Welding Instructor Rob Thoreson conducted
the event. Other attractions included the
Miller Electric and Lincoln Electric mobile welding trailers and the California
Polytechnic tractor pulling team demonstration. The Section provided four AWS
student memberships and four AWS welding jackets to the prizes.
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
International
Section
GERMANY
CALENDAR
Essen, Germany
SEPT. 1117
66th IIW Annual Assembly
www.iiw2013.com
SEPT. 16, 17
Intl Conf. on Automation in Welding
SEPT. 1621
2013 International Trade Fair
Joining, Cutting, Surfacing
SEPT. 1621
Young Welders Competitions
Read the article on page 46 of this
issue for more information.
INTERNATIONAL SALES
TECHNICAL SERVICES
Nancy C. Cole
nccengr@yahoo.com
NCC Engineering
2735 Robert Oliver Ave.
Fernandina Beach, FL 32034
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Chief Financial Officer
Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
Chief Marketing Officer
Bill Fudale..bfudale@aws.org . . . . . . . . . . . . .(211)
Chief Technology Officer
Dennis Harwig..dharwig@aws.org . . . . . . . . .(213)
Executive Assistant for Board Services
Gricelda Manalich.. gricelda@aws.org . . . . .(294)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
IT Network Director
Armando Campana..acampana@aws.org . .(296)
PUBLICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(275)
Managing Director
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
National Sales Director
Rob Saltzstein.. salty@aws.org . . . . . . . . . . .(243)
Society and Section News Editor
Howard Woodward..woodward@aws.org . .(244)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
MARKETING COMMUNICATIONS
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
Human Resources
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
MEMBER SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(480)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between Section members and AWS
headquarters.
CERTIFICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(273)
Managing Director
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WELDING JOURNAL
83
PERSONNEL
TRUMPF Appoints CEO
TRUMPF, Inc.,
Farmington, Conn.,
has named Lars
Gruenert president
and CEO of the company. He succeeds
Rolf Biekert who
served for 25 years.
Biekert leaves the
company to lead
Lars Gruenert
Maintecx, an exclusive distributor of
TRUMPF fabricating equipment in the
Midwest. Gruenert previously was executive vice president of TRUMPF GmbH
+ Co. KG, and CFO of the Laser Technology/Electronics business division.
Darrell Milton
Eriez, Erie, Pa., has transferred Darrell Milton from its metals recycling sales
team to the newly created position of account development manager for the HydroFlow line. Milton has been with
Eriez since 1991, first serving on the Cana-
Phillip Krueger
Peter Losiniecki
Joining Technologies
Appoints General Manager
Joining Technologies, East Granby,
Conn., a provider of precision fusion
processes, laser and electron beam welding, and system design and integration,
has appointed Matt Francoeur general
manager. With the company since 2005,
Francoeur most recently served as
manager of engineering, inside sales, and
production.
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84
AUGUST 2013
continued on page 87
PERSONNEL
continued from page 84
Marie Davies
Carlos Marin
Wall Colmonoy European Headquarters, Pontardawe Swansea, Wales, has appointed Marie Davies supply chain director for UK operations. Previously, Davies
worked in supply chain roles with Morgan
Crucible, Thales Group, and GlaxoSmithKline.
Wall Colmonoy, Madison Heights,
Mich., has hired Carlos Marin as manufacturing manager for its Alloy Products
Group in Los Lunas, N.Mex. Marin is a
Lean expert and a Six Sigma Black Belt.
The company supplies surfacing and brazing products, castings, and engineered
components for the aerospace, automotive, and other industrial sectors.
Koike Aronson,
Inc./Ransome, Arcade, N.Y., a supplier
of metal cutting and
positioning equipment for the metalworking industry, has
named Kim Jackson
director of engineering. Prior to joining
the company, JackKim Jackson
son headed multiple
business units of Illinois Tool Works.
tion and updates on its latest technological developments. The Web site features
a top ten list of the most commonly viewed
technologies, allowing users to access
their desired page quickly in a format designed for smartphones. The mobile Web
site also offers videos and easy download
of applications such as resistance welding
troubleshooting and material weldability.
Miyachi Europe
www.miyachieurope.com
+49 (0) 89 839403-50
Obituaries
Roderick G. Rohrberg
Roderick G. Rohrberg, 87, died May 9
in Torrance, Calif. An AWS Life Member,
he was a pioneer of orbital tube welding
and the founder of
Creative Pathways,
Inc. He earned his
degree in civil engineering from Iowa
State University, then
moved to California
in 1951 to work for
North American Aviation where he initiRoderick Rohrberg ated automated welding to eliminate leaks
in rocket engines. He left the company in
1969 to start his own precision tubular
welding operation in Torrance. He was
granted 34 patents, most concerned with
automatic welding. In 1967, he received
the Airco Award and the Howard E. Adkins Memorial Instructor Award.
WELDING JOURNAL
87
ThyssenKrupp Aerospace North America has entered a threeyear contract extension with Cessna Aircraft Co. to remain
its provider of aluminum sheet products and supply chain
services.
Lincoln Electric Holdings, Inc., Cleveland, Ohio, recently announced the U.S. Acting Secretary of Commerce, Rebecca
Blank, has presented the company with the Presidents E
Award for Exports at a ceremony in Washington, D.C.
COMING EVENTS
continued from page 58
Matheson, Basking Ridge, N.J., plans to build a new, largecapacity air separation unit to supply oxygen, nitrogen, and
argon in Mesa, Ariz. The plant is expected to be on stream
during the third quarter of 2014.
Direct Wire & Cable, Inc., has opened its new wire mill with
the renovated building covering 85,000 sq ft and will produce
its own welding cable; relocated its home office in Denver, Pa.;
and added warehouse locations in Houston, Tex., Reno, Nev.,
Portland, Ore., and Chicago, Ill.
INTEG Courses. Courses in NDE disciplines to meet certifications to Canadian General Standards Board or Canadian
Nuclear Safety Commission. The Canadian Welding Bureau;
(800) 844-6790; www.cwbgroup.org.
Gas Detection Made Easy Courses. Online and classroom courses for managing a gas monitoring program from gas detection to
confined-space safety. Industrial Scientific Corp.; (800) 3383287; www.indsci.com.
