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3 WELDING JOURNAL
CONTENTS
51 Using On-Site Orbital Welding for Power Plant Construction
A company evaluates the implementation of automation to
welding heavy-walled pipe
T. E. Gittens et al.
55 Hybrid Process Welds Thick-Walled Tubes
Cylinders used for hydraulic systems are constructed with a
combination of laser and gas metal arc welding
M. O. Gebhardt et al.
62 Welding Supports Prudhoe Bay Oilfield Operations
An overview is taken of the pivotal role welding technology
has on the oilfields of Alaska
W. C. LaPlante
68 New Processes and Metal Cored Wire Combine to Improve
Pipe Fabrication
A family-owned business cuts production time in fabricating oil-
and water-critical piping sytems
J. Cuhel and K. Packard
Welding Journal (ISSN 0043-2296) is published
monthly by the American Welding Society for
$120.00 per year in the United States and posses-
sions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
$14.00 single issue for international. American
Welding Society is located at 550 NW LeJeune Rd.,
Miami, FL 33126-5671; telephone (305) 443-9353.
Periodicals postage paid in Miami, Fla., and addi-
tional mailing offices. POSTMASTER: Send address
changes to Welding Journal, 550 NW LeJeune Rd.,
Miami, FL 33126-5671. Canada Post: Publications
Mail Agreement #40612608 Canada Returns to be
sent to Bleuchip International, P.O. Box 25542,
London, ON N6C 6B2
Readers of Welding Journal may make copies of
articles for personal, archival, educational or
research purposes, and which are not for sale or
resale. Permission is granted to quote from arti-
cles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
excluded from copyright.
Departments
Editorial ............................4
Washington Watchword ..........6
Press Time News ..................8
News of the Industry ............10
Aluminum Q&A ..................16
Letters to the Editor ............20
Brazing Q&A ......................24
Product & Print Spotlight ......26
AWS Financial Report ..........32
Coming Events....................74
Certification Schedule ..........82
Society News ....................85
Tech Topics ......................86
Errata D1.1/D1.1M:2010 ......86
Errata D14.3/D14.3M:2010 ..86
Guide to AWS Services ......105
Personnel ........................106
American Welder
Learning Track ................124
Fact Sheet......................128
Classifieds ......................130
Advertiser Index ................133
163-s Strain-Age Cracking Susceptibility of Ni-Based
Superalloys as a Function of Strain Rate, Temperature,
and Alloy Composition
Variables in welding three gamma-prime-strengthened superalloys
were examined for their influence on cracking susceptibility
D. A. Metzler
169-s Improvement of Formation Quality for Friction Stir
Welded Joints
Ambient temperature and the direction of stirring tool were studied
for their relationship to weld quality
R.-D. Fu et al.
174-s Artificial Neural Network Prediction of Weld Geometry
Performed Using GMAW with Alternating Shielding
Gases
A model was developed to predict weld geometry under different
shielding gases
S. W. Campbell et al.
182-s Effects of Welding Direction and Position on Susceptibility
to Weld Metal Transverse Cracking in Welding High-
Strength Pipeline Steel with Cellulosic Electrodes
Research was conducted to find whether factors other than preheat
and weld strength had a role in transverse cracking
S. Sarafan et al.
Features
Welding Research Supplement
51
115
62
June 2012 Volume 91 Number 6
AWS Web site www.aws.org
On the cover: Various welding processes are taught at the Rochester Arc &
Flame Center, Rochester, N.Y., including gas tungsten arc welding, as shown.
(Photo courtesy of the Rochester Arc & Flame Center.)
The American Welder
111 Tips for Preparing and Selecting Tungsten Electrodes
Learn how to make the best weld possible by selecting the
right electrode and preparing it properly
J. Sprinkle
115 Unleash Your Inner Creativity: Explore Industrial Arts
An upstate New York distributor expands his artistic interests
with a new facility that teaches welding, glass arts, and
blacksmithing
K. Campbell
121 Scouts Move from the Campground to the Welding Lab
Two Boy Scout troops become the first to earn the new
welding merit badge
June 2012_Layout 1 5/10/12 4:14 PM Page 3
EDITORIAL
Extraordinary is not a word I use often, but thats truly the kind of year it has been
for the American Welding Society. Our financial performance in 2011 was remarkably
strong, as noted in the Financial Report that begins on page 32 of this issue, providing
the healthiest numbers for the Society since it was formed in 1919. In addition to record-
high revenues in 2011, we also had the highest-ever surplus of revenues over expendi-
tures, and we were able to transfer $5 million to the Reserve Fund during 2011 because
of our positive financial results.
Beyond this, over the past year AWS has launched the American Welding Online
series of Web-based educational courses, we introduced the AWS/Lincoln Electric
Careers in Welding Trailer that will promote welding careers all over the country, and we
welcomed the International Thermal Spray Association into the fold as an AWS
Standing Committee. Further, we created a new Portuguese-language edition of the
Welding Journal for the important Brazilian market, and our dedicated volunteer net-
work worked in cooperation with the Boy Scouts of America to create the new BSA
Welding Merit Badge (see story on page 121.)
This year, we are nearing completion of the new AWS Headquarters in Doral, Fla.,
and we will be moving into the facility over the next few months. We were also able to
sell our old headquarters building this year, which helps fund the transition. With near-
ly three times the amount of floor space of our old headquarters, the new state-of-the-
art facility will support the Society effectively as we continue to expand our membership
base and our position in the global marketplace. It will allow AWS to represent itself well
as the worlds premier welding society, and it will strengthen our position and influence
both domestically and internationally. In the latter area, we have hired our first-ever out-
side international salesperson, and we developed a strong global strategy to increase our
presence overseas.
Our annual FABTECH exhibition held last November in Chicago was a tremendous
success, with a record number of attendees topping 35,400. Exhibits totaled more than
half a million square feet, with 1300 individual exhibitors showing everything imaginable
for welding, metal forming/fabrication, tube and pipe, finishing and stamping, and
coating.
Total AWS membership during 2011 was 69,566, representing a 4.1% increase over
the previous year. Member numbers continue to grow this year and have topped the
70,000 mark. To better serve our members, we are now providing our monthly Welding
Journal in electronic format to our Student Members and to members outside the United
States. In addition, we are continuing work to develop a planned presence on social net-
working sites such as Facebook and Twitter. All of this will allow AWS to become better
known and more easily accessible through a variety of media.
The AWS Foundation is continuing its capital campaign on Welding for the Strength
of America and the AWS Welder Workforce Development Program. In addition to
working with Weld-Ed to promote welding careers, the Foundation awarded $390,000 in
scholarships to some 450 students in 2011.
We have also seen good results in Certification (our largest revenue-producing busi-
ness unit), electronic and printed book sales, and magazine advertising revenues. In
other words, the desired numbers are there, and we are optimistic that 2012 will also
yield positive financial results. Our strong position
allows us to fund new programs benefiting AWS mem-
bers and the welding industry as a whole.
In all of our program development activities, AWS
welcomes input from its members and volunteers. If
you have any suggestions of how AWS can grow,
broaden its influence, or provide better member bene-
fits, please dont hesitate to contact me or any AWS
staff member.
JUNE 2012 4
Officers
President William A. Rice Jr.
OKI Bering
Vice President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Kimberly-Clark Global Safety
Vice President David J. Landon
Vermeer Mfg. Co.
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
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
J. C. Bruskotter (Past President), Bruskotter Consulting Services
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Thermadyne Industries
D. A. Flood (Dist. 22), Tri Tool, Inc.
R. A. Harris (Dist. 10), Total Quality Testing
D. C. Howard (Dist. 7), Concurrent Technologies Corp.
J. Jones (Dist. 17), Thermadyne Industries
W. A. Komlos (Dist. 20), ArcTech, LLC
R. C. Lanier (Dist. 4), Pitt C.C.
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Corp.
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
D. L. McQuaid (At Large), DL McQuaid & Associates
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), ESAB Welding & Cutting Products
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. R. Polanin (Dist. 13), Illinois Central College
R. L. Richwine (Dist. 14), Ivy Tech C.C.
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
N. S. Shannon (Dist. 19), Carlson Testing of Portland
T. A. Siewert (At Large), NIST, ret.
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
Founded in 1919 to Advance the Science,
Technology and Application of Welding
An Extraordinary Year
Robert Pali
AWS Treasurer
Editorial June 2012_Layout 1 5/10/12 3:30 PM Page 4
For Info go to www.aws.org/ad-index
cm industries_FP_TEMP 5/9/12 9:52 AM Page 5
Congressional Hearing on
Manufacturing Jobs
Where the Jobs Are: Can American Manufacturing Thrive
Again? That was the question addressed by a recent hearing
held by the House Subcommittee on Commerce, Manufactur-
ing, and Trade. Witnesses included the Secretary of Commerce
and the president of the U.S. Chamber of Commerce.
The subcommittee heard testimony that, while manufactur-
ing jobs account for just a tenth of the nations jobs, the manu-
facturing sector suffered a third of the nations job losses during
the recent recession. And while the Bureau of Labor Statistics
has reported an uptick in the number of Americans employed in
the manufacturing sector in recent months, it is unclear whether
this is a true positive indicator of any permanence. Prior to 2010,
the manufacturing sector had suffered consecutive yearly job
losses since 1997.
Witnesses also attempted to identify the factors contributing
to the overall decline in manufacturing jobs, though there was
not a general consensus. The various, at times conflicting, fac-
tors cited included the following: increased productivity; lost out-
put fueled by falling demand as a result of increased import con-
sumption; a persistently high corporate tax rate; the high cost of
health care; the rising cost of energy; regulatory burdens; and
the U.S. tort law system.
However, there was consensus regarding a general skills gap
in U.S. manufacturing, resulting in a moderate to severe short-
age of qualified workers. Indeed, it is estimated that as many as
600,000 open manufacturing positions remain unfilled for that
reason, and it is expected that the skills gap will widen further in
the coming years due to public opinion among the rising genera-
tion of workers: Manufacturing ranked last as an industry in which
1824 year olds would choose a career.
The subcommittee identified as the most serious workforce
deficiencies, in order of severity, as follows: inadequate prob-
lem-solving skills; lack of basic technical training; inadequate
employability skills such as timeliness and work ethic; and inade-
quate technology, computer, math, reading, writing, and com-
munication skills.
Career and Technical Education
Proposal Unveiled
In April, the U.S. Department of Education unveiled Invest-
ing in Americas Future: A Blueprint for Transforming Career and
Technical Education (CTE), outlining the administrations pro-
posal for reauthorizing the Carl D. Perkins Career and Technical
Education Act (Perkins).
The document is available at www2.ed.gov/about/offices/list/
ovae/pi/cte/transforming-career-technical-education.pdf.
The blueprint for a reauthorized Perkins Act is shaped by four
core principles, as listed below.
1. Alignment. Effective alignment between high-quality CTE
programs and labor market needs to equip students with 21st-
century skills and prepare them for in-demand occupations in
high-growth industry sectors;
2. Collaboration. Strong collaborations among secondary and
postsecondary institutions, employers, and industry partners to
improve the quality of CTE programs;
3. Accountability. Meaningful accountability for improving
academic outcomes and building technical and employability
skills in CTE programs for all students, based upon common def-
initions and clear metrics for performance; and
4. Innovation. Increased emphasis on innovation supported
by systemic reform of state policies and practices to support CTE
implementation of effective practices at the local level.
Key components include the following:
Allowing states to identify the in-demand occupations in
high-growth industry sectors on which CTE programs should
focus;
Establishing consortia to ensure collaboration among sec-
ondary and postsecondary institutions;
A private-sector match contribution to strengthen the par-
ticipation of employers, industry, and labor partners in program
design and execution;
Within-state competitions; and
Creation of a competitive CTE Innovation and Transfor-
mation Fund.
The most notable, and potentially controversial, aspect of the
new plan is the addition of competitive components, which are
intended to enable states to emphasize high-growth jobs and
target specific, select CTE programs rather than making discrete
allocations of money to school districts and institutions.
Federal Ethics Web Site Launched
The White House has launched a new Web site, www.ethics.gov,
which provides online access, with full-text search capabilities, to
seven different databases:
White House Visitor Records
Office of Government Ethics Travel Reports
Lobbying Disclosure Act Data
Department of Justice Foreign Agents Registration Act
Data
Federal Election Commission Individual Contribution
Reports
Federal Election Commission Candidate Reports
Federal Election Commission Committee Reports.
Especially noteworthy are the travel reports and White House
visitor logs, which have not previously been easily accessible.
Multiple Challenges Lengthen OSHAs
Standard Setting
Between 1981 and 2010, the time it took the Department of
Labors Occupational Safety and Health Administration (OSHA)
to develop and issue safety and health standards ranged widely,
from 15 months to 19 years, and averaged more than 7 years.
Experts and agency officials cited increased procedural re-
quirements, shifting priorities, and a rigorous standard of judi-
cial review as contributing to lengthy time frames for developing
and issuing standards.
These findings are set forth in a recent report from the U.S.
Government Accountability Office, available at www.gao.gov/
assets/590/589825.pdf.
WASHINGTON
WATCHWORD
JUNE 2012 6
BY HUGH K. WEBSTER
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
Contact the AWS Washington Government Affairs Office at
1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
hwebster@wc-b.com; FAX (202) 835-0243.
WW June 2012_Layout 1 5/10/12 12:57 PM Page 6
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PRESS TIME
NEWS
Nominations Sought for 10th Annual AWS Image of
Welding Awards
The American Welding Society (AWS),
Miami, Fla., has issued a call for entries for the
10th Annual Image of Welding Awards that
recognize and celebrate outstanding public
contributions promoting the image of welding
and the welding industry as a whole. This year,
a new category recognizing media outlets that
have contributed positive welding coverage has
been added. The deadline is July 31.
Presented by AWS and WEMCO, an asso-
ciation of welding manufacturers, a standing
committee of AWS, the awards will be issued
in the following categories: individual; educa-
tor; educational facility; small business (less
than 200 employees); large business (200 or more employees); distributor; AWS Sec-
tion; and media.
All individuals, organizations, and groups may be nominated for multiple categories.
Self nominations are also acceptable.
Winners will be presented with their respective awards at the Image of Welding
Awards Ceremony to be held during FABTECH, November 1214, at the Las Vegas
Convention Center, Las Vegas, Nev.
To see past winners, submit an online nomination, or download the PDF nomination
form, visit www.aws.org/awards/image.html. In addition, for your respective application
to be considered, complete the entire nomination form and submit electronically, re-
turn via email to image@aws.org, FAX to (305) 443-1552, or send via postal mail to AWS
Image of Welding Awards, 550 NW LeJeune Rd., Miami, FL 33126.
LeTourneau University Gets $560,000 for Joining Research
LeTourneau Universitys (LETU) School of Engineering, Longview, Tex., has re-
ceived $250,125 in grant funding from the Federal Highway Administration for a two-
year research project on welding on modern bridges. This is in addition to a current
$180,000 grant.
Two of our masters degree students, as well as about ten undergraduates, will be
working on this study aimed at using innovative welding technologies for designing and
manufacturing future bridges that would last over 100 years, said Dr. Yoni Adonyi,
LETUs welding/materials joining engineering program coordinator. Our partners from
industry remain the Navy Surface Warfare Center, as well as the American Iron and
Steel Institute, and NASAs Marshall Space Flight Center. We are looking at high-
frequency, friction stir, and thermal stir welding applied to joining high-strength and
corrosion-resistant steels.
Also, the university recently completed a $129,000 grant from the II-VI Foundation
that funded the development of new technology for microwave welding to join bismuth
telluride to copper for building thermo-electric generators.
Miller, ITW Welding North America Companies Reveal Tour
Miller Electric Mfg. Co., Appleton, Wis., and the ITW Welding companies of North
America, including Hobart Brothers, Bernard, Tregaskiss, Weldcraft, and Smith Equip-
ment, will be bringing the Under the Hood 2012: Learn | Weld | Connect welding
expos to four cities across the U.S.
The next tour stops include Rancho Cucamonga, Calif., June 13, 14, and Troy, Ohio,
June 20, 21. Attendees may pre-register at Millerwelds.com/weldexpo or on-site.
Under the Hood 2012 offers two days of welding opportunities that include 10 edu-
cational sessions. The Miller Road Show Truck will be present with 40 hands-on dis-
plays. Do-it-yourself welding enthusiasts are also encouraged to attend an evening event,
from 6 to 9 p.m., at each of the expos (June 13 and June 20). World-class fabricators,
bike builders, and restoration experts will be on hand. Those interested can sign up at
MillerWelds.com/underthehood. Space is limited to the first 100 registrants per location.
JUNE 2012 8
MEMBER
Publisher Andrew Cullison
Publisher Emeritus Jeff Weber
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Peer Review Coordinator Melissa Gomez
Design and Production
Managing Editor Zaida Chavez
Senior Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Paneca
Senior Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Sylvia Ferreira
sferreira@aws.org
American Welding Society
550 NW LeJeune Rd., Miami, FL 33126
(305) 443-9353 or (800) 443-9353
Publications, Expositions, Marketing Committee
D. L. Doench, Chair
Hobart Brothers Co.
S. Bartholomew, Vice Chair
ESAB Welding & Cutting Prod.
J. D. Weber, Secretary
American Welding Society
T. Birky, Lincoln Electric Co.
D. Brown, Weiler Brush
J. Deckrow, Hypertherm
D. DeCorte, RoMan Mfg.
J. R. Franklin, Sellstrom Mfg. Co.
F. H. Kasnick, Praxair
D. Levin, Airgas
E. C. Lipphardt, Consultant
R. Madden, Hypertherm
D. Marquard, IBEDA Superflash
J. Mueller, Thermadyne Industries
J. F. Saenger Jr., Consultant
S. Smith, Weld-Aid Products
N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
S. P. Moran, Ex Off., ESAB Welding & Cutting Prod.
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
R. Ranc, Ex Off., Superior Products
W. A. Rice, Ex Off., OKI Bering
R. W. Shook, Ex Off., American Welding Society
D. Wilson, Ex Off., Kimberly-Clark Global Safety
Copyright 2012 by American Welding Society in both printed and elec-
tronic formats. The Society is not responsible for any statement made or
opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not in-
tended for use without independent, substantiating investigation on the
part of potential users.
To enter this years Image of Welding
Awards, visit www.aws.org/awards/
image.html. The deadline is July 31.
PTN June 2012_Layout 1 5/10/12 1:53 PM Page 8
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ESAB_FP_TEMP 5/9/12 9:53 AM Page 9
NEWS OF THE
INDUSTRY
GE Highlights What Works in America and
Focuses on Manufacturing, Jobs
GE, along with partners, held a four-day event in Washing-
ton, D.C., dedicated to Americas long-term economic and in-
dustry growth with discussions focused on manufacturing, inno-
vation, jobs, and commitments to building a more highly skilled
workforce, among other goals.
The company will launch new programs throughout the year,
including the following: hiring 5000 U.S. veterans over the next
five years and sponsoring a Hire our Heroes partnership with
the U.S. Chamber of Commerce; opening manufacturing skill-
building centers called GE Garages and partnering with
GOOD/Corps on the What Works Project, a new interactive plat-
form inviting the public to submit stories, images, or video de-
pictions of what is currently driving American competitiveness;
and doubling the number of GE engineering interns to more than
5000 as part of an initiative proposed by the Presidents Council
on Jobs and Competitiveness to add 10,000 more engineering
graduates a year in the United States.
Lincoln Electric Selected as Welding
Equipment Supplier of Dream Machines
The Parker Brothers deliver their Dream big. Build bigger
motto on Dream Machines, Syfys new reality show that has been
picked up for six episodes. It follows Florida-based brothers Marc
and Shanon Parker as they take the most imaginative vehicles
ever seen in movies, comic books, and TV shows, then engineers
them into on-the-road realities.
The shows production company, Triage Entertainment, chose
JUNE 2012 10
Railroads Historical Lift Bridge Undergoes Crucial Repair
Illinois Constructors Corp. (ICC) recently completed vital
structural repairs on the historical 95th Street lift bridge, orig-
inally built in 1912, and owned and operated by Norfolk South-
ern Railroad in southern Cook County.
The U.S. Coast Guard determined the work schedule be-
cause the bridge spans the Calumet River and approved a lim-
ited amount of time for the project due to the rivers heavy
shipping activity level. The task was completed in 112 con-
tiguous hours.
The ICC team coordinated and performed the repair work.
The inner shaft of one of eight 15-ft-diameter sheaves was
warped, and a new shaft was needed.
A crew of ironworkers and operating engineers spent more
than two months preparing for this work in advance of the
project. The crew identified the damaged shaft inside one of
the wheels used to lift the more than 2-million-lb bridge when
performing routine maintenance on the railroad lift-bridge.
The project is unique and required extra planning since
some repairs were performed offsite, said Rusy Mitcheff, op-
erations manager, ICC. This type of work is very unusual and
has not been performed by the railroad in many years.
The bridge had two key problem areas 221 ft in the air
and on the ground on-site. When the shaft was removed, a
counterweight was needed to maintain the balance weighing
more than 1 million lb. The crane used in the repair required
five days to erect prior to the repairs and more than 36 loads
of material acted as a counterweight during the repair work.
The main span length is 210 ft, and the structure length is
210 ft.
This project was very challenging due to the historical na-
ture of the lift bridge and the limited number of hours per-
mitted by the U.S. Coast Guard...train traffic is very active
here because it includes several Amtrak runs as well as vari-
ous freight lines. We needed to anticipate and plan for sev-
eral challenges in the event they occurred, said ICC Presi-
dent John Mackanin, P.E.
The Chicago headquarters office of Collins Engineers, Inc.,
provided engineering support.
Using a Manitowoc crawler crane with 262 ft of boom, Illinois
Constructors Corp. lifts and positions a 60,000-lb, 15-ft-diame-
ter cable drum (sheave) into place in the lift bridge mechanism
after 72 continuous hours of machining and reconditioning off-
site in a local machine shop. (Photo courtesy of ICC.)
NI June 2012_Layout 1 5/10/12 3:54 PM Page 10
11 WELDING JOURNAL
Lincoln Electric as its exclusive provider of welding equipment
and personal protection gear, including VIKING helmets, and
jackets, gloves, caps, and safety glasses from the companys Red
Line welding apparel line.
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On the Syfy networks new show, Dream Machines, imaginative
vehicles are engineered into reality. Lincoln Electric has been cho-
sen as its welding equipment and personal protection gear provider.
NI June 2012_Layout 1 5/11/12 11:11 AM Page 11
Westinghouse Awarded Contract to Apply
Underwater Laser Beam Welding
Westinghouse, Pittsburgh, Pa., has been awarded a contract
to apply the underwater laser beam welding process (ULBW) at
Progress Energys Robinson Nuclear Plant in Hartsville, S.C. This
will be the first application of the process, which has been ap-
plied previously in Japan, at a U.S. nuclear plant.
Developed jointly by Westinghouse and majority owner
Toshiba Corp., the ULBW process applies stress corrosion crack-
ing-resistant weld metal underwater onto the inside diameter
surface of aged components, serving as a method of mitigation
and repair. The laser beams heat and dilution controls result in
consistent weld quality and high deposit purity.
At Robinson Unit 2, the process will be applied to reactor ves-
sel nozzle dissimilar metal welds during the fall 2013 outage.
Development of the underwater laser welding process allows
us to make welds to vessel components without the customer hav-
ing to drain their vessel, said Nick Liparulo, senior vice presi-
dent, Westinghouse Nuclear Services. He also added this results
in a shorter implementation schedule and reduced exposure for
maintenance crews and plant personnel.
Monroe County Community College to Offer
Nondestructive Testing Certificate
Monroe County Community Colleges Industrial Technology
Divisions Nondestructive Testing (NDT) certificate program has
been approved by the curriculum committee.
The program is one of the first to be offered at a community
college in the state of Michigan with larger schools in Georgia
and California. Seven new courses are derivative of the existing
Nuclear Engineering Technology associate degree program. They
also have direct relevance to the colleges existing welding tech-
nology associate degree program.
The testing program taps into the states need for hi-tech skills
in high-demand occupations. It is estimated between 6000 and
7000 NDT jobs opened up last year. In addition, the U.S. Bureau
of Labor Statistics reports 430,450 NDT- related jobs in the U.S.
alone, approximately 20,000 of which are in Michigan with salary
ranges from $37,400 to $53,690 annually or $17.98 to $25.81/h.
JUNE 2012 12
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The underwater laser beam welding process has
been applied in Japan and will be implemented at
South Carolinas Progress Energys Robinson Nu-
clear Plant. Shown is the underwater laser welding
machine (left, horizontal) getting installed into a
reactor vessel coolant loop nozzle mockup at 40 ft
of water depth. (Photo courtesy of Toshiba Corp.,
Nuclear Energy Systems.)
NI June 2012_Layout 1 5/10/12 3:54 PM Page 12
Bug-O Hosts Open House Event
On April 19, Bug-O hosted an open house at its training fa-
cility in Canonsburg, Pa. A main attraction featured welding
demonstrations with the Bug-O/Lincoln Electric pipe welding
system, portable weld prep machine tools from E.H. Wachs, Cy-
press pipe welding/cutting machines, and Bug-O overlay equip-
ment for hardfacing pipes and plates.
Among the company attendees were Chip Cable, president;
Norm Sted, vice president, sales and marketing; Matt Cable, IT;
and Mark Campbell, regional sales manager. Also present were
John Menhart with Caterpillar and vice chair of the AWS Pitts-
burgh Section, plus Vince Cirrincione III with Sky Oxygen and
an AWS member affiliated with the Pittsburgh Section.
13 WELDING JOURNAL
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Welding demonstrations were featured at Bug-Os open house. At
the event (from left) are Norm Sted, the companys vice president,
sales and marketing; John Menhart with Caterpillar and vice chair
of the AWS Pittsburgh Section; and Chip Cable, president, Bug-O.
NI June 2012_Layout 1 5/10/12 3:55 PM Page 13
Industry Notes
Astro Arc Polysoude, Inc., formed an alliance with Encompass
Machines, Inc., Rock Hill, S.C., and the Polysoude group. Also,
the company moved its U.S. headquarters and manufacturing
facility to a larger building in Valencia, Calif.
The Association for Manufacturing Technology (AMT) and
American Machine Tool Distributors Association have
merged. The new AMT will be headquartered in McLean, Va.
Trafimet USA, Hialeah, Fla., a gas metal arc, gas tungsten arc,
and plasma welding and cutting torch manufacturer, has be-
come an integral part of The Trafimet Group, Vicenza, Italy.
Allen Marine, Inc., Sitka, Alaska, will use $163,500 awarded
through the U.S. Maritime Administrations Small Shipyard
Grants Programto buy a welding fume and particulate extrac-
tion system.
Rex Cut Products, Inc., Fall River, Mass., a manufacturer of
nonwoven cotton fiber abrasive products, is changing its name
to Rex-Cut Abrasives.
MesoCoat, Inc., Euclid, Ohio, completed a milestone by
cladding the inside of steel pipe with corrosion- and wear-
resistant alloys. It expects to complete qualification with sev-
eral oil majors within the next few months.
Welders Universe, a new Web site at weldersuniverse.com, cre-
ated by a community college welding major, gives tutorials,
tips and advice, links to job boards, and a equipment/supply
retailer directory.
The HyIntensity HFL015 fiber laser from Hypertherm,
Hanover, N.H., won the Product of the Year award from the
NASA Tech Briefs Photonics Tech Briefs edition.
Arc-Zone.com, Carlsbad, Calif., is expanding its corporate head-
quarters. The space will be used for increased inventory of the
ecommerce welding accessory stores list of more than 10,000
products. Included in the expansion plans are a retail store and
separate educational space, The Ultimate Weld Shop.
A Wesgo Metals braze alloy app from Morgan Technical Ce-
ramics for the iPhone, iPod touch, and iPad helps engineers
find the right braze alloy for their applications by including the
forms in which a given alloy is offered.
Plymouth Tube Co.s steel tubing mill in Eupora, Miss., re-
cently received the 2012 American Metal Market award for
Best Welded Tube and Pipe Producer of the Year.
Precision Structural Engineering, Inc., Klamath Falls, Ore., is
working with Big Top Shelters to provide structural engineer-
ing for the U.S. military. Projects include storage shelters, air-
craft storage, and inspection services.
CGW-Camel Grinding Wheels, Niles, Ill., launched a new Web
site at www.cgwcamel.com with a database product engine for
quick referencing more than 4000 of its abrasive products along
with product videos, photos, and material safety sheets.
Ambrell, Scottsville, N.Y., has seen increased demand for its
induction heating systems and is expanding its manufacturing
facility at its U.S.-based corporate headquarters.
JUNE 2012 14
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NI June 2012_Layout 1 5/10/12 3:56 PM Page 14
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MILLER ELECTRIC_FP_TEMP 5/9/12 9:58 AM Page 15
ALUMINUM
Q&A
BY TONY ANDERSON
Q: What are the primary considerations
relating to the storage and preparation of
aluminum prior to welding, and how can
they affect the quality of my welds?
A: Good storage and preparation prac-
tices prior to welding are important for all
materials if you want to produce sound
welds and avoid weld discontinuities.
For aluminum, the level of cleanliness
during metal preparation is directly re-
lated to the quality of the completed weld.
Stringent preparation procedures prior to
welding are most important when fabri-
cations are required to meet prescribed
weld quality requirements, particularly
when the welds are subjected to radi-
ographic inspection.
Because of aluminums unique char-
acteristics, storage and preparation con-
siderations associated with obtaining
high-quality welds can be different than
for structural steels. The tough, oxide sur-
face film on aluminum, if not controlled,
can prevent fusion or become hydrated
and create porosity, and the high solubil-
ity of hydrogen in molten aluminum sub-
stantially increases the potential for
porosity from moisture and hydrocarbons.
The primary purpose of preweld
preparation for aluminum is to remove
hydrocarbons, moisture, and contami-
nated aluminum oxide prior to welding.
Removal of hydrocarbons Hydro-
carbons within the weld area produce hy-
drogen during the welding process and
cause porosity in the completed weld.
Base material is frequently formed,
sheared, sawed, and machined prior to
welding. If a lubricant is used during any
of these preweld operations, complete re-
moval of the lubricant prior to welding is
essential if high-quality welds are
required.
Since it is important to remove lubri-
cants before welding, it is advantageous
to use the minimum amount of lubricants
in preweld operations. Sawing and ma-
chining of aluminum can often be per-
formed dry. Hydrocarbons, if present, can
be removed by a number of these follow-
ing methods: wiping with solvents such as
acetone or alcohol, detergent-spray de-
greasing, steam degreasing, or wiping with
a mild alkaline solution.
Solvent cleaners are possibly the most
popular method used to remove hydro-
carbons. Most hydrocarbon solvents are
highly volatile and evaporate quickly, but
the water-based cleaners must be thor-
oughly wiped away or heat dried. A hy-
drocarbon solvent suitable for preweld
cleaning must dissolve oil and grease read-
ily, evaporate quickly, and not leave a
residue. One product called ZeroTri, a
heavy-duty degreaser by LPS, has proven
to work well Fig. 1.
Care must be taken, not only in the se-
lection of the correct solvent, but also in
its use. Adequate ventilation is essential,
and the manufacturers recommendations
should be carefully followed. Flammable
chemicals are obviously dangerous in the
presence of welding arcs.
If material has been subjected to con-
tamination from hydrocarbons, remove the
hydrocarbons before wire brushing the part
to remove aluminum oxide. Wire brushing
on an oily or greasy surface tends to smear
the contaminants into the surface, and the
wire brush becomes contaminated and un-
suitable for its intended purpose.
Removal of aluminum oxide Alu-
minum alloys rapidly develop a self-
limiting oxide film when exposed to air.
The aluminum oxide on the materials
surface has a melting point in excess of
3600F, which is around 2400F above
the melting point of pure aluminum base
material. Because of this large difference
in melting temperatures, the oxide film
can impede fusion between filler alloy
and base alloy. Flakes of oxide can be-
come entrapped during the welding
16 JUNE 2012
Fig. 1 A heavy-duty degreaser by LPS,
ZeroTri, removes hydrocarbons from an
aluminum test plate prior to welding. Use
a clean cloth or paper towel to wipe dry,
then use a stainless steel wire brush after
degreasing.
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Aluminum Q and A June 2012_Layout 1 5/10/12 4:21 PM Page 16
17 17 WELDING JOURNAL
process and form inclusions within
the completed weld.
Aluminum, with an uncontami-
nated thin oxide layer, can be success-
fully welded with the inert-gas weld-
ing processes such as gas metal arc
welding (GMAW) or gas tungsten arc
welding (GTAW), which breaks down
and removes the thin oxide during
welding. Potential problems arise
when the aluminum oxide has been
exposed to moisture. The oxide layer
is porous and can absorb moisture,
grow in thickness, and become a
major obstacle when attempting to
produce high-quality welds that are
required to have low porosity levels.
For high-quality welds, it is usually
necessary to remove the aluminum
oxide mechanically just prior to weld-
ing. Remove the oxide layer by brush-
ing with a stainless steel wire brush,
or by scraping, filing, machining, or
grinding. Be careful to use only tools
that are clean and free of contami-
nants such as oil and grease. An alter-
native to mechanical removal of alu-
minum oxide is chemical removal by
immersion in alkaline (caustic) solu-
tion, followed by a water rinse, and
then a nitric acid and water rinse. The
use of chemical cleaning, however, is
much less common as the handling
and disposal of these chemicals is
often seen as a restricting inconven-
ience.
Storage of aluminum filler metal
All aluminum filler metal should
be stored correctly to achieve high-
quality welds. The most common
problem is the exposure of wire to
moisture. This can occur quite easily
if the wire is subjected to abrupt
changes in temperature at high hu-
midity. Obtaining wire from a cool lo-
cation and immediately unpacking it
in a warm, humid area will subject the
wire to condensation from crossing
the dew point. This moisture produces
hydrated aluminum oxide on the sur-
face of the wire and, consequently,
causes low-quality, porous welds.
Also, at high humidity, small dif-
ferences between the aluminum wire
temperature and air temperature can
cause moisture condensation. For ex-
ample, at a relative humidity of 90%
and ambient air temperature of 70F,
the weld wire or aluminum plate need
only be 3F lower in temperature than
the ambient air before it will cross the
dew point and produce moisture
Fig. 2. Consequently, it is favorable to
store aluminum welding wire in a
heated area with a uniform tempera-
ture and low humidity.
Cutting, beveling, and gouging
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Aluminum Q and A June 2012_Layout 1 5/10/12 4:25 PM Page 17
lar cutting methods used on aluminum.
Unfortunately, plasma arc cutting can af-
fect the quality of the cut edge on some
aluminum alloys. The partial melting of
the grain boundaries of some aluminum
alloys can result in microcracking in the
cut edge.
The 2xxx, 6xxx, and 7xxx series (heat-
treatable) alloys are particularly prone to
this type of cracking, whereas the 1xxx,
3xxx, and 5xxx series (nonheat-treatable)
alloys are not. The cracking tendency in-
creases with metal thickness because thick
metal imposes greater restraint on the so-
lidifying metal. Some welding standards
require that the potential cracking zone
be removed mechanically to a depth of
1
8
in. (3.2 mm) before incorporating the
plasma cut edge into a welded joint.
Lasers are also used to cut aluminum,
and they can produce high-quality cut
edges. This cutting method, being a ther-
mal process, can be subject to the same
post-cut edge preparation requirements
as plasma cutting.
Abrasive water-jet cutting is capable
of producing excellent results on alu-
minum. This is not a thermal process, and
excellent results have been reported using
cut edges that have had no further prepa-
ration prior to welding.
Another cutting method for aluminum
is sawing; circular saws and band saws are
used extensively for preparing weld sam-
ples for testing. Though useful for prepar-
ing small samples, use care with band-saw
cut edges as this cutting method can smear
surface oxides along the cut edge and
cause potential welding problems. Tooth
shapes have been developed by saw blade
manufacturers that perform well on alu-
minum. Blades recommended for alu-
minum have more rake and clearance than
those for steel.
Most gouging is performed on alu-
minum with mechanical tools. Straight-
line backgouging of groove welds is often
performed by using a rotary cutting ma-
chine designed for this purpose. Some
fabricators have chosen to adapt a small
portable power saw for backgouging, re-
placing the saw blade with a cutting blade
ground to the required shape. Tungsten
carbide cutting tools are often used for
gouging machines. Arc gouging using the
carbon arc gouging method is not recom-
mended for preparing weld joints in alu-
minum. The plasma arc gouging process
is sometimes used on aluminum welds
but, because of its high heat input and
potential for microcracking when used
on some aluminum alloys, it has a more
limited application.
Weld Backing
Temporary backing strips are usually
made from copper, anodized aluminum,
stainless steel, or various ceramic materi-
als. They are used to control penetration
and are removed after welding. Care must
be taken to prevent melting the backing
material into the weld pool. Permanent
backing strips are typically required to be
made from the same alloy as the base
metal being welded. Typically, no root
opening is used when using temporary
backing material. A root opening is nor-
mally used when using permanent back-
ing material.
Preheating and Interpass
Temperatures
Limit preheating and interpass tem-
peratures to 250F for 15 min max for the
heat-treatable base metals (2xxx, 6xxx,
7xxx) and the 5xxx series alloys with more
that 3% Mg content. Overheating these
base metals can seriously reduce their
strength and produce undesirable metal-
lurgical changes.
Postweld Heat Treatment and
Aging
When heat-treatable aluminum alloys
are welded, they lose a significant amount
of their mechanical properties in the heat-
affected zone. If the base metal being
welded is in the -T4 temper, much of the
original strength can be recovered after
welding by postweld aging. If the base
metal is welded in the -T6 temper, it can
be solution heat-treated and aged after
welding, which will restore it to the -T6
temper. Depending on which filler metal
is used for welding, postweld heat treat-
ing and aging may cause problems. If the
filler metal does not respond to heat treat-
ment and aging the same way as the base
metal, the weld joint may exhibit mechan-
ical properties below those of the base
metal. Due to stress concentrations in the
weld itself, this may not be a desirable con-
dition. Therefore, if postweld heat treat-
ment and aging are performed, the filler
metal selected is important.
Metal Storage and Weld Joint
Preparation Checklist
Store all welding wire and base metal
in a dry location with minimum tempera-
ture fluctuation. Welding wire should
preferably be stored in a dry heated room
or cabinet with low humidity.
Store base metal vertically to mini-
mize moisture condensation and absorp-
tion of water contamination between
layers.
If possible, bring all filler and base
metal materials into the welding area 24
h prior to welding to allow them to reach
room temperature.
Keep welding wire covered at all
times.
Use mechanical metal-removal
methods that cut and remove metal chips;
do not use preparation methods that leave
a ground or smeared surface.
Using a coarse-disc grinding tool is
preferable to a wheel grinding tool. How-
ever, if possible, avoid the use of any type
of grinding tool as they may leave con-
taminants on the plate surface.
Do not use lubricants in the joint
preparation metal working process.
Do not use chlorinated solvents in
JUNE 2012 18
Fig. 2 This graph reveals approximate dew point conditions for airmetal tempera-
tures and relative humidity percentages.
Aluminum Q and A June 2012_Layout 1 5/10/12 4:21 PM Page 18
the welding area because they may form
toxic gases in the presence of electric
welding arcs.
Do not use oxyfuel gas cutting, car-
bon arc cutting, or gouging processes.
Avoid oxyfuel flames to preheat.
These processes can damage the heat-
affected area and promote the growth
and hydration of the oxide film present
on the surface.
Mechanically remove the plasma arc
and laser-cut edges from 2xxx, 6xxx, and
7xxx series alloys if they are to be incor-
porated into the weld.
Prepare and clean the joint prior to
assembly.
When degreasing the surfaces with
a solvent, always use a clean cloth or
paper towels to solvent clean and dry a
welding joint.
Do not use shop rags to clean weld-
ing joints, and do not use compressed air
to blow off the joint. Shop rags typically
contain contaminants and compressed
air often contains moisture and oil.
Stainless steel wire brush the joint
only after solvent cleaning. Wire brush-
ing prior to cleaning embeds hydrocar-
bons and other contaminates in the metal
surface.
Stainless steel wire brush all metal
that has been etched. The by-product
residuals from etching must be removed
prior to welding.
Clean all wire brushes and cutting
tools frequently.
19 WELDING JOURNAL
TONY ANDERSON is director of alu-
minum technology, ITW Welding North
America. He is a Fellow of the British Weld-
ing Institute (TWI), a Registered Chartered
Engineer with the British Engineering Coun-
cil, and holds numerous positions on AWS
technical committees. He is chairman of the
Aluminum Association Technical Advisory
Committee for Welding and author of the
book Welding Aluminum Questions and
Answers currently available from the AWS.
Questions may be sent to Mr. Anderson c/o
Welding Journal, 550 NW LeJeune Rd.,
Miami, FL 33126, or via e-mail at
tony.anderson@millerwelds.com.
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Aluminum Q and A June 2012_Layout 1 5/10/12 4:21 PM Page 19
LETTERS TO THE
EDITOR
Reader Questions the
Relevance of Ultrasonic
Wave-Assisted GMAW
Listed below are comments and responses
regarding the Welding Journal Research Sup-
plement paper titled Ultrasonic Wave As-
sisted GMAW in the March 2012 issue (pages
91-s to 99-s) between AWS Fellow August F.
Manz and one of the papers authors, San-
bao Lin, with the State Key Laboratory of Ad-
vanced Welding and Joining, Harbin Institute
of Technology, Harbin, China.
Lin noted it is helpful to improve future
research works by receiving critical com-
ments from welding experts and admits that
some places pointed out by the reader were
not described accurately or precisely.
Transition Current
Comment: In the discussion of drop
spray transfer (page 91-s), the authors
state the following: The drop spray is
generally characterized by uniform drop
size, regular detachment, directional
droplet transfer, and insignificant spatter,
so it is a preferred process (Ref. 5). How-
ever, the current range for drop spray
transfer is relatively narrow less than
10 A (Ref. 6)...so it is hard to maintain the
drop spray process...in an effort to solve
the above problem...
The Ref. 6, which was cited, is Part II
Control of Metal Transfer of a two-
part article by Dr. A. Lesnewich with the
title Control of Melting Rate and Metal
Transfer in Gas-Shielded Metal-Arc
Welding, Welding Journal, September
1958, pages 418-s to 425-s.
In the article, Dr. Lesnewich discusses
the current range from globular transfer
to spray transfer, of what is known as the
transition current. He states, ...the
marked change in transfer occurs within
a current range of 10 A (see page 419-s).
This is not the current range for drop spray
transfer. Gas metal arc welding (GMAW)
spray transfer has a current range on the
order of hundreds of amperes. There is
no problem to solve. It has worked fine
for more than 50 years.
Response: This is related to how to un-
derstand the drop spray transfer mode
during GMAW.
In the GMAW process, droplet trans-
fer mode consists of short circuit trans-
fer, globular transfer, and spray trans-
fer. Spray transfer is further classified
into drop spray and streaming spray. The
transitions from the globular transfer to
streaming spray are different according
to different shielding gases, welding wire
materials, and so on. Generally, most of
the descriptions use the solid steel wire
and pure argon or argon-rich gas mix-
tures. In these conditions, the transition
current range from globular transfer to
streaming spray transfer is narrow. It can
also be regarded that the current range
of drop spray transfer (between globu-
lar transfer and streaming transfer) is
narrow. This phenomenon has been de-
scribed in several papers and books (for
example, in Prof. Lancasters book, The
Physics of Welding, and Advanced Weld-
ing Processes by John Norrish).
In our research, experiments were con-
ducted in the welding conditions of weld-
ing wire of steel and shielding gas of pure
argon, shown on page 95-s. The transition
current is narrow. The narrow current
range was also observed in the experi-
ments and discussed on page 97-s.
As to the readers description, the cur-
rent range is on the order of hundreds of
amperes. It is true for streaming spray trans-
fer rather than drop spray transfer. That is
why we expect to use ultrasonic wave to ob-
tain a stable drop transfer process.
The following is taken from the 7.2.5
drop spray transfer part of Advanced Weld-
ing Processes by John Norrish, 2006,
Woodhead Publishing:
The transition to projected spray
transfer occurs over a relatively narrow
current range but it has been found [111]
that an important intermediate transfer
mode can occur in this transition range.
This mode of transfer is characterized by
the formation of a solid conic neck on the
wire tip and spherical droplets slightly
larger in diameter than the diameter of
the filler wire are initially suspended from
the tip before being detached (Fig. 7.6).
Detachment occurs very efficiently and
high droplet velocities and very low spat-
ter losses are measured. With a 1.2-mm
carbon steel wire this transfer mode oc-
curs between 250 and 270 A in argon/5%
CO
2
, drop velocities of 7 m min
1
have
been recorded and a slight increase in
melting rate is observed. The drop spray
mode is efficient and clean with very low
spatter and particulate fume levels, but,
under normal steady DC operating con-
ditions, it requires very close control of
the welding parameters and this can only
be achieved with the high-quality elec-
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Letters to the Editor June 2012_Layout 1 5/10/12 4:13 PM Page 20
21 WELDING JOURNAL
tronic power sources described in Chap-
ter 3; in addition, the operating range is
very restricted.
Contact Tube
Comment: In Fig. 3, schematic of ul-
trasonic wave-assisted gas metal arc weld-
ing (U-GMAW), there is no contact tip
shown. The absence or presence of a con-
tact tip is critical in determining the elec-
trode extension, and hence, the effect of
Joule heating.
Response: Figure 3 shows the
schematic diagram of whole U-GMAW
system. It was used to illustrate the main
system structure and explain the princi-
ples of U-GMAW. Therefore, some de-
tails of the welding torch are not shown
inside this figure. However, it does not
mean that the contact tip was ignored in
the paper. In the detailed figures, the con-
tact tip can be seen in the photograph of
welding torch in Fig. 4. Also, it is shown
at the end of the torch in Fig. 5.
Furthermore, the contact tip to work-
piece distance is given in the experimen-
tal conditions (page 95-s). Therefore, the
effect of the electrode extension was con-
sidered in our experiments.
The two figures listed below have been
updated to point out where the contact
tip is located.
Conventional GMAW
Comment: In Figs. 6 and 8, as well as
Table 1 and elsewhere, the authors use the
term conventional GMAW. There should
have been an explanation of what they
meant by this term.
Response: The conventional GMAW
doesnt have special meaning in this
paper. It is just used for comparison with
the ultrasonic wave-assisted gas metal arc
welding (U-GMAW) process. It refers to
the common GMAW conditions without
ultrasonic wave.
In other published papers, the word
conventional is also used to make a com-
parison between gas tungsten arc welding
(GTAW) and activated flux-assisted
GTAW.
Droplet Gravity
Comment: The caption for Fig. 12, and
the box shown in the figure, uses the term
droplet gravity without definition. They
probably meant droplet weight or droplet
Fig. 4 Experimental setup.
Fig. 5 Photographing method of the
metal transfer process.
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Contact tip

