Professional Documents
Culture Documents
JUNE 2016
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FEATURES
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CONTENTS
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DEPARTMENTS
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Editorial
Press Time News
Washington Watchword
International Update
News of the Industry
Business Briefs
Aluminum Q&A
Brazing Q&A
Product & Print Spotlight
AWS Financial Report
OFFICERS
President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Vice President John R. Bray
Affiliated Machinery, Inc.
Vice President Dale Flood
Tri Tool, Inc.
Vice President Thomas J. Lienert
Los Alamos National Laboratory
Treasurer Carey Chen
Cincinnati, Inc.
Executive Director Ray W. Shook
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
U. Aschemeier (Dist. 7), Subsea Global Solutions
D. J. Burgess (Dist. 8), Alstom Power
D. A. Desrochers (Dist. 1), Old Colony RVTHS
D. L. Doench (At Large), Hobart Bros. Co.
D. K. Eck (At Large), Praxair Distribution, Inc.
K. Fogleman (Dist. 16), Consultant
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
J. Knapp (Dist. 17), Consultant
M. Krupnicki (Dist. 6), Mahany Welding Supply
D. J. Landon (Past President), Vermeer Mfg. Co.
S. Lindsey (Dist. 21), City of San Diego
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
S. M. McDaniel (Dist. 19), Big Bend Community College
W. R. Polanin (At Large), Illinois Central College
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Airgas USA, LLC,
NorthCentral Region
R. W. Roth (At Large), RoMan Manufacturing
M. Sebergandio (Dist. 3), CNH America
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
M. Sherman (Dist. 10), SW&E, LLC
4 WELDING JOURNAL / JUNE 2016
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Coming Events
Certification Schedule
Welding Workbook
Society News
Tech Topics
Section News
Guide to AWS Services
Personnel
Classifieds
Advertiser Index
WELDING JOURNAL
Publisher Andrew Cullison
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Features Editor Kristin Campbell
Assistant Editor Melissa Gomez
Assistant Editor Annik Babinski
Peer Review Coord. Sonia Aleman
Publisher Emeritus Jeff Weber
Advertising
Sr. Advertising Sales Exec. Sandra Jorgensen
Sr. Advertising Sales Exec. Annette Delagrange
Manager of Sales Operations Lea Paneca
Sr. Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Evelyn Andino
eandino@aws.org
EDITORIAL
Carey Chen
AWS Treasurer
As the incoming
treasurer for 2016 to
2018, the financial
condition and future
growth prospects
appear quite robust
for AWS.
Jerry Leary
AWS had been looking at ways to make certification exams more accessible to the industry. Until recently, CWS and
CWSR test takers took a paper-based test at limited AWS
testing sites across the country, said Vanessa Gonzalez Hernandez, manager of certification programs, AWS. By partnering with Prometric, qualified applicants trying to achieve
CWS or CWSR certifications can save time and money by
avoiding long distance travel to exam sites. They can now
take computer-based exams at one of the many conveniently
located Prometric test sites, on a day and time that is most
suitable to the candidate.
To learn more about how to prepare for computer-based
testing and what to expect on the test day, visit
prometric.com/en-us/for-test-takers/prepare-for-test-day/
pages/take-a-practice-test.aspx.
This new program, created to meet the need for welding supervi
sors specifically in the aerospace defense and oil/gas manufac
turing industries of southern Arkansas, will provide handson
instruction (as displayed in the above photo).
The Southern Arkansas University (SAU) System has developed a welding engineering technology program.
Recently, the Arkansas Higher Education Coordinating
Board approved for the university to add a bachelor of science in engineering physics with an option in welding engineering technology.
Theres a need for welding supervisors to lead the welding and fabricating operations in advanced manufacturing
industries, specifically in the aerospace defense and oil/gas
manufacturing industries of southern Arkansas.
We hire locally as much as possible, and look forward to
recruiting at SAU to fill positions as they become available,
said Colin Sterling, director of Lockheed Martin Camden
Operations.
This four-year program will provide hands-on instruction
in various welding processes, welding metallurgy, material
selections for welding, maintenance of welding products,
and welding automation.
Students will take the first two years of coursework at
Southern Arkansas University Tech, including a year of general education courses and nine months of training at its
welding academy. They will finish their bachelors degree
through the SAU engineering program. WJ
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WASHINGTON WATCHWORD
BiPartisan Tariff Bill Introduced to
Help Manufacturers
The American Manufacturing Competitiveness Act of
2016, which has strong bipartisan support, would create a
new process for the consideration and approval of Miscellaneous Tariff Bills (MTBs) by the federal government. Miscellaneous Tariff Bills reduce or suspend duties on imported
products. The goal of an MTB is to lower costs by reducing
the tariff obligations on products or parts that are imported.
Presently, members of Congress introduce MTBs based
on requests received from constituent companies. It is largely an ad hoc process that produces mixed results. Under the
new process, petitions first would be made exclusively
through the International Trade Commission (ITC), an independent federal agency. The ITC would solicit comments
from the public and the administration, and conduct its own
analysis. It would then issue a public report to Congress
with its analysis and recommendations regarding products
that meet the MTB standards. The next step would be an examination by the House Ways and Means Committee, which
would then draft an MTB proposal for the full Congress to
consider.
BY HUGH K. WEBSTER
HUGH K. WEBSTER, AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania
Ave. NW, Washington, DC 20006; email hwebster@wcb.com; FAX (202) 8350243.
INTERNATIONAL UPDATE
HITRobot Group Signs Cooperation
Agreement with KUKA
Ontario, Canada, is making critical investments to support manufacturing, strengthen global competitiveness, and
help create high-value jobs. Kathleen Wynne, premier of On12 WELDING JOURNAL / JUNE 2016
approximately 450
people were in attendance with 164 mothers and daughters.
She serves as director
of workforce development at Robins &
Morton, Birmingham,
Ala., a construction
and engineering company, and is also an
American Welding Society member.
The ladies not only
explored the construction trades through
hands-on exhibits, including bricklaying
and assembling wood
frames, but they also
Rena M. Turner, the fabrication ad
learned first-hand
ministrator at Garrison Steel Fabrica
from successful industors, Pell City, Ala., tries her hand at
try women.
virtual reality welding. (Photo cour
The following inditesy of Garrison Steel Fabricators.)
viduals in attendance
left a positive impact
on the guests: Kayleen McCabe, host of DIY Networks Rescue Renovation; Dr. Philip Cleveland, deputy state superintendent of education; Greg Sizemore, vice president of envi-
ronment, health, safety and workforce development, Associated Builders and Contractors; and Bill Caton, COO, Associated General Contractors.
In addition, Garrison Steel Fabricators, Pell City, Ala., had
a booth at the event. The company appreciated support provided by Atlas Welding Supply, Tuscaloosa, Ala., and The
Lincoln Electric Co., Cleveland, Ohio. Many young women
did well trying the VRTEX virtual reality welding machine.
The program represented a partnership with Central Six
Development Council Alabama Workforce Council Region 4,
Girls, Inc. of Central Alabama, Robins & Morton, and
AIDT/Alabama Workforce Training Center.
San Jacinto College recently held a ribbon cutting for its new
campus, along the Port of Houston, exclusively for maritime
training.
Industry Notes
In the 2015 Top 250 U.S. Trade Shows list, compiled
by Trade Show News Network and ranked according to
net square footage, FABTECH placed 19th. North Americas
largest metal forming, fabricating, welding, and finishing
event, cosponsored by the American Welding Society
along with many other organizations, was held last year at
McCormick Place in Chicago, Ill. It drew 1706 exhibitors
and 43,820 attendees, plus filled 732,400 net square feet.
The Fabricators & Manufacturers Association, International and CNA recently announced Plymouth Tube
of Streator, Ill., as the 2016 Rusty Demeules Award for
Safety Excellence winner. The Streator location manufactures cold drawing seamless alloy and carbon tubing from
steel hollows. It also follows a Safety Engagement Program.
BUSINESS BRIEFS
TransCanada Awarded Contract to Build
$550 Million Natural Gas Pipeline in Mexico
TransCanada Corp., Calgary, Alberta, has been selected to
build, own, and operate the Tula Villa de Reyes pipeline in
Mexico. The construction is supported by a 25-year natural
gas transportation service contract for 886 million ft3/day
with the Comisin Federal de Electricidad, Mexicos stateowned power company.
The company expects to invest approximately $550 million in the 36-in.-diameter, 261-mile pipeline and anticipates an in-service date of early 2018. It will begin in Tula in
the state of Hidalgo, and end in Villa de Reyes, in the state
of San Luis Potos, transporting natural gas to power generation facilities in the countrys central region.
In addition, the project will interconnect with TransCanadas Tamazunchale and Tuxpan Tula pipelines, as well as
other transporters in the region.
Comau, Turin, Italy, is continuing its growth in the robotics sector. For the third consecutive year, the manufacturer
of flexible, automatic systems has recorded a double-digit
increase in articulated robot sales. This increase in 2015 was
equally distributed within the automotive and general industry. The growth, in addition to China, was concentrated
in eastern Europe and the NAFTA region. In the APAC region, the company recorded an increase in sales as well,
partly due to the establishment of production facilities and
an innovation center in China.
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ALUMINUM Q&A
BY TONY ANDERSON
Feedability of Aluminum
Filler Metal
A: First, I would like to say that you
are absolutely correct with your comparison between gas tungsten arc
welding (GTAW) and gas metal arc
welding (GMAW) for aluminum. On
some thinner material applications,
like groove joints that require complete joint penetration from one side
and more intricate work that requires
precise control over penetration and
to consistently feed the spooled welding wire when using GMAW without
interruption. Feedability is a far more
significant issue with aluminum than
steel (see Fig. 1 for some considerations for improved feedability).
The differences between feeding
steel and aluminum are primarily due
to the difference between the two materials mechanical properties. Steel
welding wires are more rigid, can be
fed more easily over a greater distance,
and withstand far more mechanical
mistreatment when compared to aluminum welding wires. Aluminum is
softer, more susceptible to being deformed or shaved during the feeding
operation, and, consequently, requires
far more attention when selecting
and setting up a feeding system for
GMAW.
Feedability is a major consideration
for all aluminum GMAW applications,
but can become even more problematic when using the smaller-diameter
wires, and the softer aluminum alloys
such as the 1100 and 4043, when compared to the harder alloys such as
5356 and 5183. Feedability problems
often express themselves in the forms
of irregular wire feed or burnbacks
(the fusion of the welding wire to the
inside of the contact tip as described
in the question).
been developed to provide more sensitivity within the braking system and
are particularly useful for improved
feeding of aluminum wire.
Liners and Wire Guides. It is very
important that liners, as well as inlet
and outlet guides (which are typically
made from metallic material when
used for a steel welding system), be
made from a nonmetallic material
such as TeflonTM or nylon to prevent
abrasion and shaving of the aluminum
wire during the feeding operation.
Drive Rolls. Only drive rolls that
have been specifically designed for
feeding aluminum should be used.
These will have U-type contours with
edges that are chamfered and not
sharp. Do not use V-shaped groove or
knurled drive rolls, which are sometimes used for steel, for feeding aluminum. Drive rolls for feeding aluminum should be smooth, aligned,
and provide the correct drive roll pressure. Drive rolls that have sharp edges
can shave the soft aluminum wire.
These shavings can collect within the
feeding system and cause burnbacks
from blockages within the liner. Excessive drive roll pressure and/or drive
roll misalignment can deform the aluminum wire and increase friction drag
through the liner and contact tip,
which can also cause burnbacks.
Contact Tips. The contact tip inner diameter and quality are of great
importance. You should only use contact tips that are made specifically for
aluminum wire welding, with smooth
system also varies. The cost of downtime from feeding problems and replacement parts can be significant as
well. For these reasons, you should
choose the feeding system that is best
suited to your application and set it up
to optimize its feeding capability.
Push and Pull Only Feeders.
These systems are generally limited to
a practical length of about 12 ft. With
the push feeders, the feeding distance
limit is a result of the flexibility of the
aluminum wire and its tendency to
buckle and bend in the liner. With the
pull feeders, it is a result of a rapid increase in friction drag in the liner, particularly if there are bends in the conduit.
Push-Pull Feeders. This feeding
system was developed to overcome the
wire feeding problems experienced by
the other systems, and these systems
are the most positive method of feeding aluminum welding wire. The pushpull systems can improve feedability in
many applications and are often essential for more critical/specialized operations such as robotic and automated
applications to ensure consistent feedability. While typically more expensive
than other feeding systems, the push-
Conclusion
When changing from welding steel
to welding aluminum with GMAW, for
optimum aluminum weld wire feedability, consideration must be given to
the following items:
Steel Wires rigid, feed more easily over a greater distance, and withstand far more mechanical abuse.
Aluminum Wire softer, more
susceptible to abrasion, requires more
attention when purchasing and setting
up the feeding system.
Spool Brake Setting tension set
at a minimum, only sufficient brake
pressure to prevent spool from freewheeling when stopping.
Liners, Inlet and Outlet Guides
made from nonmetallic material such
as TeflonTM, nylon, or plastic to prevent abrasion or shaving.
Drive Rolls designed specifically
for aluminum, U-type contours with
chamfered edges, rolls aligned and adjusted to provide correct drive roll
pressure.
Contact Tips need to be made
specifically for aluminum, smooth internal bores, polished, absent of sharp
burrs, and bore diameter 10 to 15%
larger than wire.
Weld Wire Quality cleanliness,
wire surface smoothness, and wire diameter control.
Type of Feeding System most
appropriate for application, push, pull,
push-pull, or spool-on-gun feeding
systems. WJ
TONY ANDERSON is director of aluminum
technology, ITW Welding North America. He
is a Fellow of the British Welding Institute
(TWI), a Registered Chartered Engineer with
the British Engineering Council, and holds
numerous positions on AWS technical com
mittees. He is chairman of the Aluminum As
sociation Technical Advisory Committee for
Welding and author of the book Welding
Aluminum Questions and Answers currently
available from the AWS. Questions may be
sent to Mr. Anderson c/o Welding Journal,
8669 NW 36th St., #130, Miami, FL 33166
6672; tony.anderson@millerwelds.com.
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.
For info, go to aws.org/adindex
BRAZING Q&A
BY TIM P. HIRTHE
The MiG Buddy welding gun holster can easily be mounted on carts,
tables/benches, and C-clamps. Inventor George Bertolotti recalled testing
the product for six years, through
many evolutions, and valuing input
before launching the unit at FABTECH
2015. Theres nothing like it out
there, he said. Useful for schools and
shops, the holster fits welding guns
from Miller Electric Mfg. Co., The
Lincoln Electric Co., Masterweld Products USA, Eastwood, Tweco, and
Hobart Welding Products; visit the
following site for a list of models,
which is expected to grow. Made of
highly engineered plastic, the product
also helps prevent false triggering
with keeping guns up vs. lying down.
It includes a two-piece plastic holster,
universal mounting kit, and assembly
instructions.
GeorgeB Design, LLC
migbuddy.com
(888) 2536703
For info, go to aws.org/adindex
aws.org
AWS
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The Mongoose MILLHOG beveling tool, a self-centering inner diameter clamping, right-angle drive tool
that can bevel, face, and bore simultaneously and also be supplied with a
cutter head for membrane and overlay
removal, has been upgraded with a
new battery that allows operators to
fitup boiler tube panels virtually anywhere. It is now offered with a 6.2 Ah-,
18-V rechargeable battery. Allowing up
to 1-h operation, depending on the application, the beveling tool is useful
for 58-in. I.D. to 3-in. O.D. tubes and
needs 2.25-in. minimum clearance.
Providing chatter-free operation without cutting oils, this portable tool uses
TiN-coated cutter blades with a radical
chip breaker to direct heat away from
the tube surface.
Esco Tool
escotool.com
(800) 3436926
Hypertherm
hypertherm.com
(800) 7372978
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OFFICERS
President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Vice President John R. Bray
Affiliated Machinery, Inc.
Vice President Dale Flood
Tri Tool, Inc.
Vice President Thomas J. Lienert
Los Alamos National Laboratory
Treasurer Carey Chen
Cincinnati, Inc.
Executive Director Ray W. Shook
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
U. Aschemeier (Dist. 7), Subsea Global Solutions
D. J. Burgess (Dist. 8), Alstom Power
D. A. Desrochers (Dist. 1), Old Colony RVTHS
D. L. Doench (At Large), Hobart Bros. Co.
D. K. Eck (At Large), Praxair Distribution, Inc.
K. Fogleman (Dist. 16), Consultant
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
J. Knapp (Dist. 17), Consultant
M. Krupnicki (Dist. 6), Mahany Welding Supply
D. J. Landon (Past President), Vermeer Mfg. Co.
S. Lindsey (Dist. 21), City of San Diego
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
S. M. McDaniel (Dist. 19), Big Bend Community College
W. R. Polanin (At Large), Illinois Central College
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Airgas USA, LLC,
NorthCentral Region
R. W. Roth (At Large), RoMan Manufacturing
M. Sebergandio (Dist. 3), CNH America
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
M. Sherman (Dist. 10), SW&E, LLC
M. Skiles (Dist. 9), Consultant
W. J. Sperko (At Large), Sperko Engineering Services
J. Stoll (Dist. 18), The Bohler Welding Group U.S.
H. W. Thompson (Dist. 2), UL, Inc.
R. P. Wilcox (Dist. 11), Consultant
J. A. Willard (Dist. 13), Kankakee Community College
D. R. Wilson (Past President), Welldean Enterprises
Our operating surplus came in at $11.8 million, increasing by 20% over the prior year, a new historical high for the
Society. We have managed to keep, on average, 28 cents out of every dollar received.
Our total assets were $122.1 million, increasing by $12.1 million or 10.9%. Total net assets (net worth) were at an
all-time high of $115.8 million, an increase of $10.9 million or 10.4%. The main contributing factor to our increase in
net assets this year is our operating surplus. Market gains usually add to our net assets but our investment portfolio did
not yield favorable returns in 2015; however, we did weather the volatility in the marketplace quite well, ending with
just a slight loss in our investments.
With innovation powering what we do, Fiscal Year 2015 was a year of digital initiatives. We completed our data
migration from D3 to a Sequel environment. The new database is fueling our website and Customer Relationship Management (CRM) tool. The first phase of our CRM has been implemented. It will allow access of data to better manage
our business. We also transitioned into Great Plains, our new accounting system. New functionalities will allow for efficiency and better reporting. Our e-mail system was changed to an industry-standard system. We also launched
SharePoint, a collaboration tool that facilitates the sharing, managing and accessing of files. All of these IT
enhancements will provide us with the technology needed to support our growth. AWS Learning (AWSL), our online educational platform, is another key digital initiative of great focus, not only from a content perspective that includes
quality and relevance, but from a delivery standpoint we launched a new learning management tool, Moodle, to
improve the experience. WeldLink is another endeavor we took on to enhance membership value for all industry stakeholders. WeldLink is an online welding community tool capable of storing credentials digitally, managing rsums,
assessing readiness, mapping career paths, and connecting job seekers to employers and vice-versa, among other
features.
Under continuous improvement, customer service is an area of focus we have taken on, since our constituents are of
utmost importance to us. We spend great efforts monitoring customer service performance metrics, which now include
survey-based satisfaction metrics. A new service group was launched in 2015, our Customer Operations Department
(COD). COD will allow for a better customer experience. We have started to identify technological tools that can help
the COD accomplish this goal. These initiatives are slated for 2016.
