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Bonus: The American Welder
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
elf-Shielded Elgetrode
Tough LJIbdWHlb. Musc^Uhe
i
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Features
28 Laser Welding: It's Not Just for Metals Anymore
Techniques for welding plastics with diode lasers are
examined
AWS Web site www.aws.org
S. A. Kocheny and B. Miller
38 One Machine Does It All for Laser Beam Welding and Cutting International Update 14
There are many benefits of using one machine for both Stainless Q&A 20
laser beam cutting and welding without changing the
process head RWMAQ&A 22
D. Petring and F. Schneider New Products 24
Conferences 42
The American Welder Coming Events 44
80 Welded Sculptures Pay Tribute to Fallen Heroes Society News 57
The creative vision of a retired firefighter is evident in his Tech Topics 58
welded sculptures dedicated to the fallen on 9/11
K. Campbell Errata: 01.1:2008 58
Interpretations: 01.1:2006 ....58
86 Optimizing Tungsten Electrode Performance
Weld quality often depends on the proper care and choice Guide to A WS Services 67
of the tungsten electrode New Literature 72
M. Fletcher
Personnel 76
*90 How to Choose Ergonomic Hand Tools American Welder
Know how to select hand tools that are efficient in
operation, yet comfortable to use FactSheet 92
P. Holstein Classifieds 96
Advertiser Index 99
Welding Research Supplement
45-s Welding Gun Inclination Detection and Curved Fillet Weld
Joint Tracking
Welding current is used to detect gun inclination and deviation
in a robotic system that produces a curved fillet weld
Welding Journal {\SSfi 0043-2296) is published
Y. F. Gao et al. monthly by the American Welding Society for
$120.00 per year in the United States and posses-
54-s Heat Transfer and Fluid Flow during Electron Beam sions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
Welding of 304L Stainless Steel Alloy
$10.00 per single issue for nonmembers and
A three-dimensional model was used to calculate weld pool fluid $14.00 single issue for international. American
flow patterns and their effect on weld geometry Welding Society is located at 550 NW LeJeune Rd.,
R. Rai et al. Miami, FL 33126-5671; telephone (305) 443-9353.
Periodicals postage paid in Miami, Fla., and addi-
tional mailing offices. POSTMASTER: Send address
62-s Metallurgical Investigation into Ductility Dip Cracking in changes to Welding Journal, 550 NW LeJeune Rd.,
Ni-Based Alloys: Part II Miami, FL 33126-5671. Canada Post: Publications
Mail Agreement #40612608 Canada Returns to be
The correlation of ductility dip cracking to a simulated thermal
sent to Bleuchip International, P.O. Box 25542,
cycle helped evaluate microstructure and chemical evolution in London, ON N6C 6B2
four alloys
F. F. Noecker II and J. N. DuPont Readers of Welding Journal my make copies of
articles for personal, archival, educational or re-
search purposes, and which are not for sale or re-
sale. Permission is granted to quote from articles,
provided customary acknowledgment of authors
and sources is made. Starred (*) items excluded
from copyright.
WELDING JOURNAL
PI7E55 TIME
NEWS
WELJMNSI
Publisher Andrew Cullison
U.S. Navy Awards General Dynamics $6 Million for Nuclear
Submarine Services Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
The U.S. Navy recently presented General Dynamics Electric Boat a $6.3 million
Associate Editor Howard M. Woodward
modification to a previously awarded contract for management and support of nuclear-
Associate Editor Kristin Campbell
maintenance work for submarines homeported at the Naval Submarine Base New Lon-
Peer Review Coordinator Erin Adams
don in Groton, Conn. It will continue to operate the Nuclear Regional Maintenance
Department (NRMD) at the submarine base through Sept. 30.
Publisher Emeritus Jeff Weber
In addition, the company will provide project management, planning, training, and
radiological control services to support maintenance, modernization, and repairs. A Graphics and Production
core group of about 25 Electric Boat employees is assigned to the NRMD, with surge Production Manager Zaida Chavez
groups of up to 100 shipyard employees assigned for short periods. Senior Production Coordinator Brenda Flores
800.521.9755
YOUR RESOURCE www.weldmold.com
EDITORIAL American Welding Society
Founded in 1919 to Advance the Science,
Technology and Application of Welding
John L. Mendoza
AWS Vice President
MARCH 2009
"WHEN YOU WELD YOU PUT YOUR
OWN SIGNATURE OUT THERE."
Stuart spent 13 years in the welding industry. He
developed a passion for the trade while building boats in
Louisiana.
"With Thermal Arc you get the most for your money. And
it's simple to operate so I can spend more time teaching
my students how to weld with an extremely smooth arc
and negligible spatter. And because it can be used with a
wide range of gases, materials and material thicknesses,
I can expose my students to a variety of applications'.'
STUART DUFRENE
Southern Arkansas University Tech Career Academy
Equipment Maintenance Instructor
THERMAL T^RC
www.thermadyne.com 'THERMADYNE
Northern Michigan Weiding Educators When a group of eight welding instructors sat down at their
annual best practice seminar and discussed what collaborative
Organization Goes International groups are doing for their required Career and Technical Stu-
dent Organization (CTSO), the Northern Michigan Welding Ed-
ucators (NMWE) history began. They asked what would be the
most valuable piece of education they could give their students
to better prepare them for entering the workforce and learn about
welding. The decision was to make a competition commensurate
with the official code, simulating a real work experience.
In 2001, Darin Kearns of the Wexford-Missaukee Career Tech-
nical Center, Cadillac, Mich., and Chuck Hunt from Traverse
Bay Area Intermediate School District Career-Tech Center, Tra-
verse City, Mich., spearheaded this organization to keep it all
about the students.
Collectively, the second part of NMWE/CTSO formed: not
only expose students to AWS Dl.l, Structural Welding Code
Steel, and D1.2, Structural Welding Code Aluminum, but also
give them an opportunity to take the 3-G 3/8 V-groove test in
shielded metal arc, gas metal arc, and gas tungsten arc welding.
Every October, NMWE instructors meet to discuss ways to
keep their students on track regarding relevant AWS code tests
Darin Kearns, Northern Michigan Welding Educators (NMWE) and address all issues affecting the curriculum. In addition, tours
president, and welding/metal fabrication instructor at Wexford- are taken to local welding fabrication-related businesses who are
Missaukee Career Technical Center, Cadillac, Mich., is shown in asked for their input. Each year the organization has a different
the welding lab where he teaches. Kearns helped the NMWE mem- host site, a rotation of its original ten-member team.
bers' ideas become a reality. In March, students and all instructors are involved in the AWS
MARCH 2009
codes Dl.l and D1.2 welder qualification procedures. Also, at
the March competition students test and compete against each
other for the AWS Code Welder Qualification status.
Recently, the organization has grown beyond Northern Michi-
gan. In 2008, it went international and spread to Canada.
As acting president, Kearns does not know what educational
challenges 2009 will bring, but the group stands united, keeping
it all about the students' education.
WELDING JOURNAL
Friedman Industries Starts Steei Coil
Processing Faciiity
WESTEC
WESTEC brings you exciting ideas, know-how and business connections
you won't find at other events. Find out what more than 1.3 million
manufacturers know: that WESTEC has its finger on the pulse of West
ADVANCED PRODUCTIVITY EXPOSITION Coast Manufacturing. Get to WESTEC 2009 and bring your team!
March 30 - April 2, 2009 For information visit www.we5teconline.com
Los Angeles Convention Center
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TECHNICAL TRAINING
The Hobart Institute of Welding Technology
offers our comprehensive Technical Training
courses throughout the year! Upcoming dates:
Prep for AWS Certified Welding Supervisor Exam
Jun 22-26- Aug 10-14- Nov 30-Dec 4
Prep for AWS Welding Inspector/Educator Exam
May 11-22 - Jun 8-19 Jul 13-24 - Aug 24-Sep 4
Visual Inspection
Apr 7-8 Jun 30-Jul 1 - Nov 23-24
Welding for the Non Welder
Apr 27-30- Jun 22-25- Aug 17-20- Oct 12-15
Arc Welding Inspection & Quality Control
Mar 16-20- May 4-8- Jul 27-31- Oct 19-23
Weldability of Metals, Ferrous & Nonferrous
Mar23-27- Apr20-24- May 18-22- Jun 15-19 HEAVY DUTY TUNGSTEN GRINDER
FOR 3/16" - .040"
Liquid Penetrant & Magnetic Particle Inspection
SAFETY: Enclosed diamond wheel grinding area
Apr 13-17- Aug 3-7- Oct 26-30
WELD QUALITY: 20 Ra finish improves tungsten life, starting & arc stability
WELDING JOURNAL
THE 12thALUMINUM WELDING
CONFERENCE & EXHIBITION
Conference Program
Metal Preparation for Aluminum Welding High Energy Density Beam Welding of
William Christy Aluminum
Novelis Inc. William Christy
Kingston, Ontario, Canada Novelis Inc.
Kingston, Ontario, Canada
Filler Alloy Selection Primary Characteristics
Tony Anderson Cutting Methods for Aluminum Alloys
ESAB Welding & Cutting Products Jay Cinder
Florence, SC ESAB Welding & Cutting Products
Florence, SC
Gas Metal Arc Welding of Aluminum Alloys
Mark Burke Overview of Solid State Joining
Indalco Processes for Aluminum
Mississauga, Ontario, Canada Donald J. Spinella
Alcoa Technical Center
Gas Tungsten Arc Welding and Variable Alcoa Center, PA
Polarity Plasma Arc Welding of Aluminum
William Christy Friction Stir Welding Aluminum
Novelis Inc. Jay Cinder
Kingston, Ontario, Canada ESAB Welding & Cutting Products
Florence, SC
Aluminum Weld Discontinuities:
Causes and Cures Resistance Spot Welding of Aluminum
Kyle Williams Donald J. Spinella
Alcoa Technical Center Alcoa Technical Center
Alcoa Center, PA Alcoa Center, PA
MARCH 2009
KISWE
KISVVEL
S&
! hi
Mild Steel hJ) K'SM/EL ^
Covered Electrodes
Stainless Steel
Mild Steel Covered Electrodes
& Low Alloy
Flux Cored Wires Stainless Steel
Flux Cored Wires
Mild Steel
& Low Alloy Stainless Steel
TIG & MIG Wires TIG & MIG Wires
I want to encourage you to submit nomination packages for those individuals whom you feel have a
history of accomplishments and contributions to our profession consistent with the standards set by the
existing Fellows. In particular, I would make a special request that you look to the most senior members
of your Section or District in considering members for nomination. In many cases, the colleagues and
peers of these individuals who are the most familiar with their contributions, and who would normally
nominate the candidate, are no longer with us. I want to be sure that we take the extra effort required to
make sure that those truly worthy are not overlooked because no obvious individual was available to start
the nomination process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS headquarters
in Miami, or simply follow the instructions on the Fellow nomination form in this issue of the Welding
Journal. Please remember, we all benefit in the honoring of those who have made major contributions to
our chosen profession and livelihood. The deadline for submission is July 1, 2009. The Committee looks
forward to receiving numerous Fellow nominations for 2010 consideration.
Sincerely,
Nancy C. Cole
Chair, AWS Fellows Selection Committee
The Perfect Bond.
TRUMPF lasers and laser systems supply
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tance, force, frequency, and time) twice COR-MET
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company's ridged H-frame support for
precision high-force applications. The
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user interface is configurable to be hori-
zontal or vertical, allowing the power sup- can be easily attached to the company's Welding Wire
ply to be integrated directly on the press horizontal carousel bins and offer a quick
system. Its design saves space and is mod-
ular. All of this series ultrasonic power
way to verify and monitor the position of
specific bins within the system. The bin AWSA5.34
supplies have the company's flow through markers are helpful in integrated horizon-
thermostatically controlled cooling tun- tal carousel workstations to visually track
nel. Units incorporate a patent-pending bin position.
ultrasonic modular menu adapter. N82 FC-G
Remstar International Inc.
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Laser-Punch Provides N100AFC-G
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The STRIPPIT LP-1225 laser-punch is
Remstar bin markers provide a visual
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WELDING JOURNAL
package, delivering good part quality and Feed Assist Gets Updated
accuracy. It is capable of laser cutting,
punching, forming, and tapping. In addi- Face Plate Design
tion, the machine comes equipped with a
low noise/scratch-sensitive brush bed sys-
tem and is useful for processing lighter-
gauge components. It has a capacity of
49.21 x 98.4 in. maximum sheet size, 20-
ton programmable hydraulic press drive,
and 0.250-in. maximum material thickness.
GEARHEAD PROBLEM
Nabtesco
Near-Zero Backlash High Torque Capacity Large Thrust & Moment Support Cost Competitive
The 3-D Quanta laser-camera is for
Call 866-74-TOUGH or Log on to nabtescomotion.com for more info. joint tracking and weld bead inspection.
For info go to www.aws.org/ad-index
MARCH 2009
The high-resolution product is also for Diode Laser System
high-precision butt-joint welding applica-
tions including the same material thick- Delivers High Brightness
ness. It is designed for welding processes
such as laser, GTA, or plasma. The laser-
camera is an essential module in the com-
pany's modular DIGI-LAS laser welding
system (DIGI-LAS/MDL); it can be
mounted on robots or special-purpose
welding machines due to the company's
patented error-compensation package
that enables high-speed welding with no
defects, despite joint imprecision and po-
sitioning errors. The product features a 2- The HE-diode system delivers 75 W of
D video viewing system with its own weld- power at either 808 nm from a 200-|j.m
ing area lighting for remote monitoring core 0.22 numerical aperture (NA) fiber
of the process by the operator and for cal- or 976 nm from a 400-nm core 0.22 NA
ibration purposes. fiber. It is suited for applications in mate-
rials processing and pumping solid-state
Servo-Robot Corp. laser media including plastics welding,
www.servorobot.com electronics soldering, plastics marking,
(450) 653-7868 and heat treating. The system is a fully in-
tegrated, microprocessor-controlled in-
strument that operates from 110/220 VAC
Crane Scale Includes and enables user control of diode output
Bluetooth Remote Control through either a front panel keypad or
electronic interface. Extra convenience
features include air cooling, a rack mount-
ing option, and a coaxial, visible wave-
length aiming beam.
