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November 2013
WELDING JOURNAL VOLUME 92 NUMBER 11 NOVEMBER 2013
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
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CONTENTS
40
46
Features
Departments
40
46
52
56
60
FABTECH
Check out all the events and technical presentations the
show has to offer on the welding side
Editorial ............................4
Press Time News ..................6
International Update ............10
News of the Industry ............12
Stainless Q&A ....................18
RWMA Q&A ......................24
Product & Print Spotlight ......28
AWS Show Information..........60
AWS Events at a Glance ........66
AWS Professional Program ....67
AWS Exhibit Highlights..........89
Coming Events ..................164
Certification Schedule ........166
Welding Workbook ............168
Society News....................169
Tech Topics ....................170
Official Interpretations:
A5.11, D1.3, D1.8 ..........170
Guide to AWS Services ......180
Personnel........................182
Red Hots ........................184
Logos ............................193
Classifieds ......................197
Advertiser Index ................198
52
On the cover: The Chicago River is a picturesque waterway that winds through
downtown Chicago. The Willis Tower, which at over 1,700 feet tall is one of the
worlds tallest buildings, is pictured here in the background. Photo credit
Todd Rosenberg.
WELDING JOURNAL
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Officers
President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
U. Aschemeier (Dist. 7), Miami Diver
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
R. E. Brenner (Dist. 10), CnD Industries, Inc.
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (At Large), Tri Tool, Inc.
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (Dist. 17), The Harris Products Group
W. A. Komlos (Dist. 20), ArcTech, LLC
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), NS Inspection and Consulting
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
Debbie Doench
Chair, AWS Publications, Expositions, Marketing
Committee (PEMCO)
NOVEMBER 2013
PRESS TIME
NEWS
Arcet Equipment and Machine & Welding Supply Merge
The businesses of Arcet Equipment Co., Richmond, Va., and Machine & Welding
Supply Co., Dunn, N.C., have merged. They will initially operate as wholly owned subsidiaries of a new entity known as Arc3 Gases, Inc., as a 50/50 merger.
Parker Dillard and Emmett Aldredge Jr. will serve as co-chairmen of the board of
directors of Arc3 Gases. In addition, Emmett Aldredge III will serve as co-president of
the company with Parker Dillard. The executive team includes Andy Ellen as chief financial officer and Christopher Aldredge as chief operating officer. Ray Dillard has
been named Arcets general manager, and Jeff Johnson has been named general manager of Machine & Welding Supply.
The two multigeneration family businesses will operate a total of 46 retail locations
in North Carolina, South Carolina, and Virginia as well as a beverage CO2 business serving the eastern U.S. from Delaware to Florida.
MEMBER
NOVEMBER 2013
IT TAKES
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For Info go to www.aws.org/ad-index
INTERNATIONAL
UPDATE
Gallery Exhibits Welded Pieces
by Bob Dylan
exhibition in Chemnitz, Germany, in 2007 and several subsequent exhibitions, this show, titled Mood Swings, will feature iron
works by Dylan, alongside original works on canvas and signed
limited editions, all of which will be for sale.
Seven iron gates, welded out of vintage iron and other metal
parts, created by Dylan in his studio will be featured in the exhibition and will be displayed publicly for the first time. These
gates and other objects are the outcome of the artists lifelong
fascination with welding and metalwork.
The Mood Swings exhibit will showcase ironworks by artist and singer
Bob Dylan. (Image credit: Bob Dylan, 2013 John Shearer.)
Halcyon Gallery, Mayfair, London, is presenting an exhibition
of new works by musician and artist Bob Dylan from November
16 to January 25. Building on the success of his first museum
ved
Ti
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NOVEMBER 2013
WELDING JOURNAL
11
NEWS OF THE
INDUSTRY
Bowling Green Assembly Plant Gets $131 Million Technology Investment
General Motors (GM) $131 million technology investment at the Bowling Green Assembly Plant in Kentucky such as the
first production use of a GM-patented process allowing aluminum to be spot welded to aluminum is resulting in the strongest
and most precisely built Corvette in its six-decade history.
New technologies enable more accurate and efficiently produced subassemblies, such as the frame and components attached to
it. Laser-based, three-dimensional inspection systems verify overall assembly tolerances targeted to be 25% tighter than the previous-generation Corvette.
Approximately $52 million of the investment went
to a new body shop that manufactures the cars lightweight aluminum frame in-house for the first time.
This is not only the foundation for the cars greater
driving capabilities, but also the platform on which
the 2014 Corvette Stingray is more precisely constructed. It is 99 lb lighter and 57% stiffer than the
previous-generation frame.
In addition, it is the most complex frame design in
the cars history, featuring main rails composed of five
customized aluminum segments, including aluminum
extrusions at each end, a center main rail section, and
hollow-cast nodes at the suspension interface points.
There are 439 aluminum resistance spot welds on
the Corvette Stingray coupe. GMs new resistance
spot welding process uses a patented multi-ring
domed electrode. Also, laser welding is used in the
frames tunnel subassembly to attach sheet aluminum
closeout panels to the tunnel structure. Laser-based
vision inspection for quality assurance includes Per- A 2014 Chevrolet Corvette Stingray frame makes its way down the composite
ceptron-supplied tools to monitor critical points on line in the new, $52 million body shop at General Motors Bowling Green Asevery Corvette body that comes down the line.
sembly Plant. (Photo by AJ Mast for Chevrolet.)
A recent article by Mary Perez of The Sun Herald, the newspaper covering the Mississippi Gulf Coast, paid tribute to Vera
Anderson, the Worlds Champion Welder, who died Aug. 29
at the age of 90.
She earned the title during World War II while working at Ingalls Shipbuilding in Pascagoula, Miss. Anderson was 19 when
she competed against other female welding champions. In 1944,
she won the first Womens National Welding Championship, receiving $350 in war bonds and a trip to the White House.
I was invited to have tea with Mrs. Roosevelt. She talked
about what a contribution the women were making to the war effort, Anderson later said.
continued on page 15
12
NOVEMBER 2013
Ironworkers
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IF WE DONT HAVE
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One call to Donaldson Torit is all it takes to fulll
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Youre sure to get EXACTLY WHAT YOU NEED.
Vera Anderson raises her welding torch after being named Worlds
Champion Welder in a 1944 competition. (Photo courtesy of Huntington Ingalls Industries.)
When she became the Gulf Coast Welding Champion, that
brought a challenge from Vancouver Yard of Kaisers Shipbuilding Co., which claimed the West Coast Champion, Hermina
Strmiska. She won that challenge on May 28, 1943. Then Moore
Dry Dock and Shipbuilding Co., Oakland, Cal., claimed the previous contestant was not the West Coast Champion. On Jan. 24,
1944, Anderson kept her crown by outwelding Edna Slocum.
In announcing the winner of this contest, NBC announced I
was Champion Woman Welder of the World, Anderson said.
Her story part of the National History Project along
with her picture, history, and welding trophy are on display in
the military museum at Camp Shelby, Hattiesburg, Miss.
DonaldsonTorit.com
800.365.1331
2013 Donaldson Company, Inc.
WELDING JOURNAL
15
consortium for which the total award amount is nearly $13 million. The Southeastern Economic and Education Leadership
Consortium implements a partnership in support of developing
educational/career pathways tied to national industry standards/credentials in welding, machining, and manufacturing.
In Wyoming, the Northern Wyoming Community College District has been awarded nearly $2.8 million. It is working with existing Trade Adjustment Assistance Community College and Career Training-funded programs to develop training curriculum
that lead to credentials for machinists, and award one-year certificates and two-year associates degrees in machine tool technology and welding technology.
The nexAir demo lab offers three welding stations fitted with Fronius, Lincoln Electric, Miller Electric, and Hypertherm equipment
and accessories.
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16
NOVEMBER 2013
2013
Industry Notes
Chicago Bridge and Iron will contribute $100,000 to Central
Piedmont Community College to support welding and nondestructive exam facilities at its Harper Campus, Charlotte, N.C.
Advance Welding, West Springfield, Mass., an AWS Supporting Company Member, is celebrating its 35th anniversary. The
company is Nadcap accredited with merit for fusion and resistance welding, plus brazing; ISO9001/AS9100 certified; and
is a certified FAA Repair Station.
Quality Marine Alaska, Kodiak, was recently featured in the
Alaskan Steel Men series, which follows the adventures of a team
of extreme heavy-metal welders on the Discovery Channel.
Victor TechnologiesTM, St. Louis, Mo., is positioning Tweco
as its single brand for specialty welding products/arc accessories. Starting with the Tweco Fabricator 3-in-1 welding machines, and continuing throughout the Thermal Arc product
line, all welding products will transition.
Shasta College, Redding, Calif., has expanded its cooperative
program with local businesses by working with Sierra Pacific
Industries to train students in practical welding technology
applications. They are constructing projects that will be put
into use by the company at its local wood products facilities.
GEs Measurement and Control business is expanding its portfolio of inspection technologies through a new agreement with
Thermo Fisher Scientific. The company will sell three of
Thermos products in the positive material identification area.
Hobart Institute of Welding Technology, Troy, Ohio, has been
named a Military Friendly School for 2014 by Victory Media
Inc., the media entity for military personnel transitioning to
civilian life.
The Independent Welding Distributors Cooperative recently
announced the addition of Holston Gases, Knoxville, Tenn., a
large independent supplier of many gases, to its membership.
Ten soldiers from Joint Base Lewis-McChord in Washington
graduated from its first Heating, Ventilation, Air Conditioning and Refrigeration, Veterans In Piping Welding Program.
Abbott Welding Supply, Olean, N.Y., has purchased Lind Welding Supply, Jamestown, N.Y., allowing it to provide an expanded selection of gases, welding supplies, and products.
Find
us at
Booth N854
McCormick Place
Chicago, IL
www.binzel-abicor.com
WELDING JOURNAL
17
STAINLESS
Q&A
Q: I have been using the ArcWorks software from Lincoln Electric to calculate
Ferrite Numbers for austenitic stainless
steel weld metals. However, my old computer, with the Microsoft Windows XP
operating system, is being replaced and
the new computer, with a newer version of
Windows, does not support the old software. What can I do?
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NOVEMBER 2013
WELDING JOURNAL
19
20
NOVEMBER 2013
RWMA
Q&A
ing caveat must be understood: This discussion is really relevant only for automotive-grade coated steel products, with
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NOVEMBER 2013
are many variables that must be considered, addressed if they are out of compliance, documented for reference, and,
finally, maintained for the life cycle of
the part.
Acknowledgment
I would like to thank James W. Dolfi,
former AWS Detroit Section, D8D and
Auto/Steel Partnership (ASP) Joining
Committee chairman, for his invaluable
perspective on the welding of coated
materials.
References
1. AWS D8.9:2012, Test Methods for
Evaluating the Resistance Spot Welding
Behavior of Automotive Sheet Steel Materials. Miami, Fla.: American Welding
Society.
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Range of High-Strength
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NOVEMBER 2013
value of 12 cal/cm2, and is machine washable in cold water. It repels sparks, spatters, molten metals, and is abrasion resistant. The base coat fabric is a blend of
cotton/modified acrylic fiber type F/
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The coat is available from stock in large,
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Torch Wear
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products designed to improve productivity and efficiency in day-to-day metalworking operations. The brochure showcases the companys selection of metalworking products, including magna rolls,
vibratory feeders and conveyors, magnetic
drum separators, and grate magnets. Each
product is outlined with a brief synopsis
and the application it serves. The fourpage, full-color brochure is available online and in hard copy format, by request.
ing. It cleans, contains, and filters wash
water, removing contaminants for recycling or proper discharge to drain. Benefits include the GripStart on/off system;
1500 to 2900 lb/in.2 of cleaning power; low
profile; nonskid, flat surface; manufactured to length and width requirements,
the design allows for a multitude of pad
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The company recently launched a redesigned Web site, which showcases stain-
Gentec is a total solution provider for your welding, cutting, and gas control needs.
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Our Roundo R-16S Angle Rolling Machine is only the second machine
with this technology and capacity in the world, and the only one in
the United States. It can roll any beam size either the easy way or the
hard way. It can roll a W40-in. by 211-lb. beam to a radius less than
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Welding Ingenuity +
Operational Changes =
A Saved Business
Heres how fabrication improvements and
leadership insight transformed Sintel from
nearly closing its doors to an award winner
NOVEMBER 2013
BY KRISTIN CAMPBELL
KRISTIN CAMPBELL
(kcampbell@aws.org) is associate
editor of the Welding Journal.
Fig. 1 Sintels President and CEO Nick Kulkarni (left) stands with Senior Welding Engineer Scott Keeney (center) and Director of
Engineering and Quality Jeff Falzone (right) by two welding robots in the companys facility.
41
NOVEMBER 2013
Earthmoving, Construction, and Agricultural Equipment. They also follow customer specifications, Caterpillars 1E0099
Arc Welding, and internal WPSs.
Welder Makeup
Fig. 6 After getting laser cut, stamped, brake formed, and welded, steel parts get put
on an overhead line for dry-off oven entry.
Processes Employed
Gas metal arc welding represents
99% of our welding operations, Keeney
said.
Pulsed GMA, gas tungsten arc (GTA),
Day-to-Day Operations
Traditionally, steel parts are first laser
cut, stamped, and brake formed. Welding
supervisors look at their daily dispatch report and assign parts to be made. In turn,
welders execute work orders.
After, parts attached to an overhead
line move through the dry-off oven
Fig. 6.
Any hole threads in the parts are
plugged for powder coating Fig. 7.
Then parts get washed, rinsed, an iron
phosphate coating is applied, rinsing occurs again, and a sealer is added. The curing of the powder-coated parts takes
about 1520 min; they move through this
on a line about 7 ft/min at 400F.
It takes anywhere from one to ten days
for completing each order. There are
areas for final assembly stations, staging,
and auditing. Proper packing instructions
must be followed for shipping Fig. 8.
Quality Checks
Fig. 7 In the powder coating area, one operator covers the front side of a part while another handles the back side.
43
Staying In Line
Organization is needed in the facility,
especially considering up to 15 components could make up just one part.
A real-time system developed in-house
allows visual tracking. Operators can select the pallet to work on, and its organized by the due date, Kulkarni said.
Visual management boards showing
production part approval processes allow
fast tracking. Metric boards list costs, part
numbers, and failure modes. Enterprise
resource planning software with a scheduling algorithm helps daily work plans.
44
NOVEMBER 2013
Fig. 9 Double the action, double the processing time as two welding robots in
the warehouse operate with coordinated
motion.
Facility Features
Sintel has been housed at its current
headquarter building since 1971. With additions, it now covers 150,000 sq ft.
In the warehouse, steel is delivered
three to four times a day, including thin
sheets and thicker grades.
Many types of equipment are available
for GMA, pulsed GMA, GTA, resistance,
robotic, and stud welding; nitrogen and
oxygen laser cutting; brake forming,
stamping, and pressing; computer numerical control machining; powder coating;
and assembly work Fig. 9.
The only new equipment added as part
of the turnaround were pulsed GMAW
and enhanced ventilation systems with
other safety-related improvements.
Additional capabilities include linear
measuring; nesting software; coordinate
measuring; a 150-ton moving machine for
high-volume jobs; hole punching; gas and
curing ovens; hardness testers; and an internal calibration system.
There are also divisions to house various departments, including welding; research and development; quality assurance; manufacturing and design; engineering; and maintenance because all fixturing is done in-house Fig. 10.
A cell offers many different kinds of
Additional Changes
To get a glimpse into what a shop position consists of, for example assembly or
welding, managers and support personnel
work 2 h each week in those roles. This
experience has been key to having an appreciation for someone elses job and
bringing people together.
Its the eradication of an us vs. them
culture, Kulkarni added. Were all one
team here. It shows a collective cultural
change.
Conclusion
Fig. 10 Quality Supervisor Connie Corbett is shown in the quality assurance division
where responsibilities include making two-dimensional drawings.
WELDING JOURNAL
45
Controlling
SMA Welding Fumes
in the Mining Industry
hielded metal arc welding (SMAW)
is the most common process used
in the quarry, mining, excavating,
and coal industries for equipment repair,
refurbishment, and small fabrication.
Hardfacing using an alloyed steel electrode is commonly practiced on ore and
shovel buckets, scrapers, rock crusher
jaws, and crusher liners that require a
high surface hardness to withstand impact, abrasion, and wear. Other components used in the steel mills and foundries
may require a combined resistance to severe impact and abrasion, metal-to-metal
wear resistance, heat, and corrosion. It
is important to monitor the fume generated during hardfacing operations because electrodes used in these operations
generally contain high amounts of
chromium, manganese, and nickel, all of
which may cause long-term health effects
when exposed to continuously for long
periods. In confined or poorly ventilated
areas found in some mining operations,
the removal of welding fume may not be
adequate or effective.
In this research, EFeCr-A1 was chosen for an extended study due to its
higher fume-formation rate (FFR) and
manganese content in the fumes. The
EFeCr-A1 (both diameters) is normally
used for hardfacing load-haul-dump
(LHD) buckets, dozer blades, and truck
beds. Small beads (in varying patterns)
are typically deposited on the wear surface of equipment (e.g., loader buckets,
dozer blades, or truck beds) to increase
the wear resistance of these parts that
come into contact with highly abrasive
rocks. The process of hardfacing involves
a considerable amount of welding time.
A typical LHD bucket requires about 40
h of welding to surface the inside of the
mining bucket tooth. Thus, the FFR and
the total amount of fume generated be-
Fumes were
collected under
various conditions
to determine how
to ensure welder
safety when using
shielded metal arc
consumables to
maintain heavy
equipment
46
NOVEMBER 2013
Fig. 1 Experimental setup used for collection of fume-exposure data. The two filter positions shown: 13 in. above base plate and above gravity torch and 17 in. above center of
the plate on the fume ventilation system. The dimensions of the steel plate on the gravity
welding machine are 8 12 in.
Experimental Procedures
The EFeCr-A1 grade SMAW electrodes of 532-in. (4-mm) diameter were
further studied to examine the industrial
effect of hardfacing a bucket tooth based
on welding zones. Four welding condi-
47
Table 1 Average Electrode Feed Rate and Weld Travel Speed for Each Tested Condition during Fume Analysis Experiment
Conditio
Time per
Weld (s)
Length of
Weld (mm)
DCEP Hood On
DCEP Hood O
DCEN Hood On
DCEN Hood O
90.4
93.7
91.4
94.4
170
166
159
160
Length of Spent
Electrode (mm)
101
121
131
120
Total Mass of
Electrode (kg)
1.44
1.33
1.28
1.34
Feed Rate
(mm/s)
Travel
Speed
(mm/s)
3.02
2.70
2.65
2.68
1.88
1.77
1.74
1.70
Metal
Total
Condition Tested
Weight in
(mg/mm3) 106
Fume (mg)
DCEP Hood
On Trunk
Positio
DCEP Hood
On Welder
Positio
DCEP Hood
O Trunk
Positio
DCEP Hood
O Welder
Positio
DCEN Hood
On Trunk
Positio
DCEN Hood
On Welder
Positio
DCEN Hood
O Trunk
Positio
DCEN Hood
O Welder
Positio
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
0.889
0.052
0.028
0.0067
0.012
0.001
1.599
0.092
0.040
0.013
0.022
0.0067
1.799
0.029
0.021
0.015
0.0080
0.0021
1.499
0.046
0.043
0.077
0.0042
0.0055
38.28
2.230
1.197
0.288
0.508
0.043
68.85
3.953
1.714
0.567
0.939
0.288
77.46
1.240
0.896
0.654
0.344
0.090
64.55
1.972
1.843
3.323
0.181
0.237
Fume Adjusted to
1-h Duratio
(mg/m3)
Electrode (mg/kg)
7.410
0.432
0.232
0.056
0.098
0.0083
13.33
0.765
0.332
0.110
0.182
0.056
14.99
0.240
0.173
0.127
0.067
0.018
12.49
0.382
0.357
0.643
0.035
0.046
0.618
0.036
0.019
0.00460
0.0082
0.000696
1.200
0.069
0.030
0.0099
0.016
0.0050
1.406
0.023
0.016
0.012
0.0063
1.0016
1.121
0.034
0.032
0.058
0.0031
0.0041
Note: All fume data have been adjusted to a 2-h sample time for data comparison. These values are raw manipulations of the collected data and cannot be compared to the time
weighted-average values provided by OSHA and MSHA.
Table 3 Time-Weighted-Average Values of Fume Exposure for Welder Position (Welding Zone) with Dierent Test Condition
Location and Test
Metal
Conditio
DCEP Hood on
Welder Positio
DCEP Hood O
Welder Positio
DCEN Hood On
Welder Positio
DCEN Hood O
Welder Positio
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
chromium
manganese
nickel
3.34
5.90
0.50
6.59
10.90
3.35
7.59
4.00
1.05
38.59
2.10
2.75
Bucket Tooth
Done in 8-h
Shift (mg/m3)
25.05
44.25
3.75
49.43
81.75
25.13
56.93
30.00
7.88
289.43
15.75
20.63
Note: Time-weighted-average values of fume exposure for welder position have also been extrapolated to simulate hardfacing a 13- 31-in. bucket tooth.
48
NOVEMBER 2013
Fig. 2 Comparison of VFFRs adjusted to 1-h duration at welder vs. trunk positions for
hardfacing using EFeCr-A1 SMAW electrodes on 34-in.-thick A36 structural steel base metal
(pyramid chromium, box nickel, and cylinder manganese).
Table 4 OSHA and MSHA Limits for Allowable Fume Concentration Levels for an 8-h
Shi
Element
Chromium
Manganese
Nickel
1
5
1
1
5
1
hood was on and off during the experiments. All VFFRs were calculated using
the following equation that OSHA and
MSHA use to convert total fume collected to a fume concentration:
(fume collected (mg))/(pump flow rate
(L/min) 0.001(m 3/L) sampling time
(min)) = fume concentration (mg/mg3)
(1)
With respect to polarity, welding in
direct current electrode positive (DCEP)
should increase the melt rate of the electrode, which should in return increase
FFRs and thereby VFFRs. The sums of
the chromium, manganese, and nickel
VFFRs at the fume-extraction trunk position for DCEN and DCEP are 15.4 and
8.1 mg/m 3, respectively, when the fume
hood is on, i.e., active fume extraction.