Also within continuous improvement are our efforts to refresh our CWI exam questions hence, the new
redesigned Part B. In 2015, we spent time orchestrating the release of the new Part B, which included beta testing and
collection of data in an effort to get ready for the launch in January 2016. The new part B contains a new pipe specimen
as well as larger pieces to expand the ability to test knowledge. Digitally, we are moving toward computer-based exams
via Prometrics; more on this later in the year.
In the area of international activities, we now have consultants we consider an important physical presence covering
India and the Arabian Gulf countries. We also added a consultant in China to complement our Asia Team. We continue
to explore potential new Agents abroad, and we continue to strengthen our relationship with our existing Agents.
Efforts abroad include emphasizing and communicating AWS advantages over other global/regional welding
organizations. We also have signed an exclusive global sponsorship with World Skills. World Skills is an avenue for AWS
to gain exposure abroad.
Our sales force team has grown to include a dedicated AWSL salesperson and a dedicated Latin American sales representative. The message resonating within our sales team is We have the product, go sell it.
Our financial position is the healthiest in the 96-year history of AWS. We are very proud of our achievements. Our
sincere gratitude once again goes to our entire staff and to all of our volunteers everyone played a role in our success.
We are certain you can benefit from one of the many programs and services we offer. Please visit our website at
aws.org or call us at 1-800-443-9353.
BOD approved an additional $4 million geared toward welder training, a key focus taken on by the Foundation. We
received survey data results indicating AWS is making an impact in alleviating the shortage of welders. However, there is
still a lot of work to be done.
Our 53-foot Careers-in-Welding trailer containing virtual welding machines, sponsored by one of our partners, continues to give us visibility. This mobile exhibit will continue through 2017.
In 2015, the Foundation paid for its own operating expenses for the first time using the earnings from the $20
million transfer made in 2013 by the Society to make the Foundation self-supporting. Total operating expenses were
$1.27 million for 2015.
Contributions received in 2015 and matched under the current 100% matching program amounted to $709,000. A
total of $2,735,100 was utilized from the $4 million transfer mentioned above to match existing and new Section and
District Scholarships.
Since 1991, when the AWS Foundation began offering scholarships, more than $7 million has been awarded. In 2015,
the AWS Foundation awarded $645,000 in scholarships to more than 500 recipients. Our Scholarship Wall with named
bricks continues to fill up. You can get your individualized brick, and the proceeds from the sale will go toward scholarships for future welding students. Your name can be added to this monumental wall.
To find out how you can help in the mission of alleviating the welder workforce shortage, please contact Sam Gentry
at sgentry@aws.org.
Educational Services
Revenues were $6.8 million including $1.3 million in online courses. Online product sales increased by 68.5% over
the prior year. Innovation plays a key role in our educational products. We are committed to investing in bringing higher
standards and enhanced learning. Great efforts continue to be devoted to online development, as well as revisions and
updates to our existing educational materials. Our task at hand is to teach and provide the body of knowledge while delivering the experience. We launched our Learning Library. It contains 126 modules of digital content for use by companies and educational organizations wishing to augment their welder training curricula. WeldLink our career planning
and management system specifically designed to bring together individuals, businesses, and schools in the welding
industry is now available, so please make sure you tap into this resource. Weldink mobile capabilities will be coming
soon.
Membership
Member dues revenues increased by 8.8% over the prior year. We continue to work on recruiting individual members
worldwide. Our core emphasis is to add value to our membership. Our overall membership count was 72,516.
International and student membership represents 15.4% and 16.7% of the Societys member base, respectively. We are
working on a membership community platform; stay tuned for more information.
Certification
This operating unit once again is our top revenue-producing business unit, generating $13.5 million, an increase of
10.4% when compared to 2014. CWI renewal revenues is the main driver of the increase in total revenues, followed by
Welder certification revenues ahead by 13.7%. Exam and renewal revenues generated by our international Agents
approximated $3.6 million. We have 48 international Agents. We continue to expand our global presence through new
Agents. In 2015, we extended new contracts in India, Germany, Vietnam and Australia. We have an in-country person in
India and now Saudi Arabia. International growth remains a key focus, particularly in Asia.
Technical
The 2015 D1.1 Structural Welding Code Steel edition, our flagship code, was released in summer of 2015. Revenues
from this edition as well as two other new releases helped generate $7.6 million in total book sales revenues. Technical
marked the second highest revenue generator in 2015. The acquisition of our order fulfillment partner, WEX, helped
us achieve such revenues, as we no longer had to split royalties from book sales. The ROI for this acquisition is 1.5 years,
a solid investment.
Publications
Total departmental revenues were $4 million, an increase of 3.8% when compared to 2014. We experienced an
increase in Welding Journal advertising, up 5.6% when compared to 2014. The increase in Spanish edition ad sales was
9% over 2014.
In Summary
Despite the market negative investment returns, fiscal year 2015 was another remarkable and memorable year for
the Society from a business and operational standpoint. There are, indeed, many exciting opportunities for us as we
continue our quest to innovate and improve. We are very fortunate to be in a financial position where we can readily invest. Positive financial results allow us to be productive and focus-driven without the distraction caused when an organization is experiencing a shortage of funds. We are grateful to be able to add to our financial strength, which allows us to
fully devote our focus to our mission and deliver the best value to our constituents.
Over the past years, we have been able to build a healthy reserve and at the same time we have been able to provide,
invest, and participate in initiatives that have helped us advance our position in the marketplace. It also allows us to
give back to the industry in the form of scholarships, programs and partnerships via our AWS Foundation. We continue
to focus on global expansion to satisfy our mission and grow world presence.
We are cautiously optimistic that fiscal year 2016 will achieve positive financial results. With our prudent practices,
we will ensure that we are fiscally responsible and that we continue to make sound financial decisions.
The AWS Board of Directors and AWS Foundation Trustees would like to express their appreciation to all of our
members, volunteers, industry leaders, and cooperating organizations that share our goals in helping us make this
another successful year. Appreciation is also extended to our capable staff, who helped make 2016 a success.
Fiveyear comparisons
Fiveyear comparisons
Operating Revenue
Total Assets
Net Assets
Membership
Convention (sq. ft.)
International
Dec11
Dec12
Dec13
27,774,105
64,622,045
60,250,495
69,566
169,100
3,142,800
31,683,943
79,391,335
74,944,155
68,438
174,300
3,701,300
33,548,915
95,709,601
91,181,054
69,607
217,400
3,979,400
Dec14
36,053,591
110,055,485
104,933,365
70,750
211,100
4,366,500
Chicago
Dec15
40,696,655
122,121,856
115,819,795
72,516
237,200
4,674,300
Atlanta
Chicago
800-443-9353
305-443-9353
305-443-7559 FAX
e-mail: info@aws.org
www.aws.org
2015
5,481,017
5,186,623
369,481
469,552
990,261
2,394,000
77,949,284
1,875,186
27,406,452
122,121,856
2014
$
1,556,424
4,297,489
10,316
640,424
750,108
3,680,000
2,394,000
69,076,042
250,000
27,400,682
110,055,485
1,744,218
4,557,843
6,302,061
1,581,172
3,540,948
5,122,120
92,898,265
16,085,377
6,836,153
115,819,795
122,121,856
The accompanying notes are an integral part of these combined financial statements.
42 WELDING JOURNAL / JUNE 2016
86,685,988
10,299,591
7,947,786
104,933,365
110,055,485
OPERATING:
Convention
Educational services
Marketing and corporate
communications
International activities
AWS Foundation
WEMCO
RWMA
ITSA
Membership
Certification
Technical
Publications
Administration
Building operations
Board approved programs
TOTAL CHANGE IN
OPERATING FUND BEFORE
TRANSFER
INTER-FUND TRANSFERS
TOTAL CHANGE IN
OPERATING FUND AFTER
TRANSFER
Unrestricted
Revenues
Unrestricted
Expenses
Net Change in
Unrestricted
Net Assets
Temporarily
Restricted
Net Assets
Permanently
Restricted
Net Assets
$ 4,218,464
6,784,962
800,099
5,475,598
3,330,365
1,309,364
Total
2015
$ 3,330,365
1,309,364
Total
2014
3,112,058
1,097,549
60,135
124,120
116,602
243,860
3,949,117
13,508,065
7,634,556
4,027,748
29,026
-
986,557
459,136
148,730
125,285
301,867
1,854,104
4,123,881
2,596,975
3,219,474
7,851,425
760,816
107,826
(986,557)
(399,001)
(24,610)
(8,683)
(58,007)
2,095,013
9,384,184
5,037,581
808,274
(7,822,399)
(760,816)
(107,826)
(986,557)
(399,001)
(24,610)
(8,683)
(58,007)
2,095,013
9,384,184
5,037,581
808,274
(7,822,399)
(760,816)
(107,826)
(942,797)
(256,949)
(1,029,376)
(39,564)
(43,988)
(28,817)
1,769,961
9,368,290
3,027,896
683,672
(6,137,659)
(687,843)
(66,759)
40,696,655
28,899,773
11,796,882
11,796,882
9,825,674
9,409,719
(9,409,719)
(9,409,719)
(10,368,476)
40,696,655
38,309,492
2,387,163
2,387,163
(542,802)
RESERVE:
Interest and dividends
Loss on investments, net
1,128,924
(1,224,574)
1,128,924
(1,224,574)
1,128,924
(1,224,574)
999,818
423,723
TOTAL CHANGE IN
RESERVE FUND
BEFORE TRANSFERS
(95,650)
(95,650)
(95,650)
1,423,541
5,200,000
6,704,941
$ 5,104,350
$ 8,128,482
INTER-FUND TRANSFERS
TOTAL CHANGE IN
RESERVE FUND
AFTER TRANSFERS
5,200,000
$ 5,104,350
5,200,000
5,104,350
The accompanying notes are an integral part of these combined financial statements.
JUNE 2016 / WELDING JOURNAL 43
AWS FOUNDATION:
Donations
Interest and dividends
(Loss) gain on investments, net
Net assets released from
restrictions by satisfaction
of purpose restrictions
Operating expenses
Scholarships
Fellowships
Fundraising and other
TOTAL CHANGE IN AWS
FOUNDATION FUND
BEFORE TRANSFERS
INTER-FUND TRANSFERS
Unrestricted
Revenues
Unrestricted
Expenses
Net Change in
Unrestricted
Net Assets
Temporarily
Restricted
Net Assets
Permanently
Restricted
Net Assets
257,660
1,691,840
(2,498,987)
$ 1,234,300
90,748
330,266
(470,603)
-
257,660
1,691,840
(2,498,987)
470,603
-
1,274,030
528,524
100,000
54,163
470,603
(1,274,030)
(528,524)
(100,000)
(54,163)
(78,884)
1956,717
(2,035,601)
1,184,711
Total
2015
$ 1,491,960
1,782,588
(2,168,721)
(1,274,030)
(528,524)
(100,000)
(54,163)
(850,890)
Total
2014
803,447
1,855,664
951,686
(278,615)
(418,252)
(50,000)
(280,907)
2,583,023
553,556
553,556
4,601,075
(1,111,633)
4,042,998
3,302,929
474,672
1,956,717
(1,482,045)
5,785,786
(1,111,633)
3,192,108
5,885,952
755,090
719,002
36,088
36,088
(79,927)
TOTAL CHANGE IN
PROPERTY FUND
BEFORE TRANSFERS
755,090
719,002
36,088
36,088
(79,927)
INTER-FUND TRANSFERS
166,721
166,721
166,721
360,606
TOTAL CHANGE IN
PROPERTY FUND
AFTER TRANSFERS
921,811
719,002
202,809
202,809
280,679
6,212,277
5,785,786
10,886,430
13,752,311
86,685,988
$ 92,898,265
10,299,591
$ 16,085,377
(1,111,633)
7,947,786
$ 6,836,153
The accompanying notes are an integral part of these combined financial statements.
44 WELDING JOURNAL / JUNE 2016
104,933,365
$115,819,795
91,181,054
$104,933,365
2014
10,886,430
13,752,311
1,922,078
3,393,295
1,397,443
(1,375,409)
(2,237,625)
(220,344)
290,219
(240,153)
494,291
947
(110,632)
(297,424)
163,046
316,689
1,016,895
276,884
14,973,841
14,455,100
3,680,000
(551,509)
(1,911,202)
(12,266,537)
(2,302,485)
(13,802,787)
(11,049,248)
(16,123,272)
3,924,593
(1,668,172)
1,556,424
3,224,596
5,481,017
1,556,424
$
$
$
274,814
1,348,491
1,625,186
$
$
$
The accompanying notes are an integral part of these combined financial statements.
JUNE 2016 / WELDING JOURNAL 45
Basis of Accounting
The combined financial statements have been prepared on the accrual basis of accounting in conformity with accounting
principles generally accepted in the United States of America (U.S. GAAP). The accounts of the Organizations are
maintained for internal reporting purposes in accordance with the principles of fund accounting.
Principles of Combination
The accompanying combined financial statements include the accounts of American Welding Society, Inc. and its affiliate,
AWS Foundation. All material inter-organization accounts and transactions have been eliminated in the combination.
Basis of Presentation
Net assets and revenues, gains and losses are classified into three classes of net assets based on the existence or
absence of donor-imposed restrictions. The three classes of net asset categories are as follows:
Unrestricted Net assets which are free of donor-imposed restrictions; all revenues, gains, and losses that are
not changes in permanently or temporarily restricted net assets.
Temporarily Restricted Net assets where the use by the Organizations is limited by donor-imposed stipulations
that either expire by the passage of time or that can be fulfilled or removed by actions of the Organizations pursuant
to those stipulations.
Permanently Restricted Net assets where the use by the Organizations is limited by donor-imposed stipulations
that neither expire with the passage of time nor can be fulfilled or otherwise removed by actions of the Organizations.
The transactions of the Organizations are categorized into separate funds. The purpose and net asset classification are as
follows:
Operating This fund is used to account for all unrestricted net assets of AWS, except for those accounted for
in the reserve and property funds. The operating fund also provides administrative support to the Foundation.
AWS Foundation
Total
Vanguard Investments
Stock Market Index Fund
Bond Market Index Fund
Intermediate-Term Investment Grade Bond
International Bond Index
International Stock Index Fund
Windsor II Fund
Short-Term Investment Grade Fund
U.S. Growth Fund
Morgan Growth Fund
Explorer Fund
Strategic Equity Fund
Prime Money Market Fund
AWS Section Investments
Total investments
7,279,922
3,047,261
1,833,896
2,614,944
5,951,059
2,510,460
1,224,057
1,312,608
1,295,894
1,062,625
1,057,137
200,095
$ 29,389,958
10,531,639
7,191,253
4,327,911
6,202,968
8,125,724
3,609,065
2,882,856
1,956,485
1,920,615
1,439,024
1,489,598
(1,117,812)
$ 48,559,326
$ 17,811,561
10,238,514
6,161,807
8,817,912
14,076,783
6,119,525
4,106,913
3,269,093
3,216,509
2,501,649
2,546,735
200,095
(1,117,812)
$ 77,949,284
AWS Foundation administers investments on behalf of certain affiliated sections. The investments aggregated to
approximately $1,118,000 at December 31, 2015 and are not included in the combined financial statements.
Investment loss consisted of the following for the year ended December 31, 2015:
Reserve Fund
AWS Foundation
Total
1,128,924
1,782,588
2,911,512
(1,224,574)
(95,650)
(2,168,721)
(386,133)
(3,393,295)
(481,783)
Level 3
Inputs to the valuation methodology are unadjusted quoted prices for identical assets or liabilities in active
markets that the Organizations have the ability to access.
Inputs to the valuation methodology include:
inputs other than quoted prices that are observable for the asset or liability;
inputs that are derived principally from or corroborated by observable market data by correlation or
other means.
If the asset or liability has a specified (contractual) term, the Level 2 input must be observable for substantially
the full term of the asset or liability.
Inputs to the valuation methodology are unobservable and significant to the fair value measurement.
The assets or liabilitys fair value measurement level within the fair value hierarchy is based on the lowest level of any input
that is significant to the fair value measurement. Valuation techniques used need to maximize the use of observable inputs
and minimize the use of unobservable inputs.
Following is a description of the valuation methodologies used for assets measured at fair value. There have been no changes
in the methodologies used at December 31, 2015.
Mutual funds: Valued at the net asset value (NAV) of shares held by the Organizations at year end.
The preceding methods described may produce a fair value calculation that may not be indicative of net realizable value or
reflective of future fair values. Furthermore, although the Organizations believe the valuation methods are appropriate and
consistent with other market participants, the use of different methodologies or assumptions to determine the fair value of
certain financial instruments could result in a different fair value measurement at the reporting date. The values assigned to
certain investments are based upon currently available information and do not necessarily represent amounts that may
ultimately be realized. Because of the inherent uncertainty of valuation, those estimated fair values may differ significantly
from the values that would have been used had a ready market for the investments existed and the differences could be material.
The following table represents the Organizations' financial instruments measured at fair value on a recurring basis at December
31, 2015 for each of the fair value hierarchy levels:
Fair Value Measurement at Reporting Date Using:
Total
Description
Assets:
Money Market
Mutual Funds:
Equity U.S. Large
Equity U.S. Mid/Small
Equity - International
Short-Term Bonds
Intermediate Bonds
Bonds - International
200,095
30,416,688
5,048,384
14,076,783
4,106,913
15,282,509
8,817,912
77,949,284
200,095
30,416,688
5,048,384
14,076,783
4,106,913
15,282,509
8,817,912
77,949,284
Significant Other
Observable Inputs
(Level 2)
Significant Other
Unobservable Inputs
(Level 3)
The carrying amounts for cash, cash equivalents, receivables, accounts payable and certain other assets and liabilities
approximate fair value due to the short-term maturity of these financial instruments.
52 WELDING JOURNAL / JUNE 2016
16,646
138,821
119,347
274,814
1,625,186
1,900,000
(1,348,491)
$
551,509
The goodwill arising from this acquisition results from the established business operations that were acquired. Management
has determined that an impairment of this goodwill does not exist as of December 31, 2015.
7. PROPERTY AND EQUIPMENT, NET
Property and equipment, net consist of the following as of December 31, 2015:
Land
Building and improvements
Furniture, software and equipment
Property Fund
Foundation and
Operating Fund
6,191,574
19,758,190
25,949,764
1,819,123
24,130,641
511,046
9,317,482
9,828,528
6,552,717
3,275,811
Total
$
6,191,574
20,269,236
9,317,482
35,778,292
8,371,840
$ 27,406,452
Depreciation expense was approximately $1,922,000 for the year ended December 31, 2015.
JUNE 2016 / WELDING JOURNAL 53
637,000
348,000
298,000
263,000
265,000
193,000
2,004,000
Unrestricted
Donor restricted
endowment funds
Board restricted
endowment funds
Total endowment net assets
Permanently
Restricted
$
1,032,969
Total
2,151,350
$ 10,743,130
13,927,449
23,096,543
5,342,247
5,803,184
34,241,974
$ 25,247,893
$ 16,085,377
$ 6,836,153
$ 48,169,423
Unrestricted
Endowment net assets,
beginning
Contributions and transfers
Interest and dividends
Net investment income
Released from restriction and
appropriated for expenditure
Endowment net assets,
ending
26,729,938
811,216
1,691,840
(2,498,987)
Temporarily
Restricted
$ 10,299,591
5,835,375
90,748
330,266
Permanently
Restricted
$
7,947,786
(1,111,633)
-
Total
$
44,977,315
5,534,958
1,782,588
(2,168,721)
(1,486,114)
(470,603)
(1,956,717)
$ 25,247,893
$ 16,085,377
$ 6,836,153
$ 48,169,423
Cash
Accounts receivable
Investments
Property and equipment, net
Prepaid expenses
Liabilities
Total endowment assets
661,571
25,638,059
119,962
20,819
(1,192,518)
$ 25,247,893
Permanently
Restricted
Temporarily
Restricted
Unrestricted
$
263
16,085,114
$ 16,085,377
6,836,153
$ 6,836,153
Total
$
661,571
263
48,559,326
119,962
20,819
(1,192,518)
$ 48,169,423
$
Total
44,000
23,000
67,000
Royalty Agreement
On October 26, 2005, AWS entered into a Publication Sales Agreement with WEX LLC, whereby WEX LLC was given nonexclusive worldwide rights to duplicate, package, facsimile transmit, price, promote, distribute, sell and/or lease AWSs
documents and technical publications through paper and electronic media formats and compilations. There were several
subsequent amendments resulting in higher royalties for AWS. Under the terms of the agreement, AWS earned $2,773,387
during the year ended December 31, 2015. Such amount has been included in revenues in various departments in the
Combined Statement of Activities. On July 16, 2015, AWS acquired WEX LLC (NOTE 6).