WELDING JOURNAL
Laser Welding:
It's Not Just for Metals Anymore
BY STEVEN A. KOCHENY AND BILL MILLER
A number of
welding techniques
using diode lasers
are described to
help engineers
and designers
transition into the Fig. I High-power diode laser stack. Fig. 2 Divergence of laser light from
(Photo courtesy ofDilas.) diode. Shown is 30 to 60 deg in the perpen-
expanding field dicular direction, and 25 to 35 deg in the
of plastics parallel direction.
Many project engineers associate the ventional CO2 and Nd:YAG lasers have This device has an output of 5 mW with a
term "welding" primarily with metals. In been developed into important tools in the wavelength of 780 nm. In 1995, DVDs
fact, Merriam-Webster's Online Dictionary metals-joining industry, but their use in entered the marketplace using a diode
defines welding as a transitive verb mean- the plastic industry is typically limited to laser to emit a light with a wavelength of
ing "to unite (metallic parts) by heating cutting and scribing. For plastics, diode 635 nm.
and allowing the metals to flow together lasers are used. Diode lasers are more di- Today, materials that generally com-
or by hammering or compressing with or vergent in how they deliver their energy, pose high-powered diode lasers (HPDL)
without previous heating" or "to unite have a shorter wavelength, and have out- are a mixture of gallium, indium, and alu-
(plastics) in a similar manner by heating." put powers that allow them to produce a minum on one side, and phosphorus, ar-
While years of joining metals have formed controlled melt, or welding, of the plastics. senic, and antimony on the other side
this association with welding, the ever- This article discusses the use of diode (Ref. 3). Driven by a DC current, the
increasing use of plastics as a replacement lasers for welding thermoplastics. HPDL emits a laser beam with a wave-
for metals is fostering an increased signif- length in the range of 600 to 1600 nm, de-
icance of welding for plastics. Background pending on the crystal structure of the
Although welding is the term applied diode. The HPDLs are composed of diode
to joining both metals and plastics, the In 1962, Robert N. Hall invented the bars, which are 10 mm wide and 0.1 mm
methods used to weld these materials are first semiconductor (diode) laser while high. Each diode has a power output of 40
quite different. working for General Electric (Ref. 1). His to 60 W when operated in the continuous-
For example, several metals-joining laser had an output wavelength of 840 nm wave mode. Several bars can be stacked to
processes employ filler materials to make and could only be operated in the pulsed provide greater output powers Fig. 1.
the weldments, i.e., gas metal arc, sub- mode at -1960C (-3210F) (Ref. 2). It was- These laser diodes are similar to light-
merged arc, and shielded metal arc weld- n't until 1970 that a diode laser was devel- emitting diodes (LEDs) in functionality.
ing. In contrast, when welding plastics, the oped that could operate continuously at Operating in the forward bias mode (+ on
use of filler materials is often the excep- room temperature. In 1982, the diode the P-side), electrons are infused across
tion rather than the rule. Also, the con- laser used in CD players was developed. the P-N junction and into the semicon-
STEVEN A. KOCHENY (Steve.Kocheny@leisterusa.com) is senior application welding engineer, and BILL MILLER is product sales
manager, at Leister Technologies, EEC, Itasca, III.
MARCH 2009
ductor to create photons. These photons can be presented to the parts
are then emitted in ail directions from the in the form of either a spot or
plane on the P-N junction. The cleaved a line. Each form offers its
surfaces of the laser diode act as mirrors own advantages, and selec-
to form the diode laser's resonant cavity tion should be based upon
(Ref. 4). As laser light emerges from the each application.
diode, it diverges in the perpendicular and
parallel directions, with more divergence Spot (Contour) Weiding
in the perpendicular (30-60 deg) than the
parallel (25-35 deg) direction Spot or contour welding
Fig. 2. This divergent light is generally un- refers to the use of a circular
usable as emitted from the diode; there- spot of laser energy to
fore, it needs to be shaped and collimated traverse a preprogrammed
according to the needs of the application, contour path and create a
i.e., spot or line focus (Ref. 3). weld or bond.
As mentioned previously,
Through-Transmission as the laser light is emitted
infrared Weiding (TTIR) from the diode it begins to di-
verge. Through the use of
Through-transmission infrared weld- mirrors and lenses the emit-
ing of thermoplastics is a process whereby ted light can be collimated,
laser light in the range from 800 to 1064 shaped, and focused into a
nm wavelength passes through a top (laser circular spot. This focused
transparent) part and is absorbed by ei- light can then be transmitted
ther a bottom (laser absorbent) part or a into a fiber-optic, which has a Fig. 3 Through-transmission infrared (TTIR) welding
laser absorbent layer between two parts. diameter as small as a few 100 joint design.
When the laser light is absorbed, it is |j.m. The fiber-optic can then
transformed into heat. This heat is con- convey the light to the work
ducted into both the top and bottom parts area. As the light exits from
where it softens and melts both parts. the fiber-optic it again begins to diverge,
Through the application of a clamping and is once again refocused through a lens
pressure, the melted regions of both parts and delivered to the area to be welded.
are brought into intimate contact. The The amount of energy delivered to the
forces created by the thermal expansion of work area is governed by the size of the
the materials and the externally applied laser spot at the weld interface, travel
clamping pressure compel a mixing of the speed of the laser beam, and the amount
melted areas to take place. Upon rapid of energy supplied by the diode laser mod-
cooling, the weld is formed. All of this can ule, minus losses for coupling efficiency of
occur in a fraction of a second Fig. 3. the optics.
To achieve transmission welding of ther- The input amperage supplied to the
moplastics, the two parts to be welded are diode laser control determines the
chosen so as to have considerably different amount of energy delivered by the diode
optical absorption properties at a particular laser module. A correlation of supplied
wavelength. The optical characteristics of amperage to delivered power can be de- Fig. 4 Contour welding.
the top part should be as transmissible to termined for each laser module. The op-
the laser wavelength as possible. Specially erator predetermines what power will be
pigmented products are available that allow needed for welding and inputs the corre-
for tinting of the top piece to make it appear sponding amperage into the controller. contour welding affords, it also offers the
visually opaque while still remaining trans- Most welding of thermoplastics is per- option of temperature feedback control of
missive to the laser beam. Laser absorption formed at energy levels of less than 150 W. the weld via closed-loop control of the
of the top part should be kept to a minimum The size of the laser spot is set by the power and variable weld size through ad-
to allow as much energy as possible to reach distance between the focusing lens and the justment of the focal distance.
the weld interface. If excessive laser energy laser-absorbing part, and is determined by In most contour welding applications,
is absorbed by the top part then it may start the focal length of the lens. The working the clamping force necessary to achieve a
to degrade before the bottom part has been distance can be set so that the interface for weld is supplied from an external clamp-
exposed to sufficient energy to allow for a welding can lie above or below the focal ing mechanism. This could be as simple as
weld to be created. The optical characteris- point of the lens, depending on the appli- either pressing up against a piece of glass
tics of the bottom part should allow a high cation. Spot sizes of 1 to 2 mm are recom- or using a metal frame to press adjacent to
absorption of the laser wavelength in as thin mended for welding, but the spot size can a weld area Fig. 4. In a variation of the
of a layer as possible. Combining these two be varied from as small as 0.6 mm to as contour technique, the patented Globo
optical characteristics ensures that a high large as several mm. technique offered by Leister supplies the
amount of the laser energy will be absorbed The main advantage of spot or contour clamping force necessary for welding as an
at the interface between the two parts, and welding is the flexibility this process offers integral part of the optic delivery system.
result in a more efficient use of the energy with virtually any programmable welding For this method, a glass sphere riding on
in producing a weld. The reflectivity of both path. Each weld path can be saved as a file an air bearing in the laser optic head pro-
parts should always be kept to a minimum in a Windows-based format, and chang- vides the clamping force while allowing
to reduce the loss of laser energy. ing between paths is as easy as opening a the laser energy to pass through the ball
The laser energy necessary for welding new file. In addition to the flexibility that lens to the workpiece Fig. 5.
WELDING JOURNAL
Fig. 6 - Simultaneous welding circle. Fig. 7Mask welding.
ties tend to be less than for contour markets because of its ability to produce
welding, but for certain high-volume very precise weld lines. In addition, mask
applications, simultaneous welding welding has also found a market where
may be the answer, especially if mul- large areas must be welded quickly.
tiple programs are not desired.
Conciusion
Fig. 5 Globo welding of a taillight assembly. Mask Weiding
As the benefits and opportunities for
Mask welding utilizes the same using thermoplastics for components and
transmission welding principles as assemblies increase, design and process
Line Welding the contour and simultaneous meth- engineers will be called upon more often
ods. It also requires the same externally to join these materials. Understanding the
Line welding refers to the use of a laser applied clamping pressure. Like simulta- welding methods used for joining plastics
line for welding. Instead of focusing the neous welding, mask welding also uses a and how these methods compare with
light emitted from the diode module to a laser line to produce a weld. Mask welding metals joining processes will make the
spot, the light is collimated and shaped differs from the simultaneous process in transition much easier.^
into a line. Typical weld line dimensions that it incorporates the use of a mask to
are 1 to 2 mm wide and can vary up to 120 block the transmission of the laser line as References
mm in length. This line can then be used the line is scanned over the part Fig. 7. 1. National Inventors Hall of Fame
to weld as a stationary line (simultaneous) The mask shape determines the pattern of Web site, www.invent.org.
or as a moving line (mask). Line welding weld produced, and its precision is signifi- 2. Semiconductor Laser Web site. www.
uses the same transmission welding prin- cant in determining the accuracy of the pangaea.dhs.org/school/el51/history.html.
ciples as spot welding. final weld. A precise mask is produced 3. Hessler, T 1999. Promising technol-
using photolithographic removal of pre- ogy: Laser welding of plastics. Euroforum,
Simuitaneous Line Weiding determined portions of a metallic-coated Oct. 26, 27.
glass, producing a finite pattern. The pat- 4. Sam's Laser FAQ Diode lasers.
Simultaneous welding utilizes one or tern can be as varied as required by the ap- www. repairfaq. org/sam/laserdio. htm #diocss.
more laser lines to produce a weld along a plication.
part's contour. Each laser diode is turned The mask is accurately positioned over
on at precisely the same time to allow an the parts to be welded and the clamping
entire contour to be welded simultane- fixture. The laser line is then scanned over
ously. Part geometries for simultaneous the mask. The mask acts to selectively
welding have been traditionally restricted block the laser light from entering into the
to square or rectangular shapes. It is now part. Where the laser light is allowed to
possible, however, to produce circular enter, welding is achieved. Using the mask
lines by utilizing special optic lenses welding process it is possible to produce
Fig. 6. Again, the typical line widths are 1 an area of weld instead of just a line of
to 2 mm. The optic lens can be changed to weld.
vary the diameter of the circle pattern The main advantage of this process is
from 2 to 50 mm. that it allows for very precise and very fine
The main advantage of simultaneous weld lines. Weld lines as narrow as 100 |im Change of Address?
welding lies in the short cycle time re- have been successfully made with the
quired for completing a weld. The part is mask welding process. In addition, this Moving?
positioned beneath the laser diode mod- process allows the possibility of producing
ules, and an external clamping pressure is welds with elaborate structures or con- Make sure delivery of your Welding
applied. The diodes are turned on, and the tours. During one weld sequence, it is Journal is not interrupted. Contact the
weld is achieved. No movement of the plausible to weld lines with different Membership Department with your
laser light or the parts is required during widths and shapes, as well as whole areas new address information (800) 443-
the weld cycle. Generally, the initial setup of the weld (Ref. 3). 9353, ext. 217; smateo@aws.org.
required for welding takes longer than the The mask process has found a strong
setup of a contour path, and energy densi- foothold in the medical and microfluidic
M MARCH 2009
AWS Robotic Arc Welding Conference
and Exhibition 2009
Expanding the Use of Robots in Arc Welding Beyond Traditional Applications
Sponsors;
American Welding Society Milwaukee Section
AWS D16 Committee
Caterpillar
Milwaukee Area Technical College
May 11-13
Many manufacturers shy away from automation in weiding This three-day event will incorporate many of these new
because their applications are unconventional. Short-run jobs, technologies and nontraditional applications. It will benefit the
large pieces, and even one-off jobs have historically been poor company researching automation as a new application, and
fits for Robotic Welding. With new technologies, automation those using automation successfully and working to stay
can be effectively applied, with cost and quality benefits, in current with new technologies. The conference will include a
many applications where it was not possible in the past. Many one-day tour at Caterpillar's Aurora facility and presentations
new technologies also are being introduced that can benefit discussing the successful implementation of new technologies.
the "conventional" robotic welding application.