Letters to the Editor June 2012_Layout 1 5/10/12 4:13 PM Page 21


mass. Drops do not have gravity; they
have weight or mass.
Response: The expression of the
droplet gravity is incorrect in the paper.
It should be expressed as gravitational
force, which is due to the mass of the
droplet.
Significance of Research Work
Comment: In their last sentence, the
authors state: The ultimate goal of this
method is to control the metal transfer
process by applying pulsed ultrasonic
wave to conventional GMAW or apply-
ing constant ultrasonic wave to pulsed
GMAW. It seems to me that conven-
tional GMAW works fine as it is now
practiced.
Finally, consider this does the in-
creased equipment complexity of the pro-
posed U-GMAW process yield benefits
that are worth the effort and expense?
Response: Although GMAW has been
widely applied in the welding industry
since the 1930s, great efforts have been
contributed to improve the welding qual-
ity and efficiency. Many advanced
GMAW methods have been developed,
including tandem GMAW, cold metal
transfer, arc brazing, flux cored arc weld-
ing, and laser arc hybrid welding.
The research results presented in this
paper were to prove the feasibility of the
proposed U-GMAW idea, which has
never been studied before. This is only
the first stage of our research. Imposing
ultrasonic wave onto arc welding process
has shown some positive effects, includ-
ing the increase of droplet transfer fre-
quency, the improvement of wettability
of weld bead under pure argon, and the
refinement of weld grain size. This has a
potential application in welding superal-
loy, titanium alloy, as well as Al alloy. For
example, it could be used on shaped
metal manufacturing (also called addi-
tive layers manufacturing) of aerospace
components. This is the charming feature
of welding research. Sometimes, you do
not know its use when you have a new
idea.
This part of the response answers the
readers questions on the purpose and
value of the U-GMAW technique. The
last sentence of the paper just described
one of its potential applications. The
words ultimate goal may be not accu-
rate. Changing them to one of the po-
tential application of this method may
be better.
JUNE 2012 22
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greiner_FP_TEMP 5/9/12 9:53 AM Page 23
JUNE 2012 24
BRAZING
Q&A
BY TIM HIRTHE
Q: We are brazing an assembly fabricated
from 439 stainless steel and are encounter-
ing a severe problem with failure due to cor-
rosion. The parts are showing rust at the fil-
let edges between the braze alloy and the
stainless parts. The braze alloy is BAg-24
and the joints are made using torch heating
and a black brazing flux. We had an under-
standing that by selecting a braze alloy that
contains nickel we would not have a prob-
lem with corrosion. I have included photos
showing the problem and our attempt at a
solution using BAg-21 as an alternative.
These parts are subjected to moisture in
service and the corrosion appears after only
a short time in tap water. We also find that
the steel rusts on the surface well away from
the joint after thoroughly removing the
flux. The BAg-21 joints are better but it is a
difficult alloy to work with. What is causing
this condition and are there any other
remedies we can try?
A: Every once in a while a classic brazing
problem rears its head and thats what we
see here. What you are experiencing is
called interfacial corrosion. It can occur in
the brazing of all stainless steels. It is most
common in braze joints using martensitic
and ferritic stainless steels. In extreme
cases, the braze joints exhibit corrosion
within hours and fall apart in just a few
days after exposure to tap water.
The corrosion occurs rapidly in a very
thin layer on the stainless steel where it is
in contact with the braze filler metal. With
the layer being so thin, this corrosion is
also known as knife edge attack. It is of
major concern because it occurs most
often with stainless steels brazed with sil-
ver brazing filler metals and flux, a com-
mon industrial practice. Care must be
taken in material and process selection.
The problem has been known for a long
time and great effort has been expended,
particularly by the major suppliers of sil-
ver brazing alloys, in developing solutions.
Stainless steels develop a passivation
layer of chromium oxide, effectively coat-
ing it and protecting it from oxidizing iron
on the surface. If this protection is dis-
turbed or compromised, the steel can cor-
rode. The material you are joining is a fer-
ritic grade stainless steel, Type UNS
43900, which has a composition of 78%
iron/18% chromium/1.1% titanium/0.5%
nickel with small additions of other ele-
ments. While it has a high chromium con-
tent, there is no nickel and the majority of
the alloy is iron. If the chromium content
on the surface is reduced below an ac-
ceptable level, the steel will be susceptible
to corrosion. Austenitic stainless steels are
less susceptible to this corrosion because
of their nickel content.
You were correct in your statement
that it is recommended that brazing filler
metals for joining stainless steels should
contain nickel. There is no universal way
to apply this, however. A particular filler
metal selection may work well in one case
and fail miserably in another. Take your
experience, for example. The BAg-24
(50% silver/20% copper/28% zinc/2%
nickel) filler metal is considered a general-
purpose material for stainless steel appli-
cations. It is commonly acceptable when
used on austenitic stainless steels. Figure
1 would indicate it is not acceptable on
UNS 43900 when brazed with flux and
used in aqueous applications.
Conditions necessary for interfacial
corrosion to occur are 1) stainless steel is
being used; 2) the braze filler metal se-
lected will create a condition susceptible
to this corrosion; and 3) the joints will be
exposed to aqueous solutions or humidity
in service. The difficult one to identify is
the filler metal selection. However, over
time, a great deal of manufacturing expe-
rience and research about filler metals in
these applications has been published so
insight can be gained during the product
and process design phases.
The process parameter that is gener-
ally thought to create this corrosion con-
dition relates to the use of flux. Its inter-
esting to note that, in many instances, for
the same combination of filler metal and
stainless steel, the corrosion appears when
flux is used but does not occur when fur-
nace brazed without flux. There are other
issues that can contribute to corrosion but
flux is the prime suspect.
During the brazing process the flux re-
moves the passivation layer in order to
allow the braze alloy to bond to the stain-
less steel surface. The fluxes can also re-
move chromium from the surface. You re-
ported seeing rust on the surface of the
stainless away from the joint indicating
that this had occurred. When the
chromium is removed, it leaves exposed
iron. In the braze joint, this surface be-
comes anodic to the silver braze alloy it is
in contact with and is susceptible to attack.
This attack begins on the outer fillet edges
Fig. 1 439 stainless brazed with BAg-24.
Fig. 2 439 stainless brazed with BAg-21.
Brazing Q+A June _Layout 1 5/10/12 3:59 PM Page 24
25 WELDING JOURNAL
between the braze filler metal and the
stainless steel at their interface. A crevice
is formed that creates a concentration cell
that accelerates the process. Iron ions are
removed from the steel surface and are
deposited at the fillet edge as ferrous hy-
droxide, or rust Fig. 1.
The recommendation of using a braz-
ing filler metal containing nickel is to com-
bat this attack by creating a nickel-rich
layer at the interface between the filler
metal and the stainless. This layer im-
proves the corrosion resistance of the in-
terface. It is generally effective on
austenitic stainless steels where there is
high chromium but also nickel in the stain-
less steel.
Other conditions that can add to the
corrosion may be present also. Stainless
steels are susceptible to chromium carbide
precipitation when heated and cooled im-
properly, which can reduce their corrosion
resistance. Residual flux may be present
that can accelerate the process. Microor-
ganisms may be present in the service en-
vironment that can contribute to this type
of corrosion. While these are possible, the
flux effect is the main contributor. It is
prudent that you use the least amount of
flux possible to achieve an acceptable
braze.
In looking for a remedy, you need to
take one of two approaches. Either design
the product and process in a way that re-
duces the electrochemical potential be-
tween the brazing filler metal and the
stainless steel or live with it and develop a
way to stop the attack after brazing. The
most common solution is the one you have
been pursuing, i.e., using an alternate
alloy that reduces or eliminates the corro-
sion potential between the braze filler
metal and the stainless steel at the joint in-
terface. In the case of ferritic stainless
steels, the standard is BAg-21 (63% sil-
ver/28.5% copper/6% tin/2.5% nickel).
The main drawback to this is that BAg-21
is not a very user-friendly alloy in torch
brazing. It has sluggish flow, which is due
to the lack of low-temperature wetting
constituents and its long melt range
12751475F (690800C). The effect in
arresting interfacial corrosion, however, is
dramatic as can be seen in Fig. 2.
A common way of eliminating the cor-
rosion potential is to eliminate the flux
from the process, typically by changing to
furnace brazing. Filler metals used in this
approach can be of the BAg type or of the
BAu and BNi families. Many companies
select nickel-based BNi alloys containing
chromium, with brazing performed in an
atmosphere without flux, to achieve maxi-
mum corrosion resistance. Another way to
approach the problem is to nickel plate
the stainless steel prior to brazing.
If, for some reason, you cannot do any
of these other things, you can try to put a
coating over the joint such as plating after
brazing. There are reports in the literature
that some companies cover the joint with
soft solder. These are last resorts as the so-
lutions described earlier are readily
achievable. As it appears, the BAg-21 is
successful in stopping the interfacial cor-
rosion, working to optimize the heating
process to mitigate the poor flow would
seem to be the next step.
This column is written sequentially by
TIM P. HIRTHE, ALEXANDER E.
SHAPIRO, and DAN KAY. Hirthe and
Shapiro are members of and Kay is an ad-
visor to the C3 Committee on Brazing and
Soldering. All three have contributed to the
5th edition of AWS Brazing Handbook.
Hirthe (timhirthe@aol.com) currently
serves as a BSMC vice chair and owns his
own consulting business.
Shapiro (ashapiro@titanium-braz-
ing.com) is brazing products manager at Ti-
tanium Brazing, Inc., Columbus, Ohio.
Kay (Dan@kaybrazing.com), with 40
years of experience in the industry, operates
his own brazing training and consulting
business.
Readers are requested to post their ques-
tions for use in this column on the Brazing
Forum section of the BSMC Web site
www.brazingandsoldering.com.
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JUNE 2012 26
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P and P June 2012_Layout 1 5/10/12 2:40 PM Page 26
27 WELDING JOURNAL
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JUNE 2012 28
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P and P June 2012_Layout 1 5/10/12 2:42 PM Page 28
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WELD ENGINEERING_FP_TEMP 5/9/12 1:51 PM Page 29
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described are grinding discs, cut-off
wheels, flap discs, flap wheels, belts, discs,
and tools. Included is helpful reference
information for all facets of metalwork-
ing. Hard copies of the catalog may be or-
dered online at the Web site shown.
Klingspor
www.klingspor.com
(800) 645-5555
Web Site Features Welding
and Assembly Positioners
The company has launched a new Web
site providing extensive coverage of its line
of welding and assembly positioning lifts.
Included are headstock/tailstock position-
ers, single-column types, mobile lifts, ma-
terial-handling lifts, as well as custom lifts
and positioners. Available for download
are technical drawings, brochures, and an
extensive photo gallery showcasing a wide
variety of durable equipment custom de-
signed to customers requirements.
ALM Materials Handling
www.almmh.com
(800) 544-5438
JUNE 2012 30
For info go to www.aws.org/ad-index
For info go to www.aws.org/ad-index
continued from page 28
continued on page108
P and P June 2012_Layout 1 5/10/12 2:42 PM Page 30
For Info go to www.aws.org/ad-index
OTC DAIHEN_FP_TEMP 5/9/12 9:58 AM Page 31
Fiscal 2011 year in review
Gesana Villegas, Chief Financial Officer
Fiscal Year 2011 was another remarkable year for the Society in terms of financial per-
formance. Most operational units showed improved results over last year, and many new
financial milestones were reached. The AWS financial position is the healthiest in our
92-year history. We also had other significant accomplishments, including the launch of
American Welding Online (AWO), initiation of the Careers in Welding Trailer, incep-
tion of the Boy Scout Merit Badge, implementation of the Portuguese edition of the
Welding Journal, and merger with the International Thermal Spray Association (ITSA),
among other achievements.
We attained historical high revenues, bringing in $27.8 million, an increase of 5% over
2010. We also had a record high surplus of revenues over expenses of $8 million, in-
creasing by 5.9% over 2010.
We are working toward replenishing our reserves following the purchase of our new
Doral World Headquarters office building in May 2010. The sale of our current office
building located on LeJeune Road will add to our reserves. We anticipate full replenish-
ment by 2013 or earlier, depending on the market trend. The market remained flat for
2011. Despite all of the market volatility in 2011, we ended up with a positive YTD rate
of return.
The Operating Fund transferred $5 million to the Reserve Fund during 2011 due to
positive financial results. Our positive financial results have enabled us to accumulate
cash, allowing us to fund the build out of the Doral facility with operating cash. Our move
date is scheduled for May/June 2012. We will be having an open house and ribbon-cut-
ting ceremony on September 28, 2012.
The new HQ office building will represent us well as the premier professional and tech-
nical society we are today and for many years to come. We continue to grow and expand
our position in the marketplace around the globe. Our emphasis remains on strategies and
programs to strengthen and broaden our presence domestically, as well as internationally.
In 2011, we hired our first-ever outside international sales person. In 2011, much effort
was devoted to developing a cohesive global strategy to grow international revenues prof-
itability and to continue to support the societys overall vision and mission. The strategy
will focus on global opportunities and will address key issues and challenges of our busi-
ness. It will help us strengthen our status as the worlds leading Welding Society.
We are pleased to announce that the Society has been able to maintain a net surplus
above $7 million for the past four years with the highest surplus in history of $8,032,900
for the fiscal year just ended. Our average surplus ratio for the past five years, 2007 to
2011, is 28%. Total net assets reached $60.3 million, more than tripling in the five years
since 2006, when net assets were at $19.4 million.
Historical highs were achieved in the following areas:
Total Assets = $64.6 million (increase of $8.2 million, or 14.6%, over 2010)
Total Net Assets (Net Worth) = $60.3 million (increase of $8 million, or 15.4%, over
2010)
Total Operating Revenues = $27.8 million (increase of $1.3 million, or 5.1%, over 2010)
Surplus (Excess Revenues over Expenses) = $8 million (increase of $445,000, or 5.9%,
over 2010)
AWS Foundation Highlights for 2011
The AWS Foundation is in its sixth year of the Welding for the Strength of America
and the AWS Welder Workforce Development Program Capital Campaign, raising more
than $6.5 million, including, $1.6 million donated by AWS for scholarships awards for fu-
ture welding professionals. The Foundation focuses its efforts on recruitment to the weld-
ing workforce and enhancing the image of welding as a career.
We are proud to unveil our Careers in Welding mobile exhibit, an educational expe-
rience introducing career opportunities available in welding. We are grateful to receive
funding from a donor, as well as equipment for the mobile trailer. AWS also contributed
funds toward the purchase of the mobile trailer and will provide support for ongoing mo-
bile trailer operations. The mobile exhibit has set out to enhance the overall image of
welding and inspire and excite people about a career in welding.
AMERICAN WELDING SOCIETY AND AWS FOUNDATION FINANCIAL REPORT
JUNE 2012 32
Officers
President William A. Rice Jr.
OKI Bering
Vice President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Kimberly-Clark Global Safety
Vice President David J. Landon
Vermeer Mfg. Co.
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
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
J. C. Bruskotter (Past President), Bruskotter Consulting Services
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Thermadyne Industries
D. A. Flood (Dist. 22), Tri Tool, Inc.
R. A. Harris (Dist. 10), Total Quality Testing
D. C. Howard (Dist. 7), Concurrent Technologies Corp.
J. Jones (Dist. 17), Thermadyne Industries
W. A. Komlos (Dist. 20), ArcTech, LLC
R. C. Lanier (Dist. 4), Pitt C.C.
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Corp.
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
D. L. McQuaid (At Large), DL McQuaid & Associates
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), ESAB Welding & Cutting Products
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. R. Polanin (Dist. 13), Illinois Central College
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
N. S. Shannon (Dist. 19), Carlson Testing of Portland
T. A. Siewert (At Large), NIST
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
2011 Financial Report Layout_2005 Financial Report 5/10/12 10:27 AM Page 32
AMERICAN WELDING SOCIETY AND AWS FOUNDATION FINANCIAL REPORT
33 WELDING JOURNAL
In 2011, we worked to dedicate the month of April as the National Welding Month. In 2011, the National Association of Manufac-
turers (NAM) endorsed the Manufacturing Skills Certification System, and we continue to collaborate with NAM on the deployment
of such systems worldwide.
We continue to work with Weld-Ed on various levels. With the help of Weld-Ed, there have been ongoing efforts to collect data en-
rollment and graduation rates to measure whether we are making progress in alleviating the shortage of welders. Weld-Ed funding in
2011 covered expenses relating to the printing and distribution of career packets, the creation and distribution of a new DVD titled Im-
proving Their Competitive Edge: Students in Welding, the trailer career wall, and the State of the Welding Industry Workforce round-
table where 17 executives served on the panel. Discussions at the roundtable revolved around three main priorities: building enthusi-
asm for welding, expanding industry and education collaboration, and flexibility in education and training. Weld-Ed received
continuation funding from the National Science Foundation for $3 million over three years from 2011 through 2014 to be distributed
among various organizations, and the Foundation is a sub-recipient of such funds.
In 2011, the AWS Foundation awarded $390,000 in scholarships to more than 450 students. Since 1991, when the AWS Foundation
began awarding scholarships, more than $5.3 million has been awarded to approximately 3,900 students.
There is still an immense amount of work to be done to address the critical workforce shortage in the welding industry. The AWS
Foundation continues to diligently seek funding focusing on the welder workforce. AWS continues to be committed to lead the effort
to provide trained workers at all levels for the welding profession. One hundred percent of the contribution will be used to support
welder workforce development and educational opportunities for welders, and you can assist in this effort. To find out how you can help
in the mission of alleviating the welder workforce shortage, please contact Sam Gentry at sgentry@aws.org.
AWS Highlights for 2011
Convention FABTECH was a tremendous success with a record 35,457 attendees. Exhibit space was 522,000 square feet with 1,300
exhibitors in total, including welding, forming/fabrication, tube and pipe, finishing and stamping. Show revenues for 2011 outperformed
the prior three years, including Las Vegas when we had the highest square footage. Revenues and square footage for the 2011 Chicago
FABTECH Show increased by 12.9% and 11.5%, respectively, in comparison to the 2010 Atlanta Show. In comparison to the last
Chicago show, held in 2009, increases in revenues and square footage were 20.1% and 15.6%, respectively. Our show in Mexico (AWS
WELDMEX) was once again a success in 2011, generating 35% more in revenues when compared to 2010. Attendance was close to
7,100 with 518 exhibitors. We continue to explore taking the FABTECH brand with our partners to other countries.
Educational Services We saw significant improvements within this operating unit. A majority of the programs were ahead of the
prior year, including our main program, CWI seminar revenues, which increased by 7.1% over 2010. We also realized significant sav-
ings in the area of hotel contracts. Departmental surplus increased by 53%. We launched our first AWO product in 2011. Our next prod-
uct is AWS Welding Fundamentals. AWO is one of our current main areas of focus. We foresee numerous opportunities within AWO.
Membership Total Membership count for 2011 was 69,566 and increased by 2,719, or 4.1%, over a one-year period. The retention
rate on membership renewals is at 80.2%. International and student membership represents 20.7% and 16.5% of the Societys member
base, respectively. We continue to work on developing a presence on social networking sites. Efforts are being devoted to recruit indi-
vidual and corporate level members via marketing initiatives, such as expositions, collaborating with educational institutions, using col-
lateral in Spanish to reach Latin America, exploring member collateral in other languages, and promoting member affinity programs.
Certification This operating unit continues to be the top revenue-producing business unit, generating $9.8 million in revenues in 2011.
We experienced less of a decline in CWI examination revenues, -2.8% in 2011 versus -22.1% when comparing activities in 2010 to 2009.
Renewal revenues are up 36% when compared to 2010. Our Accredited Test Facility (ATF) program continues to gain popularity, gen-
erating 37% more in revenues when compared to 2010. We added 14 new ATFs, bringing the total ATFs to 96 (77 domestic and 19 in-
ternational). Welder certification revenues are ahead by 15.5% over last year. Exam revenues generated by international agents ap-
proximated $2.3 million. Total departmental revenues increased by 9.4%. There were a total of 31,067 individual CWIs and 4,755
Certified Welders at December 31, 2011, increasing by 4.1% and 11%, respectively, over 2010.
Technical The 2010 D1.1 Structural Welding Code Steel edition is now on a five-year cycle as opposed to a two-year cycle. In its
second year of the cycle, technical hard copy book sales and electronic/subscription sales of document revenues decreased by -3.3% in
comparison to 2010, the year of release. In comparison to 2009, the increase in revenues for both book and electronic sales is 19.5%.
Total departmental revenues decreased by -9.4% when compared to 2010. It should be noted that in 2010, we received additional roy-
alties from a separate license agreement for the 2010 edition of another publication, where higher royalties are seen during the initial
year of its three-year publication cycle. We are working on translations of our core codes which will provide additional revenue sources.
Publications Total departmental revenues were $3.5 million, an increase of 5% over the previous year. Welding Journal advertis-
ing increased by 14.1% over 2010. The Spanish Welding Journal continues to do well. In 2011, we had four issues in comparison to three
issues in 2010. In 2011, we also released our first Brazilian-Portuguese version of the Journal.
In Summary
Fiscal year 2011 was an extraordinary year. Not only did we add to our financial strength, but we also worked on numerous initia-
tives to enhance our position in the marketplace. Our strategy domestically revolves around enhancing the industry while ensuring fi-
nancial strength, while we focus internationally on growing revenues profitably while supporting our global mission.
Continued on page 34
2011 Financial Report Layout_2005 Financial Report 5/10/12 10:28 AM Page 33
AMERICAN WELDING SOCIETY AND AWS FOUNDATION FINANCIAL REPORT
Five year comparisons
Dec-07 Dec-08 Dec-09 Dec-10 Dec-11
Operating Revenue 22,705,914 25,541,336 26,049,776 26,446,348 27,774,105
Total Assets 30,238,890 31,506,599 44,665,409 56,415,395 64,622,045
Net Assets 27,003,910 28,164,569 41,306,406 52,290,944 60,250,495
Membership 52,654 55,072 60,050 66,847 69,566
Convention (sq. ft.) 163,000 178,700 146,400 151,700 169,100
Growth at a Glance
Continued from page33
JUNE 2012 34
We are cautiously optimistic that fiscal year 2012 will achieve positive financial results. We will closely monitor our key financial in-
dicators to ensure that we are fiscally responsible and so that we can continue to make sound financial decisions.
Our strong Statement of Financial Position continues to gives us the ability to provide and fund future programs and opportunities
for our members, volunteers, and the welding industry. We strive to provide the highest customer service for our members.
The AWS Board of Directors and AWS Foundation Trustees would like to express their appreciation to all of our members, volun-
teers, industry leaders, and cooperating organizations that share our goals in helping us make this another successful year.
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:26 PM Page 34
550 N.W. LeJeune Road
Miami, Florida 33126
800-443-9353
305-443-9353
305-443-7559 Fax
e-mail: info@aws.org
www.aws.org
550 N.W. LeJeune Road
Miami, Florida 33126
800-443-9353, ext. 293
305-445-6628
305-443-7559 Fax
e-mail: found@aws.org
www.aws.org/foundation/index.html
REPORT OF INDEPENDENT CERTIFIED PUBLIC ACCOUNTANTS
To the Board of Directors
American Welding Society, Inc. and AWS Foundation
We have audited the accompanying combined statement of financial position of American Welding Society, Inc. and
AWS Foundation (the Organizations) as of December 31, 2011, and the related combined statements of activities
and cash flows for the year ended December 31, 2011. These combined financial statements are the responsibility of
the Organizations management. Our responsibility is to express an opinion on these combined financial statements
based on our audit. The prior year summarized comparative information has been derived from American Welding
Society, Inc. and AWS Foundations 2010 combined financial statements and, in our report dated April 11, 2011, we
expressed an unqualified opinion on those combined financial statements.
We conducted our audit in accordance with auditing standards generally accepted in the United States of America.
Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the com-
bined financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence
supporting the amounts and disclosures in the combined financial statements. An audit also includes assessing the
accounting principles used and significant estimates made by management, as well as evaluating the overall financial
statement presentation. We believe that our audit provides a reasonable basis for our opinion.
In our opinion, the combined financial statements referred to above present fairly, in all material respects, the financial
position of American Welding Society, Inc. and AWS Foundation as of December 31, 2011, and the changes in their
net assets and their cash flows for the year then ended in conformity with accounting principles generally accepted in
the United States of America.
Morrison, Brown, Argiz & Farra, LLP
Certified Public Accountants
Miami, Florida
April 18, 2012
35 WELDING JOURNAL
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:26 PM Page 35
ASSETS 2011 2010
Cash and cash equivalents $ 5,209,344 $ 4,558,121
Certificates of deposit - 202,744
Accounts and other receivables, net of allowance for
doubtful accounts of approximately $300,000 2,075,903 2,297,899
Pledges receivable, net 202,100 82,150
Inventory 46,008 65,426
Prepaid and other assets 1,185,029 1,013,269
Deposits and other receivables 397,363 61,703
Investments 32,726,192 27,229,546
Property and equipment, net 22,780,106 20,904,537
TOTAL ASSETS $ 64,622,045 $ 56,415,395
LIABILITIES AND NET ASSETS
Accounts payable, accrued expenses and other liabilities $ 1,530,872 $ 1,553,671
Deferred membership, subscription and seminar income 2,840,678 2,570,780
TOTAL LIABILITIES 4,371,550 4,124,451
COMMITMENTS
NET ASSETS
Unrestricted 50,077,915 43,137,179
Temporarily restricted 5,348,700 4,434,305
Permanently restricted 4,823,880 4,719,460
TOTAL NET ASSETS 60,250,495 52,290,944
TOTAL LIABILITIES AND NET ASSETS $ 64,622,045 $ 56,415,395
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
COMBINED STATEMENT OF FINANCIAL POSITION
DECEMBER 31, 2011 (WITH COMPARATIVE TOTALS FOR THE YEAR ENDED DECEMBER 31, 2010)
The accompanying notes are an integral part of these combined financial statements.
JUNE 2012 36
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:28 PM Page 36
Temporarily Permanently
Unrestricted Net Assets Restricted Restricted Total Total
Revenues Expenses Net Net Assets Net Assets 2011 2010
OPERATING ACTIVITIES:
Convention $ 2,417,916 $ 521,465 $ 1,896,451 $ - $ - $ 1,896,451 $ 1,649,273
Educational services 4,087,538 3,227,039 860,499 - - 860,499 561,831
Marketing and corporate communications - 555,943 (555,943) - - (555,943) (563,991)
International activities 7,000 245,411 (238,411) - - (238,411) (206,304)
AWS Foundation - 645,878 (645,878) - - (645,878) (538,394)
WEMCO 91,869 216,109 (124,240) - - (124,240) (123,040)
RWMA 101,969 186,996 (85,027) - - (85,027) (89,719)
Membership 3,103,914 1,644,351 1,459,563 - - 1,459,563 1,437,751
Certification 9,820,528 2,703,741 7,116,787 - - 7,116,787 6,502,690
Technical 4,632,299 1,679,072 2,953,227 - - 2,953,227 3,374,029
Publications 3,488,448 2,835,954 652,494 - - 652,494 698,067
Administration 8,882 4,693,481 (4,684,599) - - (4,684,599) (4,570,815)
Building operations 13,742 515,468 (501,726) - - (501,726) (506,360)
Board approved programs - 70,336 (70,336) - - (70,336) (37,000)
TOTAL OPERATING
FUND BEFORE TRANSFER 27,774,105 19,741,244 8,032,861 - - 8,032,861 7,588,018
INTER-FUND TRANSFER - (7,494,868) (7,494,868) - - (7,494,868) (7,627,915)
TOTAL OPERATING
FUND AFTER TRANSFER - - 537,993 - - 537,993 (39,897)
RESERVE:
(Loss) gain on investments - (426,913) (426,913) - - (426,913) 1,814,923
TFPS, Inc. - - - - - - 357
Interest and dividends 595,346 - 595,346 - - 595,346 536,625
TOTAL RESERVE FUND
BEFORE TRANSFER 595,346 (426,913) 168,433 - - 168,433 2,351,905
INTER-FUND TRANSFER 5,000,000 - 5,000,000 - - 5,000,000 (11,118,800)
TOTAL RESERVE FUND
AFTER TRANSFER 5,595,346 (426,913) 5,168,433 - - 5,168,433 (8,766,895)
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
COMBINED STATEMENT OF ACTIVITIES
FOR THE YEAR ENDED DECEMBER 31, 2011 (WITH COMPARATIVE TOTALS FOR THE YEAR ENDED DECEMBER 31, 2010)
The accompanying notes are an integral part of these combined financial statements.
37 WELDING JOURNAL
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:29 PM Page 37
Temporarily Permanently
Unrestricted Net Assets Restricted Restricted Total Total
Revenues Expenses Net Net Assets Net Assets 2011 2010
AWS FOUNDATION:
Donations $ 359,820 $ - $ 359,820 $ 474,886 $ 104,420 $ 939,126 $ 664,842
Interest 138,630 - 138,630 135,390 - 274,020 258,603
(Loss) gain on investments, net - 71,185 (71,185) (79,963) - (151,148) 826,731
Net assets released from
restrictions by satisfaction
of purpose restrictions 240,918 - 240,918 (240,918) - - -
Operating expenses - 126,939 (126,939) - - (126,939) (161,205)
Scholarships - 245,183 (245,183) - - (245,183) (242,290)
Fellowship - 50,000 (50,000) - - (50,000) (33,334)
Fundraising and other - 169,542 (169,542) - - (169,542) (125,762)
TOTAL AWS FOUNDATION
FUND BEFORE TRANSFER 739,368 662,849 76,519 289,395 104,420 470,334 1,187,585
INTER-FUND TRANSFER - - - 625,000 - 625,000 200,000
TOTAL AWS FOUNDATION
FUND AFTER TRANSFER 739,368 662,849 76,519 914,395 104,420 1,095,334 1,387,585
PROPERTY FUND:
Building operations 327,759 1,039,836 (712,077) - - (712,077) (142,970)
TOTAL PROPERTY FUND
BEFORE TRANSFER 327,759 1,039,836 (712,077) - - (712,077) (142,970)
INTER-FUND TRANSFER - - 1,869,868 - - 1,869,868 18,546,715
TOTAL PROPERTY FUND
AFTER TRANSFER 327,759 1,039,836 1,157,791 - - 1,157,791 18,403,745
Change in Net Assets - - 6,940,736 914,395 104,420 7,959,551 10,984,538
NET ASSETS, BEGINNING - - 43,137,179 4,434,305 4,719,460 52,290,944 41,306,406
NET ASSETS, ENDING $ - $ - $ 50,077,915 $5,348,700 $ 4,823,880 $ 60,250,495 $ 52,290,944
FOR THE YEAR ENDED DECEMBER 31, 2010 (WITH COMPARATIVE TOTALS FOR THE YEAR ENDED DECEMBER 31, 2009)
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
COMBINED STATEMENT OF ACTIVITIES (Continued)
FOR THE YEAR ENDED DECEMBER 31, 2011 (WITH COMPARATIVE TOTALS FOR THE YEAR ENDED DECEMBER 31, 2010)
The accompanying notes are an integral part of these combined financial statements.
JUNE 2012 38
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:29 PM Page 38
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
COMBINED STATEMENT OF CASH FLOWS
FOR THE YEAR ENDED DECEMBER 31, 2011 (WITH COMPARATIVE TOTALS FOR THE YEAR ENDED DECEMBER 31, 2010)
The accompanying notes are an integral part of these combined financial statements.
2011 2010
CASH FLOWS FROM OPERATING ACTIVITIES:
Change in net assets $ 7,959,551 $ 10,984,538
Adjustments to reconcile change in net assets to
net cash provided by operating activities:
Depreciation 332,880 225,357
Loss (Gain) on investments, net 578,061 (2,641,654)
Provision for losses on accounts receivable - 154,243
Write-off fixed assets 128,492 151,278
Changes in assets and liabilities:
Decrease in accounts receivables 221,996 445,107
(Increase) decrease in pledges receivable, net (119,950) 270,770
Decrease (Increase) in inventory 19,418 (5,186)
(Increase) in prepaids and other assets (171,761) (8,003)
(Increase) decrease in deposits and other receivables (335,660) 130,911
(Decrease) increase in accounts payable,
accrued expenses and other liabilities (22,799) 372,924
Increase in deferred membership, subscription
and seminar income 269,898 392,524
NET CASH PROVIDED BY OPERATING ACTIVITIES 8,860,126 10,472,809
CASH FLOWS FROM INVESTING ACTIVITIES:
Redemption of certificate of deposit 202,744 2,015,357
Purchases of property and equipment (2,336,941) (18,749,230)
(Purchase of) proceeds from investments, net (6,074,706) 9,643,426
NET CASH USED IN INVESTING ACTIVITIES (8,208,903) (7,090,447)
NET INCREASE IN CASH AND CASH EQUIVALENTS 651,223 3,382,362
CASH AND CASH EQUIVALENTS, BEGINNING OF YEAR 4,558,121 1,175,759
CASH AND CASH EQUIVALENTS, END OF YEAR $ 5,209,344 $ 4,558,121
39 WELDING JOURNAL
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:30 PM Page 39
1. NATURE OF ORGANIZATION AND SIGNIFICANT
ACCOUNTING POLICIES
Organization and Purpose
The accompanying combined financial statements include
the accounts of American Welding Society, Inc. (AWS),
its affiliate, AWS Foundation (Foundation) (collectively,
the Organizations).
All material inter-organization accounts and transactions
have been eliminated in the combination. American Weld-
ing Society, Inc. and AWS Foundation are not-for-profit en-
tities, exempt from income tax under Section 501(c)(3) of
the Internal Revenue Code and are primarily engaged in
welding technology, education and research activities. For
income tax purposes, publication advertising revenue and
rental income are considered "unrelated business income
and are subject to income tax.
On February 5, 2011, TFPS Inc.s Board of Directors voted
to dissolve TFPS, Inc. which has been inactive for several
years. The decision was made since the Organization has
not been engaged nor does it foresee engaging in profit- ori-
ented activities in the near future. The Articles of Dissolu-
tion were filed with the Division of Corporations in March
2011.
Basis of Accounting
The combined financial statements of the Organizations
are prepared on the accrual basis of accounting. The ac-
counts of the Organizations are maintained for internal re-
porting purposes in accordance with the principles of fund
accounting.
Basis of Presentation
The combined financial statements of the Organizations
have been prepared in accordance with the Financial Ac-
counting Standards Board (FASB) Accounting Stan-
dards Codification (ASC) 958 Not-for-Profit Entities.
The Organizations are required to classify their resources
into three separate classes of net assets: unrestricted, tem-
porarily restricted and permanently restricted. In addition,
the Organizations are required to present a statement of
cash flows. The three classes of net asset categories are as
follows:
Unrestricted Net assets which are free of donor-imposed
restrictions; all revenues, gains, and losses that are not
changes in permanently or temporarily restricted net assets.
Temporarily Restricted Net assets where the use by the
Organizations is limited by donor-imposed stipulations that
either expire by the passage of time or that can be fulfilled
or removed by actions of the Organizations pursuant to
those stipulations.
Permanently Restricted Net assets where the use by the
Organizations is limited by donor-imposed stipulations that
neither expire with the passage of time nor can be fulfilled
or otherwise removed by actions of the Organizations.
The transactions of the Organizations are categorized into
separate funds. The purpose and net asset classification are
as follows:
Operating This fund is used to account for all unre-
stricted net assets of American Welding Society, Inc., ex-
cept for those accounted for in the reserve and property
funds. The operating fund also provides administrative sup-
port to the AWS Foundation.
Reserve This fund is used to account for Board desig-
nated reserve funds which are to be used to supplement the
cash needs of AWS.
AWS Foundation AWS Foundations temporarily re-
stricted net assets consists of donor-restricted contributions
to be used for awards and scholarships. Permanently re-
stricted net assets consist solely of an endowment fund.
Property Fund This fund is used to account for the net
assets of American Welding Society, Inc. associated with its
new Headquarter facility located in Doral, Florida.
Deferred Membership Fees and Services
Membership and subscription revenues are deferred when
received and recognized as revenue over the life of the
membership and subscription.
Contributions and Promises to Give
Contributions received or made, including promises to give
or pledges, are recognized at fair value in the period in
which they are received or made.
Support that is restricted by the donor is reported as an in-
crease in unrestricted net assets if the restriction expires in
the reporting period in which the support is recognized. All
other donor-restricted support is reported as an increase in
temporarily or permanently restricted net assets, depend-
ing on the nature of the restriction. When a donor restric-
tion expires (that is, when a stipulated time restriction ends
or purpose restriction is accomplished), temporarily re-
stricted net assets are reclassified to unrestricted net assets
and reported in the Combined Statement of Activities as
Net assets released from restrictions.
Contributions are recognized when the donor makes a
promise to give to the Organizations, that is, in substance,
unconditional. All other donor-restricted contributions are
reported as increases in temporarily or permanently re-
stricted net assets depending on the nature of the restric-
tions. The Organizations had unconditional promises to
give of $202,100 as of December 31, 2011 (NOTE 2).
The Organizations use the allowance method to determine
the estimated unconditional promise to give that are doubt-
ful of collection. Management reviews outstanding promises
to give on an ongoing basis. The allowance is based on prior
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
JUNE 2012 40
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:30 PM Page 40
1. NATURE OF ORGANIZATION AND SIGNIFICANT
ACCOUNTING POLICIES (CONTINUED)
years experience and managements analysis of specific
promises made. Account balances are charged off against
the allowance after all means of collection have been ex-
hausted and the potential for recovery is considered remote.
Cash Equivalents
The Organizations consider all highly liquid investments
with an initial maturity of three months or less to be cash
equivalents.
Investments
The Organizations report their investments under FASB
ASC 958 Not-For-Profit-Entities. Under the codification, a
not- for-profit organization is required to report investments
in marketable securities with readily determinable fair values
and all investments in debt securities at fair value in the Com-
bined Statement of Financial Position.
Purchased securities are stated at fair market value based
on the most recently traded price of the security at the fi-
nancial statement date. Donated securities are recorded at
fair value and sold immediately. Investment gains and
losses including (realized and unrealized gains and losses
on investments, interest and dividends) are included in the
accompanying Combined Statement of Activities.
Inventory
Inventory consists primarily of work-in-process relating to
various publications and is valued at lower cost or market.
Cost is determined by the actual expenditures incurred in
the production process.
Risk and Uncertainties
The Organizations have investments in mutual funds that
are exposed to various risks, such as interest rate, market
and credit risk. Due to the level of risk associated with cer-
tain investment securities and the level of uncertainty re-
lated to changes in the value of investment securities, it is at
least reasonably possible that changes in risks in the near
term would materially affect the Combined Statement of
Activities. The Organizations, through their investment ad-
visor and investment committee, monitor the Organizations
investments and the risks associated on a regular basis,
which the Organizations believe minimizes these risks.
Property and Equipment, Net
Property and equipment, net are defined by the Organiza-
tions as assets with an initial, individual cost of more than
$1,000 and an estimated useful life in excess of one year.
Property and equipment including building improvements
are stated at cost and depreciated using the straight-line
method over the following estimated useful lives of the re-
spective assets:
Estimated Useful Lives (Years)
Building and improvements 14 29
Furniture and equipment 5 7
Software 3
Concentration of Credit Risk
Financial instruments that potentially subject the Organiza-
tions to a concentration of credit risk are cash, investments,
certificates of deposit and accounts receivable. The Organi-
zations place their temporary cash and cash equivalents with
high quality financial institutions. At times, cash deposits may
be in excess of the Federal Deposit Insurance Corporation
(FDIC) insured limits. The Organizations investments are
subject to the normal market risks of these types of invest-
ments, which are traded in equity markets. The Organiza-
tions customer base is relatively stable; management closely
monitors outstanding balances and relationships with cus-
tomers; collection losses have historically been immaterial.
Volunteer Services
A large number of people have contributed significant
amounts of time to the activities of the Organizations. Since
these contributions do not meet the criteria for revenue
recognition, they are not reflected in the Combined State-
ment of Activities.
Allocation of Expenses
The cost of performing the Organizations various activities
have been summarized on a functional basis in the accom-
panying Combined Statement of Activities. Accordingly, cer-
tain costs have been allocated among the activities benefited.
Prepaids and Other Assets
Prepaids and other assets consist primarily of an interest in
a trade show (NOTE 11) and work-in-process costs relating
to various publications that have not yet been released for
distribution. Once publications are complete and ready for
their intended use, the costs are amortized over the life of
the publications, usually between two to three years. Addi-
tionally, expenditures which relate to programs for the next
fiscal year are reported as a prepaid asset and are expensed
during the next year as the related program function takes
place.
Inter-fund Payable/Receivable
Amount principally represents advances received by the
Property Fund from the Operating Fund for operating ex-
penses. Such funds may be repaid from Property Fund net
assets after the Property Funds assets are placed in service
and the Property Fund generates income and totaled
$1,111,102 at December 31, 2011. At December 31, 2011,
the Reserve Fund had a receivable of $51,600 from the Op-
erating Fund.
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
41 WELDING JOURNAL
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1. NATURE OF ORGANIZATION AND SIGNIFICANT
ACCOUNTING POLICIES (CONTINUED)
Accounts Receivable
Accounts receivable consists of balances related to semi-
nars, certification exams, royalties and other miscellaneous
programs and are stated at the amount management expects
to collect from outstanding balances at year-end. Manage-
ment provides for probable uncollectible amounts through
a provision for bad debt expense based upon a review of out-
standing balances, historical collection information and cur-
rent economic conditions. Balances that are still outstand-
ing after management has used reasonable collection efforts
are written off through a charge to the allowance.
Impairment of Long-Lived Assets
The carrying value of long-lived assets is reviewed if the
facts and circumstances, such as significant declines in rev-
enues, earnings or cash flows, or material adverse changes
in the business climate indicate that they may be impaired.
The Organizations perform their review by comparing the
carrying amounts of long-lived assets to the estimated
undiscounted cash flows relating to such assets. If any im-
pairment in the value of the long-lived assets is indicated,
the carrying value of the long-lived assets is adjusted to re-
flect such impairment. The results of that review led to a
write-down of assets in the amount of $128,492 which re-
lated to a training facility no longer in use (NOTE 5).
Use of Estimates
The preparation of financial statements in conformity with
accounting principles generally accepted in the United
States of America requires management to make estimates
and assumptions that affect the reported amounts of assets
and liabilities and disclosure of contingent assets and lia-
bilities at the date of the financial statements and the re-
ported amounts of revenues and expenses during the re-
porting period. Actual results could differ from those
estimates.
Reclassifications
Certain costs have been reclassified from the 2010 presen-
tation in order to conform to the 2011 presentation.
Subsequent Events
The Organizations have evaluated subsequent events
through April 18, 2012, which is the date the combined fi-
nancial statements were available to be issued.
Income Taxes
American Welding Society, Inc. and AWS Foundation are
not-for-profit corporations and are exempt from federal in-
come taxes under Section 501(c)(3) of the Internal Rev-
enue Code. Accordingly, no provision for federal or state
income tax is required for revenues derived from its tax-ex-
empt function. The Organizations are taxed on unrelated
business income less the related expenses. During the year
ended December 31, 2011, there was no net income gener-
ated from unrelated business activities.
American Welding Society, Inc. and AWS Foundation rec-
ognize and measure tax positions based on their technical
merit and assess the likelihood that the positions will be
sustained upon examination based on the facts, circum-
stances and information available at the end of each pe-
riod. Interest and penalties on tax liabilities, if any, would
be recorded in interest expense and other non-interest ex-
pense, respectively.
The U.S. Federal jurisdiction is the major tax jurisdiction
where the Organizations files informational tax returns.
The Foundation is generally no longer subject to U.S. Fed-
eral or State examinations by tax authorities for years be-
fore 2008.
Adoption of Accounting Pronouncements
Fair Value Measurements
In January 2010, the FASB issued an accounting standard
update on fair value measurements and disclosures. The
update requires more robust disclosures about (1) the dif-
ferent classes of assets and liabilities measured at fair value,
(2) the valuation techniques and inputs used, (3) the activ-
ity in Level 3 fair value measurements, and (4) the transfers
between Levels 1, 2, and 3. The Organizations adoption of
the new disclosures and clarifications of existing disclosures
that were effective for interim and annual reporting periods
beginning after December 15, 2009 did not have an effect
on the Organizations combined financial statements. The
disclosures about purchases, sales, issuances, and settle-
ments in the roll forward of activity in Level 3 fair value
measurements are effective for fiscal years beginning after
December 15, 2010, and for interim periods within those fis-
cal years. The adoption of the Level 3 disclosures did not
have an effect on the Organizations combined financial
statements.
Recent Accounting Pronouncement
Amendments to Achieve Common Fair Value Measure-
ment and Disclosure Requirements in U.S. GAAP and
IFRS
In May 2011, the FASB issued an accounting standard up-
date which works to achieve common fair value measure-
ment and disclosure requirements in US GAAP and Inter-
national Financial Reporting Standards. The update both
clarifies the FASBs intent about the application of existing
fair value guidance, and also changes certain principles re-
garding measurement and disclosure. The update is effec-
tive prospectively and is effective for annual periods be-
ginning after December 15, 2011. Early application is
permitted for interim periods beginning after December
15, 2011. The Organizations are currently evaluating the
effect the update will have on their combined financial
statements.
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
JUNE 2012 42
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:31 PM Page 42
2. PLEDGES RECEIVABLE, NET
Unconditional promises to give that are expected to be col-
lected within one year are recorded at net realizable value.
Unconditional promises to give that are expected to be col-
lected in future years are recorded at the present value of
the estimated future cash flows. Amortization of the dis-
counts is included in donations in the Combined Statement
of Activities.
Pledges receivable include the following unconditional
promises as of December 31, 2011:
Amounts due in:
Less than one year $ 97,300
One to five years 117,700
Total 215,000
Less: Unamortized discount 12,900
Pledges receivable, net $ 202,100
Pledges receivable in the amount of $202,100 as of Decem-
ber 31, 2011, are restricted for awards, scholarships and the
mobile tour trailer. Management believes that all pledges
are fully collectible. Therefore, management has not
recorded an allowance for collection losses.
3. INVESTMENTS
Investments, which are comprised entirely of mutual funds,
are presented in the combined financial statements at their
fair market values and consist of the following at December
31, 2011:
Vanguard Investments Reserve Fund
Total Stock Market Index Fund $ 4,802,506
Total Bond Market Index Fund 4,061,301
Intermediate-Term Investment
Grade Bond 2,444,602
Total International Stock Index Fund 2,419,561
Windsor II Fund 1,683,463
Short-Term Investment Grade Fund 1,617,950
U.S. Growth Fund 840,614
Morgan Growth Fund 839,557
Explorer Fund 717,205
Strategic Equity Fund 716,675
Fidelity Investments Reserve Fund
Janus Short Term Bond Fund Class T 1,284,012
Pimco Low Duration Class D 1,287,454
Reserve Fund Investments 22,714,900
Vanguard Investments AWS Foundation
Total Bond Market Index Fund $ 2,970,413
Total Stock Market Index Fund 2,535,717
Intermediate-Term Investment
Grade Bond 1,638,935
Short-Term Investment Grade Fund 1,311,204
Total International Stock Index Fund 1,068,469
Windsor II Fund 720,410
Explorer Fund 496,573
Morgan Growth Fund 392,633
U.S. Growth Fund 374,248
Strategic Equity Fund 287,732
Prime Money Market Fund 13,116
General Electric Company 3,627
AWS Section Investments (1,801,785)
AWS Foundation Investments 10,011,292
Total Investments $ 32,726,192
AWS Foundation administers investments on behalf of cer-
tain affiliated sections. The investments aggregated
$1,801,785 at December 31, 2011 and are not included in
the combined financial statements.
Investment income consisted of the following for the year
ended December 31, 2011:
Reserve AWS
Fund Foundation
Interest and dividends $ 595,346 $ 274,020
Realized and unrealized
losses on investments, net
of investment fees of
$30,361 and $20,068,
respectively (426,913) (151,148)
$ 168,433 $ 122,872
4. FAIR VALUE MEASUREMENTS
The FASB establishes a framework for measuring fair
value. That framework provides a fair value hierarchy that
prioritizes the inputs to valuation techniques used to meas-
ure fair value. The hierarchy gives the highest priority to un-
adjusted quoted prices in active markets for identical assets
or liabilities (Level 1 measurements) and the lowest prior-
ity to unobservable inputs (Level 3 measurements).
The three levels of the fair value hierarchy are described as
follows:
Level 1 Inputs to the valuation methodology are unad-
justed quoted prices for identical assets or liabili-
ties in active markets that the Organizations
have the ability to access.
Level 2 Inputs to the valuation methodology include:
quoted prices for similar assets or liabilities
in active markets;
quoted prices for identical or similar assets or
liabilities in inactive markets;
inputs other than quoted prices that are
observable for the asset or liability;
inputs that are derived principally from or
corroborated by observable market data
by correlation or other means.
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
43 WELDING JOURNAL
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:31 PM Page 43
4. FAIR VALUE MEASUREMENTS (CONTINUED)
If the asset or liability has a specified (con-
tractual) term, the Level 2 input must be ob-
servable for substantially the full term of the
asset or liability.
Level 3 Inputs to the valuation methodology are unob-
servable and significant to the fair value meas-
urement.
The assets or liabilitys fair value measurement level within
the fair value hierarchy is based on the lowest level of any
input that is significant to the fair value measurement. Val-
uation techniques used need to maximize the use of observ-
able inputs and minimize the use of unobservable inputs.
Following is a description of the valuation methodologies
used for assets measured at fair value. There have been no
changes in the methodologies used at December 31, 2011.
Mutual funds: Valued at the net asset value (NAV) of
shares held by the Organizations at year end.
The preceding methods described may produce a fair value
calculation that may not be indicative of net realizable value
or reflective of future fair values. Furthermore, although
the Organizations believe the valuation methods are ap-
propriate and consistent with other market participants, the
use of different methodologies or assumptions to deter-
mine the fair value of certain financial instruments could re-
sult in a different fair value measurement at the reporting
date. The values assigned to certain investments are based
upon currently available information and do not necessar-
ily represent amounts that may ultimately be realized. Be-
cause of the inherent uncertainty of valuation, those esti-
mated fair values may differ significantly from the values
that would have been used had a ready market for the in-
vestments existed and the differences could be material.
The following table represents the Organizations financial
instruments measured at fair value on a recurring basis at
December 31, 2011 for each of the fair value hierarchy levels:
Fair Value Measurement at Reporting Date Using:
Quoted Prices
In Active Significant Significant
Markets for Other Other
Identical Observable Unobservable
Fair Value Assets Inputs Inputs
Description 12/31/11 (Level 1) (Level 2) (Level 3)
Assets:
Mutual funds $ 32,726,192 $ 32,726,192 $ - $ -
The carrying amounts for cash, cash equivalents, receiv-
ables, accounts payable and certain other assets and liabil-
ities approximate fair value due to the short-term maturity
of these financial instruments.
5. PROPERTY AND EQUIPMENT, NET
Property and equipment, net consist of the following as of
December 31, 2011:
Foundation and
Property Fund Operating Fund
Property and Equipment
for use in Current
Operations:
Land held for sale $ - $ 816,726
Building and improvements
held for sale - 3,953,703
Furniture, software
and equipment - 5,426,359
- 10,196,788
Less: accumulated
depreciation - 7,539,838
$ - $ 2,656,950
Foundation and
Property Fund Operating Fund
Property and Equipment
for use in Future
Operations:
Land $ 6,191,574 $ -
Building and improvements 14,001,120 -
20,192,694 -
Less: accumulated
depreciation 69,538 -
$ 20,123,156 $ -
Depreciation expense was $332,880 for the year ended
December 31, 2011.
New Headquarters
During May 2010, AWS entered into a commercial contract
for the purchase of a five story 120,000 square feet office
building in the City of Doral, Florida. The new facility will
become AWSs Headquarter facility as it continues to en-
hance its position as the premier professional/technical soci-
ety in welding and allied joining and cutting processes
worldwide. The contracted sales price for the property to-
taled $19,000,000; however, AWSs cash outlay at closing
totaled $17,973,267, including attorneys fees. In connec-
tion with the purchase of the new facility, AWS and the
seller also signed an addendum to the commercial contract
whereby the seller at its sole cost and expense, will complete
certain repairs, refurbishment, and replacement at the fa-
cility thereby agreeing to have AWS withhold and retain
$1,000,000 of the purchase price. The Holdback amount is
to be disbursed as needed to the seller to pay for the work
completed. As of December 31, 2011, $757,182 of the Hold-
back amount has been released for work performed. The
work is approximately 90% complete. The remainder of the
work is to be completed in conjunction with the final phase
of the interior build out and the exterior facade. All work is
estimated to be completed by the seller prior to September
2012, the Organizations new Headquarters cutting-ribbon
ceremony date.
During November 2010, the Board of Directors approved
$5,305,120 to build out the exterior fac ade and the interior
space to be occupied by the Organizations. An additional
$562,660 has been allocated for tenant space build out. Dur-
ing 2011, capital improvements amounted to $1,792,660 and
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
44 JUNE 2012
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:32 PM Page 44
5. PROPERTY AND EQUIPMENT, NET (CONTINUED)
consisted of: $1,123,719 used to build out the Organiza-
tions office space and exterior facade as well as $279,823
used to build out tenant space. The cost of the total reno-
vation includes $389,118 for certain work as stipulated per
the work agreement within the addendum to the commer-
cial contract to be paid by the seller.
On June 1, 2010, AWS also entered into a contract with a
property management and leasing company for the Doral
facility.The term of the contract was initially for six months
and renewable for a like period of time unless terminated
in writing by either party by providing written notice 30 days
prior to the date for such renewal. Under the initial term of
the agreement, AWS is to pay the management company an
amount equal to 4% of the gross income of the building, but
in no event less than $1,000 per month.
During November 2011, the minimum monthly manage-
ment fees was changed to $2,500. AWS is to also pay com-
missions for all units leased by the manager in an amount
equal to 2% of the total lease term. AWS pays supervisory
fees for tenant improvement at 3.5% of the contractors
price to build out. The new facility has not been placed into
service; the expected occupancy date is September 2012.
Approximately 20.8% of the new facility has been placed
into service through space currently leased out. Deprecia-
tion expense relating to the new facility reflected under the
Property Fund amounted to $69,538 for the year ended
December 31, 2011.
During 2011, the Company, as lessor, entered into nine op-
erating leases with third parties. The operating leases have
various terms expiring through 2021. Rental income from
leasing activities is recorded as earned over the terms of the
leases. Rental income of approximately $328,000 was
earned for the year ended December 31, 2011, and is within
the Combined Statement of Activities Property Fund.
Minimum future rentals to be received on leases, subsequent
to the year ending December 31, 2011 are as follows:
For the years ending December 31,
2012 $ 446,666
2013 307,741
2014 257,427
2015 255,193
2016 216,807
Thereafter 946,861
Total $ 2,430,695
Old Headquarters
On February 2, 2012, AWS entered into an agreement to sell
its current office facility located on 550 NW 42nd Avenue and
the adjacent apartment complex located on 4227 NW 5th
Street for $4,600,000. At time of closing, February 27th, 2012,
AWS received a 20% down payment or $920,000 and the re-
maining balance was financed by AWS. The purchaser gave a
purchase money first mortgage in favor of AWS in the sum of
$3,680,000, ten year balloon at 0% from the closing date until
the move out date which is no later than September 30, 2012,
and from the move out date until the date that is 10 years from
the closing date at 5.25% annual interest. The note will be
recorded at present value. Monthly installments of interest
only will begin on the date that is 30 days after the move out
date until and through the maturity date. A personal uncon-
ditional guaranty of collection in favor of AWS was received
from one of the principals of the holding company acquiring
the office facility at the time of closing.
Additionally, AWS entered into a lease agreement for the of-
fice facility commencing at the time of closing and ending no
later than the move out date of September 30, 2012. Under
the lease agreement, AWS as tenant has agreed to fully vacate
the second floor by no later than June 30, 2012 turning over
to the landlord the floor for landlords use. The other three
floors are to be vacated by no later than September 30, 2012.
The amount of rent under the lease agreement is $0. AWS is
responsible for the payment of all costs, expenses and obliga-
tions incurred in connection with the use and operation of the
office facility.
At the time of sale, building and related improvements
amounted to $4,772,431 and accumulated depreciation
amounted to $2,944,375. Closing costs including brokerage
commissions were $313,971. A gain was recorded from the
sale of the premises in the amount of $2,457,973.
As of December 31,2011, AWS wrote off its training facil-
ity with a carrying value of $128,492. As AWS continued to
work on securing the sale of the office building, it was de-
cided that all activities previously held at the training facil-
ity were to now take place at the new Headquarters facility
located in Doral. The costs of the training facility were
$928,359 and the accumulated depreciation was $799,867.
The write off was reflected in the statement of activities
under the Administration Department for the year ended
December 31, 2011.
6. TEMPORARILY RESTRICTED NET ASSETS
Net assets of the AWS Foundation in the amount of
$5,348,700 as of December 31, 2011, are restricted for
awards and scholarships. Net assets of $240,918 were re-
leased from donor restrictions by granting awards and
scholarships for the year ended December 31, 2011.
7. PERMANENTLY RESTRICTED NET ASSETS
Net assets in the amount of $4,823,880 as of December 31,
2011, are permanently restricted endowments which are to
provide a source of funds predominantly for educational,
research and other charitable purposes.
8. INTERFUND TRANSFER
Funds are periodically transferred from the Operating
Fund to the Reserve Fund and the AWS Foundation Fund.
For the year ended December 31, 2011, the Operating Fund
transferred $5,000,000 to the Reserve Fund, due to positive
financial results and cash flows. The Operating Fund also
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
45 WELDING JOURNAL
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:32 PM Page 45
8. INTERFUND TRANSFER (CONTINUED)
transferred $625,000 to AWS Foundation to complete the
funding goal for the Educators Scholarship Fund and to ac-
quire a mobile tour trailer.
For the year ended December 31, 2011, the Operating Fund
advanced $1,869,868 for capital improvements and other
related items for the new facility (NOTE 5). The activities
of the new facility have been reflected under the Property
Fund.
9. ENDOWMENT
The AWS Foundations (the Foundation) endowment
consists of two separate investment funds established for
welding education, research and other charitable purposes.
Its endowment includes donor-restricted endowment
funds, board fund and temporarily restricted funds. As re-
quired by accounting principles generally accepted in the
United States of America, net assets associated with en-
dowment funds are classified and reported based on the ex-
istence or absence of donor-imposed restrictions.
In June 2011, the State of Florida adopted the Florida Uni-
form Prudent Management of Institutional Funds Act
(FUPMIFA). The Foundation has interpreted the FUP-
MIFA as requiring the preservation of the fair value of the
original gift as of the gift date of the donor-restricted en-
dowment funds absent explicit donor stipulations to the
contrary. As a result of this interpretation, the Foundation
classifies as permanently restricted net assets (a) the origi-
nal value of gifts donated to the permanent endowment, (b)
the original value of subsequent gifts to the permanent en-
dowment and (c) accumulations to the permanent endow-
ment made in accordance with the direction of the applica-
ble donor gift instrument at the time the accumulation is
added to the fund. The remaining portion of the donor-re-
stricted endowment fund that is not classified in perma-
nently restricted net assets is classified as temporarily re-
stricted net assets until those amounts are appropriated for
expenditure by the Foundation in a manner consistent with
the standard of prudence prescribed by FUPMIFA.
In accordance with the FUPMIFA, the Foundation consid-
ers the following factors in making a determination to ap-
propriate or accumulate donor-restricted endowment
funds:
(1) The duration and preservation of the fund
(2) The purposes of the Foundation and the donor-
restricted endowment fund
(3) General economic conditions
(4) The expected total return from income and the
appreciation of investments
(5) Other resources of the Foundation
(6) The investment policies of the Foundation
For the year ended December 31, 2011, the Foundation has
elected not to add appreciation for cost of living or other
spending policies to its permanently restricted endowment
for inflation and other economic conditions.
Summary of endowment net assets at December 31, 2011:
Temporarily Permanently
Unrestricted Restricted Restricted Total
Donor restricted
endowment funds $ 883,615 $ 4,723,700 $ 4,823,880 $ 10,431,195
Board restricted
endowment funds - 625,000 - 625,000
Total endowment
net assets $ 883,615 $ 5,348,700 $ 4,823,880 $ 11,056,195
Change in endowment net assets at December 31, 2011:
Temporarily Permanently
Unrestricted Restricted Restricted Total
Endowment net
assets, beginning $ 807,100 $ 4,434,305 $ 4,719,460 $ 9,960,865
Interest and
dividends 138,630 135,390 - 274,020
Net investment
income (71,185) (79,963) - (151,148)
Released from
restriction and
appropriated for
expenditure (350,750) (240,918) - (591,668)
Contributions
and transfers 359,820 1,099,886 104,420 1,564,126
Endowment
net assets,
ending $ 883,615 $ 5,348,700 $ 4,823,880 $ 11,056,195
Summary of endowment assets at December 31, 2011:
Temporarily Permanently
Unrestricted Restricted Restricted Total
Investments $ 48,812 $ 5,146,000 $ 4,823,880 $ 10,019,292
Cash 342,915 - - 342,915
Pledges - 202,100 - 202,100
Property &
Equipment, net 442,433 - - 442,433
Other assets, net 49,455 - - 49,455
Total endowment
assets $ 883,615 $ 5,348,700 $ 4,823,880 $ 11,056,195
Funds with Deficiencies
From time to time, the fair value of assets associated with in-
dividual donor restricted endowment funds may fall below
the level that the donor requires the Foundation to retain as
a fund of perpetual duration. There were no such deficien-
cies in the endowment funds as of December 31, 2011.
Return Objectives and Risk Parameters
The Foundation has adopted investment and spending poli-
cies for endowment assets that attempt to provide a pre-
dictable stream of funding to programs supported by its en-
dowment while seeking to maintain the purchasing power of
the endowment assets. The Foundation expects its endow-
ment funds, over time, to provide a rate of return in excess
of the principal. Actual returns in any given year may vary.
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
46 JUNE 2012
2011 Financial Report Layout_2005 Financial Report 5/10/12 10:28 AM Page 46
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
9. ENDOWMENT (CONTINUED)
Strategies Employed for Achieving Objectives
To satisfy its long-term rate-of-return objectives, the Foun-
dation relies on a total return strategy in which investment
returns are achieved through both capital appreciation
(realized and unrealized) and current yield (interest and
dividends).
Spending Policy and How the Investment Objectives Relate to
Spending Policy
The Foundation has a policy of appropriating for distribu-
tion each year 5 percent of its endowment fund's value over
the prior 12 months through the calendar year-end pro-
ceeding the fiscal year in which the distribution is planned.
In establishing this policy, the Foundation considered the
long-term expected return on its endowment. Accordingly,
over the long term, the Foundation expects to maintain the
purchasing power of the endowment assets held in perpe-
tuity or for a specified term as well as to provide additional
real growth through new gifts and investment return.
10. COMMITMENTS AND CONTINGENCIES
Operating Leases
During 2011, the Organizations entered into various oper-
ating lease agreements involving equipment. Minimum
monthly payments are approximately $21,000. Rent ex-
pense for the year ended December 31, 2011 totaled ap-
proximately $247,000. Minimum annual payments on the
non-cancellable portion of the leases are as follows:
For the years ending December 31,
2012 $ 237,000
2013 202,000
2014 176,000
2015 172,000
2016 14,000
Total $ 801,000
Royalty Agreement
On October 26, 2005, AWS entered into a Publication Sales
Agreement with World Engineering Exchange (WEX),
whereby WEX has been given non-exclusive worldwide
rights to duplicate, package, facsimile transmit, price, pro-
mote, distribute, sell and/or lease AWSs documents and
technical publications through paper and electronic media
formats and compilations. On May 8, 2007, the term of the
agreement was amended to extend the initial period to sixty
(60) months commencing on January 1, 2006. The agree-
ment can be renewed for two (5) year periods with the same
terms and conditions except for the pricing which shall be
negotiated by the parties in good faith. On September 24,
2010, AWS exercised its renewal option; the term was
amended and restated for an additional 60 months com-
mencing January 1, 2011. On October 14, 2011, the Organ-
ization entered into a second amendment to reflect a change
in royalty percentages for lease and individual documents.
AWS royalties will increase as a result of the change.
WEX will pay AWS royalties based on the percentages in-
dicated per the agreement. The agreement is contingent
upon AWSs continued performance, which includes the
production and release of new and revised publications pe-
riodically. In addition, the list price shall be no less than the
prices as indicated in AWSs catalog. Under the terms of
the agreement, AWS earned $4,701,873 during the year
ended December 31, 2011. Such amount has been included
in revenues in various departments in the Combined State-
ment of Activities.
On May 2, 2009, AWS entered into an agreement with The
American Society of Mechanical Engineers (ASME),
whereby ASME has the nonexclusive right to reproduce
AWSs standards. ASME will pay AWS royalties equal to
25% of the net sales per quarter. Under the terms of this
agreement, AWS earned approximately $358,000 during
the year ended December 31, 2011.
11. WELDMEX LLC
On December 5, 2007, AWS entered into an agreement
with Trade Show Consulting, LLC (TSC) to create a lim-
ited liability company known as Weldmex LLC (the LLC)
to acquire and operate the Weldmex Trade Show, a show
solely owned by TSC.
In consideration for the sale, transfer and assignment of the
Weldmex Trade Show to the LLC, TSC was paid an initial
sum in the amount of $400,000 on January 2, 2008. At the
end of the 2008 Weldmex show, AWS paid TSC $122,000.
AWS paid TSC $122,000 at the end of the 2009 Weldmex
show. The existence of the LLC shall continue through Jan-
uary 30, 2013 at which point the LLC is to purchase the en-
tire percentage interest of TSC for an amount equal to 45%
of the earnings before interest, taxes, depreciation and amor-
tization (EBITDA) calculated for the 2012 Weldmex show
multiplied by a factor of 6.5. In making the calculation, rea-
sonable, non-extraordinary expenses normally associated
with the LLC not covered by the budget and as agreed by the
members of the LLC shall be subtracted from the amount of
the EBITDA. Funds for the purchase of the Weldmex Trade
Show shall come from the LLC, or, if the LLC does not have
sufficient funds, AWS shall make the payment.
The percentage interest of AWS in the LLC is 55% and the
percentage interest of TSC in the LLC is 45%. Each Mem-
ber is entitled to vote its percentage interest with respect to
any action required or permitted to be taken by the Mem-
bers under the Operating Agreement entered into or the
Florida Limited Liability Act. The business and affairs of
47 WELDING JOURNAL
2011 Financial Report Layout_2005 Financial Report 5/10/12 10:28 AM Page 47
AMERICAN WELDING SOCIETY, INC. AND AWS FOUNDATION
NOTES TO COMBINED FINANCIAL STATEMENTS DECEMBER 31, 2011
11. WELDMEX LLC (CONTINUED)
the LLC, including strategic direction and budget approval
is to be overseen under the direction and control of the Ex-
ecutive Director at AWS and the President of TSC. Allo-
cations of profit or loss will be allocated to the Members in
accordance with the percentage interest of each member.
AWS will be responsible for the management and adminis-
tration of the finances of the LLC.
As of December 31, 2011, AWS has paid TSC $644,000
under the terms of the agreement which is included under
the caption "Prepaid and other assets," in the Combined
Statement of Financial Position. Under the agreement,
AWS has received earnings in the amount of $703,100, since
inception. AWS has initiated preliminary discussions with
TSC regarding the buyout amount, said amount is driven by
the earnings for 2012 Weldmex Show taking place May 2- 4,
2012. The purchase price of TSCs interest will not be de-
termined until after the close out of the 2012 show. The buy-
out is anticipated to occur prior to January 30, 2013.
12. MANAGEMENT SERVICES
On May 17, 2010, AWS signed an association management
agreement to provide administrative services, office space,
facilities and equipment to the Gases and Welding Distrib-
utors Association (GAWDA), a not-for-profit trade asso-
ciation incorporated in Pennsylvania. As consideration for
the professionally contracted services provided under the
agreement, GAWDA pays AWS a management fee based
on the compensation and benefits to be provided by AWSs
personnel serving as the Executive Directors and Coordi-
nator positions, payable in equal monthly installments. Ad-
ditionally, GAWDA reimburses AWS for all direct pass-
through costs relating to association specific matters. As of
December 31, 2011, management fees for services provided
amounted to $283,031. At December 31, 2011, activities re-
lating to GAWDA netted out to a receivable in the amount
of $102,003 and is included in accounts receivable in the
Combined Statement of Financial Position as of December
31, 2011. The receivable was collected in full subsequent to
December 31, 2011.
13. EMPLOYEE BENEFIT PLAN
The Organizations have a simplified employee pension plan
for all full-time employees. Full-time employees are eligible
for participation in the plan the first day of the month after
they are employed. Effective June 1, 2008, the Organiza-
tions will contribute a maximum of 8% of the employees
base salary, composed of a 4% initial contribution and a
match up to 4% of an employees voluntary contribution.
The Organizations made contributions totaling approxi-
mately $476,000 during the year ended December 31, 2011.
14. EMPLOYMENT AGREEMENT
The Organizations entered into an employment agreement
with its Executive Director on December 18, 2009 for a
term of three years; the first year commencing January 1,
2010. The Organizations will provide certain benefits for
the period set forth in the agreement.
48 JUNE 2012
2011 Financial Report Layout_2005 Financial Report 5/8/12 3:34 PM Page 48
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T
he standard method for joining
heavy-wall alloy steel pipe in
power plant construction is man-
ual gas tungsten arc welding (GTAW) for
root and hot passes, followed by shielded
metal arc welding (SMAW) for fill passes.
Design engineers start with the assump-
tion that defects will be created during
field welding and make provision to re-
pair flaws when they occur. This pre-
sumption forces them to use larger in-
cluded angles for the bevel so grinding
equipment can access the flaw and pre-
pare the affected section for any needed
repair welding.
This article discusses the introduction
of automated orbital welding of heavy-
wall pipe during on-site construction of
a power plant. In our examples, the de-
cision to automate was made after the
joints were designed for manual field
welding, such that the design was not op-
timized for orbital welding. Additionally,
manual welders were trained to operate
the orbital equipment for the first time.
It is against this background that we ex-
plore the advantages of automation com-
pared to manual GTAW.
Designing for Automation
With automation, this assumption
that flaws will occur must be reversed
and/or replaced by a new assumption,
that welding can be performed flawlessly,
thereby mitigating the need for repair.
This is possible if the joints are designed
for automation, and the joining process
is optimized around all process variables.
Steps should be taken to address these
variables proactively by utilizing com-
puter-based welding programs, which can
anticipate and adjust to them.
A simple example would be the sub-
stitution of the operators manual adjust-
ment of the arc length with automatic
voltage control (AVC). The AVC moni-
tors the arc length and constantly adjusts
the voltage across the arc to maintain a
preset arc voltage. Once this variable is
optimized, the operator can then concen-
51 WELDING JOURNAL
Using On-Site Orbital Welding for
Power Plant Construction
A company took on the challenge of
producing defect-free welds in real
world field conditions while using
experienced manual welders to perform
orbital welding for the first time
TIMOTHY E. GITTENS is busi-
ness development manager at
Liburdi Dimetrics Corp.
Mooresville, N.C. GLENN R.
LACEY is director of quality and
MICHAEL KENT is piping super-
intendent for Gemma Power
Systems, Glastonbury, Conn.
BY TIMOTHY E. GITTENS,
GLENN R. LACEY, AND
MICHAEL KENT
Fig. 1 Sequence of operation for au-
tomated orbital welding.
Gittens 6-12_Layout 1 5/9/12 1:12 PM Page 51
trate on other variables, such as travel
speed. This too can be optimized and set
to a specific value or series of values to
compensate for material thickness varia-
tion, base material temperature, root
opening width and/or a number of other
inputs, which can be programmed into
the power supply.
Controlling the Variables
In more advanced power supplies, all
of the variables that can influence the
output parameters (weld result) can be
programmed in advance Fig. 1.
The automated welding sequence oc-
curs after the initiation of the sequence
start in accordance with instructions in
the weld program. The total weld se-
quence includes prepurge, arc start, ups-
lope, travel start delay, wire start delay,
all 16 weld level periods, downslope and
postpurge. In this way, the operator can
be relieved from manually controlling
most of these variables, which can con-
tribute to flaws due to poor training,
fatigue, vision, or a number of other
factors.
Once the equipment manufacturer
programs these process variables into the
power supply, it is much easier to control
the few remaining metrics that can im-
pact the results. These may include,
among others, 1) torch angle/orientation,
2) direction of travel relative to wire feed
entry, 3) shielding gas flow rate, and 4)
bead placement.
We learned from experience that once
the parameters were optimized and a
flawless bead was deposited, automation
could repeat this process until the joint
was completed, absent the operator
strengths and weaknesses or the variabil-
ity experienced from one operator to an-
other.
In addition to the control of process
variables, automation can substantially
increase deposition rates with continu-
ous wire feed and travel, thereby improv-
ing weld quality. Using automation, the
operator can move away from the arc and
fume plume, further enhancing the work
experience and minimizing safety risks.
Guidelines for Welding
Heavy-Wall Alloy Steel
Pipe On-Site
Planning
As mentioned previously, it is com-
mon for design engineers to assume flaws
will be produced, so they make provision
for repairs when they do occur by design-
ing joints with wide included angles. If,
in the planning phase of design, consid-
eration is given to utilize orbital welding,
the joint can be designed with smaller in-
cluded angles, which substantially reduce
the amount of weld metal required, the
amount of distortion realized, and the
time to complete the weld. These bene-
fits are inversely proportional to the
bevel angle of the joint. As illustrated in
Fig. 2, for the same joint thickness, there
are many options available to the design
engineer.
Rather than design in anticipation of
defects and implement orbital welding as
an afterthought, designers should plan
for automation and design for optimiza-
tion. Today, as has been the case for many
decades, fitters are allowed to absorb di-
mensional tolerances in the joint and
pass these wide tolerances on to the
welder, who has little choice but to bridge
the root openings and compensate for
the mismatch by adding filler metal, os-
cillating in the groove, or manipulating
current, as well as a wide range of other
techniques available to the skilled man-
ual welder.
Joint Design
Bad Design vs. Good Design
A good joint design is one that can be
easily assembled and the weld sequence
chosen keeps shrinkage, distortion, and
residual stresses to a minimum.
While this is readily acknowledged in
structural members, it is often ignored in
piping systems, primarily for reasons ex-
plained above and related to the ability
to repair a defect in a grooved (heavy
wall) joint.
JUNE 2012 52
SINGLE GROOVE
Fig. 2 Three joint design options.
There is about an 85% reduction in de-
posited metal from the single-V to the
narrow groove designs.
Fig.3 Weld metal volume compari-
son for 12-, 24-, and 36-in.- diameter by
2-in.-thick pipe joints.
NARROW GROOVE
COMPOUND GROOVE
Gittens 6-12_Layout 1 5/9/12 1:14 PM Page 52
The designer should keep in mind that
the less deposited metal necessary to fill
the joint, the better. This is not only for
distortion/shrinkage control, but also for
every bead/pass that is deposited there is
a chance of producing a defect or discon-
tinuity Fig. 3.
When the same thickness pipe/plate
is designed for narrow-groove welding,
there is a substantial reduction in the
number of passes, distortion, and poten-
tial defects. To produce the highest qual-
ity welds, the performance of the power
supply is crucial. The power supply
should be designed to deliver a very stiff
and stable arc, which insures good side-
wall fusion.
For best results, the pipe inside diam-
eter (ID) should be counterbored and fit-
ted accurately. Pipe fitup is another area
of neglect, resulting in increased diffi-
culty during the welding of the root and
hot passes. The better the fitup, the bet-
ter the end result.
The design of the joint at an early
stage in the process makes a significant
contribution to bottom line savings. A
combination of design, welding wire se-
lection, power supply characteristics, and
operator training is key to achieving good
results in the finished weld.
Operator Training
Training cannot be overemphasized.
It is critical to weld quality and, in addi-
tion to technical training, the operators
must be taught to take a personal inter-
est in and ownership of the process and
equipment. On this project, Liburdi Di-
metrics provided on-site operator train-
ing and technical support for equipment
maintenance, which was considered es-
sential to the success that was achieved.
The equipment included a stocked
tool kit and spare parts inventory, which
was replenished periodically. The OEM
technician repaired equipment, trained
operators on its proper use and kept the
systems running throughout the tenure
of the job.
Liburdi Dimetrics worked closely with
Gemma Power Systems to produce the
PQRs for carbon steel, stainless steel,
and P91 base materials needed for this
project. All samples passed the QC tests
without a failure.
Collaboration with OEM
Prior to the start of on-site welding,
Gemma Power Systems did an extensive
search to find the right equipment and a
manufacturer that could support the
project during the critical phase of as-
sembly. Liburdi Dimetrics was selected
based on its years of experience in power
plant pipe fabrication, its approach to
metal joining, its strong training pro-
grams, and its focus on weld quality.
Flawless Execution
Flawless execution is somewhat of a
foreign concept in most welding oper-
ations. In many training centers, the pri-
mary tool in the training booth is a grind-
ing wheel. Here again there is an over-
riding assumption that defects will be
produced and welders must learn how to
repair defects that are produced by their
53 WELDING JOURNAL
Fig. 4 Finished weld on heavy-wall P-91 pipe.
Fig. 5 Welding being performed in a tent for environ-
mental protection.
Fig. 6 Orbital welding of heavy-wall pipe with thermal
blankets.
4 5
6
Gittens 6-12_Layout 1 5/9/12 1:14 PM Page 53
own negligence, indifference, lack of
training, and/or any other human frailty
that can contribute to human error.
Flawless execution can be defined as
a zero-tolerance environment in which a
task is performed without defects, re-
jects, discontinuities, or flaws that re-
quire rework Fig. 4. It suggests that if
a job can be done correctly once, it can
be done correctly repeatedly.
Lessons Learned
Because this was a learning process
for Gemma Power Systems (utilizing
manual welders on orbital equipment for
the first time), the company evaluated a
wide range of factors including, but not
limited to, the project, the process, the
people, and the OEM partners.
The findings confirmed their assump-
tions in some areas and provided some
guidelines for future projects.
The Project
It is imperative that local (orbital
trained) site supervision is maintained
throughout the project. This supervision
is needed for continuity of practices, ob-
servation of discrepancies, and correc-
tion of inconsistencies. Welders tend to
deviate from established procedures
and/or take short cuts from time to time.
This results in flaws, which can be costly
to repair.
The Process
Welding is, by its nature a difficult
process to manage. There are many vari-
ables to control and plenty of opportu-
nities to manipulate the process to sat-
isfy the curiosity or creativity of the op-
erator. Operators can change a number
of process variables without a thorough
knowledge of its impact on the finished
weld. Unfortunately, if these defects or
discontinuities are not detected and cor-
rected in a timely manner, the economic
impact could be substantial. When
GTAW is performed in the field, it is im-
perative the arc envelope be protected
from the elements. Moisture and wind
are detrimental to the joining process
and result in defects, which can be
avoided by using tents Fig. 5.
The People
Experienced welders should under-
stand the properties of the welding arc
including the influence of torch angle,
travel speed, gas coverage, start/stop po-
sitions for each pipe diameter, the influ-
ence of joint geometry and their impact
on shrinkage, as well as root penetration.
The Partners
Partners include, but are not limited
to, orbital equipment manufacturers,
filler metal suppliers, thermal treatment
providers, design personnel, piping ex-
amination companies, and machining
equipment companies
Even when welded joints are prepared
for manual welding, orbital welding (Fig.
6) can still provide substantial benefits
such as savings in labor, improved pre-
dictability and repeatability, higher pro-
ductivity, and mitigation of operator fa-
tigue, a primary cause of weld defects
Conclusion
Orbital welding provides a distinct se-
ries of advantages over manual welding,
particularly on large-diameter and/or
heavy-wall pipe joints. Some of the pri-
mary contributors to weld defects and/or
discontinuities are lack of operator skill
and/or fatigue from constantly watching
the arc and its impact on his or her eyes.
In a physical sense, welding automa-
tion in general and orbital welding in par-
ticular help to enhance the skill of inex-
perienced operators since the power sup-
ply controls many of the process vari-
ables. For operators in the midpoint of
their careers, orbital welding comple-
ments their skills; and for operators
nearing the end of their careers, orbital
welding mitigates the impact of strained
backs and weak knees and other physical
conditions that impair their ability to per-
form these tasks in awkward, physically
demanding positions.
JUNE 2012 54