Effective September 4, 2012, AWS amended an existing agreement with The American Society of Mechanical Engineers
(ASME), whereby ASME has the nonexclusive right to reproduce the 2013 and 2015 editions of the filler metal
specifications. ASME will pay AWS royalties equal to 35% of the net sales per quarter for the 2015 edition. Under the terms
of this agreement, AWS earned approximately $921,667 during the year ended December 31, 2015.
BY MATTHEW STERNISHA
How welders at
the Carlsbad
Desalination Plant are
successfully welding
corrosion-resistant
alloys
Joints (QW-402)
Joint Design: Butt
Backing or Backing Material: See Para Gas (QW-408)
Root Spacing: See below
Fig. 1 Typical single V-groove butt joint used for SMO 254 piping at the Carlsbad
Desalination Project.
Fig. 4 Welder performing a root pass on 36-in.-diameter SMO 254 pipe utilizing the
GTAW process at the Carlsbad Desalination Project.
Fig. 5 A 3-in.-diameter, Schedule 160 SMO 254 pipe coupon that was welded
as part of training at the local union training center and used for training and
qualification.
skillset for welders in San Diego County and a growing working relationship
between the contractor and the Local.
Verification and
Inspection
The SMO 254 pipes are critical to
the process of the desalination plant.
No water can be desalted with these
pipes out of service. Therefore, these
pipes are considered process critical,
Fig. 8 Welder performing a typical weld on SMO 254 pipe. The QC inspector is
nearby to record relevant data and ensure compliance with WPS requirements for
each weld.
Temperature (F).
The following parameters were
JUNE 2016 / WELDING JOURNAL 63
Conclusion
Desalination has the potential for
huge growth within the United States,
and the Carlsbad Desalination Plant is
at the forefront of that progression.
Understanding the weldabilty and
essential variables in Alloy SMO 254 is
critical if one hopes to withstand the
highly corrosive properties of seawater
and the osmotic pressures that must
be overcome during the RO process.
SMO 254 has the ability to resist corrosion in the seawater process, as well
as handle the high pressures. It has superior weldability characteristics compared to other alloy options, such as
duplex, but it is imperative that the
risk of heat-induced cracking is considered, and measures are taken to mitigate this risk through careful monitoring and planning of the welds and
weld sequence. In addition, providing
training and obtaining a skilled workforce is also imperative to ensure
success when working with fully
austenitic stainless steels like Alloy
SMO 254.
Last, a carefully controlled and documented QC program is crucial to producing sound welds, ensuring long
service life, and avoiding weld failures
and costly repairs in the future. Successfully welding corrosion-resistant
alloys like SMO 254, utilizing the
measures mentioned previously, leaves
desalination poised to quench the
drought and spawn a new industry
within the United States. WJ
Works Consulted
1. smt.sandvik.com/en/materialscenter/material-datasheets/tube-andpipe-seamless/sandvik-254-smo/.
2. carlsbaddesal.com/.
3. weldersuniverse.com/welding_
beads.html.
4. lincolnelectric.com/en-us/
support/process-and-theory/Pages/understanding-polarity-detail.aspx.
5. rjsales.com/techdata/alloys/
254smo.html.
Matthew Sternisha
(Matthew.Sternisha@kiewit.com) is a
project manager with Kiewit Corp., Santa
Fe Springs, Calif.
Sip on This:
Welded Tanks Support
Beer Production
BY KRISTIN CAMPBELL
Fig. 1 This custom brewhouse, fabricated by MCF Craft Brewing Systems for Bale Breaker Brewing Co., Yakima, Wash., features
(from left) a 20-bbl hop back, 30-bbl whirlpool (11 ft tall), 30-bbl steam jacketed kettle, and 30-bbl mash lauter tun with an above
grist case. It also contains piping that connects the vessels and a platform with ladders, plus designed control panel systems.
(Photo courtesy of MCF.)
Fig. 2 Matt Cartwright is not scared of heights. In MCFs shop, with lift assistance,
he gas tungsten arc welds a 12-gauge shell at the top of a 12-ft-tall, 30-bbl
fermenter.
Fig. 3 MCF staff members, shown here in a group shot, value teamwork. Behind the banner (first row, center) are Sales and
Marketing Director Liz Shearer and President/Founder Charlie Frye.
Design Developments
Fig. 4 Jacob Duvall details the inside of a large flanged and dished head with a
90-deg pneumatic tool.
Fabrication Features
The company creates complete,
functional brewhouses from 10 to 40
barrels (bbl). These often include several tanks, over a small footprint,
serving different purposes in beer production with piping to connect them.
Adding platforms with ladders allows
owners to easily reach tank openings.
The company also designs control panel systems (see Fig. 1 for the setup at
Bale Breaker Brewing Co., Yakima,
Wash.).
Cellar vessels are constructed as
well. These consist of fermenters with
interior mixing apparatuses, and
bright beer tanks, from 10 to 400 bbl.
The fermenters are actually built upside down, with their legs in the air
and tank down below, so getting inside
68 WELDING JOURNAL / JUNE 2016
Floor Supervision
In MCFs shop, there are three connected bays offering workstations,
cranes, machines/tools, and a small
parts division.
Production Manager Jon Lien and
Operations Manager William Dall
share floor managing responsibilities.
We move 20 tons of steel per
month, Lien said. The former Coast
Guard serviceman also noted tank
building is seen as a personal project
where each craftsman is relied on to
complete the job.
The guys on the floor are why
were successful. They constantly deliver for us, Lien acknowledged.
Dall, a former general contractor,
stays calm in stressful situations.
Its metalcraft Tetris, Dall joked of
managing the workflow. Theres always something to do with getting
tanks ready to ship. I enjoy problem
solving.
Welding Work
Gas tungsten arc welding (GTAW)
and gas metal arc welding (GMAW) are
performed when fabricating the tanks.
For GTAW, 116-, 18-, and 332-in. rods
are used with argon gas blends, while
for GMAW, 0.045-in. wires are used
with trimix gas blends.
A majority of material thickness is
10 or 12 gauge. Challenges working on
this include achieving a balance of
penetration without superheating the
material or causing porosity.
In addition, small tanks can be hard
to work on because of accessibility.
Large tanks can be difficult because
good fitup is required when putting
top/bottom halves together, plus
welders need lifts for welding up high.
Many welds are made to not only
Personal Perspectives
Harry Stringer hasnt been with
MCF that long but brings three years
of professional welding experience
and is getting used to its tank-building
methods as he works on his first
fermenter.
Fig. 5 Trevor Keith uses GTAW on a manway more than 22 in. tall and 17 in. wide for
a fermenter that will stand 12 ft and hold 30 bbl when finished.
Inspection Importance
Supervisor Casey Antonick is in
charge of quality control and also
trains new welders.
Whats inside the tank represents
lots of money for customers, so contamination cant happen, Antonick
explained.
He described the in-house inspection process as vigorous. A quality control checkpoint management tool is
used to ensure whats built meets company standards. There are different
criteria on a tanks inside and outside,
for instance, that must be acceptable.
Several assessments take place during the construction process. Those
are mostly visual, Antonick added.
Currently, MCF is in the process of
achieving ASME Boiler and Pressure
Vessel certification.
We look for pit-free welds and
have rigorous inspections for pinholes,
pits, cracks, and inclusions, as they
lead to bacterial contamination, Frye
continued.
Procedures include penetrant and
ultraviolet porosity tests, visual inspections, and making sure edges
arent sharp. Mechanical stress and
load limit tests take place on structural parts in the weldment stage.
On cooling jackets, air and hydrostatic tests are made at different pressure capabilities for several hours. The
same goes for testing shells, where
tanks are filled with water and pressurized to ensure there are no leaks.
Finishing Front
In the beverage industry, ultrafine
finishes are of the utmost importance
on a tanks interior, because thats
where beer ingredients and liquid
are held before consumption. Ultrasmooth blending and deburring must
occur so there are no metal shavings,
which could result in bacterial
contamination.
All welds need to be free of porosity to be finished to a sanitary level,
Frye added. Fitup and preparation are
critical factors in GTA welds, which get
ground to 150-grit or more.
70 WELDING JOURNAL / JUNE 2016
Fig. 6 While constructing a 9-ft-tall conical bottom for a large fermenter, which is
built upside down, Jorge Gamez starts GTAW to join two formed pieces of stainless
steel.
Providing Project
Management, Sales Support
Marianna Huntley is project manager. In this role, she manages all customer interactions, sets expectations,
and coordinates the tanks production
schedule, which is organized in her office on a massive board.
Projects can take three to six
months. It depends on the job size,
Huntley said. She keeps open lines of
communication in quoting lead times
and providing status updates.
Sales and Marketing Director Liz
Shearer creates proposals each week to
meet specific brewery needs, including
long-term goals, and gets in touch
with many departments for estimates.
We work with award-winning
brewers. Thats a real honor, Shearer
said.
Installation Impact
In the United States, tanks get from
the shop to their new homes by semi
tractor-trailers. During the winter, accordion covers might be used as pro-
Ben Love (left) and Van Havig, owners of Gigantic Brewing Co., Portland, Ore., pose by some of their MCF stainless steel tanks that
enable them to brew seasonal beers. (Photo courtesy of Gigantic Brewing Co.)
Fig. 2 Remote project work at the Kuparuk River and Prudhoe Bay oilfields utilizing SMAW.
Projects
In Alaska, welding engineering
plays a crucial role in the fabrication,
maintenance, repair/refurbishment,
and alteration of
1) the 800-mile-long Trans-Alaskan
Pipeline System (TAPS);
2) oil/gas production facility machinery and pipework;
3) oilfield well equipment such as
casings, Bradenheads, and a countless
array of valves and fittings that require hardfacing or cladding;
4) seawater piping systems;
5) drill site and flowstation equipment and pipework;
6) waterway pipe crossings, vehicle
bridges, storage tanks, and vessels;
7) equipment platforms, building
frames, and myriad horizontal/vertical
pipe support mounts; and
8) natural gas pipeline and
pipework systems.
In addition, for each respective
welding activity, there is a corresponding need for weld inspection. Consequently, the performance of visual
weld inspection by AWS Senior Certified Welding Inspectors and Certified
Welding Inspectors, and the utilization of nondestructive examination
PQR Process
Procedure qualification records
(PQRs) utilized for project structural
applications and in the construction of
pipework and pipelines must demonstrate that the welding process proposed is capable of producing a weld
joint that will meet the specified service design and performance requirements of the weldment. For Alaskan
and Arctic service applications, importance is placed on the diligence and integrity of the PQR process and in the
accuracy of the PQR document.
The criticality of developing a comprehensive PQR is to ensure
1) the reproducibility of PQR weld
variables throughout production welding; that is, based upon the recording
of actual weld variables employed during the PQR process to achieve a compliant weld joint, a detailed WPS may
be written to provide direction
throughout production welding;
2) the weld joint meets specified/
intended service design and performance requirements by conducting rigorous NDE inspection and chemical
analysis as well as mechanical, metallurgical, and environmental testing to
ASTM G48 (Ref. 1) and A262 (Ref. 2).
The following welding engineering
Hardness, Hardenability,
and Hydrogen-Induced
Cracking
In the utilization of carbon and
low-alloy steels in cold climate regions
and/or when materials are utilized in a
H2S sour service environment, weld
deposit/heat-affected zone (HAZ)
cracking is a major concern. More
specifically, the steels are at risk of hydrogen-induced cracking (HIC), which
is also referred to as hydrogen-assist-
Project Materials
Pipeline and pipework
fabrication involves utilizing a range of pipe sizes
from 1 to 60 in. of various
wall thicknesses, ranging
from Schedule 10 to 160,
including API 5L (Ref. A)
Grades X52, X60, and X65;
ASTM A333 Grade 6; and
ASTM A335 chromiummolybdenum alloys: Grades
P5, P9, P11, P22, and P91.
In addition, pipe alloys consisting of duplex stainless
steels (i.e., 2205, 2507),
austenitic stainless steels
(e.g., TP 304L, TP 316L,
and copper-nickel (i.e.,
90/10) are employed. Materials for oilfield well construction comprise: API
5CT (Ref. B) Grades L80,
N80, J55, K55, and P110.
Structural frames, pipe supports, and oil storage tanks
encompass carbon and lowalloy steel structural shapes
and plate: ASTM A1011,
A516, A633, A36, and
A572.
74 WELDING JOURNAL / JUNE 2016
Project Weld
Codes,
Standards, and
Regulations
Fig. 4 Oilfield welding of API 5L X65 pipe of different diameters and wall thicknesses.
Evaluating Weldability
The composition of carbon and a
low-alloy steel drives hardness and
hardenability. Thereupon, to evaluate
a base metals weldability and susceptibility to HIC, this author recommends that depending upon the base
metals carbon content, the carbon
Project Pivotal
Points: Welding
Engineering
Ensuring
welders/pipeliners
meet performance qualification requirements
Conducting weld safety,
workmanship quality, materials, and technique training
Protecting personnel
and the welding work area
during construction activities (see figure below)
Specifying/planning of
process for equipment, consumables, and tooling for
the application (see figure
below)
Qualifying PQRs/WPSs
that meet code/standard,
engineering authority, and
DOT stipulations
equivalent CEIIW or CEPCM value be calculated and included in the PQR. The
CEIIW or CEPCM value provides an indication of the base metals weldability
based on hardness and hardenability.
As defined within API 5L (Ref. 2), the
CEIIW value is calculated (Equation 1)
when the base metals carbon content
is >0.12%. Also, as denoted within API
5L, the CEPCM value is calculated
(Equation 2) when the base metals
carbon content is 0.12%. For each
equation, the respective carbon equivalent value is calculated to
1) evaluate a base metals weldability;
2) estimate the minimum preheat
and interpass temperatures; and
3) approximate the minimum critical cooling rate required to mitigate
detrimental untempered martensite
from forming.
CEIIW = C + Mn/6 + (Cr + Mo + V)/5
+ (Ni + Cu)/15
[C > 0.12%]
(1)
CEPCM = C + Si/30 + (Mn + Cu + Cr)/20
+ Ni/60 + Mo/15 \ + V/10 + 5B
[C 0.12%]
(2)
Due to the significance of hardness
Alleviating HIC
A great deal of hydrogen control and
HIC information is available in code
books, articles, and handbooks. The
methods noted as follows are based
upon the literature and weld failure
lessons learned. To alleviate conditions
for weld deposit/HAZ microstructure
HIC, it must be realized there are synergic relationships that exist between
weld variables Fig. 5. In qualifying a
PQR, particularly for a cold climate region and/or a sour service environment, it is important that welding engineers be careful to
Reduce weld joint stress by mini-
Conclusion
In the land of the midnight sun,
cold climate and/or sour service conditions magnify the criticality of the
PQR qualification process. Thoughtful
welding engineering consideration
must be given to the methods and
variables involved to achieve a compliant weld joint that will meet the specified service design and performance
requirements of oil/gas project
weldments. WJ
References
1. ASTM G48, Standard Test Methods for
Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of
Ferric Chloride Solution, 2011.
2. ASTM A262, Standard Practices for
WILLIAM C. LAPLANTE
(wlaplante.cwi@gmail.com) is a welding
engineer, CWI, CWE, Anchorage/Prudhoe
Bay, Alaska.
For info, go to aws.org/adindex
Fixtures for
Tube Welding
Modular fixturing tables can
increase your speed, productivity,
and storage
Overview of Modular
Fixturing Systems
Modular fixturing is composed of
reusable, off-the-shelf components so
that the user does not have to fabricate individual fixture elements for
every new job. A good modular system
starts with a flat steel surface onto
BY PAM FARLEY
Advantages of Modular
Fixturing
Faster, More Accurate, More
Competitive Quotes
Modular fixturing makes the
quotation process for smaller operations competitive by shrinking the
Increased Productivity
on the Shop Floor
Fig. 2 A solar car chassis held in place by modular fixtures and custom fixture
plates. (Drawing by Tyler Smutz, Killstress Designs.)
Having good fixtures reduces operator error by ensuring parts are located correctly and clamped to prevent
distortion of critical dimensions. Most
welders know this but dont practice it
due to time constraints or shortage of
workers with the skill set to create
them. If you have an easy-to-use, modular system, you are more likely to create a fixture, and that system will pay
off through less rework and scrap.
Fig. 3 Closeup detail of a custom fixture plate showing toggle clamp mount
and holes that interface with modular fixtures. ((Drawing by Tyler Smutz, Killstress
Designs.)
Fig. 5 A closeup view of custom fixtures and slots to provide minute lateral adjustment.
Conclusion
Modular fixturing systems play an
expanding role in modern manufacturing operations and can bring improvements to numerous aspects of the fabrication process. The benefits of modular fixturing increase as the need for
leaner, more flexible production
grows. WJ
FABTECH Canada
Continues to Grow
BY MARY RUTH JOHNSEN
Keynote Address
Fig. 2 Two INKAS armored vehicles, including this SUV based on a Mercedes-Benz
G Class, were on display at the entranceway to the show.
Retired Canadian Army Major General David Fraser (Fig. 1) kicked off the
show with a keynote address to a
standing room-only crowd. In a talk titled Leadership, Strategy, and Innovation in the Manufacturing Business, Fraser compared the commercial
business world to the military and
found the two groups have more in
common than they do differences.
Fraser is now chief operating officer of
the INKAS group of companies,
which manufactures armored cars and
bulletproof vehicles for military and
civilian use Fig. 2.
Whether for a military or business
operation, Fraser stated, Selection of
the aim is the primary objective. Other key elements to follow are maintenance of the aim, maintenance of
morale, offensive action, security, sur-
Product Highlights
Colorful plastic flange and pipe end
protectors from Flange Armour of
Calgary, Canada, drew the attention of
showgoers Fig. 3. The Pipe Armour
end caps debuted at the show. Available to fit on 4- to 48-in.-diameter
pipes, the caps were designed to be
easily put on or pulled off by someone
wearing gloves. They come in boxes of
12, with 24 being the minimum order.
Standard color is black but companies
can order a specific color and/or have
their company logo placed in the center. Uses include pipe transportation,
sandblasting, coating, facility/construction projects, pipeline projects,
valve pup piece protection, and warehouse/yard protection. The Flange Armour products protect the raised
flange face from damage from fabrication through delivery. They come in
sizes from 2 to 48 in. and colors correspond to flange ratings. They eliminate the need for masking when sandblasting and painting.
flangearmour.com.
ing the unit. It can be used in two orientations: tabletop (horizontal) and
user-carried (vertical). It is compatible
with guns, cables, and other accessories from the company.
nelsonstudwelding.com.