If you are interested in exhibiting, registering, or learning more about this event, please contact:
Karen Gilgenbach, 262-613-3790 or Karen.gilgenbach@airgas.com
For conference details: www.aws.org/sections/milwaukee
For Info go to www.aws.org/ad-index
Butt joints on production-scale thin-steel panels were successfully made
with a hybrid laser-arc process in a shipyard environment
The use of thin steel (less than 10 mm in industrial applications. Recently, search Laboratory at The Pennsylvania
thick) in shipbuilding has increased signif- HLAW has begun making inroads in Eu- State University under commercial- and
icantly in the last 20 years, from less than ropean shipyards as well as U.S. industry government-sponsored research and de-
10% before 1990 to greater than 90% in (Refs. 4, 5). Coupled with the awareness velopment programs has been directed at
2000 (Ref. 1). The increased use of thin of HLAW capabilities are significant ad- the use of HLAW technology for joining
steel is driven by ship designs requiring a vances in available fiber-delivered laser thick-section high-strength steel (Ref. 9),
reduction in weight, offering performance technologies. Significant improvements steel pipe (Refs. 10, 11), and thin steel
increases in the final product. At the same in flexibility, compactness, reduced main- panel structures (panel seams, inserts, and
time, U.S. shipyards have faced difficulty tenance, improved electrical efficiency, stiffeners) (Refs. 12,13). This article fo-
in dealing with the inherent problems in potential for time-sharing capability, and cuses on the welding process improve-
fabricating large structures with thin ma- reduced capital investment per kilowatt ments measured during a demonstration
terial, and, as a result, have experienced of delivered power make HLAW attrac- of HLAW technology conducted at Gen-
significant cost increases due to problems tive for implementation in the U.S. heavy eral Dynamics Bath Iron Works.
associated with distortion. Currently em- manufacturing industry (Refs. 6-8).
ployed high-heat-input welding processes The hybrid laser arc welding process Conventional Processing
are responsible for much of this distortion. used in this work and depicted in Fig. 1 em-
Moreover, it has been estimated that weld- ploys laser beam welding (LBW) and gas Conventional welding processes such
ing of panel seams leads to significant ad- metal arc welding (GMAW) in a combined as submerged arc welding (SAW) offer
ditional costs during fabrication of major process that overcomes deficiencies en- low capital equipment cost and are read-
naval platforms. In order to increase countered with each individual process. ily implemented in the production envi-
affordability of ships built for the U.S. Specifically, laser beam welding provides ronments of U.S. shipyards. One signifi-
Navy, alternative low-distortion welding improved penetration at relatively fast cant drawback to conventional welding
processes must be developed, demon- travel speeds; however, difficulties are en- processes is the high level of heat input
strated, qualified, and implemented. countered with the ability to add filler necessary. Heat input (kJ/in.) to the part
It has been more than a quarter of a metal and meet joint root opening toler- has been shown to be proportional to weld
century since researchers first considered ance requirements experienced in the ship- distortion. Buckling distortion is espe-
combining a conventional welding arc yard production environment. Gas metal cially problematic in thin panel structures
with a laser beam in a hybrid process arc welding is efficient at adding material since the critical buckling strength is pro-
(Refs. 2, 3), but only recently has com- resulting in a higher root opening toler- portional to the thickness squared. For ex-
mercial laser technology advanced to a ance; however, automated welding speeds ample, the critical buckling strength in 10-
point allowing hybrid laser gas metal arc and depth of penetration are limited. mm plate is four times greater than in 5-
welding (HLAW) has begun to take hold Ongoing research by the Applied Re- mm plate, while the welding-induced lon-
S. M. KELLY, S. W. BROWN, J. F. TRESSLER, and R. P. MARTUKANITZ are with Applied Research Laboratory, The Pennsylvania State
University, State College, Pa. M. J. LUDWIG currently is with Cianbro Corp., Pittsfield, Maine. He was formerly with General Dynamics Bath
Iron Works, Bath, Maine.
MARCH 2009
gitudinal residual stress levels are rela-
tively constant for this range of thick-
nesses (Ref. 1). Masubuchi summarized
the relationship between heat input and
distortion for welding of 0.25-in. steel pan- Focused Laser Beam v
els (Ref. 14). The data presented by Ma-
subuchi indicate that a 1% increase in heat
input can correspond to a 24.7% increase
in out-of-plane distortion in 0.25-in.-thick Keyhole ^ m Gas Metal Arc
steel stiffened panel structures. \ IMms^ Welding Torch
The current shipyard welding process Inert Shielding Gas v \ 1 .1m
for butt-joint welding of 5-mm panel
seams and inserts, SAW, imparts approxi-
mately 5.6 times as much total heat than \ \ ^^r ^ Electric Arc
the hybrid welding process (Ref. 15). The
tandem submerged arc welding (TSAW) Work-piece v \ \ . ^^
\ \ \1 ' ^^ Molten Pool
process, which is receiving considerable
interest from shipyards because of its po-
tential for increased productivity, imparts
approximately 3.8 times as much heat than
a hybrid welding process for 5-mm butt-
joint welds (Ref. 16). These relatively high
levels of heat input are driven by joint
beveling and minimum root opening re-
quirements for conventional arc welding
processes, which in turn, increases the Fig. 1 Hybrid laser arc welding process (laser leading).
amount of filler material and hence en-
ergy needed to melt that material. Figure
2 provides a visual comparison of the Table 1 Demonstration Panel Fitup Measured Prior to Welding
larger fusion zones associated with SAW
compared to HLAW Sequence Type Length (ft) Root Opening Range (in.)
Hybrid Panel ' SAW Panel
Distortion Comparison in 1 Butt/Insert 20 0 to 0.030 0 to 0.030
Produotion-Scaie Paneis 2 Insert 5.5 0.030 to 0.083 0 to 0.040
3 Insert 5.75 0 to 0.030 0 to 0.020
4 Insert 5.75 0 to 0.030 0 to 0.050
Over a period of three weeks in Janu-
ary 2008, a hybrid laser arc welding
demonstration was held at Bath Iron
Works Harding Facility in East Brunswick, The demonstration allowed for direct ing process while maintaining alignment
Maine. The BIW Harding Facility is a pri- comparison of HLAW and SAW processes with the joint (without optical or tactile
mary fabrication plant that produces pan- on the basis of welding process character- joint tracking). The system also was re-
els and assemblies that are shipped over istics (weld time, heat input, and consum- quired to serve as a Class 1 laser enclosure
road to the main shipyard. The objective able usage) and welding distortion. while providing adequate exhaust gas flow
was to demonstrate the technical and eco- To accomplish the HLAW process management. Figure 3 shows the system
nomic feasibility of the HLAW process demonstration, a portable welding system hybrid welding a 20-ft panel joint at BIW.
within the current shipyard production en- was required that could provide stable lin- The system resulted in a successful and
vironment on production-scale panels. ear motion of the laser beam and arc weld- safe demonstration of hybrid welding tech-
Fig. 2 Macrographs of weld cross sections in 0.197-in.-thick DH36 steel welded with the following processes: A Single-pass HLAW; B
double-sided SAW. Both were prepared with a machined square-butt joint with no root opening.
WELDING JOURNAL
T-0-375 in. DH36
Chamfer Edge to DeL A
T = 0_188in_DH36
Fig. 5 A HLA W and B SAW demonstration panels comparing the magnitude of out-of-plane distortion adjacent to the insert after
welding. The out-of-plane deflection from a flat position is indicated (the value includes the plate thickness).
nology in the shipyard; however, improve- spot welds placed approximately 6 to 12 The SAW process was tractor-driven
ments including the addition of joint track- in. apart. The HLAW panel was also au- with a nominal travel speed of 30 in./min,
ing and development of a more portable togenously laser tack welded at 12-in. arc voltage of 30 V, and 63 in./min wire
system would be necessary prior to being spacing. Run-on/off tabs were manually feed rate. An 0.125-in.-diameter EM12K
effectively used in production. It is worth GMA welded at the start and end of the electrode and F7A2 flux were used. The
noting that the HLAW process is capable first weld in the sequence. The fitup of joint preparation required the use of a
of being implemented in a highly mecha- the two panels was measured prior to two-sided weld. The first side was welded
nized or fully automated arrangement welding and reported as a range for each with an average heat input of 17 kJ/in.
with manipulation of the laser focusing op- weld sequence in Table 1. The panels were while the second side was welded using an
tics, GMA torch, and ancillary equipment not restrained, and the insert radii were average of 23 kJ/in. The total heat input
achieved via mechanized welding tractors not welded in either panel. to weld both sides of the panel was ap-
or fixed large gantry manipulation. The single-pass hybrid laser arc weld- proximately 40 kJ/in.
The demonstration panels, shown ing process utilized an ytterbium-fiber Figure 5 compares postwelding distor-
schematically in Fig. 4, consisted of a laser operating continuously at 4500 W of tion along the longitudinal edge on the in-
0.188-in.-thick panel and a 0.375-in.-thick power, and a pulsed GMA process with a sert side of both the HLAW and SAW pan-
insert. The panel and insert were fabri- mean voltage of 24.2 V and nominal wire els. This region of the panel experienced
cated of ABS DH36 high-strength struc- feed rate of 330 in./min. The laser led the the greatest out-of-plane (z) distortion in
tural steel. Edge preparation included arc, with the laser beam focal spot and both panels due to the increased stiffness
high-definition, plasma-cut square-butt electrode separated by 0.24 in. Welding associated with the insert. The measured
joints and grinding away of primer ap- was conducted at a linear travel speed of out-of-plane distortion was 0.95 in. and
proximately 0.5 in. from the weld joint. 60 in./min. For the second weld in the se- 2.53 in. for the HLAW and SAW
The panel was supported above the shop quence (having a maximum root opening processes, respectively.
floor using lengths of 3-in.-wide C-chan- of 0.083 in.), the laser power was set to Out-of-plane distortion was measured
nels arranged parallel to the 20-ft panel 3275 W, and the wire feed speed was in- before {zb) and after (zfl) welding using a
dimension and spaced nominally 24 in. creased to 615 in./min along the joint laser displacement sensor that was
on center. C-channel was also placed be- length to provide the required fill (nomi- scanned across the plate surface. The dis-
neath the four welded joints, in a "con- nal voltage was 30.7 V). The average heat placement sensor is capable of accurately
vex" fashion, to permit complete-joint- per unit length of weld was 10 kJ/in. for measuring height differences less than
penetration hybrid welds. Panels were fit the entire panel. The welding consum- 0.005 in. The change in plate shape (Az
and tacked by shipyard personnel using ables used were ER70S-6, 0.045-in.-diam- = za-zb) was calculated over a 6-in.-
standard shipyard practice, which in- eter electrode and Ar-10CO2 shield gas square grid from the obtained data. The
cluded 0.5-in.-diameter manual GMA flowing at 95 ft3/h. resulting change in plate shape for the
MARCH 2009
Fig. 6 Change in demonstration panel shapes following A - HLAWand B SAW. The Az axis has been magnified by 230 times (com-
pared to x andy) in both A and B.
WELDING JOURNAL
weld metal tensile, and References
weld metal Charpy im-
pact testing were con- 1. Huang, T D. et al. 2003. Northrop
ducted for informa- Grumman Technology Review Journal.
tional purposes. The 2. Steen, W M., and Eboo, M. 1979.
results indicated that Metal Construction 11(7): 332.
hybrid laser arc weld- 3. Steen, W M. 1980. Journal of Applied
ing processes could be Physics 51(11): 5636.
qualified to current 4. Defalco, J. 2007. Practical applica-
i
NAVSEA standards tions for hybrid laser welding. Welding
for 5-mm-thick DH36 Journal 86(10): 47.
base material and 70S- 5. Staufer, H. 2007. Laser hybrid weld-
6 electrode. The pro- ing in the automotive industry. Welding
gram is currently sup- Journal 86(10): 36.
porting HLAW 6. Shiner, B. 2008. Nat Photon 2(1): 24.
process development 7. Brockmann, R. et al. 2007. Presented
and initiating weld at the International Congress on Appli-
Fig. 7Process cost per foot comparison for double-sided SAW, procedure and per- cation of Lasers and Electro-Optics 2007,
and single-sided HLA W in 0.188-in. -thick AB/DH36 steel. formance qualification Laser Materials Processing Conf., Or-
ofDH36andHSLA-80 lando, Fla., p. 866.
are a wide range of estimates as to the steels in 0.188- through 0.5-in. thicknesses. 8. Martukanitz, R. P. 2005. A critical
costs associated with flame straightening: review of laser beam welding. Proceedings
Summary of the Internatinal Symposium on Lasers
The cost of correcting distortion in a and Applications in Science and Engineer-
0.188-in.-thick panel by flame straight- Hybrid laser arc butt-joint welding has ing, San Jose, Calif. Vol. 5706.
ening was reported to be $1.50/ft2 in been successfully demonstrated in a ship- 9. Roepke, C, and Liu, S. Welding Jour-
1996 (estimated to be $2.14 in 2008) yard production environment on produc- nal (to be published).
(Ref. 18). tion-scale thin-steel panels. The results of 10. Reutzel, E. W, Sullivan, M. J., and
the technology demonstration allow for a Mikesic, D. A. 2006. Joining pipe with the
In general, distortion rework costs were
direct comparison with submerged arc hybrid laser-gmaw process: Weld test re-
reported to be approximately $23.00/ft2
welding. The resulting process perform- sults and cost analysis. Welding Journal
in 1996 (estimated to be $32.79 in 2008) 85(6): 66.
ance metrics for productivity, heat input,
(Ref. 18).
distortion, and filler metal used are re- 11. Reutzel, E. W et al. 2008. Journal
ported in Table 3. The estimated process- of Ship Production 24(2): 72.
Pattee et al. reported experimentally de-
termined times to flame straighten ing cost of hybrid laser arc welding of butt 12. Kelly, S. M. et al. 2006. Applied Re-
joints is $0.41/ft and the distortion rework search Laboratory, The Pennsylvania
shipbuilding steels of thicknesses rang-
cost savings could range from $0.45 to State University, Technical Memoran-
ing from 0.375 to 0.75 in. (Ref. 19).
Based on these reported times and as- $13.72/ft2. The ongoing efforts of the pro- dum, Low heat input welding for thin
gram will continue to mitigate risk asso- steel. Report No. TM 06-057.
suming that flame straightening prima-
ciated with weld qualification and cost of 13. Kelly, S. M. et al. 2006. Journal of
rily occurs during the unit fabrication
implementation.^ Ship Production 22(2): 105.
step, the cost for correcting distortion
in 0.188-in.-thick steel is estimated to 14. Masubuchi, K. 1980. Analysis of
Welded Structures. Pergamon Press.
be $65.33/ft2. Acknowledgments
15. Kvidahl, L. 2007. Personal commu-
The three flame straightening cost es- nication.