Consequently, more fume was captured
in the filters. When the fume hood was
off, the sums were 13.2 and 14.4 mg/m3
WELDING JOURNAL
49
Conclusions
DCEN with active fume extraction
captured the most fume overall.
Chromium was highest in value at the
trunk position (away from the breathing
zone) for both polarities and fume hood
conditions. With the fume hood on,
DCEN and DCEP welding produced 15
and 7.4 mg/m3 of chromium, respectively.
With the fume hood off, DCEN
and DCEP were 12.5 and 13.3 mg/m 3,
respectively.
Manganese had a higher fume value
for DCEP than DCEN for both fume
hood conditions and positions. At the
trunk position with the fume hood on,
DCEP and DCEN were 0.43 and 0.24
mg/m 3. At the welder position (breathing zone) with the fume hood on, DCEP
and DCEN were 0.10 and 0.07 mg/m 3.
With active fume extraction off, DCEP
and DCEN, the manganese contents
were 0.18 and 0.04 mg/m3.
The welding condition with the lowest fume reading for the welder position
50
NOVEMBER 2013
Acknowledgments
The authors would like to acknowledge Doug Scott of the National Institute for Occupational Safety and Health,
Spokane Research Laboratory, for his interest and support of part of this work.
The authors would also like to thank the
Environmental, Health, and Safety Department at the Colorado School of
Mines for its guidance on fume analysis,
and Jason Dardano, Paul Gibbs, and
Peerapong Kiattisaksri for their assistance with part of the fume-collection
work reported in this article.
References
1. Jenkins, N. T., Pierce, W.M.G., and
Eagar, T. W. 2005. Particle size distribution of gas metal and flux cored arc welding fumes. Welding Journal 84(10): 156-s
to 163-s.
2. Dennis, J. H., Hewitt, P. J., Redding, C. A. J., and Workman, A. D. 2001.
A model for prediction of fume formation rate in gas metal arc welding
(GMAW) [MIG/MAG welding)], globular and spray modes, DC electrode positive. The Annals of Occupational Hygiene
45(2): 105113.
3. Mendez, P. F., Jenkins, N. T., and
Eagar, T. W. 2000. Effect of electrode
droplet size on evaporation and fume
generation in GMAW. Proceedings of the
Gas Metal Arc Welding for the 21st Century Conference, Orlando, Fla.
4. Zhou, S., Norrish, J., and Chen, Z.
1998. Influence of different metal transfer modes on welding fume generation
during gas metal arc welding. Biennial
Materials Conference of the Institute of
Materials Engineering Australasia (Australia), pp. 295300. Wollongong University Press.
5. Deam, R. T., Simpson, S. W., and
Haidar, J. 2000. A semi-empirical model
of the fume formation from gas metal arc
welding. Journal of Physics D: Applied
Physics 33(II): 13931402.
6. Redding, C. J. 2002. Fume model
for gas metal arc welding. Welding Jour-
Change of Address?
Moving?
Make sure delivery of your Welding
Journal is not interrupted. Contact
Maria Trujillo in the Membership
Department with your new address information (800) 443-9353, ext. 204;
mtrujillo@aws.org.
Alabama Center
Preps Trainees for
Shipbuilding Jobs
BY MARY RUTH JOHNSEN
MARY RUTH JOHNSEN
(mjohnsen@aws.org) is editor of
the Welding Journal.
52
NOVEMBER 2013
Project Manager Tony Hopper explained the Maritime Training Center got
its start in 2007 when it was set up in a
16,000-sq-ft facility at the Brookley Aeroplex, an industrial complex and airport
that lies adjacent to the western shore of
Mobile Bay on the site of a former U.S.
Air Force base. Hopper and another instructor, Troy Cochran, have been with
the center since its beginnings. The state
broke ground on the current facility in
June 2009 and it officially opened November 8, 2010. It features classrooms,
computer labs, an electrical lab, and a
nondestructive testing lab, as well as a
meeting room with space for 200 people.
The shop floor (Fig. 1) includes 60 welding booths, a CNC plasma table, a submerged arc welding machine, a large laydown yard (Fig. 2) with overhead crane
access, a counterbalanced rough terrain
forklift, manlift, scaffolding, and a 10-ton
overhead crane and rigging for safety
training, among other equipment. Eventually, 24 more welding booths will be
added.
The facility is a National Center for
Construction Education and Research
(NCCER) accredited training unit under
the Gulf States Shipbuilders Consortium.
Its stated mission is to provide a technically trained, highly skilled, and educated workforce for industrial and maritime-related technologies, and to promote the growth and expansion of businesses through craft education.
The center does not guarantee employment upon completion of its training, nor do students have to accept a job,
if offered; however, placement rates are
high.
Companies and organizations affiliated with the center, and which offer
services and support, include the following:
Airgas USA LLC
Aker Solutions
WELDING JOURNAL
53
5
Fig. 5 The center aims to replicate real-life work situations, so
students must punch in and out each day.
Fig. 6 Examples of the types of welds students must learn to
produce.
6
Alabama Community College System
Alabama Technology Network
Austal USA
American Welding Society Mobile
Section
BAE Systems
C&G Boatworks
CLOOS Robotic Welding, Inc.
ESAB Cutting Systems
G.A. West & Co., Inc.
Gulf State Shipbuilders Consortium
Gullco
Horizon Shipbuilding
Joint Maritime Test Detatchment
(JMTD)
The Lincoln Electric Co.
Miller Electric Mfg. Co.
Morris Marine Consulting, LLC
Offshore Inland Marine & Oilfield
Services
OTC Daihen, Inc.
Performance Contractors, Inc.
Sabel Steel Industries
Signal International
Vines Consulting, LLC
WESCO
Attached to the center both physically
and in an affiliation with AIDT is the
Austal USA apprentice training site.
AIDT provides the facility and about
75% of the equipment; Austal supplies
the rest of the equipment, the instructors, and the students.
54
NOVEMBER 2013
The Curriculum
The following courses are offered at
the facility:
Structural welding
Structural fitting
Pipe welding
Pipe fitting
Nondestructive examination, which includes the visual, magnetic particle, dye
penetrant, and ultrasonic testing
methods
AutoCAD
Marine design
Ship construction
Forklift training
Manlift training
Overhead crane and rigging
Scaffold building
CNC plasma arc cutting
Marine electrical and marine machinist are expected to be added next year.
Bob Riley was Alabama governor
when the center was being built. The
governor wanted this to be a wellrounded school that would cover all aspects of the maritime industry, Hopper
recalled.
Employees of companies registered
with the center are accepted first, then
individuals with no company affiliation
are allowed to sign up for classes.
The greatest number of students take
Welding Classes
Instructors teach the shielded metal
arc, gas metal arc, and flux cored arc
welding processes, as well as oxyfuel cutting. The welding curriculum also includes math and marine terminology.
At present, the 60 welding booths are
divided equally between aluminum and
steel setups, but they can be reconfigured
if needed Fig. 3. The booths are
stocked with 18 Lincoln Electric and 42
Miller Electric power sources and wire
feeders. The center also has a demonstration area that includes equipment
from a variety of manufacturers Fig.
4. Companies that book the meeting
room also have access to the demonstration area. This gives students exposure
to a range of equipment from a variety
of manufacturers.
Our product is the student, Hopper
explained. We need to train them generically so theyre familiar with various
equipment manufacturers.
The centers aim is to replicate a realworld work experience. Students punch
in when they report to the school and out
when classes are over Fig. 5. Beside
practicing in their welding booths, they
work in the outside yard so they are exposed to the conditions found in most
shipyards.
Student Milton Cross had recently retired from the Coast Guard and was looking for a new career. His son-in-law works
for Austal and encouraged Cross to go
for training that could possibly land him
a job there as well.
I enjoy the hands-on (part of the
training), Cross said. The instructors
are attentive. They work to help you perform better.
Larry Abercrombie, another student,
said he thought the program would really be tough after he saw all the types of
welds hed have to learn Fig. 6. But
day after day I see improvement, he
said. Now when I see a new weld its not
freaking me out any more, but it takes
patience.
The center employs five full-time instructors, as well as several office staff
members. Hopper is an AWS Certified
Welding Supervisor, Certified Welding
Inspector (CWI), and Certified Welding
Educator (CWE), as well as a certified
NCCER Master Trainer. Donnie Jemison has more than 30 years of experience
in welding and is an AWS CWI, CWE,
and a certified NCCER Craft Trainer.
WELDING JOURNAL
55
56
NOVEMBER 2013
Demonstrating Conformance
to ASME Section IX
NX-2410 requires that welding consumables be what is specified in the
Welding Procedure Specifications
(WPSs). That is, when the WPS specifies
E7018-H4R, the welding consumable
purchased must meet the requirements
of that classification in the applicable
SFA filler metal specification in ASME
Section II, Part C. Those specifications
say that the filler metal manufacturer certifies the material supplied conforms to
the specification when the AWS classification is marked on the product or the
packaging. While this is sufficient to show
the material meets the requirements of
the SFA specification and Section IX,
Certificate Holders should have on file a
Certificate of Conformance for the specific trade name material(s) they are
using. A Certificate of Conformance
(sometimes known as a typical test report) is not for the specific heat/lot combination being purchased, but from some
heat/lot of that trade name consumable
that was tested at some earlier date. Interpretation III-82-10 supports this approach to complying with the first part
of NX-2410.
When the consumable does not conform to a specification in Section II, Part
C, or it is a G classification (e.g.,
E8018-G), Section IX requires that consumable to be qualified based on trade
name or other established procurement
document such as a company specification, and that trade name or company
identification has to be specified on the
WPS. No Certificate of Conformance is
needed to meet Section IX requirements
for material qualified by this route since
that material does not, by definition, con-
Fig. 1 Pad for chemical analysis of undiluted weld metal (from SFA 5.1).
form to a filler metal specification, although it may be possible to obtain a certificate when the material conforms to a
G classification.
Qualifying Manufacturers
and Distributors of
Welding Consumables
The first step is to be sure the consumables manufacturer has a manufacturing process control program that controls the raw materials and formulations
that make up the consumables. NX2420(ah) defines welding consumable
controls using the following terms:
Heats of wire.
Chemically controlled tube, wire, or
strip.
Batches of dry covering mixture, dry
flux blends, and wet flux mixes, and
chemically controlled flux mixes that
are combined with individual heats of
wire or with chemically controlled tube,
wire, or strip to make a lot of covered,
flux cored, or fabricated electrodes.
Lots of submerged arc or electroslag
flux.
Dry blend of supplementary powdered
filler metal.
Chemically controlled mix of powdered filler metal.
Welding of Consumable
Test Coupons
NX-2420 requires each heat, lot, and
combination of welding consumables to
be tested. While NX-2410(b) provides a
list of information required to be supplied to the organization doing the testing of the consumable, that organization
could be the Certificate Holder itself, so
dont read that list as a requirement to
have the consumable manufacturer do
the testing.
57
58
NOVEMBER 2013
Fig. 2 Groove weld test assembly for mechanical properties and soundness of weld
metal.
Tensile Strength
Requirements
The tensile strength of the filler metal
must meet the specified minimum tensile
strength of the base metals it will join, or
the lower of the two if the tensile
strengths are different. Tensile testing has
to be done in the as-welded condition if
the production weld will be left as-welded
and in the heat-treated condition if the
production weld will be heat treated.
Toughness Testing
Requirements
Just as the tensile strength of the weld
metal has to meet that of the base metal,
the weld metal has to be tested at or
below the test temperature of the base
metal that it will join. It must also meet
the same acceptance criteria as that base
metal or the lower of the two if the acceptance criteria are different; however,
unlike tensile strength, impact acceptance criteria for the base metal depend
upon its thickness and the lowest service
temperature of the component being
built. Impact testing has to be done in the
as-welded condition if the production
weld will be left in the as-welded condition and in the heat-treated condition if
Table 1 Impact Testing Requirements for Piping, Pumps, and Valves (Table NB2332(a)-1 Modified)
Nominal Wall Thickness
in. (mm) (Note 1)
Lateral Expansion
mils (mm)
8 (16) or less
Over 58 to 34 (16 to 19) inclusive
Over 34 to 112 (19 to 38) inclusive
Over 112 to 212 (38 to 64) inclusive
If over 212 in. (64)
No test required
20 (0.50)
25 (0.64)
40 (1.00)
Drop weight testing and Charpy testing
Note 1: For pumps, valves, and other components, use the thickness of the connecting piping.
Practical Observations
Regarding Impact Testing
The Design Specification defines the
LST for most Section III construction,
and the Owner or the Engineer has to
provide it to the Certificate Holder.
When I worked for an NPT stamp holder
back in the 1970s, we ordered welding
materials and qualified our WPSs at 32F
(0C) since the plant operating fluid was
water whereas containment structures
and spent fuel transport casks can have
very low service temperatures, but a
Summary
The manufacturer needs to control
welding consumables so that the metal
and fluxes that make up those consumables are uniquely identified by heat, lot,
batch, and blend; that control needs to
be verified by the Certificate Holder.
Each heat, lot, batch, or blend combination must be tested and must meet the
same tensile and impact test requirements as the base metal that that consumable will be used to join and those
requirements are different from those of
the filler metal (SFA) specifications.
Mechanical testing has to be done in
the same heat treatment condition as the
production weld.
Chemical composition of the weld
metal has to meet the requirements of
the filler metal specification, and
austenitic stainless steel weld metal has
to exhibit a minimum ferrite number
(FN) of 5.
WELDING JOURNAL
59
FABTECH
General Attendance Information
FABTECH 2013 Returns to Chicago
Registration
Location
McCormick Place
2301 S. Lake Shore Drive
Chicago, Illinois 60616
(312) 791-7000
www.mccormickplace.com
Show Dates and Hours
Monday, November 18, 10:00 a.m. 6:00 p.m.
Tuesday, November 19, 9:00 a.m. 5:00 p.m.
Wednesday, November 20, 9:00 a.m. 5:00 p.m.
Thursday, November 21, 9:00 a.m. 3:00 p.m.
Technology Pavilions
To guide attendees to products and services easily, the show floor
is organized into Pavilions that are geared toward specific
industries and technologies. FABTECH will encompass both
North and South halls of McCormick Place.
60
NOVEMBER 2013
3.0 Miles
3.0 Miles
5.0 Miles
Youll receive hotel support prior, during, and after the event.
Fairmont Chicago
2.7 Miles
3.0 Miles
1.8 Miles
3.2 Miles
4.0 Miles
2.2 Miles
2.0 Miles
Adjacent
Book your room through the official FABTECH hotel block and
you are guaranteed to get the best rates (if you find a lower rate,
let us know). Free shuttle service is available to and from
McCormick Place and designated event hotels.
Distance from
Convention Center
2.0 Miles
2.0 Miles
3.0 Miles
1.9 Miles
2.9 Miles
1.5 Miles
Swissotel Chicago
3.1 Miles
3.0 Miles
W Chicago Lakeshore
3.6 Miles
4.0 Miles
5.0 Miles
3.1 Miles
4.0 Miles
3.2 Miles
2.5 Miles
WELDING JOURNAL
61
Check out the new FABTECH blog. Find the latest industry news and technology updates, along
with updates on the FABTECH exposition and conference at blog.fabtechexpo.com.
Follow us on Twitter, @fabtechexpo and #fabtechexpo, to receive information and updates on the
show and the industry.
Network with hundreds of industry professionals in our FABTECH LinkedIn group and join the
active conversations.
Watch FABTECH on YouTube at youtube.com/fabtechexpo and share and discuss .
SPECIAL EVENTS/PROGRAMS
Monday, November 18
BRAZING SYMPOSIUM
Room N137
North Hall,
Booth N2299
NOVEMBER 2013
Room N227B
Mix and mingle with other attendees and exhibitors during Happy
Hour beginning at 3:00 p.m. on Tuesday, November 19. Held on
the exhibit hall floor, Happy Hour is a great way to network with
peers in a relaxed, entertaining environment while perusing the
technology in exhibitor booths. Complimentary beverage ticket
with event registration.
Judging
A team of AWS Certified Welding Inspectors will judge the
competition, based on criteria of AWS D16.4, Specification for the
Qualification of Robotic Arc Welding Personnel.
To Enter the Competition
You may register for the competition at the Robotic Welders
Competition booth on the show floor, Monday and Tuesday.
TUESDAY, NOVEMBER 19
WEDNESDAY, NOVEMBER 20
WELDING WARS COMPETITION
MONDAY, NOVEMBER 18
THURSDAY, NOVEMBER 21
ROBOTIC ARC WELDING CONTEST
Booth #N2099
Teams of three student welders (16+) can sign up online ($10 entry
fee per person). Each team will fabricate a weldment on a supplied
print using GTAW, GMAW, and plasma cutting, with sheared and
cut material provided, within a time limit of two hours. A panel of
certified welding inspectors will evaluate all weldments to AWS
D1.1 based on accuracy of project to print specifications, weld size,
overall weldment appearance, craftsmanship, professionalism,
safety, etc.
WEDNESDAY, NOVEMBER 20
7:00 a.m. 8:30 a.m.
AWS PRAYER BREAKFAST
MY FAITH AT WORK
Room N137
WELDING JOURNAL
63
Room N230A
During the AWS Opening Session and the 93rd Annual Business
Meeting, 2013 AWS President Nancy Cole will give the
presidential report and Dean Wilson will be inducted as the AWS
President for 2014. Following the induction, the 2013 Class of
AWS Counselors and Fellows will also be introduced. This
meeting is open to all AWS members and show registrants.
10:30 a.m. 11:30 a.m.
COMFORT A. ADAMS LECTURE
Room N228
Hilton
Grand Ballroom
This reception is held annually during the show and is open to all
registrants. Take advantage of this opportunity to meet the AWS
Officers, and network with members and prospects. A
complimentary hors doeuvres buffet is included, along with a
cash bar. Evening business attire.
64
NOVEMBER 2013
Room N228
As the Society and the industry it serves have grown, so has the
need to recognize outstanding scientists, engineers, educators,
and researchers. Join an assembly of distinguished award
presenters, recipients, and guests for a well-paced ceremony and
a delicious lunch. The cost for attending the ceremony is $30 and
is open to all registrants. Tickets will also be available at the door.
2:00 p.m. 3:00 p.m.
AWS NATIONAL NOMINATING COMMITTEE
OPEN MEETING
Room N135
MONDAY, NOVEMBER 18
AWS OPENING SESSION & ANNUAL
BUSINESS MEETING
TUESDAY, NOVEMBER 19
Room N135
PRICING INFORMATION
Welding Track
Member
NonMember a
$150
$235
$225
$310
1/2-Day Seminar
$335
$420
$550
$635
$775
$860
$775
$860
$150
$235
$225
$310
$75
$90b
$30
$30
$10
$10
a
b
Non-member price for AWS Sessions only includes a one-year AWS Individual Membership.
Non-member Student Professional Program price includes a one-year AWS Student Membership.
Exhibit-only attendance is FREE through November 15, 2013. Beginning Nov. 16 and
on-site, the cost to attend the exhibits is $50. FMA, SME, AWS, PMA and CCAI members
may always attend the exhibits for FREE with a valid membership card.
Non-Member
1/2-Day Workshop
$299
$299
Full-Day Workshop
$399
$399
Member
Non-Member
1 Session
$150
$175
2 Sessions
$280
$325
3 Sessions
$375
$445*
4 Sessions
$475
$545*
$680
$780*
Full Conference
(5 or more sessions)
Includes (1) $22 lunch ticket
Rates good through Oct. 4. After this date, please add $25.
*Non-member rates for 3 or more sessions include a one-year complimentary membership to one of
the co-sponsoring associations (FMA, SME, PMA, CCAI).
WELDING JOURNAL
65
SCHEDULE-AT-A-GLANCE
Monday, November 18
WELDING
SEMINARS
CONFERENCES
PROFESSIONAL
PROGRAM
EDUCATIONAL
SESSIONS
SPECIAL
PROGRAMS
W38: AWS Education Program Q&A FREE . . . . . . . . . . . . . . . . . . . . . . . . 2:00 p.m. 3:00 p.m.
W39: Brazing Symposium FREE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:00 p.m. 5:00 p.m.
AWS Professional Welders Competition - Day 1. . . . . . . . . . . . . . . . . . . . 10:00 a.m. 5:30 p.m.
Robotic Arc Welding Contest Day 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10:00 a.m. 5:30 p.m.
AWS Events Annual Business Meeting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9:00 a.m. 10:00 a.m.
Comfort A. Adams Lecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10:30 a.m. 11:30 a.m.
FINISHING
STAMPING
CUTTING
F10: NEW! Trends and
Advances in Laser
Technology B
JOB SHOP
SOLUTIONS
AUTOMATION &
ROBOTICS
LASERS
FORMING &
FABRICATING
F01: WORKSHOP: NEW! Driving the Lean TransformationAre You Prepared for Change? I
LEAN
MANAGEMENT
66
NOVEMBER 2013
SCHEDULE-AT-A-GLANCE
Tuesday, November 19
WELDING
SEMINARS
CONFERENCES
W24: So Youre the New Welding Engineer - Day 1 . . . . . . . . . . . . . . .8:00 a.m. 5:00 p.m.
W26: Thermal Spray Technology: High-Performance Surfaces . . . . . . . . 9:00 a.m. 5:00 p.m.
PROFESSIONAL
PROGRAM
W29: Session 4: Keynote Speaker 1 and Keynote Speaker 2 . . . . . . . . .8:00 a.m. 10:00 a.m.
Session 5: NSF-CIMJSEA - Modeling . . . . . . . . . . . . . . . . . . . . . .10:00 a.m. 12:00 p.m.
Session 6: NSF-CIMJSEA - Processing . . . . . . . . . . . . . . . . . . . .10:00 a.m. 12:00 p.m.
Session 7: Welding Metallurgy I . . . . . . . . . . . . . . . . . . . . . . . . .2:00 p.m. 5:30 p.m.
Session 8: Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2:00 p.m. 5:30 p.m.
EDUCATIONAL
SESSIONS
SPECIAL
PROGRAMS
TECHNOLOGY
FINISHING
STAMPING
CUTTING
C41: Introduction to
Electrocoating B
LASERS
FORMING &
FABRICATING
JOB SHOP
SOLUTIONS
AUTOMATION &
ROBOTICS
LEAN
MANAGEMENT
WELDING JOURNAL
67
SCHEDULE-AT-A-GLANCE
Wednesday, November 20
WELDING
SEMINARS
CONFERENCES
W24: So Youre the New Welding Engineer Day 2 . . . . . . . . . . . . . . . 8:00 a.m. 5:00 p.m.