Want access
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COMING EVENTS
10th International Conference on Trends in Welding Re
search & 9th International Welding Symposium of Japan
Welding Society. Oct. 1114. Hitotsubashi Hall, Tokyo,
Japan. The conference will cover the fundamental science of
welding and joining as well as a wide variety of applications
of welding and joining different materials in different industries. Full papers due June 30. Visit trends2016.org, or
e-mail twr2016@issjp.com.
AWS-SPONSORED EVENTS
For more information on AWS conferences:
aws.org/w/a/conferences/index
(800/305) 4439353, ext. 455
3rd Welding Education, Skills & Certification Conference.
Aug. 1012. Houston, Tex. This conference aims to address
the welding industry piece of the impending skills gap
puzzle.
go.aws.org/awshandboo
w
book
IMAGIN
INEE IT.
INTERNATIONAL EVENTS
19th World Conference on NonDestructive Testing. June
1317. International Congress Centre, Munich, Germany.
Contact German Society for Non-Destructive Testing, +49
30 67807-120; conference@wcndt2016.com, or
wcndt2016.com.
Additive Manufacturing Europe 2016. June 2830. RAI,
Amsterdam. This is the business-to-business show for additive manufacturing/3D printing. This years show will incorporate a 3D print show. Visit amshow-europe.com.
2016 International Conference on Material Science and Civil
Engineering. Aug. 57. Guilin, Guangxi, China. Contact +86
15919704498 or msce2016@126.com.
EDUCATIONAL OPPORTUNITIES
Advanced Blueprint Reading. Troy, Ohio. Learn design procedure, blueprint interpretation, shop drawings, the use of
measuring tools in layout and assembly, and more. Twoweek, 70-hour class. Classes begin June 13, July 11, Aug. 8,
Sept. 5, Oct. 3, Nov. 7, and Dec. 19. $850. Hobart Institute
of Welding Technology; (800) 332-9448; welding.org.
Own the
t
AWS
W Welding
e g Handbookk.
To purchase your copy by volume or chapter
pte , visit
go.aws.org/awshandboo
w
book
OWN EX
EXPE
PERT
KNOWLE
WLEDG
DGE.
Measurement range
g 0
0.1
1 to 80%
% Fe or 0.1
1 to 110 FN
polished surfaces
(860) 283-07
781
Coating Thickness
Material Analysis
Microhardness
Material Testing
e
CERTIFICATION SCHEDULE
Seminar Dates
June 510
June 510
June 510
June 510
Exam only
June 1217
June 1217
June 1217
June 1217
July 1015
July 1015
July 1015
July 1015
July 1722
July 1722
July 1722
July 1722
July 1722
July 2429
July 2429
July 2429
July 2429
Aug. 712
Aug. 712
Aug. 712
Aug. 712
Exam only
Aug. 1419
Aug. 1419
Aug. 1419
Aug. 1419
Aug. 2126
Aug. 2126
Aug. 2126
Aug. 2126
Aug. 2126
Sept. 11-16
Sept. 11-16
Sept. 11-16
Sept. 11-16
Sept. 18-23
Sept. 18-23
Sept. 18-23
Sept. 18-23
Sept. 25-30
Sept. 25-30
Sept. 25-30
Sept. 25-30
Sept. 25-30
Exam Date
June 11
June 11
June 11
June 11
June 16
June 18
June 18
June 18
June 18
July 16
July 16
July 16
July 16
July 23
July 23
July 23
July 23
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July 30
July 30
July 30
July 30
Aug. 13
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Aug. 27
Aug. 27
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Aug. 27
Sept. 17
Sept. 17
Sept. 17
Sept. 17
Sept. 24
Sept. 24
Sept. 24
Sept. 24
Oct. 1
Oct. 1
Oct. 1
Oct. 1
Oct. 1
Seminar Dates
June 510
July 2429
July 31Aug. 5
Aug. 2126
Sept. 1116
Sept. 2530
Seminar Dates
June 610
July 1822
Aug. 2226
Sept. 1923
Oct. 1721
Exam Date
June 11
July 23
Aug. 27
Sept. 24
Oct. 22
IMPORTANT: This schedule is subject to change. Please verify your event dates with the Certification Dept. to confirm your course status
before making travel plans. 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 $350 Fast Track fee. Please verify application deadline dates by visiting our website
aws.org/certication/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit
aws.org/certification or call (800/305) 4439353, ext. 273, for Certification; or ext. 455 for Seminars.
90 WELDING JOURNAL / JUNE 2016
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Veteran
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(
(welding
products)
Educator
Educational Facility
(any organization that conducts welding
education or training)
L
Large
Business
(200 or more employees)
D
Distributor
Small Business
(less than 200 employees)
Section
Media
(article or newscast promotingg welding)
aws.org
What are
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1st Place Classroom Wins:
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TRUTH
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TM
WELDING WORKBOOK
DATASHEET 365
Filler Metals
The brazing filler metals used to braze pipe and tubing
must be metallurgically compatible with the base metals
they are intended to join. In addition, they must provide
adequate strength to the joints in service.
When brazing copper, the BCuP brazing filler metals are
normally good general-purpose filler metals. They should
not, however, be used on copper-nickel alloys with a nickel
content of more than 10%.
Brazing filler metals with a broad melting range should
be selected for brazing pipe joints because of the difficulty in
maintaining the assemblies in a narrow temperature range.
Postbraze Cleaning
After the brazing filler metal solidifies, the remaining
flux and residues can be removed by wiping with a wet cloth
or by wet brushing. Cast fittings should be allowed to cool
slowly to below 300F (150C) before applying swabs to the
joints. Since most brazing fluxes are hygroscopic and may
contain active corrosive agents, they should be removed. It
is essential to remove flux residues when aluminum alloys
are brazed. WJ
Excerpted from the Brazing Handbook, Fifth Edition, published by the American Welding Society, Miami, Fla.
aws.org
WELDIN
WE
ELDING
NG EDUCA
ATTION
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TO JUST ANYONE.
AWS offers worldwide conferences
co
and seminars featuring the most
RELEVVA
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AW
WS CONFERENCES
3RD WELDING EDUCA
ATION
T , SKILLS & CER
RTIFICA
T ATTION CONFERENCE
Houston, TX / Aug 10-12, 2016
LASERS CONFERENCE
San Francisco, CA / Aug 29-30, 2016
ABSTRA
ACT SUBMISSION DEADLINE IS EXTEN
NDED TO APRIL 30, 2016
ORGANIZING SOCIE
ETIES
American Welding So
ociety (AW
WS)
Japan We
elding Societty (JWS)
CONFERENCE CO-C
CHAIRS
Tooshihiko Koseki, Th
he University of Tookyo, Japan
Stan David, Oak Rid
dge National Laboratory, USA
Tarasankar DebRoy, Penn State University, USA
Thomas J. Lienert, Los Alamos National Laboratory, USA
U
Akio Hirose, Osaka University, Japan
KEYNOTE SPEAKERS
Prof. Sudarsanam Suresh Babu, The University of Teen
nnessee, USA
Prof. Amitava De, Indian Institute of technology, India
a
Prof. Yo
oshinori Hirata, Osaka University, Japan
Prof. Hiroyuki Kokawa, To
ohoku University, Japan
Prof. Yu
u-Ming Zhang, University of Kentucky, USA
Prof. Norman Zhou, University of Waterloo, Canada
ABSTRACT SU
UBMISSION
Those who plann to give a presentation(s) at the connference are
requested to kinndly provide information in the absttract submission
form, including the title of presentation, names of ccorresponding
person and authoor(s), and an abstract of the presentatiion by April 30, 2016.
Please note thatt the title should be within 30 wordds and that the
abstract within 300
3 words.
Visit the followiing website: http://trends2016.org/abstract.html
REGISTRAT
TIO
ON
Online registration is now open at the following website.
http://trends20116.org/registration.html
Early Registratiion deadline is May 31, 2016.
REGISTRAT
TIO
ON FEES
Early Registratiion fees
Regular Partic
cipant: 80,000 JPY
Student: 40,00
00 JPY
Regular Registration fees
Regular Participant: 90,000 JPY
Student: 50,000 JPY
Accompanying Person: 15,000 JPY
Invitation Letter for Visa Application: 10,000 JP
PY
SOCIETY NEWS
Distributor
(welding products)
Section (AWS local chapter)
Media (industry and business
publications)
Veterans (all branches of the U.S.
military).
AWS
The 24th Japan International Welding Show was recently held in Osaka, Japan. The event, which is held biannually, was hosted by Sanpo
Publications, Tokyo, Japan, under its new president, Yutaka Kukital. The theme this year was Think Future, Act Now! Gateway to Great
Success in Asia. Ray Shook, AWSexecutive director, was among those in attendance. He participated in the ribbon cutting ceremony and
gave a short speech at an international reception.
JUNE 2016 / WELDING JOURNAL 97
SOCIETY NEWS
TECH TOPICS
Technical Committee Meetings
All AWS technical committee meetings are open to the public. Contact
staff members listed below or call
(800/305) 443-9353 for information.
June 15. Safety and Health Committee. Aberdeen, Md. Contact: S. P.
Hedrick, ext. 305, steveh@aws.org.
June 22. B2F Subcommittee on
Plastic Welding Qualification. Burr
Ridge, Ill. Contact: S. P. Hedrick, ext.
305, steveh@aws.org.
June 22. G1A Subcommittee on
Hot Gas Welding and Extrusion Welding. Burr Ridge, Ill. Contact: S. P.
Hedrick, ext. 305, steveh@aws.org.
New Standards Projects
Development work has begun on
the following new or revised standards. Affected individuals are invited
to contribute to their development.
Participation on AWS Technical committees is open to all persons.
C3.2M/C3.2:20XX, Standard
Method for Evaluating the Strength of
Brazed Joints. This standard describes
the test methods used to obtain
brazed strength data of the short-time
testing of single-lap joints in shear,
butt-tension, stress-rupture, creepstrength, four-point-bending, and
ceramic-tensile-button specimens.
Specimen preparation methods, brazing procedures, testing techniques,
and methods for data analysis are detailed. Sample forms for recording
data are presented. A graphical
method of data presentation relates
shear stress to overlap distance. Stakeholders: Brazing Engineers, educators,
general interest groups, and so on. Revised Standard. Contact: J. Douglass,
ext. 306, jdouglass@aws.org.
D16.1M/D16.1:20XX, Specification
for Robotic Arc Welding Safety. This
standard establishes safety requirements with respect to the design,
manufacture, and operation of arc
welding robot systems and ancillary
equipment. It also helps to identify
and minimize hazards involved in
maintaining, operating, and setting up
arc welding robot systems. Stakeholders: Organizations within the robotic
98 WELDING JOURNAL / JUNE 2016
Opportunities to
Contribute to AWS
Technical Committees
SOCIETY NEWS
Committee (C, E, G, P, U). Railroad
welding, D15 Committee (E, G).
J. Molin, ext. 304, jmolin@aws.org.
Welding sheet metal, D9 Committee
(G, P).
Educational Institutions
MEMBERSHIP ACTIVITIES
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Seaboats International
8800 Barney White Rd.
Bremerton, WA 98312
safeboats.com
Automation and Control Services
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plcexperts.com
Hoso Metal Co., Ltd.
1/F East, Bldg. E, Beifang Yong Fa
High Tech Park, Boaan District
Shenzhen, Guang Dong, China 518104
hosometal.com
Affiliate Companies
Alexander Welding
36-2 Grant Ave.
Burlington, MA 01803
Allied Environmental Mechanical, Inc.
530 Van Cortlandt Park Ave.
Yonkers, NY 10705
American Erection, LLC
230 Kittanning Pike
Pittsburgh, PA 15215
Calidad Y Asesoria En Soldadura
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C4 Welding, Inc.
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SOCIETY NEWS
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Sustaining.................................605
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Total Corporate .......................2438
Individual ...........................61,210
Student + Transitional ...........11,966
Total Members ..................73,176
MemberGetaMember Campaign
Listed here are the members participating in the 2016 Member-Get-a-Member campaign. The campaign runs from
Jan. 1 to Dec. 31, 2016. Members receive
5 points for each Individual Member
and 1 point for every Student Member
recruited.
For campaign rules and a prize list,
please see page 113 of this Welding Journal. Standings as of April 22. Call the
AWS Membership Dept. at (800) 4439353, ext. 480, for more information
G. Bieniecki, Cleveland 52
100 WELDING JOURNAL / JUNE 2016
J. W. Morris, Mobile 45
M. Krupnicki, Rochester 35
D. A. Saunders, Lakeshore 26
B. M. Scherer, Cincinnati 21
G. L. Gammill, N.E. Mississippi 20
C. J. Bridwell, Ozark 15
T. A. Harris, Johnstown-Altoona 15
Y. Lopez, International 15
R. F. Purvis, Sacramento 15
C. A. Renfro, Chattanooga 15
J. D. Schlarb, Portland 15
M. D. Stein, Detroit 15
J. Upton, Houston 15
T. E. Buckler Sr., Columbus 13
T. Geisler, Pittsburgh 12
A. I. Duron, New Orleans 12
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.
SECTION NEWS
District 1
BOSTON
March 12
Location: Embassy Suites Boston Logan Airport, Boston, Mass.
Presenter: Jim Shore, exam supervisor
and Section certication chairman
Topics: CWI Exam
Summary: The Section held its CWI
exam after a week-long seminar. Connecticut Section member Albert J.
Moore, Jr., taught the seminar during
the week, and Boston Certication
Chairman Jim Shore supervised the
test. Exam proctors were Boston Section Chairman Tom Ferri, Central
Massachusetts/Rhode Island Section
Chairman Tim Kinnaman, and District
1 Director Douglas A. Desrochers.
February 25
Location: Northland Job Corps
Speaker: Paul Mespelli, technical sales
GREEN & WHITE MOUNTAINS Geoff Putnam demonstrated dye penetrant testing for
students.
SECTION NEWS
CENTRALMASSACHUSETTS/
RHODE ISLAND/BOSTON
March 30
Location: New England Institute of
Technology, Rhode Island
Presenter: Tony Anderson, director of
aluminum technology for ITW North
America
Summary: Anderson gave an aluminum
welding technology seminar to 131
attendees.
March 5
Location: Holiday Inn by the Bay, Portland, Maine
Topic: Preparation visit for District 1
Conference on May 14
Summary: Section Chairman Russ Norris and District 1 Director Douglas A.
Desrochers met to discuss the preparations and arrangements for the District
1 Conference.
MAINE
March 4
Location: Bangor, Maine
Summary: Ariel Pelton was the 2016
Maine SkillsUSA silver medalist for
welding. According to available records
and memory, she is the rst female to
medal in the Maine state competition.
Beside being a competitive welder, she
is also a competitive cheerleader. Ariel
attends the St. Croix Regional Technical
Center in Calais, Maine, and she is enrolled in the welding program at Washington County Community College for
2016/2017.
CENTRAL MASSACHUSETTS/RHODE
ISLAND/BOSTON Aluminum seminar
presenter Tony Anderson (from left)
poses with Bristol Plymouth RVTHS Sen
ior Edward Pizarro, Old Colony RVTHS
Junior Justin Porrello (both employees of
GTR Manufacturing), Brockton, Mass.,
and District 1 Director Douglas A.
Desrochers.
CENTRAL MASSACHUSETTS/RHODE ISLAND/BOSTON Attendees listened attentively during Tony Andersons aluminum welding
technology seminar.
SECTION NEWS
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
PHILADELPHIA
April 8
Location: Dorchester Career and Technical Center, Cambridge, Md.
Summary: The Section visited the career and technical center.
READING
April 2
Location: Reading-Muhlenberg Career
& Technology Center
Summary: The Section held its student welding contest for students at
three different levels: 500, 1000, and
1500+ hours of instruction. Each level
was represented by a student from one
of the ve career and technology
schools in the area: Berks West,
Lebanon, Lancaster, Reading-Muhlen-
District 3
Michael Sebergandio, director
(717) 471-2065
drweld13@gmail.com
LANCASTER/YORK
March 31
Location: Lancaster, Pa.
Presenter: AWS President David L.
LANCASTER/YORK President Mc
Quaid (left) was presented with a paint
ing of the Lancaster countryside by
Justin Heistand, Lancaster Section
chairman.
READING The Sections student welding competition participants stood for a photo.
READING Volunteers for the Sections student welding contest were (from left) Judges
Francis Butkuz, Jim Myers, Richard Heisey, Rich Heisy, and Chevelle Houser, and Instruc
tors Hugo Garcia, Dan Millan, John Boyer, and Judge Mike Brickel.
PHILADELPHIA Section members toured the Dorchester Career and Technical Center, Cambridge, Md.: (from left, front row) Instructor
Chris Baker, District 2 Director Harland Thompson, Will Watkins, Kobi Ruark, Jody Jackson, A.J. Wiley, and Bill Giordano; (from left, back
row) Jacob Morris, Christian Jackson, Cole Willey, Micah Brooks, Tyler Pinder, and James Dixon.
JUNE 2016 / WELDING JOURNAL 103
SECTION NEWS
berg, and York Counties. Participants
in Level One included Victor Mora,
Connor Waite, Katelyn Hasson, and
Philip Matous. Participants in Level
Two included Blaine Ham, Elijah Appel, Seth Ober, William Sheetz, and
Jacob Kremser. Participants in Level
Three included Daniel Garcia, Gabriel
Rose, Dalton Gromlich, Damion Oberholtzer, and Brady Anderson.
District 4
CHARLOTTE
March 12
Location: Charlotte, N.C.
Presenter: Ray Sosko, welding instructor and faculty advisor to the Central
Piedmont Community College Student
Chapter
District 5
FLORIDA WESTCOAST
April 13
Location: Golden Corral, Brandon, Fla.
Speaker: Greg Early, district manager,
Miller Electric Mfg. Co.
Summary: Eighteen members and
guests enjoyed dinner along with Earlys
presentation on new welding products
and machines offered by the company.
CHARLOTTE Boy Scouts posed with their welded objects and volunteers (from left) Jason Blanchett, Joe Liefer, Andrew Garvin, Ray
Sosko, Paige Hoose, John McPherson, Max Miller, Mark Swett, Mike Ketner, and Zac Boze at the Sections Welding Merit Badge event.
104 WELDING JOURNAL / JUNE 2016
SECTION NEWS
District 6
Michael Krupnicki, director
(585) 705-1764
mkrup@mahanyweld.com
NORTHERN NEWYORK
April 5
Location: The Edison Club, Rexford,
N.Y.
Speaker: Lou Okonski, president, Troy
Boiler, and Chris Whalen, public utilities manager, Troy, N.Y.
Topic: The speedy repair of the burst
110-year old, 33-in.-diameter riveted
steel water main in Troy, N.Y.
Summary: Twenty-one people attended the event.
District 7
Uwe Aschemeier, director
(786) 473-9540
uwe@sgsdiving.com
District 8
D. Joshua Burgess, director
(931) 260-7039
djoshuaburgess@gmail.com
COLUMBUS
March 22
Location: Four String Brewing Co.,
Columbus, Ohio
Presenter: Jim Ellison, tour guide
Summary: Dan Cochran began home
NORTHERN NEWYORK Dave Parker, Section secretary/treasurer (left), and Lou Okon
ski, president, Troy Boiler Works, held a failed section of the citys 110yearold, 33in.
diameter water main.
Beaver Valley Student Chapter Student members enjoyed a tour of Moody Corp.: (front row from left) Dalton Bradford, Anthony Miller,
Scott Chaffee, Morgan McCrea, and Ron Campbell; (second row from left) Preston Vigna, Isaiah Hunter, Tom Geisler, and Jay Steinbach;
(third row from left) Justin Sorrell, Michael Hornstein, Brandon Leport, and Mark Kiss.