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92
AUGUST 2013
ABSTRACT
Electrodes with different W additives for hardfacing the workpieces of high-carbon
alloy steel were developed. The microstructure was observed by optical microscopy and
field emission scanning electron microscope equipped with energy-dispersive X-ray spectrometry. The phase structure was determined by X-ray diffraction. The hardness and
wear resistance, respectively, of the hardfacing surface layer were measured. The relative curve between mass fraction of each phase and temperature was calculated by
Thermo-Calc. The results show that, the microstructure of the hardfacing surface layer
without W additive consists of -Fe, -Fe, M7C3, and M23C6 carbides. However, MC
carbide initiates in the hardfacing surface layer and its amount increases with the increase of W additive, while that of M7C3 decreases. With the increase of W additive, the
hardness and wear resistance of the hardfacing surface layer both increase, and they are
the largest when the W additive is 4 wt-%. The C content of the martensite matrix decreases gradually with the increase of W additive. Moreover, only elements C and W
exist in MC carbide. With the increase of W content in the hardfacing surface layer, the
starting precipitation temperature and the largest mass fraction of MC both increase.
However, those of M7C3 both decrease.
Introduction
Workpieces manufactured with highcarbon alloy steel, such as roller and die
components, are widely applied in industrial production (Refs. 13). After being in
service for a period of time, the workpieces fail because of excessive wear (Refs.
4, 5). The shape and size of the failed
workpieces can be restored by means of
remanufacturing technologies, in which
hardface welding (hardfacing) is one of
the most effective methods (Refs. 69).
Development of high-carbon alloy steel
is characterized by the increase of Cr content so as to improve the strength and
hardenability of the steel (Ref. 10). In reJ. YANG, Y. YANG, Y. ZHOU, X. QI, and Q.
YANG (qxyang@ysu.edu.cn) are with State Key
Laboratory of Metastable Materials Science and
Technology, College of Materials Science and Engineering, Yanshan University, Qinhuangdao,
China. Y. GAO is with School of Material Science
and Engineering, Tongji University, Shanghai,
China. X. REN is with School of Engineering,
Liverpool John Moores University, Liverpool,
UK.
cent years, in order to improve its wear resistance, alloy elements W and Mo were
added (Refs. 1113).
However, related research indicated
that because of the high C content, cracks
usually initiate on the surface of the workpieces manufactured with the high-carbon
alloy steel after hardfacing, even if they
were preheated and reheated after hardfacing (Ref. 8). So, the wide application of
hardfacing technology for restoring and
remanufacturing the high-carbon alloy
steel workpieces is restricted. Moreover,
the effects of alloy elements W and Mo
are seldom reported.
Therefore, on the basis of research into
the microstructure of medium carbon steel
(Ref. 14), medium-high carbon steel
KEYWORDS
Fe-Cr-W-C Alloy
Hardfacing
Microstructure
Wear Resistance
Carbides
Experimental Procedure
Experimental Materials
WELDING RESEARCH
WELDING RESEARCH
Experimental Results
Influence of W Additive on the PhaseStructure of the Hardfacing Surface Layer
Figure 3 illustrates XRD analysis results of the hardfacing surface layers with
different W additives. As shown, without
the W additive, the phase microstructure
consists of -Fe, -Fe, M23C6, and M7C3
carbides. When the W additive is 2 wt-%,
besides -Fe, -Fe, M23C6, and M7C3 carbides, MC carbide initiates in the hardfacing surface layer. By quantitative analysis,
the content of retained austenite decreases from 15.8 to 6.4%. When the W
additive is 4 wt-%, the -Fe disappears absolutely. Meanwhile, the amount of M7C3
decreases and that of MC increases. With
Mn
Si
Cr
Ni
Content
0.10
0.300.50
0.03
0.2
0.03
0.03
0.03
Fig. 4 Microstructures of the hardfacing surface layers with different W additives. A 0 wt-%;
B 2 wt-%; C 4 wt-%; D 6 wt-%.
Fig. 5 Vertical morphologies of the hardfacing surface layers with different W additives. A 0 wt%;
B 2 wt-%; C 4 wt-%; D 6 wt-%.
Wear Resistance-Enhanced
Mechanism of the Hardfacing
Layer with W Additive
Characteristics on MC Carbide in the
Hardfacing Surface Layer
Welding Voltage
Welding Speed
140150 A
2426 V
1.11.7 mm/s
50%
From the above results, with the increase of W, the wear resistance of the
hardfacing surface layer increases. Meanwhile, the amount of MC carbide increases
while that of high-carbon alloy martensite
WELDING JOURNAL 227-s
WELDING RESEARCH
WELDING RESEARCH
Fig. 7 Wear loss of the hardfacing surface layer with different W additives.
Fig. 8 Wear morphologies of the hardfacing surface layer with different W additives. A 0 wt-%;
B 2 wt-%; C 4 wt-%; D 6 wt-%.
Cr
Si
Mn
Fe
0.67
0.67
0.67
0.67
2.05
2.05
2.05
2.05
0
0.58
1.46
1.74
0.614
0.614
0.614
0.614
0.565
0.565
0.565
0.565
Bal
Bal
Bal
Bal
Fig. 9 FESEM of the hardfacing surface layers with different W additives. A 0 wt-%; B 2 wt%;
C 4 wt-%; D 6 wt-%.
Conclusions
Fig. 10 Line energy spectrum of the granular particle in the hardfacing surface layer.
Table 4 EDS of the Martensite in the Hardfacing Surface Layers with Different W Additives (wt-%)
W Additive
Si
Cr
Mn
Fe
0 wt-%
2 wt-%
4 wt-%
6 wt-%
3.76
3.57
3.04
2.73
0.89
0.89
1.01
0.72
2.30
2.03
2.49
2.15
0.69
0.71
0.76
0.57
92.36
91.84
91.40
91.13
0.96
1.29
2.79
1) The microstructure of the hardfacing surface layer without W additive consists of -Fe, -Fe, M7C3, and M23C6
carbides. With the increase of W additive,
MC carbide initiates gradually, and the
amount of MC increases while that of
M7C3 and -Fe decreases.