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Orbital welding provides a distinct series of
advantages over manual welding,
particularly on large-diameter and/or
heavy-wall pipe joints.
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Gittens 6-12_Layout 1 5/9/12 1:15 PM Page 54
T
hick-walled hollow cylinders find widespread indus-
trial applications. The closed body allows easy en-
closure of liquid, gaseous, and grainy media, and
provides superior bending and rotational stiffness in com-
parison to solid cylinders of the same weight. These ad-
vantages make them desirable in such different products as
pipelines (enclosure of media), cranes (bending stiffness),
and power trains (rotational stiffness). An application for
hollow tubes that has particularly high demands regarding
safety as well as precision is hydraulics, and especially, tel-
escopic hydraulics.
Telescopic hydraulics employ several tubes with an
inner and an outer dead stop (except the innermost and the
outermost tubes, which only possess one dead stop). A
component is nested inside the next bigger one. Pressure
supplied to one side of the device, causes the innermost
component to move. When its outer dead stop strikes the
inner dead stop of the next bigger component, it drags
along that component Fig. 1A.
Conventionally, telescopic hydraulic components are
manufactured by turning and gun drilling from cylinders
with wall thicknesses from the inner dead stop up to the
outer one. As components can be longer than a meter, this
is a time- and material-consuming operating technique that
55 WELDING JOURNAL
Use of high-power lasers combined with
GMAW in hydraulics manufacturing
reduces time and material consumption MORITZ OLIVER GEBHARDT
(moritz.gebhardt@gmx.de) is a
PhD student at Technische Univer-
sitt Berlin, Berlin, Germany.
ANDREY GUMENYUK and
MICHAEL RETHMEIER are with
BAM Federal Institute for Materials
Research and Testing in Berlin.
Hybrid Process Welds
Thick-Walled Tubes
BY MORITZ OLIVER GEBHARDT,
ANDREY GUMENYUK, AND
MICHAEL RETHMEIER
Fig. 1 Telescopic hydraulics and their manufacturing
process. A Telescoping action of the tubes; B cur-
rent technology using chipping and gun drilling; C
new process using welded construction and prefabri-
cated center section.
Gebhardt feature_Layout 1 5/9/12 1:20 PM Page 55
can be avoided, when only the functional
ends are chipped and welded to prefabri-
cated tubes that make up the body Fig.
1B, C. Since the wall to be welded is very
thick (8 to 15 mm), a beam process is ben-
eficial regarding edge preparation, pro-
cessing time, and welding distortions.
A number of studies discuss laser
beam welding of tubes for industrial ap-
plications. In Ref. 1, the author describes
the installation of an automatic laser
beam plant for the production of tele-
scopic hydraulic cylinders. The laser
process shortens the production time
from 2.5 h of the originally employed fric-
tion welding process to about 15 min
(10%). Due to the available beam power
of 6 kW, the wall thickness of the products
is less than 8 mm. A similar process was
applied for radial welds in the production
of heat coils made from low- and high-al-
loyed steels. The wall thickness welded
were between 2.4 and 7.6 mm at outer di-
ameters of 40 to 60 mm (Ref. 2).
Laser-arc hybrid welding, i.e., the
combination of a laser beam with a gas
metal arc (GTA), gas tungsten arc (GTA),
or plasma arc (PA) welding process in a
common weld pool, is well documented
and finds widespread application in in-
dustry (Refs. 38). It is used, for example,
in the automobile industry (< 3 mm) as
well as in shipbuilding (up to 12 mm).
The CO
2
-GMA welding process is used
in oil tank volume production (Ref. 9).
Oil tanks made from low-alloyed struc-
tural steel S235JR with wall thicknesses
of 5 to 8 mm get three 5-m-long radial
welds in this process. Due to the com-
pletely different proportion of wall thick-
ness to outer diameter, and due to the
lower wall thickness, those results are not
applicable to hydraulic component pro-
duction. Laser-GMA-hybrid welding of
wall thicknesses up to 14.5 mm in combi-
nation with small outer diameters ( 135
mm) and hence extremely high stiffness,
has not been reported so far.
JUNE 2012 56
Fig. 2 Solidification crack in a partial penetra-
tion radial laser-GMA hybrid weld of a tube made
from S460NH, outer diameter of 205 mm and wall
thickness of 11.5 mm. The built-in weld bead sup-
port helps to align the tubes and prevents splat-
ters from entering the tube.
Fig. 3 Experimental setup of the welding exper-
iments. A Equipment setup; B positions of
the laser and torch.
Fig. 4 Welding result of a tube made from
S770QL. A Cross section; B parameters; C
root side; D top side; E X-ray image.
2 3
4
Gebhardt feature_Layout 1 5/9/12 1:20 PM Page 56
Solid-state lasers that supply beam
powers between 10 kW and (quite re-
cently) 30 kW while maintaining a high
beam quality (BPP < 15 mm mrad)
have been commercially available for sev-
eral years. Their high efficiency, high
beam quality, and low operational ex-
pense make them particularly suitable for
heavy wall thickness welding.
In research institutes, 20-mm butt
jointed structural steel plates were
welded single-rung using a 20-kW fiber
laser (Ref. 10). The addition of a GMAW
process dropped the weldable wall thick-
ness to 16 mm under the same conditions,
but allowed to bridge gaps of up to 0.35
mm and a misalignment of up to 1 mm.
An edge preparation or preheating of the
material allowed increasing of the wall
thickness back up to 20 mm.
Controlling Weld Cracking
A major reason preventing the more
extensive industrial use of high-power
solid-state lasers is the risk of solidifica-
tion cracking involved in laser beam
welding of components with wall thick-
nesses 10 mm (Ref. 11).
Solidification cracks are a special
form of hot cracks. Hot cracks develop
during the last stages of solidification,
while some of the melt is still present in
the growing dendritic network. The
whole mechanism of hot cracking is not
fully understood (Ref. 12). When cracks
originate and propagate in hostile envi-
ronments examination is difficult, if not
impossible, and hence an educated
guess frequently replaces an experimen-
tal proof (Ref. 13).
Despite lacking a comprehensive un-
derstanding of hot cracking, some facts
are understood. It is known that hot
cracks are influenced by the chemical
composition, the crystal structure of the
solidifying grains, the temperature field,
the mechanical condition, as well as in-
teractions between those factors (Refs.
1218).
A special problem in tube welding is
the start and end of the weld, as run-on
and run-off plates are not an option. At
the location where the welding process is
switched off, pores and cracks frequently
appear. This can be impeded by running
into the base material before deactivating
of the power sources (Ref. 19).
The closed body of thick-walled tubes,
which provides the favorable properties
mentioned above, is a yet-uninvestigated
variable concerning hot crack emergence
in beam welding at wall thicknesses >10
mm. First experiments of partial penetra-
tion laser-hybrid welding using tubes
made from a low-alloyed structural steel
showed solidification cracks Fig. 2.
This raised the question about whether
the stiff tube, the partial penetration, the
process parameters, or the material was
the source of those defects.
This report demonstrates that com-
plete joint penetration welding up to wall
thicknesses of 14.5 mm is possible yield-
ing crack-free, high-quality welds.
Materials
The samples were made from low-
alloyed, fine-grain structural steels
S460NH, S770QL, and S890QL. Table 1
shows the chemical compositions and
mechanical properties elastic limit R
p0.2
and tensile strength R
m
. All of these
steels have carbon contents of about
0.2% and contain Ti, Nb, and V, which is
typical for fine-grain steels. The content
of the critical elements P and S is low for
all, with S460NH having by far the high-
est content.
Experimental Setup
The experiments were conducted with
three different laser systems: a TruDisk
8002 disc laser with a maximum of 8 kW
beam power; a TruDisk 16002 disc laser
available to supply 16 kW of beam power;
and a YLR 20000 fiber laser with 20 kW-
57 WELDING JOURNAL
Fig. 5 Welding result of a tube made from S890QL.
A Cross section; B parameters; C root side;
D top side; E X-ray image.
Fig. 6 Bad weld quality produced by using a closed
fastening device. A Root side; B top side.
5 6
Gebhardt feature_Layout 1 5/9/12 1:20 PM Page 57
max of beam power. The disc lasers were
used with a 0.2-mm fiber in combination
with a BEO D70 optics having a focal
length of 200 mm (resulting in a 0.3-mm
focus diameter), and a digital impulse
welding current source Quinto GLC 603.
A 0.2-mm fiber and BimoHP optics with
300 mm focal length (resulting in a 0.56-
mm focus diameter) were attached to the
fiber laser.
The arc current here was supplied by
a Quinto GLC 403 digital impulse weld-
ing current source. An open fastening de-
vice, which allowed for the venting of the
tube, was employed in the experiments.
Figure 3A shows the disc laser setup.
Figure 3B shows the laser and torch po-
sitions, where is the angle between
laser and welding wire, a is the distance
between the respective points where the
laser and the welding wire touch the sur-
face, and t is the distance between the
laser and the peak of the tube (kept con-
stant in all experiments at 10 mm).
The influence of t on the wall thick-
ness regarding complete joint penetra-
tion welding is negligible. The experi-
ments were conducted with stationary
welding tool and turned tube in direc-
JUNE 2012 58
Fig. 7 Welding result of a tube made from S460NH with
a wall thickness of 11.5 mm. A Cross section; B pa-
rameters; C root side; D top side; E X-ray image.
Fig. 8 Welding result of a tube made from S460NH with
a wall thickness of 14.5 mm. A Cross section; B pa-
rameters; C root side; D top side; E X-ray image.
Table 1 Chemical Compositions and Major Mechanical Properties of Tested Materials
Normalized Quenched and Tempered
Element (wt-%) S460NH S770QL S890QL
C 0.22 0.20 0.18
Si 0.23 0.37 0.39
Mn 1.74 1.72 1.45
P 0.007 0.012 0.02
S 0.028 <0.001 <0.001
Al 0.032 0.020 0.024
Cr 0.17 0.34 0.77
Cu 0.18 0.03 0.20
Mo 0.02 0.25 0.35
Ni 0.11 0.05 0.15
Ti 0.001 0.004 0.007
Nb <0.005 <0.005 0.041
V 0.12 0.08 0.04
Fe balance balance balance
CEV
(a)
0.59 0.65 0.68
R
p0,2
/MPa 455 882 973
R
m
/MPa 625 936 1019
a CE=+Mn/6+Cr/5+Mo/5+v/5+ni/15+Cu/15
Gebhardt feature_Layout 1 5/9/12 1:21 PM Page 58
tion, resulting in an opposite welding di-
rection (v
w
). A leading arc configuration
was employed.
Some tubes were tack welded in posi-
tions 50, 170, and 290 deg from the weld
start. The tack welds were 5 deg long and
produced by autogenous laser beam
welding with reduced beam power.
The tubes were turned to remove ox-
ides, and the edges were turned to prep
the surfaces for welding. After welding,
the tubes were X-rayed, and the pictures
digitized and evaluated. This method
permits use of filters to optimize the con-
trast, thus enhancing the inspection re-
sults. The weld start- and end-regions
were neglected here, as they represent a
separate technical problem.
Welding Experiments on
Quenched and Tempered
Tubes
The welding experiments on samples
made from S770QL with a wall thickness
of 9 mm were performed using a TruDisk
8002 disc laser. Sample lengths perpendi-
cular to the welding direction were 200
mm each side (i.e., 400 mm in total) and
the outer diameter was 138 mm. The ex-
periments were conducted with 3.5 mm
distance between the processes (parame-
ter a in Fig. 3 B) at an angle of 30 deg. The
focus was positioned on the surface of the
tube.
The shielding gas used was argon with
18% CO
2
, and the welding wire was of
class G3Ni1 with a diameter of 1.2 mm. A
good weld quality was achieved using a
laser beam power of 8 kW in combination
with a wire feed speed of 8 m/min. (6.4
kW) at a welding speed of 2 m/min. The
result is displayed in Fig. 4.
In the cross section, the low weld re-
inforcement without any dents and the
well-formed root are visible. The X-ray
picture (Fig. 4E) shows spillings inside
the tube. No other anomalies are notice-
able. An equally good weld quality was
achievable on tubes made from S890QL
with 10.5-mm wall thickness and an outer
diameter of 131.5 mm. The sample length
at right angle to the welding direction was
200 mm each. A distance of 3 mm and an
angle of 30 deg were set between both
processes and the laser focus layer was
positioned 3 mm below the tube surface.
The shielding gas and welding wire were
the same as for S770QL. The experi-
ments were conducted using a TruDisk
16002 disc laser. The best results were
achieved using 10-kW laser beam power,
a wire feed speed of 10 m/min (7.6 kW) at
a traveling speed of 2.0 m/min.
Figure 5 shows the good quality of the
weld. The top side is without any dents
and the root side is well developed. No
anomalies, except the spillings at the in-
side are visible in the X-ray picture (Fig.
5D). Some samples were welded using a
closed fastening device, which hinders
venting of the tube. In this case, using the
same welding parameters and setup, ac-
ceptable weld quality was unachievable.
There are visible droppings of the weld
upper side and the root dropped nearly
along the whole length of the weld Fig.
6. By changing back to the open fastening
device, the problems vanished. This is as-
sumed to be due to a disturbance of the
keyhole by the increase of the static pres-
sure inside the tube.
Welding Experiments on
Normalized Tubes
Like for the quenched and tempered
steels, acceptable weld quality without
any cracks was achievable in welding ex-
periments using normalized steel
S460NH. Samples with a wall thickness of
11.5 mm were welded using a fiber laser
YLR 20000. The samples were 50 mm
long perpendicular to the welding direc-
tion and had an outer diameter of 136
mm. An angle of 25 deg and a distance of
3 mm were chosen between the welding
processes. The focus layer was positioned
3 mm below the weld surface.
Using the same shielding gas as in the
other experiments, the welding wire was
replaced by one of class G4Si1. Welding
on these samples was conducted with
rolled as well as sawn edge preparation,
without any noticeable effect on the weld
quality. A chamber-bevel with 45 deg and
a length of 1 mm helped to reduce weld
reinforcement and to impede the devel-
opment of dents. The best results were
obtained using 10-kW laser beam power,
a wire feed speed of 12 m/min (10.3 kW)
and a travel speed of 2.1 m/min. A sam-
ple result is displayed in Fig. 7 showing a
59 WELDING JOURNAL
Fig. 10 Measurement of tube alignment.
Fig. 9 Microhardness of a tube weld made of S770QL with
a wall thickness of 9 mm.
Gebhardt feature_Layout 1 5/9/12 1:21 PM Page 59
weld with extremely low reinforcement, a
well-developed root, and a minimum of
dents. The X-ray picture in Fig. 7D is free
from noticeable imperfections.
Samples made from S460NH having a
wall thickness of 14.5 mm and an outer
diameter of 136.6 mm were again welded
with a TruDisk 16002 disc laser, using the
same shielding gas and welding wire as in
the experiments on S890QL. The focus
was positioned 4 mm below the tube sur-
face and the processes were set to run 4
mm away from each other at an angle of
30 deg. Those samples were extensively
used for further experiments regarding
partial penetration (that are not part of
this report), whereas quality optimiza-
tion was dispensed to save material. Fig-
ure 8 shows the result at a laser power of
14 kW, a wire feed speed of 12 m/min
(10.3 kW) and a travel speed of 1.8
m/min. The upper side of the weld is
nicely imbricate, but shows small dents,
while the root is well developed and
mainly homogeneous. Not visible in the
picture are rudiments of root dropping.
This is acceptable for hydraulic cylinder
applications, as root and upper side have
to be removed before operating anyway.
The X-ray picture (Fig. 8E), is free from
any conspicuous features.
Hot Cracking
In two X-ray pictures, a single hot
crack is detectable in each. All others
were free from any major anomalies and
would have passed as Class B in DIN EN
ISO 12932 (2011) (20) regarding inner
defects. One crack was found in a sample
with 14.5-mm wall thickness made from
S460NH and the other one in a sample
with 11.5-mm wall thickness made from
S890QL. Both samples were tack welded,
and both cracks were located inside the
tack welds. It is possible to calculate the
probability that this is a coincidence. A
tube has a length of 360 deg, 45 deg are
subtracted from this due to the neglect of
the start and end area. Three tack welds,
each being 5 deg long, were placed along
the tube. They accumulate to give 15 deg.
The probability that a crack is located in-
side a tack weld by pure coincidence is
(1)
p
coinc
= 15 deg/(360 45 deg) = 0.0476
Cracks were found in two independ-
ent welds. Employing the probability de-
termined so far, the probability that
cracks are found in two tubes within the
tack welds by coincidence is
(2)
P
2coinc
= p
coinc
p
coinc
= 0.00227 = 0.2%
The converse probability, p
connect
, is
the likelihood that a connection exists be-
tween the tack welds and the hot cracks.
It is
(3)
p
connect
= 1 P
2coinc
= 0.99773 = 99.8%
This is deemed high enough to con-
clude that the hot cracks found in these
experiments were caused by the tack
welds. It is known that opening of tack
welds by welding over them can cause
cracks due to the rapid release of stored
elastic energy and the resulting sideward
movement (Ref. 21).
Hardness
High welding speeds in combination
with low heat inputs and great wall thick-
nesses are the source of high cooling
rates involving a hard and brittle mi-
crostructure at the elevated carbon
equivalents, especially of the quenched
and tempered steels. Time-temperature
measurements in the heat-affected zone
on several samples revealed rapid cooling
of the weld with resulting t
8/5
times of
about a second. This already indicates
strong weld hardening. A sample made
from tubes out of S770QL with a wall
thickness of 9 mm was tested for hardness
Fig. 9. The base material hardness is
already very high ranging at 320 0.5HV,
but is widely exceeded by the weld hard-
ness of 460 0.5HV and a peak value of
even 490 0.5HV. Accordingly postweld
heat treatment is inescapable. As it is
usual to nitrogenize (500 to 520C) tele-
scopic cylinders, this is no major disad-
vantage for the process, but may be prob-
lematic for other applications.
Alignment
Telescopic hydraulic applications de-
mand a particularly high level of preci-
sion regarding alignment of the welded
components. For a working hydraulics
misalignment of no more than 0.08 mm is
acceptable, as stated by an industrial
partner (Ref. 22). Misalignment was
measured by arranging dial extensome-
ters on the left-and right-hand sides of
the weld, 10 mm away from the weld cen-
terline. On three positions along the cir-
cumference the height was metered in re-
lation to the height at the weld start (0
deg) on both sides of the weld. The dif-
ferences between both sides were calcu-
lated to give the misalignment. The re-
sults are shown in Fig. 10. Only a single
value for the tube without tack welds is
outside of the specified tolerance. Re-
garding the accuracy of the utilized meas-
uring technique, this must be deemed ac-
ceptable as well.
As the applied clamping was rather
soft, especially in comparison to indus-
trial ones, the result is quite interesting.
Obviously, the distortions caused by the
process are very low and are hence no
major concern. The main task regarding
alignment is careful arrangement of the
parts before welding.
Conclusions
This study shows that the laser-GMA
hybrid process can make high-quality de-
fect-free welds in tubes up to 14.5-mm
wall thickness. When complete joint pen-
etration welding is applied, there is no
major risk of hot cracking, as long as tack
welds are avoided. The process allows
maintaining of very close tolerances as in
hydraulic manufacturing, without the
need for special clamping devices. Due to
the high welding speeds applicable, a sin-
gle weld can be performed in about 12 s
at the diameters presented, compared
with the conventional chipping process in
hydraulic cylinder manufacturing that
can take as long as an hour (but for the
whole tube).
When the middle part of the compo-
nent is bought prefabricated, the only
amount of material consumption is the
welding wire and the material directly at
the functional ends. The chipping process
needs to reduce the whole wall thickness
from the outer diameter and the inner di-
ameter of the respective dead stops to the
wall thickness of the tube, which may be
up to 50 % of the material.
Due to the high cooling rates involved
in laser-hybrid welding, a postweld heat
treatment is mandatory. This is no issue,
as long as the tubes are heat treated for
other purposes anyway, but must be re-
garded, when choosing this process for
manufacturing. Also, clamping devices
should be designed to allow for tube in-
side venting. Otherwise problems con-
cerning the weld quality may arise.
Acknowledgments
The IGF research project 15917N of
the research coalition Forschungsvere-
inigung Schweien und verwandte Ver-
fahren e.V. des DVS was funded via AiF
as part of the program for the promotion
of the industrial coalition for research
and development (IGF) by the German
Federal Ministry of Economics and Tech-
nology (BMWi) on behalf of an enact-
ment by the German Bundestag.
JUNE 2012 60
Gebhardt feature_Layout 1 5/9/12 1:22 PM Page 60
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References
Gebhardt feature_Layout 1 5/9/12 1:22 PM Page 61
JUNE 2012 62
W
elding engineering knowledge
coupled with welder/operator
competencies and technical ex-
pertise represents a vital technology to
help maintain the integrity of the infra-
structure required to extract and pump
oil from the Prudhoe Bay (also called the
North Slope and/or Slope) oilfields to the
Marine Terminal at Valdez, Alaska, via
the 800-mile-long Trans-Alaska Pipeline.
The Trans-Alaska Pipeline System
(TAPS) represents an expansive infra-
structure that encompasses the Trans-
Alaska Pipeline and 11 pump stations as
well as several hundred miles of feeder
pipelines. The feeder pipeline network
(Fig. 1) transports oil from well pads to
gathering centers/flow stations, which
subsequently feed into the Trans-Alaska
Pipeline.
Welding/joining technology plays a
pivotal role in the fabrication and repair
of the following:
An intricate natural gas piping system
that is essential for sustaining oil pro-
duction efforts with respect to provid-
ing energy for the heating of person-
nel quarters, operation centers/sta-
tions, and equipment facilities;
Widespread array of seawater piping
and oil equipment (e.g., wellheads,
Christmas trees, pumps) that is em-
ployed to assist in the extraction and
control of oil from in-ground deposits;
Multiple turbine power generators that
provide electrical power to the oilfield
community;
Countless pipe valves that require
hardsurfacing/cladding;
Heavy construction equipment (Fig.
2), snow plows, snow throwers, and fa-
cility machinery;
Structural steel waterway pipe cross-
ings and heavy equipment bridges,
drilling rig structural frames, and stor-
age tanks. Also, numerous horizontal
and vertical support mounts are fabri-
cated to secure above-ground pipelines
Fig. 3.
In addition, due to the fact that Prud-
hoe Bay is located on the shore of the
Beaufort Sea, specialty fabrications such
as door/stairway safety enclosures are
constructed to help protect oilfield per-
sonnel as well as wildlife such as polar
bears from surprise encounters and di-
rect contact with each other Fig. 4.
Within the TAPS infrastructure and
Prudhoe Bay oilfield, the multitude of
pipeline, structural steel assemblies, stor-
Welding technology, engineering, and inspection
knowledge are vital to the oilfield operations at the North
Slope and the Trans-Alaska Pipeline System infrastructure
Welding Supports
Prudhoe Bay
Oilfield Operations
The near view shows fabricated
pipeline support mounts while an
oilfield drilling rig is shown from afar.
BY WILLIAM C. LAPLANTE
WILLIAM C. LAPLANTE
(william.laplante@bp.com) is a
welding engineer, BP
Exploration (Alaska) Inc.,
Anchorage, Alaska. He is also
an AWS CWI and CWE.
LaPlante FINAL LAYOUT_Layout 1 5/10/12 10:29 AM Page 62
63 WELDING JOURNAL
age tanks, etc., necessitates constant vig-
ilance relative to weld inspection and cor-
rosion surveillance via visual inspection
and nondestructive examination (NDE)
technologies, including radiographic, ul-
trasonic, magnetic particle, penetrant,
and eddy current testing.
Prudhoe Bay Project
Logistics
Prudhoe Bay lies within the Arctic
Circle, which equates to extreme work-
ing, living, and equipment operating con-
ditions. North Slope personnel com-
monly referred to as Slopers say there
are four seasons at Prudhoe: June, July,
August, and winter. Winter is a long or-
deal in Alaska and this is especially true
at Prudhoe Bay. Only one airport and one
road access and service Prudhoe Bay, the
Deadhorse Airport and the Dalton High-
way (aka Haul Road). The Dalton High-
way has received a degree of notoriety
from the TV show Ice Road Truckers. Due
to severe weather conditions that affect
production scheduling, project planning
and preparation are critical so that all
welding and fabrication materials can be
trucked to Prudhoe Bay before bad
weather sets in to meet tight production
schedules. That is, plan the work and
then work the plan. It should be noted
that exceedingly large pieces of equip-
ment such as drilling rig assemblies are
barged to the North Slope through the
Bering Strait.
For pipeline applications such as pipe
replacement and repair, pipeline con-
struction schedules are extremely tight
and the work is expensive. Housing ac-
commodations for field construction
crews are also limited, so accurate work-
force manning estimates are required.
Special training is provided for person-
nel travelling to Prudhoe Bay for the first
time that encompasses safety and health
criteria; environmental regulations, poli-
cies, and procedures; and workplace haz-
ard awareness.
Weather conditions are constantly
monitored and broadcast via Harmony
radio communications in an effort to
warn workers of impending storms.
Blinding snowstorms and subzero tem-
peratures can render workers stranded
and isolated in vehicles for prolonged pe-
riods. Hence, from October 1 to May 1,
personnel working in the field must carry
duffle bags in their vehicles filled with
designated arctic clothing. Ice roads are
constructed during winter months to fa-
cilitate transportation of fabrication ma-
terials along the pipeline construction
site and to support movement of heavy
construction and pipe-laying equipment
across the tundra plains and water. Ice
roads run parallel to the pipeline and are
temporary, so the window for ice road
operation is limited to the severe cold
months (e.g., January to April). Perma-
nent, gravel-based access roads are also
constructed in applicable areas to sup-
port all-season pipeline construction and
maintenance efforts.
Fig. 1 A sampling of the Prudhoe Bay
oilfield piping network.
LaPlante FINAL LAYOUT_Layout 1 5/9/12 1:28 PM Page 63
JUNE 2012 64
In addition to project material and
equipment requirements, thoughtful
consideration is given to the acquisition
of critical personnel. Due to the remote-
ness of Prudhoe Bay, the availability and
the hiring of qualified welders, pipefit-
ters, welding inspectors, quality assur-
ance personnel, engineers, etc., to sup-
port project efforts represents a costly
and difficult challenge for companies,
thus, long-term planning is required to
successfully obtain personnel for project
applications.
Oilfield Codes, Materials,
and Welding Processes
For pipeline and project fabrication
and repair applications (Fig. 5), multiple
welding codes are utilized, including API
1104, 5CT, 6A, 650, and 653; ASME
B31.1, B31.3, and B31.4; and AWS D1.1,
D1.5, and D1.6. Also, utilized in conjunc-
tion with respective weld codes, are Na-
tional Association of Corrosion Engi-
neers (NACE) corrosion-based codes
such as NACE MR0175 (Ref. 1). In ad-
dition, certain pipelines are Department
of Transportation (DOT) classified,
where DOT requirements become ap-
plicable. NACE MR0175 is employed for
petroleum and natural gas applications
such as when metal materials are em-
ployed in the presence of water and in
hydrogen sulfide (H
2
S) containing aque-
ous media/production fluid environ-
ments (sour service). When metal mate-
rials are subjected to a H
2
S media, hy-
drogen-induced cracking (HIC), stress
corrosion cracking (SCC), and sulfide
stress cracking (SSC) become notably
problematic. In combination with weld
code requirements for Performance
Qualification Records (PQRs), NACE
MR0175 requires that PQR weld speci-
men hardness tests and weld deposit
chemical analyses be performed as well.
Within Prudhoe Bay oilfield operations,
different pipe, plate, structural, and
equipment materials are employed for
fabrication projects and repair applica-
tions such as the following:
Copper-nickel alloy 90/10 pipe.
Duplex stainless steel (i.e., 2205) and
superduplex stainless steel (i.e., 2507)
pipe.
Titanium Alloy Ti-CP Grade 2 tubing.
API 5L grades X70 pipe.
API 5CT L80 pipe.
Chromium-molybdenum pipe (e.g.,
AISI 4130).
Aluminum alloys (e.g., 6061-T6) struc-
tural members.
Austenitic 300 series stainless steel
pipe and tubing.
Turbine components such as rotors and
airfoils (e.g., Inconel 738, Incoloy 901,
A291).
ASTM structural steel plate and mem-
bers for frames, supports, and storage
tanks.
For field fabrication and repair appli-
Fig. 2 Heavy construction equipment
examples.
LaPlante FINAL LAYOUT_Layout 1 5/9/12 1:29 PM Page 64
cations, the vast majority of welding is
accomplished utilizing the shielded metal
arc welding (SMAW) process. The sub-
merged arc welding (SAW) process is
predominantly employed in shops for the
double-joining of pipe (i.e., girth weld-
ing of two, nominal length 40-ft pipe sec-
tions into one 80-ft section). Also, SAW
is employed for turbine generator, rotor
shaft buildup repair applications. Other
welding/joining processes employed are
gas tungsten arc, gas metal arc, and flux
cored arc welding. Thermite welding is
also used for electrical and copper cable
grounding connections and diffusion
brazing is utilized for turbine airfoil com-
ponent repair.
Charpy Impact Testing and
Other Requirements
For arctic fabrication applications, an
absolute criticality is placed on the thor-
oughness and detail of PQRs, Welding
Procedure Specifications (WPSs), and
welder performance qualification test-
ing. The protection of personnel and the
environment from accidents due to weld
metal and/or base material catastrophic
failure is taken very seriously. Thus, me-
chanical testing and fracture toughness
of weld metal and base materials repre-
sents a critical characteristic in PQR and
welder performance qualification.
Production welding reproducibility of
qualified PQR weld criteria is para-
mount. Oilfield materials are subjected
to bitter arctic cold on a prolonged basis;
therefore, operational requirements ne-
cessitate a fundamental understanding
65 WELDING JOURNAL
Fig. 3 Fabricated pipeline support
mounts.
Fig. 4 A door/stairway safety enclo-
sure.
LaPlante FINAL LAYOUT_Layout 1 5/9/12 1:29 PM Page 65
and awareness of mechanical testing and
metallurgical principles. For pipelines,
API Standard 1104 requires that destruc-
tive testing be employed to determine the
quality of welds for PQR qualification.
Also, for pipeline fitness-for-purpose cri-
teria and to determine the fracture
toughness characteristics of the base and
weld material, Charpy V-notch (CVN)
testing, as detailed in API 1104, is per-
formed. For fabrication and repair appli-
cations, CVN testing with specimen tem-
peratures at 50F or lower are con-
ducted for base materials in accordance
with respective specifications and weld
codes. Detailed CVN test and fracture
evaluation criteria and information are
noted within ASME SA370, ASTM A370,
and ASTM E23.
Due to the fact that many oil and nat-
ural gas pipe applications employ carbon
steel materials and encompass sour serv-
ice, NACE MR0175 requires that for
PQR qualification, hardness testing of
the weld and heat-affected zone be per-
formed as well. NACE MR0175 also re-
quires a chemical analysis of the weld de-
posit be conducted. Weld deposit analy-
sis is required due to the embrittlement
of nickel when exposed to sulfur in a H
2
S-
containing aqueous media/production
fluid environment. For extreme cold
weather fabrication applications, it is es-
sential that a metallurgical assessment of
the weld and base material be performed
prior to weldment implementation. Arc-
tic conditions magnify weldability crite-
ria such that the overall strategy is to in-
crease the weldability of the material
being welded, or at least make an effort
to overcome the weldability problems the
respective alloy presents.
Conclusion
Welding technology, engineering, and
inspection knowledge represents a vital
expertise relative to supporting oilfield
operations at Prudhoe Bay and the TAPS
infrastructure. Personnel working at
Prudhoe Bay maintain a high level of
workmanship quality standards and con-
tinuously strive to sustain a safe and ac-
cident-free workplace and a clean envi-
ronment. Compliance to API, ASME,
and AWS welding-related codes, as well
as NACE corrosion code requirements
represent essential components in
achieving high-integrity welds.
JUNE 2012 66
Fig. 5 A field shelter protects an in-
service (i.e., fluid flowing through the
pipeline during welding) pipeline repair
activity with the outside temperature
at 26F. Welders, pipefitters, NDE,
and QA personnel encounter fabrica-
tion and repair applications around the
clock in all types of weather conditions.
The above pipe material is APL 5L
grade X65, 16 in. in diameter, nominal
0.312-in. wall thickness. The SMAW
process was used with E8018-C3H4R
electrodes, in accordance with API
1104, Appendix B.
References
1. ANSI/NACE MR0175/ISO
15156-1 Petroleum and natural
gas industries Materials for
use in H
2
S-containing environ-
ments in oil and gas production
Part 1: General principles for
selection of cracking-resistant
materials, 2nd Edition. 2009.
LaPlante FINAL LAYOUT_Layout 1 5/9/12 1:30 PM Page 66
For Info go to www.aws.org/ad-index
METABO_FP_TEMP 5/9/12 9:57 AM Page 67
JUNE 2012 68
JIM CUHEL is a welding engineer with
Miller Electric Mfg. Co.
(www.millerwelds.com), Appleton, Wis.
KEITH PACKARD is a segment manager,
power generation, with Hobart Brothers Co.
(www.hobartbrothers.com), Troy, Ohio.
BY JIM CUHEL AND
KEITH PACKARD
The RMD and GMAW-P processes with
metal cored wire have helped get welders up
to speed faster in pipe welding applications,
helping to address training needs and a
shortage of qualified welders.
Miller and Hobart Article June 2012_Layout 1 5/10/12 3:26 PM Page 68
69 WELDING JOURNAL
S
wartfager Welding, Inc., is a fam-
ily-owned business that works. Ken
Swartfager began welding at an
early age under the guidance of his
grandfather and great-grandfather.
Dustin Swartfager, Kens son, also took
up the trade at an early age and is now
actively involved in the family business
Fig. 1.
Currently operated by the sixth gen-
eration, Swartfager Welding got its start
in the 1800s as a traditional black-
smithing operation. Today, it is a leading
fabricator for the rail and marine indus-
tries, as well other heavy fabrication ap-
plications, such as aggregate plants and
infrastructure.
Much of the work done by Swartfager
Welding involves pipe fabrication and
other high-pressure applications. Work-
ing to American Welding Society (AWS)
standards as well as industry-specific
certifications, such as Germanischer
Lloyd for the shipping industry the
company has relied heavily upon both
Regulated Metal Deposition (RMD)
and pulsed gas metal arc welding
(GMAW-P) processes with metal cored
wires to exceed code requirements and
improve their operation through in-
creased productivity, less postweld
cleanup, and easier operation and train-
ing for the workforce.
Some applications have cut up to 70%
of total production time out of the
process. One manual application (de-
scribed later) cut down welding time
from 30 to 7 min. Robotic applications
have also been made substantially faster.
(Germanischer Lloyd) is one of the
most painstaking things in the world to
get an accreditation for, said Dustin
Swartfager, and we have four or five
guys qualified for all of their shipping bu-
reaus so we can provide oil- and water-
critical piping systems for marine appli-
cations, and metal cored is our defined
process that made it a lot easier to get
certified. It took our certification win-
dow from normally 18 to 36 months down
to about four because every time they
sampled our stuff, they couldnt find any-
thing to balk at.
A Pennsylvania manufacturer builds critical
oil and water piping systems
new processes and
Metal Cored Wire
combine to Improve
Pipe Fabrication
Fig. 1 From left, Dustin and Ken
Swartfager of Swartfager Welding,
Inc., pose with Gary Kahle of Mathe-
son Valley Gases.
Miller and Hobart Article June 2012_Layout 1 5/10/12 3:26 PM Page 69
JUNE 2012 70
When youre dealing with high-pres-
sure piping or just something as simple
as low-pressure water piping, your weak-
est link is always your weld joint. Thats
always where your material characteris-
tics vary and everything changes.
Metal cored allows us to take about
any type of piping or tubing, 1026
through your regular A53 grades of ma-
terial, and produce a joint that is struc-
turally better, it looks better, it gives us
the ability to weld out of position and still
keep joint integrity. Spatter is at a mini-
mum when youre out of position with
GMAW-P (with metal cored wires).
We probably get a 30 to 40% increase
in production during the day because we
dont have to go back and grind all of the
spatter off the pipe. We dont have to
worry so much about fitup being perfect
on the root pass because metal cored wire
and RMD allow you to sidestep and ac-
tually make it all look nice. You can get
good backbone structure on your cover
pass with metal cored wire by just chang-
ing your gun angle. For pipe welding, it
is what everybody should be running.
Equipment and Wire
Combinations Enhance
Pipe Fabrication
Swartfager has two primary setups for
pipe fabrication: The company owns four
PipeWorx multiprocess pipe welding
systems for manual applications and also
runs an automated cell powered by the
Auto-Axcess 450 robotic welding
power source Fig. 2.
While traditional gas tungsten arc
welding (GTAW) is used in some root ap-
plications, the company relies heavily on
0.045- and
1
16-in. Metalloy 76 metal
cored wires from Hobart Brothers with
a mix of 75% argon/25% CO
2
shielding
gas for root (RMD) passes and 90%
argon/10% CO
2
for the fill and cap passes
(GMAW-P). Both manual and auto-
mated systems are capable of running
both processes.
Prior to implementing metal cored
wires, Swartfager relied almost exclu-
sively on the GTAW process for root
passes and solid wire for the remaining
passes. The introduction of metal cored
wires and RMD a precisely controlled
short-circuiting metal transfer process
helped significantly to increase travel
speeds (compared to GTAW), bridge
root openings, eliminate incomplete fu-
sion, as well as allow a welder to deposit
a thicker root pass, reduce spatter (com-
pared to conventional gas metal arc
processes) on root passes, and achieve a
better weld compared to a solid wire
Fig. 3.
Some of our applications cant use a
solid filler wire and get the right quality
for the application, said Swartfager.
Thats when we switched to a metal
cored wire on the root pass, which allows
us to get a better weld.
Using the same wire and the same ma-
Fig. 2 An automated system pow-
ered by the Auto-Axcess 450 from
Miller switches from RMD on root
passes to GMAW-P in fill and cap
passes.
Miller and Hobart Article June 2012_Layout 1 5/11/12 2:44 PM Page 70
71 WELDING JOURNAL
Fig. 3 RMD, a precisely controlled
short-circuiting metal transfer process,
helped increase travel speeds, bridge
root openings, eliminate incomplete fu-
sion, and reduce spatter when matched
with metal cored wires.
Miller and Hobart Article June 2012_Layout 1 5/11/12 2:43 PM Page 71
chine, Swartfager can then switch directly
over to the GMAW-P process for the re-
maining passes. This process helps re-
duce spatter, improve weld quality, and
has made it much easier for operators to
weld out of position Fig. 4.
Solid wire cover passes didnt look
good, said Swartfager. You had spat-
ter issues and a multitude of problems
that were hard to overcome, such as
achieving proper fillet shape while out of
position and lack of proper fusion from
the lower heat setting needed to keep the
solid wire in the appropriate spot while
being out of position.
He mentioned working with Gary
Kahle of Matheson Valley Gases (also
pictured in Fig. 1) to use metal cored
wire.
That ran great when you turned the
pipe, but we also had to get out of posi-
tion with it. That led us to pulser boxes on
existing machines and eventually to the
PipeWorx and a new mindset that any
equipment capable of running a good
pulse program with metal cored wire al-
lowed us to do things, where now we dont
have to unfixture (and refixture) a pipe.
We can go out of position with the same
wire weve become accustomed to and get
the same results, Swartfager added.
Compared to trying to weld the re-
maining passes with a solid wire and a
standard CV process, GMAW-P and
metal cored wires help Swartfager in-
crease productivity by offering faster
travel speeds and reduced repositioning
of the part to get it into position.
Either horizontal or vertical, out of
position, any way you can dream it, you
can get it done with pulsed GMA and
have a weld that looks respectable and
to print, he said. If you try to run a solid
wire and CV at the same deposition rate
(as pulsed GMA and metal cored wires
while out of position), you are going to
drop it all over the floor.
And while metal cored wires typically
run hotter than solid wires, the pulsed
GMA process provides precise control
over heat input into the pipe, preventing
distortion and costly rework.
With a pulse setup on your cover, you
can really control the heat and not slow
down, he said. Were not really wor-
ried about joules of input changing the
characteristics of the material were
working on, because the pulse program-
ming allows us to keep it from getting
that hot.
Process, Wire Combine to
Reduce Cleanup and
Rework
Swartfager reports that the combina-
tion of metal cored wires and RMD and
GMAW-P processes substantially re-
duces spatter. While this is a quality im-
provement, it also helps increase produc-
tivity by allowing workers to move on to
the next part rather than spend more
time cleaning a part.
Just the reduction in spatter from the
root pass when youre dealing with a
water pipe (is important), said
Swartfager.
The savings is substantial because
youre not putting in man hours, at your
shop rate, to grind out BBs. If you were
to take every joint on the inside of a water
pipe and grind it, and it took the guy 15
minutes at a shop rate of $75/hour, com-
pared to maybe five minutes with metal
cored, the savings are substantial. When
you look at the cover pass, when you go
out of position with solid wire, you better
have sanding consumables to clean up the
mess. With this, it takes us five seconds to
scuff up the joint and send it to paint.
JUNE 2012 72
Fig. 4 The GMAW-P process with
metal cored wires has helped reduce
spatter, improve weld quality, and
made it easier to weld out of position.
Miller and Hobart Article June 2012_Layout 1 5/10/12 3:27 PM Page 72
The reduction in spatter also reduces
the need for consumables, such as anti-
spatter solution.
We used to go through seven or eight
55-gallon drums (of antispatter solution)
a year, now were down to maybe one,
he said.
Processes Simplify
Operator Training,
Improve Performance
Like many parts of the country, west-
ern Pennsylvania where Swartfager is lo-
cated is experiencing a shortage of skilled
welders. Technology advances and sim-
plifying processes with RMD, GMAW-P,
and metal cored wires have substantially
helped get new welders up to speed
faster.
The technology allows you to bridge
the gap between education and lifetime
work hours in a field, said Swartfager.
You take somebody who has a basic,
good understanding but who might not
be as proficient as someone who has done
it for ten years with the technology
thats available now, you can get an end
result almost as good or as good in weeks
instead of years. You can give them all
the tools necessary to complete a job, do
everything the right way in a shorter
amount of time. You keep your invest-
ment lower to get the same return. With-
out the new equipment, that just would-
nt be possible.
Because processes like RMD main-
tain a consistent arc length even at vary-
ing electrode extensions, welding opera-
tors who may not be as skilled at main-
taining wire electrode extension can still
have good control of the process.
RMD is an excellent way to get a root
pass from guys who might not be able to
do it with GTA, he added. It gives you
the ability to take somebody off the
street, teach them how to listen for a
sound (sizzling bacon), and produce a
weld that is acceptable anywhere for any
application. Instead of six months of
hands-on training in the shop, you get
what you need out of them with two
weeks and some practice. It is probably
one of the greatest things weve seen in
welding in the last 15 years.
The same ease of use translates to the
GMAW-P processes with metal cored
wires.
My guys spend as much time out of
position and in nonuser-friendly welding
positions as they do laying a flat bead,
said Swartfager. Half their day is spent
welding out of position. Without this ap-
plication, theyd just be dripping filler
wire all over everything. It keeps it where
it needs to be.
In addition, he noted it allows you to
control the arc and pool, plus make sure
you have good deposition and tie-in to
the weld.
The equipment and process itself are
also designed to simplify training and im-
prove operator performance. In manual
applications where Swartfager uses metal
cored wire and the multiprocess pipe
welding systems on both the root and hot
pass, operators only have to hit a button
to switch processes from RMD to
GMAW-P. In applications where a GTA
root is required, switching back to a wire
process is as simple as picking up the gun
and pulling the trigger.
You can go from cover pass back to
the GTA root pass (on the next pipe) by
touching the GTA pedal, explained
Swartfager. He further mentioned you can
switch from wire to wire and back to GTA
by clicking the switch or pushing the foot
pedal, and there is minimal downtime.
Just in operator time and keeping
everything in a nice, tight, neat package,
it probably saves you half an hour to 40
minutes each day.
Proof in the Final Product
One recent application that shows the
overall benefits of metal cored wires with
RMD and GMAW-P involved a proto-
type part built from 6-in.-diameter,
Schedule 120 pipe.
A competitive shop, using solid wires,
quoted the fabrication process for each
part at 30 min. Using the PipeWorx sys-
tem with metal cored wires, laying an
RMD root pass and a GMAW-P hot pass,
Swartfager was able to produce the same
part in seven to eight min.
These results wont be universal or
proportional to every application, but it
showcases the possibilities when imple-
menting this system approach.
We want to be on the cutting edge
every time, thats the only way we
progress, concluded Swartfager.
73 WELDING JOURNAL
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Miller and Hobart Article June 2012_Layout 1 5/10/12 3:28 PM Page 73
COMING
EVENTS
SME Annual Conf. June 35, Cleveland Marriott Downtown
Hotel, Cleveland, Ohio. Sponsored by the Society of Manufac-
turing Engineers. www.sme.org/conference.
17th Beijing-Essen Welding and Cutting Fair. June 47. New
China Intl Exhibition Centre, Beijing, China. www.cmes.org/
essen/en/index.htm.
North American Manufacturing Research Conf. (NAMRC). June
48, University of Notre Dame, South Bend, Ind. Sponsored by
the Society of Manufacturing Engineers. www.sme.org/namrc.
Global Petroleum Show. June 1214. Stampede Park, Calgary,
Alb., Canada. http://globalpetroleumshow.com.
Alloys in Power Plant Technology. June 12, 13. ABBA Berlin
Hotel. Berlin, Germany. Sponsored by VDI, Association of Ger-
man Engineers. www.vdi.de/materialsinpowerplants.
The Energy Boom: Get on the Bandwagon. June 12, 13, San
Diego, Calif. Sponsored by the American Welding Society.
www.aws.org/conferences.
Review of Progress in Quantitative Nondestructive Evaluation
(QNDE). July 1520. Hyatt Regency Tech Center, Denver, Colo.
Contact heidil@iastate.edu or www.qndeprograms.org.
Optimizing Operations through Continuous Improvement Conf.
June 2628. Loews Vanderbilt Hotel, Nashville, Tenn. Sponsored
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65th Annual Assembly of the International Institute of Weld-
ing (IIW). July 813. Hyatt Regency Hotel Denver and Colorado
Convention Center, Denver, Colo. Sponsored by the American
Welding Society, Edison Welding Institute, and Welding Research
Council. Featured will be a conference on Welding for Repair and
Life Extension of Plants and Infrastructure. For complete infor-
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GAWDA Annual Convention. Sept. 912. The Broadmoor, Col-
orado Springs, Colo. www.gawda.org/activities/annual-conven-
tion/colorado-springs-2012.
IMTS 2012, Intl Manufacturing Technology Show. Sept. 1015.
McCormick Place, Chicago, Ill. Sponsored by the Association for
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6th Intl Quenching and Control of Distortion Conf. Sept. 1013.
Radisson Blu Aqua Hotel, Chicago, Ill. Sponsored by the Heat
Treating Society of ASM International; www.asminternational.org/
content/Events/qcd/.
15th Annual Aluminum Welding Conf. Sept. 18, 19, Seattle,
Wash. Industry experts will survey the state of the art in aluminum
NOTE: A DIAMOND ( ) DENOTES AN AWS-SPONSORED EVENT.
JUNE 2012 74
continued on page 76
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welding technology and practice. Sponsored by the American
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ICALEO, 31st Intl Congress on Applications of Lasers and
Electro-Optics. Sept. 2327. Anaheim Marriott Hotel, Anaheim,
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2012 Intl Conf. on Advances in Materials Science and Engineer-
ing. Sept. 27, 28. Bangkok, Thailand. Singapore Society of Me-
chanical Engineers. www.smss-sg.org/amse2012/index.htm.
Sheet Metal Welding Conf. XV. Oct. 25, VisTaTech Center,
Livonia, Mich. This is the premier conference dedicated to ad-
vancing the science and technology of sheet metal welding. Spon-
sored by the AWS Detroit Section. www.awsdetroit.org.
2nd Intl Welding and Joint Technologies Congress and 19th
Technical Welding Sessions. Oct. 35. Civil Engineering School,
Polytechnic University of Madrid, Spain. Sponsored by the Span-
ish Welding Assn. www.cesol.es/jornadas2012.htm.
TITANIUM 2012, 28th Annual Conf. and Expo. Oct. 710. Hilton
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METALCON Intl 2012. Oct. 911. Donald E. Stephens Conven-
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Aluminum Week 2012. Oct. 1518. Renaissance Chicago Down-
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JUNE 2012 76
continued from page 74
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HGG Stationary Pipe Cutting Machines (SPC) will easily
save you over 30% on welding and fitting costs. With 27
years experience in machine manufacturing and 3-D
profile-cutting services, HGG is your solution source.
Find out how much our SPC will save you:
Phone: 1-330-461-6855
Email: americas@hgg-group.com
Web: hgg-group.com
SERIOUS AIR FOR SERIOUS PLACES
continued on page 78
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CE June_Layout 1 5/10/12 3:34 PM Page 76
For Info go to www.aws.org/ad-index
harris_FP_TEMP 5/9/12 9:54 AM Page 77
JUNE 2012 78
EuroBLECH 2012, 22nd Intl Sheet Metal Working Technology
Exhibition. Oct. 2327. Hanover Exhibition Grounds, Hanover,
Germany. www.euroblech.com.
LME 2012, Lasers for Manufacturing Event. Oct. 23, 24, Renais-
sance Schaumburg Convention Center Hotel, Schaumburg, Ill.
Laser Institute of America. www.lia.org/lmesd.
Manufacturing with Composites. Oct. 23, 24, Charleston Con-
vention Center, North Charleston, S.C. Sponsored by the Society
of Manufacturing Engineers. www.sme.org/mfgcomposites.
National FFA Convention and Expo. Oct. 2427. Indianapolis,
Ind. Future Farmers of America. www.ffa.org.
ASNT Fall Conf. Oct. 29Nov. 2. Rosen Shingle Creek Resort, Or-
lando, Fla. www.asnt.org/events/conferences/fc12.htm.
EXPO IAS 2012, 6th Conf. on Uses of Steel, 19th Rolling Conf.
Nov. 68. City Center, Rosario, Santa Fe, Argentina. www.siderur-
gia.org.ar/conf12/Home.html.
20th National Quality Education Conf. Nov. 11, 12. Hyatt Re-
gency Louisville, Louisville, Ky. Contact American Society for
Quality (ASQ), (800) 248-1946; www.asq.org.
FABTECH. Nov. 1214. Las Vegas Convention Center, Las
Vegas, Nev. This exhibition is the largest event in North America
dedicated to showcasing the full spectrum of metal forming, fab-
ricating, tube and pipe, welding equipment, and myriad manufac-
turing technologies. Contact American Welding Society,
(800/305) 443-9353, ext. 264; www.fabtechexpo.com and
www.aws.org/conferences.
Indian Industrial Trade Fairs. Nov. 2124. India Expo Centre,
Delhi, India. Hannover Messe/CeMAT. http://bit.ly/zVd4mM.
Power-Gen Intl Show. Dec. 1113. Orange County Convention
Center, Orlando, Fla. www.power-gen.com.
JOM-17, Intl Conf. on Joining Materials. May 58, 2013. Kon-
ventum Lo Skolen, Helsingr, Denmark. Institute for the Joining
of Materials (JOM) in association with the IIW. Cosponsored by
AWS, TWI, Danish Welding Society, Welding Technology Insti-
tute of Australia, University of Liverpool, Cranfield University,
Force Technology, and ABS (Brazilian Welding Assn.). E-mail
Osama Al-Erhayem at jom_aws@post10.tele.dk.
Educational Opportunities
How to Weld Titanium Workshop. June 26, Edison Welding
Institute, 1250 Arthur E. Adams Dr., Columbus, Ohio. Intl
Titanium Assn. www.titanium.org; (303) 404-9400.
Fundamentals of Brazing. Sept. 2527, Wyndham Hotel San
Jose, San Jose, Calif. Lucas Milhaupt, a Handy & Harman Co.
(800) 558-3856. www.lucasmilhaupt.com/en-US/training/upcom-
ingtrainingeventsdetail/29.
Best Practices for High-Strength Steel Repairs. I-CAR courses
for vehicle repair and steel structural technicians. www.i-car.com.
800-886-5418
Fax 810-632-6640
www.heckind.net
BEVEL-MILL