W25: Thermal Spray Basics FREE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:00 p.m. 4:00 p.m.
RWMA SCHOOL
W27: RWMA Resistance Welding School Day 1 . . . . . . . . . . . . . . . . 7:45 a.m. 5:30 p.m.
PROFESSIONAL
PROGRAM
EDUCATIONAL
SESSIONS
SPECIAL
PROGRAMS
TECHNOLOGY
FINISHING
STAMPING
CUTTING
FORMING &
FABRICATING
JOB SHOP
SOLUTIONS
AUTOMATION &
ROBOTICS
LEAN
MANAGEMENT
NOVEMBER 2013
LASERS
68
SCHEDULE-AT-A-GLANCE
Thursday, November 21
WELDING
SEMINARS
RWMA SCHOOL
W27: RWMA Resistance Welding School Day 2 . . . . . . . . . . . . . . . . 8:00 a.m. 3:45 p.m.
PROFESSIONAL
PROGRAM
W31: Session 14: NSF-CIMJSEA Mechanical & Corrosion Properties . . . .8:00 a.m. 11:30 a.m.
Session 15: Weldability Topics . . . . . . . . . . . . . . . . . . . . . . . . . .8:00 a.m. 11:30 a.m.
SPECIAL
PROGRAMS
AWS Certication Exam (advance application required) . . . . . . . . . . . . .7:00 a.m. 6:00 p.m.
TECHNOLOGY
STAMPING
LASERS
FORMING &
FABRICATING
JOB SHOP
SOLUTIONS
LEAN
MANAGEMENT
STAMPING
FINISHING, COATING
Contact AWS,
Martica Ventura
mventura@aws.org
800-443-9353
Contact PMA,
Marianne Sichi
msichi@pma.org
216-901-8800
Contact CCAI,
Kelly LeCount
Kelly@goyermgt.com
859-356-1030
FORMING &
FABRICATING,
JOB SHOP,
MANAGEMENT,
TUBE & PIPE
Contact FMA,
Julie Maddock
juliem@fmanet.org
888-394-4362
Contact SME,
Ila Lee
ilee@sme.org
800-733-4763
WELDING JOURNAL
69
Development of a Macro/Micro
Telerobotic Welding System for Working
in the Nuclear Pipeline Maintenance
Haichao Li, Hongming Gao and Na Dong,
State Key Lab of Advanced Welding and
Joining, Harbin Institute of Technology, and
YuMing Zhang, University of Kentucky
Monday, November 18
1:00 p.m. 5:30 p.m.
SESSION 1:
AUTOMATION AND SENSORS
Room N139
F. 3:30 p.m.
70
NOVEMBER 2013
Room N140
F. 3:30 p.m.
SESSION 3:
APPLIED TECHNOLOGY I
Room N230A
Room N139
E. 3:00 p.m.
F. 3:30 p.m.
TUESDAY, NOVEMBER 19
8:00 a.m. 10:00 a.m.
SESSION 4:
KEYNOTE ADDRESSES
Room N139
B. 9:00 a.m.
Room N140
Room N139
71
F. 4:30 p.m.
WEDNESDAY, NOVEMBER 20
E. 4:00 p.m.
F. 4:30 p.m.
72
B. 8:30 a.m.
C. 9:00 a.m.
D. 9:30 a.m.
Room: N140
NOVEMBER 2013
Room N140
B. 8:30 a.m.
C. 9:00 a.m.
D. 9:30 a.m.
Room N139
Room N140
F. 4:00 p.m.
73
Room N135
THURSDAY, NOVEMBER 21
8:00 a.m. 11:30 a.m.
SESSION 14:
Room N139
NSF-CIMJSEA MECHANICAL & CORROSION
PROPERTIES
Chair: Prof. Y.M. Zhang, University of Kentucky
A. 8:00 a.m.
B. 8:30 a.m.
C. 9:00 a.m.
D. 9:30 a.m.
F. 4:00 p.m.
74
NOVEMBER 2013
Room N140
B. 8:30 a.m.
C. 9:00 a.m.
D. 9:30 a.m.
Eric Przybylowicz, Derek Jones and Bryan Riggs, The Ohio State
University, Columbus, Ohio.
Microwave Welding
75
CONFERENCES
MONDAY, NOVEMBER 18
Room N135
In todays modern welding and fabrication industry, joining dissimilar metals together is required in order to maximize the beneficial properties of both metals. This discussion will focus on the
requirements of NDE procedure qualifications using computed
radiography (CR) and ultrasonic testing (UT). Also discussed
will be some specific application of each technique.
10:15 a.m. 10:30 a.m. Coffee Break
10:30 a.m. 11:05 a.m.
The Welding of Nickel Alloys to Stainless Steels
76
NOVEMBER 2013
TUESDAY, NOVEMBER 19
WEDNESDAY, NOVEMBER 20
Room N227b
DAY 1 TUESDAY
8:00 a.m. 8:30 a.m.
Welding Costs
Pete Ullman, Techniweld
What is Productivity?
Fritz Saenger, Consultant
11:00 a.m. 12:00 p.m.
The Automation Decision
Jeff Noruk, Sevo Robot Corp
12:00 p.m. 1:00 p.m. Lunch
WELDING JOURNAL
77
Room N128
NOVEMBER 2013
WELDING JOURNAL
79
Surface dust levels not to exceed quantity rating 1 in accordance with ISO 8502-3.
Soluble salts on the surface shall not exceed 20 mg/m2
How important is it to follow all these rules? What if it is impractical or impossible to achieve these conditions? Should thermal
spray still be attempted?
Unknowingly these rules are quite often broken and these coatings still perform well. What happens when we purposely break
these rules? We will discuss applying these coatings to hand-tool
prepped surfaces (no abrasive blasting), red-hot welds, wet surfaces, icy surfaces, and dusty surfaces. Questions about soluble
salts will be answered.
Room N128
81
SEMINARS
TUESDAY, NOVEMBER 19
WEDNESDAY, NOVEMBER 20
MONDAY, NOVEMBER 18
Room N227A
Room N230A
This 16-hour seminar will help you prepare for the ASME
Section IX, B31.1, and B31.3 examination for endorsement or
Part C of the CWI. Note that endorsements are supplemental
inspection credentials available to AWS Certified Welding
Inspectors (CWIs) and Senior Certified Welding Inspectors
(SCWIs), but non-CWI/SCWIs can also participate in the seminar and examination to enhance their educational background.
Participants are expected to provide their own codebooks. Please
note that there is a separate application and fee required to take
the certification exam.
METALLURGY APPLIED TO
EVERYDAY WELDING
Room N138
Room N227A
Room N137
82
NOVEMBER 2013
Room N138
When a discontinuity is OK
Mechanical properties
WEDNESDAY, NOVEMBER 20
THURSDAY, NOVEMBER 8:30 a.m. 4:30 p.m.
BUILD IT BETTER
Room N134
Code requirements
WEDNESDAY, NOVEMBER 20
THURSDAY, NOVEMBER 21
Room N230B
CORROSION OF WELDS:
CAUSES AND CURES
Room N138
A sample weld specification containing acceptance criteria is presented and discussed, after which students use the specification
and visual inspection tools to evaluate the weld replicas using a
series of specific questions and scenarios.
By attending, you can learn:
How to use weld-measuring instruments
83
Weld-Ed in Action
Jodi Lancaster
Ms. Lancaster will share how she is utilizing the Weld-Ed professional development Information at Livingston Area Career Center.
10:00 a.m. 12:00 noon
Intergranular corrosion
Erosion/corrosion
Crevice corrosion
Galvanic corrosion
EDUCATIONAL SESSIONS
Room N131
Room N131
84
NOVEMBER 2013
85
RWMA
RESISTANCE WELDING SCHOOL
WEDNESDAY, NOVEMBER 20
Welding Controls
Don Sorenson, Director of Engineering, ENTRON Controls, LLC
Room N227A
Room N227A
86
NOVEMBER 2013
H - Hilton Chicago
C - Convention Center
Sunday November 17
2:00 p.m. 4:00 p.m.
(H) Room Marquette
C7B Subcommittee on Electron Beam
Welding and Cutting
Staff Contact: C. Lewis, ext. 306
4:30 p.m. 6:00 p.m.
(H) Room Marquette
C7C Subcommittee on Laser Beam
Welding and Cutting
Staff Contact: C. Lewis, ext. 306
6:00 p.m. 8:00 p.m.
(H) Room Marquette
C7 High Energy Beam Welding and
Cutting Committee
Staff Contact: C. Lewis, ext. 306
Monday November 18
8:00 a.m. 5:00 p.m.
(C) Room N127
C2 Committee and Subcommittees on
Thermal Spraying
Staff Contact: J. Rosario, ext. 308
8:00 a.m. 12:00 p.m.
(C) Room N230B
D10P Subcommittee on Local Heat
Treating of Pipework
Staff Contact: C. Lewis, ext. 306
WELDING JOURNAL
87
N1436
Alabama Laser
www.alabamalaser.com
N618
N854
N307
Airgas, Inc.
www.airgas.com
N1174
WELDING JOURNAL
89
N1449
N2828
N472
Allcryo
www.allcryo.com
N547
N772
ALM will feature its positioners available in single column (headstock) capacities, 5000 lb
and head/tailstock, plus fixed or adjustable capacities from 8000 to 65,000 lb. They can be
used to raise and position weldments or assemblies to a convenient height and working
position.
N228
American Institute of
Steel Construction
www.aisc.org
American Society for
Nondestructive Testing
www.asnt.org
90
NOVEMBER 2013
N247
N331
N1957
The American Society for Nondestructive Testing will showcase its network of sources, including technical expertise, personnel certification requirements, career opportunities,
industry developments/evolving technology,
and technology transfer.
American Technical
Publishers
www.atplearning.com
N2834
N1700
N1599
See us @ Booth
N2215
WELDING JOURNAL
93
N2094
AWS Foundation
www.aws.org/foundation
N2499
N2299
AWS Publications/
N2100
World Engineering Xchange
www.awspubs.com
World Engineering Xchange (WEX) will spotlight welding and engineering industry publications, including its support for welding education by working on behalf of the American
Welding Society.
N2099
N2293
Welding Inspectors will evaluate all weldments to AWS D1.1 based on accuracy of
project to print specifications, weld size, overall weldment appearance, craftsmanship,
professionalism, and safety. For more information, visit www.aws.org/education.
AMET, Inc.
www.ametinc.com
N2092
N2467
Antec will offer its autodarkening welding helmets and filters. All products meet the ANSI
Z87.1,CE EN379 standards.
APEL International
www.apelfilters.com
Visit us at FABTECH
Booth N2052
Chicago, IL
November 18-21, 2013
www.dryrod.com
94
NOVEMBER 2013
N419
N649
AN EXTRAORDINARY
MACHINE DEMANDS AN
EXTRAORDINARY OFFER.
Aquasol Corp.
www.aquasolwelding.com
N639
N2669
N2642
Arc Products
www.arcproducts.com
N1125
Arc Products will feature its mechanized welding products, including seam tracking equipment, torch height control (AVC), magnetic
arc control, and a complete line of orbital arc
welding equipment. The company will also
offer separate components or assembly of
complete turn-key welding packages.
N974
Arc Specialties will offer its automated and robotic equipment. The company is a supplier
for engineering services, systems integration,
service, parts, and training.
Arcon Welding
Equipment LLC
www.arconweld.com
N2317
ArcOne
www.arc1weldsafe.com
N1865
Dedicated to the personal protection of welding professionals, ArcOne will highlight its
autodarkening welding helmets, respiratory,
and head/face protection, including the iDF
intelligent darkening filter.
N417
N623
ATI Stellram
www.atistellram.com
Atlanta Drive Systems, Inc.
www.atlantadrives.com
N2330
N317
N2107
WELDING JOURNAL
97
Avani Environmental
N2600
Intl., Inc.
www.avanienvironmental.com
Avani Environmental will feature its ventilation
and exhaust equipment for vocational and industrial facilities.
N2157
Axelent, Inc.
www.axelentusa.com
N2119
N2809
Bernard
www.bernardwelds.com
BeamMaster (AGT)
www.beam-master.com
N2082
Axxair-USA
www.axxairusa.com
N2008
Bellman-Melcor LLC
www.bellmanmelcor.com
N2866
98
NOVEMBER 2013
N2121
N836
Bevel Tools
www.beveltools.com
N2567
BF Entron Ltd.
www.bfentron.co.uk
N208
Bluco Corp.
www.bluco.com
N2411
N325
N329
N2541
N549
N2004
Bradford Derustit will present its pickling products for stainless and other metal cleaning
products. Demonstrations and information on
new products will also be available.
Broco, Inc.
www.brocoinc.com
Bruker AXS, Inc.
www.bruker.com
N406
N1583
Bug-O Systems/Weld
Tooling Corp.
www.bugo.com
Buhin Corp.
www.buhincorp.com
N1815
N1987
Buhin will show industrial confined space ventilators along with accessories such as ducting, couplers, and reducers. It will further
show its new, intrinsically safe 12-in. VelocityPN pneumatic ventilator.
Built Systems
www.builtsystems.net
N1482
Built Systems will showcase its height-adjustable modular manufacturing systems. Additional products will include flexible assembly
workstations, height-adjustable machine
bases, and material handling equipment that
incorporates Kaizen/Lean and 5S principles.
N700
C.M.M. will showcase its capabilities in project management, design, and detailing light,
medium, and heavy automation for welding.
N2109
Cadi will showcase its high-conductivity copper alloys (RWMA Classes) in rod, bar, coil,
plate, seam weld wheels, electrodes, and
special shapes. It will also highlight its custom
finished machined items, produced internally
from the RWMA materials listed above, with
resistance welding machinery and controls.
Cambridge Vacuum
Engineering
www.camvaceng.com
N1949
C-spec
www.cspec.com
N2005
Cambridge Vacuum Engineering will demonstrate its electron beam welding machines. Its
equipment range includes systems ranging
from 50 to 200 kV with beam powers up to
100 kW.
N1494
C.M.M. SRL
www.nuovacmm.com
N1589
Capital Weld Cleaners will present its electrochemical cleaners that clean discoloration
from recently welded stainless steel material.
CDS Corp.
www.cdsindexers.com
N2858
CDS will exhibit its high-precision motion control products. The company specializes in indexing and servo controlled turntables, precision link conveyors, walking beams, part
handlers, and other heavy-duty positioning
equipment.
CEIA USA
www.ceia-usa.com
N2445
N2419
Cerbaco Ltd.
www.cerbaco.com
N2020
Brought to you by
Removes
contaminants from
compressed air
Eliminates
arc-sputter
Prolongs life
of electrodes
Cleaner, faster,
smoother cuts
Ask your
supplier for a
Motor Guard Filter
LD-R
Portable
Bench Positioner
Auto Picle
Portable Pipe Cutting
Versagraph Extreme
Thermal Cutting Machine
Positioners
Headstock & Tailstock
www.koike.com
For Info go to www.aws.org/ad-index
CGW-Camel Grinding
Wheels USA
www.cgwcamel.com
N2241
N347
N546
N2821
Changzhou Zhengyang
Welding Material Co. Ltd.
www.zywelding.com
N338
Chart, Inc.
www.chartindustries.com
N2155
N2409
N1988
Cheil will exhibit its bonded abrasive products, including depressed center and cut-off
wheels.
N1991
Changzhou Longren
N2822
Mechanical & Electrical Co. Ltd.
www.longrenwelding.com
Changzhou Shine Science
& Technology Co. Ltd.
www.shine-xunan.com
N459
Chicago Pneumatic will feature its tools, including the new CP3850 series grinders that
offer fast material removal, economical operation, and operator ergonomics.
CK Worldwide
www.ckworldwide.com
N2211
Clara Vision
www.weldingexpert.net
N2571
N372
N261
N1849
N203
COB Industries will be introducing pipe purging technology, including the QuickPurge II,
an inflatable purge dam that is impossible to
overinflate. It will also be showcasing the
PurgEye weld purge monitors, welding enclosures, pipe freezing systems and plugs, plus
performing pipe purging demonstrations.
N1383
Compressed Air
www.airbestpractices.com
N2845
Computers Unlimited
(TIMS Software)
www.cu.net
For info go to www.aws.org/ad-index
TIMS will feature its software systems for specialty gas and welding supply distributors.
Highlights include fully integrated cylinder
tracking/management, order processing for
gases, hardgoods and rental equipment, inventory/warehouse management, truck routing/dispatching, electronic vendor price updates, EDI and e-commerce, and imaging
with data analysis tools.
Concoa, Inc.
www.concoa.com
N2174
N1679
Wel
Series
76543210/644320.3-,50.+4*0+)(23,+'-&023,%(3,05$64432#
0
0
0
0
0
0
"$4+!+ 3,0!,35020(643,0!6432+6-50-%4+)#
0
0 0
0
0
530546),62,002)000"020%-530
0
0
0
0
00
0
0 0
0
0
)0(62')05433-5#
0
0
(*+330
-+30.3-,0
0
0
0
6$$3626)(30)0546+)-3550
0 0
0
5433-0.+4*%403$3)5+30
0
0
0
*3-+%!0650!+4%235#
0 0
Wave-Pulse GMAW
%-4+2(355350
0
#
0
0
"$4+!+ 3,0$235340!,35020+24%6--&06)&0!6432+6-#
0
0
0 0
0 0
46),62,00$24040($&06),0426)5320,646#
0
0
0 0
0 0
0
"$4+)6-0.3-,0,6460!)+42+)06),0)34.2+)#
0
0
0
0 0
36!-3550+)43264)0.+4*0"
0732+3502'45#
0
0
0
0
0
New
GMAW
Machines with multi-process modes.
See us in Chicago at
Fabtech/AWS
,6+*3)%56#(!00
00 0000"
""
For Info go to www.aws.org/ad-index
Construction Electrical Products will showcase its power distribution products for temporary power needs. On display will be its single-phase and 3-phase products, including
480-V units for welding applications.
Cor-Met, Inc.
www.cor-met.com
Why Weld
Manually?
N2166
N1831
CoreTemp Abrasives
N1594
www.coretempabrasives.com
K-BUG 1200
Smallest trackless, digital
compact llet welder in the
industry
Quick Setup - runs directly
on the work
Rugged, reliable gear
driven design, includes
3-year warranty
Capable of traveling
up to a 75 incline
Visit us at Fabtech
Booth N1815
1-800-245-3186
www.bugo.com
Corewire Ltd.
www.corewire.com
N515
CS Unitec, Inc.
www.csunitec.com
Cyl-Tec, Inc.
www.cyl-tec.com
Construction Electrical
Products
www.cepnow.com
1-866-733-3272
N2629
N628
Dakota Ultrasonics
N1933
www.dakotaultrasonics.com
Dataweld, Inc.
www.dataweld.com
N570
DE-STA-CO
www.destaco.com
N1846
Cyl-Tec will exhibit its compressed gas cylinders, cylinder services, and cylinder accessories. Products include DOT/TC highpressure, acetylene, aluminum, portable
cryogenic, and beverage carbonation
cylinders.
N429
Dengensha America will promote its complete line of resistance welding equipment, including pedestal welding machines, lightweight and servo weld guns, automatic nut
and bolt feeders, controls, consumables, and
spare parts.
Dinse is a manufacturer of robotic and manual air- and water-cooled welding guns for all
applications, including aluminum or soft material applications utilizing push pull technology. The company will also feature its cold and
hot wire feeding systems for laser welding and
plasma brazing.
D/F Machine Specialties will highlight its design, development, and manufacture of American made GMAW guns and GTAW torches
for robotic and welding automation equipment. The company will show its line of waterand air-cooled torches featuring tandem,
open-arc, gasless, sub arc, hardbanding,
hardfacing, and overlay welding torches for
steel and aluminum.
N729
Diamond Ground
Products, Inc.
www.diamondground.com
N2439
Dinse, Inc.
www.dinse-us.com
N2057
N2136
Direct Wire will offer its welding cables, including the Flex-a-Prene and Ultra-Flex with
their unique flexibility and durability.
Diversi-Tech, Inc.
www.diversitech.ca
N2455
N1989
MORE POWER
TO BUILD
D e d i c a te d to Tra i n i n g t h e B e s t W
elders
i n t h e Wo
TECHNICAL TRAINING
Technical training at the Hobart Institute of Welding Technology is
designed to provide training for personnel involved with welding support
groups. Those who need a practical working knowledge of welding such
as engineering, quality control & management personnel will find these
one & Two week courses very beneficial. The courses are comprised of
approximately 80% classroom lecture/discussion & 20% laboratory
demonstration. Courses are available to provide either a generalized
background or to target specific areas related to welding.
As an additional service for manufacturing, service industries, educational
& government agencies, the Hobart Institute of Welding Technology has
the facilities to develop specialized training to meet specific needs &
requirements. Specialized training involves the designing of special skill
courses to meet specific objectives (tool steel welding, sanitation piping,
aerospace, etc.)
The Institute maintains a staff of instructors, technicians & training experts who are available to teach welding
skill & qualification/certification courses at any location. Field training is available to all industrial firms, contractors,
utility companies, etc. Advise us of your requirements & our staff will help evaluate your training needs, determine
possible solutions & implement the necessary training.
rld.
N1990
N2534
DualDraw LLC
www.DualDraw.com
N328
Durum USA
www.durumusa.com
N315
Easom Automation
Systems, Inc.
www.easomeng.com
N1985
Dynaflux, Inc.
www.dynaflux.com
N1882
N2870
ELCo Enterprises
www.wire-wizard.com
N616
Dynatorch, Inc.
www.dynatorch.com
N1874
Dynatorch will promote its CNC plasma, oxyfuel, and laser cutting machines with both
plate and tube capability, which are compatable with air plasma and high-end mechanized plasma. Fiber lasers are also available
.
N636
Elcometer, Inc.
www.elcometerndt.com
N2167
E. H. Wachs Co.
www.ehwachs.com
Electron Beam
Technologies, Inc.
www.electronbeam.com
N536
N1897
N2546
Aerospace Grade
Brazing & Welding
Alloys
N206
N1145, N1449
ESAB will highlight its complete line of welding and cutting equipment and welding filler
metals. With more than 100 years of experience, the company is committed to providing
customized solutions for their customers.