2) Hardness and wear resistance of the
hardfacing surface layers both increase
with the increase of W additive, which are
greatest when W additive is 4 wt-%.
3) Only the elements C and W exist in
MC carbide. With the increase of W content in the hardfacing surface layer, the
starting precipitation temperature and the
mass fraction maximum of MC both increase. However, those of M7C3 both
decrease.
4) With the increase of W additive, the
C content in the martensite of the hardfacing surface layer decreases gradually,
from 3.76 to 2.73 wt-%.
WELDING RESEARCH
References
WELDING RESEARCH
1. Ashok, K. S., and Karabi, D. 2008. Microstructure and abrasive wear study of (Ti,W)
C-reinforced high-manganese austenitic steel
matrix composite. Materials Letters 62(24):
39473950.
2. Dennis, W. H., and William, V. G. 2008.
Crystallography and metallography of carbides
in high-alloy steels. Materials Characterization
59(7): 825841.
3. Khodir, S. A., Morisada. Y., Ueji. R., and
Fujii, H. 2012. Microstructures and mechanical
properties evolution during friction stir welding
of SK4 high-carbon steel alloy. Materials Science
and Engineering A 558(15): 572578.
4. Pellizzari, M., Molinari, A., and Straffelini, G. 2005. Tribological behaviour of hot
rolling rolls. Wear 259(712): 12811289.
5. Yang, K., Yu, S. F., Li, Y. B., and Li, C. J.
2008. Effect of carbonitride precipitates on the
abrasive wear behaviour of hardfacing alloy.
Applied Surface Science 254(16): 50235027.
6. Zhou, Y. F., Yang, Y. L., Yang, J., Hao, F.
F., Li, D., Ren, X. J., and Yang, Q. X. 2012. Effect of Ti additive on (Cr, Fe)7C3 carbide in arc
surfacing layer and its refined mechanism. Applied Surface Science 258(17): 66536659.
7. Mirjana, F., and Endre, R. 2011. Strain
hardening of austenite in FeCrCV alloys
under repeated impact. Wear 270(11-12):
800805.
8. NAVA, J. C. 2009. Cost-effective thermal
spray coatings for the boiler industry. Welding
Journal 88(7): 3841.
9. Buchanan, V. E., McCartney, D. G., and
Shipway, P. H. 2008. A comparison of the abrasive wear behaviour of iron-chromium based
hardfaced coatings deposited by SMAW and
electric arc spraying. Wear 264(7-8): 542549.
10. Ghaziof, S., Raeissi, K., and Golozar, M.
A. 2010. Improving the corrosion performance
of CrC amorphous coatings on steel substrate
by modifying the steel surface preparation. Surface and Coatings Technology 205(7):
21742183.
11. Zhang, B. S., Yi, Y. J., Zhang, W., Liang,
C. H., and Su, D. S. 2011. Electron microscopy
investigation of the microstructure of unsupported NiMoW sulfide. Materials Characterization 62(7): 684690.
12. Ivanova, G. V., Shchegoleva, N. N.,
Serikov, V. V., Kleinerman, N. M., and Belozerov. E. V. 2011. Structure of a W-enriched phase
in FeCoCrWGa alloys. Journal of Alloys
and Compounds 509(5): 18091814.
13. Fu, X. L., Ge, H. L., Xing, Q. K., and
Peng, Z. J. 2011. Effect of W ion doping on
magnetic and dielectric properties of NiZn ferrites by one-step synthesis. Materials Science
and Engineering B 176(12): 926931.
14. Ramana, P. V., Reddy, G. M., Mohandas,
T., and Gupta, A. V. S. S. K. S. 2010. Microstructure and residual stress distribution of
similar and dissimilar electron beam welds
Maraging steel to medium alloy medium carbon
steel. Materials & Design 31(2): 749760.
15. Oh, Y. S., Son, I. H., Jung, K. H., Kim,
D. K., Lee, D. L., and Im, Y. T. 2011. Effect of
initial microstructure on mechanical properties
in warm caliber rolling of high-carbon steel. Materials Science and Engineering: A 528(18):
58335839.
16. Nayak, S. S., Anumolu, R., Misra, R. D.
K., Kim, K. H., and Lee, D. L. 2008. Mi-
Fig. 11 Relation curves between mole fractions of alloy elements and temperature. A MC;
B M7C3; C M23C6 carbides.
Fig. 12 Curves between mass fraction of each phase and temperature in the hardfacing surface layers
with different W contents. A 0 wt-%; B 2 wt-%; C 4 wt-%; D 6 wt-%.
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Make sure delivery of your
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KEYWORDS
Critical Weld Spacing
Shunting
Resistance Spot Welding
Model Development
ABSTRACT
Shunting is a phenomenon difficult to avoid in production
welding, and it is of practical interest to quantitatively determine
the minimum weld spacing. However, the large number of factors involved in shunting make it difficult to isolate their influence, let alone obtain a quantitative understanding of their effects. In this study, the shunting process was understood through
an analysis of the electrical resistances along the welding and
shunting paths. An analytical model was derived based on the
equivalence of the joule heat generated in welding and that was
needed to create the weldment. The constants in the model were
determined through experiments. Using the experimental results from a previous study, specific models were derived for several gauges of mild and dual-phase steels of various surface conditions. The models were then used to study the effects of process
parameters on the minimum weld spacing needed to create certain sizes of shunted welds. The critical or minimum weld spacing was then plotted as a function of several variables. The effects of several process variables such as electrode force, welding
time, shunt weld size, and sheet thickness on shunting were
clearly demonstrated. Such relationships are crucial in understanding the effects of process variables on shunting, and can be
used in quantitative determination of minimum weld spacing to
avoid the adverse effect of shunting and put as many welds as
possible onto a structure.