PLATE BEVELERS
Model 9000
Bevel up to 1
3
/16
Fast, accurate bevels
Easy to operate
Model PRO 12
Bevel at 10 feet
per minute
Power Feed
SEVERAL MODELS AVAILABLE
continued from page 76
continued on page 80
For info go to www.aws.org/ad-index
For info go to www.aws.org/ad-index
CE June_Layout 1 5/10/12 3:34 PM Page 78
For Info go to www.aws.org/ad-index
arc one_FP_TEMP 5/9/12 9:39 AM Page 79
Canadian Welding Bureau Courses. Welding inspection courses
and preparation courses for Canadian General Standards Board
and Canadian Nuclear Safety Commission certifications. The
CWB Group, www.cwbgroup.org.
Art Using Welding Technology Classes and Workshops. Miami,
Fla. With artist and sculptor Sandra Garcia-Pardo. Meet the
artist at www.theartlink.org; (786) 547-8681.
ASM Intl Courses. Numerous classes on welding, corrosion, fail-
ure 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.
Basic and Advanced Welding Courses. Cleveland, Ohio. The
Lincoln Electric Co.; www.lincolnelectric.com.
Basics of Nonferrous Surface Preparation. Online course, six
hours includes exam. Offered on the 15th of every month by The
Society for Protective Coatings. Register at www.sspc.org/training.
Boiler and Pressure Vessel Inspectors Training Courses and
Seminars. Columbus, Ohio; www.nationalboard.org; (614) 888-
8320.
CWI/CWE Course and Exam. Troy, Ohio. A two-week prepara-
tion and exam program. Hobart Institute of Welding Technology;
(800) 332-9448; www.welding.org.
CWI/CWE Prep Course and Exam and NDT Inspector Training
Courses. An AWS Accredited Testing Facility. Courses held year-
round in Allentown, Pa., and at customers facilities. Welder
Training & Testing Institute; (800) 223-9884; info@wtti.edu;
www.wtti.edu.
CWI Preparatory and Visual Weld Inspection Courses. Classes
presented in Pascagoula, Miss., Houston, Tex., and Houma and
Sulphur, La. Real Educational Services, Inc. (800) 489-2890;
info@realeducational.com.
Consumables: Care and Optimization. Free online e-courses on
the basics of plasma consumables for plasma operators, sales,
and service personnel; www.hyperthermcuttinginstitute.com.
Crane and Hoist Training for Operators. Konecranes Training
Institute, Springfield, Ohio; www.konecranesamericas.com; (262)
821-4001.
Dust Collection Seminars. Free, full-day training on industrial
ventilation basics and OSHA, EPA, and NFPA regulations.
Presented throughout the year at numerous locations nation-
wide. Camfil Farr APC, www.farrapc.com/offices; (866) 669-6750.
EPRI NDE Training Seminars. Training in visual and ultrasonic
examination and ASME Section XI. Sherryl Stogner (704) 547-
6174; sstogner@epri.com.

JUNE 2012 80
Fischers Feritscope

FMP30
is the ideal solution for fast,
precise measurement of ferrite
content of constructional steels,
welded claddings, austenitic
stainless steels and duplex steels.
Non-destructive measurement
in the range of 80% Fe or 0-120
WRC number.
Battery or AC powered
Large, backlit display
Automatic probe recognition
Statistical evaluation
USB interface
Multiple application memories
FISCHER DataCenter Software
1-800-243-8417 1-860-683-0781 Fax: 1-860-688-8496
www.Fischer-Technology.com info@fischer-technology.com
Measurement
of the Ferrite Content in Austenitic
and Duplex Steel
FERITSCOPE

FMP30

























































For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index
continued from page 78
CE June_Layout 1 5/10/12 3:35 PM Page 80
When critical welding conditions necessitate
performance without compromise, you can depend
on Arcos to provide you with a comprehensive line
of premium quality high alloy, stainless and nickel
electrodes to conform to your stringent requirements.
You can be assured of our commitment to superior
welding products because Arcos quality meets or
exceeds demanding military and nuclear application
specications. Arcos dedication to excellence has
earned these prestigious certications:
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For Info go to www.aws.org/ad-index
arcos 2_FP_TEMP 5/9/12 9:40 AM Page 81
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION SEMINAR DATES EXAM DATE
Corpus Christi, TX Exam only July 7
New Orleans, LA July 813 July 14
Phoenix, AZ July 813 July 14
Memphis, TN July 813 July 14
Miami, FL July 813 July 14
Orlando, FL July 1520 July 21
Milwaukee, WI July 1520 July 21
Los Angeles, CA July 1520 July 21
Sacramento, CA July 1520 July 21
Louisville, KY July 1520 July 21
Kansas City, MO July 2227 July 28
Cleveland, OH July 2227 July 28
Denver, CO July 29Aug. 3 Aug. 4
Philadelphia, PA July 29Aug. 3 Aug. 4
San Diego, CA Aug. 510 Aug. 11
Chicago, IL Aug. 510 Aug. 11
Miami, FL Aug. 510 Aug. 11
Baton Rouge, LA Aug. 510 Aug. 11
Bakersfield, CA Aug. 1217 Aug. 18
Charlotte, NC Aug. 1217 Aug. 18
Rochester, NY Exam only Aug. 18
San Antonio, TX Aug. 1217 Aug. 18
Miami, FL Exam only Aug. 18
Portland, ME Aug. 1924 Aug. 25
Minneapolis, MN Aug. 1924 Aug. 25
Salt Lake City, UT Aug. 1924 Aug. 25
Pittsburgh, PA Aug. 1924 Aug. 25
Seattle, WA Aug. 1924 Aug. 25
Corpus Christi, TX Exam only Sept. 8
Houston, TX Sept. 914 Sept. 15
St. Louis, MO Sept. 914 Sept. 15
New Orleans, LA Sept. 914 Sept. 15
Miami, FL Sept. 914 Sept. 15
Anchorage, AK Exam only Sept. 22
Miami, FL Exam only Oct. 18
Tulsa, OK Oct. 1419 Oct. 20
Long Beach, CA Oct. 1419 Oct. 20
Newark, NJ Oct. 1419 Oct. 20
Nashville, TN Oct. 1419 Oct. 20
Portland, OR Oct. 2126 Oct. 27
Roanoke, VA Oct. 2126 Oct. 27
Detroit, MI Oct. 2126 Oct. 27
Cleveland, OH Oct. 2126 Oct. 27
Atlanta, GA Oct. 28Nov. 2 Nov. 3
Corpus Christi, TX Exam only Nov. 3
Dallas, TX Oct. 28Nov. 2 Nov. 3
Sacramento, CA Oct. 28Nov. 2 Nov. 3
Spokane, WA Oct. 28Nov. 2 Nov. 3
Las Vegas, NV Exam only Nov. 14
Syracuse, NY Dec. 27 Dec. 8
Houston, TX Dec. 27 Dec. 8
Reno, NV Dec. 27 Dec. 8
Los Angeles, CA Dec. 27 Dec. 8
Miami, FL Dec. 27 Dec. 8
9Year Recertification Seminar for CWI/SCWI
For current CWIs and SCWIs needing to meet education
requirements without taking the exam. The exam can be taken
at any site listed under Certified Welding Inspector.
LOCATION SEMINAR DATES EXAM DATE
San Diego, CA July 914 No exam
Miami, FL July 1621 No exam
Orlando, FL Aug. 2025 No exam
Denver, CO Sept. 1015 No exam
Dallas, TX Oct. 1520 No exam
New Orleans, LA Oct. 29Nov. 3 No exam
Miami, FL Nov. 26Dec. 1 No exam
Certified Welding Supervisor (CWS)
LOCATION SEMINAR DATES EXAM DATE
Minneapolis, MN July 1620 July 21
Miami, FL Sept. 1014 Sept. 15
Norfolk, VA Oct. 1519 Oct. 20
CWS exams are also given at all CWI exam sites.
Certified Radiographic Interpreter (CRI)
LOCATION SEMINAR DATES EXAM DATE
Dallas, TX July 1620 July 21
Chicago, IL Sept. 1014 Sept. 15
Pittsburgh, PA Oct. 1519 Oct. 20
The CRI certification can be a stand-alone credential or can
exempt you from your next 9-Year Recertification.
Certified Welding Sales Representative (CWSR)
CWSR exams will be given at CWI exam sites.
Certified Welding Educator (CWE)
Seminar and exam are given at all sites listed under Certified
Welding Inspector. Seminar attendees will not attend the Code
Clinic portion of the seminar (usually the first two days).
Certified Robotic Arc Welding (CRAW)
WEEKS OF, FOLLOWED BY LOCATION AND PHONE NUMBER
Aug. 10, Nov. 9 at
ABB, Inc., Auburn Hills, MI; (248) 3918421
Aug. 20, Dec. 3 at
Genesis-Systems Group, Davenport, IA; (563) 445-5688
Oct. 22, Oct. 26 at
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
July 9, Oct. 15 at
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
July 9, Sept. 10, Nov. 5 at
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at:
MATC, Milwaukee, WI; (414) 297-6996
Certified Welding Engineer (CWEng) and Senior Certified
Welding Inspector (SCWI)
Exams can be taken at any site listed under Certified Welding
Inspector. No preparatory seminar is offered.
International CWI Courses and Exams Schedules
Please visit www.aws.org/certification/inter_contact.html.
JUNE 2012 82
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.
AWS Certification Schedule
Certification Seminars, Code Clinics, and Examinations
Cert Schedule JUNE_Layout 1 5/10/12 9:40 AM Page 82
An unprecedented opportunity
to meet and learn from the worlds
best minds in welding
in Americas Mile-High City
Follow us on
Twitter at iiw2012
8-13 July 2012
Hosted by:
The American Council of IIW
IIW Annual Assembly

July 811

Opening Ceremony

American Evening with live rodeo

Gala Banquet

Technical commissions and study groups

Social events and technical tours


International Conference on Welding for Repair and
Life Extension of Plants and Infrastructure

July 1213

Houdremont Lecture: Welding and Materials


Considerations for Repair and Life Extension

Session 1 Design and Risk Assessment for Repair

Session 2 Automated Repair Procedures

Session 3 Repair and Life Extension of Power


Generation Plant and Equipment

Sesson 4 Repair and Life Extension of Power


Generation Plant and Equipment II

Session 5 Repairs for Cyclical Service

Session 6 Repair for Energy Applications

Session 7 Codes and Standards

Session 8 Repair of Machinery and Equipment

Session 9 Repair of Special Materials

Final Plenary Session Expert Panel Q&A on Repairs


Register online by visiting our website
www.iiw2012.com




















































































































































































The American Council of IIW
Hosted by:
ly 2012 u 8-13 J


















The American Council of IIW
ly 2012








































































at witter TTw
ollow us on F


















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iiw_FP_TEMP 5/9/12 8:36 AM Page 83
Hosted by:
A distinguished panel of aluminum-industry experts will survey the state of the art
in aluminum welding technology and practice during this two-day conference.
September 18
th
- 19
th
/ Seattle, W
Register early and save.
Early Bird Attendee
Member Rate $575 / Non-member Rate $705
For the latest conference information and registration visit our web site at
www.aws.org/conference or call 800-443-9353, ext. 264.
Earn PDHs toward your AWS recertification when you attend the conference.

September 18

/ Seattle, W
th
- 19
th
September 18

/ Seattle, W

For the latest conference information and registration visit our web site at

aws org/confe wwww
For the latest conference information and registration visit our web site at

or call 800-443-9353, ext. 264 .aws.org/conference
For the latest conference information and registration visit our web site at

or call 800-443-9353, ext. 264
For the latest conference information and registration visit our web site at

For the latest conference information and registration visit our web site at

Earn PDHs toward your

WS recertification when you attend the conference. A Earn PDHs toward your
.aws.org/confe wwww.

WS recertification when you attend the conference.
or call 800-443-9353, ext. 264 .aws.org/conference

WS recertification when you attend the conference.
. or call 800-443-9353, ext. 264