JUNE 2016 / WELDING JOURNAL 105
SECTION NEWS
District 9
AUBURN/OPELIKA
March 7
Location: Jim and Nicks Barbeque,
Homewood, Ala.
Presenter: Bruno Stuck, global manager for transformer assessment,
Siemens AG
Summary: The meeting was shared
with the IEEEs Alabama Section.
Stuck gave a presentation on transformers, testing, process, and services
from Siemens.
NEWORLEANS
April 19
Location: Best Western Landmark Hotel, Metairie, La.
Presenter: Guy Rogers, regional sales
manager, fall protection, Louisiana/
Missippi, Honeywell Industrial Safety
Topic: Proper tting of fall protection
Summary: The Sections April meeting
was sponsored by Airgas USAs CherylLynn Malloy, district manager, Gulf
District 10
NORTHWEST PENNSYLVANIA
April 12
Location: Colony Pub and Grille, Erie,
Pa.
Presenter: Matt Albright, Lincoln
Electric Co.
Topic: Advanced welding equipment
District 11
NEW ORLEANS Section ViceChairman DJ Berger (far right) presented CherylLynn Mal
loy, district manager, gulf coast region, Airgas USA, with a sponsor recognition award.
106 WELDING JOURNAL / JUNE 2016
States region. Rogers delivered a presentation on the importance of properly tted and applied fall protection. A
50/50 raffle was held, and proceeds
were dedicated to Section student
activities.
SECTION NEWS
Ferris State University Student
Chapter
March 511
Location: Chauvin, La.
Topic: FSU AWS Student Chapters
New Orleans spring break service trip
Summary: Eleven members of the FSU
Student Chapter worked to help nish
the rebuild of a house that was destroyed by Hurricane Katrina. The
work included laying ooring, plumbing, painting, siding, and putting on
trim. Associate Professor Jeffrey Carney is the chapter academic advisor.
CHICAGO
March 16
Location: Fox Valley Career Center,
Maple Park, Ill.
Summary: The Section supported the
schools Welding Student of the Year
welding competition by providing volunteers and a judge on behalf of the
Section. Craig Tichelar helped choose
the ve student winners, including T.J.
Ostreko, who won Student of the Year.
March 24
Location: Cooper Hauk Restaurant,
Burr Ridge, Ill.
Summary: The Sections board appointed a chairman for its April meeting, discussed old and new business, and supported the next appointed chairman at
its board meeting.
District 12
District 13
CHICAGO John Heseltine (from left), Cliff Iftimie, MartyVondra, Craig Tichelar, and Bob
Zimny met at the Cooper Hauk Restaurant for the Section board meeting.
CHICAGO The Fox Valley Career Center hosted a Welding Student of the Year welding competition, and the Section volunteered and
helped judge. (Front row, from left) Chad Wehrli, Josh Shank, Joseph Gagnon, Mike Romano, and T. J. Ostreko, Student of the Year winner;
(back row from left) Gene Heinsohn, David Beer, Mike Coope, Craig Tichelar, Laura Swartz, Adam Hipple, and Ryan Lohrey.
JUNE 2016 / WELDING JOURNAL 107
SECTION NEWS
District 14
Robert L. Richwine, director
(765) 606-7970
rlrichwine2@aol.com
INDIANA
April 7
Location: Shipiros Deli, Indianapolis,
Ind.
Speaker: Dave Jackson, Section chair
Summary: The Section met to nalize
plans for the upcoming Mid-West Team
Welding Tournament and to elect officers for the 201617 year. J. Everett
ST. LOUIS
April 7
Location: Hil Bax Technical Center, St.
Louis, Mo.
Presenters: Cee Kay Supply, Inc., and
Section Executive Committee
Summary: The Section attended the
14th annual Mini-Weld Show, where
factory representatives came out to
demonstrate and display their equipment for guests. Door prizes, ranging
INDIANA The Section conducted and judged the local SkillsUSA competition. Shown
(from left) are Charles Cessna, Bennie Flynn, Mac Banks, David Jackson, Gary Dugger,
Gary Tucker, and Past AWS President Richard Alley.
ST. LOUIS Vendor representatives at the Sections 14th annual MiniWeld Show.
108 WELDING JOURNAL / JUNE 2016
District 15
David Lynnes, director
(701) 893-2295
dave@learntoweld.com
District 16
Karl Fogleman, director
(402) 677-2490
fogleman3@cox.net
IOWA
March 21
Location: Van Gorp Corp., Pella, Iowa
Presenter: Brian Griffith, Van Gorp
Corp.
Topic: W.I.N.E. of welding and weld
inspection
Summary: Section members had dinner
and enjoyed a presentation by Griffith,
who spoke about welding, inspection,
and processes at the company. Attendees toured the facility after his
presentation.
SECTION NEWS
KANSAS The Section met at Criders Institute of Welding Technology and toured the facility.
ANNOUNCE YOUR
SECTIONS ACTIVITIES
If you would like to submit a calendar listing, send along the following
information: Section name; activity
name, date, time, and location; and
speaker name, title, affiliation, and
subject. If some of your meeting
plans are pending, include the name
and e-mail or phone number of a
contact person for the event.
Please keep in mind the Journal
publication cut-off is usually the
20th of the month, for 2 months
ahead. For example, if you want to
have your September meeting in the
August Journal calendar, the deadline is June 20.
IOWA Section members visited Van Gorp Corp., Pella, Iowa, and toured the facility.
SECTION EVENTS
CALENDAR
Please note events are subject to change.
Reach out to the listed contact to conrm.
Colorado
Contact Bob Teuscher for more information about Colorado events at (303)
893-3602 or by e-mail at
bobteuscher@hotmail.com.
New Orleans
Meetings are usually the third Tuesday
North Texas
Meetings are the third Tuesday of each
month: dinner at 6:30 pm, program at
7 pm
Humperdinks, 700 Six Flags, Arlington,
Tex. Bring three canned goods for the
Holston Valley
Contact Jon J. Cookson for more information about Holston Valley events at (757)
897-3748, or by e-mail at
jjcookson@northeaststate.edu.
SECTION NEWS
KANSAS
April 14
Location: Criders Institute of Welding
Technology, (CIWT) Grain Valley, Mo.
Presenters: Stan Crider, CIWT, and Tim
Cronin, national sales manager, Ace Industrial Products
Summary: The Section met at CIWT for
a tour of the facility and a presentation
about air ltration systems from
Cronin.
District 17
EASTTEXAS
March 16
Location: Papacitas Restaurant,
Longview, Tex.
Presenter: John Laurence Busch, historian and author
Topic: Steam Coffin Captain Moses
Rogers and the Steamship Savannah
break the barrier
Summary: Busch described why the
Savannah is the rst example of globalized high technology in history.
April 14
Location: Papacitas Restaurant,
Longview, Tex.
Speakers: Jerry Knapp, District 17 director, and J. Jones, Section treasurer
Summary: Jones shared that April was
Welding Month, and reviewed the Image of Welding awards and scholarship
opportunities for members. Knapp
presented President McQuaids message to members, and told of his jour-
TULSA
March 4
Location: Tulsa Technology Center
(TTC), Riverside Campus, Tulsa, Okla.
Topic: Tulsa Engineering Foundations
Science, Technology, Engineering, and
Mathematics (STEM) competition
Summary: The Tulsa Engineering
Challenge is an event for students
grades four through twelve who are interested in STEM. More than 1100
students from schools across the Tulsa
region attended. More than 80 volunteers helped with judging the 14
competitions.
March 22
Location: Oklahoma Technical College
(OTC), Tulsa, Okla.
Presenter: Rodney Riggs, Section secretary and OTC instructor
Topic: Fundamentals of GTAW
Summary: Section board members and
OTC instructors put on a technical
presentation and assisted with hands-
TULSA The group gathers after TIG Night at Oklahoma Technical College.
TULSA District 17 Director Jerry Knapp (from left) and AWS Board Advisors Jay
Rufner, Barry Lawrence, and Ray Wilsdorf stand with three students from local schools
at the Tulsa Engineering Challenge.
SECTION NEWS
on training for those interested in
learning the basics of GTAW. More
than 50 people attended.
March 29
Location: Tulsa Technology Center
(TTC), Tulsa, Okla.
Presenter: Ray Wilsdorf, instructor at
TTC, Wilsdorf Mfg., LLC
Summary: Eight students received
their certicates of completion for the
ve-week CWI preparation course held
at TTC.
District 18
District 19
District 20
um, and postheat treatment for decorative and architectural blown glass). Several attendees were then invited to learn
glassblowing hands-on after the
presentation.
COLORADO
February 12
Location: Lakewood, Colo.
Presenters: Corey Silverman and Horace
Marlowe, C&H Glassworks
Summary: For the Sections annual
Ladies Night meeting in February, Silverman and Marlowe presentated various glassblowing techniques and discussed its similarities to welding (material preparation, working of the medi-
SPOKANE
April 6
Location: Spokane Community College,
Spokane, Wash.
Presenter: Efram Abrams, AWS
representative
Topic: AWS publications and online
resources
Summary: Abrams covered AWS publications and supplied several handouts.
His main focus was on new AWS online educational opportunities that t
TULSA Instructors Ray Wilsdorf (far left) and Ralph Johnson (far right) stand with the
eight students who completed their CWI preparation course.
COLORADO Demonstration of the initial shaping technique of heated glass for the Sections annual Ladies Night at C&H Glassworks.
JUNE 2016 / WELDING JOURNAL 111
SECTION NEWS
February 17
Location: Pueblo, Colo.
Presenters: Chris Rizzi, ASNT Level III
and Vestas NDT program coordinator,
and Brian Wood ASNT Level II and consultant for Vestas Towers America.
Summary: The Colorado Sections of
ASNT and AWS held a joint meeting.
Presentations were made on the inspection of DSA welds on critical components of wind towers using manual
phased array ultrasonic testing. Members also toured the Vestas Towers
America facility.
March 11
Location: Ramada Plaza Denver Central,
Denver, Colo.
Event: 7th Annual Welding the Rockies
Symposium New Technology in
Welding
Summary: The Section organized and
hosted its 7th annual Welding the Rockies Symposium, an all-day conference
that focused on new technologiy in
welding. Eight topics were covered over
the day, ranging from developments in
additive manufacturing to 3D weld
viewing, from virtual-reality-controlled
mobile welding to robotic control in
GMAW.
COLORADO Welding Symposium attendees listened to keynote speaker Dr. Jerry Jones.
COLORADO Members of ASNT and AWS Colorado Sections enjoyed a joint meeting at Vestas Towers America.
Colorado School of Mines Student Chapter Student Chapter members stand with Dr. Stan David from the Oak Ridge National Labora
tory after his talk about a science base for the joining technologies of the future. (From left are) Prof. Michael Andreassen (Denmark),
Zhifen Wang, Nathan Switzner, Rashed Alhajri, Juan Wei, Minrui Gao, Dr. Stan David, Stephen Liu, Zhenzhen Yu, Drew White, Prof. Ruidong
Fu (China), Jon Watson, and Prof. Namhyun Kang (Korea).
112 WELDING JOURNAL / JUNE 2016
Mail: Form with your payment, to AWS Call: Membership Department at (800) 443-9353, ext. 480
Fax: Completed form to (305) 443-5647 Online: www.aws.org/membership
CONTACT INFORMATION
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Please check each box that applies to the Membership or service youd like, and then add the cost together to get your Total Payment.
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STUDENT MEMBERSHIP
q AWS STUDENT MEMBERSHIP (with digital Welding Journal magazine)................................................$15
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Option available only to students in U.S., Canada & Mexico.
PAYMENT INFORMATION
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card.
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SECTION NEWS
tivity that now requires synthesis of
many disciplines. Dr. David spoke to
Student Chapter members and took a
photo with students following his talk.
IDAHO/MONTANA
March 13
Location: BYU-Idaho, Rexburg, Ida.
Presenter: Denis Clark, PE/CWI and
Principal at DEClark Welding, PLLC
Topic: Welding fumes: What you need
to know about them
Summary: Melvin Royster Weaver received a Section Meritorious Award for
his active participation in nearly every
Section meeting over the past decade.
Royster, owner of Royster Welding,
LLC, travels, at minimum, 150 miles
round trip to attend the Sections meetings. Tevan Boersma received a belated
Student Chapter Member Award for assisting with the reactivation of the BYUIdaho student chapter. Boersma was
also awarded the Section Meritorious
Award.
District 21
and the importance and benets of being a student member with LATTC
students. He also described the
process of how to form a student chapter and handed out membership
forms, Careers in Welding magazines,
AWS stickers, and a list of available
student scholarships.
SAN DIEGO
April 4
Location: Yuma, Ariz.
Event: Arizona SkillsUSA State
Championships
Summary: Students from the Arizona
Western College Ernest Lopez Welding
Institute helped to set up the welding
fabrication competition as well as competed. Faculty and staff were proud that
the AWC SkillsUSA Student Chapter,
with its advisor James Veldhuis, won
several gold and a silver medal at this
years state championship; winning the
gold in team fabrication: Pedro Ordaz,
Diego Espinoza, and Jonathan
Ballinger; winning the gold in related
technical math: Victor Cortez, who also
LOS ANGELES/INLAND EMPIRE Los Angeles Trade Technical College Welding Instructor Darlene Thompson (far left) and her students
pose for a group photo with Section Program Committee Chairman Tony Gonzalez (front center).
JUNE 2016 / WELDING JOURNAL 115
SECTION NEWS
won the silver medal in individual welding; winning the gold in customer service: Joanna Pratt; and winning the gold
in prepared speech: Braiden Campbell.
These students will represent the state
of Arizonas college programs at this
years SkillsUSA national championship
in Louisville, Ky., in June.
District 22
CENTRAL VALLEY
April 8
Location: College of the Sequoias,
Tulare, Calif.
SAN DIEGO Professor Samuel Colton (from left), Larry Lebsock, Pedro Ordaz, Chapter
President Joanna Pratt, Jonathan Ballinger, Diego Espinoza, Victor Cortez, Braiden Camp
bell, Alonzo Lorona, and Advisor James Veldhuis at the Arizona SkillsUSA State Champi
onships in Yuma, Ariz.
CENTRAL VALLEY Winners of the Sections high school welding competition celebrate
with a photo.
CENTRAL VALLEY Participants from ten local high schools gather for a photo after the Sections high school welding competition.
PUBLICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . . . .(275)
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Andrew Cullison.. cullison@aws.org . . . . . . . . . . .(249)
ADMINISTRATION
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Definitions and Symbols, Structural Subcommittees on Reinforcing Steel, Bridge Welding, Stainless
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Brazing and Soldering, Methods of Weld Inspection, Welding in Marine Construction, Welding of
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PERSONNEL
NAM Creates COO Position
The National Association of Manufacturers (NAM), Washington, D.C.,
has announced Todd Boppell as its
chief operating officer (COO), a newly
created position within the association. Boppell will work directly with
NAM President and CEO Jay Timmons
to lead all aspects of NAMs internal
operations, focusing specifically on finance and administration, membership, and strategic development. For
the past four years, Boppell has been a
partner and COO at Meshfrog, Inc., a
consulting company he cofounded. He
was also president of Nexa Technologies, a software company.
partner brands,
Weldmark, and
warehouse and
importing operations. Werkley,
based in Indianapolis, Ind.,
previously served
as district sales
manager/TIG specialist for Techniweld USA. He also
Keith Werkley
worked at ITWs
Weldcraft/Miller
Electric line of business and Jackson
Products.
Ed Welburn
Michael Simcoe
916-714-4944
Training classes and Workshops
For the past 40 years HDE has been the provider of
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of industrial lasers in manufacturing, education and
research. Regularly scheduled classes are offffered in:
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w..hdetechnologies.com
8698 Elk Grove Blvd., 1-194, Elk Grove, CA, 95624
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PERSONNEL
Talan Products,
Cleveland, Ohio, a
metal stamping
and tube forming
processer, has
hired Fred Chordas as engineering
manager. Chordas
has 31 years of experience in the
metal stamping industry, with a foFred Chordas
cus on automotive
and heavy truck.
In his new role, Chordas will assist Talans customers in, among other
things, designing products for manufacturability.
aws.org
CALLL FO
OR PA
PAPER
APERS
RS
40TH IN
NTERNATTIO
ONAL
BRAZING AND S
SOLLDERING SYMPOS
SIUM
Presented by the Am
mericcan Welding Society (A
AW
WS)
November 116, 20016 - Las Vegas, NV
The AW
WS C3 Committee on Brazing and Soldering invites yoou take part in this prestigious
program by submitting a research papeer for consideration. This is your opportunity to present
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The program
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missions must be receivved on or
before Septembber 3, 2016 and authors will be notifieed whetherr their papers have beenn accepted
for presentationn at the Symposium.
PERSONNEL
OBITUARIES
Emily Guile
Gerken, age 88,
passed away
peacefully in hospice with her family April 11. She
was the beloved
wife for 61 years
of Past AWS President John Gerken
(19871989)(deceased); loving
Emily G. Gerken
mother of Tom
Gerken, Becky
(Phil) Sido, and Jack Gerken; grandmother of Laura (Jeff) Pond, Katie
Sido, Nicola and Will Gerken; and
great-grandmother of Teagan and Riley Pond. She was known as a great
woman and a force within AWS.
aws.org
2016 AWS
LIIVVE CONNFERENNCES
Lasers Coonference
Aug 29 300, 2016
Lasers have taaken off and moved into hossts of new
applications. Count
C
them: Hybrid Laser arrc welding,
additive manuufacture, cladding, heat treatment,
t
and
more. Come to the Lasers Conference on August
29-30 in San Francisco and find out whatt s in it for
you and your company.
19th Annual
A
Aluminum Co
Conference
Sep 20
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WELDING RESEARCH
ABSTRACT
Ultrasonic additive manufacturing (UAM) is a solidstate joining process used to build
up a solid part from thin metal foils. The major process parameters are vibration ampli
tude, normal force, and weld speed. In this study, the upgraded version of UAM, called
very highpower ultrasonic additive manufacturing (VHPUAM), which has a higher
power capability to produce a larger vibration amplitude and larger normal force than
UAM, was used to fabricate samples from aluminum 3003H18 (Al3003H18) foils. A total
of six VHPUAM samples were fabricated from a TestBed machine and SonicLayer7200
commercial VHPUAM systems. The effects of increasing vibration amplitude and normal
force on the change in the bulk hardness of Al3003H18 foil were investigated. The
results revealed that vibration amplitude played a more significant role in decreasing
hardness or softening behavior in Al3003H18 foil when a larger vibration amplitude was
applied. There was also a clear correlation between the bulk hardness of Al3003H18 foil
and the average ultrasonic power used, where the hardness decreased with increasing
ultrasonic power in samples fabricated from both VHPUAM machines.
KEYWORDS
Ultrasonic Additive Manufacturing Aluminum Alloy Microhardness
SolidState Joining Process Control/Monitoring
Introduction
Ultrasonic additive manufacturing
(UAM) is a solid-state joining process
used for fabricating complex geometry
parts from thin metal tapes or foils
(Ref. 1). The process utilizes ultrasonic
welding of 100200-m-thick foils by
joining one layer on top of another
layer with 20 kHz ultrasonic frequency, 1428 m vibration amplitude,
8001500 N normal force, and 2550
K. SOJIPHAN (kittichais@kmutnb.ac.th) is with Department of Welding Engineering Technology, College of Industrial Technology, King
Mongkut's University of Technology North Bangkok, Bangkok, Thailand. S. S. BABU is with Department of Mechanical, Aerospace, and Bio
medical Engineering, The University of Tennessee, Knoxville, Tenn. A. BENATAR is with Department of Materials Science and Engineering, The
Ohio State University, Columbus, Ohio. A. MANONUKUL is with National Metal and Materials Technology Center, National Science and Tech
nology Development Agency, Khlong Luang, Pathum Thani, Thailand. M. NORFOLK is with Fabrisonic, LLC, Columbus, Ohio.