The authors express their sincere grat-
16. Porter, N. 2007. High-speed tan-
timates and the experimentally deter- itude to the following people for their con-
dem SAW. Presented at the AWS 5th
mined distorted square footage for tributions and support: G. Woods (ONR
Charting the Course in Welding: U.S.
HLAW and SAW demonstration panels ManTech Program); E. Good, J. McDer-
Shipyards Conference.
(6 and 74 ft2, respectively) were used to mott, B. Rhoads, C. Sills (Applied Re-
17. U.S. Department of Defense, Fab-
estimate the potential cost savings for a search Laboratory at The Pennsylvania
rication, Welding, and Inspection of Ships
HLAW process. The results indicate that State University); D. Brown, D. Dennis,
savings due to reduced distortion using Structure, Report No. MIL-STD-1689A
W Thidobeau, K. Elwell, D. Bisson, K.
(SH), 1990.
the HLAW process could range from Leavitt, E. Ingstrum, G. Marquis (Gen-
18. EWI, Navy Joining Center. 1996.
$0.45/ft2 to $13.72/ft2. eral Dynamics Bath Iron Works); R. Wong
Results of empirical evaluation of tech-
(Naval Surface Warfare Center-Carde-
niques to control distortion in thin section
Ongoing Efforts rock Div.); and L. Kvidahl and T D.
panels. Report No. 40113GNF.
Huang (Northrop Grumman Ship Sys-
19. Pattee, H. E., Evans, R. M., and
Through the supporting Navy Manu- tems).
Monroe, R. E. 1970. Effect of flame and
facturing Technology program, benchmark This material is based upon work sup-
mechanical straightening on material
welding procedure qualification testing of ported by the Office of Naval Research
properties of weldments. Report No. SSC-
HLAW 5-mm-thick DH36 has been con- through the Naval Sea Systems Command
207, Ship Structure Committee.
ducted in accordance with NAVSEA under contract N0024-02-D6604 DO 361
20. NAVSEA 1995. Requirements for
S9074-AQ-GIB-010/248 requirements and DO 432. Any opinions, findings, con-
welding and brazing procedure and per-
(Ref. 20). The test matrix included visual clusions, or recommendations expressed
formance qualification. Report No.
inspection, radiographic inspection, and in this article are those of the authors and
NAVSEA S9074-AO-GIB-010/248.
transverse bend and tensile testing re- do not necessarily reflect views of the Of-
quired for the base material. In addition, fice of Naval Research or the Naval Sea
longitudinal bend testing, microhardness. Systems Command.
MARCH 2009
MEXICO MEXICGH
Working together to bring the latest welding, fabricating and metal forming technology to the Mexican market
region in Mexico.
8,000 attendees
WiH
60,000 sqf
400 exhibitors
For more information on reserving booth space for this exciting event, contact:
Three-dimensional laser material pro- key to this flexible production, allowing is perfect for achieving good and reliable
cessing has benefited in recent years from the quick change of the processes just by results. Thus, even machines with moder-
the developments in high-brightness disk automatically changing the gas type and ate accuracy such as articulated robots can
and fiber lasers. The advantages of these flow rate, focal and nozzle position, and operate at higher speeds than usual.
lasers are fiber-coupled beam guidance, laser power and speed. The so-called "au- Nonlinear tailored blanks processed
high beam quality, high laser efficiency, tonomous nozzle" provides the gas jet for with the combi-head demonstrate the
good pulsability, small size, and decreased cutting and the shielding gas for welding identical path concept. Figure 1 shows a
investment costs. Additionally, the inher- (Ref. 5). The unique concept of the coax- specimen machined with a 6-axis robot.
ent advantages shortened process ial nozzle design permits an open space As shown in the figure from left to right,
chains, high flexibility, and accuracy of between the optics and nozzle (even dur- the edges are first prepared by laser cut-
combination processing in which cutting ing cutting) for the integration of a cross- ting, then put together, and welded along
and welding are accomplished with the jet. This jet is essential in order to protect the same path. Finally, cuts in the welded
same processing head make 3-D laser pro- the optics from smoke and spatter during blank are precisely positioned to each
cessing ever more attractive (Ref. 1). the welding process, when we require only other. Even the limited accuracy of a robot
What makes brightness relevant for a low volume, smooth gas flow from the at a cutting and welding speed of 8 m/min
combined cutting and welding is the en- coaxial nozzle. provides constant good weld joints, be-
larged operating window allowed for Combi-processing has several economic cause only the reproducibility of the same
changing head distance. A "slim" focal advantages compared to individual cutting path is required. Besides tailor-welded
zone of a bright enough laser allows for and welding systems. These include short, blanks, another application of the identi-
cutting narrow kerfs with a small nozzle integrated process chains; high machine uti- cal path concept is the processing of coils
standoff and for excellent welding condi- lization; flexible and cost-efficient produc- to produce "endless" coil material by laser
tions with a larger standoff with the same tion of variants; and savings in handling, trimming the ends of coils and laser weld-
nozzle even without changing the focal positioning, and clamping of parts. ing them together. Figure 2 shows cutting
distance relative to the nozzle exit (Ref. 2). Also, the following technological ad- and welding speeds on automotive sheets
A new combi-head design for machines vantages can be listed: identical tool cen- with 4.0-kW laser power from a fiber laser
with integrated beam guidance is pre- ter points (TCP) for both cutting and with a 150-|im-diameter fiber. With
sented in this article. The design results welding; and the free choice of an opti- smaller fiber diameters, i.e., higher beam
in improved features for optimized 3-D mized sequence of cutting and welding op- quality, even higher speeds are possible.
processing. Furthermore, a programma- erations with respect to technical and eco- On the other hand, if an application does
ble laser modulation control allows a high nomic criteria. These features enable not require or cannot handle such high
variation of speeds in 3-D contours and higher accuracy and shorter tolerance speeds, a laser with lower power can be
leads to burr-free cuts in the complete chains. For example, no tracking system used, with corresponding cost reductions.
speed range of the application. is needed for welding because the edges
A typical application of the 3-D combi- can previously be cut with the combi-head Essentials for 3-D
head technology is illustrated by means of and thus the coordinates of the weld track
trimming, aperture cutting, and welding along these edges are perfectly known by Capability
operations on automotive B-pillars. the system. Since the TCP remains the
same when welding, the path for the weld Those examples show that there are
joint is precisely defined within the ma- reasonable 2-D applications for combi-
Added Value by Combi- processing, but typically the welding in
chine coordinates.
Processing combi-processing is used to manufacture
3-D assemblies from 3-D raw parts such
The possibility of carrying out laser The Identical Path Concept as deep-drawn sheets, blanks, profiles, or
cutting and welding operations on one Whenever cutting and welding opera- tubes. Hence, the following 3-D capabili-
machine without changing the process tions in combi-processing can use an iden- ties from the machine, the processing
head offers many benefits in laser pro- tical path with the same clamping, the pre- head, and the process are required:
cessing (Refs. 1-4). The combi-head is the cision in repeating the cut/weld contour Appropriate machine kinematics, pro-
DIRK PETRING (dirk.petring@ilt.fraunhofer.de) and FRANK SCHNEIDER are with Fraunhofer-Institute for Laser Technology ILT,
Aachen, Germany.
MARCH 2009
Edge preparation by laser cutting Laser weiding Cuts in weided biank
1,5kW, N,11 bar 2,2 kW, Ar 15 l/min 1,5 kW, N,11 bar
1 1.7 2
sheetthickness / mm
WELDING JOURNAL
distance sensor
autonomous nozzle
Fig. 3 Combi-head on a gantry robot with axis- Fig. 4 Low-speed cutting affects quality: backside of a sheet with
integrated beam guidance. three cuts and photos of corresponding cut edges, all cut at a speed of
1 mlmin. Top: laser power 2 kW, cw; middle: laser power 0.5 kW, cw;
bottom: laser power 0.5 kW (average), peak power 2 kW, pulsed with
f = 250 Hz, duty cycle 0.25.
matically by the machine control being overlapping of pulses individually for each robot (RLP16 from Reis) with a Laserfact
programmed accordingly. And, of course, velocity. In addition, by adapting the am- combi-head F2-X Fig. 6. The laser
the combi-head allows precise manual ad- plitude, the depth and level of the modu- source was an IPG fiber laser YLR4000
justment of the laser beam focus in lateral lation are tuned according to the required SS with a 100-|a,m-diameter process fiber.
and axial direction. process characteristics. The large contours were cut at 15 m/min,
A suitable beam quality and the cor- the holes at 3-9 m/min, depending on their
rect layout of the collimation and fo- 3-D Applications diameter and the material thickness. For
cussing optics according to the demands the smallest radii, the pulsed mode was
of the combined processes are the crucial The impact of the features that sup- used. The welding speed was 3 m/min for
boundary conditions to be successful with port 3-D performance (high beam qual- the lap weld through the reinforcement
the above-described concept. ity, an optimized combi-head, and the plate (1.3 mm) and the pillar (1.4 mm).
modulation control) is demonstrated in The maximum laser power was 2.5 kW.
Laser Power Modulation an automotive application example, Depending on the details of the cut con-
namely combi-processing of a B-pillar. tour, the overall processing time for cut-
Depending on the contour involved, Driven by the use of modern hot-formed ting and welding a B-pillar as in Fig. 5 is
the speed of the tool center point (TCP) high-strength steels for crash-relevant car in the range of 1 min.
can vary dramatically in 3-D applications. body components, laser trimming and cut- Another demonstration of combi-pro-
A factor of 10 or 20 between speeds on ting of apertures in these parts is well es- cessing capabilities is the possibility of
straight paths and around small radii is tablished because those materials are dif- welding a circular joint just before pre-
not unusual. Reduced quality occurs in ficult to cut mechanically. With the avail- cisely cutting the holes at the edge of the
low-speed sections in the form of burrs ability of combi-processing, it even be- weld joint to produce a gap-free, sealed
when cutting and irregular joints during comes possible to integrate welding oper- hole, preventing subsequent crevice cor-
welding. In combi-processing, as in stan- ations into the process chain with the same rosion Fig. 7. The coordinates of the
dard cutting or welding, a simple laser setup leading to the benefits already weld are known in the machine and with
power control with respect to speed is an discussed. an identical path plus an offset, a precise
effective answer for some of the problems First, several holes are cut into the position of the cut relative to the weld is
due to speed variation. However, to B-pillar. Second, the final dimensions are possible thanks to the common TCP for
achieve a burr-free cut quality over the cut. Next, a reinforcing sheet is welded on cutting and welding. As both processes
whole speed range, an adaptive laser the pillar and, finally, holes are cut can be done one after the other, there is
power modulation is necessary Fig. 4. through the reinforcing sheet and the no additional positioning. Another option
A programmable laser modulation con- B-pillar Fig. 5. is the welding on of additional functional
trol has been developed that allows us to All operations are performed in one parts such as nuts, studs, or mounting
adapt modulation frequency, duty-cycle, clamping, thus high positional tolerances plates.
and amplitude of the laser power to the between the outer contour and the holes, In fact, there are many possibilities for
effective speed. By the control of pulse including those in the weld-on part, are intelligent process chains opened up by
frequency and duty cycle, it is possible to guaranteed. the integration of laser cutting and weld-
adjust both the average power and spatial The processing was done on a gantry ing processes in a flexible manufacturing
1. Welding 2. Cutting
environment. And beside the improve- Fig. 6 Combi-head at work. Cutting and welding process on the B-pillar with a gantry-
ment of existing processes, completely robot. (Photo courtesy ofLaserfact GmbH.)
new product designs are also possible and
can be cost-efficiently manufactured.
A speed-adapted laser power modula- and welding: Laser beam quality enhances
Conclusions tion control.^ process efficiency and flexibility. 2nd In-
ternational Workshop on Fiber Lasers,
For 3-D combination processing with Acknowledgments Dresden, July.
high-quality results at economically at- 3. Schneider, F, Petring, D., and
tractive processing times, the following The work has been partially funded by Poprawe, R. 2005. Integrated laser pro-
elements are essential: the German Federal Ministry of Econom- cessing Cutting and welding with a
ics and Technology BMWi in the InnoNet- combined processing head. Proceedings of
A 3-D machine or robot with high dy- Program (koLas, 16IN0426). We would LIM, 3rd International WLT-Conference on
namic response and accuracy, such as a like to thank our industrial project part- Lasers in Manufacturing, Munich, Ger-
gantry robot with linear direct drives ners Reis Robotics, Laserfact, and LBBZ many, June 13-16, pp. 133-135.
and integrated beam guidance. for their cooperation. 4. Petring, D. 2008. Enhanced capabil-
ities of laser welding by hybridization and
A laser with a fiber-coupled beam de- combination techniques. Proceedings of
livery and good beam quality such as a References the 70th Laser Materials Processing Con-
fiber or disk laser. ference ofJLPS, Osaka, Japan, May 27, 28,
1. Petring, D. 2005. One head does it pp. 7-12.
A combi-head, featuring optimized 3- all New technology allows 3-D laser 5. Petring, D. 2005. Laser cutting and
D capabilities as a result of its slender beam cutting and joining. Welding Journal welding with one tool. The FABRICATOR,
design, short length, and fast distance 84(8): 49-51. October, pp. 40, 41.
control with a dynamic z-axis. 2. Petring, D. 2006. Combined cutting
WELDING JOURNAL
CONFERENCES
International Brazing & Soldering Conference come into use the problem comes back in different forms to haunt
the welding metallurgist. A crack costs money, takes time to re-
Orlando, Fla. pair, and interrupts production. So where does one go for help?