WS recertification when you attend the conference.
aluminum conf_FP_TEMP 5/9/12 8:27 AM Page 84
SOCIETYNEWS
SOCIETYNEWS
BY HOWARD M. WOODWARD
woodward@aws.org
85 WELDING JOURNAL
The AWS Membership Committee
met April 3 in Sacramento, Calif. Follow-
ing the business meeting, the members
toured Tri Tool, Inc., hosted by Member-
ship Committee member and District 22
Director Dale Flood. Other members par-
ticipating were AWS Vice President David
Landon, District 2 Director Harland
Thompson, District 20 Director Bill Kom-
los, AWS past President Lee Kvidahl, past
District 1 Director Russ Norris, Mark
Davidson, and David Trees. Representing
AWS staff were Cassie Burrell, senior as-
sociate executive director; and Rhenda
Kenny, director, member services.
Membership Committee Meets in California
The updated, 68-page, American Na-
tional Standard, ANSI Z49.1:2012, Safety in
Welding, Cutting, and Allied Processes, has
been released and is available as a PDF for
free download from the AWS Web site
www.aws.org.
Spelled out are the responsibilities of
managers, supervisors, educators, and work-
ers to ensure welding, cutting, and allied
processes are performed safely.
The standard discusses types of work-
place ventilation for controlling potentially
hazardous fumes and gases, and methods
for protecting workers and others from ra-
diation and spatter from the welding
processes.
Also presented are how to prevent fires,
explosions, and worker injury, and when to
employ firewatchers and how long to main-
tain a firewatch; and what to do when a fire
emergency arises. Information is also pro-
vided for ensuring public safety during a
demonstration as at a trade fair.
Other topics include the safe use of
torches, cylinders, and hoses, safely work-
ing in confined spaces, and information af-
fecting specific processes, including oxyfuel
gas welding and cutting, arc welding and cut-
ting equipment, resistance welding safety,
electron beam welding and cutting
processes, laser beam cutting and welding,
and brazing and soldering safety.
This consensus standard is referenced in
OSHA regulations and the safety regula-
tions of most states and cities.
In print for 68 years, the first edition of
Z49.1 was published in 1944 as an Ameri-
can War Standard. This 2012 edition is the
tenth revision, replacing Z49.1:2005.
Shown during the Membership Committee tour of Tri Tool, Inc., are (from left) Cassie Burrell, Lee Kvidahl, David Landon, Mark Davidson,
Rhenda Kenny, Russ Norris, David Trees, Dale Flood, and Harland Thompson. Not shown is Bill Komlos.
Vintage Z49.1 Welding Safety Standard Updated and Still Free
Society News JUNE_Layout 1 5/10/12 10:30 AM Page 85
JUNE 2012 86
Tech Topics
B2.1/B2.1M:2009-ADD1, Specification
for Welding Procedure and Performance
Qualification. Addenda. 2/23/12.
B2.4:2012, Specification for Welding
Procedure and Performance Qualification
for Thermoplastics. Rev. 4/10/12.
C1.1M/C1.1:2012, Recommended Prac-
tices for Resistance Welding. Rev. 2/17/12.
D8.9M:2012, Test Methods for Evaluat-
ing the Resistance Spot Welding Behavior
of Automotive Sheet Steel Materials. Rev.
2/22/12.
D14.6/D14.6M:2012, Specification for
Welding of Rotating Elements of Equip-
ment. Rev. 2/23/12.
Z49.1:2012, Safety in Welding, Cutting,
and Allied Processes. Rev. 3/9/12.
Reaffirmed Standards
Approved by ANSI (3/29/12)
B2.1-8-024:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Austenitic
Stainless Steel (M-8/P-8/S-8, Group 1),
1
16
through 1
1
2 Inch Thick, ER3XX, As-Welded
Condition, Primarily Plate and Structural
Applications.
B2.1-8-025:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding followed by
Shielded Metal Arc Welding of Austenitic
Stainless Steel (M-8/P-8/S-8, Group 1),
1
8
through 1
1
2 Inch Thick, ER3XX and E3XX-
XX, As-Welded Condition, Primarily Plate
and Structural Applications.
B2.1-1-210:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding with Con-
sumable Insert Root of Carbon Steel (M-
1/P-1/S-1, Group 1 or 2),
1
8 through 1
1
2 Inch
Thick, INMs-1 and ER70S-2, As-Welded or
PWHT Condition, Primarily Pipe Applica-
tions.
B2.1-1-211:2001(2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding with Con-
sumable Insert Root followed by Shielded
Metal Arc Welding of Carbon Steel (M-1/P-
1/S-1, Group 1 or 2),
1
8 through 1
1
2 Inch
Thick, INMs-1, ER70S-2, and E7018, As-
Welded or PWHT Condition, Primarily Pipe
Applications.
B2.1-8-212:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Austenitic
Stainless Steel (M-8/P-8/S-8, Group 1),
1
16
through 1
1
2 Inch Thick, ER3XX, As-Welded
Condition, Primarily Pipe Applications.
B2.1-8-213-97 (R2012), Standard Weld-
ing Procedure Specification (SWPS) for
Shielded Metal Arc Welding of Austenitic
Stainless Steel (M-8/P-8/S-8, Group 1),
1
8
through 1
1
2 Inch Thick, E3XX-XX, As-
Welded Condition, Primarily Pipe Applica-
tions.
B2.1-8-214:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding followed by
Shielded Metal Arc Welding of Austenitic
Stainless Steel (M-8/P-8/S-8, Group 1),
1
8
through 1
1
2 Inch Thick, ER3XX and E3XX-
XX, As-Welded Condition, Primarily Pipe
Applications.
B2.1-8-215:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding with Con-
sumable Insert Root of Austenitic Stainless
Steel (M-8/P-8/S-8, Group 1),
1
8 through 1
1
2
Inch Thick, IN3XX and ER3XX, As-
Welded Condition, Primarily Pipe Applica-
tions.
B2.1-8-216:2001(R2012), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding with Con-
sumable Insert Root followed by Shielded
Metal Arc Welding of Austenitic Stainless
Steel (M-8/P-8/S-8, Group 1),
1
8 through 1
1
2
Inch Thick, IN3XX, ER3XXX, and E3XX-
XX, As-Welded Condition, Primarily Pipe
Applications.
ISO Draft Standards
for Public Review
Copies of the following draft interna-
tional standards are available for review
and comment through your national stan-
dards body, which in the United States is
ANSI, 25 W. 43rd St., 4th Fl., New York,
NY, 10036; (212) 642-4900. Any com-
ments regarding ISO documents should
be sent to your national standards body.
In the United States, if you wish to par-
ticipate in the development of interna-
tional standards for welding, contact An-
drew Davis, adavis@aws.org, (305) 443-
9353, ext. 466.
ISO/DIS 14732.2 Welding personnel
Qualification testing of welding opera-
tors for fully mechanized welding and weld
setters for fully mechanized welding and au-
tomatic welding of metallic materials
ISO/DIS 15615.2 Gas welding equip-
ment Acetylene manifold systems for
welding, cutting and allied processes
Safety requirements in high-pressure devices
Technical Committee
Meetings
All AWS technical committee meet-
ings are open to the public. To attend a
meeting, contact the secretary listed.
June 12, Safety and Health Commit-
tee. Columbus, Ohio. Contact Steve
Hedrick, steveh@aws.org, (305) 443-9353,
ext. 305.
June 28, Committee on Personnel and
Facilities Qualification. Cleveland, Ohio.
Contact Steve Hedrick, steveh@aws.org,
(305) 443-9353, ext. 305.
New Standard Project
Development work has begun on the
following revised standard. Affected indi-
viduals are invited to contribute to this
work. Participation on AWS Technical
Committees and Subcommittees is open
to all persons. Contact Efram Abrams,
eabrams@aws.org; ext. 307, for complete
information.
D8.1M:2007 (R20XX), Specification for
Automotive Weld Quality-Resistance Spot
Welding of Steel. This document contains
both visual and measurable acceptance cri-
teria for resistance spot welds in steels.
The information may be used as an aid by
designers, resistance welding equipment
manufacturers, welded product producers,
and others involved in the automotive in-
dustry and resistance spot welding of
steels. Stakeholders: Resistance welding
and automotive communities.
Standards Approved by ANSI
A4.5M/A4.5:2012 (ISO 15792-3:2011
MOD), Standard Methods for Classifica-
tion Testing of Positional Capacity and Root
Penetration of Welding Consumables in a
Fillet Weld. New. 3/9/12.
A5.1/A5.1M:2012, Specification for Car-
bon Steel Electrodes for Shielded Metal Arc
Welding. Rev. 4/10/12.
A5.9/A5.9M:2012, Specification for Bare
Stainless Steel Welding Electrodes and Rods.
Rev. 2/17/12.
A5.31M/A5.31:2012, Specification for
Fluxes for Brazing and Braze Welding. Rev.
2/17/12.
Errata
AWS D1.1/D1.1M:2010
Structural Welding Code Steel
The following errata, in addition to
previously announced corrections (see
www.aws.org), have been identified and
will be incorporated into the next reprint.
Page 150, note h Correct See 4.25
and 4.28 to See 4.26 and 4.29.
Page 193, 5.1 Correct 4.15 refer-
ence to 4.16.
Errata
AWS D14.3/D14.3M:2010
Specification for Welding Earthmoving,
Construction, and Agricultural Equipment
The following errata, in addition to
previously announced corrections (see
www.aws.org), have been identified and
will be incorporated into the next reprint-
ing of this document.
Page 15, Table 5 Incorrect Yield
Strength Range Change Yield
Strength range for Class III from 4045
to 4055.
Society News JUNE_Layout 1 5/10/12 8:43 AM Page 86
87 WELDING JOURNAL
Two Members Attain Distinguished Status
Nominate Your Candidate for the M.I.T. Prof. Masubuchi Award
November 5, 2012, is the deadline for
submitting nominations for the 2013 Prof.
Koichi Masubuchi Award.
This award is presented each year to
one person, 40 years old or younger, who
has made significant contributions to the
advancement of materials joining through
research and development.
Nominations should include a descrip-
tion of the candidates experience, list of
publications, honors, and awards, and at
least three letters of recommendation
from fellow researchers.
This award is sponsored by the Dept.
of Ocean Engineering at Massachusetts
Institute of Technology (M.I.T.), this
award includes a $5000 honorarium.
E-mail your nomination package to
Todd A. Palmer, assistant professor, The
Pennsylvania State University,
tap103@psu.edu.
Robotic and Automatic Welding
The D16 Committee on Robotic and
Automatic Welding seeks general interest
and educators to help revise:
D16.1M/D16.1, Specification for Robotic
Arc Welding Safety; D16.2M/D16.2, Guide
for Components of Robotic and Automatic
Arc Welding Installations; D16.4M/D16.4,
Specification for the Qualification of Ro-
botic Arc Welding Personnel. Brian Mc-
Grath, bmcgrath@aws.org; ext. 311.
Soldering; Joining Nickel Alloys
The B2E Subcommittee on Soldering
Qualifications; G2C Subcommittee on
Nickel Alloys to review B2.3/B2.3M, Spec-
ification for Soldering Procedures and Per-
formance Qualification. Contact Steve
Hedrick, steveh@aws.org; ext. 305.
Local Heat Treating of Pipe Work
The D10P Subcommittee for Local
Heat Treating of Pipe to revise D10.10,
Recommended Practices for Local Heating
of Welds in Piping and Tubing. Contact B.
McGrath, bmcgrath@aws.org; ext. 311.
Magnesium Alloy Filler Metals
A5L Subcommittee on Magnesium
Alloy Filler Metals to assist in the updat-
ing of AWS A5.19-92 (R2006), Specifica-
tion for Magnesium Alloy Welding Elec-
trodes and Rods. Contact Rakesh Gupta,
gupta@aws.org, ext. 301.
Soldering; Joining Nickel Alloys
The B2E Subcommittee on Soldering
Qualifications; G2C Subcommittee on
Nickel Alloys to review B2.3/B2.3M, Spec-
ification for Soldering Procedures and Per-
formance Qualification. Alex Diaz,
adiaz@aws.org; ext. 304.
Thermal Spray
C2 Committee on Thermal Spraying
seeks educators, general interest, and
users volunteers to revise C2.16, Guide for
Thermal Spray Operator Qualification;
C2.21, Specification for Thermal Spray
Equipment Acceptance Inspection; and
C2.25, Specification for Thermal Spray
Feedstock Solid and Composite Wire and
Ceramic Rods. Efram Abrams,
eabrams@aws.org, ext. 307.
The C4 Committee on Oxyfuel Gas
Welding seeks general interest and edu-
cators to help revise C4.1, Criteria for oxy-
gen cut surfaces and roughness gauge;
C4.2, Recommended Practices for Safe
Oxyfuel Has Cutting Torch Operation,
C4.3 Recommended Practices for Safe
Oxyfuel Gas Heating Torch Operation,
C4.4 Recommended Practices for Heat
Shaping and Straightening with Oxyfuel
Has Heating Torches, and C4.7 Recom-
mended Practices for Safe Oxyacetylene
Welding of Steel. Efram Abrams,
eabrams@aws.org, ext. 307.
Surfacing Industrial Mill Rolls
D14H Subcommittee on Surfacing and
Reconditioning of Industrial Mill Rolls
to revise AWS D14.7, Recommended Prac-
tices for Surfacing and Reconditioning of
Industrial Mill Rolls. Contact Matt Rubin,
mrubin@aws.org, ext. 215.
Automotive Welding
The D8 Committee on Automotive
Welding seeks members to help prepare
standards on all aspects of welding in the
automotive industry.
The next meeting of the D8 Commit-
tee will be held during the week of the
Great Designs in Steel 2012 conference
and exhibition (May 16), Laurel Manor
Conference Center, Livonia, Mich. Con-
tact Efram Abrams, eabrams@aws.org;
ext. 307. To submit an online application
visit www.aws.org/171T.
Opportunities to Contribute to AWS Welding Standards and Codes
Philip Zammit
Bennie D. Flynn
Bennie D. Flynn, Indiana Section, and Philip Zammit, Spokane Section,
have attained the status of AWS Distinguished Member for their outstand-
ing participation in the Societys leadership, professional development, and
membership recruitment activities.
To qualify for distinguished member status, applicants must accrue 35
points or more from at least four categories: national AWS leadership, local
AWS leadership, professional development, and AWS membership recruit-
ment. If you believe you qualify, contact the AWS Membership Department
at (800) 443-9353, ext. 260.
To order custom reprints of Welding Journal articles in quan-
tities of 100 or more, or electronic posting of articles, contact
Rhonda Brown, Foster Printing Services, rhondab@fosterprint-
ing.com; (866) 879-9144, ext. 194; www.marketingreprints.com.
To order individual copies of Welding Journal articles, contact
Edalia Suarez, suarez@aws.org, or Ruben Lara, rlara@aws.org.
To order AWS standards, books, and other publications,
contact World Engineering Xchange, www.awspubs.com; call
toll-free in the United States (888) 935-3464; elsewhere call
(305) 826-6192; or FAX (305) 826-6195.
How to Order Journal Article Reprints and AWS Documents
Society News JUNE_Layout 1 5/10/12 8:43 AM Page 87
JUNE 2012 88
Member-Get-A-Member Campaign
Listed below are the members partici-
pating in the 20112012 Member-Get-A-
Member Campaign. Standings are as of
April 20, 2012. For rules and prize list, see
page 97 of this Welding Journal, or visit
www.aws.org/ mgm. Call the AWS Mem-
bership Dept. at (800) 443-9353, ext. 480,
with any questions about your member-
proposer status.
Winners Circle
Listed are the sponsors of 20 or more In-
dividual Members per year, since June 1,
1999. The superscript denotes the number of
years the member has earned Winners Cir-
cle status.
E. Ezell, Mobile
8
J. Compton, San Fernando Valley
7
J. Merzthal, Peru
2
G. Taylor, Pascagoula
2
L. Taylor, Pascagoula
2
B. Chin, Auburn
1
S. Esders, Detroit
1
M. Haggard, Inland Empire
1
M. Karagoulis, Detroit
1
S. McGill, NE Tennessee
1
B. Mikeska, Houston
1
W. Shreve, Fox Valley
1
T. Weaver, Johnstown/Altoona
11
G. Woomer, Johnstown/Altoona
1
R. Wray, Nebraska
1
Presidents Guild
Sponsored 20 or more new members
M. Pelegrino, Chicago 25
E. Ezell, Mobile 23
Presidents Roundtable
Sponsored 919 new members
R. Holdren, Columbus 9
Presidents Club
Sponsored 38 new members
J. Walker, Blackhawk 6
D. Biddle, Milwaukee 5
T. Palmer, Atlanta 5
J. Vincent, Kansas City 4
D. Wright, Kansas City 4
G. Bish, Atlanta 3
B. Flynn, Indiana 3
B. Goerg, Fox Valley 3
D. Hale, East Texas 3
J. Mehta, San Francisco 3
J. Miller, Oklahoma City 3
G. Mulee, South Carolina 3
P. Phelps, Western Carolina 3
Presidents Honor Roll
Sponsored 2 new members
T. Baber, San Fernando Valley
T. Baldwin, Atlanta
M. Boggs, Stark Central
O. Burrion, S. Florida
P. Carney, Philadelphia
J. Compton, San Fernando Valley
G. Fehrman, Philadelphia
J. Gordy, Houston
C. Hendzel, Fox Valley
G. Holl, Lexington
G. Jacobson, Cumberland Valley
J. Lopez-Padilla, Cuautitlan Izcalli
J. Mueller, Ozark
G. Sanford, Houston
H. Suthar, Charlotte
M. Wheeler, Cleveland
T. White, Pittsburgh
C. Whitesell, Tulsa
Student Member Sponsors
M. Pelegrino, Chicago 90
D. Berger, New Orleans 55
G. Bish, Atlanta 50
D. Saunders, Lakeshore 43
N. Baughman, Stark Central 37
A. Alvarez, Houston 35
T. Palmer, Atlanta 35
R. Belluzzi, New York 34
M. Box, Mobile 34
R. Hammond, Birmingham 33
D. Schnalzer, Lehigh Valley 30
H. Hughes, Mahoning Valley 28
M. Anderson, Indiana 24
S. Siviski, Maine 24
W. England, West Michigan 23
V. Facchiano, Lehigh Valley 23
M. Boggs, Stark Central 22
G. Gammill, NE Mississippi 21
B. Scherer, Cincinatti 21
R. Huston, Olympic 20
J. Lopez-Padilla, Cuautitlan Izcalli 20
R. Richwine, Indiana 20
J. Theberge, Boston 20
T. Green, Central Arkansas 19
C. Daily, Puget Sound 19
J. Fox, NW Ohio 19
R. Hutchinson, Long Beach/Or. Cty 19
S. Robeson, Cumberland Valley 18
R. Wahrman, Triangle 18
A. Baughman, Stark Central 17
J. Bruskotter, New Orleans 17
J. Ciaramitaro, N. Central Florida 17
W. Davis, Syracuse 17
J. Dawson, Pittsburgh 17
C. Donnell, NW Ohio 17
R. Evans, Siouxland 17
R. Jones, Houston 16
S. Miner, San Francisco 16
E. Norman, Ozark 16
J. Gable, El Paso 15
B. Wenzel, Sacramento 15
J. Daugherty, Louisville 14
D. Pickering, Central Arkansas 14
H. Browne, New Jersey 13
M. Haggard, Inland Empire 12
J. Johnson, Madison-Beloit 11
E. Ramsey, Johnstown-Altoona 10
R. Simpson, Charlotte 10
T. Geisler, Pittsburgh 9
C. Kipp, Lehigh Valley 9
J. Kline, Northern New York 9
R. Ledford, Jr., Birmingham 9
A. Webel, Central Michigan 9
G. Smith, Lehigh Valley 8
C. Bills, Mid-Ohio Valley 7
C. Hobson, Olympic Section 7
T. Moore, New Orleans 7
J. McCarty, St. Louis 7
C. Taylor, Charlotte 7
D. Zabel, SE Nebraska 7
J. Boyer, Lancaster 6
M. DAndrea, Kern 6
S. Poe, Central Michigan 6
T. Shirk, Tidewater 6
W. Wilson, New Orleans 6
S. Colton, Arizona 5
J. Ginther, Pittsburgh 5
B. Amos, Mobile 4
A. Badeaux, Washington, D.C. 4
J. Crocker, North Texas 4
A. Reis, Pittsburgh 4
H. Rendon, Rio Grande Valley 4
J. Saterland, Spokane 4
J. Smith, Greater Huntsville 4
P. Deslatte, New Orleans 3
A. Holt, St. Louis 3
J. Meyer, San Francisco 3
G. Seese, Johnstown-Altoona 3
AWS Member Counts
May 1, 2012
Grades
Sustaining ......................................532
Supporting.....................................329
Educational ...................................616
Affiliate..........................................481
Welding Distributor........................57
Total Corporate ..........................2,015
Individual .................................59,090
Student + Transitional ...............11,894
Total Members.........................70,984
Society News JUNE_Layout 1 5/10/12 8:43 AM Page 88
89 WELDING JOURNAL
SECTIONNEWS
SECTIONNEWS
District 1
Thomas Ferri, director
(508) 527-1884
thomas_ferri@thermadyne.com
Shown at the April Boston Section event are (from left) presenter James Montgomery, Dave
Paquin, and Chair Bob Lavoie.
Shown at the Maine Section meeting are from left (front row) Jim Kein, John Rayburn, Russ Norris, Dick Gregoire, Scott Lee, and Mark
Legel; (standing) Ralph Ruel, Pat Kein, Bob Bernier, Mark Merry, and Paul McClay.
Russ Norris (far right) supervised the Boston
Section CWI exam in March assisted by Tim
Kinnaman and Nissa Norris.
Patrick Belsole (left) is shown with Vince
Murray at the New Jersey Section event.
BOSTON
MARCH 24
Activity: The Section hosted a CWI exam
for 38 attendees. The event was held at the
Four Points by Sheraton Hotel in Revere,
Mass. Russ Norris was the test supervisor,
assisted by Nissa Norris and Tim Kinna-
man.
APRIL 10
Activity: The Boston Section members
toured New England Sculpture Service Co.
in Chelsea, Mass. Managing partner James
Montgomery detailed the companys lost
wax bronze foundry procedures for cast-
ing intricate works by numerous artists.
MAINE
MARCH 20
Activity: The Section held its spring direc-
tors meeting at Southern Maine Commu-
nity College in South Portland, Maine.
CWI Mark Legel, welding department
head at the college, conducted the pro-
gram. Topics included the upcoming Dis-
trict 1 conference, CWI seminars and tests,
and nominations for Section awardees.
Participating were Jim Kein, John Ray-
burn, Russ Norris, Dick Gregoire, Scott
Lee, Ralph Ruel, Pat Kein, Bob Bernier,
Mark Merry, and Paul McClay.
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
Society News JUNE_Layout 1 5/10/12 8:44 AM Page 89
JUNE 2012 90
Don Smith (left) is shown with Bob Petrone
at the April New Jersey Section program.
Eric Dolan (left) and Bob Petrone are shown
at the April New Jersey Section meeting.
James Rosenthal (left) receives his Gold
Member certificate from Mike Chomin,
Philadelphia Section outgoing chair.
Ken Temme (left) receives his chairmans pin from Mike Chomin (center), outgoing
Philadelphia Section chair, and Harland Thompson, District 2 director.
Shown at the April New Jersey Section event are (from left) District 2 Director Harland
Thompson, Chair Herb Browne, speaker Bruce Benson, and Al Fleury.
Shown at the April Philadelphia Section tour are (from left) incoming Chair Ken Temme,
Walt Emerle, outgoing Chair Mike Chomin, and Jim Kehoe.
Charles Minnick (front left) receives a speaker gift from Mike Chomin, Philadelphia Section chair, at the March program.
Society News JUNE_Layout 1 5/10/12 8:45 AM Page 90
91 WELDING JOURNAL
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
District 4
Roy C. Lanier, director
(252) 321-4285
rlanier@email.pittcc.edu
District 3
Michael Wiswesser, director
(610) 820-9551
mike@welderinstitute.com
NEW JERSEY
MARCH 20
Speaker: Patrick Belsole
Affiliation: Hypertherm
Topic: High-performance cutting methods
Activity: The program was held at Snuffys
in Scotch Plains, N.J.
APRIL 16
Speaker: Bruce Benson
Affiliation: Boy Scouts of America (BSA)
Topic: The new BSA welding merit badge
Activity: The Section hosted a manufac-
turers night event in Scotch Plains, N.J.
Don Smith received the District Educator
Award, and Eric Dolan received the Dis-
trict Meritorious Award.
PHILADELPHIA
MARCH 28
Activity: The Section members visited the
Miller Welding Technologies training cen-
ter in Swedesboro, N.J., for some hands-
on experience with the companys latest
equipment for welding aluminum with the
gas tungsten arc and the pulsed gas metal
arc welding processes. Charles Minnick,
training director, conducted the program.
APRIL 11
Activity: The Philadelphia Section visited
the UA Local 322 training facility in
Winslow, N.J. Walt Emerle, director of
training, and Jim Kehoe, business man-
ager, led the tour and hosted a dinner for
the members. James W. Rosenthal re-
ceived his Gold Member certificate for 50
years of service to the Society. Bill Dotson,
Lincoln Electric district manager, pre-
sented Rosenthal a gift for his 47 years with
the company. Outgoing Chair Mike
Chomin received an appreciation plaque
from Chair Ken Temme.
Greg Brakefield (right) receives a speaker-
appreciation plaque from Damen Johnson,
Florida West Coast Section chair.
Carl Matricardi (left), District 5 director, and
Gale Mole (center), South Carolina Section
chair, are shown with speaker Chris Eure.
Presenters at the Columbus Section tour of the JCPenney Logistic Center are (from left)
Jon VanEuwen, Jessica Rannow, and Andrea Ray.
Howard Jones (far right) receives his Life
Member certificate from Carl Matricardi
(center), District 5 director, and Gale Mole,
South Carolina Section chair .
FLORIDA WEST COAST
APRIL 11
Speaker: Greg Brakefield, manager engi-
neering and quality
Affiliation: GMF Industries, Inc.
Topic: Requirements for obtaining and
maintaining AISC certification
Activity: The program was held at Fron-
tier Steakhouse in Tampa, Fla.
SOUTH CAROLINA
MARCH 15
Speaker: Chris Eure, lead inspector
Affiliation: AMEC, World Trade Center
Topic: The importance of weld inspections
before, in-process, and final
Activity: District 5 Director Carl Matri-
cardi presented Howard Jones a Life
Member certificate for his years of service
to the Society.
COLUMBUS
MARCH 14
Activity: The Section joined members of
other local technical societies to tour the
JCPenney Logistics Center in Columbus,
Ohio. Jessica Rannow, senior logistics en-
gineer, and engineers Jon VanEuwen and
Andrea Ray conducted the program.
PITTSBURGH
APRIL 17
Speaker: Ryan Bucurel, welding engineer
Affiliation: Westinghouse
District 7
Don Howard, director
(814) 269-2895
howard@ctc.com
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
Society News JUNE_Layout 1 5/10/12 8:45 AM Page 91
JUNE 2012 92
Speaker Ryan Bucurel (right) is shown with
Brad King, Pittsburgh Section chair.
Vadim Nakonechnyy (left) is shown with
Eric Zumbrun, Chattanooga Section chair.
The NE Mississippi Section members are shown during their tour of Anel Corp.
Fronius presenters (from left) Matt Brooks,
Keith Shaver, and Chris Hobson are shown
at the Chattanooga Section event.
Dave Silverman (left), Clinton Cunninghan
(center), and Dylen Kielur received awards
for their welding skills at the Pittsburgh Sec-
tion meeting.
Pittsburgh Section members are shown at the April meeting.
Topic: Underwater laser beam welding
Activity: Clinton Cunninghan, Dave Sil-
verman, and Dylen Kielur received awards
for their achievements in the recent weld-
off contest. This Pittsburgh Section event
was held at Springfield Grille in Mars, Pa.
CHATTANOOGA
MARCH 27
Speaker: Keith Shaver, area sales manager
Affiliation: Fronius USA LLC
Topic: New Fronius welding equipment
Activity: Following the talk, Matt Brooks,
senior application engineer, and Christo-
pher Pawlowicz, sales system engineer, as-
sisted by Vadim Nakonechnyy, gave
demonstrations of the Delta Spot system
using a consumable metal tape, and a mod-
ified short-arc process called cold metal
transfer. The event was held at the Fro-
nius facility in Chattanooga, Tenn.
NASHVILLE
MARCH 22
Activity: The Section members met at
World Testing, Inc., for dinner and a view-
ing of the History Channel video Modern
Marvels: Welding. A committee was formed
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
Society News JUNE_Layout 1 5/10/12 8:45 AM Page 92
93 WELDING JOURNAL
to plan the District 8 welding competition.
Named were Don Carnahan, Josh
Burgess, Marion Brown, Rodney Patter-
son, and Joe Livesay, District 8 director.
NE MISSISSIPPI
MARCH 22
Activity: The Section members toured the
Anel Corp. plant in Winona, Miss. Dan
James, engineering manager, conducted
the program.
WESTERN CAROLINA
MARCH 20
Speaker: Edward Craig
Affiliation: TIP TIG USA, Inc.
Topic: Semiautomatic GTAW hot wire
welding system
Activity: Following the talk, company
welder James Drake demonstrated the
Central Alabama C. C.
Student Chapter
DECEMBER 2
Activity: The Chapter members conducted
a car-washing fund-raiser to benefit a
home for veterans at Satterfield Welding
Supply in Alexander City, Ala.
JANUARY 27
Activity: The Central Alabama C. C. Stu-
dent Chapter toured Robinson Iron Corp.
in Alexander City, Ala. Scott Howell, vice
president, conducted the tour.
process. The event was held at Byers Pre-
cision Fabricators in Hendersonville, N.C.
Western Carolina Section members are (from left) Tony Roseborough, Tim McAnally, Steve Matson, Chris Anders, Stewart Payne, Jonathan
Bear, Keith Massey, Bill Plumstead, Paul Ballard, Howard Smith, Chair Eric Blau, Sam Randall, Bill Lindsey, Jimmy Roberts, Robert
Sadler, Carl Reese, Steve Wheat, and Jerry Cannon. Photos taken by Wesley Smith.
Central Alabama C. C. Student Chapter members shown during their December fund-raising event are (from left) Andrew Hall, Philip
Caswell, William Butt, Brandon Grant, Winfred Fleetion, Chair Walter Lawton, Crystal Cooley, Chris Harvell, and Michael Slick.
James Drake demonstrated a precision weld-
ing process for the Western Carolina Section
members.
Central Alabama C. C. Student Chapter members shown during their January tour are (from left) Scott Howell, Russell Fields Jr., Terance
Jenkins, Ron Van Houten, William Butt, Sheri Mayhan, and Chris Harvell.
District 9
George Fairbanks Jr., director
(225) 473-6362
ts@bellsouth.net
Society News JUNE_Layout 1 5/10/12 8:46 AM Page 93
JUNE 2012 94
James Brody Scott received the Lawson State
C. C. Student Chapter Award in March.
Shown at the April Mobile Section event are (from left) Chair Brenda Amos, James Sulli-
van, Andre Nicholas, Jerry Betts, and Dick Corbin.
Shown at the April New Orleans Section pro-
gram are (from left) Chair Aldo Duron,
speaker Gerrard Riche, and Vice Chair
Jimmy Goodson.
Owen Brown (right) is shown with Aldo
Duron, New Orleans Section chair.
Shown at the Mahoning Valley meeting are
(from left) Bob Matteson, Mike Gromada,
and Robert Day.
Chair Aldo Duron (left) is shown with Roy
Larille at the New Orleans Section program.
Shown at the March New Orleans Section program are from left (seated) Paul Hebert, Chair Aldo Duron, and District 9 Director George
Fairbanks; (standing) Mike Skiles, Jimmy Goodson, Al Theriot, Ed Dixon, Buddy Delaune, Bruce Hallila, Paul DeSlatte, and Bill Rice,
AWS president.
Speaker Bill Rice, AWS president, chats with
Brenda Amos, Mobile Section chair.
Ron Pierce (left) is shown with speaker
Thom Burns and Brenda Amos, Mobile Sec-
tion chair.
Society News JUNE_Layout 1 5/10/12 8:46 AM Page 94
95 WELDING JOURNAL
Lawson State C. C.
Student Chapter
MARCH 13
Activity: James Brody Scott was selected
by Advisor Roy Ledford Jr., Birmingham
Section, to receive the Student Chapter
Member Award. Scott has served as Chap-
ter chair, has a 4.0 GPA, and has completed
several welding procedure qualifications.
He was named the Outstanding Student
in the Welding Technology Program,
helped coordinate the LSCC welding sem-
inar, and will participate in the SkillsUSA
state welding competition.
MOBILE
MARCH 8
Speaker: Bill Rice, AWS president, CEO
Affiliation: OKI Bering
Topic: AWS today and its advances
Activity: The program was held at AIDT
Maritime Training Center in Mobile, Ala.
APRIL 12
Speaker: Thom Burns, director of techni-
cal services
Affiliation: AlcoTec Wire Corp.
Topic: Improving aluminum weld quality
Activity: The door prize winners were
James Sullivan from Locklin Technical
Center, Andre Nicholas from Signal Ship
Repair, Jerry Betts from Hargrove, and
Dick Corbin from WESCO Gas & Weld-
ing Supply. The meeting was held at Saucy-
Q Bar B Que in Mobile, Ala.
NEW ORLEANS
MARCH 15
Speaker 1: Bill Rice, AWS president, CEO
Affiliation: OKI Bering
Topic: Update on AWS activities
Speaker 2: Gregory Cain, engineer
Affiliation: Oxylance, Inc.
Topic: Underwater and demolition elec-
trodes
Activity: The meeting was sponsored by
IWS Gas & Supply, Inc., at Caf Hope in
Marrero, La. District 9 Director George
Fairbanks presented awards to Jimmy
Goodson, Al Theriot, Ed Dixon, Buddy De-
laune, Bruce Hallila, Paul DeSlatte, Paul
Hebert, Chair Aldo Duron, and Mike
Skiles, Acadiana Section chair.
APRIL 17
Speaker: Gerrard Riche, regional VP
Affiliation: Airgas, Inc.
Topic: Impact of the helium shortage
Activity: This meeting was sponsored by
Airgas at its new Kenner, La., facility. Fol-
lowing the talk, Riche led a tour of the fa-
cility. Local representatives from DeWalt
Power Tools and ESAB demonstrated
their latest products. Owen Brown was pre-
sented the Section Educator Award and
Roy Larille received the Section Private
Sector Instructor Award.
MAHONING VALLEY
APRIL 19
Activity: The Section held an executive
meeting in Caf Capri in Boardman, Ohio,
to make plans for the 37th annual Jim Best
Memorial Golf Outing for August 3 and
the District 10 meeting. Bob Matteson re-
ceived his Life Member Award for 35 years
of service to the Society. Mike Gromada
received the Section CWI of the Year
Award, and Robert Day received the Sec-
tion Educator Award.
NORTHWEST OHIO
MARCH 21
Activity: The Section members met in Per-
rysburg, Ohio, to learn about metal ana-
lyzing techniques. Adam Robinson, a
Niton representative, discussed how metal
analyzers function and can print out the
chemical compositions of alloys. Michael
Nighswander from Diamond Inspection
Services explained how his company uses
its Niton analyzer to ensure the correct
piping is being installed at local refineries
and a local shipyard.
LAKESHORE
MARCH 12
Speaker: Jeffrey Noruk, president
Affiliation: Servo-Robot Corp.
Topic: WiKi-SCAN welding inspection sys-
tem using laser scanning
Activity: The Section elected officers for
the coming year. The program was held at
Machuts Supper Club in Two Rivers, Wis.
MADISON-BELOIT
MARCH 21
Activity: The Section members toured
E.K. Machine Co., Inc., in Fall River and
Columbus, Wis. The presenters included
Steven Slack and Kristen Dykstra who dis-
cussed the history of the company. Chair
Ben Newcomb presented Walter S.
Griskavich his AWS Life Member certifi-
cate for 35 years of service to the Society.
Mike Wilkinson received his Silver Mem-
ber certificate for 25 years service.
District 10
Richard A. Harris, director
(440) 338-5921
richaharris@windstream.net
Lakeshore Section Chair John Zielonka
(left) is shown with speaker Jeffrey Noruk.
Life Member Walter S. Griskavich (right) is
shown with Ben Newcomb, Madison-Beloit
Section chair, at the March 21 meeting.
Silver Member Mike Wilkinson (right) re-
ceives his certificate from Ben Newcomb,
Madison-Beloit Section chair.
Greg Early demonstrated welding equipment
at the March Indiana Section meeting.
District 11
Robert P. Wilcox, director
(734) 721-8272
rmwilcox@wowway.com
District 12
Daniel J. Roland, director
(715) 735-9341, ext. 6421
daniel.roland@us.ncantieri.com
District 13
W. Richard Polanin, director
(309) 694-5404
rpolanin@icc.edu
District 14
Robert L. Richwine, director
(765) 378-5378
bobrichwine@aol.com
Society News JUNE_Layout 1 5/10/12 8:46 AM Page 95
JUNE 2012 96
Indiana Section Vice Chair Bennie Flynn
(right) accepts a scholarship fund donation
from Pat Garten at the March 15 event.
Indiana Section Chair Gary Tucker (left)
and Beau McHaffey talk shop at the Indi-
ana state SkillsUSA event.
Welcoming the Kansas Section to Kasa Fab
are (from left) Taunya Heil and Sarah and
Vicki Robidou.
The Kansas Section members are shown during their Kasa Fab tour in April.
R. J. Zelaya, Kasa Fab weld robotics man-
ager, addressed the Kansas Section.
Ivy Tech Student Chapter members are (from left) Carissa Whitesell, Ron Potter, Lenny
Robinson, Chair Beau McHaffey, Jeremy Misa, Cory Fenters, instructor Martina Miller,
Brent Scroggins, Dustin Hawkins, Jason Shaw, Simon Reber, Josh Noble, and Advisor Bob
Richwine, District 14 director.
Bob Richwine, District 14 director, judged
entries at the Indiana SkillsUSA welding
event.
INDIANA
MARCH 15
Activity: The Section met at Sutton-
Garten Co. in Indianapolis for a demon-
stration of Miller Electrics latest products.
Greg Early performed the demonstrations.
Pat Garten was thanked for his donation
to the Sections scholarship fund.
MARCH 17
Activity: The Indiana Section hosted a
CWI test for 32 applicants in Brownsburg,
Ind. The proctors included Chair Gary
Tucker, Gary Dugger, Bennie Flynn, Tony
Brosio, and Bob Richwine, District 14 di-
rector.
APRIL 14
Activity: The Indiana Section members
participated in the state SkillsUSA weld-
ing contest held at Walker Career Center
in Indianapolis. Working the event were
Chair Gary Dugger, Tony Brosio, Bennie
Flynn, Gary Tucker, Jeremy Misa, Beau
McHaffey, and Bob Richwine, District 14
director.
Ivy Tech Institute of Welding
Student Chapter
APRIL 11
Activity: The first community activity of
the newly formed Indiana Section-spon-
sored Student Chapter was a fund-raising
project featuring welded Walking Man
sculptures that were sold throughout the
city of Anderson, Ind., to raise money for
charity. The chairman is Beau McHaffey,
and the advisor is Bob Richwine, District
14 director.
Society News JUNE_Layout 1 5/10/12 8:47 AM Page 96
99 WELDING JOURNAL
The Kansas City members are shown at the Lincoln Seminar in March.
Dennis Pickering (purple shirt), speaker and Central Arkansas Section chair, is shown with
welding students and their instructor, Thomas Green (red shirt), at the April program.
Shown at the March North Texas Section program are (from left) Glenn McArdle, Mark
Fogle, speaker Tom Sitton, and Donnie Williams, co-chair.
Shown at the Central Arkansas event are
(from left) Terry Harper, Dennis Pickering,
and Nick Counts.
KANSAS
APRIL 19
Activity: The Section members toured
Kasa Fab metal fabrication plant in Salina,
Kan., to study its laser cutting, punch press,
painting, and welding operations. The pre-
senters included Taunya Heil, Sarah and
Vicki Robidou, and R. J. Zelaya. Mike
Haug, CEO, presented details about the
company for the 35 attendees.
KANSAS CITY
MARCH 7, 8
Activity: The Section members partici-
pated in a submerged arc welding seminar
presented by Lincoln Electric Co. at its fa-
cility in Lenexa, Kan. The presenters in-
cluded Alonzo Yost, Sam Phillips, Rob
Dickerson, Brad Rillema, Jason Scales,
Paul Hannen, and Jamie Kappeler.
CENTRAL ARKANSAS
NOVEMBER 11
Activity: Nick Counts was presented a
welding hood for winning the Welsco Expo
welding contest from Dennis Pickering
and Terry Harper. The meeting was held
at Bryant High School in Bryant, Ark.
APRIL 12
Speaker: Dennis Pickering, chair
Affiliation: Arkansas Career Training In-
stitute, instructor
Topic: AWS and his welding experiences
Activity: Attending were Thomas Green
and his welding students. The program was
held at Arkansas State University in Heber
Springs, Ark.
NORTH TEXAS
MARCH 20
Speaker: Tom Sitton, regional director
Affiliation: Nelson Stud Welding
Topic: New stud welding technology
Activity: The program was held in Arling-
ton, Tex.
APRIL 17
Speaker: Barney Burks, sales engineer
Affiliation: SOWESCO, Inc.
Topic: GMAW feeder units
Activity: The event was held at Humper-
dincks Restaurant in Arlington, Tex.
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 17
J. Jones, director
(940) 368-3130
jjones@thermadyne.com
Society News JUNE_Layout 1 5/10/12 8:47 AM Page 99
JUNE 2012 100
Speaker Barney Burks (left) is shown with
Bill Hall, North Texas Section chair.
Houston Section veteran members cited at
the January program are (from left) Steven
Roper, Harry Harris, and M. Asif Latif.
Ron Theiss tries on a Harley Davidson for
size at the Houston Section February event.
Speaker Barney Burks (left) chats with Den-
nis Eck at the April Houston Section event.
Houston Section past chairs are (from left) Dennis Eck, Ron Theiss, Richard Wright, Car-
olyn Johnson, Haskall Ray, Robert Anderso, Jerry Koza Jr., Chris Bloch, M. Asif Latif, John
Stoll, John Husfeld, and John Bray, District 18 director.
Shown at the Sabine Sections program are (from left) District 18 director John Bray, Mor-
ris Weeks, Roger Dean, Ethan Trade, and Chair John McKeehan.
Tulsa Section Chair Paul Wittenbach (left)
is shown with speaker Mark Smith.
TULSA
MARCH 27
Speaker: Mark Smith, president
Affiliation: Mark Smith Training Services
Topic: Characteristics of successful people
Activity: The program was held at Shilohs
Restaurant in Tulsa, Okla.
HOUSTON
JANUARY 18
Speaker: John Mendoza, AWS past presi-
dent
Affiliation: Lone Star Welding
Topic: History of the CWI
Activity: Harry R. Harris received his Life
Member certificate for 35 years of mem-
bership. Silver Member certificates were
presented to Steven D. Roper and Muham-
mad Asif Latif for 25 years of service to
the Society. The event was held at Bradys
Landing in Houston, Tex. Past chairs in at-
tendance included Dennis Eck, Ron
Theiss, Richard Wright, Carolyn Johnson,
SABINE
JANUARY 17
Speaker: John Bray, District 18 director
Affiliation: Affiliated Machinery, presi-
dent
Topic: Update on AWS activities
Activity: Ethan Trade received the Student
Chapter Member Award and Jason Bing-
ham received the Section Educator
Award. The program was held at La Can-
tina Mexican Grill in Beaumont, Tex.
FEBRUARY 21
Speaker: Randy Watson, lieutenant
Affiliation: Jefferson County Sheriffs
Dept.
Topic: Using good judgment to be safer
Activity: Jim Stuckey received the Section
Dalton E. Hamilton CWI of the Year
Award. The program was held at La Can-
tina Mexican Grill in Beaumont, Tex.
Haskall Ray, Robert Anderson, Jerry Koza
Jr., Chris Bloch, M. Asif Latif, John Stoll,
John Husfeld, and John Bray, District 18
director.
FEBRUARY 15
Activity: The Houston Section hosted a
students night program at Bradys Land-
ing in Houston, Tex. for more than 250 stu-
dents. Kent Weeks and Dave Atkinson ad-
dressed the students about the history of
Harley Davidson motorcycle frames and
how they are built.
APRIL 18
Speaker: Barney Burks, sales engineer
Affiliation: SOWESCO, Inc.
Topic: Optimizing GMAW power sources
and feeders
Activity: Following the talk, Burks offered
a hands-on demonstration for the 65 at-
tendees. The meeting was held at Bradys
Landing in Houston, Tex.
District 18
John Bray, director
(281) 997-7273
sales@afliatedmachinery.com
Society News JUNE_Layout 1 5/10/12 8:47 AM Page 100
101 WELDING JOURNAL
District 19
Neil Shannon, director
(503) 201-5142
neilshnn@msn.com
Shown at the January Houston Section program are (from left) speaker John Mendoza, Dan Sowa, Eileen Husfeld and son, Chris Vander-
seice, Justin Gordy (front), Dan Jones, Grant Piltier, Justin Kirby, Eric Vann, Barney Burks Jr., and John Bray, District 18 director.
Alaska Section members are shown with speaker Ron Theiss (standing, far left).
The Sabine Section members are shown at the January meeting.
Jason Bingham(right) is shown with John
Bray, District 18 director, at the January
Sabine Section event.
Lt. Randy Watson (right) receives a speaker
plaque from Morris Weeks at the Sabine Sec-
tion program in February.
Jim Stuckey (left) is shown with John McK-
eehan, Sabine Section chair, in February.
ALASKA
MARCH 21
Speaker: Ron Theiss, AWS CWI
Topic: Qualifying welding procedures
Theiss, a member of the Houston Section,
was in Anchorage, Alaska, to present a
CWI training class.
OLYMPIC
MARCH 20
Activity: The Section members toured the
Society News JUNE_Layout 1 5/10/12 8:48 AM Page 101
JUNE 2012 102
Tacoma Steel plant in Tacoma, Wash. At-
tendees included students from Lincoln
High School and Bates Technical College.
Jeff Klein and Dan Gadsden guided the
tour; the highlights included a robotic
welding cell and a variety of precision
metal cutting operations. District 19 Di-
rector Neil Shannon presented Chair Sjon
Delmore the District Directors Award.
PUGET SOUND
APRIL 6
Speaker: Dale Cooper, CWI
Affiliation: Airgas NorPac, sales manager
Topic: Efficient welding of carbon steels
Activity: Arthur Schnitzer of Everett Com-
munity College (ECC) received a Section
$500 scholarship award. Chair Steve Pol-
lard received the District Directors Cer-
tificate Award from Neil Shannon, Dis-
trict 19 director. Recognized were Grant
Goldsmith and Steve Pollard who pre-
sented a flame straightening workshop at
ECC, and Ken Johnson who organized the
welding portion of the state SkillsUSA
event at Renton Technical College, as-
sisted by Section members Chad Ross, Dan
Sheets, Steve Neilson, and Robert White,
who served as judges.
SPOKANE
APRIL 18
Activity: The Section members and guests
visited Spokane Community College to
tour its new welding department facilities.
David Minerath and Brandon Adkins
from Quest Integration took turns dis-
cussing and demonstrating SolidWorks
computer-aided design applications for
welding fabrication.
COLORADO
APRIL 12
Activity: The Section members visited
Aims Community College in Windsor,
Colo., for a presentation by Zac Kreider,
welding instructor, on using welding in au-
tomotive collision repair. Included in the
talk and the tour were welding and flame
straightening, repairs to upholstery and
electrical components, and body repairs
and painting.
Dan Gadsden (left) and Jeff Klein heft the
Olympic Section speakers appreciation gift
during the Tacoma Steel plant tour.
Puget Sound Section Chair Steve Pollard
(right) is shown with Neil Shannon, District
19 director.
Students from Everett Community College and Lake Washington Technical College pose
with their door prizes provided by Airgas at the Puget Sound Section program.
Shown are Puget Sound Section members with Renton Technical College students.
David Minerath (left) and Brandon Adkins
demonstrated computer-aided welding for
the Spokane Section members.
Shown at the Olympic Section tour of
Tacoma Steel are District 19 Director Neil
Shannon (left) with Chair Sjon Delmore.
District 20
William A. Komlos, director
(801) 560-2353
bkoz@arctechllc.com
District 21
Nanette Samanich, director
(702) 429-5017
nan07@aol.com
Society News JUNE_Layout 1 5/10/12 8:48 AM Page 102
103 WELDING JOURNAL
Colorado Section members are shown with presenter Zac Kreider (red shirt) at Aims Community College.
Mack Frost (left) receives a lifetime achievement award, shown with his wife, Joyce, and
Dale Flood, District 22 director.
Co-Chairs Liisa Pine (left) and Sharon Jones are shown with Dale Flood, District 22 direc-
tor, at the San Francisco Section meeting.
Shown at the San Francisco Section program are speakers (from left) Matt Miller, Co-
Chair Liisa Pine, and Dale Flood, District 22 director.
District 22
Dale Flood, director
(916) 288-6100, ext. 172
d.ood@tritool.com
District Presentation
MARCH 14
Activity: Dale Flood, District 22 director,
presented McKinley Mack Frost a life-
time achievement award. His local weld-
ing industry initiated this award to recog-
nize Frosts service as an educator and to
the welding industry. He started certifying
welders in 1984, and created a metal sculp-
ture program at Columbia College in 2002.
The presentation was made in Sonora,
Calif.
SAN FRANCISCO
APRIL 4
Activity: The Section met at Spengers
Restaurant in Berkeley, Calif., for presen-
tations by Liisa Pine, co-chair; Matt Miller
from Lincoln Electric; and Dale Flood,
District 22 director. The topic was current
and future welding job opportunities in the
Bay Area and northern California. Pine
also reported on Section plans and activi-
ties. Flood presented Pine and Sharon
Jones certificates of appreciation for serv-
ing as co-chairs.
Society News JUNE_Layout 1 5/10/12 8:49 AM Page 103
JUNE 2012 104
New AWS Supporters
Sustaining Members
Bradford Marine Bahamas
Queens Hwy, Freeport, Grand Bahama
Representative: John Biggs
www.bradfordmarinebahamas.com
Bradford Marine Bahamas offers planned
or emergency cost-effective repairs to yachts,
coastal freighters, tankers, tugs, barges, re-
search and naval vessels, as well as cruise ship
service vessels. Its welding and fabrication de-
partment is ABS and AWS certified. For more
information or to schedule repairs, contact Dan
Romence, general manager, (242) 352-7711;
dan@bradfordmarinebahamas.com.
Alabama Robotics Technology Park
6505 U.S. Hwy. 31, Tanner, AL 35671
Representative: Rick Maroney
www.alabamartp.org
The Alabama Robotics Technology Park is
an industrial and educational facility that of-
fers day and evening classes in robotics, mate-
rial handling, overhead crane, forklift, indus-
trial safety, manual and robotic welding, and
AWS Certified Robotic Arc Welding. All
classes are certified with opportunities for two-
year and four-year degrees.
Supporting Companies
Accuwright Industries, Inc.
1350 N. Mondel Dr.
Gilbert, AZ 85233
Cincinnati Thermal Spray, Inc.
5901 Creek Rd.
Cincinnati, OH 45242
MESSER Eutectic Castolin Switzerland S.A.
PO Box 360, St. Sulpice
Vaud 1025, Switzerland
New England Plasma Development Corp.
14 Highland Dr., PO Box 369
Putnam, CT 06260
Praxair Surface Technologies
146 Pembroke Rd.
Concord, NH 03301
United Surface Technologies Pty. Ltd.
26-32 Aberdeen Rd.
Altona, Victoria 3018, Australia
Educational Institutions
Berrien County H. S.
500 E. Smith Ave.
Nashville, GA 31639
Blue River Career Programs
801 St. Joseph St.
Shelbyville, IN 46176
Bumgarner Welding & Inspection
89 N. 350 E.
Washington, IN 47501
Center for Employment Training
4153 Market St., Ste. C
San Diego, CA 92102
Coldspring H. S.
PO Box 39
Coldspring, TX 77331
Davidson County C. C.
297 DCCC Rd.
Thomasville, NC 27360
General Technical &
Safety Training Centre Co.
Makkah Stree, Eastern Province
Dammam, Saudi Arabia
Heartland Career Center
79 S. 200 W.
Wabash, IN 46940
Hoosier Hills Career Center
3070 Prow Rd.
Bloomington, IN 47404
Ivy Tech C. C. Industrial
Technology Welding
3100 Ivy Tech Dr.
Valparaiso, IN 46383
Kankaver Valley H. S.
3923 W. State Rd. 10
Wheatfield, IN 46392
Kokomo Area Career Center
2415 S. Berkley Rd.
Kokomo, IN 46902
Lord Fairfax C. C. Workforce Solutions
173 Skirmisher Ln.
Middletown,VA 22645
Southside Virginia C. C.
200 Daniel Rd.
Keysville, VA 23947
Twin Lakes H. S.
300 S. 3rd St.
Monticello, IN 47960
West Central H. S.
1852 S. U.S. Hwy. 421
Francesville, IN 47946
Affiliate Companies
Cleveland Pump Repair & Services
1761 Highland Rd.
Twinsburg, OH 44087
Mackay Manufacturing, Inc.
10011 E. Montgomery Dr.
Spokane, WA 99206
MAF Metal Alloy Fabrication
6060 86 Ave. SE
Calgary, AB T2C4L7, Canada
Metal Arts LLC
1145 S. Gordon
Wichita, KS 67213
Multiplaz North America
1625 17th St., Ste. 5
Santa Monica, CA 90404
Western Industrial Machining
170 Airport Dr., Ste. B
Westminster, MD 21157
Honorary Meritorious Awards
William Irrgang
Memorial Award
This award is given to the individual
who has done the most over the past five
years to enhance the Societys goal of ad-
vancing the science and technology of
welding. It includes a $2500 honorarium
and a certificate.
International Meritorious
Certificate Award
This honor recognizes recipients sig-
nificant contributions to the welding in-
dustry for service to the international
welding community in the broadest terms.
The award consists of a certificate and a
one-year AWS membership.
National Meritorious
Certificate Award
This award recognizes the recipients
counsel, loyalty, and dedication to AWS
affairs, assistance in promoting cordial re-
lations with industry and other organiza-
tions, and for contributions of time and
effort on behalf of the Society.
George E. Willis Award
This award is given to an individual
who promoted the advancement of weld-
ing internationally by fostering coopera-
tive participation in technology transfer,
standards rationalization, and promotion
of industrial goodwill. It includes a $2500
honorarium.
Honorary Membership Award
This award acknowledges eminence
in the welding profession, or one who is
credited with exceptional accomplish-
ments in the development of the welding
art. Honorary Members have full rights
of membership.
The deadline for nominating candidates for these awards is December 31 prior to the year of the awards presentations. Send can-
didate materials to Wendy Sue Reeve, wreeve@aws.org; 550 NW LeJeune Rd., Miami, FL 33126.
Society News JUNE_Layout 1 5/10/12 8:49 AM Page 104
105 WELDING JOURNAL
Guide to AWS Services
550 NW LeJeune Rd., Miami, FL 33126; (800/305) 443-9353; FAX (305) 443-7559; www.aws.org
Staff extensions are shown in parentheses.
AWS PRESIDENT
William A. Rice
brice@oki-bering.com
1411 Connell Rd.
Charleston, WV 25314
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Sr. Associate Executive Director
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
Chief Financial Officer
Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
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)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
Human Resources
Director, Compensation and Benefits
Luisa Hernandez.. luisa@aws.org . . . . . . . . .(266)
Director, Human Resources
Dora A. Shade.. dshade@aws.org . . . . . . . . .(235)
International Institute of Welding
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
GOVERNMENT LIAISON SERVICES
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors fed-
eral issues of importance to the industry.
CONVENTION and EXPOSITIONS
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
Director, Convention and Meeting Services
Selvis Morales.....smorales@aws.org . . . . . .(239)
ITSA International Thermal
Spray Association
Senior Manager and Editor
Kathy Dusa.kathydusa@thermalspray.org . . .(232)
RWMA Resistance Welding
Manufacturing Alliance
Manager
Selvis Morales.....smorales@aws.org . . . . . .(239)
WEMCO Association of
Welding Manufacturers
Manager
Selvis Morales.....smorales@aws.org . . . . . .(239)
Brazing and Soldering
Manufacturers Committee
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
GAWDA Gases and Welding
Distributors Association
Executive Director
John Ospina.. jospina@aws.org . . . . . . . . . .(462)
Operations Manager
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401)
INTERNATIONAL SALES
Managing Director, Global Exposition Sales
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . .(297)
Corporate Director, International Sales
Jeff P. Kamentz..jkamentz@aws.org . . . . . . .(233)
Oversees international business activities involving cer-
tification, publication, and membership.
PUBLICATION SERVICES
Department 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
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Section Web Editor
Henry Chinea...hchinea@aws.org . . . . . . . . .(452)
MEMBER SERVICES
Department 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
Department Information . . . . . . . . . . . . . . . . .(273)
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all inter-
national certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Certification Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification pro-
grams, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Director, Education Development
David Hernandez.. dhernandez@aws.org . . .(219)
AWS AWARDS, FELLOWS, COUNSELORS
Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards, Fellow and Counselor
nominees.
TECHNICAL SERVICES
Department Information . . . . . . . . . . . . . . . . .(340)
Managing Director
Andrew R. Davis.. adavis@aws.org . . . . . . .(466)
International Standards Activities, American Coun-
cil of the International Institute of Welding (IIW)
Director, National Standards Activities
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Manager, Safety and Health
Stephen P. Hedrick.. steveh@aws.org . . . . . .(305)
Metric Practice, Safety and Health, Joining of Plas-
tics and Composites, Welding Iron Castings, Welding
in Sanitary Applications, Personnel and Facilities
Qualification
Senior Manager, Technical Publications
Rosalinda ONeill.. roneill@aws.org . . . . . . .(451)
AWS publishes about 200 documents widely used
throughout the welding industry.
Senior Staff Engineer
Rakesh Gupta.. gupta@aws.org . . . . . . . . . .(301)
Filler Metals and Allied Materials, International Filler
Metals, UNS Numbers Assignment, Arc Welding and
Cutting Processes
Staff Engineers/Standards Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Thermal Spray, Automotive Resistance Welding, Oxy-
fuel Gas Welding and Cutting
Stephen Borrero... sborrero@aws.org . . . . .(334)
Brazing and Soldering, Brazing Filler Metals and
Fluxes, Brazing Handbook, Soldering Handbook,
Railroad Welding, Definitions and Symbols
Alex Diaz.... adiaz@aws.org . . . . . . . . . . . . . .(304)
Welding Qualification, Sheet Metal Welding, Aircraft
and Aerospace, Joining of Metals and Alloys
Brian McGrath .... bmcgrath@aws.org . . . . .(311)
Methods of Inspection, Mechanical Testing of Welds,
Welding in Marine Construction, Piping and Tubing,
Friction Welding, Robotics Welding, High-Energy
Beam Welding
Matthew Rubin.....mrubin@aws.org . . . . . . .(215)
Structural Welding, Machinery and Equipment
Notes: Official interpretations of AWS standards may
be obtained only by sending a request in writing to An-
drew R. Davis, managing director, Technical Services,
adavis@aws.org.
Oral opinions on AWS standards may be ren-
dered, however, oral opinions do not constitute offi-
cial or unofficial opinions or interpretations of AWS.
In addition, oral opinions are informal and should
not be used as a substitute for an official interpreta-
tion.
AWS FOUNDATION, INC.
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
Gerald D. Uttrachi
Executive Director, Foundation
Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Corporate Director, Workforce Development
Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
The AWS Foundation is a not-for-profit corporation es-
tablished to provide support for the educational and scien-
tific endeavors of the American Welding Society.
Promote the Foundations work with your financial sup-
port. Call (800) 443-9353 for information.
Society News JUNE_Layout 1 5/10/12 8:50 AM Page 105
TMI Names President and
Board Chair
The Manufacturing Institute (TMI),
Boca Raton, Fla., has named Jennifer Mc-
Nelly president, succeeding Emily De-
Rocco. McNelly previously served as sen-
ior vice president. Ronald Bullock was
elected chairman of the TMI board of
trustees for a two-year term. Bullock, who
is chairman of Bison Gear & Engineering
Corp. in St. Charles, Ill., succeeds Robert
Ratliff, retired chair, president, and CEO
of AGCO, in this voluntary position.
Airgas Transitions
Leadership
Airgas, Inc., Radnor, Pa., has an-
nounced Airgas founder Peter McCaus-
land will assume the role of executive
chairman of the board of directors, and
Michael L. Molinini, current executive
vice president and COO, will succeed him
as president and CEO. Molinini was also
elected to serve as a company director, ex-
panding the board to eleven directors.
Colfax Makes CEO
Reassignments
Colfax, Fulton, Md., a diversified
global manufacturing and engineering
company, announced that board member
Steven E. Simms has agreed to join the
company on a full-time basis as CEO. Clay
Kiefaber, previously president and CEO,
has been named CEO of the companys re-
cently acquired ESAB business. Kiefaber
will also be an executive vice president of
Colfax and will continue to serve as a Col-
fax director. Simms has 20 years senior ex-
ecutive experience, most recently as exec-
utive vice president at Danaher Corp.
Eriez Fills Two New Posts
Eriez, Erie, Pa., has promoted Jaisen
Kohmuench to the newly created position
deputy managing director, Eriez Flota-
tion division USA. John Blicha has
been appointed to the newly created posi-
tion marketing communications manager.
Kohmuench joined the company ten years
ago as a research engineer, and most re-
cently served as manager R&D Process
Group. Blicha, with 16 years experience,
previously served as director of marketing
at Molded Fiber Glass Tray Co.
BLACOH Fluid Control
Expands Customer Service
BLACOH Fluid Control, Inc., River-
side, Calif., has named Terri Simmons
global customer service manager, and Bill
Bendel technical sales manager. Simmons,
with 20 years of experience in the business,
previously worked at Dover Corp.s sub-
PERSONNEL
JUNE 2012 106
Jaisen Kohmuench John Blicha
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continued on page 108
Personnel June_Layout 1 5/10/12 12:54 PM Page 106
ENERGY INDUSTRY:
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problems and develop solutions for
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Your unique challenges can be solved by some of the most talented researchers in the world. Te National
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elite researchers from four universities could adequately address.
To fnd out more about this free one-day workshop, visit www.aws.org/CIMJSEA or contact program
coordinator Janet Beard at (61) 292-1182.
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sidiary Wilden Pump. Bendel, also with 14
years experience, most recently worked at
McMaster-Carr.
Engineer Hired at
Beckwood Press
Beckwood Press
Co., St. Louis, Mo., a
supplier of hydraulic
press and automated
systems, has named
Dan Frederich tech-
nical support engi-
neer and electrical
controls specialist.
Frederich, with ten
years of experience in
the manufacturing in-
dustry, will also assist with robotic system
integration, control panel layout, and
commissioning of machines.
BHI Energy Appoints COO
BHI Energy, Plymouth, Mass., has
named Jimmy Morgan COO of the com-
panys Power Services division. Morgan,
who also serves as a director of the AWS
Foundation, previously worked for West-
inghouse Electric Corp. for six years in ex-
ecutive management positions, including
vice president of installation and modifi-
cation services, and president of the
wholly owned subsidiary Machining and
Welding, Inc.
Fronius USA Hires Two
Sales Representatives
Fronius USA, LLC, Brighton, Mich.,
has hired Vadim Nakonechnyy and Josh
Campana as sales/application technicians
for its Welding Technology division.
Nakonechnyy, based in Chattanooga,
Tenn., will support the Southeast region.
Campana will work in the Central region,
supporting customers in Wisconsin, Illi-
nois, and parts of Iowa and Missouri.
Moldex Names Sales VP
Moldex-Metric, Culver City, Calif., a
supplier of hearing and respiratory pro-
tection products, has appointed Bill
Schubach vice president sales, North
America. Previously, Schubach served as
director of national accounts.
JUNE 2012 108
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continued from page 106
Web Site Features Welder
Training Videos and Jobs
A new Web site, Online Underwater
Welding Guide, features a collection of
professionally made videos on a variety of
welding topics from the five-min-long
Flux Cored Welding Basics movie to the
Basic MIG Welding program that runs 37
min. The eight-min-long Underwater
Welding video details both wet welding
and dry welding using hyperbaric habitats
and emphasizes the skills welders need to
succeed in the craft. Other videos are ti-
tled Deep Sea Welding, A Day in the Life of
an Underwater Welder, Starting a Fire in the
Water: So You Want to Be an Underwater
Welder in Canada, and Navy Underwater
Welding. The site offers extensive infor-
mation on welder training, schools, blogs,
and job opportunities in underwater cut-
ting, rigging, fitting, and inspection. Un-
derwater welding schools are listed for
California, Canada, Florida, Louisiana,
North Carolina, Texas, and Washington.
The sites many other features include nu-
merous random search terms covering
the entire field of the equipment, train-
ing, and welding diver jobs, some paying
as much as $200,000 per year.
Underwater Welding
www.underwaterweldingguide.org
PRODUCT & PRINT
SPOTLIGHT
continued from page 30
Personnel June_Layout 1 5/10/12 12:54 PM Page 108
welder member_FP_TEMP 5/9/12 7:59 AM Page 109
Entry deadline is July 31, 2012
An Association of Welding Manufacturers
For more information and to submit a nomination form online,
visit www.aws.org/awards/image.html or call 800-443-9353.
The Image of Welding Awards Program recognizes outstanding
achievement in the following categories:

Individual
(you or other individual)

Section
(AWS local chapter)

Large Business
(200 or more employees)

Small Business
(less than 200 employees)

Distributor
(welding products)

Educator
(welding teacher at an institution, facility, etc.)