Etal/Indux Sa De Cv
N630
Etal manufactures resistance welding consumables and brazing alloy products for automotive manufacturers along with heating
and ventilating applications.
Evobeam
www.evobeam.com
N223
Factory Cat
www.factorycat.com
N2164
N1169
Fastenal Co.
www.fastenal.com
N2461
Fastenal will present Fast Solutions, industrial vending that brings the option for on-hand
inventory to the factory floor and allows customers to track/control consumption of virtually anything.
N264
N2070
N1996
FH Automation
www.fhautomation.com
N1899
Fibre-Metal By Honeywell
www.fibre-metal.com
N2261
Filter 1
www.filter-1.com
N2354
Flame Technologies new products will include flow gauges, flow meters, cutter kits,
large size exothermic burning bars, Scorpion
heavy-duty hose, and more. On display will be
the new HydroMist line of industrial cooling
fans, utilizing flash evaporation technology,
which results in dramatically cooled air.
N2023
Frommelt Safety will offer its automated barrier doors/curtains to protect personnel from
hazards associated with manufacturing
processes. Ideal alternative to light curtains,
integrated PLe (Cat. 4) interlock switches on
high-speed door provide protection by restricting access and guard against process
hazards. New Defender model features many
upgrades.
N1161
N2168
N219
Fusion, Inc.
www.fusion-inc.com
N1833
Fusion will highlight its paste brazing and soldering filler metals, dispensers, and automatic machines. Rotary soldering machines
will demonstrate joining brass/copper parts.
Also featured will be post braze cleaners and
ultrasonic cleaning tanks. Personnel will be
available to discuss application needs in
steel, stainless, copper, brass, aluminum, and
carbide.
N2068
G & J Hall Tools will premier its electromagnetic drills and annular cutters.
N340
Gasflux Co.
www.gasflux.com
N374
GAWDA
www.gawda.org
N321
Goss, Inc.
www.gossonline.com
N2049
Grainger
www.grainger.com
N1879
N2869
Gullco International
www.gullco.com
N2204
N1155
Genesis Systems Group will feature its capabilities in designing, building, and implementing robotic arc welding systems, assembly
automation systems and robotic tooling, material handling, nondestructive inspection
cells, and robotic waterjet cutting systems.
N641
N2105
Goffs will showcase its weld screens constructed with a strong, lightweight extruded
aluminum frame to create a retractable barrier to sparks, fumes, and contaminants;
block 100% UV light; and stand up to the
toughest shop environments. Custom configurations are available.
Gullco will highlight its design and manufacture of welding and cutting automation systems for applications in shipbuilding, tank and
bridge construction, railcar, and other heavy
fabrication industries.
N1822
safety to customers in a wide range of industries, including oil and gas, power generation,
aerospace, and transportation.
HARDSURFACING
HARDSUR
RFA
FACING
NICKEL
NICK
EL ALLOYS
STAINLESS STEEL
LOW ALLO
ALLOY
CARBON
C
ARBON STEEL
Select-Arc,
c, Inc. produces
pr
over
50 premium
emium ux cored
cor and metal
cored
ed stainless steel welding
electrodes.
odes. This broad
br
range of
austenitic, martensitic, ferritic
and duplex wir
wires
es is designed
for a wide variety of welding
applications from
fr
auto exhaust
parts to cryogenic
yogenic tanks, marine
environments
onments to power generation
plants, food and pharmaceutical
processing
ocessing equipment to textile
facilities - and many more.
mor
These exceptional stainless steel
electrodes
odes deliver outstanding
welding characteristics such as:
U Finely rippled, well
washed beads
U Smooth arcc transfer with
minimal spatter
U Freely
eely peeling slag to
minimize cleanup
U Higher deposition rates and
travel speeds
U Intergranular
corrosion
granular corr
resistance
And, of course, all Select-Ar
Select-Arc
stainless steel electr
electrodes are
backed by the nest in valueadded support and our
renowned
enowned customer ser
service.
For moree information on
Select-Arcs complete line of
stainless steel electr
electrodes, call us
at 1-800-341-5215 or visit our
website at www
w.select-arc.com.
w.
www.select-arc.com.
Stainless Steel
Tubular Electrodes
N2123
H. C. Starck GmbH
www.hcstarck.com
Haynes International will feature its HASTELLOY and HAYNES high-performance alloys for use in corrosion and high-temperature applications. Standard products include
wire and welding consumables, pipe and
tube, sheet and plate, fittings, and bar.
N411
H. C.Strarck will promote its high-tech powders and components made of technology
metals, advanced ceramics, and welding and
thermal spray powders. The Amperit portfolio
has thermal spray powders, including carbides, oxides, MCrAlYs, and metals. Technical support is available
N2218
N332
N1972
Hisco
www.hisco.com
N523
SAVE MONEY
GET BETTER RESULTS
ad
N217
S
0%he U
10e in t
Heromin Machinery
Canada Ltd.
www.heromin.ca
TY
E
SAF
AS S
G
ARE XPERT
WE
E
Haynes International
www.haynesintl.com
Hisco will offer its services as a specialty distributor serving the electronic assembly and industrial manufacturing markets. The companys inventory includes adhesives, silicones,
tapes, films, precision hand tools, and clean
room materials.
N2000
N323
Hobart Brothers
www.hobartbrothers.com
N831
Hyundai Welding
www.hyundaiwelding.com
N2666
Hobart Brothers will highlight its filler metals, including tubular wires (flux-cored and metalcored), solid wires, and covered electrodes
under the brand name Hobart.
N627
Hot Coils
www.hotcoils.com
N774
IBEDA/Superflash
N400
Compressed Gas Equipment, Inc.
www.oxyfuelsafety.com
IBEDA/Superflash will display its lines of
flashback arrestors, quick connectors, manifolds, heating equipment, thermal spray, and
other compressed gas components. The
booth will feature demonstrations of its flashback arrestors and gas mixers.
N1694
Ideal Welding Systems will feature its automated resistance welding equipment for
sheet metal and wire fabricated products. On
display will be the CSR102 automated welding machine for 2D or 3D sheet metal and wire
welded products, such as electrical enclosures, ATMs, cash registers, metal shelving,
The W-80 is a straight cut-off machine that cuts 2" 8" pipe at 90, 30 off 90, and
3712 off 90. The pipe is conveyed into the cutting area via a motorized carriage. An
encoder allows for travel display in inches on a counter on the main controller. Kerf or
bevel is not compensated for. The remote control box on the carriage enables the
operator to perform functions required to load and clamp the pipe into the chuck. The
cutting is done in an enclosure to capture sparks and smoke.
2323 East Pioneer Ste. A, Puyallup, WA 98372 USA (253) 848-9288 Fax: (253) 848-9295 sales@watts-specialties.com
N1867
IMPACT Engineering will display its ARCAgent monitoring equipment that supports all
arc welding processes in manual and robotic
applications. It provides control of weld production metrics, part tracking, quality, and
process analysis.
N371
N2649
Your partner in
wear-resistant
consumables.
See us at FABTECH 2013
McCormick Place
Chicago, Illinois
Booth #N1125
AR12-117
The Lincoln Electric Co. All Rights Reserved.
www.lincolnelectric.com
P: 714.683.2430
F:714.683.2500
1177 N. Grove St.
Anaheim, CA 92806
For Info go to www.aws.org/ad-index
International Welding Technologies will display its lines of portable and special-purpose
stud welding equipment and fasteners.
Innerspec Technologies
www.innerspec.com
InterTest, Inc.
www.intertest.com
N452
Intercon Enterprises will be showcasing its InterPurge line of pipe-purging equipment, including purging units and monitors, pipealignment clamps, and other pipe-welding
accessories. Baer hardware and weld-on
hinges will be displayed, as well as TIGRIP
plate-lifting clamps and under-the-hook lifting
equipment.
Integrated Manufacturing
Group, LLC
www.imgprecision.com
International Thermal
Spray Association (ITSA)
www.thermalspray.org
N1388
N2130
International Welding
Equipment, LLC
www.iwestore.com
MIG [GMAW]
Electrodes [
N1688
International Welding
N270
Technologies, Inc.
www.internationalwelding.com
N407
Interactive Safety
Products, Inc.
www.helmetsystems.com
N2153
[
[
IPG Photonics
www.ipgphotonics.com
N470
N1474
N1684
Ironworkers Management
N2006
Progressive Action Cooperative
Trust (IMPACT)
www.impact-net.org
The IMPACT booth will detail the unions services as a Labor Management Taft Hartley
Trust, to expand job opportunities for Union
1-800-521-0332
N161
N1384
JASIC Technologies
America, Inc.
www.jasictech.com
N434
Laser Markers
Laser Welders
Laser Cutting
Systems
Resistance
Spot Welders
Hot-bar Reflow
Soldering Systems
and More!
Javelin Industrial
www.javelinindustrial.com
N1884
Javelin Industrial will display its portable fabrication equipment, including collapsible pipe
stands, V-heads, pipe rollers, grinder holders,
and grounding equipment designed for
shops, oil field, on-site fabrication, and
pipeline welding.
N700
Jenoptik Laser
Technologies
www.jenoptik.com
N2465
Jetline Engineering
www.jetline.com
N730
Jetline will feature its equipment for automated arc welding systems at the show. Displayed will be weld fixtures with cold and hot
wire, joint tracking, arc-length, travel and oscillation controls, vision systems, and the
9900 Computer Controller for complete system control.
Jiangsu Meixin
N422
Photoelectric Technology Co., Ltd.
www.sh-lanya.com
Jiangsu Meixin will display its newest products including an extensive line of autodarkening welding masks, instruments, and associated products.
N345
N2811
N2404
Since 1948, Miyachi Americas purpose has been to help its customers solve
manufacturing challenges by engineering and building high quality, precision welding,
soldering, sealing, marking and cutting equipment to satisfy their most critical and
demanding needs.
Contact us today for a FREE sample evaluation. Half a century
of experience, combined with a wide range of technologies to
choose from, ensures you'll find the right equipment for YOUR
application.
http://offers.miyachiunitek.com/wj13
Corporate Office: 1820 S. Myrtle Ave. P.O. Box 5033 Monrovia, CA 91017-7133
Tel: (626) 303-5676 FAX: (626) 358-8048 info@miyachiamerica.com
www.miyachiamerica.com 24/7 Repair & Service: 1-866-751-7378
See us at FABTECH booth #N2079
www.htg.cc
.htg.cc
N2069
JP Nissen Co.
www.nissenmarkers.com
N718
N654
N2441
N2429
Kalas Wire will display samples of its ISO-certified welding cables used in the oil and gas
industries.
N356
Kimberly-Clark Professional
www.kcprofessional.com
N1804
N661
N955
Kennametal Stellite
www.stellite.com
N539
Keystone Fastening
Technologies
N2856
N2655
N2840
The Klimawent booth will present the companys line of local exhausts for welding
fumes, fans, vehicle-exhaust extractors, filtering units, and a range of other ventilation
products.
N334
N1808
N806
t
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See Us At Fabtech
Booth N2847
N606
Kuka Systems
North America, LLC
www.kukanao.com
N330
KULLEN-KOTI GmbH
www.kullen.de
LA-CO Industries/Markal
www.markal.com
N423
N2003
LA-CO Industries will display its line of handheld, industrial-grade marking products designed for applications in the welding, industrial, and metal fabrication markets.
N2825
N167
LeTourneau University
www.letu.edu
N1798
N1820
N216
N1111, N1125,
N1411, N1425
www.lincolnelectric.com
Lincoln Electric representatives will be available to answer your questions and provide
demonstrations of the companys fabrication
equipment, consumables, automation, software, and training products. On display will be
the Power Wave, SuperGlaze, and
VRTEX virtual arc welding trainer, among
other welding equipment.
N872
N352
N2252
Model PRO 12
Bevel at 10 feet
per minute
Power Feed
800-886-5418
Fax 810-632-6640
www.heckind.net
See us at FABTECH booth #S2209
Code Data
DW-A55EH
Rutile-based
Outstanding Features
Typical chemistr y of all weld metal (%) and Diffusible hydrogen content (mL/100g)
Si
Mn
Ni
Example
0.05
0.63
1.17
0.010
0.007
0.38
[H]d
6.9
AWS Spec.
0.12
0.90
1.60
0.03
0.03
0.50
8.0
0.2%P.S
(ksi)
T.S
(ksi)
Elongation
(%)
Example
81
87
29
93
98
AWS Spec.
58
70 - 90
22
Not specified
20
Test method: AWS A5.20, Welding parameter: 250A-29V, Shielding gas: 75%Ar-25%CO2, As welded
Diameters: 0.045
Spool size: 28lbs, 44lbs
XR-Series
Kobelco XR-Series
available now:
DW-308L-XR/E308LT0-1/4
DW-309L-XR/E309LT0-1/4
DW-316L-XR/E316LT0-1/4
Kobelcos XR-Series wires drastically reduce
Hexavalent CR production
KOBELCO WELDING OF
AMERICA INC.
LORS Machinery/
2611
Resistance Welding Solutions, Inc.
www.lors.com
LPR Global, Inc.
www.lprglobal.com
N2169
Lucas-Milhaupt Global
Brazing Solutions
www.lucasmilhaupt.com
N2230
N1699
N2405
Machitech Automation
N1690
www.machitechautomation.com
The Machitech Automation booth will highlight the companys CNC cutting equipment
and a wide range of cutting systems using
laser, plasma, waterjet, and robotic technologies.
MAGMAWELD
www.magmaweld.com
BURR MONSTER
N236
Magmaweld will display its welding consumables, welding and cutting machines, and automation equipment.
Magnatech, LLC
www.magnatechllc.com
N2200
Th
N1584
is
n
i
F
T
g
in
ch
u
o
mONSTER tOOL
MADE IN USA
sales@monstertool.com
www.monstertool.com
WELDING JOURNAL 131
Material Management
Solutions, Inc.
www.mmsracks.com
N1385
Material Management Solutions will showcase its new touch-screen-controlled, hydraulic tree rack storage system designed to
hold up to 95,000 lb, with inventory control
and other features.
Matheson
www.mathesongas.com
N2661
Mathey Dearman
www.mathey.com
N625
Matuschek Welding
N2833
Products, Inc.
www.matuschekwelding.com
Matuschek Welding Products will feature resistance welding controllers, instrumentation,
and equipment for the sheet metal and microwelding industries. Shown will be mid- and
MCR Safety
www.mcrsafety.com
N518
N2111
Meta will demonstrate its vision-guided welding robot and laser sensor-driven welding positioner at the booth. To be introduced at the
show will be a weld bead detection system for
pipe coating control, and an ERW inspection
system that measures weld joint offset as well
as bead width and height.
N2306
Meltric Corp.
www.meltric.com
N2031
Metabo Corp.
www.metabousa.com
MeltTools, LLC
www.melttools.com
N2841
Mercer Abrasives
N2808
A Division of Mercer Tool Corp.
www.mercerabrasives.com
Mercer Abrasives will showcase its wire
wheels and files for the welding industry, in-
Metallizing Equipment
Co., Pvt., Ltd.
www.mecpl.com
N2444
N409
N2447
Metal Science
Technologies Pty., Ltd.
www.metalscience.com.au
N520
N1125
Michigan Pneumatic
N2074
Tool, Inc.
www.michiganpneumatic.com
Michigan Pneumatic Tool will display its line
of air-powered tools for the manufacturing,
marine, petrochemical and construction industries.
N436
Micro Air will showcase its industrial air cleaners, dust collectors, clean-air booths, environmental booths, downdraft tables, mist collectors, and wet collectors.
Midalloy
www.midalloy.com
N1857
N2079
N2017
MK Products will introduce its new CobraTurn digital turntable for all welding
processes at the show. Also featured will be
its Cobramatic aluminum welding and orbital tube welding systems.
Motofil Robotics SA
N1892
N1590
MTI Instruments will demonstrate its Microtrak PRO 2D laser sensor for automated weld
joint tracking and bead inspection that works
on shiny surfaces in harsh environments.
MK Products, Inc.
www.mkproducts.com
Multiquip, Inc.
www.multiquip.com
Multiquip will feature its line of light construction equipment, welding machines, generators, and lighting systems for the construction,
industrial, telecom, government, and oil and
gas markets.
Multi-Contact USA
N2673
www.multi-contact-usa.com
Multi-Contact will showcase its ISO 9001-certified electrical connectors with applications in
the test measurement, power-distribution, automation, medical, and renewable-energy industries.
N474
Orbital Welding
of Sanitary Process Lines
made EZ
SIMPLE OPERATION
Making a perfect weld is now as
simple as selecting tube/fitting O.D.
and wall thickness, and pressing
Start Weld! The intuitive symbolbased touch screen interface
minimizes operator training and
qualification time.
AFFORDABLE TECHNOLOGY
The modular EZ Orbital System is
used with standard GTAW power
sources. Priced at 1/3 of industry
standards, this affordable tool
should be in every welders toolbox.
N842
National Kwikmetal
Service LP
www.nks.com
N2804
N1854
Nederman, Inc.
www.nedermanusa.com
N2469
N348
N2133
N456
N516
Ningbo Geostar
N1587
Photoelectric Technology Co., Ltd.
www.geostargroup.cn
www.MagnatechLLC.com
Founded in 1919 to advance the science, technology and application of welding and allied joining
and cutting processes worldwide, including brazing, soldering and thermal spraying
www.aws.org/conference
www
w.aws.org/conference
.aws.org/con
.
AWS
A
WS
S Conference:
Conferre
ence:
SO
YOURE
REE THEE NEW
N
WELDING
N ENGINEER
NG
ENGIN
NEER
November 19-20, 2013
McCormick Place
Chicago, Illinois
Ho
How
w tto
o ge
gett up tto
o speed quic
quickly.
kly. How
How to
to ask the right questions.
Ho
How
w tto
o ge
gett the results yyou
ou need, sa
save
ve mone
money,
y, and sta
stayy out of tr
trouble!
ouble!
This two-day
two-day conf
conference
ference is ffor
or
o manager
managers,
s, engineer
engineers,
s, designers,
designers, and o
others
thers with
with welding
welding responsibility
responsibility but limited
limited
e
exposure
xposure tto
o or back
background
ground in w
welding.
elding. The conference
confer
e ence ffocuses
oc
o uses on ar
arcc w
welding
elding applications, but
but the principles
principles have
have
u
universal
niversal applicability.
applicability. Presentations
Presentations and discussion
discussion are based
based on the Application
Application Analysis
Analysis Worksheet,
Wo
Worksheet, whi
which
ch was
was
d
developed
eveloped tto
o tteach
each a senior col
college
lege cou
course
rse tto
oe
engineers
ngineers about
about to
to enter
enter industry,
industry, with
with the objective
objective off helping
helping them
them
d
develop
evelop a path tto
ou
understand
nderstand and deal
deal wi
with
th the challenge
challengess the
theyy w
were
ere abou
aboutt tto
o fface.
ace
a .
N542
N2853
N2089
Norton Abrasives
www.nortonindustrial.com
N461
Osborn
www.osborn.com
N2836
Osborn will exhibit its vast array of manufactured brushes from a small paint brush to a
large furnace roll.
N842
N2873
Oxylance, Inc.
www.oxylance.com
N2149
NSRW
www.nsrw.com
N2618
NSRW will present its copper alloys and refractory metals, including beryllium copper,
chrome copper, zirconium copper, C11000,
and C10100. The company will also show its
standard welding components and designand-build custom parts.
N1799
Olympus NDT
www.olympus-ims.com
N2449
New!
New
ew!
Olympus will showcase its test, measurement, and imaging instruments for welding
applications, including the new OmniScan
MX2, IPEX UltraLite videoscope, WeldRover,
and various scanners and ultrasonic thickness gauges.
OR Lasertechnology, Inc.
www.or-laser.com
N370
N1919
OR Lasertechnology will show its laser systems. Information will be available on its system sales, wire sales, repair service, laser
welding training, and job shop services.
Orbitalum Orbital
N636
Cutting + Welding
www.ehwachs.com/orbitalum
Orbitalum will present its portable tube saws;
tube facing and pipe end prep machines; and
orbital welding systems, including power supply/controllers, and open and closed welding
heads.
ORS Nasco
www.orsnasco.com
N1467
Denition of Prrecision
For info go to www.aws.org/ad-index
Optrel AG
www.optrel.com
Integrated Camera
Small Sp
Spot Collimator
The S1 TITAN
TIT
TAN
TA
Ultra light and exceptionally
ceptionally accur
accurate
hhsales@Bruk
hhsales@Bruker-Elemental.net
uker-Elemental.net
r-
Handheld XRF
N420
Pace Technologies, a supplier of metallographic equipment and supplies, will offer cutoff saws, polishers, and analytical equipment.
N2434
N242
Pan Taiwan Enterprise will present its personal protective equipment, including welding
helmets, hard hats, welding goggles, spectacles, face shields, hearing protection, respirators, coveralls, welding gloves, safety wear,
safety harnesses, and welding accessories.
N243
Panchmahal will feature wire rods for drawing; and cored wires in coil and cut lengths.
Pandjiris, Inc.
www.pandjiris.com
N2011
N2803
N2172
PDS Bartech will display portable heat treating machines, gas and electrical furnaces,
and supplies.
N2849
N2206
Pferd, Inc.
www.pferdusa.com
N1841
N2052
N2289
Polymet Corp.
www.polymet.us
N1401
N415
Praxair, Inc.
N1432, S2325
www.praxairdirect.com
Pro-Fusion Technologies
www.pro-fusiononline.com
PT-Mat
www.ptamaterial.com
Praxair Surface
N416
Technologies/TAFA, Inc.
www.praxairsurfacetechnologies.com
Precitec, Inc.
www.precitec.us
N2830
N2209
N306
PTR-Precision
Technologies, Inc.
www.ptreb.com
N2649
Preston-Eastin, Inc.
www.prestoneastin.com
N666
PushCorp, Inc.
www.pushcorp.com
N355
N519
N1582
PROFAX/LENCO
www.profax-lenco.com
N1825
Quality Equipment
Distributors, Inc.
www.qeddirect.com
N1986
N2566
Raajratna, an ISO 9001:2008 accredited company, will feature its line of stainless steel wires.
Radyne Corp.
www.radyne.com
N2042
N673
Rasco, a work-wear manufacturer, will feature its newest available products, including
its garments certified to NFPA 2112 and
ASTM F1506.