April 26-29 The experts will be at Weld Cracking VII. You will obtain an-
swers to your current problems and will be better prepared to
This three-day conference will provide one of the most com- solve cracking problems in the future. You can also learn about
prehensive technical programs available to the brazing and sol- the latest equipment including induction heating, a wireless heat-
dering communities. You'll discover the latest trends, products, treat system, and portable X-ray diffraction equipment. The use
processes, and techniques available. Join hundreds of other pro- of fracture mechanics will be explored. Descriptions will be given
fessionals, scientists, and engineers from around the globe who on the heat-affected zone and on the many types of cracks that
are involved in the research, development, and application of accompany welding. Base materials covered will include various
brazing and soldering in valuable networking opportunities, pre- steels, the stainless steels, aluminum, and titanium.
conference educational programs, and exhibits.
Thermal Spray and Coatings Conference
12th Aluminum Welding Conference November 16
Toronto, Ont., Canada
May 5 and 6 Welding of Chrome-Moly Steels Conference
November 17
A panel of aluminum industry experts will survey the state of
the art in aluminum welding technology and practice. You will The welding of chrome-moly steel goes back to the days when
also have the opportunity to network with speakers and other tubing was oxyacetylene welded to make up the fuselages of the
participants, as well as to visit an exhibition showcasing products early prealuminum airplanes. It all required outstanding preci-
and services available to the aluminum welding industry. sion on the part of the welder, and even though the methods have
Aluminum lends itself to a wide variety of industrial applications changed, the welding of 4130 steel still requires utmost precision.
because of its light weight, high strength-to-weight ratio, corrosion The welding of chrome-moly steels requires great skills on all par-
resistance, and other attributes. However, because its chemical and ties involved, and not just the welding: heat treatment and non-
physical properties are different from those of steel, welding of alu- destructive examination are essential to a successful weld. The 2%
minum requires special processes, techniques, and expertise. Cr-1 Mo steels are popular materials for boilers and pressure ves-
sels. More recently, the modified 9 Cr-1 Mo steel is now widely
specified in the electric utilities and is moving into the oil and gas
Shipbuilding Conference industry. Conventional welding processes are all used effectively
New Orleans, La. on 4130, 2/^ Cr-1 Mo and modified 9 Cr-1 Mo steels. Newer
June 16 and 17 processes such as hybrid welding have also become popular.
Welding is the most vital and fundamental manufacturing AWS/DVS Electron Beam Welding Conference
process in the construction of ships and metal hull boats. Keeping November 17 and 18
in tune with the progress of new innovative developments, as well
as their potential value and impact to the industry is essential for This event will include a two-day technical program and a half-
those in the shipbuilding community. This conference will address day tutorial. Join scientists, engineers, and technical personnel
the critical importance of welding in the shipbuilding industry by from around the globe who are involved in the research, devel-
providing current information on new and emerging technologies opment, and application of electron beam welding.
being developed for shipbuilding applications. The conference will
also provide opportunities for you to network informally with ex- Welding the Corrosion-Resistant Alloys Conference
perts from academia and industry, as well as with your fellow par- November 18
ticipants. An exhibition showcasing products and services avail-
able to the shipbuilding industry will also be featured. Interest in welding corrosion-resistant alloys is extraordinarily
high. The reasons include the entry of the duplex stainless steels
2009 FABTECH International & AWS Welding and other high-performance grades. Another is the unstable prices
in nickel, molybdenum, and titanium. When the price of nickel
Show Conference Schedule hit the roof, many fabricators switched from 316 to 201 stainless
Chicago, 111. because of the latter grade's lower nickel content. Research is
feverish throughout the world in the development of new and
Weld Cracking: "The Heat-Affected Zone" Conference cheaper methods of producing titanium. Will a lower-cost tita-
November 16 nium make the metal more popular? The overall activity is in-
tense. Cladding and strip overlay processes have become more
One of production welding's greatest moments, the construc- popular means of protecting parts exposed to heavy corrosion.
tion of the Liberty ships during World War II, was accompanied Duplex stainless is now being welded for over-the-road tankage.
by a new problem. Weld cracking was observed on some of these New processes, like friction stir welding and thermal stir welding,
ships, and the reason for the cracking was a mystery. The cause will be discussed. Keep abreast of this exciting new world in weld-
has since been determined, but as new metals and alloys have ing where corrosion-resistant alloys have taken center stage.
For more information, please contact the AWS Conferences and Seminars Business Unit at (800) 443-9353, ext. 455. You can also visit the
Conference Department at www.aws.org/conferences for upcoming conferences and registration information.
MARCH 2009
NORTH AMERICA'S LARGEST METAL FORMING,
FABRICATING & WELDING TRADE SHOW
More than 1,100 suppliers. New technology. Problem-solving solutions.
Joining Dissimilar Metals Conf. March 3,4, Orlando, Fla. Con- Welding Society, DSL.FORCE Technology. Send e-mail inquiries
tact American Welding Society, (800/305) 443-9353, ext. 455; visit to jom_aws@postl0. tele. dk.
www.aws.org.
AISTech 2009, The Iron & Steel Technology Conf. and Expo and
Laser Additive Manufacturing Workshop. March 3, 4, Holiday Asia-Pacific Partnership Technology Showcase 2009. May 4-7, St.
Inn, Riverwalk, San Antonio, Tex. As a cooperating society, AWS Louis, Mo. Contact Association for Iron & Steel Technology
members will receive discounted registration fees. Contact Laser www.iss.org.
Institute of America, www.laserinstitute.org.
Int'l Thermal Spray Conf. and Expo (ITSC). May 4-7, Flamingo
Lean for the Supply Chain. March 3-5, Crown Plaza Hotel, San Las Vegas Hotel, Las Vegas, Nev. Sponsored by ASM Int'l Ther-
Jose, Calif. Contact Society of Mfg. Engineers, (800) 733-4763, mal Spray Society, German Welding Society, and Int'l Institute of
www.sme.org. Welding. Visit www.asminternational.org/itsc.
GAWDA, Gases and Welding Distributors Assn., Spring Man- Offshore Technology Conf. May 47, Reliant Center, Houston,
agement Conf. March 22-24, Sheraton Chicago Hotel & Towers, Tex. Visit www.otcnet.org/2009.
Chicago, 111. Visit www.gawda.org.
12th Aluminum Welding Conf. May 5,6, Toronto, Ont., Canada.
ILSC Int'l Laser Safety Conf. March 23-26, John Ascuaga's Contact American Welding Society, (800/305) 443-9353, ext. 229;
Nugget Hotel, Reno, Nev. Sponsored by Laser Institute of Amer- visit www.aws.org.
ica, www.laserinstitute.org/conferences/ilsc; or call (407) 380-1553.
Robotic Arc Welding Conf. and Expo. May 11-13, Milwaukee
Spring Robot Safety Conf. March 23-25, Knoxville Marriott, Area Technical College, Milwaukee, Wis. Cosponsored by the
Knoxville, Tenn. Contact Robotic Industries Assn. at AWS Milwaukee Section and D16 Committee on Robotic and Au-
ria@informz.net or ria@robotics.org. tomatic Welding. Includes tour of Caterpillar's facility in Aurora,
111. Contact Karen Gilgenbach at karen.gilgenbach@airgas. com, or
ABB Automation & Power World 2009. March 24-26, Orlando call (262) 613-3790.
World Center Marriott, Orlando, Fla. Visit
www. abb. com/a&pworld. RAPID 2009. May 12-14, Renaissance Schaumburg Convention
Center, Schaumburg, 111. Contact Society of Mfg. Engineers, (800)
Heat Treating of Light Alloys. March 25, 26, Doubletree Hotel, 733-4763, www.sme.org/rapid.
Anaheim, Calif. Visit www.asmintemational.org.
Advanced Manuf. Expo, and Plant Maintenance & Design Engi-
WESTEC. March 30-April 2, Los Angeles Convention Center, neering Show. May 19-21, Place Bonaventure, Montreal, Que.,
Los Angeles, Calif. Contact Society of Mfg. Engineers, (800) 733- Canada. Contact Society of Mfg. Engineers, (800) 733-4763,
4763; or visit www.sme.org/westec. www.sme.org.
MicroMfg. and NanoMfg. Conf. & Exhibits. March 31-April 1, EASTEC. May 19-21, Eastern States Exposition Grounds, W
Sheraton Bloomington Hotel, Minneapolis, Minn. Contact Soci- Springfield, Mass. Contact Society of Mfg. Engineers, (800) 733-
ety of Mfg. Engineers, (800) 733-4763, www.sme.org/micro, 4763; or visit www.sme.org/eastec.
www. sme. org/nano.
AWS/Weldmex. June 2-4, Monterrey, Mexico. Contact Ameri-
North American Steel Construction Conf. and AISC Steel Con- can Welding Society, (800/305) 443-9353, ext. 229; or visit
struction Expo. April 1-4, Phoenix, Ariz. Visit www.aisc.org. www.aws.org.
2nd Annual Global Marine Renewable Energy Conf. April 15, Beijing-Essen Welding & Cutting Fair. June 2-5, Shanghai, China.
16, The Carnegie Institution for Science, Washington, D.C. Con- Visit www. beijing-essen-welding. de.
tacts (877) 463-3846; info@globalmarinerenewable.com.
AeroMat 2009 Conf. and Expo. June 7-11, Dayton Convention
The Aluminum Assn. Spring Meeting. April 20-22, Omni La Center, Dayton, Ohio. Call ASM customer service (800) 336-
Mansion del Rio, San Antonio, Tex. Visit www.aluminum.org. 5152, ext. 0; e-mail customerservice@asminternational.org; or visit
http://asmcommunity.asmintemational.org/content/Events/aeromat
GAWDA Spring Management Conf. 2. April 21-24, Asheville, 09/.
N.C. Sponsored by Gases and Welding Distributors Assn. Visit
www.gawda.org. Weld Cracking VII 'The Heat-Affected Zone' Conf. June 9, 10,
Columbus, Ohio. Contact American Welding Society, (800/305)
IBSC, 4th Int'l Brazing and Soldering Conf. April 26-29, Hilton 443-9353, ext. 229; or visit www.aws.org.
Hotel in the Walt Disney World Resort, Orlando, Fla. Cospon-
sored by AWS and ASM International. Contact American Weld- First Int'l Conf. on Welding Technologies. June 11-13, Gazi Uni-
ing Society, (800/305) 443-9353, ext. 229; visit www.aws.org. versity, Ankara, Turkey. Visit www.icwet09.org.
JOM-15,15th Int'l Conf. on the Joining of Materials, and 6th Int'l Shipbuilding Conf. June 16, 17, New Orleans, La. Contact
Conf. on Education in Welding. May 3-6, Helsing0r, Denmark. American Welding Society, (800/305) 443-9353, ext. 229; or visit
Organized by JOM Institute, supported by Dansk Metal, Danish www.aws.org.
MARCH 2009
Western Manufacturing Technology Show. June 16-18. North- National Robot Safety Conf. XXI. Oct. 26-29, Hyatt Regency,
lands Park-AgriCom, Edmonton, Alb., Canada. Contact Society Dearborn, Mich. Contact Robotic Industries Assn. at
of Manufacturing Engineers, (800) 733-4763; or visit ria@informz.net or ria@robotics.org.
www.sme.org.
ICALEO, 28th Int'l Congress on Applications of Lasers &
7th Int'l Expo on Electric Power Equipment and Technology and Electro-Optics. Nov. 2-5, Hilton in the Walt Disney World
6th Int'l Expo on Electrical Engineering, Electrical Equipment, Resort, Orlando, Fla. E-mail Laser Institute of America at
and Contractors' Supplies. July 8-10. Shanghai Int'l Expo Cen- conferences@laserinstitute.org; or visit www.icaleo.org.
ter, Shanghai, PR, China. Visit www.2456.com/ep.
FABTECH International & AWS Welding Show now including
Essen Welding Fair (Schweissen & Schneiden). Sept. 14-19, METALFORM. Nov. 15-18, McCormick Place, Chicago, 111. This
Essen, Germany. Visit www.messe-essen.de. show is the largest event in North America dedicated to showcas-
ing the full spectrum of metal forming, fabricating, tube and pipe,
welding equipment, and technology. Contact American Welding
25th ASM Heat Treating Society Conf. and Expo. Sept. 14-17, In- Society, (800/305) 443-9353, ext. 455; or visit www.aws.org.
diana Convention Center and RCA Dome, Indianapolis, Ind.
Visit www.asmintemational.org. Weld Cracking VII. Nov. 16, Chicago, 111. Held during the
FABTECH International & AWS Welding Show. Contact Amer-
GAWDA Annual Meeting. Sept. 20-23, Grand Hyatt Hotel, San ican Welding Society, (800/305) 443-9353, ext. 455; or visit
Antonio, Tex. Sponsored by Gases and Welding Distributors Assn. www.aws.org.
Visit www.gawda.org.
Int'l Electron Beam Conf. Nov. 17, 18, Chicago, 111. Held dur-
SOUTH-TEC. Oct. 6-8, Charlotte Convention Center, Charlotte, ing the FABTECH International & AWS Welding Show. Contact
N.C. Contact Society of Mfg. Engineers, (800) 733-4763; or visit American Welding Society, (800/305) 443-9353, ext. 455; or visit
www. sme. orglsouthtec. www.aws.org.
Welding of Corrosion-Resistant Alloys Conf. Oct. 6,7, New Or- Welding Chrome-Moly Steels Conf. Nov. 17, Chicago, 111. Held
leans, La. Contact American Welding Society, (800/305) 443- during the FABTECH International & AWS Welding Show. Con-
9353, ext. 229; or visit www.aws.org. tact American Welding Society, (800/305) 443-9353, ext. 455; or
visit www.aws.org.
The Aluminum Assn. Annual Meeting. Oct. 25-27, Charleston
Place, Charleston, S.C. Visit www.aluminum.org. Welding Corrosion-Resistant Alloys Conf. Nov. 18, Chicago, 111.