Educational Facility
(any organization that conducts welding
education or training)

Media
(open to industry and business publications)
Know an individual, company,
educator, or educational
facility that exemplifies what
welding is all about?
Nominate them for the





































































































































































































































































































































































Section

(you or other individual)


Individual

achievement in the following categories:


elding W The Image of

















Educator

(welding products)
Distributor

(you or other individual)


achievement in the following categories:
wards Program recogn AAw elding

















achievement in the following categories:
outstanding wards Program recognizes



















































(less than 200 employees)
Small Business

(200 or more employees)


Large Business

WS local chapter) (A
Section

















(open to industry and business publications)
Media

education or training)
ganization that conducts welding (any or
Educational Facility

(welding teacher at an institution, facility


Educator

(less than 200 employees)


Small Business
(200 or more employees)
Large Business
















(open to industry and business publications)
education or training)
ganization that conducts welding
Educational Facility
, etc.) (welding teacher at an institution, facility






































































































image of weldiing_FP_TEMP 5/9/12 8:37 AM Page 110
THE AMERICAN WELDER
111 WELDING JOURNAL
T
ungsten boasts the highest melt-
ing point of any metal 6192F
(3422C) making it the ideal
option for carrying the welding current
to the arc during the gas tungsten arc
welding (GTAW) process. Its hardness
and high temperature resistance help
ensure a steady arc transfer, while also
preventing the electrode from being con-
sumed during welding, or splitting and
causing contamination of the weld.
There are several types of tungsten
electrodes available for GTA welding,
each providing distinct arc characteris-
tics and current-carrying capacity, and
each of which is best suited for specific
power sources and materials. In accor-
dance with the American Welding
Society (AWS) A5.12 and ISO 6848 stan-
dards, each tungsten electrode features a
specific color code on the tip that identi-
fies its type. Most tungsten electrodes
are available in industry standard
lengths of 7 in. and in a variety of diam-
eters ranging from 0.040 to
5
32 in.
To help ensure the best GTAW per-
formance, welding operators should
always select the proper tungsten elec-
trode for the material and amperage.
They also need to take care to prepare
the tungsten electrode properly. Doing
so ensures the best arc performance and
weld quality, not to mention it can elim-
inate a lot of frustration and potential
rework Fig. 1.
Tips for Preparing and Selecting
Tungsten Electrodes
For the best gas tungsten arc
welding performance, welders
should select the proper tungsten
electrode for the material and
amperage being used
By Joshua Sprinkle
JOSHUA SPRINKLE is regional manager, Weldcraft, Appleton,
Wis., customerservice@weldcraft.com, www.weldcraft.com.
Fig. 1 Selecting the proper tungsten
electrode for the application, as well as
preparing it correctly, can help improve
GTA welding performance and prevent
costly rework and downtime.
Sprinkle AmWeld Feature new_Layout 1 5/10/12 1:08 PM Page 111
2% Ceriated (AWS Classification:
EWCe-2; Color Code: Gray). Because
they offer excellent arc starts, 2% ceriat-
ed tungsten electrodes work well for
welding carbon and stainless steels, nick-
el alloys, and titanium, particularly for
tube and pipe applications, thin sheet
metal work, or delicate parts. These
tungsten electrodes perform best in DC
welding but they can also be used profi-
ciently in AC. They contain a minimum
of 97.30% tungsten and 1.80 to 2.20%
cerium, and when ground to a point can
be used in place of balled pure tungsten
when AC welding on aluminum and pro-
vide approximately 30 to 40% more cur-
rent-carrying capacity.
1.5% Lanthanated (AWS Classification:
EWLa-1.5; Color Code: Gold) and 2%
Lanthanated (AWS Classification: EWLa-
2; Color Code: Blue). Both 1.5 and 2% lan-
thanated tungsten electrodes offer excel-
lent arc starting at low amperages, pro-
vide long electrode life and stability, and
have a low burn-off rate. They also resist
tip wear; however, 2% lanthanated tung-
sten electrodes are widely viewed out of
the two as having superior characteristics.
The 2% lanthanated tungsten electrodes
are often used in critical applications,
such as in the aviation industry, and can
be used to replace 2% thoriated tungsten
electrodes. Both electrodes are well suit-
ed to welding carbon steel, stainless steel,
nickel alloys, titanium, and aluminum.
The 1.5% lanthanated tungsten elec-
trodes contain a minimum of 97.80%
tungsten and 1.301.70% lanthanum,
while the 2% lanthanated type contains
97.3% tungsten and 1.82.2% lanthanum.
Both tungsten electrodes work well
on AC or DC electrode negative when
they have been prepared with a pointed
end, and because they can maintain that
point, they are also good for DC welding
steel and stainless steel.
These electrodes are suitable for AC
welding and, like ceriated electrodes,
allow the arc to be started and main-
tained at lower voltages. They can also
be balled for use with AC sine wave
power sources.
Pure Tungsten (AWS Classification:
EWP; Color Code: Green). Pure tung-
sten electrodes contain 99.50% tungsten
and are typically less expensive than
their alloyed counterparts. They offer
especially good arc stability for AC weld-
THE AMERICAN WELDER
JUNE 2012 112
Fig. 2 These figures demonstrate
how to prepare tungsten electrodes
for DC electrode negative welding
and AC welding with wave shaping
power sources.
Sprinkle AmWeld Feature new_Layout 1 5/10/12 1:08 PM Page 112
THE AMERICAN WELDER
113 WELDING JOURNAL
ing with a balanced waveform and pro-
vide a clean, balled tip when heated.
Pure tungsten electrodes also provide
good arc stability for AC sine wave weld-
ing on aluminum and magnesium, but
should not be used with inverter-based
power sources or for DC welding.
Rare Earth (AWS Classification:
EWG; Color Code: Varies per manufac-
turer). Rare earth tungsten electrodes
contain a combination of alloying ele-
ments, including cerium, lanthanum, and
yttrium. As a rule, rare earth tungsten
electrodes provide excellent arc stability
for both AC and DC processes, and tend
to last longer than thoriated tungsten.
These electrodes also do a good job at
resisting splitting and allow welding
operators to use a smaller diameter size
than when welding with other types of
tungsten electrodes. They are an excel-
lent choice in machine torch applications
where voltage (i.e., tungsten spacing
from workpiece) is consistent and weld
time (duty cycle) is long.
2% Thoriated (AWS Classification:
EWTh-2; Color Code: Red). The 2% tho-
riated tungsten electrodes offer good arc
starts and provide a high current-
carrying capacity. They contain a mini-
mum of 97.30% tungsten and 1.70 to
2.20% thorium, and have a low rate of
consumption, which helps minimize arc
wandering and reduces the chance of
weld contamination. These 2% thoriated
tungsten electrodes can be used for AC
welding, but they excel in DC electrode
negative (straight polarity) GTAW on
carbon and stainless steel, nickel, and
titanium.
Welding operators should note that
2% thoriated tungsten electrodes con-
tain low levels of radioactivity.
Therefore, they must always follow man-
ufacturers warnings, instructions, and
the Material Safety Data Sheet (MSDS)
for their use.
Zirconiated (AWS Classification:
EWZr-1; Color Code: Brown).
Zirconiated tungsten electrodes work
well for welding aluminum and magne-
sium. They contain 98.6% tungsten and
0.70.9% zirconium and are known for
their ability to ball up easily in AC appli-
cations. Zirconiated tungsten electrodes
are typically able to handle higher cur-
rent loads than other types of tungsten
electrodes, without splitting. For this
reason, they also tend to cause minimal
tungsten contamination. They are also
known for providing good arc stability
and reliable arc starts.
Proper Tungsten
Preparation
Depending on the type of tungsten
electrode, preparation consists of creat-
ing one of three shapes: balled, pointed,
or truncated. Following are recommen-
dations for each.
Balled Tungsten Electrodes
The balled shape is common for pure
tungsten electrodes, particularly for the
AC process on sine wave and conven-
tional square wave GTAW power
sources. To ball the tungsten electrode,
apply the AC amperage recommended
for the electrode diameter. The ball will
form itself. In order to reduce the risk of
the tip falling off or causing arc instabil-
ity, the diameter of the balled end
should not exceed 1.5 times the diameter
of the electrode. For example, a
1
8-in.
electrode should form, at the most, a
3
16-
in.-diameter end.
Pointed Tungsten Electrodes
A pointed shape can be used for pure,
ceriated, lanthanated, rare earth, and
thoriated tungsten electrodes when
using inverter AC and DC welding
processes. It also works well for welding
with lower currents on thinner materials,
as it directs the welding current into a
focused arc and helps prevent them from
distorting. It is not recommended to use
a pointed tungsten electrode for higher-
current applications since the tip can
come off, leading to contamination.
To grind the tungsten electrode to a
point, use a grinding wheel (Borazon
or diamond) specially designated for the
purpose of helping to prevent contami-
nation. Grind the tungsten electrode
straight on the wheel (i.e., not at a 90-
deg angle) to ensure that the grind
marks run the length of the tungsten
electrode, which reduces ridges that can
lead to arc wandering Fig. 2. To ease
arc starting and ensure a focused arc,
grind the taper to a distance of no more
than 2.5 times the electrode diameter
(e.g., the taper on a
1
8-in. tungsten elec-
trode should be
1
4
5
16 in. long). Tungsten
grinding can also be completed with a
special tungsten grinder.
Note: when grinding thoriated tung-
sten electrodes, make sure to control
and collect the dust, have an adequate
ventilation system at the grinding sta-
tion, and follow manufacturers warn-
ings, instructions, and MSDS.
Truncated Tungsten
Electrodes
For higher current applications, a
truncated or flat tip works well. The flat
land helps prevent the tungsten elec-
trode from being transferred across the
arc and/or from balling. Start by grinding
the tungsten electrode to a taper (as
explained above) and then grind a 0.010-
to 0.030-in. flat land on the end.
Conclusion
Selecting the right tungsten electrode
for the material being welded and the
power source available is a good first
step in ensuring positive gas tungsten arc
welding performance. Take the time to
learn which is best for the application at
hand and learn the proper technique for
preparation. Doing so can minimize
problems with arc starting, stability, and
contamination.
To help ensure the
best GTAW
performance,
welding operators
should always
select the proper
tungsten electrode
for the material
and amperage.
Sprinkle AmWeld Feature new_Layout 1 5/10/12 1:08 PM Page 113
general corporate_FP_TEMP 5/9/12 7:58 AM Page 114
W
hen Michael Krupnicki decid-
ed last spring to pursue his
dream of creating a welding,
glass, and blacksmithing center, he could
only imagine just how festive the outlet
would turn out.
As the president of Mahany Welding
Supply Co., Inc., Rochester, N.Y.,
Krupnicki wanted to add courses at a
new location that offered a broad appeal
but still involved heat see lead photo.
He had taught welding programs at
the companys distribution facility for
nine years and felt the time had come to
expand. Continuing to hold various
welding courses at a new venue along
with glass and blacksmithing seemed like
a good fit.
People had been commenting for
years that they wished there was a high-
quality glass art training facility in the
local area. In addition, the local black-
smith organization needed a new home
for its activities. It just made sense to
design and create a purpose-built facility
for all three activities, Krupnicki said.
Building a Multipurpose
Training Ground
Construction of the Rochester Arc &
Flame Center, located just east of
Mahany Welding Supply, started last
August. The site is on property the com-
pany acquired when land for its welding
training facility was purchased in 2000.
THE AMERICAN WELDER
115 WELDING JOURNAL
Unleash Your Inner Creativity:
Explore Industrial Arts
Michael Krupnicki, executive
director of the Rochester Arc &
Flame Center, Rochester, N.Y.,
takes control while working with
a borosilicate glass tube. He
also teaches welded metal
sculpture at the facility.
BY KRISTIN CAMPBELL (kcampbell@aws.org) is associate editor of the Welding Journal.
A new facility in upstate New York offers students
courses in welding, the glass arts, and blacksmithing
Campbell AW Article June 2012_Layout 1 5/10/12 4:29 PM Page 115
THE AMERICAN WELDER
JUNE 2012 116
Planning the new welding lab was
fairly easy, since we had nine years of
learning what worked and what didnt.
Planning the glass and blacksmithing
space was more of a challenge since I
had no experience in either field,
Krupnicki said.
Fortunately, he had assistance in
designing the flameworking studio. The
New York State Designer Blacksmith
Association, Genesee Region, also
accepted his invitation to be their new
host.
Our suppliers loved what we were
doing and provided a tremendous
amount of help with new equipment,
Krupnicki added.
The 5000-sq-ft center includes differ-
ent training areas and an art gallery
entrance with metal and glass objects
made by its instructors Fig. 1.
A ribbon-cutting ceremony was held
in early January, followed by a public
open house. Classes started shortly after
that.
News of the facility has spread like
wildfire throughout the local art commu-
nity, Krupnicki said.
Hands-on Courses Allow
Learning Various Trades
The center offers numerous introduc-
tory, intermediate, advanced, and pro-
fessional programs.
All costs, including safety gear, class
materials, and consumables, are covered
in the course price. The 3-h samplers run
$75; full-day workshops, $150; night
courses, $240$450; and the companys
360-h job readiness program with
Monroe Community College is $6500.
New events include couples date
night sessions, kids workshops, and 4-h
corporate team-building gatherings.
A cornerstone of my philosophy in
providing public training is to offer a
variety of courses, with a variety of dura-
tions, and a variety of price ranges,
Krupnicki said.
Also, projects vary depending on the
course, but every student leaves with
something they made.
Welding Details
The center has courses available in
gas metal arc welding (GMAW), shield-
ed metal arc welding (SMAW), gas tung-
Fig. 1 The Rochester Arc
& Flame Center features
many welding, glass, and
blacksmithing courses to ac-
commodate all skill levels.
Fig. 2 The center pro-
vides training in various
welding processes, includ-
ing gas tungsten arc weld-
ing, as shown.
Fig. 3 Held in January, the centers
first gas metal arc welding workshop at-
tracted 14 students.
1 2
Campbell AW Article June 2012_Layout 1 5/10/12 4:29 PM Page 116
THE AMERICAN WELDER
117 WELDING JOURNAL
sten arc welding (GTAW), oxyfuel and
plasma cutting, and metal sculpture
Figs. 2, 3.
Kevin J. Adair, an American Welding
Society Certified Welding Inspector,
serves as the centers welding director.
Richard Battaglia, Richard Belair,
Kate Cosden, Andrew Krupnicki, Jake
Martin, Tom McGarry, Willie Shoemaker,
and Ross Temple also provide welding
instruction.
The welding shop has 16 booths.
Each station contains a new GMAW,
GTAW, and SMAW machine. Other
equipment includes plasma cutting
machines; CNC plasma table; ironwork-
ing device; band and abrasive chop saws;
grinding and measuring tools; and
clamps.
Creative students have fabricated
metal sculptures such as hexagon shapes
welded together as abstract art, small
bracket-shaped pieces tacked in a long
spiral design, and a miniature building
Fig. 4.
Glass Art Highlights
Instruction is provided in both soft
and borosilicate glass, fusing and slump-
ing, cold working, and kiln casting for
beginners through a master level.
Artist Milon Townsend, the centers
glass director, helped develop those pro-
grams. Craig Iamon and Marusca
Ciccarelli Gatto teach glass courses as
well.
The flameworking studio contains a
large table that seats 10 students; 2 addi-
tional private flameworking stations;
more than 40 torches; large supply of
glass and related tools for sale to stu-
dents; access to the welding shop for
stands, displays, and fixtures; and sever-
al annealing kilns.
The kiln/cold shop has many kilns for
fusing and slumping, plus grinding, dia-
mond polishing, and other hand tools.
Employing techniques, whether it is
using a torch to melt and shape a large
piece of glass or cutting small glass
Fig. 4 A metal sculpture recently fabricated during a class in conjunction with the
Rochester Institute of Technology features several hexagon shapes welded together
in an abstract design.
Fig. 5 Artist Milon Townsend, the centers glass director, created this black and white owl using borosilicate glass. The other
image depicts glass jewelry pendants along with picture frames and a night light made by students.
Campbell AW Article June 2012_Layout 1 5/10/12 4:29 PM Page 117
THE AMERICAN WELDER
JUNE 2012 118
pieces and arranging them to be fused,
forms unique creations. This includes
animal and human figures, picture
frames, jewelry, suncatchers, and night
lights in various designs with an array of
color options Fig. 5.
Blacksmithing Work
The smithing division features black-
smithing, bladesmithing, and copper-
smithing programs Fig. 6. Soon, tin-
smithing will be offered.
Candace Martens, president of the
New York State Designer Blacksmiths
and now the centers blacksmithing
director, rallied her colleagues to move
their equipment into the facility.
Additional instructors include William
Banker, John Fee, Brian Martens, Mike
Nelson, John Rausch, Richard
Rightmyer, Robert Trout, Harry Heur,
Mike Houser, Henry Offerman, and
Richard Renker.
The blacksmithing shop holds five
coal-fired forges; three propane-fired
forges; an array of anvils, vises, and belt
grinding devices; plus assorted hand
tools.
Forging individual pieces by heating
them until malleable, then using tools
for shaping, create items such as metal
flowers, large hooks, knife blades, plant
hangers, and pizza cutters Fig. 7.
Coming Back for More
In the centers first three months of
existence, it has welcomed 190 welding
students, 80 glassblowing students, and
43 blacksmithing students.
Taking a course will usually pique
interest in pursuing another track.
Historically, more than 30% of our
welding students would come back and
take additional classes. Now, we are see-
ing our welding students coming back for
blacksmithing, blacksmiths taking weld-
ing, and strong interest from all the met-
als students to try glass, Krupnicki said.
A few students enjoyed welding so
much they decided to pursue the trade as
a career. They enrolled in the companys
vocational training program, which cur-
rently has record enrollment with gradu-
ates obtaining good-paying jobs at local
companies in need of qualified welders.
Future Goals
Looking ahead, Krupnicki hopes the
new center succeeds financially so it can
stay vibrant, keep up-to-date equipment
and supplies, and retain instructors.
But I didnt create it for the possible
financial return on investment, he said.
I created it to give people of all walks of
life the opportunity to release their
inner fire and explore the flame arts in a
first-class studio.
This fall, the center is looking for-
ward to hosting Boy Scouts so they can
learn techniques to earn the new
Welding Merit Badge.
Also, the center would like to obtain
leading guest instructors from around
the nation to deliver relevant programs.
If the business model is successful,
we will look to franchise the concept in
other cities, Krupnicki said.
Fig. 6 A student exhibits a black-
smithing technique known as fullering to
create a metal leaf.
Fig. 7 Artist Keith Price used his
blacksmithing skills to make this flower.
All photos courtesy of the Rochester
Arc & Flame Center (www.rocafc.com),
Rochester, N.Y.
Campbell AW Article June 2012_Layout 1 5/10/12 4:29 PM Page 118
June 1213, 2012 / San Diego
AWS Conference on
The Energy Boom:
Get on the Bandwagon
Welding and Cladding in the Expanding Energy Markets
The demands for new and improved welding technology from the expanding energy
markets are starting to pay off in the development of superior hybrid welding processes,
new filler metals, and a host of cladding procedures. Much of this new welding technology
will be discussed at the AWS Energy II Welding Conference on June 12-13, in San Diego.
The technologies are showing up in nuclear power plants, in coal-fired utilities, and especially
in the new 1,700-mile-long pipelines designed to bring oil and natural gas to American markets.
On the agenda will be talks on Lincoln Electrics new laser hot wire cladding process and the ICE
process from ESAB in Sweden, which is intended for wind power fabrication. Other topics will include
the successes of the new P87 filler metal, the variety of applications for explosive welding, and from
Edison Welding Institute, a close look at the less expensive plasma/MIG hybrid welding process.
Earn PDHs toward your AWS recertification when you attend the conference.
For the latest conference information and registration, visit our web site
at www.aws.org/conferences or call (800) 443-9353, ext. 264.
in the new 1,700-mile-long pipelines designed to bring oil and natural gas to
The technologies are showing up in nuclear power plants, in coal-fired utilities, and especially
will be discussed at the
new filler metals, and a host of cladding procedures. Much of this new welding technology
markets are starting to pay of
The demands for new and improved welding technology from the expanding energy
elding and Cladding in the Expanding Energy Markets W

in the new 1,700-mile-long pipelines designed to bring oil and natural gas to
The technologies are showing up in nuclear power plants, in coal-fired utilities, and especially
WS Energy II W A will be discussed at the
new filler metals, and a host of cladding procedures. Much of this new welding technology
f in the de arting to pay offf
The demands for new and improved welding technology from the expanding energy
elding and Cladding in the Expanding Energy Markets

in the new 1,700-mile-long pipelines designed to bring oil and natural gas to
The technologies are showing up in nuclear power plants, in coal-fired utilities, and especially
elding Conference on We
new filler metals, and a host of cladding procedures. Much of this new welding technology
f in the development of superior hybrid welding processes,
The demands for new and improved welding technology from the expanding energy
elding and Cladding in the Expanding Energy Markets

American markets. in the new 1,700-mile-long pipelines designed to bring oil and natural gas to
The technologies are showing up in nuclear power plants, in coal-fired utilities, and especially
elding Conference on June 12-13, in San Diego.
new filler metals, and a host of cladding procedures. Much of this new welding technology
f in the development of superior hybrid welding processes,
The demands for new and improved welding technology from the expanding energy

American markets.
The technologies are showing up in nuclear power plants, in coal-fired utilities, and especially
elding Conference on June 12-13, in San Diego.
new filler metals, and a host of cladding procedures. Much of this new welding technology
f in the development of superior hybrid welding processes,

Earn PDHs toward your
elding Edison We
the successes of the new P87 filler metal, the variety of applications for explosive welding, and from
process from ESAB in Sweden, which is intended for wind power fabrication. Other topics will include
On the agenda will be talks on Lincoln Electric
in the new 1,700-mile-long pipelines designed to bring oil and natural gas to

WS recertification when you attend the conference A Earn PDHs toward your
elding Institute, a close look at the less expensive plasma/MIG hybrid welding process.
the successes of the new P87 filler metal, the variety of applications for explosive welding, and from
process from ESAB in Sweden, which is intended for wind power fabrication. Other topics will include
On the agenda will be talks on Lincoln Electric
in the new 1,700-mile-long pipelines designed to bring oil and natural gas to

WS recertification when you attend the conference
elding Institute, a close look at the less expensive plasma/MIG hybrid welding process.
the successes of the new P87 filler metal, the variety of applications for explosive welding, and from
process from ESAB in Sweden, which is intended for wind power fabrication. Other topics will include
s new laser hot wire cladding process and the ICE On the agenda will be talks on Lincoln Electric
in the new 1,700-mile-long pipelines designed to bring oil and natural gas to

WS recertification when you attend the conference
elding Institute, a close look at the less expensive plasma/MIG hybrid welding process.
the successes of the new P87 filler metal, the variety of applications for explosive welding, and from
process from ESAB in Sweden, which is intended for wind power fabrication. Other topics will include
s new laser hot wire cladding process and the ICE
American markets. in the new 1,700-mile-long pipelines designed to bring oil and natural gas to

. WS recertification when you attend the conference
elding Institute, a close look at the less expensive plasma/MIG hybrid welding process.
the successes of the new P87 filler metal, the variety of applications for explosive welding, and from
process from ESAB in Sweden, which is intended for wind power fabrication. Other topics will include
s new laser hot wire cladding process and the ICE
American markets.

For the latest conference information and registration, visit our web site
.aws.org/conferences or call (800) 443-9353, ext. 264. at www
For the latest conference information and registration, visit our web site
.aws.org/conferences or call (800) 443-9353, ext. 264.
For the latest conference information and registration, visit our web site
.aws.org/conferences or call (800) 443-9353, ext. 264.
For the latest conference information and registration, visit our web site

energy conf_FP_TEMP 5/9/12 8:28 AM Page 109
www.AmericanWeldingOnline.com
Online Welding Safety Certificate Course
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Three-hour self-paced course covers electric shock, vision and skin protection,
ventilation, fire protection, handling of gases, and much more.
Sample seminar at awo.aws.org/seminars/safety
OSHAestimates that
4 out of every 1,000
welders will
experience a fatal
injury or accident over
their working lifetime
Online W g Safety Certificate Course eldin Online W g Safety Certificate Course
injury or accident over
experience a fatal
welders will
4 out of every 1,000
estimates that OSHA
g Safety Certificate Course g Safety Certificate Course
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
their working lifetime
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
their working lifetime
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
their working lifetime
injury or accident over
their working lifetime
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Sample seminar at awo.aws.org/seminars/safety Sample seminar at awo.aws.org/seminars/safety Sample seminar at awo.aws.org/seminars/safety
awo safety_FP_TEMP 5/9/12 2:55 PM Page 120
THE AMERICAN WELDER
121 WELDING JOURNAL
In early March, 24 Boy Scouts earned the new merit badge
for welding at the Business & Technology Center of
Metropolitan Community College (MCC-BT), Kansas City,
Mo. It is believed these scouts from Kansas Citys urban core
became the first in the country to earn the new badge Figs.
15.
The Scouts, who are between the ages of 14 and 17, earned
their badges under the supervision of the MCC-BT faculty,
American Welding Society members, and Scout leaders. The
Scouts are members of the Heart of America Council, which
serves 19 counties in and around the Kansas City metropolitan
area.
In April, nine Scouts from the Mohegan Council, Worcester,
Mass., and two from the Nashua Valley Council, Leominster,
Mass., also earned the badge. The group included Venturing
crew member Christina Fallavollita, making her most likely the
first young woman nationwide to receive the badge Fig. 6.
Venturing is a Boy Scouts of America (BSA) program open to
both young men and women from ages 13 to 21.
The Welding merit badge is part of the BSAs new science,
technology, engineering, and math (S.T.E.M.) curriculum,
which is designed to help Scouts develop critical skills that are
relevant and necessary in todays competitive world. It is the
latest in a new group of career-oriented merit badges the BSA
is offering. The requirements the Scouts must meet to receive
the badge can be found on page 123.
When the new badge was announced, Janice Downey, BSA
senior innovation manager, said, Welding is such an important
part of our nations growth and stability. The Welding merit
badge is a good fit with preparing Scouts for their future and
offers them a fun way to explore skills that can grow into a
hobby or career. Their new skill may even be helpful for mak-
ing or repairing items for their troop.
The Welding merit badge is one of about 130 options Scouts
can choose from. Scouts earn merit badges in order to advance
through the organizations ranks, with 21 needed to achieve the
rank of Eagle Scout.
Groups of Boy Scouts
in Missouri and
Massachusetts were
among the first to
earn the new Welding
merit badge
Scouts Move from the
Campground to the Welding Lab
The Boy Scouts of Americas Welding merit badge.
Johnsen Feature June 2012_Layout 1 5/9/12 1:33 PM Page 121
THE AMERICAN WELDER
JUNE 2012 122
Fig. 1 The 24 Missouri Scouts who
became the first in the country to earn
the Welding merit badge.
Fig. 2 AWS Vice President Dave
Landon provided instruction to the Mis-
souri Scouts on some of the basic weld-
ing processes, safety requirements,
and careers in welding.
Fig. 3 The Scouts received a lesson
in welding safety from MCC-BT Weld-
ing Coordinator Tim Gill.
Fig. 4 AWS District 16 Director Den-
nis Wright watches one of the Scouts
practice his gas metal arc welding
skills.
Fig. 5 The Scouts were required to
weld their initials. Here Tyler Lager-
mann shows off his plate.
Acknowledgments Figures 15 were provided courtesy of Alex Grigsby, campus communica-
tions coordinator, MCC-BT. Figure 6 is courtesy of Lisa Fallavollita.
Fig. 6 Eleven Massachusetts Scouts earned the Welding merit badge in April.
Front row from left: Justin Mahan, Patrick McKeon, Christina Fallavollita, David Dor-
man. Back row: Matt Barakian, Ed Eubank, Chris Gannon, Andy Meindersma, Nolan
Guathier, Ed Salate, Joel Sylvester. Not pictured: Ben Pierce.
1 2 5
3 4
Johnsen Feature June 2012_Layout 1 5/9/12 1:33 PM Page 122
THE AMERICAN WELDER
123 WELDING JOURNAL
How to Earn the Boy Scouts Welding Merit Badge
The requirements for the Boy Scouts Welding Merit Badge can be found on the organizations
Web site at www.scouting.org. They are quoted below.
1. Do the following:
a. Explain to your counselor the hazards you are most likely to encounter while welding, and what
you should do to anticipate, help prevent, mitigate, or lessen these hazards.
b. Show that you know first aid for, and the prevention of, injuries or illnesses that could occur
while welding, including electrical shock, eye injuries, burns, fume inhalation, dizziness, skin ir-
ritation, and exposure to hazardous chemicals, including filler metals and welding gases.
2. Do the following:
a. With your counselor, discuss general safety precautions and Material Safety Data Sheets
(MSDS) related to welding. Explain the importance of the MSDS.
b. Describe the appropriate safety gear and clothing that must be worn when welding. Then, pres-
ent yourself properly dressed for welding in protective equipment, clothing, and footwear.
c. Explain and demonstrate the proper care and storage of welding equipment, tools, and protec-
tive clothing and footwear.
3. Explain the terms welding, electrode, slag, and oxidation. Describe the welding process, how
heat is generated, what kind of filler metal is added (if any), and what protects the molten metal
from the atmosphere.
4. Name the different mechanical and thermal cutting methods. Choose one method and describe
how to use the process. Discuss one advantage and one limitation of this process.
5. Do the following:
a. Select two welding processes, and make a list of the different components of the equipment re-
quired for each process. Discuss one advantage and one limitation for each process.
b. Choose one welding process. Set up the process you have chosen, including gas regulators,
work clamps, cables, filler materials, and equipment settings. Have your counselor inspect and
approve the area for the welding process you have chosen.
6. After successfully completing requirements 1 through 5, use the equipment you prepared for
the welding process in 5b to do the following:
a. Using a metal scribe or soapstone, sketch your initial onto a metal plate, and weld a bead on
the plate following the pattern of your initial.
b. Cover a small plate (approximately 3 in. 3 in. in.) with weld beads side by side.
c. Tack two plates together in a square groove butt joint.
d. Weld the two plates together from 6c on both sides.
e. Tack two plates together in a T joint, have your counselor inspect it, then weld a T joint with
fillet weld on both sides.
f. Tack two plates together in a lap joint, have your counselor inspect it, then weld a lap joint with
fillet weld on both sides.
7. Do the following:
a. Find out about three career opportunities in the welding industry. Pick one and find out the
education, training, and experience required for this profession. Discuss this with your coun-
selor, and explain why the profession might interest you.
b. Discuss the role of the American Welding Society in the welding profession.
Johnsen Feature June 2012_Layout 1 5/9/12 1:34 PM Page 123
THE AMERICAN WELDER
LEARNING TRACK
JUNE 2012 124
The primary goal of the College of
Southern Idahos (CSIs) welding pro-
gram is to prepare students for success-
ful careers in the rapidly expanding field
of welding and fabrication. The curricu-
lum is designed to meet the current
needs of business and industry. Faculty
members are selected on the basis of
successful work experience as well as
teaching qualifications, and the instruc-
tion takes place in small classes to
encourage students full participation.
Evening classes have maintained good
attendance levels. Many local companies
send their personnel there for training.
The spacious 300-acre Twin Falls campus
offers many recreational and education-
al attractions, including a 50-ft dome
planetarium, the largest facility of its
kind in the state.
Welding Training Pathways
The welding program has undergone
significant changes over the past four
years that have resulted in an updated
curriculum, new faculty and staff, new
equipment, and an expanded welding lab
featuring 31 welding booths, 15 roll-
around stations, and new automation
features added to enhance safety.
Terry Patterson, CSI Trade and
Industry Department chair (Fig. 1),
explained, We have two primary path-
ways that students can choose for their
education: A technical certificate, which
is generally around a one-year program;
and a two-year Associate of Applied
Science degree offering. We also have
some options for students if they want to
go to work immediately with a postsec-
ondary certificate.
College of Southern Idaho Offers a
Unique Welder Training Experience
HOWARD M. WOODWARD
(woodward@aws.org) is associate editor
of the Welding Journal.
Fig. 1 A recent College of Southern Idaho welding class is shown with faculty members (front row, from left) Lab Assistant Cody
Thornton, Instructor Juan Martinez, Trade and Industry Department Chair Terry Patterson, and Instructor Kent Parish.
BY HOWARD M. WOODWARD
Expanded facilities and smaller classes deliver an
improved training environment
2 College of Southern Idaho 6-2012_Layout 1 5/10/12 12:52 PM Page 124
THE AMERICAN WELDER
125 WELDING JOURNAL
The SENSE Program
The CSI welding program is in com-
plete alignment with the American
Welding Societys Schools Excelling
through National Skills Standards
Education (SENSE) program, which
offers students an industry-recognized
credential accepted worldwide. The
SENSE program was developed by AWS
to create a benchmark of competencies
for training facilities to follow.
The college has been utilizing SENSE
training for three years, and the results
have been excellent. Previously, CSI
graduates left the welding program with
good welding skills. Now, in addition to
developing good welding skills, they are
prepared with knowledge of blueprint
reading, weld testing and inspection, and
have greater confidence in their abilities
to function and excel in this challenging
field.
Program Details
The program begins with basic intro-
ductions and continues on to each area
of welding, including gas tungsten arc
welding (GTAW), gas metal arc welding
(GMAW), flux cored arc welding
(FCAW), and shielded metal arc welding
(SMAW) of plate and pipe, and thermal
cutting processes. Testing and welding
qualifications are made available to
qualified students. As technological and
interpersonal skills are also essential to
success in the welding field, additional
courses are required in the areas of com-
munications, computer applications,
mathematics, leadership, supervision,
and professional development skills.
Fig. 3 Student Freddy Lopez said,
Its really a hands-on experience and
we do a little bit of everything here.
Lopez has already decided to pursue a
career in the sanitary welding field.
Fig. 2 Welding students Kendon
Freeman (left) and Shay Capson are
progressing well with their gravity car
project. Freemans goal is to become
AWS certified so he will qualify for
better-paying jobs.
LEARNING TRACK
2 College of Southern Idaho 6-2012_Layout 1 5/10/12 12:52 PM Page 125
THE AMERICAN WELDER
JUNE 2012 126
Welding Technology students are
introduced to blueprint reading, indus-
trial safety, applied leadership, metal-
lurgy, machining operations, welding
procedures, material management, first-
aid and CPR, ornamental iron work,
and metal forging (Figs. 2, 3). The per-
sonal assets necessary to succeed in this
program are a desire to work with metal
and be a part of a team; and possess
good hand-eye coordination and prob-
lem-solving skills.
Welding Personnel
The welding course instructors
include Associate Professors Kent
Parish and Juan Martinez (Figs. 4, 5),
both AWS Certified Welding Inspectors.
Certified Welding Educators, and both
possessing 25 years experience in indus-
try. Parish has four years of teaching
experience at CSI and Martinez has one
year teaching experience at CSI and
ten years teaching at Boise State
Universitys Selland College. Cody
Thornton (Fig. 1), a graduate of the col-
leges Applied Science Welding and
Metal Fabrication program and a
Certified Welder, serves as lab assistant.
Martinez said, We have to respond,
and we do respond very well to the
changing technical requirements for the
welding field. The college is strategical-
ly placed regionally near oil fields,
mines, and wind power. There are some
very, very lucrative opportunities com-
ing up for students who successfully
complete our program. Especially in the
wind-generation and energy areas.
Martinez and his students recently
visited a welding engineering facility
designing precision planetary probes.
LEARNING TRACK
Fig. 4 Instructor Kent Parish (left)
and a student review the fine points of
weld inspection.
Fig. 5 Instructor Juan Martinez
(right) works with Daniel McCrorey in
the College of Southern Idaho welding
lab.
2 College of Southern Idaho 6-2012_Layout 1 5/10/12 12:52 PM Page 126
THE AMERICAN WELDER
127 WELDING JOURNAL
He said, Most of these students are
hardworking blue-collar students with
farm and agriculture backgrounds. Why
not aspire to be a NASA welding engi-
neer? Why not aspire to weld underwa-
ter in exotic locations? We have to pro-
vide our students every opportunity to
be successful. Welding is not just build-
ing bridges and buildings, its a whole art
culture.
Parish noted, What we have in the
CSI welding program that a lot of the
academic programs dont have is that we
know our students inside and out. We
know their personal lives and the little
glitches theyve had to deal with. We
have them in here a minimum of 20
hours a week. We know and care about
our students.
Our students are involved in the
community. We have built targets for a
local gun club, weve built rolling chairs
for a young man who was paralyzed over-
seas in Iraq who wants to compete in the
Paraplegic Olympics, and we have helped
to design a mono-ski thats being used in
Sun Valley to help injured veterans.
Welding Program Outlook
Gerald Beck, CSI president said,
Welding was one of the first profession-
al technical programs here at the
College of Southern Idaho. And no mat-
ter what the economy has done, welding
has always pulled through with good
placement, and good numbers of stu-
dents wanting to take welding. The job
selection of where they go across the
United States and out onto drilling rigs,
underground, and everything else they
do is just an exciting thing to witness.
(CSI) students are able to get a lot
of field experience as well as what they
do actually at the college. Each year sev-
eral of the welding students put together
various art projects that go up for sale.
We have quite a community following.
I think welding will continue to grow
in the west. Therefore, I think that the
program has a very positive future.
I see welding students coming back
10, 15, 20 years after they graduated
wanting to know where their teacher is.
The same thing with the teachers, out
looking at where their students have
gone and how well they've done in the
industry. Are they foremen, have they
moved into management? Its exciting to
see there is such a bond between our stu-
dents and the teachers. Welding is one
program that definitely develops that
bond.
Outreach Training Facilities
Technology Dean Todd Schwarz
noted, We now have the equipment to
do mobile training, to actually reach out
and do custom training for business and
industry and maybe even get into some
high schools. Relationships we have with
industry and our secondary partners are
better than theyve been in the last ten
years. The trajectory for the quality of
the programs has been on a pretty steep
upslope and I really dont see that slow-
ing down any time soon. We really want-
ed to set ourselves apart and we're get-
ting very close to being there.
Patterson added, Through a grant,
we were able to put together a mobile
welding trailer so that we can take our
techniques and equipment out to high
schools and to industry and basically
take the lab to their doorsteps. Thats
something that will be starting this year.
If you pay attention to the labor market,
statistics as far as jobs and the baby
boomers retiring, theres going to be a
shortage of skilled technical people,
specifically in the welding industry. No
question about it.
The Important Other Stuff
The all-important questions about
gaining a college education are readily
answered in the college catalog available
online. Included are answers to tuition,
housing, and other expenses, class
schedules, on-campus athletics, local
attractions, library facilities, as well as
how to apply for tuition assistance from
scholarships, grants, and loans. Visit the
CSI Web site (www.csi.edu) to download
the catalog, take a virtual tour of the
campus, and request a Spend a Day
with Us personalized tour of the cam-
pus to meet the faculty and staff and
have all of your questions answered in
person.
College of Southern Idaho
www.csi.edu; info@csi.edu
315 Falls Ave., PO Box 1238
Twin Falls, ID 83303-1238
(208) 733-9554
(800) 680-0274 (Idaho and Nevada)
Contacts:
Terry Patterson (208) 732-6402
CSI Trade and Industry Office
(208) 732-6300
LEARNING TRACK
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2 College of Southern Idaho 6-2012_Layout 1 5/10/12 12:53 PM Page 127
THE AMERICAN WELDER
JUNE 2012 128
FACT SHEET
Power sources deliver output current
and voltage with the electrical character-
istics that make arc welding possible. For
shielded metal arc welding (SMAW)
(Fig. 1), two types of power sources are
used: static machines that convert the
energy supplied by electric power com-
panies and motor generators that com-
bust fuel (chemical energy). The selec-
tion of a power source is the most impor-
tant and most expensive element of the
welding electrical circuit and is the first
consideration in implementing the
SMAW process.
When selecting a power source for
SMAW, the following factors should be
considered:
Type of welding current required
Output characteristics of the power
source
Amperage range required
Positions in which welding will be done
Primary type of power available at the
workstation.
The selection of the type of current
alternating current (AC), direct current
(DC), or both is based largely on the
kind of welds to be made and on the types
of electrodes that are suitable for use. For
AC welding, a transformer or an alter-
ator-type power source can be used. For
DC welding, the choice is between a
transformer-rectifier or motor-generator
power source. When both AC and DC are
to be used, a single-phase transformer-
rectifier or an alternator-rectifier can be
used. Otherwise, two welding machines
are required, one for AC and one for DC.
Either AC or DC can be used for
SMAW. The specific type of current and
the output of the power source influence
the performance of the electrode. Each
current type has advantages and limita-
tions, which should be considered when
selecting the type of current for a specific
application. You must consider the dis-
tinctive performance in each of the fol-
lowing areas:
Instances of Excessive Voltage Drop.
When the work is located a long distance
from the power source, long electrical
cables will be required. The resistance to
current flow in long cables may affect the
output of the welding power source and
the welding characteristics of the
process. The voltage drop in the welding
cables is lower with AC, so if the welding
is to be done at a long distance from the
power supply, AC is more efficient. Long
cables that carry AC should not be coiled
because the inductive losses encoun-
tered in such cases can be substantial.
Welding with Low Current. With
small-diameter electrodes and low weld-
ing currents, DC provides better operat-
ing characteristics and a more stable arc.
Arc Initiation. Striking the arc is gen-
erally easier with DC, particularly if
small-diameter electrodes are used.
With AC, the welding current passes
through zero during each half cycle,
requiring periodic re-ignition of the arc.
This presents problems for arc starting
and arc stability.
Maintaining Constant Arc Length.
Welding with a short arc length (low arc
voltage) is easier with DC than with AC.
The shortest practical arc length is pre-
ferred for optimum physical properties
of the weld metal. Therefore, the ability
to weld with a short arc length is an
important consideration, except when
electrodes with a high iron powder con-
tent are to be used. With these elec-
trodes, the deep crucible formed by the
heavy covering automatically maintains
the proper arc length when the electrode
tip is dragged on the surface of the joint.
Arc Blow. Alternating current rarely
presents a problem with arc blow
because the magnetic field is constantly
reversing (120 times per second). Arc
blow can be a significant problem with
DC when welding ferritic steel.
Unbalanced magnetic fields that arise
can deflect the arc and eject the trans-
ferring metal droplets.
Out-of-Position Welding. For vertical
and overhead welds, DC is somewhat
better than AC because the welding per-
formance is better at lower amperages.
However, with suitable electrodes, satis-
factory welds can be made in all posi-
tions with AC.
Metal Thickness. Both sheet metal
and heavy sections can be welded using
DC. Welding sheet metal with AC pro-
duces a less desirable weld than with
DC. Arc stability is better with DC at the
low current levels required for thin
materials. However, properly sized and
designed AC electrodes, such as the
E6013 types, are used for sheet metal
applications.
Mechanical Properties. As a rule,
welds made with direct current electrode
positive (DCEP) have better mechanical
properties, especially weld metal tough-
ness. Skilled welders can exercise a
greater degree of control of the average
arc length with DCEP. The shorter arc
results in lower traces of dissolved ele-
ments that originate from the air.
Output Current Considerations for SMAW
Excerpted from Welding Handbook, Ninth Edition, Volume 2, Welding Processes, Part 1.
Fig. 1 Structural steel welding with the
shielded metal arc process.
Fact Sheet June 2012_Layout 1 5/10/12 4:05 PM Page 128
Welding Fundamentals
AWSs American Welding Online is introducing a self-paced online seminar designed to
provide technical knowledge and insight to non-welders who work in the welding and
fabricating industry.
Welding Fundamentals is an approximately 1-hour course that can be taken at your own
speed and convenience. The course provides a fundamental overview of welding, focusing
on the most widely used welding processes. Fundamental instruction is presented on
welding theory, equipment, safety, weld design, metallurgy, welding inspection, and quality
control.
Professional Development Hours and a certificate of completion will be provided upon
completion.
For more information, visit American Welding Online at
awo.aws.org
New online course








































