Introduction
Shunting in resistance spot welding is the diversion of the welding current from the weld to be made to a nearby existing weld
(Ref. 1). If a significant proportion of welding current flows
through the previously made weld, the heat generated may not be
sufficient for making a weld of designated size. In general, shunting may have significant influence on weld quality when making
more than one weld on a workpiece, which is common in sheet
metal manufacture and repair. Quantitatively predicting the critical weld spacing to avoid significant reduction in weld size due to
shunting has practical significance (Ref. 1). The distribution of
welding current in shunting is illustrated in Fig. 1. The proportion
of the diverted current is determined by the relative electrical resistance values in the shunting and welding paths. Therefore, determination and control of relative resistance in welding are of ultimate importance. Helped by the advances in numerical
simulation techniques, efforts have been made to analyze the effect of shunting on weld nugget growth (Refs. 24), with some implication on the critical weld spacing. However, the highly variable
and dynamic nature of electrical and thermal processes in welding makes it difficult to quantitatively understand the effect of
shunting either by analytical analysis or numerical modeling. Because of a serious lack of material properties, especially as functions of temperature, a numerical modeling of the resistance spot
welding process generally relies on idealized material behaviors
and process setup. As a result, numerical predictions are more
qualitative than quantitative, and empirical studies such as the
ones by Howe (Ref. 5) and Wang et al. (Ref. 6) have been dominant in shunting study.
Y. B. LI, Q. SHEN, and M. LOU are with Shanghai Jiao Tong University, Shanghai, China. B. WANG is with Zhejiang Normal University, Jinhua, China.
H. ZHANG (hozhang@eng.utoledo.edu) is with University of Toledo, Toledo, Ohio.
WELDING RESEARCH
Fig. 2 Cross-sectional views of the shunt and shunted welds made on 2mm bare mild steel, with 8-mm weld spacing. The shunted welds were made
with a PVC plastic film placed on the faying interface. The welding parameters were welding current = 6 kA, welding time = 500 ms, and electrode force
= 2.8 kN.
WELDING RESEARCH
bS
2L
bulk
11
1
1
A 1 d 2 + d 2 sin = d 2 + d 2 sin
S
0
I
0
I
24
4
8
bS
L2
bulk
d 0 + d I2 t
bulk
(Spacing d
) + ( t )
2
d 0 + d I2 t
bS
=C
bS bulk
(Spacing d
) + ( t )
2
d 0 + d I2 t
(1)
bW
2t
bulk
the left by the shunt weld when the shunted weld is being made as
shown in Fig. 3, the actual force at the faying interface, Fappl, is
different from the applied electrode force, Felectrode, because of
the resistance of the top sheet to bending. This is similar to an
analysis of expulsion in resistance welding by estimating the net
force exerted by the electrodes at the faying interface (Ref. 7). Approximating the top (or bottom) sheet as a cantilever beam allows
for an estimate of the force at the faying interface that is responsible for affecting the contact resistance when making the shunted
weld. Through an analogy to the maximum deflection under a concentrated loading as formulated in any fundamental structural
analysis such as Ref. 8, the following relation can be derived for
the configuration in Fig. 3:
bW
The cross-sectional area of the welding path can be approximated by the average of the contact area at the faying interface
(or the projected area of the shunted weld), and that at the electrode-sheet interface
bW
11
1
= d 2 + d 2
24 I 4
appl
=C
bW
t
bulk
cW
= C
cW 1 bulk
+C
cW
= C
cW 1 bulk
cW 2 cont
+C
(Spacing 0.5d )
cW 1 bulk
+C
cW 2 cont
electrode
(3)
t3
(Spacing 0.5d )
appl
The constants CcW1 and CcW2 can be regarded as the weighting factors of the contributions from the bulk and surface resistances in the contact cylinder. They contain the effects of surface
contaminants, other surface characteristics such as roughness and
coating, and the contact cylinder height. The net force exerted on
the faying interface at the shunted weld, resulting from the applied
electrode force, is Fappl = applAW, and the contact resistance can
therefore, be expressed as
= C
(2)
d 2 +d 2
I
t3
0
cW
bW
electrode
And RbW can be written as the following, with a constant CbW for
the effect of all other fixed variables
=F
cW 2 cont
)F
appl
IW =
RbS
Rbs
I
+ RbW + RcW
(5)
( )
(2t ) 4 d
1
2
= td
2
WELDING RESEARCH
and that of the nugget. Therefore, the total heat needed for the
shunted weldment is approximately
1
1
c d 3 + c td 2 d 3 = c d 3 + c td 2
n
h
n
h
3
3
I2
W
(R
bW
+R
cW
=I
bS
R +R +R
bS
bW
cW
2
R +R
bW
cW W
t
C
+ C
+C
cW 2 cont
cW 1 bulk
bW bulk d 2 + d 2
I
t3
F
electrode
3
Spacing 0.5d
0
WELDING RESEARCH
c d 3 + c td 2 = I 2
n
2
2
d
+
t
Spacing
0
I
C
bS bulk
2
d0 + d I t
2
2
+ t
Spacing d d
t
0
I
C
+C
bW
bulk
bS
bulk
2
d 2 +d 2
+ d 2 t
d
I
0
+
C
+
C
cW 1 bulk
cW 2 cont
3
electrode
3
Spacing 0.5d
0
) ( )
0.95t
( ) + (Spacing 0.495d
2
c t
c
6 y
5
+
2
2
d
d
c t3
+
I
7
F
electrode
Spacing 0.5d
0
(6)
Examples
The model shown in Equation 6 relates the shunted weld to the
shunt weld and other process variables. However, the material
properties and process parameters are not sufficient, even if they
are available, to determine the constants in the model. The influence of the unavoidable random factors as well as the large number of assumptions and simplifications made when deriving the
( ) (
= I 2
2
2
0.95t + Spacing 0.495d 0.495d
0
I
c
2
3
d 0 + d I2 t
c1 d 3 + c2 td 2 d 02 + d I2 t 2
c
c
t
6 y
5
+c
+c4
4
2
2
d +d
c t3
I
7
F
electrode
Spacing 0.5d
0
) ( )
model make accurate analytical calculation of the constants irrelevant. The constants in Equation 6, however, can be determined
and the equation explicitly expressed using the experimental results such as those obtained in Ref. 6.
Before fitting the equation using the experimental observations, a simplification is necessary on the constants of Equation 6.