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WELDING JOURNAL
Held during the FABTECH International & AWS Welding Show. presented in Pascagoula, Miss., Houston, Tex., and Houma and
Contact American Welding Society, (800/305) 443-9353, ext. 455; Sulphur, La. Contact: Real Educational Services, Inc., (800) 489-
or visit www.aws.org. 2890, info@realeducational.com.
Power-Gen Int'l. Dec. 8-10, Las Vegas, Nev. Contact American Environmental Online Webinars. Free, online, real-time semi-
Welding Society, (800/305) 443-9353, ext. 455; or visit nars conducted by industry experts. For topics and schedule, visit
www.aws.org. www.augustmack.com/Web%20Seminars.htm.
Boiler and Pressure Vessel Inspectors Training Courses and Fabricators and Manufacturers Assn. and Tube and Pipe Assn.
Seminars. Columbus, Ohio. Call (614) 888-8320; visit Courses. Call (815) 399-8775; visit www.fmametalfab.org.
www.nationalboard.org.
Firelighter Hazard Awareness Online Course. A self-paced, ten-
CWI/CWE Course and Exam. Troy, Ohio. This is a ten-day pro- module certificate course taught online by fire service profes-
gram. Contact Hobart Institute of Welding Technology, (800) sionals. Fee is $195. Contact Industrial Scientific Corp., (800)
332-9448, www. welding, orgltechnicallschedule2008.html. 338-3287; www. indsci. com/serv_trainJfha_online. asp.
CWI/CWE Prep Course and Exam and NDT Inspector Training. Gas Detection Made Easy Courses. Online and classroom cours-
Courses. An AWS Accredited Testing Facility. Courses held year- es for managing a gas monitoring program from gas detection to
round in Allentown, Pa., and at customers' facilities. Contact: confined-space safety. Contact Industrial Scientific Corp., (800)
Welder Training & Testing Institute, (800) 223-9884, 338-3287; www. indsci. comlservJrain. asp.
info@wtti.edu; visit www.wtti.edu.
Hellier NDT Courses. Contact Hellier, 277 W Main St., Ste. 2,
CWI Preparatory and Visual Weld Inspection Courses. Classes Niantic, CT 06357; (860) 739-8950; FAX (860) 739-6732.
MARCH 2009
Inspection Courses on ultrasonic, eddy current, radiography, dye
penetrant, magnetic particle, and visual at Levels 1-3. Meet SNT-
TC-1A and NAS-410 requirements. Contact TEST NDT, Inc.,
TRIANGLE
(714) 255-1500, www.testndt.com. ^ ENGINEERING, INC.
&
Introduction to Welding and Materials Joining Course. Training Services for the Welding Industry
for high school, technical, and community college instructors.
June 15-26, Texas State T.C., Waco, Tex.; July 13-24, Pennsylva- Home of the "Monster Coupon"
nia College of Technology, Williamsport, Pa.; Aug. 3-14, Yuba
College, Marysville, Calif. The $500 fee includes hotel, two meals,
2 3/4" O.D.x 5/8" Wall = Unlimited Thickness Qualification
and course materials. Visit Weld-Ed at www.weld-
ed.org/workshops or contact Beth Plas at (440) 366-7036, Weld engineering and consulting - WPS, PQR
bplas@loramccc. edu. > Welder training and qualification coupons
Laser Safety Online Courses. Courses include Medical Laser 24 Hour Procedure Qualifications
Safety Officer, Laser Safety Training for Physicians, Industrial Destructive test equipment
Laser Safety, and Laser Safety in Educational Institutions. > Full testing services Sustaining
Contact Laser Institute of America, (800) 345-3737, Member
www. laserinstitute. org. P.WH.T. Services
Hosted
ed by:
The American Welding Society established the honor of Counselor to recognize individual members
for a career of distinguished organizational leadership that has enhanced the image and impact of the
welding industry. Election as a Counselor shall be based on an individual's career of outstanding
accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in the
welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the welding
industry. The individual's organization shall have shown an ongoing commitment to the industry, as
evidenced by support of participation of its employees in industry activities.
Leadership of or within an organization that has made a substantial contribution to training and
vocational education in the welding industry. The individual's organization shall have shown an ongoing
commitment to the industry, as evidenced by support of participation of its employee in industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS headquarters
in Miami, or simply follow the instructions on the Counselor nomination form in this issue of the Welding
Journal. The deadline for submission is July 1, 2009. The committee looks forward to receiving these
nominations for 2010 consideration.
Sincerely,
Alfred F Fleury
Chair, Counselor Selection Committee
PROFESSIONAL PROGRAM ABSTRACT SUBMITTAL
Annual FABTECH International & AWS Welding Show
Chicago, IL - November 15-18, 2009
Submission Deadline: March 13, 2009
(Complete a separate submittal for each paper to be presented.)
Primary Author (Full Name):
Affiliation:
Mailing Address:
City: City:
State/Province: State/Province:
Zip/Mail Code: Zip/Mail Code:
Country: E-Mail: Country: E-Mail:
Answer the following about this paper
Original submittal? Yes NoD Progress report? Yes NoD Review paper? Yes NoD Tutorial? Yes NoD
What are the welding/Joining processes used?
What are the materials used?
What is the main emphasis of this paper? Process Oriented Materials Oriented Modeling
To what industry segments is this paper most applicable?
Has material in this paper ever been published or presented previously? Yes No^
If "Yes", when and where?
Is this a graduate study related research? Yes NoQ
If accepted, will the author(s) present this paper in person? Yes D Maybe D NoD
Keywords: Please indicate the top four keywords associated with your research below
Technical Approach, for technical papers only (100 words max.) - Explain the technical approach, experimental methods
and the reasons why this approach was taken.
Results/Discussion (300 words max.) - For technical papers, summarize the results with emphasis on why the results
are new or original, why the results are of value to further advance the welding science, engineering and applications.
For applied technology and education papers, elaborate on why this paper is of value to the welding community,
describe key aspects of the work developed and how this work benefits the welding industry and education.
Conclusions (100 words max.) - Summarize the conclusions and how they could be put to use - how and by whom.
NOTE: Abstract must not exceed one page and must not exceed the recommended word limit given above
Note: The Technical Program is not the venue for commercial promotions of a company or a product. All presentations should avoid
the use of product trade names. The Welding Show provides ample opportunities for companies to showcase and advertise their
processes and products.
Return this form, completed on both sides, to
City: City:
State/Province: State/Province:
Zip/Mail Code: Zip/Mail Code:
Country: Email: Country; Email:
Poster Requirements and Selection Criteria:
Only those abstracts submitted on this form will be considered. Follow the guidelines and word limits indicated.
Complete this form using MSWord. Submit electronically via email to techpapers(a)aws.orq or print and mail.
Maximum size - 44 inches tall x 30 inches wide. (Vertical format, please).
Must be legible from a distance of 6 feet. A minimum font size of 14 pt. is suggested.
Posters must be submitted to AWS as a single flat printed medium (e.g. laminated print or foam core board mount).
Any technical topic relevant to the welding industry is acceptable (e.g. welding processes & controls, welding procedures, welding design
structural integrity related to welding, weld inspection, welding metallurgy, etc.).
Submittals that are incomplete and that do not satisfy these basic guidelines will not be considered for competition.
Posters accepted for competition will be judged based on technical content, clarity of communication, novelty/relevance of the subject & ideas
conveyed and overall aesthetic impression.
Criteria by category as follows:
(A) Student (B) Student (C) Student (D) Professional
Students enrolled in 2 yr. college For students enrolled in For students enrolled in graduate For anyone working in the welding
and/or certificate programs at time baccalaureate engineering or degree programs in engineering or industry or related field.
of submittal. engineering technology programs engineering technology at time of Poster must demonstrate technical
Presentation need not represent at the time of submittal. submittal. or scientific concepts. Emphasis is
actual experimental work. Rather, Poster should represent the Poster should represent the placed on original contributions
emphasis is placed on student's own experimental work. student's own experimental work. and the novelty of the presentation.
demonstrating a clear Emphasis is place on Poster must demonstrate technical Potential relevance to the welding
understanding of technical demonstrating a clear or scientific concepts. Emphasis is industry is important and should be
concepts and subject matter. understanding of technical placed on originality and novelty of demonstrated.
Practical application is important concepts and subject matter. ideas presented. (E) High School
and should be demonstrated. Practical application and/or Potential relevance to the welding Junior or Senior high school
potential relevance to the welding industry is important and should be students enrolled in a welding
Industry is important and should demonstrated. concentration at the time of
be demonstrated. submittal.
Presentation should represent
technical concepts and application
to the welding industry.
Practical application and creativity
are important and should be
demonstrated.
Check the category that applies:
D (A) Student 2-yr. or D (B) Student 4-yr. 0(0) Graduate D (D) Professional D (E) High School
Certificate Program Undergraduate Student
Poster Title (max. 50 characters):
Poster Subtitle (max. 50 characters):
Abstract:
Introduction (100 words) - Describe the subject of the poster, problem/issue being addressed and it's practical implications for the welding
industry.
Technical Approach & Results (200 words) - Explain the technical approach. Summarize the work that was done as it relates to the subject of
the poster.
Conclusions (100 words) - Summarize the conclusions and how they could be used in a welding application.
This year, AWS Weldmex will include show that will bring metalworking man- trols, roll forming, cutting, safety equip-
FABTECH Mexico and Metalform Mex- agers, suppliers, engineers, and purchas- ment, finishing, saws, handling equip-
ico to create the largest welding, metal- ing agents together in one location. Hav- ment, shears, industrial gases, testing
working, and fabrication show in Latin ing all the latest metalworking products, equipment, laser beam cutting and weld-
America. The 60,000-sq-ft show will take services, and information in one place at ing, plate/structural fabrication, tubing
place June 2-4 in Monterrey, Mexico. one time and communicated in the Span- and piping, metalworking equipment,
Nearly 100 of the top metalworking sup- ish language is a value for companies and welding consumables, plasma cutting,
pliers and service companies have already metalworking professionals throughout power sources, soldering, presswork-
signed up to exhibit at the show. Latin America." ing/stamping, and welding equipment and
Ray Shook, AWS executive director, AWS Weldmex will include brazing, accessories. For more information, visit
said, "We expect more than 8000 atten- punching, bending/folding, resistance the new AWS Weldmex Web site at
dees to take advantage of this convenient welding, coil processing, robotics, con- www. awsweldmex. com.
WELDING JOURNAL
[]]
MARCH 2009
Shown during the January HW meeting in Paris, France, are (from AWS President Victor Matthews (left) and AWS Executive Direc-
left) Ernest Levert, past AWSpresident; Ray Shook, AWS executive tor Ray Shook (center) recently signed a Professional Coopera-
director; Klaus Middeldorf, chief executive officer of the German tion Agreement with Alain Houdart, president of the Institut de
Welding Society; and Kazutoshi Nishimoto, president, Japan Weld- Soudure (French Welding Institute) in Villepinte, France. The
ing Society. The group had just signed an agreement for the first In- agreement creates an avenue for cooperation between the two so-
ternational Electron Beam Welding Conference to be held Nov. 17, cieties in areas related to membership eligibility, technical activi-
18, 2009, during the FABTECH International & AWS Welding Show. ties, exhibitions, and publications.