awo fundamentals_FP_TEMP 5/9/12 8:41 AM Page 129
JUNE 2012 130
CLASSIFIEDS
CAREER OPPORTUNITIES
The world's first and only completely
online NDT & CWI training program!
NDT Training to meet global standards
including SNT-TC-1A, ISO 9712, etc.
Visit www.worldspec.org today and save
$100 instantly by entering the discount
code: aws59c2
Call toll free: 1-877-506-7773
CERTIFICATION
& TRAINING
Quality Assurance Coordinator
Select-Arc, Inc., the manufacturer which sets The Standard of Excellence in
Tubular Welding Electrodes, is expanding and seeking a Quality Assurance
Coordinator for our headquarters in Fort Loramie, Ohio.
This position, which reports to the Quality Manager, is responsible for all aspects
of effective implementation of ISO 9001, Military, Automotive, ASME and other
industry / customer Quality Management Systems requirements. This person should
have good communication skills and the ability and the experience to interface with
all functions of the organization, including customer and supplier interaction.
Multi-Plant Quality System experience is a plus.
The candidates should be capable and willing to grow and develop within the
organization to assume higher level responsibility for the quality function.
Select-Arc prefers candidates who meet the following requirements:
CQM, CQE or CQA (IRCA) Certified
Certified or be willing to achieve IRCA Lead Auditor Certification
A minimum of 5 years experience, preferably in a welding-related industry
Degree in Welding Technology or Engineering related discipline
Literate in Word, Excel, Access, PowerPoint and Quality Data Analysis
Competitive salary and comprehensive benefits package are offered.
E-mail (mseitz@select-arc.com), FAX (888) 511-5217 or mail rsum to Melvin
Seitz, Quality Manager at Select-Arc, Inc., 600 Enterprise Dr., PO Box 259, Fort
Loramie, OH 45845. No Phone Calls, Please.
Select-Arc, Inc. is an Equal Opportunity Employer.
CWI PREPARATORY
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80+ HOUR COURSE
MORE HANDSON/PRACTICAL APPLICATIONS
Pascagoula, MS July 213 & Sept. 1021
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EXTRA INSTRUCTION TO GET A HEAD START
Pascagoula, MS July 513 & Sept. 1321
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40 HOUR COURSE
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Pascagoula, MS July 913 & Sept. 1721
Houston, TX July 2327 & Oct. 15
Houma, LA Aug. 2024
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Test follows on Saturday at same facility &
includes additional self study for weekend
FOR DETAILS CALL OR E-MAIL:
(800) 489-2890
info@realeducational.com
Also offering: 9Year CWI Recertification,
RT Film Interpretation, MT/PT/UT Thickness,
Welding Procedure Fundamentals,
CWS, SCWI, Advanced Inspection Courses
2012
Quality Control Examiner
Mechanical contractor is seeking an
experienced individual to perform quality
control functions related to industrial piping
system installations in the Western USA.
Experience in industrial piping and/or high
purity piping systems required. AWS-CWI
required. Mail rsum to:
HARDER MECHANICAL CONTRACTORS
Attn: QC Manager
PO Box 5118
Portland, OR 97208-5118
Or E-mail to:
harder@hardermech.com
Place Your
Classified Ad Here!
Contact Frank Wilson,
Senior Advertising
Production Manager
(800) 443-9353,
ext. 465
fwilson@aws.org
June 2012 WJ CLASSIFIEDS_Classified Template 5/10/12 3:37 PM Page 130
SERVICES
Oxygen Analyzers,
Purge Dams, Flow Meters

www.OrbitalWelding.com
for Pipe Welding
408-567-0232
CAREER OPPORTUNITIES (contd)
JOE FULLER LLC
We manufacture tank turning rolls
3ton through 120ton rolls
www.joefuller.com
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184
Our products are made in the USA
EQUIPMENT FOR SALE OR RENT
For sale or rent
The worlds very
best portable end
prep tools and
abrasive saws
800-343-6926
www.escotool.com
To support its significant growth globally and domestically, AWS is seeking a highly quali-
fied individual to supervise marketing and PR activities related to all its products, services,
and programs, worldwide. Reporting to the AWS Executive Director, this individual will also
have oversight of AWS education programs (live and online) and trade show activities, and
will be involved in developing partnerships and possible acquisitions, especially in the areas
of exhibitions and publications. Specific duties include:
Managing and administrating marketing and public relations activities, including develop-
ment and promotion of new products.
Acting as liaison with AWS trade show partners.
Planning and implementation of AWS exhibit activities domestically and abroad.
Supervising activities related to Convention and Meeting Services.
Supporting the AWS Publications, Exposition and Marketing Committee (PEMCO), as well
as Presidential Task Groups and other committees.
Working with the AWS Foundation to maximize effectiveness of Careers-in-Welding and
Image-of-Welding programs and activities.
Solid writing and editing skills are required, as well as negotiating skills, computer
capability, and the overall ability to represent AWS to government entities, the press, and
other professional organizations. Professional experience within the welding industry
strongly desired. Interested parties should email rsum, a cover letter, and salary require-
ments to:
Dora Shade
AWS Human Resources Director
dshade@aws.org
AWS VP OF MARKETING
Technical Sales Representatives
Welding/Thermal Spray
Looking for a career development
opportunity? Due to continued expan-
sion Eutectic has openings for suitably
qualified personnel to fill positions in
Idaho, Kentucky, New Jersey, Utah and
Illinois.
Ideal candidates will have experience in
welding and/or thermal spray with an
industrial background.
Responsibilities include providing
technical support to end users and
developing new opportunities in the
specified territory. Training will be
provided. Please visit our website at
www.eutecticusa.com.
Send rsum to:
Human Resources Dept.
Eutectic Corporation
N94 W14355 Garwin Mace Dr.
Menomonee Falls, WI 53051
FAX (262) 532-4692
e-mail: irma.nueske@eutecticusa.com
131 WELDING JOURNAL
June 2012 WJ CLASSIFIEDS_Classified Template 5/10/12 3:37 PM Page 131
JUNE 2012 132
EQUIPMENT FOR SALE OR RENT (contd)
MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1-Ton thru 60-Ton
Tank Turning Rolls
Used Equipment for Sale
www.mitrowskiwelding.com
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
Place Your
Classified Ad Here!
Contact Frank Wilson,
Senior Advertising
Production Manager
(800) 443-9353,
ext. 465
fwilson@aws.org
Americ/Schaefer Ventilation Equipment . . . . . . . . . . . . . . . . . .76
www.schaeferfan.com . . . . . . . . . . . . . . . . . . . . . . .(800) 779-3267
Arc One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
www.Arc1Weldsafe.com . . . . . . . . . . . . . . . . . . . . . .(800) 223-4685
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . .81, IBC
www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460
Atlas Welding Accessories, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .30
www.atlaswelding.com . . . . . . . . . . . . . . . . . . . . . .(800) 962-9353
AWS Education Services . . . . . . . . . . . . . . .84, 107, 119, 120, 129
www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353
AWS Membership Services . . . . . . . . . . . . . . . . . . . .109, 114, 134
www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353
Bluco Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
www.bluco.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 535-0135
Bradford Derustit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
www.derustit.com . . . . . . . . . . . . . . . . . . . . . . . . . .(714) 695-0899
Camfil Farr Air Polution Control . . . . . . . . . . . . . . . . . . . . . . . . .2
www.camfilfarrapc.com . . . . . . . . . . . . . . . . . . . . .(800) 479-6801
Champion Welding Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
www.ChampionWelding.com . . . . . . . . . . . . . . . . .(800) 321-9353
CM Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
www.cmindustries.com . . . . . . . . . . . . . . . . . . . . . .(847) 550-0033
Commercial Diving Academy . . . . . . . . . . . . . . . . . . . . . . . . . . .73
www.commercialdivingacademy.com . . . . . . . . . . .(888) 974-2232
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
www.cor-met.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
Diamond Ground Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . .11
www.diamondground.com . . . . . . . . . . . . . . . . . . .(805) 498-3837
Divers Academy International . . . . . . . . . . . . . . . . . . . . . . . . . .27
www.diversacademy.com . . . . . . . . . . . . . . . . . . . . .(800) 238-3483
Electron Beam Technologies, Inc. . . . . . . . . . . . . . . . . . . . . . . . .28
www.electronbeam.com . . . . . . . . . . . . . . . . . . . . . .(815) 935-2211
ADVERTISER
INDEX
June 2012 WJ CLASSIFIEDS_Classified Template 5/11/12 11:17 AM Page 132
ESAB Welding & Cutting Products . . . . . . . . . . . . . . . . . . . . . . .9
www.esabna.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 372-2123
FABTECH 2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186-s
www.fabtechexpo.org . . . . . . . . . . . . . . . .(800) 443-9353, ext. 297
Fischer Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
www.fischerengr.com . . . . . . . . . . . . . . . . . . . . . . . .(937) 754-1750
Fischer Technology, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
www.fischer-technology.com . . . . . . . . . . . . . . . . . .(800) 243-8417
Flex-Cable, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
www.flexcable.com . . . . . . . . . . . . . . . . . .(800) 245-3539, ext. 114
Fronius Perfect Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
www.fronius-usa.com . . . . . . . . . . . . . . . . . . . . . . .(810) 220-4414
Gedik Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
www.gedikwelding.com . . . . . . . . . . . . . . . . . . .+90 216 378 50 00
Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
www.greinerindustries.com . . . . . . . . . . . . . . . . . .(800) 782-2110
Gullco International, Inc. - U.S.A. . . . . . . . . . . . . . . . . . . . . . . .11
www.gullco.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(440) 439-8333
Harris Products Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
www.harrisproductsgroup.com . . . . . . . . . . . . . . .(800) 733-4043
Heck Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
www.heckind.net . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 886-5418
HGG Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
www.hgg-group.com . . . . . . . . . . . . . . . . . . . . . . . .(330) 461-6855
H&M Pipe Beveling Machine Co., Inc. . . . . . . . . . . . . . . . . . . .19
www.hmpipe.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(918) 582-9984
Hobart Inst. of Welding Technology . . . . . . . . . . . . . . . . . . . . . .28
www.welding.org . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 332-9448
Hodgson Custom Rolling, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .7
www.hcrsteel.com . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 263-2547
Hypertherm, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
www.hypertherm.com . . . . . . . . . . . . . . . . . . . . . . .(800) 643-0030
Image of Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
www.aws.org/awards/image.html . . . . . . . . . . . . . .(800) 443-9353
International Institute of Welding 65th Annual Assembly . . .83
www.iiw2012.com . . . . . . . . . . . . . . . . . . . . . . . .info@iiw2012.com
Intercon Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
www.intercononline.com . . . . . . . . . . . . . . . . . . . . .(800) 665-6655
Jinzhou Institute of Metal Material . . . . . . . . . . . . . . . . . . . . . .27
www.jzmm.com . . . . . . . . . . . . . . . . . . . . . . . . . .+86 416 4675064
Lincoln Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC
www.lincolnelectric.com . . . . . . . . . . . . . . . . . . . . .(216) 481-8100
Magnatech LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
www.magnatechllc.com . . . . . . . . . . . . . . . . . . . . . .(860) 653-2573
Mathey Dearman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
www.mathey.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 725-7311
Mercer Abrasives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
www.mercerabrasives.com . . . . . . . . . . . . . . . . . . .(800) 221-5202
Metabo Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
www.metabo.us . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 638-2264
Midalloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
www.midalloy.com . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 776-3300
Miller Electric Mfg. Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
www.MillerWelds.com . . . . . . . . . . . . . . . . . . . . . . .(800) 426-4553
Motor Guard Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
www.motorguardplasma.com . . . . . . . . . . . . . . . . .(800) 227-2822
National Bronze & Metals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . .22
www.nbmmetals.com . . . . . . . . . . . . . . . . . . . . . . . .(713) 869-9600
OTC Daihen, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
www.daihen-usa.com . . . . . . . . . . . . . . . . . . . . . . . .(888) 682-7626
Pferd, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
www.pferd.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(918) 633-4616
Select Arc, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC, 75
www.select-arc.com . . . . . . . . . . . . . . . . . . . . . . . . .(937) 295-5215
SKM Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
www.skmproducts.com . . . . . . . . . . . . . . . . . . . . . .(570) 383-3062
Special Metals Welding Products, Co. . . . . . . . . . . . . . . . . . . . .14
www.specialmetalswelding.com . . . . . . . . . . . . . . .(800) 624-3411
Sumner Manufacturing Co., Inc. . . . . . . . . . . . . . . . . . . . . . . .106
www.sumner.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(888) 999-6910
Tip Tig, USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
www.tiptigusa.com . . . . . . . . . . . . . . . . . . . . . . . . . .(828) 337-2695
Triangle Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
www.trieng.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(781) 878-1500
Tri Tool, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
www.tritool.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(888) 874-8665
Universal Tube & Rollform Equipment Corp. . . . . . . . . . . . . . .80
www.utubeonline.com . . . . . . . . . . . . . . . . . . . . . . .(419) 872-2364
Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
www.WeldEngineering.com . . . . . . . . . . . . . . . . . .(508) 842-2224
Weld Hugger, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
www.weldhugger.com . . . . . . . . . . . . . . . . . . . . . . . .(877) 935-3447
IFC = Inside Front Cover
IBC = Inside Back Cover
OBC = Outside Back Cover
Visit the AWS Interactive Ad Index: www.aws.org/ad-index
133 WELDING JOURNAL
June 2012 WJ CLASSIFIEDS_Classified Template 5/11/12 11:17 AM Page 133
buyers guide_FP_TEMP 5/9/12 7:58 AM Page 134
Introduction
Strain-age (reheat) cracking generally
occurs in gamma-prime or gamma-double-
prime-strengthened alloys during post-
weld heat treatment (PWHT) or
subsequent exposure of as-welded parts to
elevated temperature service. Residual
stresses, developed during restrained cool-
ing, immediately following weld bead so-
lidification or produced by differential
thermal expansion during PWHT heat up
are generally thought to be the driving
force for cracking. Alloy matrix hardening
during PWHT or subsequent service
(through gamma-prime or gamma-double-
prime precipitation) transfers the strains
produced by these residual stresses onto
the materials grain boundaries, with sec-
ondary grain boundary carbides often act-
ing as crack initiation sites. Additionally,
volume contraction associated with hard-
ening phase precipitation, can provide ad-
ditional stresses/strains that exacerbate
cracking (Refs. 2, 4). This scenario, how-
ever, can only occur if hardening (by sec-
ond-phase precipitation) proceeds more
quickly than stress relief through recovery
or recrystallization mechanisms.
Previous work (Ref. 1) documented the
use of modified tensile specimen geome-
try and fixed thermomechanical test con-
ditions to provide a means of comparing
the strain-age cracking susceptibility of
nickel-based superalloys. This Gleeble-
based controlled heating rate test (CHRT)
method essentially locked in one stan-
dard heat-up rate through the gamma-
prime precipitation temperature range,
one fixed test temperature and extension
rate within this temperature regime, cho-
sen to represent a grand average of
PWHT heat-up conditions for sheet and
plate materials. In actual practice, PWHT
heat-up rates may vary considerably, de-
pending on part geometry and available
heat treat furnace capability. The amount
of time spent in the gamma-prime precip-
itation temperature range, roughly 1400F
(760C) to 1600F (871C), may change
from part to part, as well as the rate that
residual stresses relax through part defor-
mation (strain rate) during PWHT. Simi-
larly, gamma-prime (or gamma-
double-prime) precipitation kinetics and
the total amount (volume fraction) of
gamma-prime precipitated can vary con-
siderably with alloy composition. Re-
ported correlations between alloy
composition and PHWT cracking have
varied substantially, depending on the test
methods used to assess strain-age cracking
susceptibility (Refs. 4 6). This study rep-
resents an attempt to quantify the effects
of different CHRT temperatures, exten-
sion (strain) rate at test temperature, and
alloy equilibrium gamma-prime volume
fraction/precipitation kinetics on the
strain-age cracking response of three com-
mercial gamma-prime hardened, Ni-based
superalloys.
Experimental Method
A classic Box-Behnken (face-centered
cubic) response surface design was chosen
for this study. The controlled heating rate
test temperature, extension (strain) rate at
test temperature, and alloy equilibrium
gamma-prime volume fraction were se-
lected as experimental inputs. Elongation
to break, as a semiquantitative measure of
strain-age cracking resistance, was the pri-
mary experimental response (output). The
actual design contained 12 runs in one
block with three replicated center points
for experimental error assessment. This
design is illustrated in Table 1.
Three common Ni-based superalloys
were chosen for evaluation over the defined
SUPPLEMENT TO THE WELDING JOURNAL, JUNE 2012
Sponsored by the American Welding Society and the Welding Research Council
KEYWORDS
Reheat Cracking
Strain Rate
Superalloys
Ni-Based Alloys
Postweld Heat Treatment
DAVID A. METZLER is Senior Mechanical
Metallurgist, Haynes International, Kokomo, Ind.
ABSTRACT
Gamma-prime strengthened Ni-based superalloys comprise a family of criti-
cal construction materials for modern gas turbines used in land-based power-
generation applications and aviation applications. Strain-age cracking during post-
weld heat treatment (PWHT) remains a critical issue in the widespread use of
higher-strength members of this alloy family. Previous work (Ref. 1) focused on
development of a simple, Gleeble-based controlled heating rate test method
and specimen configuration that was used to compared the relative strain-age
cracking susceptibility of several gamma-prime and gamma-double-prime forming
alloys, especially in terms of their composition and total hardening phase precip-
itation capacity (volume fraction). This study, in contrast, investigated the effects
of test temperature, strain rate, and alloy composition on strain-age cracking sus-
ceptibility using classic, response-surface DOE methods in temperature/strain-
rate space, combined with elements of this previously developed experimental
method. Observed results were rationalized in terms of known gamma-prime pre-
cipitation kinetics.
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Strain-Age Cracking Susceptibility of Ni-
Based Superalloys as a Function of Strain
Rate, Temperature, and Alloy Composition
The influence of test temperature, strain rate, and alloy composition on cracking
susceptibility of three Ni-based superalloys was examined
BY DAVID A. METZLER
metzler new_Layout 1 5/11/12 3:25 PM Page 163
range of modified CHRT conditions. All al-
loys were commercial gamma-prime
strengthened materials. The end points of
the gamma-prime volume fraction range
were represented by alloys known to be rel-
atively resistant (HAYNES 263 alloy) and
very susceptible (HAYNES R-41 alloy) to
strain-age cracking. These alloys and their
compositions are listed in Table 2. Gamma-
prime volume fraction was estimated from
thermodynamic phase stability calculations
performed with Pandat software and v7.0
of the Ni-Data database of thermodynamic
properties published by
Thermotech, Ltd. Calcula-
tions were performed at
931F (500C) to repre-
sent the maximum frac-
tion of gamma-prime that
each material could po-
tentially precipitate (its
capacity to precipitate
gamma-prime). Other
phases, expected to form
at time scales well beyond
CHRT test duration were
suspended from the calcu-
lations (Ref. 1). Fortu-
nately, the calculated
equilibrium gamma-prime
volume fraction for
HAYNES 282 alloy (0.240) fell close
enough to the design value (0.225) to be us-
able without introducing excessive experi-
mental error. This eliminated the need to
employ a noncommercial alloy composition
to fill in the equilibrium gamma-prime
volume fraction midrange value.
The controlled heating rate test speci-
men blanks were cut from 0.063-in.- (1.69-
mm-) thick mill annealed sheet, transverse
to the final rolling direction, using a me-
chanical shear. (For gamma-prime strength-
ened alloys, the mill annealing cycle consists
of a batch furnace anneal at the appropri-
ate solution treatment temperature, fol-
lowed by a water quench.) These blanks
were finish machined to the dimensions de-
picted in Fig. 1 and Blanchard ground to re-
move the as-pickled sheet surface. A
Type-K thermocouple was percussion
welded at the mid-span of each specimen
and 1-in. (25.4-mm) gauge marks were
added to each specimen, centered at mid-
span. This specimen geometry (Fig. 1) was
designed (Ref. 1) to ensure that specimens
fractured near mid-span when CHRT
tested. These specimens were mounted in a
PC-controlled Gleeble 1500D between
flat austenitic stainless steel jaws. A protec-
tive atmosphere was not used in these tests.
Each specimen was heated to 1100F
(594C) at 100F (56C) per second, then
heated to the test temperature at 30F
(16.7C) per minute. Each specimen was
pulled to failure at the indicated extension
rate. Elongation to failure was calculated
from posttest measurements of the length
increase between the 1-in. (25.4-mm) gauge
marks. Tests were conducted in essentially
random order, including the three center
points.
After elongation measurement, a small
longitudinal section (including the frac-
ture surface) was cut from each specimen,
mounted in epoxy, and prepared using
standard metallographic techniques. Sam-
ples were first electrolytically etched with
5% oxalic acid in hydrochloric acid (HCl)
for optical metallography, then re-pre-
pared and re-etched (also electrolytically)
with 15 g of chromic acid (CrO
3
) plus 10
mL of concentrated sulfuric acid (H
2
SO
4
)
dissolved in 150 mL of 85% phosphoric
acid (H
3
PO
4
) (Ref. 3) before examination
in a Zeiss Supra 40 SEM for evidence of
gamma-prime precipitation.
Results
Controlled heating rate test results as
a function of test temperature, extension
rate, and estimated equilibrium gamma-
prime volume fraction are listed in Table
3. A Pareto chart of the main effects is de-
picted in Fig. 2 and includes a 90% confi-
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Fig. 1 Specimen geometry used in CHRT response surface experi-
ment.
Fig. 3 Main effects plot for CHRT elongation as function of temper-
ature, extension rate, and equilibrium gamma-prime volume fraction.
Fig. 2 Pareto chart of main effects (vertical line represents 90% con-
fidence level for statistical significance).
Table 1 CHRT Response Surface Experiment Design
Test Extension Rate Estimated Alloy Gamma-Prime
Temperature F (C) in./min (mm/min) Volume Fraction
1500 (816) 0.332 (8.43) 0.225
1400 (760) 0.063 (1.60) 0.225
1600 (871) 0.063 (1.60) 0.225
1400 (760) 0.600 (15.2) 0.225
1600 (871) 0.600 (15.2) 0.225
1400 (760) 0.332 (8.43) 0.150
1600 (871) 0.332 (8.43) 0.150
1500 (816) 0.332 (8.43) 0.225
1400 (760) 0.332 (8.43) 0.300
1600 (871) 0.332 (8.43) 0.300
1500 (816) 0.063 (1.60) 0.150
1500 (816) 0.600 (15.2) 0.150
1500 (816) 0.063 (1.60) 0.300
1500 (816) 0.600 (15.2) 0.300
1500 (816) 0.332 (8.43) 0.225
metzler new_Layout 1 5/10/12 1:18 PM Page 164
dence level significance line.
Temperature, extension rate, and equi-
librium volume fraction gamma-prime
were significant at the 90% confidence
level. The (volume fraction gamma-prime)
term was also significant, revealing sub-
stantial nonlinear elongation behavior
(curvature) with respect to this variable.
This behavior is further illustrated in Fig.
3 (main effects plot of the three experi-
mental inputs).
The fitted response surface model was
described by the following expression:
Elongation (%) = 214.105 0.417448*T
+ 229.014* Extension Rate +
1045.21*VF

+ 0.00016625*T
2

0.123836*T* Extension Rate


0.343333*T* VF

24.1011* Extension
Rate
2
50.9001* Extension Rate *
VF

1313.33* VF

2
(T in F, Extension Rate in in./min.; VF

= equilibrium volume fraction of gamma-


prime by thermodynamic calculation.)
This model exhibited a correlation co-
efficient (R
2
) of 0.89 (0.70, adjusted for
degrees of freedom). Although the inter-
action terms were included in the regres-
sion equation, none of these terms were
statistically significant and can be dropped
from the model with little loss of accuracy,
giving the following:
Elongation (%) = 23.9457 + 512.905*
VF

+ 15.8287* Extension Rate
0.037*T 1312.38* VF

,2
This simplified model also exhibited an
adjusted (for degrees of freedom) R
2
of
0.70.
Optical Metallography
An overview of microstructures pro-
duced by CHRT within the experimental
envelope described above is contained in
Fig. 4AC. In 282, grain boundary separa-
tion was present in all samples except those
tested at 1400F (760C)/0.600 in. (15.2
mm)/min extension rate.
Lack of separation prob-
ably accounted for the
high elongation (38.1%)
exhibited under those
test conditions. At
1600F (871C)/0.600 in.
(15.2 mm)/min exten-
sion rate, considerable
grain boundary separa-
tion was present, yet
grains exhibited signifi-
cant plastic deformation
near the fracture. This
likely contributed to im-
proved performance
(18.3% elongation)
under those conditions.
No significant amount of
secondary carbide pre-
cipitation was found in
post test specimen grain
boundaries.
R-41 test specimens exhibited little ev-
idence of plastic deformation under all
test conditions, except at the fracture sur-
face, itself. This was only observable at the
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Fig. 4 Post-CHRT microstructures at various temperatures (vertical axis)
and extension rates (horizontal axis). A 282; B R-41 alloy; C 263
alloy.
Table 2 Composition of Alloys Used for Response Surface Experiment
Alloy R-41 HAYNES282 HAYNES263
Element wt-% wt-% wt-%
Al 1.49 1.46 0.57
B 0.01 0.00 0.00
C 0.09 0.06 0.06
Co 10.69 10.11 19.91
Cr 19.42 19.67 19.91
Cu 0.01 0.00 0.00
Fe 3.72 0.20 0.36
Mn 0.01 0.04 0.41
Mo 9.91 8.36 5.77
Si 0.05 0.04 0.23
Ti 3.11 2.08 2.19
V 0.02 0.01 0.00
W 0.05 0.00 0.00
Nb 0.00 0.00 0.00
Ni 51.43 57.97 50.59
Estimated Gamma 0.30 0.24 0.15
Prime Volume
Fraction at 931F (500C)
A B
C
metzler new_Layout 1 5/10/12 1:18 PM Page 165
1400F test temperature. Specimens tested
at higher temperatures exhibited only in-
tergranular failure. The grain boundaries
in this alloy contained a nearly continuous
film of secondary carbide precipitation
after testing at all temperature/extension
rate conditions. (This
film was not present in
pretest microstruc-
tures.) The formation
of these continuous
grain boundary car-
bide films probably
provided a low-energy
fracture propagation
path along the grain
boundaries. This, cou-
pled with a partially
gamma-prime hard-
ened matrix, likely
exacerbated intergran-
ular fracture beyond
that normally encoun-
tered in Ni-based al-
loys in this
temperature range.
Alloy 263 exhibited
grain boundary sepa-
ration at all test temperatures. Only minor
amounts of plastic deformation were
found at 1400F and 1500F (816C). At
1600F (871C), this alloy contained sig-
nificant grain elongation and some dy-
namic recrystallization after testing at
0.332 in. (8.43 mm)/min even though sig-
nificant grain boundary separation had oc-
curred. As expected, this specimen showed
(relatively) high elongation (26.0%) to
failure. No significant amount of second-
ary carbide precipitation was found in
posttest specimen grain boundaries.
Electron (SEM) Metallography
Some early investigators (Ref. 7) ques-
tioned whether gamma-prime actually
precipitated during a similar test regime in
Inconel X-750 alloy. To address this
question, post CHRT specimens were also
examined by SEM for signs of gamma-
prime precipitation, especially in areas ad-
jacent to grain boundaries that had clearly
separated. A different etchant (described
above) was used to reveal gamma-prime
particles in relief. An overview of these
structures is illustrated in Fig. 5AC.
Gamma-prime particles were not visi-
ble in 282 alloy after 1400F testing at any
extension rate. At 1500F/0.332 in. (8.43
mm)/min, some very fine, gamma-prime
appeared to have precipitated in grain in-
teriors. Some blocky carbides were also
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Fig. 5 Post-CHRT microstructures at high magnification at various tem-
peratures and extension rates. Inset magnified 2. (CHRT test elongations
shown on micrographs.). A 282 alloy; B R-41 alloy; C 263 alloy.
Table 3 CHRT Results, Box-Behnken Response Surface Experiment
Test Extension Rate Estimated Gamma-Prime Elongation to Failure Pretest Posttest
Temperature F (C) in./min (mm/min) Volume Fraction 1-in. (25.4-mm) Gauge Marks GS (ASTM) GS (ASTM)
1500 (816) 0.332 (8.43) 0.225 23.4 4.0 4.0
1400 (760) 0.063 (1.60) 0.225 20.3 4.0 3.5
1600 (871) 0.063 (1.60) 0.225 13.8 4.0 3.5
1400 (760) 0.600 (15.2) 0.225 38.1 4.0 4.0
1600 (871) 0.600 (15.2) 0.225 18.3 4.0 4.0
1400 (760) 0.332 (8.43) 0.150 22.5 3.5 3.5
1600 (871) 0.332 (8.43) 0.150 26.0 3.5 DRX?
1500 (816) 0.332 (8.43) 0.225 22.2 4.0 4.0
1400 (760) 0.332 (8.43) 0.300 13.1 6.0 6.0
1600 (871) 0.332 (8.43) 0.300 6.3 6.0 6.0
1500 (816) 0.063 (1.60) 0.150 14.0 3.5 3.5
1500 (816) 0.600 (15.2) 0.150 21.9 3.5 3.5
1500 (816) 0.063 (1.60) 0.300 7.3 6.0 6.0
1500 (816) 0.600 (15.2) 0.300 11.1 6.0 6.0
1500 (816) 0.332 (8.43) 0.225 22.5 4.0 4.0
A B
C
metzler new_Layout 1 5/10/12 1:18 PM Page 166
found in grain boundaries. At 1600F/
0.063 in. (1.60 mm)/min, gamma-prime
clearly had formed during heat up and
testing. Small, secondary carbide particles
had also precipitated in grain boundaries.
The presence of these smaller, but non-
continuous grain boundary carbides would
not likely reduce grain boundary ductility
to the degree that a continuous secondary
carbide film would. A gamma-prime de-
nuded zone was present near grain bound-
aries where secondary carbide
precipitation had occurred. At the higher
extension rate, 0.600 in. (15.2 mm)/ min,
no gamma-prime particles were visible in
posttest specimens.
Gamma-prime particles were clearly
present in R-41 over the entire range of test
conditions. Grain boundaries contained
nearly continuous deposits of small second-
ary carbides and numerous, larger blocky
carbides, often located at grain boundary
triple points. No gamma-prime denuded
zones were apparent near grain boundaries.
As expected, higher test temperatures and
slower extension rates (more time at test
temperature) yielded lower elongations
during CHR testing. Gamma-prime parti-
cles were more easily distinguished follow-
ing tests that yielded the lowest elongations.
Posttest gamma-prime appeared to be
present in 263 alloy under all conditions ex-
cept 1600F/0.332 in. (8.43 mm)/min. These
test conditions also produced partial dy-
namic (or meta-dynamic) recrystallization,
again suggesting that significant gamma-
prime precipitation had not occurred.
These conditions also yielded the highest
elongation in the entire test matrix. Al-
though some large, blocky carbides were
present in grain boundaries, their presence
would not likely reduce the observed
CHRT elongation significantly because
they did not form a continuous film (easy
fracture path). Discreet, secondary carbide,
grain boundary precipitates were not gen-
erally resolvable.
Discussion
DOE Analysis
Standardized main effects results pro-
duced by this response surface experiment
showed that volume fraction gamma-
prime, test temperature, and extension
rate were significant at the 90% confi-
dence level. As expected (qualitatively),
higher extension rates favored higher test
elongation results, simply by reducing the
total amount of time specimens spent in
the gamma-prime precipitation tempera-
ture regime. The magnitude of this effect
did not change significantly with alloy
identity. (The gamma-prime volume frac-
tion/extension rate interaction was not sta-
tistically significant.)
Similarly, higher test temperatures
generally favored lower test elongation re-
sults. Although the temperature/extension
rate interaction fell just below statistical
significance (at the 95% CL), it was the
largest two-factor interaction yielded by
this experiment and is illustrated in Fig. 6.
This plot suggests that at high exten-
sion rates, temperature plays a more im-
portant role than at low extension rates. At
the standard CHRT extension rate,
0.063 in. (1.60 mm)/min, test behavior ap-
pears to vary little with temperature (in
the gamma-prime precipitation regime).
Test time may be long enough such that
alloy gamma-prime precipitation capabil-
ity (gamma-prime equilibrium volume
fraction) becomes dominant over short-
term precipitation kinetics. At higher ex-
tension rates, thermally activated
precipitation kinetics limit the rate at
which elongation decreases during
CHRTs.
The main effect of equilibrium gamma-
prime volume fraction on CHRT elonga-
tion was strongly significant. Its
second-order effect was also statistically
significant, indicating strong nonlinear
CHRT elongation vs. equilibrium gamma-
prime volume fraction behavior. The main
effects plot (contained in Fig. 3, right-hand
curve) illustrates this behavior. Alloy 282,
whose calculated equilibrium gamma-
prime volume fraction was 0.24, exhibited
anomalously high CHRT elongations. The
sluggish gamma-prime precipitation rate
characteristic of this alloy (Fig. 7) appar-
ently limits the amount of elongation re-
duction under all CHRT conditions visited
in this experiment, as opposed to R-41 and
263, where equilibrium gamma-prime vol-
ume fraction primarily controls CHRT
behavior.
These DOE results are also supported
by the SEM microstructural observations
conducted in this study. Post-CHRT R-41
specimens contained observable gamma-
prime particles over the entire tempera-
ture/extension rate space of this
experiment. Similarly, 263 post-CHRT
specimens contained observable gamma-
prime particles, except at the highest test
temperature, 1600F. In contrast, gamma-
prime particles were only observable in
282 alloy at the highest test temperature
and lowest extension rate.
Conclusions
1) The CHRT (strain-age cracking) re-
sponse of several gamma-prime harden-
able Ni-based superalloys can be described
in terms of a simple quadratic model in
test temperature, extension rate, and equi-
librium volume fraction gamma-prime
(alloy composition) space as follows:
Elongation (%) = 23.9457 + 512.905*
VF

+ 15.8287* Extension Rate
0.037*T 1312.38* VF

2
2) Test temperature and extension rate
effects behaved linearly; their exhibited
curvature was less than observed experi-
mental error. The CHRT elongation de-
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Fig. 6 Extension rate/test temperature interaction plot. Fig. 7 Comparative age-hardening kinetics of several wrought
gamma-prime-strengthened alloys (Ref 8).
metzler new_Layout 1 5/10/12 1:18 PM Page 167
creased with increasing test temperature
and increased with extension rate.
3) The effect of equilibrium gamma-
prime volume fraction was strongly non-
linear, with the 282 alloy exhibiting
anomalously large CHRT elongations.
4) This nonlinear behavior appears to
be caused by 282s sluggish gamma-prime
precipitation kinetics relative to the R-41
and 263 alloys. The R-41 and 263 alloys
developed observable gamma-prime par-
ticles under almost all test conditions vis-
ited in this study, while 282 only exhibited
observable precipitation at the highest test
temperature and low extension rates.
5) The overall CHRT behaviors of the
41 and 263 alloys are determined more by
the total amount of gamma prime that can
potentially precipitate (alloy composition)
than precipitation kinetics, whereas in 282
alloy, sluggish precipitation kinetics dom-
inate its CHRT response.
6) All fabrication history gathered to
date on the 282 alloy has indeed suggested
that this alloy is quite resistant to strain-
age cracking.
Acknowledgments
Lori Meacham, John Cotner, and Mark
Richeson of Haynes International are grate-
fully acknowledged. Meacham assisted with
Gleeble-based CHRT operation and pro-
gramming. Cotner and Richeson provided
electron and optical metallography skills
necessary to complete this study.
References
1. Metzler, D. A. 2008. A Gleeble-based
method for ranking the strain-age cracking sus-
ceptibility of Ni-based superalloys. Welding Jour-
nal 87(10): 249-s to 256-s.
2. C. T. Sims, and W. C. Hagel, eds. 1972. The
Superalloys, pp. 529531, New York, N.Y., Wiley.
3. Radavich, J. F. 1997. Electron metallog-
raphy of alloy 718. Superalloys 718, 625, 707 and
Various Derivatives, E. A. Loria, ed. The Miner-
als, Metals and Materials Society, pp. 1718.
4. Norton, S. J., and Lippold, J. C. 2003. De-
velopment of a Gleeble-based test for postweld
heat treatment cracking susceptibility. Trends in
Welding Research, Proc. of the 6th International
Conference, ASM International, pp. 609614.
5. Prager, M., and Shira, C. S. 1968. Welding
of precipitation hardenable nickel-base alloys.
WRC Bulletin No. 128.
6. Rowe, M. D. 2006. Ranking the resistance
of wrought superalloys to strain-age cracking.
Welding Journal 85(2): 27-s to 34-s.
7. Dix, A. W., and Savage, W. F. 1971. Fac-
tors influencing strain-age cracking in Inconel
X-750. Welding Journal 50(6): 247-s to 252-s.
8. HAYNES 282 brochure, www.hay-
nesintl.com/pdf/h3173.pdf, p. 10.
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metzler new_Layout 1 5/10/12 1:18 PM Page 168
Introduction
High-strength aluminum alloys, such
as 7xxx, are commonly used in modern in-
dustry because they are lightweight and
highly durable (Ref. 1). These alloys are
difficult to weld using conventional fusion
welding techniques because the quality of
the welded joint deteriorates under the
presence of porosity, hot cracking, and
distortion (Refs. 2, 3). Friction stir welding
(FSW), a novel solid-state welding process
invented in 1991 at TWI, was developed to
solve these problems (Ref. 4). In FSW, the
interaction of a nonconsumable and rotat-
ing tool with workpieces creates a joint
through frictional heating and plastic de-
formation at temperatures below the
melting point of the welded alloys. This
way, the metal in the welded zone reaches
a soft state, and a circumferential metal
flow is obtained all around the contact sur-
face between the FSW tool and weld
joints.
The formation quality of friction stir
welded joints relies on the deformation
ability and flow of the metal around the
FSW tool. Inappropriate weld parameters
and conditions result in weld defects, such
as flashes, tunnels, and voids. Thus, inves-
tigations on the flow mechanism of the
plastic metal around the FSW tool have
been carried out using various methods
(Refs. 58). At the same time, consider-
able efforts have been devoted to under-
standing the effect of process parameters
or the profiles of the FSW tool on the ma-
terial flow behavior of friction stir welded
joints (Refs. 911). However, despite ad-
vancements in the study of weld joint qual-
ity, further optimization of weld parame-
ters and conditions remains a key issue
because of the special formation processes
of the FSW. Determining methods that
can improve the formation quality of fric-
tion stir welded joints is a worthwhile
endeavor.
In recent years, increasing attention
has been paid to submerged FSW because
it improves the mechanical properties of
friction stir welded joints (Refs. 1215).
The principle of submerged FSW is that
the welds are placed into a liquid medium,
and weld processing is carried out under a
specific ambient temperature. This
method is highly suitable for aluminum al-
loys that are sensitive to excessive heating
during welding processes (Ref. 16). The
peak temperature of the weld thermal cy-
cles at heat-affected zones can be effec-
tively decreased by forced cooling during
submerged FSW. However, the effects of
submerged FSW on controlling the for-
mation quality of friction stir welded joints
are rarely reported.
In the present work, the effects of weld
conditions are systematically investigated,
such as the rotational directions of the
FSW tool and welding in air and under-
water, on the formation quality of weld
joints under a wide range of welding pa-
rameters. This work aims to more effec-
tively elucidate the relationship between
weld conditions and weld defects. The
findings can serve as reference for indus-
trial fabrication.
Experimental Procedure
All welding procedures were per-
formed on high-strength 7050 aluminum
alloy plates with a thickness of 5.8 mm,
width of 80 mm, and length of 180 mm.
Improvement of Formation Quality for
Friction Stir Welded Joints
This study takes into account the rotational direction of the stir tool,
cooling rates around the weld zones, and fabrication of defect-free joints
BY R.-D. FU, R.-C. SUN, F.-C. ZHANG, AND H.-J. LIU
KEYWORDS
Friction Stir Welding
Welding Condition
Formation Quality
FSW Tool
Rotational Direction
Weld Ambient Temperature
Aluminum Alloys
R.-D. FU (rdfu@ysu.edu.cn), R.-C. SUN, and
F.-C. ZHANG are with State Key Laboratory of
Metastable Materials Science and Technology,
Qinhuangdao, Hebei Prov., P.R. China. FU and
ZHANG are also with College of Materials Sci-
ence and Engineering, Yanshan University, Qin-
huangdao, Hebei Prov., P.R. China. H.-J. LIU is
with State Key Laboratory of Advanced Welding
Production Technology, Harbin, Heihongjiang
Prov., P.R. China.
ABSTRACT
The weld, ambient temperature, and direction of a friction stir welding (FSW)
tool play roles as important as that of the welding parameters in the FSW process.
On the assumption that the weld parameters are the same under different direc-
tions, the joint welded using a stir tool rotated in a counterclockwise direction ex-
hibits better formation quality than does the joint welded in a clockwise direction.
The formation quality of the joints welded underwater clearly improves compared
with that of the joints welded in air. Excellent weld joints free from defects are ob-
tained in the present range of the FSW parameters for joints welded underwater
and the stir tool rotated in the counterclockwise direction. The investigation of
the flow path of the softened metal around the FSW tool reveals that the flow pat-
tern of the softened metal driven by the shoulder and the pin varies with the ro-
tational direction of the FSW tool, weld ambient temperature, and weld parame-
ters. An excessively high weld input is detrimental to sound flow and avoidance of
weld defects. By contrast, moderately decreasing the ambient temperature around
the weld zone can improve the formation quality of the weld joints, regardless of
the other weld conditions.
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Fu et al Supplement June 2012_Layout 1 5/10/12 1:27 PM Page 169
The chemical composition of the alloy is
6.00% Zn, 2.2% Mg, 2.24% Cu, and
0.05% Ni, with the balance made up of Al.
Welds were produced using CNC
FSW equipment. The nonconsumable
FSW tool with left-hand screw threads is
made of H13 steel. The diameters of the
shoulder and pin are 12 and 6.2 mm, re-
spectively. The length of the pin is about
5.3 mm. The welding direction was paral-
lel to the rolling direction of the plate,
and the rotation axis of the tool was nor-
mal to the plane of the plate. Four weld-
ing conditions were chosen in the weld
process: the rotational directions of the
stir tool were clockwise and counter-
clockwise, and the welds were exposed to
air and submerged in water. The welds
were submerged in water at a depth of ap-
proximately 30 mm from the top surface
of the plates. The range of travel speed
was 40 to 200 mm/min, and the range of
rotational speed was 350 to 1000 rev/min.
The penetration depth was controlled
through the actual shoulder plunge depth
at approximately 0.5 mm. The tempera-
ture history of the welds during FSW was
continuously recorded using a multichan-
nel thermodetector.
Metallographic samples were ground,
polished, and etched using Kellers
reagent (1 mL hydrofluoric acid, 1.5 mL
hydrochloric acid, 2.5 mL nitric acid, and
95 mL water). Micrographs of the entire
weld joint were observed using an optical
microscope.
Results and Discussion
Welding in Air and Underwater with the
FSW Tool Rotated Clockwise
The cross-section morphology of the
joints friction stir welded in air with the
FSW tool rotated clockwise at different
travel and rotational speeds is shown in
Fig. 1. The tunnel defect forms at the ad-
vanced side (AS) of the friction stir welded
joints under all welding parameter ranges.
The size of the tunnel defect decreases
with increasing travel speed, but not with
rotational speed. This result indicates that
decreasing weld heat input under the
same weld conditions prevents tunnel de-
fects at the AS of the friction stir welded
joints. This observation also shows that
the metal around the defects exhibits vor-
tex-like flow features that cause disor-
dered flow.
Figure 2 shows the cross-section mor-
phology of the joints welded underwater
with the same weld parameters as that
used for the joint welded in air. Although
the weld defects continue to form under
all weld parameter ranges, the size of the
weld defects clearly decreases. On the
basis of the joints welded in air (Fig. 1), we
deduce that the cause of weld defects may
be closely related to the excessive heat
input for the joints welded in air. Increas-
ing only the travel speed cannot effectively
eliminate weld defects because the flow
mode of the softened metal around the
weld defects has an important effect: an
excessively high travel speed may result in
the transformation of the metal flow from
ordered to disordered mode, i.e., a vortex-
like flow, which is often considered abnor-
mal and should be avoided in FSW
processes.
Welding in Air and Underwater with the
FSW Tool Rotated Counterclockwise
Figure 3 shows the cross-section mor-
phology of the joints welded in air with the
FSW tool rotated counterclockwise under
different weld parameters. At a rotational
speed of 350 to 600 rev/min and travel
speed of 40 to 100 mm/min, the weld de-
fects disappear from the weld joint. For
the joints welded at a rotational speed of
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Fig. 1 Cross-section morphology of the joints welded in air with different welding parameters and
clockwise rotational direction of the FSW tool.
Fig. 2 Cross-section morphology of the joints welded underwater with different welding parame-
ters and clockwise rotational direction of the FSW tool.
Fu et al Supplement June 2012_Layout 1 5/10/12 1:27 PM Page 170
1000 rev/min, the weld defects persist, and
the size of the defects decreases with in-
creasing travel speed. An exception is
when the tunnel defect forms again for the
joint welded at a rotational speed of 350
to 1000 rev/min when the travel speed is
200 mm/min. The size of the defects de-
creases with increasing rotational speed
and when the formation position of the de-
fects shifts upward. This result can be at-
tributed to an increase in weld heat input
for increasing rotational speed. As a re-
sult, the flowability of the softened metal
increases. The above-mentioned varia-
tions of weld defects with the weld param-
eters are in contrast to those observed in
the FSW tool rotated clockwise.
In addition, the metal flow mode and
formation mechanics of the weld defect
can be clearly observed from the travel
speed variations of the defects for the
joints welded at a rotational speed of 1000
rev/min. Figure 3 shows that metal flow
can be divided into two parts, namely,
shoulder extrusion zone I and pin stirring
zone II. The formation of the weld defects
at the top of the AS is closely related to the
metal flow driven by shoulder extrusion
and pin stirring. Moreover, the flow driven
by the shoulder becomes incomplete at
lower travel speeds, i.e., at the moment the
weld heat input is so high that the softened
metal under the shoulder cannot facilitate
flow with the rotational movement of the
shoulder. The above-mentioned results
further demonstrate that an excessively
high heat input is detrimental to the for-
mation quality of weld joints under most
weld conditions.
The joints welded underwater with dif-
ferent weld parameters and the FSW tool
rotated counterclockwise are shown in Fig.
4. Compared with the joints welded in air
(Fig. 3), those welded underwater at the
same weld parameters are free of defects.
This result indicates that the range of the
optimum FSW parameter expands when
the joints are welded underwater and the
FSW tool is rotated counterclockwise.
Discussion
Role of Rotational Direction in Weld
Formation
The results show that the quality of the
joints welded with the FSW tool rotated
counterclockwise is superior to that of the
joints welded in the clockwise direction. In
addition, the formation positions of the
weld defects differ when the rotational di-
rection of the FSW tool is altered, i.e., the
weld defect is located at the bottom zones
of the AS for clockwise rotation, and at the
top zones of the AS for counterclockwise
rotation. This result reveals that the metal
flow direction should change when the ro-
tational direction is altered. The metal flow
around the FSW tool is shown in Fig. 5.
Generally, the weld zones of weld
joints are divided into two parts. The first
is zone I, where the softened metal driven
by the shoulder occurs via a horizontal
flow around the axle of the FSW tool. The
second is zone II, where the softened
metal driven by the screw thread on the
pin is positioned either downward or up-
ward in the spiral flow with respect to the
rotational direction of the FSW tool (Ref.
17). When the FSW tool rotates clockwise,
aside from the horizontal flow of the metal
driven by the shoulder in zone I, an addi-
tional flow runs from zones I to II driven
by the pressure force of the shoulder. In
zone II, the metal first occurs downward in
the spiral flow driven by the stirring of the
screw thread on the pin. Once the metal
reaches the bottom of the joints, the flow
direction of the metal is reversed, as
shown by the arrows in Fig. 5A. When the
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Fig. 3 Cross-section morphology of the joints welded in air with different welding parameters and
counterclockwise rotational direction of the FSW tool.
Fig. 4 Cross-section morphology of the joints welded underwater with different welding parame-
ters and counterclockwise rotational direction of the FSW tool.
Fu et al Supplement June 2012_Layout 1 5/10/12 1:27 PM Page 171
flow is complete, no weld defects form at
the AS of the weld joint. However, the
flow at the AS stops because the tempera-
ture of the bottom metal is lower than that
of the upper metal. Meanwhile, the down-
ward flow from zone I does not cross paths
with the upward flow. Consequently, weld
defects form at this position.
When the FSW tool rotates counter-
clockwise, the metal flow direction in zone
II is opposite to that in the clockwise rota-
tion Fig. 5B. This flow from zones II to
I crosses paths with the downward flow
from zone I at the top position near the
AS. The good mixture between the two
flows effectively prevents the formation of
weld defects at the position where the
temperature is high. Thus, the probability
that weld defects will form is lower in the
counterclockwise direction than in the
clockwise direction.
However, although the counterclock-
wise direction of the FSW tool can effec-
tively decrease the occurrence of weld de-
fects, it does not completely eliminate weld
defects, similar to welding at high rotational
or travel speeds. Cavity or groove-like de-
fects can be caused by insufficient heat
input and abnormal stirring (Ref. 18). In-
sufficient heat input has been widely ac-
cepted as being related to the deterioration
of the flowability of the metal around the
FSW tool. Abnormal stirring is seldom con-
sidered, but it is an important factor in
metal flow under certain conditions. Fig-
ures 14 show that the features of the vor-
tex-like flows around the location of the
weld defect almost merge regardless of the
rotational direction of the FSW tool. This
near-merging demonstrates that abnormal
stirring can also result in weld defects.
Therefore, the weld defect formed in the
counterclockwise direction may be related
to abnormal stirring, which stems from the
wiping effect among the interfaces between
layers extruded by the FSW tool in the weld
zone. Consequently, the wiping effect re-
sults in the lack of mixing and a vortex-like
flow around the pin (Ref. 19).
Role of Cooling Conditions in
Weld Formation
A comparison of the results
for air and underwater weld-
ing with all other conditions
constant reveals that the for-
mation quality of the joints
welded underwater is superior
to the quality of those welded
in air. This finding indicates
that the formation quality of
the joints can be improved
through the acceleration of
the cooling rate around the
weld zone. As previously dis-
cussed, if the metal flow exhibits a vortex-
like feature, the occurrence probability of
weld defects increases. The formation of a
vortex-like flow is related to both excessive
heat input and the slide-stick wiping
flow. To obtain insight into the relation-
ships between weld defects and weld heat
input, we measured the transversal tem-
perature distribution of four group joints
welded with the FSW tool rotated coun-
terclockwise Fig. 6. The weld tempera-
ture fields of the joints welded at rota-
tional speeds of 350 and 1000 rev/min are
shown in Fig. 6A and B, respectively.
First, the peak temperature around the
pin for the joints welded underwater sig-
nificantly decreases compared with that
for the joints welded in air. Moreover, the
weld temperature at the RS is higher than
that at the AS for the joints welded at low
and high weld parameters. According to
previous studies (Refs. 14, 20), high tem-
peratures can promote the plasticization
of a welded base metal. The quality of
joints welded at high heat input is better
than that of joints welded at low heat
input. However, excessive heat input can
change the friction conditions and flow
paths of plasticized metal. Under hot pro-
cessing with stick conditions, excessive
material flow results in flash formation,
surface galling, and nugget collapse.
Under cold processing with slip condi-
tions, insufficiently flowing material re-
sults in surface incomplete fill, wormhole,
or incomplete consolidation defects on
the AS. The optimum processing condi-
tions for preventing flow-related defects
are postulated to occur at a temperature
where the stick-slip wiping flow occurs,
and the material flowing from the region
ahead of the pin tool is precisely balanced
with the material flowing back into the va-
cated region behind the tool (Ref. 17).
When welded in air conditions, metals
show higher plasticization than when they
are welded underwater because of high
heat input. The flow resistance of plasti-
cized metal increases because of the wip-
ing effect that occurs between each layer
driven by the FSW tool. In addition, al-
though the flowability of welded metal in-
creases with increasing heat input, the
flow path also varies to form flashes rather
than flow downward. The balance be-
tween the flow from the region in front
and behind the pin is broken. Conse-
quently, incomplete filling at the AS re-
sults in tunnel defects.
In underwater welding, the excessive
heat in plasticized metals is quickly dissi-
pated by ambient water, causing a de-
crease in wiping effects. The stick friction
becomes the dominant factor that pro-
motes plasticized metal flow together with
the rotation of the FSW tool.
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A
B
Fig. 5 Metal flow around the FSW tool. A Clockwise direction; B counter-
clockwise direction.
Fig. 6 Thermal history of the joints welded in air and under-
water. A 350 rev/min; B 1000 rev/min.
A
B
Fu et al Supplement June 2012_Layout 1 5/10/12 1:27 PM Page 172
Conclusions
The conclusions derived are summa-
rized as follows.
1. The rotational direction of the stir
tool plays an important role in weld for-
mation during FSW. The quality of the
joints welded using the stir tool rotated
counterclockwise is superior to that of the
joints welded in the clockwise direction,
regardless of the other weld conditions.
2. Accordingly, the cooling rates
around the weld zones also play a role as
important as that of the other weld condi-
tions in the weld formation of friction stir
welded joints. The quality of the joints
welded underwater is better than that of
the joints welded in air, regardless of the
other weld conditions.
3. Defect-free joints are obtained
under all weld parameters when the joints
are welded underwater and the FSW tool
is rotated counterclockwise. The fabrica-
tion of defect-free joints also indicates
that the ranges of optimum FSW parame-
ters expand under this weld condition.
4. Controlling the plasticized state and
flow patterns of the metal around the stir
tool is essential in fabricating defect-free
joints.
Acknowledgments
The authors acknowledge the financial
support of the Modern Welding Production
Technology State Key Laboratory and the
National Science Foundation for Distin-
guished Young Scholars (No. 50925522).
References
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3. Uday, M. R., Ahmad, F. M., Zuhailawati,
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Introduction
Shielding gases are fundamental to the
operation of the gas metal arc welding
(GMAW) process and there are a number
commonly used, each with its own specific
properties, i.e., ionization potential, which
creates unique arc characteristics (Refs.
17). Shielding gases are also commonly
used in a variety of premixed combina-
tions of two or more gases in order to take
advantage of the beneficial properties of
each gas (Refs. 8, 9). Recently, however,
there has been some positive research
(Refs. 14) into the effects of alternating
shielding gases in both GMAW and, to a
lesser extent, gas tungsten arc welding.
This method involves discretely supplying
two different shielding gases, each with a
duty cycle of 50%; i.e., while one gas is
flowing the other is not, which results in a
continuous shield with varying properties.
These studies have shown beneficial re-
sults including an increased travel speed,
reduced porosity, and increased strength.
For example, Campbell et al. (Ref. 1) re-
ported the use of alternating shielding
gases can reduce the overall weld cost by
approximately 17% while also consider-
ably reducing distortion. Chang (Ref. 2)
reported the use of alternating shielding
gases created beneficial effects on the
weld pool and, as shown in Fig. 1 (Ref. 3),
different flow vectors were created in the
weld pool for different gases used. How-
ever, when alternating between shielding
gases, complex flow patterns were created
that caused a dynamic action in the weld
pool and this is known to be a result of the
fluctuation between these individual
shielding gas flow vectors. The dynamic
nature of the shielding gas delivery is
known to be influenced by factors such as
(a) arc pressure variation, (b) variation in
weld pool fluidity, and (c) arc pressure
peaking.
As several industry sectors (e.g., ship-
building and road transportation) move
toward thinner and stronger materials in
order to reduce the overall mass of the
structure (Refs. 10, 11), it is widely recog-
nized that these thinner materials are
more susceptible to distortion induced by
the heat input generated by the welding
processes used during fabrication. Distor-
tion is a result of the nonuniform expan-
sion and contraction of the weld material
due to the heating and cooling cycle (Ref.
11) and although computational models
can be used to help predict the magnitude
of weld-induced distortion (Ref. 12), as a
result of the number of variables involved
(Ref. 13) including material properties,
welding procedure, structural design, and
manufacturing procedure (each of which
have numerous sub variables) results in
such models being specific to the data
used in the model generation. However,
the effort required to rectify the distortion
from the steel structure is highly resource
intensive. For that reason it is beneficial to
eliminate as much distortion at the source
as possible and this is largely achievable
through good practices, mainly related to
reducing the heat going into the steel
structure and the concentration of heat in
specific areas. Further, there is an increas-
ing demand for quality prediction in
todays ever-increasing automated soci-
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ABSTRACT
An artificial neural network (ANN) model has been applied to the prediction of key
weld geometries produced using gas metal arc welding (GMAW) with alternating shield-
ing gases. This is a recently developed method of supplying two individual shielding gases
to the weld area in which the gases are discretely supplied at a given frequency. The model
can be used to predict the penetration, leg length, and effective throat thickness for a
given set of weld parameters and alternating shielding gas frequency.
A comparison of the experimental and predicted geometries matched closely and
demonstrates the effectiveness of this software approach in predicting weld outputs.
The model has shown that the application of alternating shielding gases increases the
penetration and effective throat thickness of a fillet weld while the leg length is
reduced.
A sensitivity analysis was performed that showed travel speed is the most influen-
tial input parameter when predicting weld geometries. This is to be expected for any
given welding setup due to the influence of the travel speed on the heat input. The
sensitivity analysis also showed that the shielding gas configuration had the lowest in-
fluence on the output of the model. The output from the model has demonstrated that
the use of alternating shielding gases during GMAW results in a step change in the
weld metal geometry. This suggests that, in the case of alternating shielding gases, an
increased travel speed is required to produce a similar weld geometry to that of the
conventional Ar/20%CO
2
technique.
KEYWORDS
Gas Metal Arc Welding
Artificial Neural Networks
Alternating Shielding Gases
S. W. CAMPBELL and A. M. GALLOWAY are
with Department of Mechanical Engineering,
University of Strathclyde, Glasgow, Scotland. N.
A. MCPHERSON is with BAE Systems Surface
Ships Ltd., Glasgow, Scotland.
Artificial Neural Network Prediction of Weld
Geometry Performed Using GMAW with
Alternating Shielding Gases
A sensitivity analysis showed travel speed is the most influential input parameter
when predicting weld geometries
BY S. W. CAMPBELL, A. M. GALLOWAY, AND N. A. MCPHERSON
Campbell Supplement June 2012_Layout 1 5/10/12 1:30 PM Page 174
ety, and it is imperative that there is a high
level of consistency in the process in order
to satisfy this demand.
While the external fillet weld geometry
can be measured, there is no way of know-
ing the penetration of the weld without the
aid of nondestructive testing although im-
proved accuracy may be obtained by sec-
tioning and polishing the sample. As both
of these geometry details are important in
terms of weld integrity, it is clear that an
optimized approach needs to be taken
such that the maximum penetration and
effective throat are deposited to satisfy the
structural integrity demands with the con-
verse being the case in terms of minimiz-
ing the weld heat input and final distor-
tion. Hence, in an attempt to achieve the
optimum weld geometry conditions, the
implementation of various model simula-
tion environment software, such as artifi-
cial neural networking (ANN), offers con-
siderable predictive strength to this
optimization approach.
Artificial neural networks are mathe-
matical or computational models that are
able to capture and represent complex
input-output relationships. They are dis-
tributed, adaptive, generally nonlinear
learning machines built from many differ-
ent processing elements (PEs) (Ref. 14).
McCulloch and Pitts (Ref. 15) developed
the first neural networks in 1943 based
upon their understanding of neurology;
this operated using simple and/or logic
functions and made several assumptions
as to the operation of neurons. Major ad-
vances were made around 1960 when
Rosenblatt (Ref. 16) designed and devel-
oped the perceptron, which was con-
structed by multiple layers and allowed the
system to learn to associate a given input
to an output. Around the same time,
Widrow and Hoff (Ref. 17) developed the
ADALINE (ADAptive LINear Element)
system, an analogue electronic device that
operated on the Least Mean Square
(LMS) learning rule. Werbos (Ref. 18) de-
veloped the backpropagation learning
method in the early 1970s and although
this learning method took a number of
years to gain popularity, it is now probably
the best known and applied learning
method used today. The interconnectivity
of the PEs defines the topology of the net-
work. There are three main network
topologies commonly implemented:
Multilayer Perceptron (MLP)
Generalized Feed-Forward (GFF)
Modular Feed-Forward (MFF)
Neural networks can be used to predict
any process as long as sufficient data are
generated to accurately train and validate
the model. The GMAW process is ex-
tremely complex and involves the interac-
tion of several nonlinear welding vari-
ables. Artificial neural networks have the
ability to develop patterns and detect sub-
tle link/trends that are too complex to be
observed via other techniques, therefore
allowing for the strong indicators of new
situations of interest. In addition, other
computational modeling environments
are unidirectional, i.e., calculate an output
for a given set of input variables, and often
require extensive computational power to
process complex models whereas ANNs
are bidirectional and have the ability to
predict the input variables required to
produce a given output. The ANNs can,
therefore, be employed to accurately pre-
dict mechanical properties and other im-
portant weld characteristics without the
need for destructive testing, while precise
models will provide confidence in the
welds produced.
The basic architecture of an ANN is
shown in Fig. 2 and consists of intercon-
nected processing elements in the differ-
ent layers of the system:
An input layer represents the raw
data that are fed into the system
One or more hidden layers the out-
put of which is determined by the activities
of the inputs and the weights of the con-
nections
An output layer conveys the signals
to the environment and is dependent upon
the processes and weights of the hidden
units.
This type of computational model can
be effectively applied to the welding
process where the input layer consists of
the welding parameters and the output
layer is made up of the weld geometry, me-
chanical properties, and other factors as a
consequence of the input parameters.
Artificial neural networks were first
applied to the welding process around the
early 1980s (Refs. 19, 20). Since then they
have been used extensively in the predic-
tion of weld characteristics such as me-
chanical properties (Refs. 2125) and
have been shown to be fairly accurate in
determining tensile strength, hardness,
elongation, and impact energy. They have
been used to determine the weld quality
(Ref. 26) based upon differing input set-
tings including current, voltage, and gas
compositions. Artificial neural networks
have also been implemented for the pre-
diction of weld-induced deformation
(Refs. 27, 28) and weld geometry (Refs.
2931). Although ANNs have previously
been used for the prediction of various
welding parameters, there have been no
publications for the prediction of welding
parameters while implementing this novel
technique of alternately supplying shield-
ing gases. Further information on the his-
torical development of ANNs toward
welding processes is reported elsewhere
(Refs. 32, 33).
Experimental Setup
The material used throughout was 6-
mm-thick DH36 grade steel in the form of
60-mm-wide bar with a typical chemical
composition shown in Table 1. The bars
were tacked together in the form of an in-
verted T as shown in Fig. 3.
The average welding parameters are
shown in Tables 2A and 2B. The gas flow
was controlled using an electronic control
unit (Fig. 4), which allowed the alternating
frequency to be accurately set prior to
welding while implementing an oscillo-
scope for validation. The basis of the unit
was two timing circuits (one for each gas)
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Fig. 1 Arc pressure and fluid flow vectors (Ref. 3). Fig. 2 Multilayer perceptron architecture with one hidden layer.
Campbell Supplement June 2012_Layout 1 5/10/12 1:30 PM Page 175
that generated a continuous square wave
at a specified frequency. The output from
the timing circuits was then used to con-
trol the current supply to the solenoid
valves in order to regulate the flow of each
gas. The unit incorporated an invert func-
tion to supply opposite signals to each
valve for alternation precision, thus gen-
erating a pressure-time graph comparable
to that shown in Fig. 1. It is important to
recognize that although the alternating
frequency is a variable during experimen-
tation, each gas is supplied for 50% of the
time regardless of the frequency. Since the
flow rate of each gas was preset at 15
L/min (when flowing continuously), the
overall gas consumption remained 15
L/min independent of the frequency. At
present, the device used for alternating
the shielding gases is an experimental unit
that is not currently commercially avail-
able. However, the unit is a simple setup
that was minimal in cost to generate. The
potential savings and benefits (Ref. 1) of
the system are likely to substantially out-
weigh any modest capital investment re-
quired to implement the technology on a
commercial scale.
There are various filler materials used
in industry depending upon the applica-
tion and the ability of each to be used in a
particular weld position including solid
wire, metal cored wire, and flux cored
wire. One-mm metal cored wire (EN 758:
T46 4 M M 1 H5), which has a typical all-
weld-metal chemical composition as
shown in Table 3, was used throughout ex-
perimentation with a constant feed speed
of 90 mm/s.
All experimental welds were deposited
on an automatic welding rig where the
plate, held rigid, moved at a preset speed
under a fixed welding nozzle as shown in
Fig. 4. The nozzle used was adapted so as
to allow the helium to be directly supplied
to the welding zone Fig. 5. In each case
the welds were produced using a torch
preset at a 45-deg angle and fixed in
position.
A precalibrated, portable arc monitor-
ing system (PAMS) was used throughout
to accurately obtain the welding arc volt-
age and current. The on-board A-D con-
verter of the PAMS unit has a 14-bit reso-
lution that results in the voltage being
accurate to approximately 0.012 V and the
current to approximately 0.12 A. The sam-
ple frequency of the unit is 5 kHz and will
therefore accurately represent the aver-
age parameters even when alternating be-
tween gases since the sample frequency (5
kHz) is very much greater than the alter-
nating frequency (28 Hz).
Model Development
The software implemented for this
study was NeuroSolutions, which had pre-
viously been used successfully for the pre-
diction of weld geometries (Ref. 31) and
distortion (Ref. 27). A total of 45 samples
was produced (9 for each gas configura-
tion), a hold-out method was used
throughout the model generation process,
in which 40 samples were used for the
training of the model while the remaining
5 (one for each gas configuration) for test-
ing. These data are displayed in Table 2A.
The same five test data sets were used
throughout in order to produce a direct
comparison on the accuracy of the model
using each of the topologies. Throughout
model generation, each model was run
three times and the average error taken.
This was done since the same topology
with the same training data can produce so
many different sets of final weights. There
are three main reasons behind this:
There are many symmetries in the input-
output mapping created by the MLP.
There is no guarantee that the problem
has a single solution.
The final weights are obtained in an iter-
ative fashion from random initial values.
The following network topologies were
considered:
Multilayer Perceptron (MLP)
Generalized Feed-Forward (GFF)
Modular Feed-Forward (MFF)
Mathematically, the output from each
of the models is the same and can be rep-
resented as shown in Equation 1:
where O is the output, I
n
is the n
th
input
sample, w
n
is the weight of the n
th
sample,
and n is the number of samples.
It was found that although the MLP
topology produced a higher mean square
error than the GFF and MFF topologies,
when comparing the percentage errors of
the test data sets it was found that the
MLP topology produced the lowest error
and was therefore selected.
There is an optimum number of itera-
tions for training the model and, conse-
quently, the number of learning iterations
had to be determined. The model was
O l w
n
n
n
n
=
=