WELDING RESEARCH
is three times larger in VHP-UAM (9
kW maximum) than in UAM and is capable of producing larger normal force
(15 kN maximum) and larger vibration
amplitude (52 m maximum). Two
4.5-kW transducers instead of one
transducer in UAM are combined in a
push-pull configuration to produce
maximum power of 9 kW, as shown in
Fig. 1A.
Several researchers have been investigating the relationship between
the process parameters and the bond
quality of the UAM parts (Refs. 2,
1014). Major process parameters
studied include normal force, vibration
amplitude, and weld speed. The metallic bond quality is measured in terms
of linear weld density (the ratio of
bonded area over the entire interface)
and bond strength. It was found both
linear weld density and strength increase with higher normal force and
higher vibration amplitude, and decrease with higher weld speed (Refs.
13, 15). However, the weld speed
should not be so low as to affect the
productivity rate and cause localized
melting or sticking of the foil material
on the sonotrode surface. This leads to
equipment downtime because the
sonotrode needs to be cleaned and in
some cases resurfaced (Ref. 10).
While most researchers focus on
improving the bond quality, there are
limited works and knowledge regarding the change in bulk properties, such
as hardness of the foils after UAM and
VHP-UAM. Kong et al. (Ref. 16) was
the first to report the change in microhardness at the weld interface of aluminum 6061 UAM foils when different
levels of normal force, vibration amplitude, and weld speed were used. Their
results showed increasing hardness in
the foil processed with higher normal
force, larger vibration amplitude, and
lower weld speed (Ref. 16). It was also
Al3003-H18 foil due to UAM processing. Interestingly, the result was opposite in VHP-UAM, where Sriraman et
al. (Ref. 4) reported decreased hardness in hard-temper copper C11000
foil after VHP-UAM. It was proposed
that dynamic recrystallization and dynamic recovery as a result of tempera-
Table 1 List of Sample ID with Number of Layers and Sets of Vibration Amplitude and Normal Force Used to Fabricate All Al3003H18
VHPUAM Samples
Sample ID
Number of Layers
TB10285340
TB10384000
TB10388000
SL66285340
SL80344000
SL80345340
10
10
10
66
80
80
28
38
38
28
34
34
5340
4000
8000
5340
4000
5340
WELDING RESEARCH
Experimental Procedures
TB10285340
TB10384000
TB10388000
SL66285340
SL80344000
SL80345340
2%
2%
10%
4%
5%
6%
Results
The optical micrographs of the selected Al3003-H18 VHP-UAM samples
are displayed in Fig. 2. These images illustrate the macro view of the deposited layers from bottom to top showing
the voids or unbonded regions distribJUNE 2016 / WELDING JOURNAL 187-s
WELDING RESEARCH
ness from the 20 indentations measured at the central region of the first
foil layer deposited on the substrate,
while Layer Number 10 is the last layer or the top-most layer of the VHPUAM samples.
The result showed a slight decrease
in foil hardness in sample TB-10-285340, where hardness in Layer Number 1 was equivalent to the original
foil hardness and hardness decreased
gradually in the upper layers. This implies that using vibration amplitude of
28 m and normal force of 5340 N
rarely affected the hardness of the
original foil. In contrast, the bulk
hardness of the deposited foil increased from bottom layers to top layers in sample TB-10-38-8000, although the overall hardness of 55-60
VHN was 10-15 VHN lower than hardness of the original foil. Unlike samples TB-10-28-5340 and TB-10-388000, sample TB-10-38-4000 showed
neither an increasing trend nor a decreasing trend in hardness from bottom layers to top layers.
It is also worth mentioning that increasing vibration amplitude from 28
to 38 m greatly affected the bulk
hardness in the deposited foil, whereas
increasing in normal force from 4000
to 8000 N had much less effect on the
change in hardness. Increasing vibra-
WELDING RESEARCH
trix regions well below the current layer that was being welded. In contrast,
the 34-m vibration amplitude from
the SL7200 machine was high enough
to cause an additional input of energy
or power into the bottom layers where
the accumulative effect occurred.
It was also worth noting that although the process parameters of samples TB-10-28-5340 and SL-66-285340 are similar, their overall bulk
hardness values were different. However, this experiment did not provide
concrete evidence of why the SL7200
machine caused a larger drop in hardness as compared to the TB machine.
In order to assess the effect of ultrasonic power on the change in the
bulk hardness of VHP-UAM samples,
Fig. 6 demonstrates the measured
electrical power drawn from the TB
machine during VHP-UAM of the
three samples. It is known that during
UAM and VHP-UAM, the measured
electrical power drawn from the UAM
and VHP-UAM machine increased
with the higher levels of normal force
and vibration amplitude (Ref. 20). It
was seen that the amount of electrical
power drawn was greatly affected by
increasing the vibration amplitude but
was less affected by increasing the normal force. When the vibration amplitude of 28 m was used in sample TB10-28-5340, the average power was
550 W as compared to as high as 1189
W in sample TB-10-38-4000 and 1234
W in sample TB-10-38-8000 when vibration amplitudes were set at 38 m.
It was also noticed that in all three
samples, the power seemed to reach
the maximum around 2.5 s. This was
possibly related to the increase in
rigidity or stiffness during vibrations
in VHP-UAM where the sonotrode had
a solid grip on the foil and the base
plate, and larger power were necessary
to maintain the same amount of vibration amplitudes.
Since the levels of power vs. time
oscillated without a unique trend in
each weld pass, the average power
used to bond each layer is plotted in
Fig. 7 against the layer number from
bottom to top of VHP-UAM samples
for better comparison. It can be seen
that the actual average power level
used gradually decreased with increasing build height or in the higher layers
bonded, i.e., it took less power to produce the same vibration amplitude
JUNE 2016 / WELDING JOURNAL 189-s
WELDING RESEARCH
Discussion
Effect of Process Parameters on
Hardness Variation
The average hardness of Al3003H18 foil after VHP-UAM varied with
vibration amplitude and normal force
as well as weld speed used to fabricate
the samples. The power level used during welding increased with higher vibration amplitude and normal force
during process parameter settings. It
was also learned that the power level
reduced, meaning less power was required to produce the same amount of
amplitude when bonding upper layers.
In addition, the design of the fixture
was very different between the TB machine and SL7200 machine; typically,
it was relatively difficult to get as solid
a grip on the baseplate on the TB machine as compared to the SL7200 machine. Thus, the TB machine provided
less stiffness during VHP-UAM and
caused different amounts of energy
dissipation into the foil, resulting in
higher final hardness in the asprocessed condition despite using similar power. However, this subject is not
the current focus of this research and
the subtle difference of the existing ultrasonic actuators is the subject of ongoing research at Fabrisonic.
The data in Fig. 8 also shows hardness drop from the original Al3003H18 foil hardness. There is a larger
drop in hardness (i.e., more softening
behavior taking place in the bulk of
the foil during VHP-UAM processing)
when higher vibration amplitude and
power were used. Although the hardness values of samples TB-10-38-4000
were slightly lower than the hardness
of sample TB-10-38-8000, there was
hardly any difference in hardness values between samples SL-80-34-4000
and SL-80-34-5340. This implied that
there existed some ranges of vibration
amplitudes and power levels at which
increasing in normal force resulted in
higher bulk hardness of Al3003-H18
WELDING RESEARCH
vibration amplitude.
Thus, the amount of
plastic deformation and
plastic heating at the interface was larger at a
higher vibration amplitude. This was confirmed by higher thickness reduction of
Al3003-H18 foil at a
higher normal force and
a higher vibration amplitude in samples TB10-28-8000 and SL-8034-5340.
Figure 9 displays the
schematic of the stored
energy change during
typical thermo-mechanical processing of
Al3003. It is known that
after rolling or cold
working, the material
possesses higher stored
energy in the form of a
A
B
larger volume of dislocations, grain boundaries,
and smaller grain sizes,
Fig. 10 Microstructures variations in the top three layers
while upon hot working
of Al3003H18 VHPUAM samples. A Asprocessed TB
the material achieves an
10285340; B heattreated 343C, 2 h, TB10285340.
intermediate energy
The images are obtained from an image quality map using
state (Ref. 21). During
the electron backscattered diffraction technique.
UAM and VHP-UAM,
onset of dynamic recrysfoil in VHP-UAM samples. Therefore,
tallization and dynamic recovery took
with careful consideration between ulplace in the Al3003-H18 microstructrasonic power and bulk foil hardness,
ture. Depending on whether the relait may be possible to use the power
tive amount of additional stored enerlevel in addition to other process pagy through plastic deformation or the
rameters as a means to achieve the dereleased energy via dynamic recovery
sired homogeneity or range of the bulk
and dynamic recrystallization, the fihardness or bulk material properties
nal energy in the as-processed UAM or
of VHP-UAM samples.
VHP-UAM condition may be larger or
smaller than the initial energy state of
as-received Al3003-H18 foil. Since
Microstructure and Properties
UAM has less power than VHP-UAM
Correlation
and thus less energy during processing, the temperature rise and plastic
deformation may not be high enough
In order to understand the hardento produce extensive volume of dying and softening behavior of Al3003namic recrystallization, the final
H18 foils in VHP-UAM samples, it
stored energy of UAM was expected to
was important to analyze the linkage
be higher than that of VHP-UAM.
between processing and material
Thus, the hardening could be reproperties by looking at the thermoferred to as the increase in stored enmechanical cycles in VHP-UAM. Durergy in lower power UAM and the
ing VHP-UAM, the level of cyclic desoftening was referred to as the deformation increased with an increased
crease in stored energy in higher
number of welding passes or number
power VHP-UAM as shown in Fig. 9B.
of layers deposited on top. The
The lower hardness results in this
amount of shear deformation felt at
work supported this phenomena that
the interface also rose with increased
WELDING RESEARCH
Hence, the trend of increasing or decreasing depended on which effect was
higher between hardening behavior
through additional work hardening
and softening through adiabatic heating, which induced the dynamic recovery process. Sriraman et al. reported
peaks of transient temperature exist at
the bottom interfaces, while another
layer was deposited during VHP-UAM
(Ref. 20). This means that although
the peak temperatures at the interface
may not be as high (in the order of
100150C), and the duration of
those peak temperatures may be relatively short (in the order of 50 ms),
changes in hardness was possible as a
result of changes in microstructure
and reduction in foil thickness.
When larger shear deformation occurred at the interface as a result of
higher vibration amplitude, there was
more accumulated dislocation density
and higher stored energy in the foil.
The higher stored energy together
with increasing temperature during
VHP-UAM process enhanced the driving force for dynamic recovery and/or
dynamic recrystallization to occur, and
thus resulted in decreased bulk foil
hardness. It was also noted that the increased weld speed during metallic
bonding above the 50th layer resulted
in less heat dissipation time. This can
also give rise in the degree of softening effect in the bottom layers of VHPUAM samples fabricated from the
SL7200 machine.
Sriraman et al. also reported the decrease in peak temperatures at the
bonded interfaces at taller build height
or when more layers were deposited
due to lower ultrasonic energy transmitted into the sample (Ref. 20). Their
finding agrees well with the current result, where the ultrasonic power decreases with increasing build height as
less ultrasonic power was supplied by
the VHP-UAM machine while metallic
bonding an additional layer as the
sample gets taller. This result also
agreed with the observed phenomenon of a lack of bonding with an increase in specimen height, as demonstrated by Gilbert (Ref. 24).
However, this hypothesis is yet to
be proven. It is also possible that the
vibration of the whole dynamic system during VHP-UAM, while the
sonotrode is in contact with the sample, could generate different vibration
Conclusions
Increases in vibration amplitude
and normal force resulted in large
deformation in the bulk of VHP-UAM
samples, as seen in a large reduction
in thickness of VHP-UAM samples
processed at larger vibration
amplitudes.
The hardness in taller VHP-UAM
samples showed a trend of lower hardness in bottom layers and higher hardness in top layers, which was largely
due to the accumulative effects of
thermo-mechanical cycles of plastic
deformation and heating generated at
each interface.
After heat treatment at 343C for
2 h, all layers of Al3003-H18 foils in
VHP-UAM samples reached the same
final hardness (near 40 VHN) and
were the same as the heat-treated
original foil, implying the onset of recrystallization occurred.
As the build got taller, less power
was used to provide specific amplitude
and thus less change in stored energy,
microstructure, and hardness compared to the original as-received
Al3003-H18 foil.
There is a correlation between
hardness and ultrasonic power, where
hardness of Al3003-H18 foils decreased with increased ultrasonic power drawn from VHP-UAM systems.
Acknowledgments
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ABSTRACT
The ideal currentindependent metal transfer characterized by ensured robust droplet
detachment at a relatively small size at any reasonable low current, which can sustain the
arc, has been successfully realized in the first part of this study by applying a highpower
density pulsed fiber laser to irradiate the droplet neck. The desired onedropletperlaser
pulse (ODPP) mode was ensured. The droplet flying trajectory deflected from the wire
axial due to the use of a single laser. This second part of the study focuses on how relevant
parameters influence the metal transfer behavior, especially the droplet deflection that af
fects the controllability of bead formation. To facilitate the study, the relevant parameters
were categorized into three major types: laser positioning, laser pulse waveform, and arc
parameters. A series of experiments was conducted to examine their effects on successful
ODPP transfer and deflection minimization. In particular, the optimal laser incident point
and angle for most submissive droplet detachment and smallest droplet deflection were
first determined. Secondly, the minimums of the laser peak power and duration for stable
ODPP were determined. Finally, the droplet deflections under different welding currents
in the desirable low range, as well as different torch orientations and arc lengths, were
measured and analyzed.
KEYWORDS
Gas Metal Arc Welding (GMAW) Process Control Metal Transfer
Droplet Laser Irradiation
Introduction
In conventional gas metal arc welding (GMAW), the metal transfer mode
is dominantly determined by the welding current. Relatively low currents
produce short-circuiting or large drop
globular transfer, which typically generates spatter and unstable arcs. To
produce more desirable drop spray
transfers, a current higher than the
spray transition current is needed. Unfortunately, such currents cause signif-
transfer controllability (droplet detachment ability) that is current independent, i.e., can detach the droplet at any
current in the reasonable range as demanded by the application. Such ideal
current-independent metal transfer
control is especially crucial for advanced applications like welding of ultrathin sheets and additive manufacturing that demand precise process
controls.
As has been reviewed in the first
part of this study, many innovations,
such as surface tension transfer (STT),
cold metal transfer (CMT), and ultrasonic assisted GMAW, have achieved
significant improvements on metal
transfer control by electrical, magnetical, mechanical, and radiating ways
(Refs. 619). However, they all are still
far away from the ultimate/ideal goal:
current-independent metal transfer,
i.e., detaching droplets of the desired
size at any current in the reasonable
range especially at reasonably low current for free flight transfer.
A recent innovation having the potential toward this ultimate goal for
the ideal metal transfer control is laserenhanced GMAW, proposed and continuously studied at the University of
Kentucky. Huang explored the use of a
direct diode laser (862 W, 14 1-mm
focus line) to irradiate the droplet
(Refs. 2022). However, the enhancement on the metal transfer controllability is quite weak due to the very low
J. XIAO and S. J. CHEN (sjchen@bjut.edu.cn) are with the Engineering Research Center of Advanced Manufacturing Technology for Automo
tive Components, Ministry of Education, Beijing University of Technology, Beijing, China. J. XIAO is also with the Institute for Sustainable Man
ufacturing, University of Kentucky, Lexington, Ky. G. J. ZHANG is with the State Key Laboratory of Advanced Welding and Joining, Harbin In
stitute of Technology, China. Y. M. ZHANG (yuming.zhang@uky.edu) is with the Institute for Sustainable Manufacturing and Department of
Electrical and Computer Engineering, University of Kentucky, Lexington, Ky.
WELDING RESEARCH
Fig. 4 Metal transfer with laser aimed at droplet neck, 60deg incident angle.
Experimental System
Figure 1 shows the experimental
configuration the same as the one
used in the first part of this study. The
JUNE 2016/ WELDING JOURNAL 195-s
WELDING RESEARCH
A
Fig. 5 Metal transfer with the laser aimed at different positions on the droplet.
A Laser aimed at droplet midtop position; B laser aimed at droplet wiretip position;
C laser aimed at droplet mid position; D laser aimed at droplet midbottom position.
No.
4
5
6
7
8
85
75
60
45
30
WELDING RESEARCH
A
14
15
10
20
19
37
326
463
WELDING RESEARCH
A
Fig. 8 Metal transfer under different laser peak powers: A 90%; B 60%.
Fig. 9 Effect of laser peak power on drop
deflection and velocity.
Fig. 10 Typical metal transfer with different laser pulse frequences: A 10 Hz; B 20 Hz.
Current (A)
17
18
19
40
80
120
10
20
30
WELDING RESEARCH
A
C
Fig. 12 Droplet deflection under different
welding currents.
Fig. 11 Metal transfer under different welding currents: A Welding current I = 120 A,
laser pulse frequency 33 Hz; B welding current I = 80 A, laser pulse frequency 20 Hz;
C welding current I = 40 A, laser pulse frequency 10 Hz.
Fig. 13 Illustration of weld gun orientation: A Gun tilting left; B gun tilting right.
WELDING RESEARCH
A
Fig. 14 Metal transfer under different gun orientations: A Gun tilting left; B gun
tilting right.
Fig. 15 Effect of gun orientation on
droplet deflection.
1719. The presented high-speed image sequences show the droplet deflection tended to decrease with the welding current, given the laser pulse energy and droplet size.
The droplet deflections in Experiments 1419 were measured and are
shown in Fig. 12. As can be seen, the
droplet radial deflection was almost
negligible when the droplet was surrounded by the 120-A current arc.
This is explainable because the droplet
was actually surrounded and restrained by the arc-related forces,
mainly the electromagnetic force and
plasma dragging force. The electromagnetic force is proportional to the
square of the welding current. The
higher the current is, the more axially
restrained the droplet becomes; therefore, the smaller the deflection will be.
Gun Orientation. During GMAW,
the arc, reflected by the arc shape, affects the distribution of the arc forces.
In laser pulse-controlled GMAW,
droplet detachment and flying trajectory may be affected by changing the
arc deflection. In Experiments 20 and
21, the gun was tilted right and left,
respectively, for 15 deg. In particular,
the laser incident angle was changed
to 75 deg to avoid blocking of the laser
beam when tilting the gun. The results
of Experiment 5, where is zero and
the other parameters were the same,
are also referred for comparison. Figure 13 illustrates tilting of the gun and
Fig. 14 shows typical metal transfers
Conclusions
In the first part of this study, the ideal current-independent metal transfer
was successfully achieved by using a
high-power-density laser pulse to irradiate the droplets. The current paper further experimentally verified the effect
of key process parameters on the
droplet detachment behavior, especially
the droplet deflection after being detached. The major parameters include
the laser positioning parameters, laser
pulse waveform parameters, and arc parameters. Their effects on the resultant
metal transfer can be summarized as
follows:
1) The optimal laser incident position was determined to be the droplet
WELDING RESEARCH
neck position. If aimed at the main
body of the droplet, the laser pulse will
penetrate the liquid droplet to induce
a partial explosion. The optimal range
of the laser incident angle was determined to be 4560 deg in order to
minimize droplet deflection.