First, both and can be chosen as 0.495, so the shunting current
path extends just slightly into the electrode impression mark and
the shunt weld, as illustrated in Fig. 1. Similarly, can be taken as
0.95. As the accurate bulk and contact resistivity values are generally difficult to obtain, their effects can be better represented by
lumped coefficients, determined through curve fitting using experimental results that are categorized according to the surface
conditions. Standard curve fitting procedures such as those provided by commercial software packages can be used in the calculation. Equation 6 can be simplified, by consolidating the coefficients, as
0.495d
2
2
(7 )
The constants in Equation 7, c1, c2, c3, c4, c5, c6, and c7, can be
determined through experiments with sufficient replications and
as many combinations of variables as possible. They are clearly
material dependent, and the surface condition plays an important
role in affecting the values of these constants. It should be noted
that although the model shown in the equation is generic, a fitted
model developed for a specific material system should be limited
to that material in the ranges of the relevant material properties.
To illustrate the procedure of determining the constants and
the use of the model in understanding shunting, the experimental
observations in a previous study (Ref. 6) were used to obtain the
explicit models for the material systems studied. The experiments
include two types of materials: mild steel (MS) and dual-phase
steel (DP) of several gauges. Several types of surface conditions
were used, including bare steel surface, pure zinc-coated or hotdipped galvanized (HDG) surface, plastic insertion of a thin
polyvinyl chloride (PVC) film, and their combinations. Because of
the overwhelming influence of the contact resistance the experimental data were classified into four groups according to the surface conditions at the faying interface for the shunted welds: bare
steel surface (MS), zinc-coated (HDG) surface, bare steel (MS)
+ plastic insert, and zinc-coated (HDG) + plastic insert. The values of these four types of contact resistances are expected to be
very different, in addition to being unknown. Therefore, they were
treated separately to avoid complications and inaccuracy in quantifying the shunting relations using Equation 7.
The constants in the equation were determined through curve
fitting using Mathematica8 (Ref. 9) for each of the four types of
surface conditions. A fixed size of electrode indentation, dI, taken
Table 1 Constants of Equation 7 for the Materials with the Four Types of Surface Conditions Tested in the Experiments
c1
c2
c3
c4
c5
c6
c7
1.22239 109
3.08145 1017
378747.0
158244.0
0.893066
0.892577
0.999269
DP steel (HDG)
8.93766 1014
2.68256 109
492327.0
329371.0
0.0868412
0.0868538
1.00023
2.37641 109
1.73576 1012
240506.0
169569.0
0.0916093
0.0918372
1.00044
Fig. 4 Effect of sheet thickness on weld spacing: A Of the mild steel with
d0 = 4.8 mm, I = 6 kA, y = 205 MPa, F = 2.3 kN, = 350 ms; B of the
HDG DP steel with d0 = 5.9 mm, I = 8 kA, y = 665 MPa, F = 4.0 kN,
= 500 ms.
tic insert when welding DP steels Fig. 4B. The effect of plastic
insert in HDG DP steels is not as significant as in the MS. This
could be the result of a nullified influence of the zinc coating by
the plastic film.
Effect of Welding Time
In Fig. 5, the shunt weld size was fixed at 4.8 mm for a 1.5-mm
MS. It shows that increasing welding time is an effective means of
minimizing the effect of shunting as it puts more heat into a weld
and reduces the weld spacing needed. When welding time is short,
the time to melt the interface takes a significant proportion of the
entire welding time. The electric current diverted by the shunt
weld results in a large percentage of heat loss, and a large weld
spacing is necessary in order to avoid shunting. With a long welding time, however, it takes a small fraction of the total time for the
contact resistance to disappear when the interface melts, and
more current and heat are distributed to the shunted weld as a result. This effect is more profound when the plastic insert is used
at the faying interface. The diversion of electric current from the
welding path into the shunting path is magnified by the plastic in-
WELDING RESEARCH
sert when welding time is short, and less heat is directed to the
shunted weld, resulting in a larger weld spacing necessary than in
a bare steel. When the welding time is long, however, the increased contact resistance from the plastic insert actually works to
the benefit of reducing weld spacing because more heat is generated at the shunted weld compared with the case of bare steel. This
explains that the weld spacing needed for welding with the plastic
insert is significantly smaller than that without the plastic insert.
WELDING RESEARCH
Fig. 6 Effect of electrode force on weld spacing: A Of the mild steel with
d0 = 4.8 mm, I = 6 kA, y = 205 MPa, t = 1.5 mm, = 350 ms; B of the
DP steel with d0 = 5.9 mm, I = 8 kA, y = 665 MPa, t = 1.2 mm, =
500 ms.
Fig. 5 Dependence of weld spacing on welding time for the mild steel with
d0 = 4.8 mm, I = 6 kA, y = 205 MPa, F = 2.3 kN, t = 1.5 mm.
As several DP steels of different grades were used in the experiment, the yield strength can be regarded as a variable. The
weld spacing requirements as functions of yield strength from 300
to 900 MPa are plotted in Fig. 7. Similar to the dependence of weld
spacing on other variables in the HDG DP steels, the yield
strength of the sheet material has a smooth effect on the weld
spacing. Increasing the yield strength results in an increase in weld
spacing at a fixed electrode force, as a sheet with a large yield
strength is less compliant and a small intimate contact is produced
at the faying interface. However, such an intimate contact has a
smaller impact on the overall contact resistance in HDG steels, as
the molten zinc can easily fill the root opening at the faying interface. A larger rise in weld spacing should be expected when welding bare steels.
The horizontal projected length and, therefore, that of the
shunting path decrease when the shunt weld size increases as seen
in Fig. 1. The actual shunting path and, therefore, the shunting effect change along with the shunt weld even with fixed weld spacing. Figure 8 shows the dependence of weld spacing on the shunt
weld size in order to achieve a certain sized shunted weld. As expected, weld spacing increases with the shunt weld size, and for
the same sized shunt weld a larger shunted weld requires a larger
weld spacing.
The combined effect of the electrode force and welding time
on weld spacing can be presented using a contour plot as shown
Fig. 8 Effect of shunt weld size on weld spacing in bare MS steels. y = 205
MPa, I = 6 kA, F = 2.3 kN, t = 1.5 mm, = 350 ms.