N2254
N2061
GO ORANGE
Grand Prize:
FABTECH 2013
Booth #N2436
Reis Robotics, an automation technology company, will showcase its capabilities for turnkey
solutions in all major application fields.
Resistance Welding
N1700
Manufacturing Alliance (RWMA)
www.aws.org/rwma
RWMA is a standing committee of the American Welding Society. It is an alliance of companies and individuals who all have a common interest and focus the resistance
welding process. Since 1935, RWMA has
been the authoritative source of information
and experience for the resistance welding industry. Its mission is to advance resistance
welding technology, broaden its use, and
promote its economic benefits. RWMA is
driven by active subcommittees that develop
programs and initiatives to advance the resistance welding process, its education, and
promotion.
RWMA offers an intensive two-day course
about the basics of resistance welding once a
year through the Emmet A. Craig Resistance
Welding School. The school is designed to
give operators, production supervisors, engineers, and others the opportunity to study,
better understand, and further their knowledge in the theory, applications, and equipment used in resistance welding.
t
Es
N2236
ab
er
ica
N1967
Rex-Cut Abrasives will display its high-performance, nonwoven cotton fiber and other
premium abrasive products.
Rexarc International
www.rexarc.com
N544
N1861
RoboVent will exhibit its line of clean air products, designed to improve manufacturing performance.
Rofin-Sinar, Inc.
www.rofin.com
N849
Rolled Alloys
www.rolledalloys.com
N506
Rhino Cutting Systems will highlight its custom-engineered oxyfuel and plasma cutting
machines for 2D and 3D bevel and complete
weld prep applications.
Rolled Alloys will present its extensive inventories of plate, sheet, bar, pipe, fittings, and
welding materials maintained in nickel alloys,
duplex stainless steels, stainless steels, titanium, and cobalt alloys.
N209
N1871
Robotiq will showcase its line of robotic tooling, designed to maximize return on investment in high-mix automated manufacturing.
Robotmaster-In-House
Solutions
www.inhousesolution.com
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Rex-Cut Abrasives
www.rexcut.com
hTip
.com
N505
N1684
RoMan Manufacturing, a manufacturer of highcurrent, low-voltage power sources, will offer information on its line of more than 7000 designs,
customizable to any configuration, specification, or requirement.
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N259
7
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CALL
FOR
PAPERS
www.aws.org/rwma
A STANDING COMMITTEE OF
Email: ___________________________________________
Phone: ___________________________________________
Address: ________________________________________________________________________________________________________________
City/State/Zip: ___________________________________________________________________________________________________________
PROPOSED TITLE: (10 words or less) ____________________________________________________________________________________________________
_______________________________________________________________________________________________________________________
_______________________________________________________________________________________________________________________
Please complete Author Application Form and submit it, along with an abstract, to 8669 NW 36 St., #130, Miami, FL 33166.
Attn: Patrick Henry, Education Development Dept., RWMA Spring 2014 International Symposium on Advances in Resistance Welding
or email it to: phenry@aws.org or complete the online form at aws.org/rwma-authors
N211
rose plastic will offer its line of plastic-protective packaging systems. The products are
useful for the metalforming, fabricating, and
welding markets.
N100
N1971
Sakura of America
N2815
www.sakuraofamerica.com/
industrial
Sanrex Corp.
www.sansha.co.jp
Sakura will exhibit its markers and writing instruments that range from broad to ultrafine
marking for removable or permanent applications. Its solid-paint markers mark on almost
any surface indoors and outdoors. Low-chloride/low-halogen and glow-in-the-dark versions
will also be available.
Sandvik Materials
N1869
Technology
www.smt.sandvik.com/nafta
Saf-T-Cart, Inc.
www.saftcart.com
N572
N1836, N1934
N221
N2366
N425
N149
Schaefer Ventilation
www.schaeferfan.com
N2847
Sciaky, Inc.
www.sciaky.com
N223
Scrape-N-Burr
www.scrapenburr.com
N166
Scrape-N-Burr with DuaLast edge technology blades will be on display. The companys welder/metal fabricators heavy-duty
weldment and work area cleanup tool was designed for the harsh environment of the welding and metal fabrication industries.
N540
Selectrode Industries will offer its welding alloys of all types and sizes. The companys
supplies are either unbranded and bulk packaged or printed, packaged, and private labeled under a customers brand name.
N154
Senor Metals will show its copper-based alloys; brazing and welding wires; spot welding
electrode caps; EDM wires; high-copper alloys such as chromium, chromium zirconium,
cadmium, and tellurium coppers, and components made from these alloys; extruded rods;
profiles; tubes; wires; fastener wires; Ingots;
centrifugal castings; and components.
Servo-Robot, Inc.
www.servorobot.com
N1936
N346
N2547
N443
Shanghai Gonglue
N440
Machinery & Elect Tech Co., Ltd.
www.xunweld.com
Sellstrom will display a range of safety products, including goggles, protective glasses,
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
N1921
Shenzhen Stahlwerk
N2466
Welding Technology Co., Ltd.
www.stahlwerk-welding.com
Sherwin, Inc.
www.sherwininc.com
N2820
N2817
N220
SMK will display its incorrect nut setting detection system for nut/bolt welding that detects with
high accuracy whether or not a nut/bolt is set
correctly immediately prior to welding.
Soph, Inc.
N1382
sia Abrasives will exhibit its complete abrasive systems as well as products tailored to
specific requirements and applications for the
surface treatment of every type of material.
Soph, a full-service magnetic workholding supplier, will offer electro, permanent, and electropermanent magnets for workholding, material
handling, quick die, and mold clamping.
Sideros Engineering
www.siderosonline.com
N1597
Simufact-Americas LLC
N1968
www.simufact-americas.com
Simufact-Americas, a software and service
company specializing in simulation of the
manufacturing process, will showcase its
Simufact.welding and Simufact.forming
software.
N1586
Sorex Welding, a welding consumables manufacturer based in Taiwan, will exhibit SMAW
electrodes and its FCAW, GMAW, GTAW, and
SAW materials. Also on display will be the
companys flux cored wires.
N2861
N2040
N1492
N408
N2673
N1887
N1697
Steelmax Tools
www.steelmax.com
Smith Equipment
www.smithequipment.com
N1136
Southern Welding
Systems Intl
www.swsintl.com
N1922
Steelmax Tools will offer a range of metalworking tools for the fabricator, welder, and
MRO. There will be many new introductions
with live demonstrations. On display at its
N2423
SteelTailor, Ltd.
www.steeltailor.com
N874
Steiner Industries
www.steinerindustries.com
N2025
Steiner Industries will exhibit its line of protective clothing, gloves, and welding supplies
designed to promote safety and increase productivity in the workplace.
N1483
Strecker will be featuring its line of welding machines, offered with training and installation.
N2249
Strong Hand Tools will introduce its high-precision, German-made Siegmund welding tables
for heavy-duty fixturing. On demonstration will
be the BuildPro MAX modular welding table
along with the companys FrameBuilder welding table kits for efficient 2D and 3D framing.
N1943
Stud Welding
Associates, Inc.
www.studwelding.com
N2806
Suhner Industrial
N2047
Products, Inc.
www.suhnerabrasivesusa.com
Sulzer Metco US, Inc.
www.sulzer.com
N404
Sumner Manufacturing
Co., Inc.
www.sumner.com
N2473
N552
Sunstone Engineering
N2033
www.sunstonespotwelders.com
Sunstone Engineering will exhibit microwelding
solutions and an offering consisting of capacitive discharge, AC, pulse-arc, micro GTA, and
laser welding products. To help determine the
best solution for its customers, the company offers a free sample evaluation as well as consulting for custom spot welding applications.
N320
Superior Abrasives will showcase industrialgrade coated and nonwoven abrasive products such as quick-change discs, belts, specialties, and engineered products.
No page charges
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N155
N1559
9
N1585
Superior Products
www.superiorprod.com
N2134
Swagelok Company
www.swagelok.com
N2416
Taylor Winfield
Technologies, Inc.
www.taylor-winfield.com
N2071
N2264
N2533
N2028
Techalloy
www.techalloy.com
N1125
Techflex, Inc.
www.techflex.com
N2832
Techniweld
www.techniweldusa.com
N1974
TECMEN Electronics
Co., Ltd.
www.techmen.cn
N2131
TECMEN will exhibit its autodarkening welding helmets, which are approved by ANSI,
CSA, DINplus, Din-Gepruft, GS, CE, and
AS/NZS under the newest standards. Also
shown will be its high-quality autodarkening
filter, welding masks, powered air-purifying
respirator, and welding accessories.
N200
WONDER GEL
Stainless Steel Pickling Gel
WELD AFTER
WELD BEFORE
www.derustit.com
For info go to www.aws.org/ad-index
Telwin SPA
www.telwin.com
N670
Telwin will show its line of arc welding machinesfor the SMAW, GMAW, and GTAW
processes and plasma cutting machines.
These high-quality, Italian-made products are
distributed in more than 120 countries.
Tempil
www.tempil.com
Tennessee Rand, Inc.
www.tennrand.com
N2003
N1125/N871
Terralux
wwwterraluxportable.com
N103
Thermacut, Inc.
www.thermacut.com
N855
GH2T
GANTRY SERIES
N215
Thermion, Inc.
www.thermioninc.com
N418
Thermo-Calc Software
www.thermocalc.com
N1484
pany will also feature its range of linear friction welding machines.
3M
www.3m.com/occsafety
N825
3M will exhibit its line of welding safety products. Featured will be the Speedglas brand,
which is a vital part of the companys diverse
range of personal protective equipment.
THR Machinery
www.thrmachinery.com
N1592
N439
N2844
N2054
ALL NEW
W 2-TON ALUMINUM GANTRY
RY!
3 Available
Av
in 8', 10', 12' & 15' or 3
m, 4 m & 5 m beam lengths
3 2 Metric To
Ton (4,400 lb)
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3 Quick Tw
Two-Person
Assembly
3 Adjustable Span
No pinch points
spacer prevents
pinched ngerrs
A-Frame legs
lock in closed
or opened position
w w w. s u m n e r. c o m
888.999.6910
See us at FABTECH booth #N552
SUMNER MANUFACTURING
M
COMPANY,
Y,, INC.
INC
TJ Snow Co.
www.tjsnow.com
N800
T.J. Snow will feature its new, used, and remanufactured resistance spot, projection,
seam, and flash/butt welding machines. The
company also offers multigun and portable spot
welding guns, all related consumable copper
components, weld checkers, and force gauges.
Information will be provided on its in-plant welding machine service and welding seminars.
N2170
Torchmate
www.torchmate.com
N1125
Torchmate will show its CNC gantry tablebased plasma cutting systems, including the
Torchmate X table and expandable Growth
Series CNC prototyping system. Most systems can be customized with a router, waterjet,
engraver, glue gun, or other tools.
Trafimet USA
www.trafimetusa.com
N2273
Tregaskiss
www.tregaskiss.com
N836
Trendex Information
Systems, Inc.
www.trendexsys.com
N2032
N611
process orbital welding system. Live machining and welding equipment demonstrations
will be performed.
Tri-Mer Corp.
www.tri-mer.com
N1894
N2636
Tsubaki KabelSchlepp
America
www.ustsubaki.com
N1920
N2234
VERNON Tool
www.vernontool.com
N1486
U-Mark, Inc.
www.umarkers.com
N525
U-Mark will feature its broad array of innovative markers for industrial and professional
use, including paint markers, ink markers,
and specialty markers. Shown will be its new
M-15 broad tip permanent marker. Information will also be provided on its competative
distributor programs.
N2128
N318
Arc-In-Motion/ProArc Quality will show a positioner suitable for thermal spray and welding, as well as its new design, high-efficiency
Athlete series CNC plasma cutting machine.
N2215
N1125
N2453
Victory Plasma Systems will exhibit its line of industrial downdraft and water table plasma cutting systems, which are available in sizes ranging from 4 8 to 14 40 ft with a Cutmaster
A120, Auto-Cut 100300 A, or Ultra-Cut
100400 A plasma units with an XT or Victory II
controller. The company fabricates, delivers,
and installs complete turnkey systems, and
also builds rail and pipe-cutting systems.
N1491
VSM Abrasives
www.vsmabrasives.com
N1932
N305
N2867
Visual Components
N2084
www.visualcomponents.com
high-productivity abrasives, power tools, tooling, chemical tools, and environmental solutions for the metalworking industry.
N600
N2271
N1125
Wayne Trail Technologies will feature its automated systems used in the metalforming,
joining, and fabricating industries. Market
segments include press automation; robotics,
welding, and fixturing; laser systems; tube
bending and fabricating; hydroform and struc-
Weld-Aid Products
www.weldaid.com
Weartech
www.weartech.net
Weld-Aid will show its NOZZLE KLEEN coatings that maximize tip, nozzle, and diffuser life;
WELD KLEEN coatings that minimize the
need for grinding by preventing spatter buildup;
LUBE-MATIC coatings that maximize tip and
liner life; and BRITE ZINC, which provides a
high-luster, zinc-rich, rust-inhibiting coating for
the repair of galvanized steel.
N1125
Weiler Corp.
www.weilercorp.com
N2431
N1818
N2228
N2009
Weldas Co.
www.weldas.com
N1843
Weldcoa
www.weldcoa.com
N2225
Weldcraft
www.weldcraft.com
N1136
N1997
WTTI offers students the necessary occupational training and certifications that can lead to
employment in the welding field. The companys industrial services division supports industrys demand for training, certification, and
inspection. It also stocks plate and pipe
coupons for welding or brazing, and offers procedure or performance qualification testing.
Welker will display its innovative, flexible automation components used for locating, clamping, lifting, sliding, positioning, and ejecting.
WEMCO
www.aws.org/wemco
N1700
Weldsale LLC
www.weldsale.com
N811
Weldship Corp.
www.weldship.com
N421
N2018
Welding Alloys will feature its low- and high-alloyed cored wires, hardfaced wear plates, automated welding equipment for surfacing applications, and solutions for industrial welding,
surfacing, and joining applications through its
Integra Services.
Weldlogic, Inc.
www.weldlogic.com
N2539
N1947
N445
West Chester
Protective Gear
www.westchestergear.com
N2458
Western Enterprises
N2266
www.westernenterprises.com
Winnox Industries Ltd.
www.winnox-weld.com
N446
Winnox Industries will show its range of products that includes copper alloys, aluminum alloys, leather welding gloves and jackets,
leather and fiberglass welding blankets, welding curtains, welding tool bags, and leather
and polyester cable covers.
Wirecrafters
www.wirecrafters.com
N1945
N342
N2066
N861
Wolf Robotics, a robotic metalworking integrator, will highlight its standard cells and custom-engineered systems for arc welding and
cutting, machine tending, and material-removal applications. The company provides
24/7 customer service, operation and process
training, and a complete parts department.
N2217
Xiris will be exhibiting machine vision inspection products for the welding/metal fabrication
and tube and pipe industries including the
XVC-O weld camera for monitoring open arc
welding; the XVC-S weld camera for monitoring submerged arc welding tube and pipe production; and the WI2000p postweld inspection system that detects quality defects.
N818
N532
N545
Zarbeco LLC
www.zarbeco.com
N571
N2087
Zhejiang Changzheng
N438
Project Carbon Electrodes Co. Ltd.
www.czcarbon.com
Zhejiang Xinrui Welding
Material Co., Ltd.
www.xinruigroup.com
N442
N444
N1994
Zhengzhou Anxin
Abrasives Welding
N1956
N304
ZJ Industries, Inc.
www.zjindustriesinc.com
N1917
ZRID.Pty. Ltd.
www.zrid.us
N1992
N343
N2846
Wuxi Ronniewell Machinery will feature its capabilities for manufacturing wind tower welding equipment. The company has CE and ISO
certificates for its equipment.
N447
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COMING
EVENTS
ASNT Fall Conf. and Quality Testing Show 2013. Nov. 47, Rio
Hotel, Las Vegas, Nev. The American Society for Nondestructive
Testing. www.asnt.org.
Crane Users Conf. Nov. 1214, Hyatt French Quarter Hotel, New
Orleans, La. www.craneconference.com.
POWER-GEN Intl Event. Nov. 1214, Orange County Convention Center, Orlando, Fla. www.power-gen.com/event-info.html.
Intl Conf. for Vision Guided Robotics. Nov. 1315, Georgia Institute of Technology, Atlanta, Ga. www.visiononline.org/events/.
AWS Professional Program. Nov. 1821. FABTECH, McCormick Place, Chicago, Ill. Numerous sessions offered on the
latest in welding research and commercial developments. Pick
one day or attend the entire four-day program. Sponsored by
American Welding Society. (800/305) 443-9353, ext. 223;
www.fabtechexpo.com.
FABTECH 2013. Nov. 1821, McCormick Place, Chicago, Ill.
This exhibition is the largest event in North America dedicated to
showcasing the full spectrum of metal forming, fabricating, tube
and pipe, welding equipment, and myriad manufacturing technologies. American Welding Society. (800/305) 443-9353, ext. 223;
www.fabtechexpo.com.
Welding Dissimilar Metals Conf. Nov. 18. FABTECH, McCormick Place, Chicago, Ill. Sponsored by American Welding
FABTECH India colocated with Weld India. April 1012. Pragati Maidan Exhibition Complex, New Delhi, India. Concurrent
with the 2014 Intl Congress of the IIW. Cosponsored by AWS,
FMA, SME, PMA, CCAI, and India Institute of Welding.
www.fabtechexpoindia.com.
JOM, 18th Intl Conf. on Joining Materials. April 2629. Konventum LO-Skolen, Helsingr, Denmark. In association with the
Intl Institute of Welding, cosonsored by American Welding Society, Japan Welding Society, Welding Technology Institute of Australia, Brazilian Welding Society, and others. E-mail
jom_aws@post10.tele.dk; download brochure at www.aws.org/wj/
JOM-18-CallForPapers.pdf.
continued on page 167
www.tokinarc.com
e-mail: trading@tokinarc.co.jp
When
you think
of
hardfacing...
think
of
POSTLE FIRST
35 years
and a dedicated
team of hardfacing
specialists can help.
Pi POSTLE
I N D U S T R I E S, I N C.
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EMAIL:
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CERTIFICATION
SCHEDULE
EXAM DAT
Jan. 11
Jan. 16
Jan. 18
Jan. 25
Feb. 1
Feb. 1
Feb. 1
Feb. 1
Feb. 15
Feb. 15
Feb. 15
March 1
March 1
March 8
March 8
March 8
March 8
March 8
March 15
March 15
March 15
March 15
March 22
March 29
March 29
March 29
March 29
April 5
April 5
April 5
April 12
April 12
April 12
April 12
April 17
April 19
May 3
May 3
May 3
May 10
May 10
May 10
May 10
May 31
June 7
June 7
June 7
June 14
June 14
June 14
June 19
June 28
June 28
June 28
EXAM DATE
Jan. 11
April 5
July 19
Sept. 20
Oct. 18
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 Web site 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.
166 NOVEMBER 2013
COMING EVENTS
continued from page 165
Educational Opportunities
Metal & Steel Middle East 2014. May 1517. Cairo, Egypt. Visit
www.metalsteeleg.com.
7th Offshore Energy Expo and Conf. Oct. 28, 29. Amsterdam RAI,
WELDING
WORKBOOK
Datasheet 344
Location
Remarks
Porosity
Weld metal
Scattered
Cluster
Piping
Aligned
Elongated
Inclusions
Slag
Tungsten
Incomplete fusion
Incomplete joint penetration
Undercut
Underfill
Overlap
Laminations
Delaminations
Seam and lap
Lamellar tear
Cracks (including hot and cold cracks)
Longitudinal
Transverse
Crater
Throat
Root
Toe
Underbead and HAZ
Concavity
Convexity
Weld reinforcement
Weld metal
Weld metal
Weld metal
Weld metal
Weld metal
Weld metal, weld interface
Weld metal, weld interface
Weld metal, weld interface
Weld metal
Weld interface
Weld metal
Weld interface
Base metal
Base metal
Base metal
Base metal
Weld metal, HAZ, base metal
Weld metal, HAZ, base metal
Weld metal
Weld metal
Weld interface, HAZ
Weld interface, HAZ
HAZ
Weld metal
Weld metal
Weld metal
Excerpted from the Welding Handbook, Vol. 1, ninth edition, and AWS A3.0M/A3.0:2010, Standard Welding Terms and Definitions.
168 NOVEMBER 2013
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
Shown Sept. 20 at the AWS Foundation Wall at the Societys World Headquarters in Miami, Fla., a mason mounts the first set of 129 bricks
purchased by donors to the Foundations scholarship fund.
erald Uttrachis editorial in last
months Welding Journal (page 4)
explained how the AWS Foundation has been increasingly successful over
the years. Under his energetic leadership
as chairman, the various scholarship programs have flourished, topped off by the
option for donors to have their names,
company logos, or memorials chipped in
stone for permanent display on the AWS
Foundations Scholarship Wall at the Societys World Headquarters in Miami, Fla.
Every day, passersby pause to read the
names engraved into the bricks that are
displayed in a sheltered, beautifully landscaped location, highlighted by a bluetiled fountain flanked by two pools.
Installation of the first set of 129 bricks
was completed Sept. 23, but there remains
Tech Topics
Interpretation AWS D1.3
Structural Welding Code Sheet Steel
Subject: Welder qualification requirements
Code Edition: D1.3/D1.3M:2008
Code Provisions: 4.7 and 4.8
AWS Log: D1.3-08-I12
Inquiries:
1) Per AWS D1.3:2008, must a welder
perform a qualification test using each WPS
that will be used in production?
2) Per AWS D1.3:2008, if the only difference between the WPS a welder qualified to and the WPS a welder used in production was a change in current and voltage, does the welder need to requalify?
3) Per AWS D1.3:2008, must a welder
be qualified to a WPS used in production
or can it be any properly documented WPS?
4) Per AWS D1.3:2008 can a WPS be removed, revised, or never be used at all in
production without voiding the passing and
qualifying test that the welder achieved to
the documented WPS?
5) Per AWS D1.3:2008, is there any difference in regard to welder qualification requirements between a prequalified WPS
(Clause 3) and a WPS qualified by testing
as defined in Clause 4?
Responses:
1) No, see 4.7.1.2.
2) No, 4.7 does not address voltage and
current changes as essential variables for
welder performance qualification.