2) Experiments indicated that, as the
laser pulse power increased, the droplet
deflection decreased while the velocity
of the detached droplet increased. The
minimum laser peak duration for a robust ODPP transfer was determined.
The laser pulse frequency exactly
equaled the metal transfer frequency.
Given the welding current, the droplet
mass/droplet deflection decreased/increased, respectively, with the laser
pulse frequency.
3) A higher welding current produced a greater axial electromagnetic
force, restraining the droplet deflection. The droplet deflection also
could be effectively reduced by tilting
the welding gun or using a relatively
short arc.
Acknowledgments
WELDING RESEARCH
ABSTRACT
The physical process of underwater wet flux cored arc welding (FCAW) was visually
sensed and investigated. An image capture system was developed to monitor the
bubbles, droplets, and arc behaviors via avoiding the serious disturbances from the harsh
water environment. The complex dynamic behaviors of the bubbles evolution were de
scribed and explained according to their transient images. The acquired clear images of
droplets showed the typical metal transfer mode, i.e., the repelled globular transfer with
large droplet size and low transfer frequency. Subsequently, the welding arc characteris
tics were examined, revealing it was compressed by the water environment and had spe
cial intensive drifting and deviation behaviors on the cathode spot. High electric poten
tial gradient and current density of the arc were disclosed and possible reasons were
given. Finally, the uneven and asymmetric weld joint appearance was probably caused by
the special welding process under water, especially the unstable droplet transfer.
KEYWORDS
Underwater Welding Droplet Transfer Arc Behavior Visual Sensing
Bubbles
Introduction
More and more metal structures
have been serving in the sea for exploring natural resources and conducting many other activities. Due to corrosion, storm loads, damage made by
vessels, dropped objects, and fatigue,
maintenance and repair of the metal
offshore structures have necessitated
research and development on underwater welding technologies (Ref. 1).
The arc welding methods applied under water mainly include hyperbaric
and wet welding (including local-dry
underwater welding). Generally, the
hyperbaric underwater welding methods are considered as a technology
C. B. JIA (jiachuanbao@sdu.edu.cn), Y. ZHANG, B. ZHAO, J. K. HU, and C.S. WU are with the Key Laboratory for LiquidSolid Structural Evolu
tion and Processing of Materials Ministry of Education, Shandong University, Jinan, P.R. China.
202-s
WELDING RESEARCH
Fig. 1 Schematic of the image capture system for underwater wet FCAW.
WELDING RESEARCH
bubbles were difficult to observe because of the serious disturbances from
the harsh environment.
To conclude, the exact shapes and
behaviors of welding arc, droplets, and
bubbles are still not clear enough according to current research results. Research on the mechanisms of the interactions under the impact of the water
environment strongly requires the support of the visual images to further understand and improve the technology.
In this paper, a high-speed camera
was employed to construct a visual
sensing system to monitor the welding arc, droplets, and bubbles. Clear
images were acquired to provide evidence of some given inferences about
the complex physic-chemical phenomenon. The bubbles evolution,
metal transfer, arc behaviors, and
weld joint appearance were carefully
described and analyzed. Furthermore,
the relevant interaction mechanisms
were preliminarily discussed by the
authors.
Experimental Procedures
Welding System
Bead-on-plate welding experiments
were designed and conducted in shallow
water (0.4 m) in an oblong tank. It is
worth mentioning that the wet welding
process, even at very shallow water, is
already very different from the air. The
weld appearance was acquired much differently from that obtained in air, indicating the seriously compressed welding
arc (Ref. 13). Therefore, the chosen low
depth could maximize the influences of
the water environment and minimize
the influences of other variables that
could be affected by pressure (Ref. 24).
A welding power source, LET 500, was
employed to keep the arc voltage constant during the welding process. Meanwhile, an ordinary wire feeder driven by
a DC motor was controlled to feed the
wire with different speeds via adjusting
Fig. 3 Typical bubbles during underwater wet FCAW. A Bubble floatation and new
bubble generation; B bubble with maximum volume; C a growing bubble.
Values
Material of Base
Metal
Workpiece
Dimension
mm
Welding
Speed
mm/min
Welding
Current
A (average)
Arc
Voltage
V
Wire
Extension
mm
Q235
8 300 100
200
205
30
16
WELDING RESEARCH
Results
Typical Bubble Evolution
Underwater wet FCAW is a selfshielded welding method in nature,
which is shielded by the continuously
generated slag and gases. On one hand,
the welding arc burns in the generated
bubbles, which are full of gases. On the
other hand, the slag on the bead surface
protects the weld pool from the water
environment. The two protections provide the possibility to obtain a stable
welding process and high-quality weld
joints. The mechanism of how the reacJUNE 2016 / WELDING JOURNAL 205-s
WELDING RESEARCH
A
Discussion
Typical Bubble Evolution
Process Analysis
The mechanism of the protections
during wet FCAW can be described
more specifically.
First, the flux-cored wire is directly
exposed in the water environment.
Once the wire contacts the substrate,
the current will produce heat and the
temperature around that area will rise
rapidly.
Second, the flux in the wire will
melt and the gas will be generated
from the decomposed flux. Meanwhile, the surrounding water will be
ionized into hydrogen and oxygen or
be vaporized into steam. Subsequently, bubbles around the welding area
will form to provide a protective
atmosphere.
Third, the welding arc is then ignited in the bubbles after the breakdown
of the gas under the open circuit voltage. The arc could generate more energy and heat to produce bubbles continuously. Consequently, the droplet
transfer and molten weld pool behaviors also proceed in the bubbles. The
WELDING RESEARCH
A
WELDING RESEARCH
ing effect due to the cold water environment, and the electromagnetic
pinch force caused by the increasing
current density in the arc column (Ref.
13).
As shown in Fig. 8, if we zoom in on
the images at 0.167 and 0.179 s, the
droplets could be observed in more detail. Figure 8A clearly shows the
droplet being pushed away from the
arc and obviously deviating from the
wire axis. The size was more than
twice that of the wire diameter. The
welding arc under the molten metal
was strong and bright. As for Fig. 8B,
the huge droplet was being lifted by
complex forces. And the surrounding
bubble was also growing larger. It can
be inferred that the larger volume
molten droplet extended the hightemperature field. Subsequently, the
shorter distance from the previous
bubble wall to the molten droplet resulted in more vaporized water.
According to the research results
of conventional GMAW, a possible
contributor causing the repelled globular transfer mode was the cathode
jet force on the droplets based on the
static force balance theory (Ref. 16).
Subsequently, it was deduced that the
drifting cathode spot might cause
varying force values and directions,
which resulted in random flying
paths of the droplets. In addition, the
gas flow drag force was also considered an important part of the complex forces during welding (Ref. 25).
Further research and analysis of the
forces will be conducted in another
paper.
As previously mentioned, the weld
appearance was uneven and the weld
bead was oblique. This phenomenon
could be explained and predicted by the
complicated droplet transfer and welding arc behaviors. The captured repelled
large droplet transfer mode especially
caused random flying paths and uncertain landing locations. Large droplets
also resulted in the intense fluctuation
of the weld pool. In this case, the uneven and asymmetric weld bead was not
an accident. Furthermore, the complex
and periodically evolving bubbles surrounding the arc area had an inevitable
impact on the arc and droplets behaviors. Some physic-chemical interactions
provided extra forces on the droplets
and finally affected their transfer paths
and dimensions.
higher electric potential gradient. Second, with the impact of the surrounding water environment, vaporized and
ionized water produced hydrogen and
oxygen that take part in the ionization
of the arc plasma (Refs. 13, 28). Note
that a big proportion of the complex
gases was H2 (6295%) (Ref. 28).
Due to different thermal conductivity and the thermal pinch effect, the
arc column electric potential gradients
in the hydrogen, vapor, and oxygen atmosphere were about 20, 8, and 4
times that in the argon atmosphere,
respectively (Ref. 26). Therefore, the
water environment and special mixed
gas led to the high arc electric potential gradient.
The welding current density in the
arc column could be calculated based
on the set current (measured as 205 A)
and arc diameter. At the anode spot on
the wire tip, the arc diameter was
about 2.28 mm, and correspondingly,
the arc diameter at the substrate was
about 4.98 mm. Subsequently, the
current density in the arc column has
a maximum value about 5024 A/cm2
and a minimum value about
1053A/cm2 (near the substrate). Assuming the arc was a circular truncated cone, the average current density
through the arc can be calculated according to the given equation:
I=
I
205
=
VC / h 1 (4.982 + 4.98
2.28 + 2.282 )/400
3
= 1894 A/cm2
(1)
Conclusions
1) During underwater wet FCAW,
the bubbles, welding arc, and molten
droplets continuously interacted with
each other, and the very complex behaviors were captured by the developed visual sensing system. Two background light sources, i.e., a large dysprosium lamp and laser were employed to monitor the bubbles inside
and outside, respectively. The bubbles
grew violently in a pulsed way with
varying speed rather than in a continuous, smooth way. And the bottom
bubbles on the substrate surface could
cover the weld pool.
WELDING RESEARCH
2) The typical droplet transfer
mode during this underwater welding
experiment was classified as repelled
globular transfer with large droplets
and low frequency. Under the given
condition, the metal transfer frequency was obviously lower than the bubbles evolution frequency. This may
have caused the extra forces on the
droplets due to the unstable gas flow
of the evolving bubbles. The big volume molten droplets were repelled by
the complex forces, among which the
cathode jet force and gas flow drag
force may have contributed.
3) The arc cathode spot was captured drifting on the substrate intensively and continuously with very high
frequency and speed. This behavior
was negative for maintaining a stable
welding process and made the forces
on the droplets more complicated. The
authors deduced that the oxide distribution and cold cathode substrate
caused this phenomenon. Adding
more oxides in the flux was considered
a feasible method to reduce the arc
drifting and deviation.
4) Under the impact of the water environment, the average electric potential gradient of the arc column was apparently much higher than other conventional GMAW methods. The special
arc burning atmosphere, including hydrogen, oxygen, and vapor, caused the
higher thermal conductivity and consequently higher electric potential gradient. The welding arc current density increased significantly due to the compression by the environment.
5) The asymmetric weld appearance
and uneven surface with distortions
were closely concerned with the complicated physical welding process.
High-frequency evolving bubbles, lowfrequency droplet transfer, and drifting arc were the main factors influencing the welding process stability. The
repelled large droplet transfer mode
especially caused random transfer
paths, uncertain landing locations,
and intense fluctuation of the weld
pool. And it was considered one of the
most important factors causing the
uneven weld appearance.
Acknowledgments
The authors are grateful for the financial support for this research from
mensional simulation of underwater welding and investigation of effective parameters. Welding Journal 92(8): 239-s to 249-s.
16. Zhang, H. T., Dai, X. Y., Feng, J. C.,
and Hu, L. L. 2015. Preliminary investigation on real-time induction heating-assisted underwater wet welding. Welding Journal 94(1): 8-s to 15-s.
17. Kim, Y. S., and Eagar, T. W. 1993.
Analysis of metal transfer in gas metal arc
welding. Welding Journal 72(1): 269-s to
274-s.
18. Shi, Y., Liu, X., Zhang, Y. M., and
Johnson, M. 2008. Analysis of metal transfer and correlated influences in dual-bypass GMAW of aluminum. Welding Journal
87(9): 229-s to 236-s.
19. Madatov, N., Pokhodnya, I., and
Kostenko, B. 1965. High speed x-ray cinematography of the underwater welding arc.
Weld Prod 12(9): 72 to 73.
20. Guo, N., Du, Y. P., Feng, J. C., Guo,
W., and Deng, Z. Q. 2015. Study of underwater wet welding stability using an x-ray
transmission method. Journal of Materials
Processing Technology 225: 133138.
21. Fu, Y. L., Feng, J. C., Du, Y. P., Deng
Z. Q., Wang, M. R., and Tang D. Y. 2016.
Classification of metal transfer mode in
underwater wet welding. Welding Journal
95(4): 133-s to 140-s.
22. Shi, Y. H., Wang, G. R., Zhong, J. G.,
Liu, S., and Liang, M. 2000. Edge detection
of weld seam image during underwater
flux-cored arc welding. Manufacturing Automation 22(11): 37 to 39.
23. Liu, S. 2000. Research on the welding area information of underwater fluxcored arc welding. PhD dissertation.
Guangzhou, South China University of
Technology.
24. Santos, V. R., Monteiro, M. J., Rizzo,
F. C., Bracarense, A. Q., Pessoa, E. C. P.,
Marinho, R. R., and Vieira, L. A. 2012. Development of an oxyrutile electrode for wet
welding. Welding Journal 91(12): 319-s to
328-s.
25. Guo, N., Guo, W., Du, Y. P., Fu, Y. L.,
and Feng, J. C. 2015. Effect of boric acid on
metal transfer mode of underwater fluxcored wire wet welding. Journal of Materials
Processing Technology 223: 124128.
26. Hirotaira, A., and Hasegawa, M.
1978. Welding arc phenomenon (supplement). 164, Beijing, China Machine Press.
27. Hrabovsky, M., Konrad, M.,
Kopecky, V., and Sember, V. 1997. Processes and properties of electric arc stabilized
by water vortex. IEEE Transactions on Plasma Science 25(5): 833 to 839.
28. Yushchenko, K. A., Gretskii, Y. Y.,
and Maksimov, S. Y. 1998. Study of physico-metallurgical peculiarities of wet arc
welding of structural steels. Underwater
Wet Welding and Cutting, pp. 629. Woodhead Publishing.
WELDING RESEARCH
ABSTRACT
Polymeric materials, despite being thermal insulators, are now being welded using
different welding techniques. In the current work, the feasibility of the friction stir weld
ing (FSW) process on 16mmthick Nylon 6 plates was studied. The effects of rotational
speed on the weld quality were investigated by the temperature development, micro
mechanical properties, crystallization growth, and fracture analysis of the joints. Results
showed the dependence of temperature and tensile values on rotation rates was insignif
icant. However, appearance of considerable defects at higher rotation rates, observed in
visual and microscopic analysis, indicated that Nylon 6 is weldable only at lower rotation
rates due to its low melt viscosity. Moreover, identical fracture locations during tensile
tests revealed that the interface of weld zone on the retreating side was the weakest
part of the joint. It can be attributed to the lack of bonding at the interface of the weld
zone on retreating side and relatively low crystallinity in the retreating side region. Due
to different rheological and physical properties of polymers than metals, the flow
phenomenon in Nylon 6 was found to be different from that of metals, resulting in a dis
tinct isolated pin plunged zone.
KEYWORDS
Friction Stir Welding Nylon 6 Polymer Material Flow Threaded Pin
Introduction
The use of polymeric materials has
grown widely in various sectors such
as packaging, building, electronic, automotive, and aerospace industries.
Particularly, Nylon 6 has wide engineering applications and is used in
large quantities in automotive oil
pans, gears, slides, cams, bearings, fluid reservoirs, and the sports industry
(Ref. 1). Polymeric materials offer
many advantages over metal and its alloys owing to certain distinct properties: light weight, high specific
strength, high specific modulus, design flexibility, low production costs,
good corrosion and environmental resistance, thermal and electrical insulation, and durability (Ref. 2).
Increase in use of a particular material, on the other hand, increases the importance of the joining process. In engineering, the production of a single piece
from molding is an ideal situation because it eliminates many steps of assembling. However, due to the complexity of parts and dissimilarity in joining
components in some cases, efficient
joining processes are necessary.
Friction stir welding (FSW), among
modern joining techniques, is now
widely considered as a joining process,
owing to its low-cost production and
eco-friendly process. Moreover, by using this technique, the weld joint can
be accomplished by controlling fewer
parameters, such as rotational speed,
feed rate, plunge depth, and tool dimension (Ref. 3). Since its inception, a
variety of metal alloys has been successfully joined by this process. Investigations regarding their mechanical
and microstructural properties are
widely reported in literature. However,
in the case of polymers, application of
FSW to produce joints is a relatively
new approach and requires further investigation. The nonconductor nature
of polymers makes it challenging to
weld them, especially in the case of a
thick workpiece. However, some polymeric materials have been successfully
friction stir welded up to the maximum workpiece thickness of 10 mm.
The results, in order to achieve the
maximum strength, are characterized
through various means and reported
in literature.
In order to avoid the root defect
fracture and to enhance the weld
strength, different approaches have
been adopted to eliminate this particular defect. For this purpose, Arici et
al. (Ref. 4) used double passes of the
tool on 5-mm-thick polyethylene (PE)
sheets. Pirizadeh et. al. (Ref. 5) used a
bobbin tool on 5-mm-thick acrylonitrile butadiene styrene (ABS) sheets.
However, in the case of polymers with
low melt viscosity or low melting temperatures, such as Nylon 6, which has
a melt viscosity of 300 Pa-s at 250C
(low shear rate) (Ref. 6), double passes
A. ZAFAR (adeel_ze@ymail.com), M. AWANG (mokhtar_awang@petronas.com.my), S. R. KHAN, and S. EMAMIAN are with the department
of mechanical engineering, Universiti Teknologi Petronas, Perak, Malaysia.
WELDING RESEARCH
welding speed
and rotation rate)
compared to
Fig. 3 Configuration of the tensile test specimen.
Inaniwa et al.
(Ref. 12) work.
from the weld zone to the base materiHowever, considering the Nylon 6
al. Similarly, a clear distinction beproperties especially low melt viscositween the shoulder-affected zone and
ty behavior, it is believed that higher
pin-affected zone could be seen.
revolution pitch will produce enorCurrent work involved studying the
mous flash. Flash formation has been
process on 16-mm-thick Nylon 6
reported by Panneerselvam et al. (Ref.
plates by investigating the tempera13) as well. On the other hand, the gap
ture development, micromechanical,
between shoulder and workpiece will
and thermal properties of the joint.
certainly lead to the formation of a
With the aim to reduce the flash forcrown above the weld zone.
mation, a small-diameter shoulder tool
Material flow, due to its direct relawith right-hand threaded pin was
tion with weld quality, has been thorused. Moreover, marker material inoughly investigated on metals by varisert technique was utilized to examine
ous means. Lorrain et al. (Ref. 14) and
the flow phenomenon and stirring
Li et al. (Ref. 15) used foil insert techuniformity in the weld.
nique, Edwards and Ramulu (Ref. 16)
used powder as a tracer material, SeiMaterials and Method
del and Reynolds (Ref. 17) utilized the
marker material insert technique,
In the present investigation, 180whereas Colligan (Ref. 18) inserted
mm-long
weld passes were made on
small steel balls in aluminum to study
16-mm-thick Nylon 6 (Polyamide-6)
material flow. Colligan (Ref. 18) conplates in butt joint configuration at
cluded that material moved behind the
room temperature. Bridgeport VMC
pin and deposited on the retreating
2216 CNC machine was utilized for
side. In another study on aluminum
FSW of specimens welded at a 0-deg
6061, Guerra et al. (Ref. 19) reported
tilt angle and FSW-TS-F16 FSW madifferent flow on advancing side (AS)
chine was used to prepare welds at a 3and retreating side (RS). Seidel and
deg tilt angle.
Reynolds (Ref. 17) observed that the
The FSW tool used in this study
majority of the material in the weld
was machined from H13 tool steel rod
nugget simply moved around the pin
Fig. 1. The pin of the tool was made
and displaced behind the pin.
right-hand threaded for uniform stirThe material flow in polymeric maring, while rotating in a clockwise diterials has been studied on poly
rection (Ref. 13). The tool was heat
methyl methacrylate (PMMA) by
et al. (Ref. 20). They compared
treated before being used for welding
Simoes
and, therefore, its hardness was intheir flow study with the Arbegast
creased to 56 HRC from 24 HRC.