Member-Get-A-Member Campaign
Listed are the Jan. 21 tallies. For rules and B. Donaldson, British Columbia 2 T Strickland, Arizona 17
prize list see page 69 of this Welding Journal E. Dupree, Tidewater 2 B. Hallila, New Orleans 16
or visit www.aws.orglmgm. Call the Member- F. Hendrix, New Jersey 2 C. Donnell, Northwest Ohio 15
ship Dept., (800) 443-9353, ext. 480, regarding R. Johnson, Detroit 2 M. Arand, Louisville 14
your proposer point status. T Johnson, Pittsburgh 2 W Harris, Pascagoula 14
Winner's Circle G Lawrence, N. Central Florida 2 R. Hutchinson, Long Bch./Or. Cty. 14
Sponsored 20+ new members. J. Livesay, Nashville 2 J. Roberts, Sacramento 14
The superscript indicates the number of J. Padilla, Cuautitlan Izcalli 2 G Smith, Lehigh Valley 14
times the member has achieved Winner's Cir- S. Luke, Acadiana 2 A. Mattox, Lexington 13
cle status since June 1, 1999. J. Nash, Atlanta 2 R. Rummel, Central Texas 13
J. Compton, San Fernando Valley' R. Pitt, Tidewater 2 D. Saunders, Lakeshore 13
E. Ezell, Mobile6 J. Poison, LA./Inland Empire 2 A. Stute, Madison-Beloit 13
J. Merzthal, Peru^ J. Rule, Cleveland 2 D. Taylor, Kern 13
G. Taylor, Pascagoula^ J. Sisson, Niagara Frontier 2 J. Daugherty, Louisville 12
L. Taylor, Pascagoula^ K. Smith, North Texas 2 J. Marshall, Siouxland 12
B. Mikeska, Houston1 A. Stute, Madison-Beloit 2 R. Evans, Siouxland 11
R. Peaslee, Detroit1 D. Thomason, Chicago 2 J. Theberge, Boston 11
W. Shreve, Fox Valley B. Whatley, Albuquerque 2 C Kipp, Lehigh Valley 10
M. Karagoulis, DetroitA1 M. Yung, Portland 2 D. Vranich, N, Florida 10
S. McGill, NE Tennessee1 P. Zammit, Spokane 2 D. Zabel, Southeast Nebraska 10
T Weaver, Johnstown/Altoona1 Student Member Sponsors C Abram, Columbus 9
G. Woomer, Johnstown/Altoona1 Sponsored 4 or more students. A. Badeaux, Washington, D.C 9
R. Wray, Nebraska1 D. Berger, New Orleans 110 S. Colton, San Diego 9
M. Haggard, Inland Empire1 B. Benyon, Pittsburgh 41 D. Kowalski, Pittsburgh 9
President's Roundtabie A. Baughman, Stark Central 36 R. Ledford Jr., Birmingham 9
Sponsored 9-19 new members. M. Boggs, Stark Central 36 R. Norris, Maine 9
E. Ezell, Mobile 16 R. Jones, Puget Sound 36 V. Facchiano, Lehigh Valley 9
P. Betts, Mobile 12 A. Rowe, Philadelphia 36 M. Rabo, Sacramento 8
President's Ciub A. Zinn, Eastern Iowa 34 G Saari, Inland Empire 8
Sponsored 3-8 new members. T Moore, New Orleans 32 N. Carlson, Idaho/Montana 7
L. Contreras, South Florida 8 J. Carney, Western Michigan 26 W Galvery Jr., Long Bch./Or. Cty. 7
R. Ellenbecker, Fox Valley 6 E. Norman, Ozark 26 J. Geesey, Pittsburgh 7
J. Compton, San Fernando Valley 5 S. Siviski, Maine 26 S. MacKenzie, Northern Michigan 7
C. Daon, Israel 5 T Geisler, Pittsburgh 24 C Schiner, Wyoming 6
W. Rice, Tri-State 5 J. Kline, Northern New York 24 K. Caliva, New Orleans 5
D. Wright, Kansas City 5 D. Newman, Ozark 2 D. Kearns, Northern Michigan 5
M. Hackl, Cuautitlan Izcalli 4 R. Newman, Maine 24 R. Olesky, Pittsburgh 5
R. Newman, Maine 4 R. Cook, Utah 23 J. Reed, Ozark 5
B. Vernyi, Cleveland 4 D. Howard, Johnstown-Altoona 23 H. Evans, Portland 4
C. Becker, Northwest 3 B. Suckow, Northern Plains 23 W Geiger, N. Central Florida 4
B. Franklin, Mobile 3 L. Clark, Milwaukee 22 C Hobson, Olympic Section 4
L. Moss, Sangamon Valley 3 H. Hughes, Mahoning Valley 22 S. Robeson, Cumberland Valley 4
P. Newhouse, British Columbia 3 D. Schnalzer, Lehigh Valley 22 G Rolla, LAVInland Empire 4
M. Rahn, Iowa 3 J. Rule, Cleveland 21 J. Ciaramitaro, N. Central Florida 3
M. Wheat, Western Carolina 3 R. Munns, Utah 20 D. Hamilton, Chattanooga 3
President's Honor Roii A. Duron, New Orleans 19 J. Hayes, Oklahoma City 3
C. Alfaro, San Diego 2 J. Fox, Northwest Ohio 19 T Hopper, Mobile 3
M. Boggs, Stark Central 2 D. Pickering, Central Arkansas 18 D. Saunders, Holston 3
M. Boyer, Detroit 2 R. Schmidt, Philadelphia 18 M. Shelton, Sabine 3
R. Boyer, Nevada 2 J. Boyer, Lancaster 17 S. Tennant, Fox Valley 3
WELDING JOURNAL
AWS Makes Big Plans with Arkansas Weid Expo
Angela Harrison, chairman and CEO of
WELSCO, Inc., North Little Rock, Ark., is
shown with Sam Gentry (left), executive direc-
tor, AWS Foundation; and Ray Shook, AWS ex-
ecutive director, at the Arkansas Welding Expo.
More than 1700 welding enthusiasts attended
the event that showcased the products of more
than 35 suppliers. Shook and Gentry met with
Harrison and Charles Ross, vice president of
purchasing, to determine how the Society can
work with the company to make next year's show
even better. Ross said, "Welsco holds the Expo
every December and makes an effort to invite
students and instructors. We look forward to hav-
ing the students attend, they are the future of
our industry." WELSCO is the largest woman-
owned gas and welding supply distributor in the
United States. More information on the Expo
can be found at www.welsco.com.
District 2
Kenneth R. Stockton, director
(908)412-7099
kenneth.stockton@pseg.com
PHILADELPHIA
JANUARY 14
Activity: The Section members toured
the UA Local 420 training facility to see
demonstrations of Liburdi Dimetrics P-
300 with a Model F weld head orbital pipe
welding system and some Wachs pipe
prep equipment. Apprenticeship Train- Presenter Don Brown (left) is shown with Chairman Gary Atherton at the Philadelphia Sec-
ing Director Steve Sweeny and Don tion program.
Brown, precision welding applications
manager, conducted the tour.
District 3
Michaei Wiswesser, director
(610)820-9551
mike@welderinstitute.com
District 4
Roy C. Lanier, director
(252)321-4285
rlanier@email.pittcc.edu Florida West Coast Section members are shown at the January 14program.
District 6
District 5
Steve Mattson, director
Kenneth Phy, director
(315)218-5297
k.phy hoitec.com
(904) 260-6040
steve.mattson @yahoo.com
NORTHERN NEW YORK
FLORIDA WEST COAST DECEMBER 2
JANUARY 14 Speakers: Mike Todd and Chris Lanese,
Speaker: Edward M. Beck, RE. welding instructors
Affiliation: Mactech Engineering and Affiliation: Capital Region Board of Co-
Consulting Inc. operative Educational Services (BOCES)
Topic: How NDT can get you into trou- Topic: The welding program presented at
ble and how logic can get you out Capital Region BOCES, Albany, N.Y.
Activity: A gift certificate for Walden Activity: Warren Alexander made a pres-
Lakes Country Club was raffled to raise entation on his techniques for perform-
funds for the Section scholarship fund. ing uphill submerged arc welding. The Edward Beck (left) receives a speaker ap-
The program was held at Frontier Steak program was held at Mill Road Restau- preciation plaque from Al Sedory, Florida
House in Tampa, Fla. rant and Tavern in Lantham, N.Y. West Coast Section chairman.
WELDING JOURNAL
DETROIT
JANUARY 8
Activity: The Section members toured
the Industrial Automation facility in
Orion Township, Mich. Bethany Duncan,
senior applications engineer, made a
presentation, then conducted demonstra-
tions of various materials-handling and
tool-changing issues often encountered
in the welding industry plus some tips on
methods for improving workplace pro-
ductivity. Assisting was Catherine Mor-
ris, senior account manager.
The speakers at the Northern New York Sec-
tion meeting were (from left) Mike Todd, Story-teller Grady Bauer held everyone's
Chris Lanese, and Warren Alexander. attention at the Mobile Section meeting. NORTHWEST OHIO
DECEMBER 18
i
Activity: Jim Czywocki, welding instruc-
District 8 tor, conducted the members on a tour of
WH4\ m
District 9 of a five-year apprentice training pro-
gram and advanced training for journey-
George D. Fairbanks Jr., director men who want to specialize.
SI
(225) 473-6362
fits @ bellsouth.net
MOBILE
Speaker Kevin Summers (right) is shown
JANUARY 8
Speaker: Ken Haga, territory manager
District 12
Sean P. Moran, director
with Steve Whitney, Dayton Section chair. Affiliation: Industrial Air Quality (920) 954-3828
Topic: Welding fume abatement sean.moran@hobartbrothers.com
Activity: Grady Bauer, the Section's vet-
eran jokester, entertained with a selec- LAKESHORE
tion of funny stories. JANUARY 8
Activity: The Section members toured
the AZCO plant in Appleton, Wis., to
District 10
Richard A. Harris, director
study the company's equipment and
methods for welding angle box structures
(440) 338-5921 and tubing. Dave Jansen, project man-
richaharris alltel.net ager, conducted the program. Following
the tour, a dinner meeting was held at
MAHONING VALLEY the Main Event in Little Chute, Wis.,
JANUARY 15 where a question and answer session was
Activity: The Section held an executive conducted regarding the tour.
committee meeting at Harry & Jean's
Restaurant in Canfield, Ohio. Discussed
were plans for the upcoming season. MILWAUKEE SECTION
Thanked for their continued support of COMING EVENT
Mobile Section Chair Joshua Sanders (left) the Section's activities were Air Gas MAY 11-13, 2009
presents a speaker gift to Ken Haga. Great Lakes, Akron Testing Lab and
Welding School, Boardman Steel, Brilex Robotic Arc Welding Conf. and Expo,
District 7
Don Howard, director
Tech Services, Cedar Steel, City Machine
Technologies, Northeast Fabricators,
Columbiana Boiler Co., Converse All
Milwaukee Area Technical College,
Milwaukee, Wis. Co-hosted by the
Milwaukee Section and the D16
(814)269-2895 Metal Services, Diamond Steel Construc- Committee on Robotic and Auto-
howard@ctc.com tion, Falcon Foundry Co., Northeast Fab- matic Welding. Theme: Expanding
ricators, and Youngstown Oxygen and the use of robots in arc welding be-
DAYTON Welding Supply. yond traditional applications. In-
JANUARY 13 cludes a full-day tour of the Caterpil-
Speaker: Kevin Summers, robotics and lar facility in Aurora, 111. E-mail
automation strategy manager
Affiliation: Miller Electric Co.
Topic: Welding cost containment
District 11
Eftihios Siradakis, director
karen.gilgenbach@airgas.com; or call
(262) 613-3790; or visit http://sec-
tions. aws. org/milwaukee/Links/A WS_
Activity: The program was held at Amber (989)894-4101 RAWC2009.pdf.
Rose Restaurant in Dayton, Ohio. ft. siradakis @ air gas. com
MARCH 2009
Northern Plains Section members and welding students posed for a group shot at Northland College.
1 I
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AMERICAN
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WELDING
SOCIETY u
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ri
District 13
W. Richard Polanin, director
(309) 694-5404
rpolanin @ icc.edu
District 14
Tuiiy C. Parker, director Shown at the Detroit Section program are (from left) presenters Bethany Duncan and Cather-
(618)667-7795 ine Morris with Section Chair John Bohr.
tparke@millerwelds.com
District 15
Mace V. Harris, director
(612)861-3870
macevh aol.com
NORTHERN PLAINS
NOVEMBER 18
Activity: The Section members met with
welding students at the Northland Col-
lege welding shop in East Grand Forks,
Minn., to see demonstrations of Smith
Equipment welding products by Dale
Johnson and Lincoln Electric machines
by Paul Hewitt. Following the program,
the group traveled to Rydell Toy Shop, a
custom hot rod shop in Grand Forks,
N.Dak. Doug Peterson discussed several
projects in various stages of completion
including the Grand Master, a joint proj-
ect with Chip Foose of Foose Design. Doug Peterson demonstrates metal shaping for Northern Plains members at Rydell Toy Shop.
WELDING JOURNAL
District 19
Neii Shannon, director
(503)419-4546
neilshnn @msn. com
ALASKA
JANUARY 16
Speaker: Steve Stuart, underwater
welder
Affiliation: American Marine
Topic: Underwater welding in Alaska
Activity: Peter Millar received his Life
Membership Certificate Award for 35
years of service to the Society. Louis
Alvord was presented the Silver Mem-
bership Certificate Award for 25 years of
service. The program was held at Peggy's
Restaurant in Anchorage, Alaska.
BRITISH COLUMBIA
NOVEMBER 25
Activity: In a private presentation, Avaral
East Texas Section members and guests are shown at Norris Cylinder in Longview, Tex. Rao of Powertech received his Silver
Membership Certificate Award for 25
District 16
David Landon, director
years of service to the Society.
(641) 621-7476
dlandon @ vermeermfg.com
District 20
Wiiiiam A. Komios, director
(801) 560-2353
bkoz arctechlic. com
District 17
J. J. Jones, director COLORADO
(940)368-3130 DECEMBER 11
Jjones @ thermadyne. com Speaker: Conor Tracy, CWI
Affiliation: Front Range Community
EASTTEXAS College, welding instructor
NOVEMBER 18 Topic: The college's course offerings
Activity: Sally Mitchell conducted the Activity: This students' night program,
Section members on a tour of the Norris held at the college, was sponsored by
Paul Hewitt demonstrated the latest Lin- Cylinder facility in Longview, Tex., to General Air, a local welding supply com-
coln products for the Northern Plains Sec- study the manufacture of cylinders used pany. Section Chair James Corbin en-
tion members. for welding and cutting applications. couraged the students to continue their
Representatives from four schools at- studies to earn an associate degree in the
tended: Dan Brlcker, Caddo Career & welding program. Dave Murphy of DMD
Technology Center; Bryan Baker, Tyler Torch was presented the Section Merito-
Jr. College; Harris Williams, Welding In- rious Award.
stitute in Shreveport, La.; and Bill Kiel-
hom, LeTourneau University. IDAHO/MONTANA
JANUARY 16
Activity: The Section members toured
TULSA Diversified Metal Products in Idaho
NOVEMBER 19 Falls, Idaho. Featured were the opera-
Speaker: Les Jointer, director tions in its shops for processing carbon
Affiliation: Ocean Corp. steel and stainless steel projects. The
Topic: Underwater welding and inspec- company is involved in projects for re-
tion newable energy, nuclear waste manage-
ment, and commuter trains. Conducting
the tour were Nathan McMasters, presi-
dent, and Maria McCosh, quality assur-
District 18
John Bray, director
ance manager. McCosh owes her success
in part to receiving an AWS scholarship.
Read her Member Milestone story on
Speaker Les Jointer (left) is shown with (281) 997-7273 page 76 of this Welding Journal. Paul
Jamie Pearson, Tulsa Section chairman. sales @ affiliatedmachinery.com Tremblay unveiled the banner presented
MARCH 2009
Front Range Community College students attended the Colorado Section students' night program.
Idaho/Montana Section members are shown during their Diversified Metal Products tour.
WELDING JOURNAL
Speaker Steve Kent (left) is shown with
The Utah Section members are shown at Hunt Mystery Theater. Brad Bosworth, Fresno Section chairman.
r
SAN FRANCIS!
r
SECTION
^~~~
Shown at the Fresno Section open house are (from left) Tom Smeltzer, Chair Brad Bosworth, Simon Engel is shown with Liisa Pine, San
District 22 Director Dale Flood, speaker Steve Kent, and Kent Baucher. Francisco Section chair.