1
(1) *
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Fig. 3 Weld detail showing geometries measured. Fig. 4 Automatic welding rig (Insert: gas control unit).
Table 1 Chemical Composition of DH36
Steel (trace indicates nondeliberate additions)
Element Chemical Compostion
(wt-%)
Carbon 0.15
Silicon 0.35
Manganese 1.38
Phosphorus 0.013
Sulfur 0.012
Chromium 0.017 (trace)
Molybdenum 0.001 (trace)
Nickel 0.018 (trace)
Aluminum 0.026
Copper 0.01 (trace)
Niobium 0.025
Nitrogen 0.003
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Table 2A Training/Testing Weld Data
Weld Parameters Weld Outputs
Shielding Gas Voltage (V) Current (I) Travel Speed (mm/s) Penetration (mm) Leg Length (mm) Effective Throat (mm)
Configuration
Ar/20%CO
2
21.7 158 2.0 1.168 6.739 4.626
Ar/20%CO
2
23.6 157 2.0 1.471 6.541 4.710
Ar/20%CO
2
26.0 157 2.0 0.992 7.628 4.943
Ar/20%CO
2
22.0 151 2.5 1.483 6.249 4.626
Ar/20%CO
2
23.9 154 2.5 1.044 6.687 4.182
Ar/20%CO
2
26.1 157 2.5 1.070 6.894 4.357
Ar/20%CO
2
21.9 152 3.0 1.078 5.300 3.298
Ar/20%CO
2
23.8 158 3.0 1.391 6.371 3.916
Ar/20%CO
2
26.1 158 3.0 1.136 6.506 4.228
Alternating @ 2 Hz 21.8 153 2.0 1.229 6.803 5.637
Alternating @ 2 Hz 23.4 156 2.0 1.421 6.977 4.646
Alternating @ 2 Hz 26.4 159 2.0 1.365 7.171 4.616
Alternating @ 2 Hz 22.0 157 2.5 1.020 6.559 4.964
Alternating @ 2 Hz 23.7 156 2.5 1.269 5.789 3.807
Alternating @ 2 Hz 25.8 159 2.5 1.116 7.634 5.236
Alternating @ 2 Hz 21.9 152 3.0 1.107 5.365 4.748
Alternating @ 2 Hz 23.4 155 3.0 1.426 5.319 4.556
Alternating @ 2 Hz 26.2 154 3.0 1.342 5.498 4.200
Alternating @ 4 Hz 21.6 150 2.0 1.148 6.913 5.752
Alternating @ 4 Hz 23.9 155 2.0 1.494 6.680 5.091
Alternating @ 4 Hz 25.8 156 2.0 1.499 6.582 4.879
Alternating @ 4 Hz 21.7 157 2.5 1.277 6.196 4.818
Alternating @ 4 Hz 23.7 155 2.5 1.315 6.467 4.869
Alternating @ 4 Hz 25.6 157 2.5 1.371 6.207 4.032
Alternating @ 4 Hz 21.9 154 3.0 1.235 5.727 4.798
Alternating @ 4 Hz 23.8 159 3.0 1.581 4.969 3.333
Alternating @ 4 Hz 26.1 156 3.0 1.290 5.699 4.407
Alternating @ 6 Hz 21.7 154 2.0 1.338 6.416 5.680
Alternating @ 6 Hz 23.5 159 2.0 1.690 6.352 4.855
Alternating @ 6 Hz 25.6 159 2.0 1.347 7.069 4.563
Alternating @ 6 Hz 22.0 152 2.5 1.172 6.239 4.975
Alternating @ 6 Hz 24.3 153 2.5 1.577 5.926 4.044
Alternating @ 6 Hz 25.5 156 2.5 1.198 6.303 3.928
Alternating @ 6 Hz 21.8 156 3.0 1.069 5.133 3.812
Alternating @ 6 Hz 24.0 151 3.0 1.216 5.703 3.679
Alternating @ 6 Hz 25.6 156 3.0 1.702 5.856 3.609
Alternating @ 8 Hz 21.7 155 2.0 0.915 7.326 5.589
Alternating @ 8 Hz 24.0 158 2.0 1.039 7.279 4.475
Alternating @ 8 Hz 25.9 158 2.0 1.522 7.368 4.617
Alternating @ 8 Hz 21.9 154 2.5 1.141 6.459 4.664
Alternating @ 8 Hz 23.9 153 2.5 1.244 6.490 4.093
Alternating @ 8 Hz 26.0 155 2.5 1.415 6.901 4.265
Alternating @ 8 Hz 22.2 153 3.0 1.503 5.364 4.449
Alternating @ 8 Hz 24.0 157 3.0 1.263 5.370 4.014
Alternating @ 8 Hz 26.0 155 3.0 1.711 5.886 3.940
Table 2B Validation Weld Data
Weld Parameters Weld Outputs
Shielding Gas Voltage (V) Current (I) Travel Speed (mm/s) Penetration (mm) Leg Length (mm) Effective Throat (mm)
Configuration
Alternating @ 5 Hz 21.7 153 2.0 1.288 6.835 5.675
Alternating @ 5 Hz 23.8 156 2.0 1.534 6.922 4.923
Alternating @ 5 Hz 25.8 157 2.0 1.421 7.052 4.652
Alternating @ 5 Hz 21.9 157 2.5 1.201 6.177 4.955
Alternating @ 5 Hz 24.0 154 2.5 1.363 6.431 4.366
Alternating @ 5 Hz 26.1 155 2.5 1.315 6.661 4.211
Alternating @ 5 Hz 22.1 154 3.0 1.218 5.295 4.352
Alternating @ 5 Hz 23.9 157 3.0 1.341 5.480 3.934
Alternating @ 5 Hz 25.8 156 3.0 1.523 5.794 3.892
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trained using between 4000 and 20,000 iter-
ations, with 8000 iterations producing the
lowest percentage error and, therefore, the
most accurate approximation. Contrary to
what would be logically expected, the neu-
ral network can become overtrained and
the percentage error actually increases
above 8000 iterations (Ref. 14).
The number of hidden layers of pro-
cessing elements (PEs) that are not con-
nected directly to the external world was
established. There are two extreme cases
for the number of hidden layers: either the
network has too many PEs to do the job,
or it has too few. The model was run with
15 hidden layers; it was found that the 1
hidden layer model re-
turned the lowest per-
centage error of the test
data.
Momentum learning
was then applied to the
model, which is an im-
provement to the straight
gradient-descent search
in the sense that a mem-
ory term is used to speed
up and stabilize conver-
gence. The use of a mo-
mentum coefficient
helps stop the learning
process getting stuck in a
local minimum or flat
spot. In momentum
learning, the equation to update the weights
becomes Equation 2.
where w
ij
is the weight that connects the i
th
PE to the j
th
PE, n is the iteration number,
is the step size,
i
is the computed error at
the i
th
PE, x
j
is the flow of activations at the
j
th
PE, and is the momentum constant.
The use of momentum learning results
in the weighting changing proportionally
to how much they are updated in the pre-
vious iteration. The momentum constant
can have a value of between 0 and 1. It was
determined that a value of 0.7 produced
the most accurate model.
The final stage in the model develop-
ment is specifying when the weights are up-
dated. Online learning updates the weights
after the presentation of each data set. In
contrast, batch learning updates the weights
w n w n n x n
w n w n
ij ij i j
ij ij
+
( )
=
( )
+
( ) ( )
+
( )

1
1

(( ) ( )
(2)
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Fig. 5 Welding torch showing adapted nozzle.
Fig. 7 Effect of shielding gas configuration on predicted penetration.
Fig. 6 Comparison of experimental and predicted geometries.
Fig. 8 Temperature contours at a 200-A welding current (Ref. 25) for
the following: A Argon; B helium.
Table 3 Chemical Composition of Welding
Wire
Element Chemical Compostion
(wt-%)
Carbon 0.05
Silicon 0.5
Manganese 1.3
Phosphorous <0.015
Sulphur <0.015
A
B
Campbell Supplement June 2012_Layout 1 5/11/12 2:31 PM Page 178
after the presentation of the entire training
set. It was found that batch learning updates
returned the lowest final error.
After this procedure, it was deter-
mined that the following network archi-
tecture provides the best-fitting model:
Model Topology Multilayer Perceptron
Iterations 8000
Hidden Layers 1
Momentum Coefficient 0.7
Weight Updating Batch
The model, constructed according to
the network architecture specified previ-
ously, was then validated against experi-
mental data (Table 2B) not contained
within the training or testing data. This
was used solely to ensure the model was
learning the trends among the training
data, with the testing data being used for
comparison in the later discussions.
Prediction of Weld Geometry
The model generated has been shown
to accurately represent the weld penetra-
tion, leg length, and effective throat thick-
ness by comparing the actual values with
those predicted by the NeuroSolutions
package as shown in Fig. 6. The software
has been shown, on average, to overesti-
mate weld penetration by 0.06 mm and un-
derestimate leg length and effective throat
thickness by 0.23 and 0.52 mm, respec-
tively. When compared with the experi-
mental data, this equates to percentage er-
rors of 4.9, 3.4, and 9.6%, respectively,
which is deemed as highly accurate in any
ANN study.
The trained model was then applied to a
given set of input parameters with the only
variable being the shielding gas composi-
tion. The results (Fig. 7) show that the ad-
dition of helium has resulted in an increase
in penetration, due to the narrower, more
concentrated arc column that helium pro-
duces (Ref. 34), as depicted in Fig. 8.
Additionally, the prediction has shown
that increasing the frequency of shielding
gas alternation from 2 to 8 Hz resulted in
a 0.03-mm increase in penetration. As a
consequence, for a given level of penetra-
tion, the travel speed can be increased re-
ducing the cost of the weld. It has been de-
termined that for an equivalent level of
penetration, the travel speed for alternat-
ing shielding gases can be increased, on
average, by 28% over the Ar/20%CO
2
base case, and therefore has the potential
to greatly increase the productivity of the
welding process. This confirms the find-
ings of Campbell et al. (Ref. 1), which
demonstrated that the travel speed can be
increased by 18% on the second pass and
82% on the third pass, thus resulting in an
overall time reduction of 22%.
It has been widely publicized that plate
distortion is a function of heat input. It has
been reported that lower heat input weld-
ing processes result in less heat-induced
distortion (Refs. 1, 35). The decrease in
heat input, which would be as a result of
the increased travel speed used to produce
the equivalent levels of penetration when
using alternating shielding gases, will also
have beneficial effects with regard to
weld-induced distortion.
The model has also shown that the ap-
plication of alternating shielding gases re-
sults in a shorter leg length (Fig. 9), thus
confirming the experimental results and is
a consequence of the concentrated arc col-
umn that helium produces (Ref. 34). The
effective throat thickness is shown to in-
crease with the use of alternating shielding
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Fig. 9 Effect of shielding gas configuration on predicted leg length. Fig. 10 Effect of shielding gas configuration on predicted effective throat.
Fig. 11 A Weld profile showing the concavity of a typical weld produced using Ar/20%CO
2
; B weld profile showing the convexity of a typical weld pro-
duced using alternating shielding gases.
A B
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gases (Fig. 10); this is primarily linked to
the added convexity of the weld metal with
the addition of helium.
The macro images (Fig. 11) show that
a typical alternating shielding gas weld
produces a narrower weld with increased
convexity (while Fig. 3 shows the meas-
ured dimensions). This, along with the re-
sults generated by the ANN model, show
there is a trend between the shielding gas
and the weld geometry. As reported by
Kang et al. (Ref. 3), alternating shielding
gases creates complex flow vectors within
the molten weld pool, whereas constant
gas flows produce a steady flow vector. It
was reported that helium produces a flow
vector that circulates inward, which will
result in a narrower, more convex, weld
profile. This is most probably due to the
Marangoni effect in that the shielding gas
configuration affects the surface tension
of the weld, resulting in a thermocapillary
convection phenomenon. As the
Marangoni effect is governed by the tem-
perature gradient on the weld pool surface
and the temperature coefficient of the sur-
face tension, it follows that, as helium has
a higher arc power density than argon, it
consequently produces a smaller cathode
spot, an increased electromagnetic force,
and an increase in the temperature gradi-
ent of the weld pool surface. Conse-
quently, helium will have a greater
Marangoni effect than argon and will thus
create greater surface tension, which ex-
plains the narrower weld with greater pen-
etration shown in Fig. 11.
Sensitivity Study
A sensitivity study is an extremely pow-
erful tool in the NeuroSolutions package
that can be used to determine the influ-
ence of each of the input variables on the
output of the model.
In order to perform the sensitivity analy-
sis, the neural network must first be
trained as normal. The analysis then per-
turbs each of the inputs, one at a time, by
a known variance from the mean while
keeping all other variables at their respec-
tive means and measuring the change in
the output.
The sensitivity for the input k can be ex-
pressed as shown in Equation 3.
where S
k
is the sensitivity for input k, y
ip
is
the i
th
output obtained with the weights
fixed for the, p
th
pattern, o is the number
of network outputs, p is the number of pat-
terns, and
2
k
is the variance of the input
perturbation.
This, when applied across the training
data, can compute how much a change in
the input affects the output. The sensitiv-
ity of a model is not only important in the
context of this model, i.e., determining the
key factors for weld penetration, etc., but
also aids the training of the model with in-
puts of high sensitivities having more im-
portance in the mapping.
Sensitivity of Results
The results of the sensitivity study, Fig.
12, show that the travel speed is the most
influential input variable in affecting the
output variables. This is to be somewhat
expected since the heat input, Q, is directly
related to the travel speed through Equa-
tion 4.
where V is the voltage (V), I is the current
(A), is the thermal efficiency factor, and
TS is the travel speed (mm/s).
The sensitivity study results show that
the shielding gas configurations have the
lowest contribution of the inputs on the
weld geometries. However, this cannot be
taken at face value and is a result of the
sensitivity study perturbing the alternating
frequency, e.g., comparing an alternating
frequency of 5.9 Hz with 6 Hz. As can be
seen in Figs. 6, 8, and 9, although there is
a slight change in the geometries using dif-
ferent frequencies of alternation, the
greatest step change is observed between
the use of premixed Ar/20%CO
2
and al-
ternating at 8 Hz; although, in fact, any
frequency of alternation provides a similar
step change. Figures 6, 8, and 9 also show
that alternating shielding gases have a pos-
itive effect on the level of weld penetration
while also reducing leg length and in-
creasing the effective throat thickness.
Conclusions
A comparison of experimental and
predicted results show that ANN software
can be successfully employed to generate
a model to predict multiple weld geome-
tries. The results of the sensitivity analysis
were in agreement with both findings of
the experimental investigations and find-
ings in other literature.
The ANN model has shown the ability
to accurately identify subtle differences in
the weld geometry, and has consequently
produced a relationship linking the fre-
quency of alternation to the weld penetra-
tion that has not previously been recog-
nized. In doing so, this has shown that
there is an inherent relationship between
the frequency of alternation and the travel
speed.
It has also been found that by training
the model in reverse, the model can be im-
plemented to determine the weld param-
eters required to produce a weld of speci-
fied geometry. The implementation of an
ANN model for the prediction of the weld
parameters necessary to satisfy a given
geometry requirement can reduce the
time required compared to determining
the parameters experimentally, producing
a noticeable economic benefit.
As a consequence of computational
models becoming ever more advanced,
their ability to accurately predict key weld
geometries for a given set of parameters
will help increase confidence that the re-
sultant weld will be of this desired quality.
Acknowledgments
The authors would like to acknowledge
the funding provided by BAE Systems
Surface Ships Ltd., which made this re-
search possible. Additional thanks are due
to Dr. Martyn Lightfoot of the Ship-
builders and Shiprepairers Association
and Simon Beckett of BAE Systems for
their support.
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Q
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TS
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*
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*
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JUNE 2012, VOL. 91 180-s


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Fig. 12 Sensitivity analysis results.
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Campbell Supplement June 2012_Layout 1 5/10/12 1:30 PM Page 180
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son, N. A., and Woods, K. 2005. The application
of artificial neural networks to weld-induced
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28. Lightfoot, M. P., McPherson, N. A.,
Woods, K., and Bruce, G. J. 2006. Artificial neu-
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30. Nagesh, D. S., and Datta, G. L. 2010. Ge-
netic algorithm for optimization of welding
variables for height to width ratio and applica-
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for TIG welding process. Applied Soft Comput-
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31. Beckett, S., MacPherson, M. J., and
McPherson, N. A. 2011. Improved welding con-
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C. 1993. Use of neural networks for parameter
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33. Anderson, K., Cook, G. E., Ramaswamy,
K., and Karsai, G. 1990. A novel approach to-
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and weld geometry. Recent Trends in Welding
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34. Jnsson, P. G., Eagar, T. W., and Szekely,
J. 1995. Heat and metal transfer in gas metal arc
welding using argon and helium. Metallurgical
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AWS Debuts Careers in Welding Trailer
The AWS Careers in Welding Trailer offers many attractive features to get
young people excited about welding industry careers.
In particular, the mobile exhibit showcases the following:
Five of The Lincoln Electric Co.s VRTEX 360 welding simulators that feed
computer-generated data with a virtual welding gun and helmet equipped with in-
ternal monitors;
Interactive educational exhibits, including a display wall featuring 11 indus-
try segments with trivia questions, fun facts, and industry artifacts;
Day in the Life of a Welder exhibit with videos depicting real-life environ-
ments in which welders work;
Life-size welder highlighting welding as a safe profession;
Social media kiosk; and
Welding scholarship information.
The 53-ft, single expandable trailer designed and built by MRA experiential
tours and equipment covers 650-sq-ft of exhibit space.
It is expected the trailer will be on the road for 1824 weeks in 2012. To learn
more and view its schedule, visit www.explorewelding.com.
WELDING JOURNAL 181-s
Campbell Supplement June 2012_Layout 1 5/10/12 1:30 PM Page 181
Introduction
Transverse weld metal cracking is
known as a potential defect in field weld-
ing of high-strength steel transmission
pipelines especially when using the
shielded metal arc welding (SMAW)
process with cellulosic electrodes. This
type of cracking is known to be related to
the weld metal hydrogen content and can
occur hours after completion of welding
(Refs. 15). Although no standard proce-
dure exists for the assessment of suscepti-
bility of transverse cracking in pipeline
welding, M. Fiedler et al. have proposed
guidelines for such assessment based on
bend testing and investigated the effects of
preheat and weld metal strength (Ref. 6).
On the other hand, field experience has
shown that cracking occurs more in the six
oclock position of pipeline girth welds
(Refs. 7, 8). This defect needs to be treated
seriously, especially as sometimes it could
not be detected through common radi-
ographic inspection methods (Ref. 8).
A review of the literature shows that in
spite of much research being performed on
the subject of the assessment of hydrogen
cold cracking susceptibility, either in the
heat-affected zone (HAZ) or the weld
metal (Refs. 9, 10), the problem of higher
susceptibility of cracking as related to weld-
ing direction and welding position has not
gained much attention. The aim of the pres-
ent research is to establish whether factors
other than preheat and weld metal strength
can play a significant role in the tendency
for transverse weld metal cracking and
whether such behavior can be reproduced
under laboratory conditions. The result can
be expected to have an important impact on
the selection of preventive measures with
respect to avoidance of hydrogen cracking
in welding of high-strength steels especially
in field welding of transmission pipeline
construction projects.
Experimental Procedure
The chemical composition of the base
material is given in Table 1. It was a 20-
mm-thick steel plate obtained from a pipe
mill, which used the same base material
for production of 56-in. OD API 5L X 70
pipes. The plates were cut into 300-mm-
long by 125-mm-wide pieces to be able to
place them in the fixture. The plates were
welded to each other by the SMAW
method. Consumable materials used in
different passes were as follows:
AWS E6010, 4 mm diameter for root
pass.
AWS E8010-P1, 4 mm diameter for hot
and filling passes.
AWS E8010-P1, 5 mm diameter for cap
passes.
The welding process was conducted
with the voltage in the range of 2324 V
and the current in the range of 120160 A.
A fixture was designed to weld pipeline
materials in the form of plate segments in
various positions Figs. 1, 2. The fixture
was made of 80-mm-thick steel plates with
six removable clamps incorporated. After
fixing the test coupon plates into the fix-
ture, welding was performed. The welds
were made with various preheats includ-
ing that recommended by previous re-
searchers (Ref. 6) and with no preheat.
For other welding parameters such as volt-
age, current, and travel speed, the actual
field welding conditions for an actual 56-
in. transmission pipeline with the same
thickness but for various positions around
the girth weld were used.
Experiments were designed mainly to
investigate the effects of two specific pa-
rameters: welding position and direction.
The combinations of welding parameters
tested are shown in Table 2. Trial number
3 was arranged parallel to trial number 1
with preheat in order to check if the test
setup was sensitive enough to the known
parameter of preheating. Weld directions
similar to that of actual field girth welding
were considered, i.e., in overhead position
JUNE 2012, VOL. 91 182-s
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ABSTRACT
The higher tendency for weld metal
transverse cracking at certain positions
as observed in field welding of high-
strength pipeline steels was investigated
under laboratory conditions. Experi-
mental results confirmed reproducibil-
ity of such behavior and significance of
a number of variables. It is shown that
welding position and welding direction
can contribute interactively in terms of
the provision of the conditions for hy-
drogen cold cracking in the weld metal.
A higher level of hydrogen absorption
in the overhead position and an inward
weld direction are proposed to be the
metallurgical factors involved in an in-
crease in cracking susceptibility at the
six oclock position in pipeline girth
welds.
KEYWORDS
Shielded Metal Arc Welding
SMAW
Weld Metal
Transverse Cracking
Hydrogen Cracking
Welding Position
Welding Direction
S. SARAFAN and F. M. ALEK GHAINI
(fmalek@modares.ac.ir) are with Dept. of Mate-
rials Engineering, Tarbiat Modares University,
Tehran, Iran. E. RAHIMI is with AMA Industry
Co., Tehran, Iran.
Effects of Welding Direction and Position on
Susceptibility to Weld Metal Transverse
Cracking in Welding High-Strength Pipeline
Steel with Cellulosic Electrodes
Welding position and welding direction can contribute interactively in terms of the
provision of the conditions for hydrogen cold cracking in weld metal
BY S. SARAFAN, F. M. ALEK GHAINI, AND E. RAHIMI
Sarafan Supplement June 2012_Layout 1 5/10/12 1:33 PM Page 182
welding from the edges of plate inward
and in flat position welding from the plate
center outward. Figure 3 illustrates the
two directions schematically.
After completion of welding, the test
plates were kept in the fixture for 24 h to
allow any potential delayed hydrogen
cracking process to take effect. Then a ra-
diographic test was performed according
to API 1104 (Ref. 11) to check if any
cracks could be identified. However, be-
cause hydrogen cracks can be so minute
that they may not be identified through ra-
diography, the weld specimens were sub-
jected to bend testing. On the other hand,
it is known that fisheyes can occur in bend
tests in the presence of diffusible hydro-
gen in carbon steel (Ref. 1). Thus, a dehy-
drogenization treatment was performed
for 16 h at 250C in the furnace in order to
eliminate the possibility of formation of
fisheye defects during bend testing and to
avoid mistaking them for hydrogen cracks.
From each test run, two longitudinal spec-
imens were taken out by machining. One
specimen was subjected to bend testing;
the other was subjected to metallographic
examination. The bend test conditions
and dimension of the mandrel were simi-
lar to those used by a previous researcher
due to the similarity (Ref. 6) in the objec-
tives of the test. In this bend test, a 180-
mm mandrel was used. The bend test spec-
imen consisted partly of weld metal and is
shown in Fig. 4. The setup for bending of
specimens with a 180-mm-diameter man-
drel is shown in Fig. 5.
For metallographic examination, the
specimens were machined and ground in
two different directions: from top and side
faces of the specimens. Thus, the mirror of
the face of the weld metal, which was
under tension in bend testing, was also
subjected to metallographic examination.
The hardness survey tests were performed
along with the metallographic studies.
The diffusible hydrogen was measured
by the mercury method based on AWS
A4.3 (Ref. 12). This method and appara-
tus are mainly designed for measuring dif-
fusible hydrogen for basic low-hydrogen
electrodes, and in this sense the capacity
of the container for the volume of hydro-
gen was 60 mL. Based on Yurioka et al.
(Ref. 3) for cellulosic electrodes, if the
specimen for testing diffusible hydrogen is
immediately quenched after welding, the
amount of diffusible hydrogen could be
around 60 mL/100g. However, when the
specimen after welding was given 10 min
to allow some hydrogen to escape before
quenching, the amount of diffusible hy-
drogen was brought down to 15 mL/100g.
Thus, it was decided this delay time before
quenching would be a good solution to en-
able using the available equipment for
comparison purposes between various
welding conditions of cellulosic elec-
trodes. It must be mentioned that the re-
sult obtained with this 10-min delay can-
not and should not be compared with
those obtained with the normal proce-
dure. The welding consumable for hydro-
gen measurement was the E8010-P1 type
with diameter 5 mm, which according to
the welding procedure was used for fill
and cap weld layers.
Results and Discussion
No crack was identified in radiographic
examination of any of the welds tested, but
cracks were observed in a number of bend
tests. Metallographic examination of the
corresponding samples taken in the as-
welded condition (i.e., no bending) also
revealed transverse weld metal cracks with
similar relative severity confirming the va-
lidity of the bend test Fig. 6A. Both in
the bend test and metallographic exami-
nations, cracks if present were located in
the upper part of the thickness (i.e., in the
fill passes just before the cap pass). The
crack lengths ranged from 0.5 to 5 mm.
From Table 2, it appeared that with the
application of preheat, as would have been
expected, the number of cracks identified
in the bend tests were reduced signifi-
cantly and almost eliminated. On the
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Table 1 Chemical Composition of Base
Metal (wt-%)
C 0.08 Ti 0.018
Mn 1.6 P trace
Si 0.15 S trace
Cr trace V 0.04
Ni 0.15 Cu 0.004
Nb 0.044 Mo 0.2
Fig. 1 Fixture with six removable clamps and the
plate in place.
Fig. 2 Two different positions of welding: A
Overhead position; B flat position.
Fig. 3 Two different directions of welding: A
From the edges of the plate inward: B from the
plate center outward.
Fig. 4 Dimensions of bend test specimen. Width
= 10 mm, length = 300 mm, thickness = 20 mm.
Table 2 Results of Weld Tests on API X70 Pipe Plate
Welding position Overhead Flat
Trial Number 1 2 3 4 5 6
Welding progression
Preheat temperature (C) 20 20 130 20 20 20
Interpass temperature (C) 40 40 140 40 40 40
Heat input (kj/mm
-1
) 3.3 4 3.2 4.7 5.1 3.3
Cracks observed in RT 0 0 0 0 0 0
Cracks observed in bend test 25 4 3 1 15 22
Electrodes
A
B
A
B
Sarafan Supplement June 2012_Layout 1 5/11/12 2:33 PM Page 183
other hand, the number of cracks ob-
served in the bend tests were significantly
affected by variations in the welding pa-
rameters. Considering the results pre-
sented in Table 2, welding in the overhead
position and an inward welding direction
both have had an important impact on in-
creasing the cracking tendency.
Weld metal diffusible hydrogen content
measurement tests were performed in the
flat and overhead positions. The results as
shown in Table 3 indicate that a higher level
of hydrogen was absorbed in the overhead
position. The average diffusible hydrogen in
the weld metal made with E8010-P1 type
electrode in the overhead position with a
10-min delay before quenching came up as
42 mL/100g in comparison with 19 mL/100g
in the flat position. The above figures as
shown in Table 3 were obtained by averag-
ing out the results of four measurements.
The table also shows the calculated stan-
dard deviations. Statistical analysis of the
result of hydrogen measurements can be
made by using t distribution test (Ref. 13).
Analysis shows that with a 90% confidence
limit the estimate for diffusible hydrogen
content with 10 min delay time in the over-
head position is 42 13 mL/100g but that
in the flat position is 193.3 mL/100g. The
above analysis indicates that the difference
between the diffusible hydrogen content is
significantly affected by the weld position.
However, considering the complexity of the
test procedure, and the fact there was not
much track record available in the factory
on hydrogen absorption in the weld metals
of cellulosic electrodes used, it is too early
to quantify the effect of weld position on hy-
drogen for a cellulosic electrode.
From Table 2, it is apparent the heat
input in the overhead position was lower
on average compared to that in the flat
position. With the lower heat input, a
higher cooling rate is experienced.
Therefore, it can be proposed that weld-
ing in the overhead position can result in
an increase in the susceptibility to cold
cracking by providing a higher cooling
rate that, in turn, may result in a higher
level of diffusible hydrogen remaining in
the weld metal after the completion of
welding. However, by increasing the cool-
ing rate, a harder microstructure can be
formed in carbon manganese weld metal
and, at the same time, the escape of dif-
fusible hydrogen can be slowed down.
Hardness measurements indicate some
correlation between hardness and weld
position (i.e., welding heat input). The
maximum, average, and minimum hard-
ness of the weld metal in the fill passes
measured in more than ten locations of a
weld made in the overhead position was
205, 179, and 138 HV, respectively, in
comparison with 201, 175, and 110 HV
for a weld made in the flat position. As
can be seen, considering the variations
and uncertainties usually involved in
hardness measurements and the weld mi-
crostructures, it is only the minimum
hardness in the flat position that can be
interpreted as lower.
So far, the effect of the welding posi-
tion has been discussed, so now the ques-
tion must be addressed of how weld di-
rection can affect weld metal transverse
cracking. It is a known fact that hydrogen
cracking is not only affected by the
amount of weld metal diffusible hydro-
gen and the microstructure, but also by
the magnitude of residual stresses. The
most important hypothesis that was ar-
rived at and is now put forward is that
welding direction can affect the state of
weld residual stresses and that, in turn,
can affect the tendency toward hydrogen
cracking. Inward welding directions
along with an overhead welding position
occur together when field welding at the
6 oclock location of transmission
pipelines with the SMAW process using
cellulosic electrodes. So, in continuation,
the researchers are pursuing the means
to test the relation of weld direction and
weld residual stresses. This will include
calculation of weld residual stresses by
simulation and numerical methods sup-
ported by direct measurements of resid-
ual stresses by destructive and nonde-
structive techniques.
Conclusions
The higher tendency for transverse
cracking of the weld metal in the 6
oclock position in field welding of high-
strength transmission pipelines with
the SMAW process using cellulosic
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Table 3 Results of Diffusible Hydrogen Measurements
Electrode Type E 8010-p1
Trial No. 1 2
Welding Position Flat Overhead
Delay Time (s) 600 600
Specimens 1 2 3 4 1 2 3 4
Diffusible Hydrogen
(mL/ 100g) 16.2 22.4 20.3 17.1 36.5 58.5 31.5 41.4
Standard Deviation 2.86 11.73
T test distribution by 193.3 4213.5
confidence limit of 90%
Fig. 5 Three-point bend test with 180-mm-di-
ameter mandrel.
Fig. 6 Examination of cracks in specimen
with inward progression and overhead weld po-
sition in the following: A 20x metallographic
specimen that does not bend through the thick-
ness and from side view; B bent specimen.
The appearance of cracks in both examinations
is transverse with 45 deg.
A
B
Sarafan Supplement June 2012_Layout 1 5/11/12 2:34 PM Page 184
electrodes is reproducible under labo-
ratory conditions by separately testing
the effects of welding position and
welding direction.
The number of cracks revealed after
bending the specimens increases both
when welding in the overhead position
and when welding with inward weld
runs.
The increased cracking tendency ob-
served at the 6 oclock position is the
combined effect of the welding direc-
tion and the welding position.
The diffusible hydrogen content of the
weld metal made with a cellulosic elec-
trode in the overhead position is more
than that in the flat position.
References
1. Bailey, N., and Coe, F. R. 1973. Welding
steels without hydrogen cracking. Abington
Publishing and ASM International pp. 57.
2. Lancaster, J. F. 1999. Metallurgy of Weld-
ing. 6th edition, Abington Publishing.
3. Yurioka, N., and McDonald, J. 1999.
Weld metal hydrogen cracking in pipeline girth
welds. First International Conference on Weld
Metal Hydrogen Cracking in Pipeline Girth
Welds, Wollongong, Australia.
4. Sawhill, J. M., Dix, A. W., Savage W. F. 1974.
Modified implant test for studying delayed crack-
ing. Welding Journal 53(12): 554-s to 560-s.
5. Borland, J. C. 1960. Cracking tests for as-
sessing weldability. British Welding Journal. Oc-
tober, pp. 623637.
6. Fiedler, M., Fischer, J., Posch, G., and
Berger, W. 2006. Investigation of HAC-suscep-
tibility of multilayer welds with the bead bend
test procedure and examples. Bohler Welding
Austria GmbH, Kapfenberg, Austria.
7. ESAB Welding Handbook, Consumables
for manual and automatic welding, 8th edition.
8. Malek, F., Roshani, M. A., Akhavan, M.,
and Gholizade, S. 2008. Detectability of trans-
verse cracks in gas and oil pipeline girth welds.
2nd International Conference on Technical In-
spection and NDT. Tehran, Iran.
9. Sarafan, S., Malek, F., and Rahimi, E.
2010. Weld metal hydrogen cracking in pipeline
constructions. International Pipeline Conference
(IPC), Calgary, Canada.
10. Pitrun, M. 2004. The effect of welding
parameters on levels of diffusible hydrogen in
weld metal deposited using gas shielded rutile
flux cored wires. University of Wollongong,
Wollongong, Australia.
11. ANSI/API 1104, Welding Pipelines and
Related Facilities, 19th edition. Washington,
D.C.: American Petroleum Institute.
12. AWS A4.3-93, Standard Methods for De-
termination of Hydrogen Content of Martensitic,
Bainitic, and Ferritic Steel Weld Metal Produced
by Arc Welding. 1993. Miami, Fla.: American
Welding Society.
13. Triola, M. F., and Guardino, K. 1997. El-
ementary Statistics, 7th edition, Addison Wesley
Longman.
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Submit a New Products
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