(Ref. 21) flow model and observed
Rotational speed, due to its main
that the pin-affected zone remained
contribution in the FSW process, has
isolated and straight along the pin.
been studied (Ref. 22). It was thereTheir results showed no cross flow
WELDING RESEARCH
A
0
0
3
25
25
25
15
15
15
1000
500, 400, 300
300
WELDING RESEARCH
A
showed a large cavity with a slight improper bond on the RS in Fig. 5D.
Moreover, weld zones were also analyzed at higher magnification. Micrographs shown in Fig. 6AD are the higher magnifications of Fig. 5AD, respectively. It is clear rotation speed has a significant effect on the microstructure of
the welds. The 300 rev/min with 0-deg
angle specimen in Fig. 6A showed uniform and perfect surface quality, whereas the specimens at higher rotation
rates or a 3-deg tilt angle showed a relatively rough surface Fig. 6BD. It is
assumed that fracture is easy to occur in
rough surface compared to smooth surface, as it can provide stress concentration points.
From the above detailed description, it can be deduced that, due to low
melt viscosity compared to other polymers, such as ABS (Ref. 11), PE (Ref.
22), PP (Ref. 24), and PMMA (Ref. 25),
Nylon 6 is weldable only at lower rotation speeds.
WELDING RESEARCH
B
Fracture Analysis
The fractured area in any place of the
welded joint is a direct indication of the
weakest part of that joint. In the present investigation it was noted that all
specimens of each set of parameters exhibited identical fracture location,
which is at the interface of the WZ on
the retreating side (IW-RS). However,
interface of the WZ on the advancing
side (IW-AS) remained intact. One fractured specimen for each rotation rate is
shown in Fig. 8. It is also important to
note here the specimen welded at 500
rev/min (Fig. 8C) also showed fracture
at the IW-RS, despite the fact it contains a tunnel defect. It indicates that
the IW-RS is weaker than the tunnel
defect.
Inaniwa et al. (Ref. 12) and N.
Mendes et al. (Ref. 11) also observed
the same fracture locations in their
study on FSW of different polymers.
This prefered fracture location in these
specimens can be related to the formation of flash preferrentially on the retreating side. In general, flash forma-
Temperature Analysis
Temperatures measured at 1 mm below the pin tip are shown graphically in
Fig. 10. An increase in temperature
with the increase of rotation speed is
obvious and can be observed in the
graph. Although the temperature differences at low rotation rates are not
significant, noticeable differences in
weld quality were observed. Cavities,
tunnel defect, and smoke during the
process were seen above 400 rev/min
rotation speeds. A maximum temperature of 167C at 1000 rev/min showed
large amounts of flash formation with
the emission of smoke. Smoke is a combination of different volatiles, majorly
Analysis of Crystallinity
In order to analyze the postweld
thermal conditions of the joint and to
investigate the reason of identical fracture locations, the degree of crystallinity of different sections of the
WZ was analyzed using DSC curves.
The specimens, for this purpose, were
taken from the base material (BM),
weld center (WC), AS, and RS. The degree of crystallinity of any polymer
has a direct relation to its mechanical
and physical properties. Increase in
the degree of crystallinity has shown
increase in tensile strength, stiffness,
WELDING RESEARCH
A
Wc = Hm/Hm 100%
Fig. 8 Fractured specimens during tensile tests welded at the following: A 300 rev/min
with 0deg angle; B 400 rev/min with 0deg angle; C 500 rev/min with 0deg angle; D
300 rev/min with 3deg angle.
(1)
Fig. 9 SEM micrographs of fractured surfaces, observed at the interface of the RS toward
the weld zone, welded at the following: A 300 rev/min with 0deg angle; B 400 rev/min
with 0deg angle; C 500 rev/min with 0deg angle; D 300 rev/min with 3deg angle.
yield point, and hardness, but a reduction in impact strength (Refs. 2830).
WELDING RESEARCH
lar phenomenon
was observed on
the adjacent right
and left
sides of the
plunged
Fig. 12 Sectioning scheme of material flow specimens.
area. This
restriction
of WZ withFigure 13A shows the specimen bein the plunged area is also mentioned
fore welding with marker material in
and Rodrigues (Ref. 20) in
by Simoes
the longitudinal direction (parallel to
their study of PMMA.
welding direction). After welding, verIn order to observe the y-direction
tical cross sections of the specimen
flow (parallel to WD) of the specimen,
were made to observe the flow in
marker materials were placed transx-direction, which is perpendicular to
versely (perpendicular to WD) on the
the welding direction (WD). It can be
AS (I), weld interface (II), and RS (III),
clearly seen in Fig. 13B that thin markas shown in Fig. 14A. After welding,
er material, when placed on the RS (I),
horizontal sections were prepared. It is
spread all over the welding zone,
clear from Fig. 14BD marker material
equivalent to pin diameter. Similarly,
after stirring was displaced behind the
in Fig. 13C, marker material placed on
pin. The maximum displacement
AS (II) stirred and spread in complete
measured in Fig. 14C, D was remarkwelding zone. This spreading indicates
ably very long, 11 mm, whereas the dia uniform stirring, either marker maameter of the pin is 7.5 mm. However,
terial is on the AS or the RS. However,
distribution of marker material
in both cross sections it can be ob(shown in Fig. 14C, D) was uniform,
served that marker material at the top
but narrowing of marker material at
of the specimen is not well stirred and
the end was observed. It is believed
positioned toward the AS. It is bethe farthest narrow part is squeezed
lieved this unstirred area is due to a
and extruded by the pin. This extrusmall, unthreaded part of pin near the
sion phenomenon is similar to Collishoulder. Furthermore, it is also obgans (Ref. 18) material flow study on
served the depth of the WZ is equivaFSW of aluminum alloy, in which he
lent to the pin plunged length. It
considered the welding process due to
shows there was no cross flow from
stirring and extrusion. As the material
the plunged area to the unplunged
of the AS in Fig. 14B is prone to flow
zone at the bottom of the pin. A simi216-s WELDING JOURNAL / JUNE 2016, VOL. 95
Conclusions
Systematic work was carried out on
the friction stir welding of 16-mmthick Nylon 6 plates using a threaded
pin tool with a small-diameter shoulder. Based on the aforementioned results and discussion, the following
conclusions can be made:
WELDING RESEARCH
A
A
Acknowledgments
Fig. 15 Specimens before welding with marker material at the bottom, middle, and top of
the following: A AS; B RS; C longitudinal section of postweld specimen AS; D RS.
Nylon 6, due to its low melt viscosity, is weldable only at lower rotation rates. Therefore, a 300 rev/min
rotation speed and 25-mm/min feed
rate has given comparatively good
weld results at 0-deg tool angle.
At higher rotation rates, squeezing out of excess plasticized material
and defects formation in the weld
zone were observed.
A small-diameter shoulder, on the
other hand, reduced the amount of
flash by reducing the primary heat.
The processing temperatures,
measured 1 mm below the pin plunged
zone, were quite below the thermal
degradation temperature of Nylon 6
(350C). Thus, it is assumed the Nylon
6 in the stirring zone did not undergo
extreme thermal degradation, although minor reduction in molecular
References
1. A Guide to nylon. Available:
ptsllc.com/intro/Nylon_intro.aspx.
2. Magnus, C. Feasibility Study of Metal
to Polymer Hybrid Joining. 2012.
3. Liu, F. C., Liao, J., and Nakata, K.
2014. Joining of metal to plastic using friction lap welding. Materials & Design 54(2):
236244.
4. Arici, A., and Sinmazelk, T. 2005.
Effects of double passes of the tool on friction stir welding of polyethylene. Journal of
Materials Science 40(6): 33133316.
5. Pirizadeh, M., Azdast, T., Ahmadi, S.
R., Shishavan, S. M., and Bagheri, A. Friction stir welding of thermoplastics using a
newly designed tool. Materials & Design
54(2): 342347.
6. Olabisi, O., and Adewale, K. 1997.
Handbook of Thermoplastics. Vol. 41. CRC
press.
7. Aydin, M. 2010. Effects of welding
parameters and pre-heating on the friction
JUNE 2016 / WELDING JOURNAL 217-s
WELDING RESEARCH
stir welding of UHMW-polyethylene. Polymer-Plastics Technology and Engineering
49(5): 595601.
8. Bilici, M. K., and Ykler, A. I. 2012.
Influence of tool geometry and process parameters on macrostructure and static
strength in friction stir spot welded polyethylene sheets. Materials & Design 33(1):
145152.
9. Ahmadi, N. B. M. A. H., Ashenai
Ghasemi, F., and Eslami Farsani, R. 2012.
Influence of pin profile on quality of friction stir lap welds in carbon fiber reinforced polypropylene composite. International Journal of Mechanics and Applications.
10. Bagheri, A., Azdast, T., and Doniavi,
A. 2013. An experimental study on mechanical properties of friction stir welded
ABS sheets. Materials & Design 43(1):
402409.
11. Mendes, N., Loureiro, A., Martins,
C., Neto, P., and Pires, J. N. 2014. Effect of
friction stir welding parameters on morphology and strength of acrylonitrile butadiene styrene plate welds. Materials & Design 58(6): 457464.
12. Inaniwa, S., Kurabe, Y., Miyashita,
Y., and Hori, H. 2013. Application of friction stir welding for several plastic materials. Proceedings of the 1st International Joint
Symposium on Joining and Welding. Osaka,
Japan, p. 137.
13. Panneerselvam, K., and Lenin, K.
2014. Joining of Nylon 6 plate by friction
stir welding process using threaded pin
profile. Materials & Design 53(1): 302307.
14. Lorrain, O., Favier, V., Zahrouni, H.,
and Lawrjaniec, D. 2010.Understanding
the material flow path of friction stir welding process using unthreaded tools. Journal
of Materials Processing Technology 210(3):
603609.
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WELDING RESEARCH
ABSTRACT
The authors recently demonstrated that the arc plasma and electron flow in an arc
could be separated. This separability provided the foundation to develop an ability to
adjust the heat and arc pressure distribution without changing the current. To better
understand this property, a novel system was developed based on the split anode.
The distribution of the pressure and heat from the separated arc plasma was analyzed
quantitatively. It was verified that the arc pressure mainly concentrated in the arc
plasma. Also, the heat input from the arc plasma exceeded that from the eletron flow.
To explore possible applications of this separability, a novel process, namely,
separated plasma transferred arc weld surfacing (SPTAWS) is proposed. Grade D steel
workpieces were hardfaced using this process. As the separated electron flow
increased, the heataffected zone (HAZ) of the deposited bead was reduced. The mi
crostructure with SPTAWS was found to be better than with conventional plasma
transferred arc weld surfacing (PTAWS), especially in the finegrain zone. The grain is
more refined and uniform.
KEYWORDS
Plasma Arc Arc Separability Arc Pressure Arc Heat SPTAWS
Introduction
In 1802 Petrov discovered the phenomenon of continuous electrical discharge, and in 1911 Mathers described the plasma as a heat source
for the first time (Refs. 1, 2). Subsequently, scientists proposed many arc
welding methods including submerged arc welding (SAW), gas tungsten arc welding (GTAW), gas metal
arc welding (GMAW), and plasma arc
welding (PAW) (Ref. 3). Scientists
also proposed many hardfacing methods, including plasma spray, plasma
transferred arc weld surfacing
(PTAWS), and plasma transfer wire
arc (PTWA) thermal spraying (Refs.
48).
S. J. CHEN, R. Y. ZHANG, F. JIANG (jiangfan@bjut.edu.cn), and Z. Y. YAN are with the Ministry of Education Engineering Research Center of Ad
vanced Manufacturing Technology for Automotive Components, Beijing University of Technology, China. Y. M. Zhang is with the Institute for
Sustainable Manufacturing and Department of Electrical and Computer Engineering, University of Kentucky, Lexington, Ky.
WELDING RESEARCH
A
stand the PA and expand the application range from the conventional PA.
Measurement of
Experimental System
This experimental study relied on
the analysis of the data from measurements of pressure and heat associated with the arc. Scientists around
the world have made great progress in
the measurement of arc pressure. The
pressure of plasma arc has been measured by pendulum with rotary optical
encoder, U-tube
barometer, and
piezoelectric pressure transducer
(Refs. 2123). The
temperature field
in the arc column
was measured by
infrared radiation
(IR) and spectroscopy (Refs. 2426). The current
distribution was
measured by a series of annular anodes and split anode method (Refs.
27, 28). In the previous study, the authors measured the distribution of
pressure and heat of the completely
separated arc plasma and electron
flow. However, systematic measurements needed to study the properties
of the partially separated arc plasma
and electron flow were lacking. Such
properties and degree of the partial
separation were critical for free control on the pressure and heat. An experimental setup was thus established
to provide the ability to study the partial separation.
Experimental Type
1
2
3
4
5
6
Pressure
Pressure
Pressure
Heat
Heat
Heat
1000
50
50
1000
50
50
0100
50
50
0100
50
50
3.0
3.0
2.53.5
3.0
3.0
2.04.0
4
48
4
4
48
4
WELDING RESEARCH
A
Experimental Procedure
In all experiments, the plasma
torch had a 3-mm orifice diameter,
4.8-mm tungsten diameter, and 4mm tungsten setback. Pure argon
(99.99%) was used for the shielding
gas and plasma gas, and the flow rate
for the shielding gas was 12 L/min.
The major parameters for the designed experiments are given in Table
1, including the current of the PAW
(CP), the current of the GTAW (CG),
plasma gas flow rate, and arc length.
The current flowing through the plasma torch was 100 A. The electron
flow was separated from the arc plasma, with the CG from 0 to 100 A representing conventional PAW, partial
separation at different degrees, and
full separation. The CP reduced from
100 to 0 A, accordingly.
(1)
(2)
WELDING RESEARCH
creased. The velocity of the arc plasma was influenced by voltage and
temperature, and the effect of the
voltage depended on the polarity of
charged particles and the direction of
the electric field. Based on the fundamental law of electricity that like
charges repel and opposite charges attract, the acceleration direction of the
cations was toward the cathode, and
the acceleration direction of the negatively charged particles was toward
the anode. The temperature had a
negative effect on the velocity of all
the particles in the arc plasma as the
temperature decreased. In this case,
compared to temperature, the voltage
had a smaller influence on the velocity of the arc plasma. The velocity of
the arc plasma thus decreased as the
arc length increased. As shown in Fig.
5, the peak of the pressure curve decreased as the arc length increased.
The results from Experiment 3 are
shown in Fig. 6. The plasma gas flow
rate was changed at three levels, 2.5,
3.0, and 3.5 L/min. The arc length remained 4 mm and the CP and the CG
remained 50 A, respectively. When
other conditions were unchanged, the
initial velocity of the arc plasma increased as the plasma gas flow rate increased, based on the fluid dynamics.
In addition, the running distance of
the arc plasma remained unchanged.
The final velocity of the arc plasma,
when reaching the workpiece, in-
WELDING RESEARCH
Fig. 7 Energy output of the arc plasma and the electron flow
under different currents in Experiment 4. Arc length, 4 mm;
plasma gas flow rate, 3 L/min. The current is given as CPCG.
creased as the plasma gas flow rate increased. As can be seen in Fig. 6, the
peak value has been significantly increased as the plasma gas flow rate increased, the pressure of the arc plasma was reducing as the arc radius increased, and the pressure mainly distributed within the 2.5 mm radius.
Heat Distribution
As shown in Table 1, Experiments
46 are designed to measure the heat
from the arc plasma and electron flow
under different conditions. The results are shon in Figs. 79. The points
on the lines are the measurements. In
the Y-axis, the energy output is calculated based on Equations 1 and 2.
As illustrated in Fig. 7, the current
is applied at seven pairs; and in the Xaxis, the first number represents the
CP and the second represents the CG.
The sum of the two currents remained 100 A. In all experiments, the
arc length was 4 mm. As seen from
Fig. 7, as the separated electron flow
(the CG) decreases (i.e., toward the
right in the current axis in the figure),
the heat of the electron flow (the lower curve in the figure) decreases, but
the heat of the arc plasma (the upper
curve) (as reflected by the temperature elevation of the cooling water)
increases because the proportion of
the electron flow that is not separated
increases. Further, as can be observed, the heat of the arc plasma was
greater than the electron flow. The
first reason was that the heat being
received by the electron flow receiver
mainly came from the anode spot and
decreased as the separated electron
flow (the CG) decreased. The heat of
the electron flow receiver decreased
as the separated electron flow de-
WELDING RESEARCH
Fig. 10 Schematic of the separated plasma transferred arc weld surfacing (SPTAWS)
where 14 are the plasma gas, powders, powder feeding gas, and shielding gas.
increment of the heat from the separated electron flow was smaller than
the reduction of the heat from the
arc plasma. As the arc length increased, the distance from the orifice
exit to the workpiece increased. The
travel distance and the radius of the
arc plasma both increased. The heat
loss through the radiation and air
convection both increased. The heat
received by the arc plasma receiver
thus reduced as the arc length increased. For the electron flow receiver, the separated electron flow (the
CG) was unchanged despite the increase in the arc length. The heat
from the electron flow was thus un-
Separated Plasma
Transferred Arc Weld
Surfacing
Principle and System
As verified previously, the heat input
and arc pressure on the base metal can
be both reduced from the conventional
PAW and adjusted by changing the degree of the separation. A novel process,
namely the separated plasma transferred arc weld surfacing (SPTAWS), is
thus proposed and developed. Its test
platform is shown in Fig. 10. As illustrated, the system includes a power
source (transferred arc power source or
WELDING RESEARCH
A
Experimental Procedure
Plasma transferred arc weld surfacing (PTAWS) is a standard technology
used for hardfacing. Surfacing experiments were thus conducted using
both the SPTAWS process and the
PTAWS to compare. Grade D steel
plates were used as the base metal
with dimensions 250 100 10 mm.
The high-chromium, iron-based alloy
powders were used for cladding. The
particle size was between 53 and 150
mm. The guidance terminal was re-
WELDING RESEARCH
A
achieved using
different heat inputs. Of course,
the microstructures changed accordingly and the
separation was
determined to
achieve the desired microstructures without affecting the deposited
bead appearance and powder melting.
Conclusions
In this study, the property of arc
separability was analyzed by measurement. It was verified that the pressure distribution of arc plasma was affected by the ratio of the CP and the
CG (the electron flow separated from
the arc plasma), arc length, and the
plasma gas flow rate, but the ratio of
the currents was the main factor and
the effects from the arc length and
the plasma gas flow rate were insignificant. The heat applied into the
workpiece through the electron flow
was less than that from the arc plasma. Based on the measurement and
the property of the arc separability,
the separated plasma transferred arc
weld surfacing (SPTAWS) process is
proposed and was tested on Grade D
steel for surfacing. The influence of
current on the macro profile and mi-
WELDING RESEARCH
A
Fig. 16 Microstructures in the HAZ of the bead cross section produced by PTAWS. Current = 130 A without separation. A Coarse
grains; B fine grains in Zone I; C Zone II contains both coarse grains and fine grains.
Fig. 17 Microstructures in the HAZ of the bead cross section produced by SPTAWS. Total current = 130 A with 40 A separation of the
electron flow. A Coarse grains; B fine grains in Zone I; C Zone II contains both coarse grains and fine grains.
crostructure of the bead cross sections was investigated. For conventional PTAWS, increasing the current
from 110 to 150 A expanded the
HAZ. For SPTAWS, the HAZ decreased as the separated electron flow
increased. According to microstructure analysis, it was found that the
SPTAWS produced beads with finer
and more uniform grains than the
conventional PTAWS, especially in the
fine-grain zone, because of the effect
from the separated electron flow.
Acknowledgments
References
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WELDING RESEARCH
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