When a plastic film was inserted into the faying interface when
making the shunted weld, the effects of electrode force and welding time on the required weld spacing were different from those
observed in welding bare steels. In Fig. 10, a long welding time reduces the weld spacing, which is similar to what was observed in
Fig. 5, while the weld spacing is fairly insensitive to the electrode
force. This observation is consistent with that in Fig. 6A, where increasing electrode force is no longer effective in reducing weld
spacing when the electrode force reaches a certain level. The
largest weld spacing appears at the corner of maximal electrode
force and minimal welding time. The different roles the electrode
force plays in welding bare and plastic insertion-filled faying interfaces are the result of the containment of the plastic film in the
contact area by the electrode force, as discussed in the previous
section on the effect of electrode force. As the plastic insertion
represents an extreme of contaminated sheet surfaces that is not
normally encountered in practice, the trend, rather than the value,
of the weld spacing shown in the figure is more important. Many
of the surface contaminates such as grease, etc., may disappear
under the intensive heating in resistance spot welding and, therefore, their influence on weld spacing is more suitably represented
by Fig. 9 than Fig. 10.
WELDING RESEARCH
in Fig. 9. For this bare steel, both the electrode force and welding
time reduce the weld spacing needed to produce a weld of the
same size as the shunt weld. Increasing either electrode force or
welding time individually can shorten the weld spacing from approximately 32 to 26 mm, and simultaneously raising these two
welding parameters to 3.0 kN and 500 ms, respectively, may render an identical-sized weld to the shunted one with a weld spacing of only 21 mm.
tems in the range of experiment. Extrapolation is not recommended, especially in the cases of large variation in contact resistance.
Acknowledgment
Summary
WELDING RESEARCH
In this study, the shunting process was analyzed and an analytical model was produced. Using the models for several material
systems developed by fitting the experimental observations, the
influences of several factors on the minimum weld spacing were
explicitly and quantitatively expressed. The important findings are
summarized as follows:
1. The analytical model fits well with the experimental results
on all four types of drastically different surface conditions for the
mild and dual-phase steels of various gauges;
2. For all the factors considered, without exception, a large
weld spacing is always needed in order to make a large shunted
weld;
3. In general, the required minimum weld spacing goes up with
the sheet thickness, and a high contact resistance at the faying interface amplifies this dependence;
4. The effect of electrode force is accurately accounted for in
the analytical model by considering the net force at the faying interface. In general, it reduces the weld spacing required. However,
its effect on weld spacing is affected by other factors, such as the
surface condition;
5. Welding time is effective in reducing weld spacing, and an
excessive contact resistance such as generated by inserting a plastic film at the faying interface may help in minimizing the weld
spacing by generating more heat at the shunted weld;
6. The models also allow for an understanding of the effect of
sheet yield strength. A sheet of high yield strength requires a large
weld spacing because of its high resistance to deformation under
an electrode force;
7. The size of the shunt weld directly affects shunting as it dictates the shunting path;
8. Contact resistance plays a dominant role in shunting, and
zinc-coated surfaces generally behave significantly different than
bare steels;
9. The models also reveal the complex interactions among the
process parameters in affecting shunting. For instance, the electrode force and welding time interact with the surface contact resistance in affecting shunting. Such an interaction is prevalent in
shunting.
Through a carefully planned experiment, this analytical model
can be used to describe the influence of process parameters on
shunting in resistance spot welding a specific material. The conclusions derived, however, are only applicable to the material sys238-s AUGUST 2013, VOL. 92
1. Tumuluru, M. D., Zhang, H., and Matteson, R. 2011. Procedure development and practice considerations for resistance welding. ASM Handbook on Welding (Volume 6). Materials Park, Ohio: ASM International.
2. Chang, H. S. 1990. A study on the shunt effect in resistance spot
welding. Welding Journal 69(8): 308-s to 317-s.
3. Tsai, C. L., Dai, W. L., Dickinson, D. W., and Papritan, J. C. 1991.
Analysis and development of a real-time control methodology in resistance spot welding. Welding Journal 70(12): 339-s to 351-s.
4. Browne, D. J., Chandler, H. W., Evans, J. T., James, P. S., Wen, J.,
and Newton, C. J. 1995. Computer simulation of resistance spot welding
in aluminum (Part 2). Welding Journal 74(12): 417-s to 422-s.
5. Howe, P. 1994. Spot weld spacing effect on weld button size. Proceedings of Sheet Metal Welding Conference VI, Paper C03. AWS Detroit
Section.
6. Wang, B., Lou, M., Shen, Q., Li, Y. B., and Zhang, H. 2013. Shunting effect in resistance spot welding steels Part 1: Experimental study.
Welding Journal 92(6): 182-s to 189-s.
7. Zhang, H., and Senkara, J. 2012. Resistance Welding: Fundamentals
and Applications. CRC Press/Taylor & Francis Group, 2nd edition, Boca
Raton, London, New York.
8. Gere, J. M., and Timoshenko, S. P. 1997. Mechanics of Materials,
PWS Publishing Co.
9. Mathematica 8, Wolfram Research, Inc., v. 8.0.1.0, Copyright
19882011.
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Q
Q
No page charges
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Q
Welding
W
elding Journal
Three-Dimensional Simulation of
Underwater Welding and Investigation of
Effective Parameters
The three-dimensional finite difference method was used to obtain temperature profiles,
thermal history curves, and cooling times for single-pass underwater wet weldments
ABSTRACT
The results of three-dimensional numerical simulation of wet underwater welding
in thin steel plates were studied. Temperature profile, thermal history curves as well
as cooling time for single-pass underwater wet weldments were obtained by solving
the appropriate heat transfer equations using the three-dimensional finite difference
method. The model was validated using experimental data for the air welding process.
The effect of the parameters such as material, surrounding fluid, convective heat coefficient (hc), arc heat model, and the method of heat losses from the plate were investigated through modeling and analyzing ten different case studies. The obtained
results indicate that the type of surrounding fluid has a significant role in the temperature variations during welding and consequently cooling time is much lower in
underwater welding compared with welding in air. The effect of material type could
not be distinguished, obviously because of the rapid cooling in wet welding. The analysis using the Tsai model for hc in comparison with constant values indicates the Tsai
model can predict hc successfully, when its value is 10006000 W/m2K. The method
of arc heat estimation is important when the temperature distribution in short vertical distances from the weld interface is considered and, at other positions, there is no
difference between the two used arc heat estimations. The results show that the convective heat transfer is more effective than radiation in temperature calculations;
therefore the radiation can be neglected.