3a) For the first part of the question: No,
see response to inquiry (1).
3b) For the second part of the question:
Yes, see 4.8.1.1.
4) Yes.
5) No, see 4.8.1.1.
Interpretation D1.8
Structural Welding Code
Seismic Supplement
Subject: Use of permanent magnets
Code Edition: D1.8/D1.8M:2005
Code Provisions: 7.9 and Annex F
AWS Log: D1.8-05-I01
Inquiry: Are permanent magnet yokes allowed to be used under AWS D1.8:2005,
paragraph 7.9 and Annex F?
Response: No.
Interpretation AWS A5.11
Specification for Nickel and Nickel-Alloy
Welding Electrodes for Shielded
Metal Arc Welding
Subject: Preheat temperature
Code Edition: AWS A5.11/A5.11M:2010
Code Provisions: Figs. 2 and 3
AWS Log: A5.11-10-I1
Inquiry: Should the provisions of Note 6 to
Figure 2 and Note 4 to Figure 3 be interpreted as specifying the minimum preheat
temperature?
Response: Yes.
170 NOVEMBER 2013
Volunteers are sought to contribute to the following technical committees. Visit www.aws.org/technical/jointechcomm.html
Methods of Weld Inspection, The B1
Committee seeks educators, general interest, and end users. Resistance Welding
Equipment, J1 Committee seeks educators,
general interest, and users. Thermal Spraying and Automotive Welding, the D8 and
C2 Committees seek educators, general interest, and end users. Machinery and
Equipment and Surfacing and Reconditioning of Industrial Mill Rolls, D14 Committee and D14H Subcommittee seek professionals. Contact E. Abrams, eabrams
@aws.org.
Safety and Health Committee seeks ed-
Committee seeks general interest and educational members. Local Heat Treating of
Pipe, D10P Subcommittee seeks professionals. Mechanical Testing of Welds, B4
Committee seeks professionals. Contact B.
McGrath, bmcgrath@aws.org.
Reactive Alloys, G2D Subcommittee
seeks volunteers. Titanium and Zirconium
Filler Metals, A5K Subcommittee seeks
professionals. Welding qualifications, B2B
Subcommittee seeks members. Friction
Stir Welding of Aluminum Alloys for Aerospace Applications, D17J Subcommittee
seeks members. A. Diaz, adiaz@aws.org.
tion entitles AWS Life Members to attend any of the technical sessions occurring during the four-day period.
Registration forms are available in
issues of the Welding Journal, as well as
in the Advance Program that was mailed
to members previously. You may also
request the form from the Membership
Department at (800) 443-9353, ext. 260.
South Seattle C. C.
6000 16th Ave. SW
Seattle, WA 98106
South-Western Career Academy
4750 Big Run South Rd.
Grove City, OH 43123
Member-Get-A-Member Campaign
Listed are the members participating
in the June 1Dec. 31, 2013, campaign.
Members receive 5 points for each Individual and 1 point for each Student Mem-
20+ Points
Jackie Morris, Mobile 40
Robert Richwine, Indiana 25
Dereck Wheeler, Oklahoma City 25
1519 Points
Joseph Vincent, Kansas City 18
SECTIONNEWS
Shown at the Lancaster Section board meeting are from left (sitting) Fred Wallbillick, John Ganoe, and Mark Malone, (standing) Chair
Justin Heistand, Robert Blauser, Mike Sebergandio, John Boyer, David Watson, and Brian Gross.
District 1
District 2
District 4
NEW JERSEY
TIDEWATER
District 3
District 5
LANCASTER
AUGUST 28
Activity: The Section board met to plan
activities for the upcoming year to include
more student involvement and discuss setting up a Section scholarship. The meeting was held at Lancaster County Career
& Technical Center in Mount Joy, Pa. At-
SEPTEMBER 11
Speaker: Tommy Boyers, regional sales
manager
Affiliation: Sonatest, Inc.
Topic: Phased array ultrasonic inspection
Activity: The program was held at
Spaghetti Warehouse in Tampa, Fla.
Pittsburgh Section members are shown during their tour of Caterpillar in September.
SOUTH CAROLINA
SEPTEMBER 19
Activity: The Section members toured the
EnviroSep Fluid & Heat Recovery Systems
facility in Georgetown, S.C. Paul Richey,
operations manager, led the tour, assisted
by Seth Evans, quality control manager,
and David Harvey, account foreman.
District 6
Shown during the South Carolina Section tour of EnviroSep are (from left) guides Seth
Evans, Paul Richey, and David Harvey, with Section Chair Gale Mole.
District 7
COLUMBUS
SEPTEMBER 11
Speaker: Bill Bruce, director of welding
and materials technology
Affiliation: Det Norske Veritas (U.S.A.),
Inc. (DNV), Dublin, Ohio
Topic: Industry response to pipeline construction quality issues identified by federal regulators
Activity: The talk concluded with a video
and a productive question and answer period. The event, attended by members of
several local technical societies, was held
at La Scala Restaurant in Columbus, Ohio.
PITTSBURGH
SEPTEMBER 10
Activity: The Section members toured the
Caterpillar facility in Houston, Pa., to
study the manufacture of mining, turbine,
and locomotive equipment. Section Chair
John Menhart and Dave Summers served
as tour guides.
NOVEMBER 2013
District 8
Carl Matricardi, Dist. 5 director, spoke at the
Chattanooga Section program.
Detroit Section members, students, and guests are shown at the September event.
CHATTANOOGA
DRAKE WELL
SEPTEMBER 12
Speaker: Carl Matricardi, Dist. 5 director
Affiliation: Welding Solutions, Inc.,
founder and president
Topic: Cause of the billboard collapse in
Snellville, Ga.
Activity: Awards were presented to Keith
Coe, Dusti Jones, David Hamilton, Sam
Davis, and David Ivy. Joe Livesay, Dist. 8
director, attended the event.
SEPTEMBER 19
Activity: The members discussed plans for
sponsoring the spring District conference,
starting a Section scholarship, chartering
a Student Chapter, and holding a welding
competition. Erik Speer was elected technical representative and membership committee chair. Robert Fugate was elected
publicity committe chair and Section webmaster.
District 9
District 11
CENTRAL LOUISIANA
JULY 25
Speaker: George Fairbanks, Dist. 9 director
Affiliation: Fairbanks Inspection & Testing, general manager
Topic: An overview of AWS and how AWS
can enhance your business
Activity: The program was held at Tunks
Cypress Inn in Boyce, La.
District 10
DETROIT
SEPTEMBER 12
Activity: The Section held its annual student night featuring the presentation of
scholarships totaling $37,500 to 37 students. Alex Pazkowski, a veteran SkillsUSA competitor, related his experiences
earning the silver medal in the WorldSkills
welding contest in Leipzig, Germany. The
scholarship recipients included Blake
Parks, Nathaniel Vanderhoof, Zachary
Boylard, Bradley Bills, Isira Abeyagunawardana, Andrew Klos, Zackery Brown,
Charles Adams, Nathan Latimer, Kyle
Christensen, Lyle Pompa, Jason Fields,
Joshua Ward, Philip Brown, Joseph Giles,
Justin Greene, Marissa Guysky, Brian
District 12
LAKESHORE
SEPTEMBER 12
Activity:The Section toured ACE (Aluminum Center of Excellence) Marine, a
division of Fincantieri Marine, in Green
Bay Wis. Jeff Frank, production manager,
led the tour and described the precision
tooling used to build the U.S. Coast Guard
Response Boat-Medium.
District 13
The Lakeshore Section members are shown during their tour of ACE Marine.
CHICAGO
SEPTEMBER 8
Activity: The Section held its annual summer safari adventure and buffet dinner
outing at Brookfield Zoo. Heading the
event were Tech Chair Craig Tichelar, Jeff
Stanczak, Lisa Moran, and Bob Zimny.
District 14
Several Chicago Section members are shown during their outing at the Brookfield Zoo.
TRI-RIVER
SEPTEMBER 24
Speeaker: John Durbin, welding technology director
Affiliation: Ivy Tech C.C.
Topic: Oxyfuel cutting safety
Activity: The meeting was held at the college in Evansville, Ind.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
Bob Worthington helps a Boy Scout earn his
welding merit badge at the Kansas City Section training program.
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
KANSAS CITY
FEBRUARY 9
Activity: The Section held its second allday welding merit badge training class for
17 Boy Scouts. The program was held at
the Metropolitan Community College
Business and Technology Campus in
Kansas City, Mo.
NOVEMBER 2013
District 17
J. Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
NORTH TEXAS
SEPTEMBER 17
Speaker: Graham Bettis, project engineer
Affiliation: Texas DOT, Bridge division
Topic: D1.5, Bridge Welding Code
OKLAHOMA CITY
SEPTEMBER 19
Speaker: Jacob Fort
Affiliation: Fronius USA
Topic: Cold metal transfer
Activity: The program was held at Golden
Corral in Oklahoma City, Okla.
District 18
HOUSTON
SEPTEMBER 18
Speaker: Richard Holdren, senior welding engineer
Affiliation: ARC Specialties
Topic: The sense and nonsense of procedure qualification
Activity: Among the 135 attendees were
40 students from Industrial Welding Academy. The meeting was held at Bradys
Landing in Houston, Tex.
District 19
PUGET SOUND
SEPTEMBER 5
Speaker: Robert Heffernan, welding applications engineer
Affiliation: Praxair
Topic: New high-tech pipe-cutting equipment
Activity: Ken Johnson, Dist. 19 director,
and Rob White are working on two new
seminars. The event was held at Ivars
Salmon House in Seattle, Wash.
District 20
District 21
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
SAN FRANCISCO
SEPTEMBER 4
Speaker: Andre Lopez, owner
Affiliation: All Metals Welding
Topic: Portable welding operations
Activity: Following the talk, the 41 attendees had a chance to examine the speakers
rig truck outfitted for his portable welding business. Andres Ochoa received his
Gold Member certificate for 50 years of
service to the Society. This past chairmens
night program was attended by past chairs
Andres Ochoa, Andre Lopez, Joe Meyer,
Dale Phillips, Richard Hashimoto, and
Tom Smeltzer.
International
Section
GERMANY
SEPTEMBER 18
Activity: Chair Christian Ahrens presented general information about the Sections status and plans for participating in
FABTECH and the GSI Conference in
January in Miami, and the efforts to obtain ATF status for GSI SLV Munich.
Ahrens also discussed plans for offering
Andres Ochoa (left) receives his Gold Member certificate from Joe Meyer at the San
Francisco Sections past chairmens night
event.
CWI seminars. Dick Seif invited Section
members to visit AWS World Headquarters in Miami. Peter Knauf was named a
Silver Member for his 25 years of service
to the Society. The meeting was held during the Essen Trade Fair in Essen, Germany. The next meeting for election of officers and new business will be held in
Berlin, Sept. 15, 16, 2014.
WELDING JOURNAL 179
Nancy C. Cole
nccengr@yahoo.com
NCC Engineering
2735 Robert Oliver Ave.
Fernandina Beach, FL 32034
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
INTERNATIONAL SALES
PUBLICATION SERVICES
Director, Operations
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Technical Activities Committee
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
MARKETING COMMUNICATIONS
Human Resources
TECHNICAL SERVICES
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between members and AWS headquarters.
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
Executive Director
John Ospina.. jospina@aws.org . . . . . . . . . .(462)
Operations Manager
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401)
MEMBER SERVICES
CERTIFICATION SERVICES
EDUCATION SERVICES
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
Gerald D. Uttrachi
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards and Fellow and Counselor nominations.
Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Automotive, Resistance Welding, Machinery and
Equipment, Methods of Inspection
PERSONNEL
SigmaTEK Appoints VP
SigmaTEK Systems, LLC, a provider
of CAD/CAM nesting and manufacturing
process automation, has promoted John
Reynolds to vice president of engineering.
Reynolds, with the company since 1999,
most recently served as vice president of
operations.
Sabre Tubular
Appoints Trainer
Sabre Tubular Structures, Alvarado,
Tex., a manufacturer of steel power-delivery poles and substation structures, has
named Donnie Williams technical trainer.
Williams, an AWS
Certified Welding
Inspector and Certified Welding Educator, is an active
member of the AWS
North Texas Section.
Previously, he served
as education supervisor at Lincoln College of Technology in
Donnie Williams Grand Prairie, Tex.
Member Milestones
Mike Weller Tapped for Education Award
Mike Weller, president, Miller Electric Mfg. Co., Appleton, Wis., has received the Technical Education Champion Award from the Wisconsin Technical College District Boards Association. The annual award recognizes
business leaders for their support of local technical schools
and addressing key industry issues. Weller was recognized
for his work with Fox Valley Technical College (FVTC).
Among other initiatives, Weller recently served as treasurer and team leader for Friends of FVTC, an advocacy
group that secured 240,000 sq ft of new facilities. He has
led the 30-year Miller-FVTC partnership to establish the
Mike Weller
colleges Advanced Manufacturing Technical Center that
opened in 2011 to expand its welding programs, has served
as an adjunct instructor at the college, is active in the K12 engagement programs, and is an advocate for Wisconsin technical institutions with the governors office. Weller joined AWS in 1995. In 2003, he was named an Honorary
Member by the AWS Board of Directors.
MECHANIZED
WELDING
SYSTEMS
FABTECH
Booth N611
RED HOT
Products
Twin-Wire Arc Spray System
See Us at FABTECH
Booth N854
See Us at FABTECH
Booth N511
See Us at FABTECH
Booth N2121
See Us at FABTECH
Booth N2834
Manual Rollover
Positioners for Welding
Bluco Corporation will display
its new line of manual roll-over
positioners at FABTECH 2013.
These positioners can be
used as stand-alone fixturing
solutions, or complement
your existing Bluco fixturing
system. There are several
styles and lengths of positioners available to suit your application. Stop by
Booth N2411 and speak to a Bluco sales engineer.
Bluco Corporation
3500 Thayer Ct.
Aurora, IL 60504
(800) 535-0135
www.bluco.com
See Us at FABTECH
Booth N2411
184
RED HOT
Products
Wall Tracking Fillet Welder
See Us at FABTECH
Booth N1815
See Us at FABTECH
Booth N429
See Us at FABTECH
Booth N2439
See Us at FABTECH
Booth N2328
See Us at FABTECH
Booth N2439
185
Products
Fischer SUPER COUPON
Qualifies all Thicknesses
186
(847) 537-8800
sales@ehwachs.com
www.ehwachs.com
Goss Incorporated
1511 Route 8
Glenshaw, PA 15116
(800) 367-4677
Fax: (412) 486-6844
office@gossonline.com
www.gossonline.com
See Us at FABTECH
Booth N2049
RED HOT
RED HOT
Products
Contact us at ussales@gullco.com
See Us at FABTECH
Booth N627
H & Ms unique split horseshoe design permits easy placement over pipe
sections. A quick-operating boomer assembly securely locks the machine
to the pipe for an entire 360-degree rotation. No repositioning is ever
needed! H & Ms Cuboid Spacer System keeps the spacers on the machine
to minimize downtime.
H&M Pipe Beveling Machine Co.
311 East Third Street, Tulsa, OK 74120
(918) 582-9984 Fax: (918) 582-9989
info@hmpipe.com http://hmpipe.com/machines
Welder Shaver
Heck Industries has added a
new hand held weld shaver to
their line of fabricating equipment. The new weld shaver
uses standard carbide inserts
in a milling cutter to shave
weld beads flush to a work
piece. Used for cleaning butt
welds and corner welds. The
weld shaver will remove only the weld and not damage surrounding
materials such as conventional grinding of joints. The 2 horsepower
Model WS-625 will quickly remove welds at 6-8 feet per minute. For more
information and a catalog please contact Heck Industries.
Heck Industries
(800) 886-5418
Fax: (810) 632-6640
www.heckind.net
Industrial Maid
351 South 12th Road
Cortland, NE 68331
(877) 624-3247
www.industrial-maid.com
See Us at FABTECH
Booth S2209
See Us at FABTECH
Booth S3193
187
RED HOT
Products
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ABSTRACT
A real-time vision system was previously developed to measure three-dimensional
(3D) weld pool surface in gas tungsten arc welding (GTAW). The measured surface was
characterized/parameterized by its width, length, and convexity. These characteristic
parameters were found capable of predicting the weld joint penetration as measured
by the backside bead width. However, to control the weld joint penetration, the welding current should be adjusted. It is unclear if these characteristic parameters may still
be used to predict the weld joint penetration in an acceptable accuracy when the weld
pool varies substantially. To answer this question and estimate the penetration under
varying weld pools, various dynamic experiments under different welding conditions
were conducted using varying welding currents to acquire (frontside weld pool surface) characteristic parameters and corresponding backside bead width as data pairs.
Data analysis revealed a nonlinear correlation of the backside bead width with the
characteristic parameters. Further, the backside bead width at a particular location requires characteristic parameters from its neighboring weld pools to estimate if the pool
varies. Hence, a dynamic adaptive neuro-fuzzy inference system (ANFIS) model was
developed to correlate the backside bead width nonlinearly to characteristic parameters in neighboring weld pools and used to online predict the backside bead width in
real-time. It was found that the weld joint penetration as measured by the backside
bead width was able to be predicted in real-time from the characteristic parameters in
neighboring weld pools with an acceptable accuracy despite variations in weld pools by
the nonlinear ANFIS model developed.
Introduction
Sensing and control of the weld joint
penetration are fundamental issues of concern in automated welding. For a fully
penetrated weld pool, the joint penetration specified by its backside bead width
could be sensed by a backside sensor.
However, a frontside sensor is preferred
because of the limitations of the backside
sensor in sensor access and motion match
between the welding torch and the sensor.
Extensive research has been performed to
monitor the welding process using various
frontside sensing techniques (Refs. 18).
Different types of information have been
extracted and interpreted to describe the
state of the welding process. Among the
many proposed frontside sensing methods,
Y. K. LIU, W. J. ZHANG, and Y. M. ZHANG
(ymzhang@engr.uky. edu) are with Institute for
Sustainable Manufacturing and Department of
Electrical Engineering, University of Kentucky,
Lexington, Ky.
the weld pool geometry is believed to provide valuable insights into the state of the
welding process. Important information,
such as weld defects and joint penetration,
are contained in the surface deformation
of the weld pool in the gas tungsten arc
welding (GTAW) process (Refs. 911). A
skilled welder can extract information
about the weld joint penetration by directly viewing the frontside weld pool. This
KEYWORDS
Weld Joint Penetration
Nonlinear
Dynamic
Penetration
Neuro-fuzzy
ANFIS
Machine Vision
Weld Pool
GTAW
Experimentation
Vision-Based Sensing System Overview
WELDING RESEARCH
Fig. 1 Experimental setup with the proposed sensing system. In this system,
an illumination laser generator projects a 19 19 dot matrix structured light
pattern on the weld pool region. An imaging plane is installed with a distance
about 100 mm from the torch. A camera is located behind the imaging plane.
WELDING RESEARCH
Before the experiments were conducted to produce the data pairs for analysis and modeling, a welding experiment
was used to demonstrate the data and data
preparation involved. As shown by this illustrative experiment, the data of interest
from experiments include inputted welding current, inputted welding speed, and
measured frontside weld pool surface
characteristic parameters as given in Fig.
3. The backside weld bead width in Fig. 3
is measured from the backside weld bead
(1)
Laser Projection
angle/ (deg)
35.5
Welding Speed/(mm/s)
12
Arc Length/mm
4
Frame Rate/(fps)
30
Fig. 4 Image of backside weld bead in the demonstrative welding experiment. The backside bead width can be measured offline and the results are
shown in Fig. 3.
Neuro-Fuzzy Modeling
As demonstrated, the backside bead
width correlates with the characteristic parameters nonlinearly and dynamically
when the weld pool varies. The neurofuzzy models are suitable for modeling this
type of correlation. This is because fuzzy
systems can be used to model human intelligence, which is typically nonlinear.
However, the extraction of human intelligence, e.g., extracting how the human
welders estimate the weld joint penetration from their observation of weld pools,
is difficult and tedious. The neuro-fuzzy
approach (i.e., the fusion of the neural networks and fuzzy logic)
provides an effective
method to determine
the parameters in
fuzzy models (extract- Fig. 5 Measured data in seven welding experiments. A Inputted welding the fuzzy rules that ing parameters (welding current and speed); B measured frontside weld
represent the human pool characteristic parameters and backside bead width.
intelligence) using automated learning techniques developed in
this study is a generalized bell membership
neural networks and has found success in
function (MF), which is specified by three
various areas (Refs. 1417). In particular,
parameters (Ref. 18):
the adaptive neuro-fuzzy inference system
(ANFIS) developed by Jang (Refs. 18, 19)
A p ; a ,b ,c
using a hybrid learning procedure posji
j
ji ji ji
sesses the advantages of adaptive rule
1
changing capability, fast convergence rate,
=
and does not require extensive experience
2b
ji
about the process to construct the fuzzy
p c
j
ji
rules. Recently, ANFIS has been em1+
ployed to model nonlinear functions, idena
ji
tify nonlinear components in control
(3)
systems, and predict chaotic time series
(Refs. 2022). Hence, ANFIS will be used
where pj (j = 1,..., M) is the fuzzy variables
to model the backside bead width to the
with M being the number of fuzzy varicharacteristic parameters. As preparation,
ables, and aji, bji, cji are the input fuzzy
neuro-fuzzy modeling and ANFIS modelmembership function parameters. In this
ing are briefly reviewed below.
study, the fuzzy variables will be the charA typical fuzzy rule in a Sugeno-type
acteristic parameters that are the input
model (Ref. 18) has the form
variables of the model.
WELDING RESEARCH
Fig. 3 Input signal (welding current and speed), measured frontside weld
pool characteristic parameters (the weld pool width, length, and convexity) and
backside bead width in a demonstrative welding experiment. Note that the current and weld pool convexity have been rescaled for better illustration.
Fig. 6 Static model-based estimation results. A Linear modeling of the joint penetration; B nonlinear ANFIS modeling of the joint penetration.