Introduction
Ship salvage, harbor clearance, wreck
removal, underwater pipelines, and conveyer equipment repair oftentimes require extensive underwater cutting and
welding. Beginning in the mid-1930s, with
the substitution of welding for lesser quality mechanical methods of joining, the
overall cost and time spent on the job
could be reduced considerably (Refs.
13).
Underwater welding processes are
classified as dry or wet based on their exposure to the ambient environment.
Processes that are physically protected
from the surrounding water are classified
P. GHADIMI (pghadimi@aut.ac.ir) and
H. GHASSEMI are associate professors, and
M. GHASSABZADEH is a PhD student, Dept.
of Marine Technology, Amirkabir University of
Technology, Tehran, Iran. Z. KIAEI is a PhD student, Dept. of Chemical Engineering, Tarbiat
Modares University, Tehran, Iran.
KEYWORDS
Underwater Welding
Wet Welding
Finite Difference
Three-Dimensional Modeling
Shielded Metal Arc Welding
(SMAW)
Gas Tungsten Arc Welding
(GTAW)
WELDING RESEARCH
WELDING RESEARCH
Plate Thickness
(mm)
Left Plate
Air
St37
Right Plate
St37
B
18
C
23
Methodology
Thermal Model
The specific form of the energy equation generalized for the three-dimensional
modeling, utilizing the stationary coordinate and unsteady heat conduction to analyze the heat transfer, is developed as
R x R y R z
+
+
x
y
z
= C
T x , y , z ,t
+ Q x , y , z ,t
R = K
x
T
y
T
R = K
z
(2)
T
x
N +K
x
T
y
N +K
y
T
z
+ q +q +q =0
s
)
(1)
R = K
(3)
Welding
Current (I)
Welding Speed
(mm/s)
Arc Efficiency
Heat Input
(k Jmm)
101
1.8
50%
10
0.409
WELDING RESEARCH
Fig. 4 Maximum temperature values along the following: A The vertical line; B the parallel line relative to the weld interface.
WELDING RESEARCH
Fig. 5 Thermal history of a point in the following: A Parallel direction; B vertical direction to the welding trajectory.
Tn
i +1 , j ,k
Tn
i , j +1 ,k
i , j ,k
Tn
i , j ,k +1
+T n
i 1 , j ,k
2T n
i , j ,k
( )
i , j ,k
i , j ,k
(x )
i , j ,k
)n
2T n
+T n
i , j 1 ,k
2T n
i , j ,k
(z )
+T n
i , j ,k 1
)n
i , j ,k
i , j ,k
i , j ,k
+ T n
+T n
1 i +1 , j ,k
i 1 , j ,k
+ T n
+T n
2 i , j +1 ,k
i , j 1 ,k
+T n
(6)
+ T n
i , j ,k 1
3 i , j ,k +1
i , j ,k
i , j ,k
t
x
, =
2
{1
t
y
, =
=1 2 + +
(4)
(5)
T n+1 = .T n
where t is the time space. By using Equations 4 and 5, the temperature for a typical internal node is obtained as
T n+1 T n
z 2
,
(7)
(8)
(9)
0 0
0 0 0
1
A= 0
B= 0
0 0 0
0 0
1
(10)
Computer codes should be carefully validated before being used to predict the
welding process in underwater situations.
For this purpose, the validity of the current
numerical code has been checked and compared against the published data reported
by Attarha and Sattari-Far (Ref. 17). They
carried out GTAW experiments in the air
for joints comprised of 200 200 3-mm
Fig. 6 Comparison of the resulting thermal history curves for the following points: A 1; B 10; C 12; D 22.
T T0(K)
1.85
9.079
18.5
52.6
56
278
556
2778
Underwater Welding
tempt to prevent excessive/hard martensite formation. This method involves controlling the carbon equivalent (CE) of the
base metal and the electrode. To prevent
underbead cracking, a base plate with a
Mild Steel
AISI 304
Table 4 Thermo-physical Properties of Mild Steel and AISI Type 304 Stainless Steel Used in the Simulation (Refs. 17, 19)
Temperature
(C)
100
200
300
400
600
800
1200
1300
1500
k (J/mK)
Cp(J/kgK)
(kg/m3)
14.6
462
7900
15.1
496
7880
16.1
512
7830
17.9
525
7790
18.0
540
7550
20.8
577
7660
23.9
604
7560
32.2
676
7370
33.7
692
7320
120
700
7320
Temperature
(C)
100
200
300
400
500
600
700
800
1000
1200
k (w/mK)
Cp (J/kgK)
(kg/m3)
51.9
486
7700
50.7
486
48.2
515
45.6
548
41.9
586
38.1
649
33.9
708
30.1
770
24.7
624
26.8
548
29.7
548
WELDING RESEARCH
WELDING RESEARCH
h= 675(Ts Tw)1/4
(11)
(12)
where Th is the hot body absolute temperature (K), Tc is the cold surroundings absolute temperature (K), and Ac is the area
of the object (m2). The epsilon () coefficient is equal to 0.85 for the weathered
stainless steel in water (Ref. 26), which is
used in the present calculations.
The heat input distribution of the arc
has a Gaussian distribution on the top face
of the workpiece. The general equation is
(Ref. 21)
Table 5 The Studied Cases and Their Applied Parameters in the Underwater Welding Computational Model
Case No.
Material
Epsilon
Radiation
hConv.
(W/m2K)
Surrounding
Fluid
Studied
Parameter
1
2
3
4
5
6
7
8
9
10
Qexp
Qexp
Q1/2
Qexp
Qexp
Qexp
Qexp
Qexp
Qexp
Qexp
304L
mild
304L
304L
304L
304L
304L
304L
304L
304L
0.85
085
0.85
0.85
0.85
0.85
0.85
0
0
0.85
Tsai
Tsai
Tsai
0
400
1000
6000
Tsai
0
h(T)
Water
Water
Water
Water
Water
Water
Water
Water
Water
Air
Reference case
Material
Arc Heat
Heat Loss
Convection
Convection
Convection
Heat Loss
Heat Loss
Surrounding Fluid
Fig. 8 Temperature distributions along the vertical direction for four different hc values: A t = 10 s; B t = 20 s; C t = 30 s; D t = 40 s.