WELDING RESEARCH
Fig. 7 Nonlinear static ANFIS model surface for different weld pool convexities. A Convexity = 0.07 mm; B convexity = 0.27 mm. Nonlinearity is substantial for both small and large convexities. Here Widthb is the model calculated backside bead width using the given convexity with the frontside weld pool surface length and width as parameters.
where d
js are the so-called consequence
parameters. The final output of the fuzzy
model is (Ref. 18)
y=
W ( i1 ,i 2 ,i 3 ) y ( i1 ,i 2 ,i 3 )
i1 = 1 i 2 = 1 i 3 = 1
(5)
W (i 1 ,i 2 ,i 3 ) = A ji
j =1
(p j )
(6)
The output Equation 5 together with the
weighting Equation 6, membership function
Equation 3, and the fuzzy rule Equation 4
form an ANFIS model. Its model parameters aji, bji, cji, and djs can be identified using
the Matlab ANFIS toolbox from experimental data pairs.
Once a model is identified, its quality/performance can be evaluated using
the model average error and maximum
error defined by
E ave
1
=
N
k =1
used
RMSE =
( y ( k ) y ( k ))
k =1
E max = max y ( k ) y ( k ) ,( k = 1, N )
316-s NOVEMBER 2013, VOL. 92
(7)
(8)
(9)
(10)
y ( k ) y ( k )
/N
(11)
(12)
B
Fig. 8 Arc effect. The joint penetration at instant k is determined by neigh-
RSS 1 RSS 2
F =
p2 p1
RSS 2
N p
2
(13)
WELDING RESEARCH
through the neural network learning algorithm/process the data pairs from Fig. 5B.
The total number of the data pairs from
Fig. 5B is N = 945, which is enough for an
ANFIS model with 50 parameters.
It can be seen from Fig. 6B that the
modeling accuracy is improved using the
proposed ANFIS model. In Fig. 6A severe
model errors are primarily observed in
data ranging from 270 to 290, 390 to 500,
and 580 to 650. These errors have been
substantially reduced in Fig. 6B. Thus, the
nonlinearity does improve the capability of
the model in approximating the correlation between the frontside weld pool characteristic parameters and the backside
bead width. The obtained nonlinear model
has an average model error 0.40 mm, the
maximum model error 1.87 mm, and
RMSE 0.52 mm, all of which are smaller
than the static linear model.
To statistically justify the usage of nonlinear ANFIS model, F test is adopted to
compare linear model (Model 1) and nonlinear ANFIS model (Model 2).The definition of F test is given by
Joint Penetration
The above static ANFIS model is a sophisticated nonlinear realization of Equation 11, which correlates the backside
bead width and the weld pool characteristic parameters at the same instant. Al-
The dynamic linear model can be expressed as the following moving average
(MA) model as a special simple case of
Equation 14
Partition
Width
Length
Convexity
2
2
2
wide, narrow
long, short
large, small
Fig. 10 Nonlinear dynamic ANFIS model surface for different weld pool convexities: A Convexity=0.07 mm; B convexity=0.27 mm.
WELDING RESEARCH
Fig. 11 Contribution of the weld pool convexity to the backside bead width. A Confidence input subspace; B contribution of the convexity to the bead width.
(k ) =
j = n
(k + j )
(k + j )
(k + j )
j = n
j = n
(15)
(k ) = C
j = n
(k + j )
(k + j )
(k + j )
j = n
j = n
(16)
where Cn is the nonlinear operating point,
Fig. 12 Nonlinear dynamic ANFIS model surface for different weld pool
lengths. A Length = 4.5 mm; B length = 5.5 mm; C length = 6.5 mm.
Wb = 1.9228W 0.6178L
12.3188C 1.2070
(17)
using data from steady-state
experiments where the welding parameters are kept constant in each particular
experiment. Its gains for the
width and length, 1.9228
and 0.6178, are comparable
with 1.48 and 0.74. The positive effect of the width and
negative effect of the length on the backside weld bead width remain unchanged.
However, because of the thermal inertia
of the welding process, the proposed dynamic model can provide more accurate
information about the welding process
using neighboring weld pools when the
process is dynamic.
While the dynamic correlation between
the weld pool and penetration is easily understood, the nonlinear correlation needs
elaboration. The nonlinear model surface
shown in Fig. 11 suggests substantial nonlinearity when the weld pool convexity is
either small or large. Interestingly, the
negative effect of the convexity in steady
state (12.3188 in Equation 17) is much
more significant than that from the linear
MA part in the nonlinear dynamic ANFIS
model (0.46). It seems to suggest that the
effect of the convexity is much less significant in this study when the weld pool
varies. Given the range of the convexity in
this study is 0.07 to 0.27 mm, if the correlation between the weld pool convexity
and the penetration is linear, the contribution of the convexity on the weld penetration would be just 0.09 mm = 0.46* 0.2
mm that is negligible. This is apparently
contradictory to experimental observations that the convexity/concavity of the
weld pool surface plays a significant role
in determining the weld penetration and
the results from modeling data from
steady-state weld pools as in Ref. 12.
Hence, ANFIS cannot be correctly understood without its nonlinear part.
The effect from the nonlinearity requires an appropriate analysis method to
understand correctly. The key is not to use
the nonlinear model to extrapolate. To explain, consider a weld pool as a point in
the three-dimensional input space defined
with the three characteristic parameters of
the weld pool as orthogonal coordinates.
All the weld pools used to form the data
0.64
0.52
0.54
0.43
Average Model
Error (mm)
0.50
0.40
0.42
0.34
Maximum Model
Error/mm
1.93
1.87
1.79
1.74
WELDING RESEARCH
linear dynamic ANFIS model can best estimate the joint penetration using the
characteristic parameters of neighboring
weld pools.
Figure 10 plots the nonlinear dynamic
ANFIS model surface for when both the
weld pool convexitties are small and large.
As can be seen, the nonlinearity is substantial for both cases. Table 3 lists the
RMSE, average model error, and maximum model error for four models,
respectively.
WELDING RESEARCH
pairs to identify the model construct a subspace in the input space. A dense subspace, within which the density of the
points is sufficient, is considered a confidence input subspace from which sufficient data has been used to identify the
nonlinear model and can be used as the
domain for the nonlinear models inputs.
With the above analysis in mind, Fig. 11
was obtained from the nonlinear model to
analyze the contribution of the convexity
to the penetration. In Fig. 11A, the width
and length of the weld pools used to form
the experimental data pairs for identification are plotted and six subregions with
dense points are identified. For each such
subregion, the minimum and maximum
convexity can be found from the experimental data used. The width and length
range and corresponding convexity range
from each subregion defines one of the six
subspaces that form the confidence input
subspace. In Fig. 11B, for each set of width
and length, the convexity varies from the
corresponding minimum to the maximum.
The resultant characteristic parameters
are inputted into the nonlinear ANFIS
model to calculate the backside bead
width. The range of the calculated backside bead width as plotted in Fig. 11B thus
Dynamic
1
0.90
2
0.45
3
1.27
0
1.70
b1(j), J=3,..., 7
Static Gain
1.48
b2(j), J=3,..., 7
Static Gain
-0.47
b3(j), J=3,..., 7
Static Gain
0.46
b0
0.85
Conclusions
Dynamic experiments have been performed on 2.03-mm, 304 stainless steel pipe
using the DCEN GTAW process. The welding current and traveling speed vary
randomly to provide complete-joint-penetration welds with different weld pool surfaces. The resultant weld joint penetration
specified by the backside bead width varies
from 2 to 6 mm. Based on the obtained experimental data, the following conclusions
are drawn:
1) The complete joint penetration can
be estimated with demonstrated accuracy
by the three characteristic parameters of
the weld pool surface. All three parameters are important in determining the weld
penetration.
2) The correlation between the
frontside weld pool surface characteristic
parameters and joint penetration is dynamic and nonlinear.
3) The weld joint penetration during
complete joint penetration welding can
be monitored in real-time using the developed nonlinear dynamic ANFIS model
with sufficient accuracy.
Acknowledgment
This work was funded by the National
Science Foundation under grant CMMI0927707.
References
1. Richardson, R. W., and Gutow, D. A.
1984. Coaxial arc weld pool viewing for process
monitoring and control. Welding Journal 63(3):
4350.
2. Richardson, R. W., and Edwards, F.
S. 1995. Controlling GT arc length from arc
light emissions. Trends in Welding, Proceedings
of the 4th International Conference, pp. 715720.
3. Li, P. J., and Zhang, Y. M. 2001. Precision sensing of arc length in GTAW based on
arc light spectrum. Journal of Manufacturing
and Science Engineering, 123: 6265.
4. Ma, H. B., and Wei, S. C., 2010. Binocular vision system for both weld pool and root
gap in robot welding process. Sensor Review
30(2): 116123.
5. Fan, C. L., Lv, F., and Chen, S. 2009. Visual sensing and penetration control in aluminum alloy pulsed GTA welding. International
Journal of Advanced Manufacturing Technology
42(1): 126137.
6. Lin, T., Chen, H. B., Li, W. H., and Chen,
S. B. 2009. Intelligent methodology for sensing,
modeling, and control of weld penetration in robotic welding system. Industrial Robot: An In-
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
Introduction
Spent nuclear fuel reprocessing facilities need to be constructed from materials
offering high performance and reliability,
ones that in particular have a high corrosion resistance to nitric acid. Therefore,
nitric acid-resistant stainless steel grades
having ultralow-carbon (ULC) contents,
such as Types 304ULC and 316ULC, are
currently used for the main components of
reprocessing plants (Ref. 1). However, it
has been found that intergranular corroK. SAIDA (saida@mapse.eng.osaka-u.ac.jp),
Dr. Eng., is a professor in the Division of Materials & Manufacturing Science, Graduate School of
Engineering, Osaka University. Y. NISHIJIMA is
a graduate student in the Division of Materials &
Manufacturing Science, Graduate School of Engineering, Osaka University. K. NISHIMOTO,
Dr. Eng., is a professor in the Department of the
Application of Nuclear Technology, Fukui University of Technology. K. KIUCHI is with the Nuclear Science and Energy Directorate, Japan
Atomic Energy Agency. J. NAKAYAMA is with
the Natural Resources & Engineering Business,
Kobe Steel, Ltd.
sion occurred in devices in the reprocessing line after a short period of test operation. To improve intergranular corrosion
resistance, there is an urgent demand that
these materials be replaced with ones with
improved intergranular corrosion resistance, making them more resistant to such
an environment.
Recently, highly pure corrosion-resistant stainless steels containing a large
amount of nickel (Ni) have been developed as nitric acid-proof alloys to replace
existing Types 304ULC and 316ULC
stainless steels (Ref. 2). For example,
KEYWORDS
Extra-High Purity
25Cr-35Ni Stainless Steel
Hot Cracking Susceptibility
Hot Ductility
Grain Boundary Segregation
Molecular Orbital Analysis
Lanthanum Addition
Scavenging Effect
Si
Mn
Ni
Cr
Ti
La
U21
U22
U23
U24
U25
U26
U27
U28
0.0059
0.0038
0.0042
0.0008
0.0014
0.0038
0.0180
0.0036
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
0.0005
0.0004
0.0004
0.0036
0.0110
0.0005
0.0004
0.0003
0.0001
0.0032
0.0092
0.0009
0.0008
0.0003
0.0003
0.0003
34.76
35.81
34.36
35.05
35.85
35.82
35.39
35.12
26.14
26.22
25.98
22.89
22.73
25.78
25.92
25.71
0.15
0.11
0.12
0.20
0.21
0.12
0.14
0.13
0.0008
0.0038
0.0044
0.0011
0.0007
0.0052
0.0045
0.0036
0.0013
0.0033
0.0036
0.0009
0.0009
0.0041
0.0049
0.0043
0.003
0.008
0.021
WELDING RESEARCH
Fig. 2 Dimensions of the specimen for evaluating hot ductility by the Gleeble test.
Fig. 4 SEM microstructure of crack and crack surface in weld metal U22 after
transverse-Varestraint testing.
WELDING RESEARCH
ing temperature
range. The crack
surface occur- Fig. 5 Location and temperature range of hot cracking in the weld metal U22.
ring in the Varestraint test was
observed using a
the weld metal could be classified into two
scanning electron microscope (SEM). The
types cracks occurring distant from the
hot ductility (reduction of area) of the
weld interface and those occurring adjaweld metal was evaluated via the Gleeble
cent to the weld interface. The mitest at 8731573 K applying a crosshead
crostructure of the crack surface occurring
speed of 6 mm/s.
adjacent to the weld interface is shown in
The dimensions of the specimen for the
Fig. 4. Two characteristic morphologies
Gleeble test are shown in Fig. 2.
were observed in the crack surface,
namely, the crack surface on the highHot Cracking Susceptibility
temperature side (adjacent to the weld inEvaluated by Transverseterface) had a dendritic structure with a
Varestraint Test
trace of melting, while that on the low temperature side (distant from the weld interThe characteristic contribution of P
face) was an intergranular fracture (withand S on the hot cracking susceptibility
out melting) together with slip lines. The
was investigated using extra-high-purity
morphological features of the crack sur25Cr-35Ni steels (fully austenitic stainless
face suggest that the former crack could be
steels) in the present study.
regarded as solidification cracking, while
the latter was due to ductility-dip cracking.
Hot Cracking Behavior
In addition, some regions, which have
both morphological features, existed on
An example of hot cracks occurring in
one crack surface (called the transient
a transverse-Varestraint test of a particuzone (Ref. 4)).
lar extra-high-purity 25Cr-35Ni steel is
The hot cracking behavior of an extrashown in Fig. 3 (specimen U22, aughigh-purity 25Cr-35Ni steel (specimen
mented strain 0.83%). Cracks occurring in
U22) occurring in the transverse-Vare-
Fig. 7 Effects of P and S contents in steel on solidification and ductility-dip cracking susceptibilities.
Fig. 8 Regression analyses of solidification and ductility-dip cracking susceptibilities as functions of P and S contents.
Fig. 9 Average hot ductility of weld metals at the ductility-dip temperature range.
WELDING RESEARCH
Fig. 10 Schematic illustration of analysis mode of microsegregation during welding. A Segregation during solidification; B segregation and desegregation during cooling.
WELDING RESEARCH
susceptibilities by employing extra-highpurity steels, where the effects of coexisting elements were negligible.
Mechanism of Ductility-Dip
Crack Generation in Extra-HighPurity Steels
As described previously, the solidifica-
Table 2 Material Constants Used for Numerical Simulation of Grain Boundary Segregation
Part A Material Constants and Initial Conditions
Solute Element
4, 36, 110
0.76, 32, 92
1705
1.35 102
1705
1.69 102
D0 = 4.70 10-9
Q = 33.6 (kJ/mol)
D0 = 4.50 109
Q = 36 (kJ/mol)
D0 = 8.70 10-4
Q = 273 (kJ/mol)
D0 = 7.50 104
Q = 236 (kJ/mol)
D0 = 1.00 10-4
Q = 2.49(eV)
D0 = 1.00 104
Q = 250 (eV)
D0 = 1.70 10-5
Q = 1.71 (eV)
D0 = 1.40 105
Q = 2.70 (eV)
Kv0 = 4.5
EvF = 1.47 (eV)
Kv0 = 4.5
EvF = 1.47 (eV)
Diffusion coefficient of
complexes in solid (m2/s),
D = D0exp(-Q/kT)
Equilibrium concentration of
vacancy, Cv = Kv0exp(EvF/kT)
Eqilibrium concentration of
complexes at solute
concentration Cc,
Cc = KcCVCsexp(EvcF/kT)
Segregation energy (J/mol)
Interaction parameter (J/mol)
Kc = 12.0
EvcF = 0.41 (eV)
Kc = 12.0
EvcF = 0.90 (eV)
G 0 = 50500
G 0 = 75000
It has been recognized that the ductility-dip cracking susceptibility was closely
related to the deformability of materials
at an elevated temperature, and therefore, the hot ductility (reduction of area)
of the weld metals was evaluated by the
Gleeble test. Average values of the reduction of area for the weld metals within
the ductility-dip cracking temperature
range (from 30 K below the BTR to just
below the BTR itself) are summarized in
Fig. 9. The hot ductility decreased in the
order of U21 > U22 > U23 or U21 U24
> U25; namely, it decreased with an increase in P and S contents in the steel (in
addition, it has been confirmed that any
fracture surfaces formed an intergranular fracture). It follows that the ductilitydip cracking susceptibility would
heighten with a deterioration in the hot
ductility.
78300
10.0
1.0
100
WELDING RESEARCH
Fig. 12 Relationship between initial contents and grain boundary concentrations at 1643 K of P and S.
To elucidate the deterioration mechanism of the hot ductility of extra-highpurity 25Cr-35Ni steels, grain boundary
segregation of P and S in the weld metal
was numerically analyzed. The present
analysis model of microsegregation involves segregation during the solidification stage (Stage I) and segregation/desegregation during the cooling stage
(Stage II) following solidification under
the initial condition of an inhomogeneous
distribution formed by solidification segregation (Ref. 16). To simplify the computation procedure, the solidification segregation behaviors of P and S to the cell
boundary were calculated for pseudo-binary systems of (Fe 25 mass-% Cr 35
mass-% Ni) P and (Fe 25 mass-% Cr
35 mass-% Ni) S using the finite differential method (FDM) scheme. Furthermore, the cosegregation effect of P with S
was considered in the nonequilibrium
grain boundary segregation following solidification segregation using pseudoternary systems of (Fe 25 mass-% Cr 35
mass-% Ni) P S. The outline of the numerical models used in the present study
is as follows:
1. Solidification Segregation (Stage I)
The distribution of solutes in the solid
phase during the solidification process was
calculated by the nonequilibrium solidification segregation theory (Ref. 16). This
Fig. 13 Schematic illustration of the cluster model used for molecular orbital analysis by the DV-X
method.
J =D
i
i +1
S +S
i
(1)
x = J S J
i
i i
i 1 i 1
(2)
S =
i
i 1
x
k
3 k =1
(3)
WELDING RESEARCH
C =
i
2D t
x (S + S
i
i 1
B
B
C B C B
C Ci
i 1
i
S i +1
S
i 1
x
x
i
i 1
i
(4)
N
2
i 1
N i
x C = x + x
0
k
k
k
k =1
k =1
i =1 k =1
N
i
i
x C S + x + x
i
i
k
k
i = j +1 k =1
k =1
(5)
x C L
i
i
CS =K
j
nes
CL
j +1
(6)
where Knes is the nonequilibrium distribution coefficient between solid and liquid
328-s NOVEMBER 2013, VOL. 92
Fig. 15 Effect of the amount of La addition on solidification and ductility-dip cracking susceptibilities.
phases, and CjS and CLj + 1 are solute concentrations of solid and liquid phases at
the solid/liquid interface, respectively. The
nonequilibrium distribution coefficient
can be represented by
nes
K +
es
1+
, =R
2D L
(7)
grain boundary (equilibrium concentration) CGB(t) of P and S during cosegregation at a temperature T and time t are
given by
C
GB ,P
C P exp(G P / RT )
B
P
1+C exp(G P / RT ) + C S exp(G S
B
B
C S exp(G S / RT )
B
=
1+C P exp(G P / RT ) + C S exp(G S
B
B
(t ) =
C (t )
GB ,S
/ RT )
(8)
/ RT )
G P = G P + C S (t t )
G
0
=G S +
0
N
P
C (t t )
N
(9)
where CBP and CBS are the bulk concentrations of P and S, G0P and G0S are the
segregation energies of P and S, respectively, is the interaction parameter, and
R is the gas constant. The solute concentrations of P and S at grain boundaries at
time t, CN(t) are expressed by
4D t
= 1 exp P
P d
(0)
C P (t ) C P (0)
N
N
C (t ) C P
GB ,P
N
2 D t
P
erfc
P d
4D t
= 1 exp S
S d
(0)
C S (t ) C S (0)
N
N
C
(t ) C S
GB ,S
N
2 D t
S
S
d
erfc
(10)
P = C
(t )/C P
S = C
(t )/C S
GB , P
GB , S
(11)
N 1
x x + x
N
k
k
k =1
k =1
N 1
B ,P
C
C (t t )
GB , P
N
x k
x
k =1
2
D
t
S
C S (t )=
N
N
N 1
x x + x
N
k
k
k =1
k =1
N 1
B ,S
C (t t )
C
GB , S
N
x k
k =1
N
C P (t )=
N
(12)
during the cooling stage was also calculated based on a one-dimensional diffusion model (see Fig. 10B). During the desegregation processes, it was assumed that
solute diffusion also occurred in excess of
the solubility limit of a solute element (i.e.,
supersaturation was permitted).
Analysis Conditions
WELDING RESEARCH
WELDING RESEARCH
The binding strength of the grain boundary was numerically analyzed by a molecular orbital analysis (DV-X method (Ref.
18)). Figure 13 schematically illustrates the
cluster model used in the present computation, the 15 coincidence boundary (simulating a high-angle grain boundary) of -Fe
consisting of 67 atoms. One or two Fe atoms
on a grain boundary were replaced by P or
S atoms to simulate grain boundary segregation. The binding strength of a grain
boundary was evaluated from the bond
order between intergranular and intragranular Fe atoms in the near neighborhood of
P and S atoms (it is known that the bond
order is linearly correlated with the interatomic bond strength).
The calculated bond orders of the Fe
atom at a grain boundary for different segregation situations are shown in Fig. 14. In
this figure, Fe67 indicates the nonsegregated situation, Fe66X1 and Fe65X2,
Fe65X1Y1 (X, Y = P, S) indicate the segregated situations where one and two intergranular Fe atoms were replaced by an
X and/or Y atom, respectively. Thus,
Fe65X2 as well as Fe65X1Y1 means
that grain boundary segregation has proceeded further compared to Fe66X1,
and furthermore Fe65X1Y1 indicates
the situation of P and S cosegregation.
When P and S were segregated at grain
boundaries, the bond orders of the Fe atoms
were reduced compared to the nonsegregated situation, and the bond orders decreased with an increase in the number of
segregated P and S atoms. The bond orders
of the Fe atoms when S was segregated to a
grain boundary were lower than those for P
segregation. However, the fact that the calculated bond order of an Fe atom in
Fe65P1S1 ranked between those in Fe65P2
and Fe65S2 prevented the confirmation of
any discernible effect of cosegregation with
P with S in the present analysis.
Mechanism of Ductility-Dip
Crack Generation
To clarify the mechanism of the improvement for the hot cracking susceptibility by La addition, microstructures of
the La-containing weld metals were analyzed. Microscopic observation revealed
that fine products were formed in the Lacontaining weld metals. These fine products were then identified by the extraction
residue method. Figure 16 shows the Xray diffraction patterns of extraction
residues from weld metals U26U28. La
phosphide (LaP2) and La sulfide (LaS2)
were identified in every weld metal. Furthermore, the Ni-La intermetallic compound (Ni5La) was additionally identified
in the weld metal U28 (veryhigh La
added to the steel) as shown in Fig. 17.