Q = qo o e
d 2
r
r2
0
2 rdr
(13)
q = q x , y ,t
s
3VI
r2
b
3
exp y vt
r2
b
+ x 2
(14)
A A
v
Q=
( )
2 A
(15)
where Av, Ai, Ar, and a are the arc voltage, arc current, arc radius (approximately
equal to electrode radius), and arc efficiency, respectively.
The effects of the heated parameters including the material type, surrounding fluid,
arc heat input model, convective heat transfer relation, and the mesh structure are
studied in ten different simulated cases. All
of the investigated cases and their govern-
(W/m2K4)
298
5.6697E8
0.53
I(A)
Voltage (V)
rb(m)
Speed (m/s)
200
23
2.5 10-3
2.5 10-3
WELDING RESEARCH
WELDING RESEARCH
Fig. 9 Thermal history curves for various hc values used in the simulation, at the following points: A 2; B 10; C 13; D 18.
Material Selection
In Fig. 3, the finite difference simulation results for the weldment temperature
history at points with different distances
from the weld interface are compared with
the experimental findings by Attarha and
Sattari-Far (Ref. 17), as described in the
model validation section.
As can be observed, the calculated results conform well with the experimental results and the rate of the temperature
changes has a similar trend as in the experimental case in all three studied points.
Consequently, the model can be used to
simulate and predict the wet underwater
welding heat transfer phenomenon in subsequent steps in this work.
Case No.
hc (W/m K)
Case 1
Case 5
Case 6
Case 7
Tsai equation
400
1000
6000
43.42
57.46
46.76
41.10
Fig. 10 Percentage of the temperature difference between Cases 1 and 3: A Along the vertical; B along the parallel lines to the welding path.
It was previously explained that a precise solution for the arc heat model is an
exponential form of Equation 11 that is
applied in the current study for modeling
the underwater welding process. To investigate the effect of the type of arc heat
model used in the simulation method, a
simpler but less precise model as the exponential form is used in Case 3, as described in Equation 15. The maximum
temperatures along the lines vertically and
parallel to the weld interface are calculated, where Case 1 is assumed as the reference case and case 3 is compared against
it. The error percentages of the absolute
temperatures resulting from solving Case
3, relative to Case 1, are reported in Fig.
10.
In the short distances along the vertical
direction to the welding path, there is a distinct difference between the resulting temperatures from the two models. In the
meantime, there is no considerable difference between the two arc heat models in the
parallel direction to the weld interface, except for the first point. Therefore, Q1/2
model could not be as accurate as the Qexp
model in the HAZ or the local temperature
calculations specially in the vertical direction. However, if an overall and not local re-
Conclusion
A three-dimensional heat transfer
model was developed to study underwater
welding of thin steel plates. The exponential estimation for the arc heat formulation was used in the modeling procedure.
WELDING JOURNAL 247-s
WELDING RESEARCH
in the underwater
welding because of
the rapid cooling phenomenon. The effect
of the fluid was studied by comparing the
thermal histories and
the temperature distribution in the water
and air environments.
The results showed
that the fluid type has
a considerable effect
in
the
welding
process, and as a reFig. 11 Thermal history curves for different heat loss types: A At point sult, the plate is
3; B at point 9; C at point 15.
cooled much more
rapidly in water in
comparison with the
air. The efficacy
Tsais and Masubuchis semi-empirical coranalysis of hc was performed via four case
relation, defining the surface heat transfer
solutions using the Tsai model and three
coefficient of the underwater weldments,
constant values of hc in the energy equawas used to determine the heat loss through
tion. The obtained results demonstrated
the surface of the welded plate. The explicit
that the Tsai model can predict hc successform of the finite difference method (FDM)
fully when its value is between 1000 and
was used to solve the energy equation. The
6000 W/m2K, especially when it is closer to
computed results were compared against
6000 W/m2K. The arc heat estimation was
the experimental data to ensure that the
investigated using a simpler estimation
modeling and solution method are reliable.
noted by Q1/2 in comparison with the exThe effect of the modeling parameters inponential form. It was concluded that,
cluding the material type, the type of the
when the temperature distribution in
surrounding fluid, the convective heat
short vertical distances from the weld intransfer coefficient (hc) value, the arc heat
terface is considered, the Q1/2 model is not
model, and how heat is lost from the plate
as precise as the Qexp model, while there
were investigated through ten case
is no difference between the two used arc
studies.
heat estimations at the other positions.
Two steel type characteristics were
The analysis of the curves resulted from
used to study the material effect in wet
four different situations considering
welding. However, it seems the material
and/or ignoring the convection/radiation
effect could not be distinguished obviously
C
WELDING RESEARCH
hc (W/m2K)
(Epsilon)
Case 1
Case 4
Case 8
Case 9
Tsai equation
0
Tsai equation
0
0.85
0.85
0
0
43.42
1537.96
43.58
524.19
298
298
298
457
15. Isikilar, Y. V., and Girgin, I. 2011. Numerical modeling of underwater welding. Journal
of Naval Science and Engineering 7(2): 1129.
16. Moneer, H. A., Mudar A. A., and Laith
S. A. 2011. Finite difference simulation of low
carbon steel manual arc welding. Thermal Science 15(1)2 07214.
17. Attarha, M. J., and Sattari-Far, I., 2011.
Study on welding temperature distribution in
thin welded plates through experimental measurements and finite element simulation. Journal of Materials Processing Technology, Vol. 211,
pp. 688694.
18. Salonitis, K., Stournaras, A., Tsoukantas, G., Stavropoulus, P., and Chryssolouirs, G.
2007. A theoretical and experimental investigation on limitations of pulsed laser drilling. J.
Mater. Process. Technol. Vol. 183, pp. 96103.
19. Yilbas, B. S., Arif, A. F. M., and Abdul
Aleem, B. J. 2010. Laser welding of low carbon
steel and thermal stress analysis. Optics & Laser
Technology, Vol. 42, pp. 760768.
20. Tsai, C. L., and Masubuchi, K., 1979.
Mechanisms of rapid cooling in underwater
welding. Applied Ocean Research 1(2): 99110.
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