Mechanism of Improvement in
Hot Cracking by the Addition of La
Conclusions
In the present report, the hot cracking
behavior of extra-high-purity 25Cr-35Ni
steel was investigated, and quantitative influences of minor and impurity elements
on the hot cracking susceptibility were
clarified. Furthermore, the effect of La addition to the steel was investigated to further improve the hot cracking susceptibility of extra-high-purity stainless steels.
The results obtained may be summarized as follows:
1) Cracks occurring in the transverseVarestraint test of extra-high-purity 25Cr35Ni steels could be classified into solidification and ductility-dip cracks. The
solidification cracking susceptibility remained at a usefully low level, while the
ductility-dip cracking susceptibility exceeded that of Type 310EHP stainless
steel when the P and S contents were high.
2) The DTR and BTR of extra-highpurity 25Cr-35Ni steel could be expressed
by the compositional parameter of P + 1.22
S and P + 1.19 S, respectively. Namely, S essentially enhanced the ductility-dip and solidification cracking susceptibilities approximately 1.2 times as effectively as P.
Furthermore, the amount of P + 1.22 S in
steels should be limited to approximately 90
ppm to obtain a sufficiently low hot cracking susceptibility in 25Cr-35Ni steel welds.
3) A grain boundary segregation analysis revealed that P and S (especially S)
were segregated to grain boundaries in the
weld metal during welding. A molecular
orbital analysis suggested that there was a
possibility that grain boundary segregation of P and S led to grain boundary embrittlement at the hot cracking temperature. It was deduced that ductility-dip
cracking could be attributed to grain
boundary embrittlement due to grain
boundary segregation of P and S.
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
A Cu/Ni porous composite interlayer was used to enhance the brazing performance of sapphire to Inconel 600. The porous interlayer was placed in between thin
sheets of active brazing filler metal, BAg-8 with 2 wt-% titanium. It was expected that
the porous interlayer would reduce the thermal coefficient mismatch, which can create unwanted residual stresses during cooling that may lead to weakened or failed
joints. In this research, the effect of titanium (Ti), nickel (Ni), and copper (Cu) diffusion into the Cu/Ni porous interlayer was evaluated. The brazing process was conducted at 830C for 30 min in a high-vacuum environment at a pressure of 1 104 Pa.
The brazed interface was observed by SEM, and an elemental analysis was conducted
using SEM-EDS. Microscopic observation has indicated the formation of a thin, black
reaction layer on the sapphire side, which is believed a TiOx compound. Elemental
mapping was also conducted using EPMA to highlight the distribution of the elements.
It was found that the Ti distribution on the sapphire interface was discontinuous and
resulted in interdiffusion between Ti, Ni, and Cu, which subsequently reduced the
thermodynamic activity between metal-ceramic interfaces. In the present study, a
compound of Ni3Ti was revealed to influence the formation of the thin reaction layer.
Introduction
In recent years, there has been a growing interest in the joining processes for ceramics due to their excellent mechanical
properties and unique applications, especially in the electronics industry. Typically,
ceramics are characterized by low density,
high strength, corrosion resistance, and
ability to withstand high operating temperatures. However, ceramics are brittle and
difficult to form or machine, which limits
their direct use in product fabrications. To
overcome this limitation, various the techniques for joining ceramics to metal have
been proposed since the metal component
is easily fabricated and both the properties
of the material could be utilized in a single
product (Refs. 1, 2). Furthermore, for most
commercial applications, a metallic part is
required to be joined to the ceramic component (Refs. 3, 4).
T.
ZAHARINIE
(rinie34@gmail.com),
F. YUSOF (farazila@um.edu.my), M. HAMDI
(hamdi@um.edu.my), and M. FADZIL (ibnjamaludin@um.edu.my) are with Center of Advanced Manufacturing and Material Processing,
Department of Engineering Design and Manufacture, Faculty of Engineering, University of
Malaya, Kuala Lumpur. T. ARIGA
(ttariga@keyaki.cc.u-tokai.ac.jp) is with Department of Materials Science, School of Engineering, Tokai University, Kanagawa, Japan.
KEYWORDS
Brazing
Composites
Interlayer
Ceramics
Nickel
Titanium
Sapphire
Alumina
Experimental Procedure
A Cu/Ni porous composite was used as
an interlayer in brazing sapphire to Inconel 600. The sapphire (single-crystal,
99.999% purity) and Inconel 600 were obtained from Yamatake Corp., Japan. The
sapphire was prepared in a disc form measuring 0.7 mm thick with a diameter of 20
mm, while the Inconel 600 sample size
was 23 23 mm2 with a thickness of 1 mm
for the SEM analysis and 4 mm thickness
for EPMA. The Cu/Ni porous composite
interlayer is prepared from pure porous
copper (Cu) and pure porous nickel (Ni)
sheets. The porous Cu and Ni sheets were
Table 1 EDS Analysis of SEM Micrograph of Brazed Joint/Sapphire Interface at 500 (at.-%)
Region
Ti
Al
Ag
Cr
Fe
Ni
Cu
A
B
C
D
E
F
2.22
2.09
46.63
0
2.32
0
58.71
75.3
31.66
95.6
44.58
73.82
9.45
5.09
0.3
1.99
3.17
0
3.99
1.49
5.01
0
13.69
1.8
0.4
0
0.34
2.41
0
0.76
3.47
0.73
0.79
0
0
1.52
3.59
4.54
4.05
0
9.34
6.97
18.17
10.77
11.21
0
26.89
15.13
WELDING RESEARCH
WELDING RESEARCH
Al
Ag
G
H
I
J
K
2.42
0.53
1.06
1.05
89.52
11.9
2.28
1.99
1.16
Ti
12.5
21.5
12.83
23.04
Ni
Cu
38.71
60.2
38.31
69.67
8.06
25.86
14.97
46.08
6.15
leads to the formation of a very thin reaction layer that weakens the joining interface,
which may result in failure of the brazed
sapphire interface.
There is also a reduction phenomenon of oxygen by Ti at the surface near the
sapphire resulting in the formation of an intermetallic TixOy compound (Ref. 25).
However, it appears that the oxygen content is very high compared to titanium in
this zone. This may also suggest that high
oxygen content could lead to the formation
of a brittle intermetallic that would not accommodate the thermal expansion mismatch between joining sapphire with
Inconel 600 (Ref. 25).
An EPMA was conducted to map the
constituent elements, especially the distribution of Ti at the brazed joint. Figure 6
shows the distribution maps with colored
legends indicating the concentration of the
elements. High concentration of Ag, Cu,
and Ni were significantly observed in the
middle of the brazed area. The rich Ag was
isolated in the center of the braze layer, and
it is believed that the Ag from the filler
metal diffused into the porous layer (Cu
and Ni) and formed wavelike structures.
There was no trace of Ti element in the
middle of the brazed area. However, a rich
Ti element was significantly observed near
the brazing interface. The wavelike struture
of Ti (as indicated in the figure) formed on
both sides of the brazing interface. This
structure was almost identical with lacework phase revealed by Vianco et al.
(Refs. 8, 26). In addition to the Ti element,
the Cu and Ni elements were also traced in
the wavelike structures, distributed in similar fashion to the rich Ti element. The
EPMA analyses confirmed that the Ti dif-
Conclusions
The effects of Ti, Ni, and Cu diffusion
into a Cu/Ni porous composite as well as
the influences on metallic bonding at the
sapphire interface in sapphire brazed to Inconel 600 were investigated. From the results, it appears that titanium (Ti) is an
active element, well known for wetting the
ceramic surface even in very small percentages. However, a strong Ti and Ni interaction rather than Ti and Cu during brazing
have obstructed the thermodynamic activity
of Ti. In this research, a Ni3Ti compound
was thought to be altering the thermodynamic activity in the brazing filler metal
near the sapphire side and limiting the diffusion of Ti reacting with the oxide from
the sapphire to form a reaction layer. As a
result, only a very thin reaction layer was
formed on the sapphire. The high-oxygen
percentage at the sapphire interface contributed to the formation of a brittle intermetallic TiOx layer.
The research has shown that the elements of the porous interlayer may alter the
thermodynamic activity of the active filler
metal. It is proposed that the composition
of the porous interlayer should be carefully
WELDING RESEARCH
WELDING RESEARCH
Introduction
Three main factors affect hydrogeninduced cracking (HIC) susceptibility in
weldments. They are as follows (Refs.
13):
Presence of hydrogen
Residual stresses
Susceptible microstructure.
The diffusible hydrogen (H) content is
generally considered the effective fraction
of hydrogen in weldments HIC (Refs. 2,
48). At relatively low temperature (i.e.,
between 100 and 200C), the diffusible
atomic hydrogen accumulated forms the
molecule hydrogen, which has very high
pressure at room temperature (Refs. 6, 9,
10). Therefore, HIC, which is sometimes
known as cold cracking or delayed cracking (Refs. 6, 9), is formed after solidification of fusion welding. On the other hand,
residual stresses developed during cooling
take place at a comparatively low temperA. FOTOUH (fotouh@ualberta.ca) is a research
assistant, Mechanical Engineering Dept., University of Alberta, Edmonton, Alberta, Canada. M.
El-SHENNAWY is an associate professor, Mechanical Engineering Dept., Faculty of Engineering, Taif University, Taif, Saudi Arabia. R. ELHEBEARY is professor emeritus, Mechanical
Design and Production Dept., Faculty of Engineering, Cairo University, Giza, Egypt.
KEYWORDS
Modeling
Hydrogen-Induced Cracking
(HIC)
Implant Test
Implant Static Tensile Limit
Stress
Maximum Heat-Affected Zone
(HAZ) Hardness
Shielded Metal Arc Welding
(SMAW)
Gas Metal Arc Welding
(GMAW)
150
Base Metal
Sample
Steel Designation
Mechanical Properties
Ultimate Tensile
Strength, MPa
Elongation,
%
C-Mn
DIN: 17Mn4
350
580
37
DIN: St 52-3N
420
595
30
MSZ: E420C
623
775
21
MSZ:KL3
295
535
23
ASTM:387-G11
310
585
19
DIN:20CrMo5
710
1150
DIN: St 37-2
260
320
54
HSLA
Implant backing
plate (heat sink)
WELDING RESEARCH
Fig. 3 Effect of H on the implant test results for steel B: 0.42 (CE) and
at t800/500 of 4.5 s.
WELDING RESEARCH
(E .I / v )fm
t T1 /T2 =
2k
T1 T2
(T2 To ) (T1 To )
1 (E .I v )fm 2
t T1 /T2 =
S
4k S
1
1
(T T )2 (T T )2
2 0
1
0
(3)
(E .I / v )fm
2 s
Sc =
1
1
T T + T T
( 2 0 ) ( 1 0 )
(2)
Fig. 4 Effect of H on the implant test results for steel E: 0.58 (CE) at
t800/500 of 4.5 s.
(4)
Base Metal
Sample
A
B
C
HSLA
D
E
F
Implant backing
plate (heat sink)
Chemical Composition, %
CE,
%
Si
Mn
Cr
Mo
Ni
Cu
Al
0.130
0.148
0.210
0.220
0.118
0.198
0.063
0.241
0.266
0.450
0.210
0.505
0.188
0.181
1.400
1.380
1.250
1.260
0.528
1.060
0.517
0.017
0.018
0.020
0.020
0.011
0.017
0.028
0.012
0.012
0.020
0.012
0.003
0.016
0.012
0.034
0.029
0.120
1.320
1.250
0.016
0.010
0.009
0.060
0.536
0.215
0.014
0.015
0.130
0.050
0.700
0.047
0.115
0.018
0.001
0.005
0.070
0.130
0.010
0.010
0.001
0.018
0.324
0.120
0.150
0.020
0.185
0.017
0.038
0.049
0.018
0.008
0.021
0.020
0.38
0.42
0.48
0.52
0.58
0.69
and 500C (t800/500); 2) the base metal carbon equivalent (CE); and 3) the diffusible
hydrogen content (H). There are some
other minor factors that also affect the values of imp and HV10MAX (i.e., the susceptibility to HIC), such as the carbon content
and the yield strength (Refs. 4, 6, 12, 13, 29);
however, the present study focuses on the
three major effective factors (i.e., t800/500,
CE, and H) and their effect on imp and
HV10MAX. In this study, these three major
effective factors were considered the essential variables that were used to develop the
mathematical models for both imp and
HV10MAX.
The following part is divided into two
main sections: the first section, assessment
of HIC susceptibility, is to demonstrate
the observed effects of t800/500, CE, and H
on imp and HV10MAX; the second section,
modeling of HIC susceptibility, is to illustrate how these three welding factors (i.e.,
t800/500, CE, and H) are interactively inte-
Electrode Type
Classifications
(AWS Designation)
Electrode
Diameter (mm)
Type of Flux
Si
A5.05-81
E7010-G
3.25
4.00
5.00
0.14
0.14
0.60
A5.01-81
E6013
3.25
4.00
5.00
0.06
0.40
A5.01-81
E7018
3.25
4.00
5.00
0.05
0.08
Cellulose
Rutile
Basic
1.0
1.2
Chemical Composition, %
Mn
Mo
Mechanical Properties
Yield
Point
MPa.
Tensile
Strength
MPa.
0.20
420
480590
0.50
390
470590
0.06
0.90
400
510630
0.90
1.5
460
560
grated to affect imp and HV10MAX; additionally, the second section discusses how
to incorporate the interactively integrated
effect of the three major welding factors
into simplified mathematical models developed to simulate imp and HV10MAX.
Assessment of HIC Susceptibility
Figures 3 and 4 show implant stresstime curves that indicate the effect of different values of the diffusible hydrogen
content (H) on the implant test results for
both C-Mn steel with CE of 0.42 and
HSLA steel with CE of 0.58, respectively,
at t800/500 of 4.5 s. The first part of these
implant stress-time curves was developed
as a result of the different stresses that
were applied until the implant limit stress
(imp) was reached, which is represented
by the horizontal lines in the curves. The
logarithmic regression was used to plot the
linear relationship in the first part of the
implant stress-time curves. These developed linear relationships were plotted not
to represent any physical property except
the general trend of the first part of the implant stress-time curves (i.e., to demonstrate that the time to fracture increased
by decreasing the applied static stress). R2
values in Figs. 3 and 4 represent the goodness of fit of the logarithmic regression
used to plot the first part of the curves.
The horizontal lines in Figs. 3 and 4
demonstrate that the value of imp decreases by increasing H, and this increases
the risk of HIC at a constant value of
t800/500. Using the logarithmic regression,
Figs. 5 and 6 show the relationship between imp and H for both C-Mn and
HSLA steels, respectively, at different values of CE and t800/500. Generally, Figs. 5
and 6 illustrate that at certain t800/500 and
CE when the value of H decreases, the
value of imp increases, and this reduces
the susceptibility to HIC.
The implant test results for both C-Mn
steel with CE of 0.42 and HSLA steel with
CE of 0.58 were plotted at H of 30 mL/100
WELDING JOURNAL 339-s
WELDING RESEARCH
Fig. 7 Effect of t800/500 on the implant test results for steel B: 0.42 (CE)
at H of 30 mL/100 g.
WELDING RESEARCH
Fig. 8 Effect of t800/500 on the implant test results for steel E: 0.58 (CE)
at H of 30 mL/100 g.
Coating
Electrode Type
Classifications
(AWS Designation)
Electrode Conditions
Diffusible Hydrogen
Content H (IIW),
mL/100 g
SMAW
Cellulose
A5.05-81
E7010-G
Not
Recommended
1.7
40
SMAW
Rutile
A5.01-81
E6013
1 h at temperature
150C
1.7
30
SMAW
Basic
A5.01-81
E7018
2 h at temperature
260C
1.7
GMAW
Solid Wire
CO2 Shielding
Gases
A5.18-79
ER70S-6
Not
Recommended
1.7
Ppm ( x , y ) =
n
(x i x ) ( y i y )
i =1
n
(5)
n
(x i x ) ( y i y )
i =1
i =1
moment coefficient for two numerical parameters (i.e., x and y), n is the number of
readings for parameters x and y, x is the average of parameter x readings, y is the average of parameter y readings, and i is the
counter of the readings number n.
Ppm can take values from 1.00 to 1.00.
At Ppm = 1.00, there is a perfect direct correlation between the two numerical parameters. At Ppm = 0.00, there is no correlation at all between the numerical
parameters. For Ppm = 1.00, there is a
perfect inverse correlation between the
two numerical parameters.
As illustrated previously, the main welding factors controlling imp can be considered to be the maximum HAZ hardness
(HV10MAX) and the diffusible hydrogen
content (H). Table 6 shows the values of Ppm
between imp and its controlling welding
factors (i.e., HV10MAX and H) for the tested
C-Mn steels and HSLA steels. For C-Mn
steels (i.e., CE: 0.38 to CE: 0.48), the values
of Ppm for the imp-HV10MAX relationship
are relatively high, which means that
Table 5 Implant Test Welding Conditions and Cooling Times from the Thermocouple and from the Adams Model
Electrode Type
Welding Conditions
T800/500
(s)
Cellulose (E7010-G)
Rutile (E6013)
Basic (E7018)
3.25
125
24
2.5
1.2
4.0
170
25
2.5
1.7
5.0
225
28
2.5
2.5
1.0
200
27
4.5
1.2
1.2
250
30
4.5
1.7
1.2
250
30
3
2.5
Thick, 30 mm,
using the thermocouple
4.7
5.8
10.1
4.9
6.5
9.8
Thick, 30 mm,
using Adams model
4.5
6.3
9.3
4.5
6.3
9.3
15.7
29.7
67.3
14.8
30.9
65.1
16.5
33.1
71.5
16.5
33.1
71.5
WELDING RESEARCH
Fig. 11 Microstructure images of (Ref.19): A The C-Mn steel A: 0.38 CE base metal; B a Widmansttten ferrite in the coarsened grain HAZ region at
t800/500 of 4.5 s; and C an acicular ferrite in the HAZ coarsened grain region at t800/500 of 16.5 s.
WELDING RESEARCH
Fig. 12 Effect of base metal CE on the results of the implant test for
A: 0.38 (CE), B: 0.42 (CE), and C: 0.48 (CE) at H of 40 mL/100 g and
t800/500 of 9.3 s.
(6)
Fig. 13 Effect of base metal CE on the results of the implant test for
steels D: 0.52 (CE), E: 0.58 (CE), and F: 0.69 (CE) at H of 40 mL/100
g and t800/500 of 6.3 s.
0.77
0.65
0.47
0.76
0.71
0.64
the values of imp measured from the implant tests (impM) for CE ranges of
0.380.48 (i.e., C-Mn steels), 0.520.69 (i.e.,
HSLA steels), and 0.380.69 (i.e., both CMn and HSLA steels), respectively.
The second parameter that can be used
to assess HAZ susceptibility to HIC is the
maximum HAZ hardness (HV10MAX),
which is affected by t800/500 and CE (Refs.
14, 19). Table 8 shows the values of Ppm
for HV10MAX-t800/500 and HV10MAX-H relationships. For both the C-Mn steels category (with CE ranging between 0.38 and
0.48) and HSLA steels category (with CE
ranging between 0.52 and 0.69), the dominating welding factor affecting HV10MAX
is t800/500, as shown in Table 8. By increasing the CE domain to cover the range between 0.38 and 0.69, the Ppm for the
HV10MAX-t800/500 relationship was low-
Value for
C-Mn
Value for
HSLA
Value for
C-Mn and HSLA
a
b
a
b
1060.38
42.72
1.42
0.23
1509.98
44.81
2.40
0.26
1011.04
102.87
1.26
0.39
(10)
(11)
(12)
WELDING RESEARCH
WELDING RESEARCH
Fig. 20 The relation between the measured imp (impM) and the calculated imp (impC) for C-Mn steels.
Fig. 21 The relation between the measured imp (impM) and the calculated imp (impC) for HSLA steels.
Conclusion
The effect of each welding factor (i.e.,
diffusible hydrogen content (H), cooling
time between 800 and 500C (t800/500) and
carbon equivalent (CE)) on HIC susceptibility was investigated. The susceptibility
of HAZ to HIC was assessed using implant static tensile limit stress (imp) and
maximum HAZ hardness (HV10MAX).
The experimental results showed that imp
increased, decreasing the susceptibility to
HIC, by increasing t800/500; on the other
hand, imp decreased, increasing the susceptibility to HIC, by increasing CE and
H. Additionally, it was shown through experimental results that HV10MAX increases by increasing CE or reducing
t800/500, and this increases the susceptibility to HIC.
Based on the calculated values of Ppm,
the dominating factor affecting imp for
the C-Mn steel category (i.e., for CE:
0.380.48) was found to be HV10MAX,
while the dominating factor affecting imp
was H for the HSLA steels category (i.e.,
for CE: 0.380.48); this can be attributed
to relatively high percentages of the alloying elements that exist in HSLA steels,
such as V, Ni, Cr, and Mo. The dominating welding factor affecting HV10MAX was
Table 8 Pearsons Product-Moment Coefficients between HV10MAX and Its Controlling Welding
Factors
Steel
C-Mn
(CE: 0.38 to CE: 0.48)
HSLA
(CE: 0.52 to CE:0.69)
C-Mn and HSLA
(CE: 0.38 to CE: 0.69)
0.68
0.44
0.68
0.44
0.45
0.70
Fig. 22 The relation between the measured imp (impM) and the calculated imp (impC) for C-Mn and HSLA steels.
Value for
C-Mn
Value for
HSLA
Value for
C-Mn and HSLA
a
b
a
b
170.16
743.30
3.33
114.42
359.74
207.93
24.23
5.20
437.33
94.26
68.54
62.74
WELDING RESEARCH
WELDING RESEARCH
Statement of Ownership, Management and Circulation for U.S. Postal Service (Required by U.S.C. 3685)
1.
3
5.
7.
8.
9.
10.
11.
12.
13.
15.
16.
49,702
50,080
48,029
None
None
48,350
None
None
None
48,029
None
48,350
160
None
None
None
160
48,189
1,513
49,702
99.7%
164
None
None
None
164
48,514
1,566
50,080
99.7%
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