FRESNO
District 21
Nanette Samanich, director
JANUARY 15
Speaker: Steve Kent, owner
tended the event. District 22 Director
Dale Flood and Kent Baucher, a past Dis-
trict 22 director, attended the program.
(702)429-5017 Affiliation: Kent Performance Center
Nan07@aol.com Topic: Race car fabrication and welding
4130 chrome-moly tubing using gas tung- SAN FRANCISCO
sten arc process JANUARY 7
District 22
Dale Flood, director
Activity: The Section hosted an open
house event at Kent Performance Cen-
ter in Fresno, Calif. Welding educators
Speaker: Simon L. Engel, president
Affiliation: HDE Technologies, Inc.
Topic: Laser beam welding
(916)288-6100, ext. 172 from Fresno City College, Reedley Col- Activity: The program was held at
flashflood@email.com lege, and California State University at- Spenger's Restaurant in Berkeley, Calif.
MARCH 2009
Guide to AWS Services
American Welding Society
550 NW LeJeune Rd., Miami, FL 33126
www.aws.org; (800/305) 443-9353; FAX (305) 443-7559
(Staff telephone extensions are shown in parentheses.)
WELDING JOURNAL
Nominees for National Office AWS Publications Sales
William Irrgang Memorial Award profession, or to one who is accredited Director, Solutions Opportunity Squad
Sponsored by The Lincoln Electric Co. with exceptional accomplishments in the Connie Bowling, ext. 308, cbowling@aws.org
in honor of William Irrgang, the award, development of the welding art, upon
adminstered by AWS, is given each year whom the Society deems fit to confer an 550 NW LeJeune Rd., Miami, FL 33126
to the individual who has done the most honorary distinction. Honorary Members (305) 445-6628; (800) 443-9353, ext. 293
over the past five years to enhance the So- have full rights of membership. General Information:
ciety's goal of advancing the science and (800) 443-9353, ext. 689; vpinsky@aws.org
technology of welding. It includes a $2500 National Meritorious Certificate Award
honorarium and a certificate. This certificate award recognizes the re-
cipient's counsel, loyalty, and dedication AWS Mission Statement
George E. Willis Award to AWS affairs, assistance in promoting
Sponsored by The Lincoln Electric Co. cordial relations with industry and other The mission of the American Welding
in honor of George E. Willis, the award, organizations, and for contributions of time Society is to advance the science,
adminstered by AWS, is given each year and effort on behalf of the Society. technology, and application of
to an individual who promoted the ad- welding and allied processes,
vancement of welding internationally by International Meritorious including joining, brazing, soldering,
fostering cooperative participation in Certificate Award cutting, and thermal spraying.
technology transfer, standards rationali- This honor recognizes recipients' sig-
zation, and promotion of industrial good- nificant contributions to the welding in-
will. It includes a $2500 honorarium and dustry for service to the international It is the intent of the American Welding
a certificate. welding community in the broadest terms. Society to build AWS to the highest qual-
The awardee is not required to be an AWS ity standards. Your suggestions are wel-
Honorary Membership Award member. Multiple awards may be given. come. Please contact any staff member or
The honor is presented to a person of The award consists of a certificate and a AWS President Victor Y. Matthews, as
acknowledged eminence in the welding one-year AWS membership. listed on the previous page.
MARCH 2009
ions for the
Elihu Thomson Resistance Welding Award for 2010.
mmmm.
///r--
The Elihu Thomson Resistance Welding Award is awarded annually by the RWMA Committee to a living individual who has made
an outstanding contribution to the technology and application of resistance welding, as evidenced by one or more of the following:*
Authored one or more technical papers on a resistance welding subject published in the AWS Welding Journal or any other
industry-recognized publication.
Developed innovations in resistance welding equipment or technology.
Made a unique application of resistance welding in a production environment.
Other contributions as the RWMA Governance Committee shall deem worthy of recognition. i
WHO WAS ELIHU THOMSON? Elihu Thomson, bom in Manchester, England on March 29, 1853, was an engineer and inventor who
was instrumental in the founding of major electrical companies in the United States, the United Kingdom and France. His family moved to
Philadelphia in 1858. By 1880 he established, with Edwin J. Houston, the Thomson-Houston Electric Company. In 1892, this merged with
the Edison General Electric Company to become the General Electric Company. Thomson's name is further commemorated by the British
Thomson-Houston Company (BTH), and the French companies Thomson and Alstom. His early companies are also involved in the history
of The General Electric Company Limited (GEC) in Britain and the Compagnie Generale d'Electricite' in France.
Thomson was a prolific inventor, being awarded over 700 patents. For example, he invented the induction wattmeter mechanism used in
electric meters. He was the first recipient of the American Institute of Electrical Engineers AIEE (now Institute of Electrical and Electronics
Engineers (IEEE) Edison Medal, bestowed upon him in 1909 "for meritorious achievement in electrical science, engineering and arts as
exemplified in his contributions thereto during the past thirty years." Ironically, Thomson and Houston had been involved in a very public and
acrimonious dispute with Edison in 1877-78 over etheric force. He was a founder member, as well as the second president, of the
International Electrotechnical Commission. He served as acting president of MIT during 1920-1923. Thomson died in his estate in
Swampscott, Massachusetts, on March 13, 1937.
Please take the time to nominate someone who you feel would be worthy of this prestigious award.
You can nominate them by completing the form, and faxing it directly to
RWMA Headquarters at 305-442-7451 or e-mail it to rwma@aws.org.
You may also go to www.aws.org/rwma/awards/elihu.html and click on "Nominate Someone Now."
NEW
LITERATURE
Industrial Skills Training principles of metallurgy, joint design and
symbols, general techniques and safety
DVDs Detailed In Catalog practices, oxyfuel gas cutting, brazing and
braze welding, shielded metal arc (SMA)
welding principles, SMA structural and
oBfliU ICJCT pipe welding, principles of gas tungsten
IJ jMiiiiir ^'"llli V arc (GTA) welding, GTA structural and
IIH^jilii'" i^ ttt M pipe welding, principles and techniques
ITCLEARNING DVD / Videotape Series of gas metal arc welding, causes and cor-
rections of weld defects, and plasma arc
l:srl cutting. Other general topics offered in-
clude hydraulic systems, maintenance
management, training the trainer, electri-
?-sr*._^ sfSBr-'" cal maintenance and safety, plus many
- :.!-sraM,,r'iM M ^tj 6 45
M!!'* ' " F nda k other titles. The catalog and more detailed
Hitin,i,&,ft>!SB ttiniirfawW'futMwumw-
course information can be downloaded
from the Web site.
Hexavalent Chromium
White Paper Offered
Hexavalent Chromium: What You Need
to Know has been released for industrial
manufacturers involved in welding, stain-
less steel fabrication, and thermal spray
coatings. It discusses the control and cap-
ture of hexavalent chromium to comply
with OSHA's permissible exposure level
requirements. The white paper was writ-
continued on page 74
For info go to www.aws.org/ad-lndex
MARCH 2009
Be part of the 45th SkillsUSA Championships, where since
1969, industry experts have been choosing the top student
welders in the United States.
Donaldson Torit
www.donaldsontorit.com.Printed
M;
(800) 365-1331
MARCH 2009
Welding Corrosion Resistant Alloys Conference
Chicago, November 18th, 2009
Earn PDH's toward your AWS recertification or renewal when you attend the conference!
continued from page 76 Schmitz was responsible for managing the was named an AWS Fellow (1991).
Disk Laser Group and overseeing the de- DeLong graduated from Lehigh Uni-
velopment of a new diode-pumped solid versity in 1943 with a degree in metallur-
ident and chief operations officer. Previ-
laser system at the TRUMPF Laser gical engineering. During WW II, he
ously he served as president and chief ex-
GmbH facility in Schramberg, Germany. served in the Chemical Warfare Branch of
ecutive officer of Airoom, Inc.
the U.S. Army. He worked for Teledyne-
McKay in welding research from 1950 to
Oxford Alloys Designates Rockford Toolcraft Taps 1984 when he retired as vice president of
corporate development. During his ca-
Export Sales Director Sales Manager reer, he was granted 15 patents for his
work and authored numerous technical
Oxford Alloys, Inc., Baton Rouge, La., Rockford Toolcraft Inc., Rockford, 111., papers published widely in industry jour-
a tool and die builder and metal stamping nals. He led the effort for international
has named John A. Robinson director of
firm, has named Doug Kosch sales man- standardization of magnetic measurement
export sales. Before joining the company,
ager. With the company for 18 years, of ferrite. DeLong, named an ASM Inter-
Robinson worked with Techalloy, Central
Wire Group, a producer of stainless steel Kosch most recently worked as die esti- national Fellow in 1977, was active in the
mating engineer since 2001. International Institute of Welding, Weld-
and nickel wire.
ing Research Council, chaired the AWS
A5 Committee on Filler Metals and the
Sales Director Appointed at Aluminum Association Technical Activities Committee, and
NanoSteel President Joins ITAC served on the AWS Safety and Health
Committee and its subcommittees, the
Steve Larkln, president of The Alu- Project Committee on Ni and Cr+6 haz-
The NanoSteel Co., Providence, R.I., ards, and the Task Group on Health Haz-
minum Association, Arlington, Va., has
has appointed Mike Place sales director for ards. He also was a member of the NEMA
joined the Industry Trade Advisory Com-
the company's portfolio of Super Hard Task Group that developed OSHA Mate-
Steel coating, overlay, and wear plate so- mittee (ITAC). The committee, operating
under the U.S. Department of Commerce rial Safety Data Sheets and product warn-
lutions. Previously, Place worked for Liquid ing labels. His many awards include the
International Trade Administration, is
Metal Coating Solutions as national sales Comfort A. Adams Lecture Award
missioned to strengthen the nation's ne-
director and field operations manager. (1974), R. D. Thomas Memorial Award
gotiating position by enabling the U.S.
government and private industry to dis- (1974), National Meritorious Award
play a united front when negotiating trade (1985), and Honorary Membership
Multlqulp Names President agreements with other nations. Award (1986). He was a founding member
of the Unitarian Society of York, and re-
Multiquip, Carson, mained active until his death. He loved
Calif., has appointed gardening, working outside, and dis-
Mike Howlett presi-
dent of its General Obituaries cussing the latest breakthroughs in many
fields of science. DeLong is survived by his
Construction Equip-
ment internal divi-
William T. DeLong wife, Bernadean (Bunny); her live-in care-
taker, Connie; sons John, Thomas, and
sion. Most recently, James; and six grandchildren.
Howlett served as
vice president of op- ^^^^^>^flH
erations.
Mike Howlett Jan-Eric Nelson
V A1
Canadian provinces to support the signif- welding, concrete, masonry, and seismic
icant business growth in the region. projects, he was a journeyman welder
Lowrie, formerly a consumable sales man- through the Ironworkers Union Local
ager for Hypertherm, will support distrib- 433. He worked both as self-employed and
utors in the Manitoba, Saskatchewan, and employed as a construction inspector with
WE ^1I
Northern Alberta provinces. Tucker will
work with distributors in Southern Al-
WlMWm^m the IUOE Local 12, Twining Labs, Con-
verse Consultants, City of Los Angeles-
berta and British Columbia. Con Ad, and the Los Angeles County San-
itation Districts and OSHPD. He held
memberships in ICC/ICBO, MCIA,
TRUMPF Names VP William T. DeLong SEIU, and ACIA. He enjoyed gardening,
reading, and taking many continuing edu-
TRUMPF Inc. has appointed Chris- cation classes pertaining to his work. Nel-
tian Schmltz vice president, lasers, based William (BUI) T. DeLong, 87, died Dec. son is survived by his wife, Terri; daughters
at the company's North American head- 30 in York, Pa. An AWS Life Member, he Cinthia Nelson and Suzi Lighten; mother,
quarters in Farmington, Conn. Previously, served as AWS president (1981-1982) and Hanna Nelson; and two grandchildren.
MARCH 2009
ASCC
CONFERENCE
B
IMCA ciscQicca For Info go to www.aws.org/ad-index and much more!
^TOEDJ^-'
THE AMERICAN WELD
Welded Sculptures
Pay Tribute to
Fallen Heroes
A retired firefighter devotes his time and energy creating
various figures for a new memorial in remembrance of 9111
BY KRISTIN CAMPBELL
Fig. 1 The unique firefighter, built using pieces of steel, looks ready to rescue someone with
its complete gear in tow. "He's pretty spectacular, and I'm really happy with my results,"
Gonzalez said.
lored cut sections of Vi-in. steel. "Each The firefighter's special details include
piece had to be perfect," Gonzalez said. the following:
He used gas metal arc welding with flux Helmet with a shield that reads
cored wire to individually weld these F.D.N.Y. 343 to honor the number of fire-
parts placed in different angles. Two plas- fighters lost on 9/11
ma cutting devices helped achieve the Universal face anyone could identify
correct proportions and flows. with
The sculpture has two textures Traditional firefighter jacket, pants,
from the boots to the waist and from the and shoes worn Fig. 2 Long sections of twisted steel com-
waist to the helmet. "I started from the A large pike pole, used to look for prise this original rendition honoring the
bottom and worked my way up," fire, held in the left hand and a pike axe WTC. A Tower 1 with four wings on its
Gonzalez said. With a general idea in held in the right hand top and 9-11-01 marked on one of its
mind, this figure came together by slowly Big fists on both sides representing beams; B the sculpture of Tower 2; and
building upward. strength C ashes coming out of the dust design
shown in Tower 2.
WELDING JOURNAL
THE AMERICAN WELD
Fig. 3 Awaiting use, donated steel rests on a grassy patch for more Fig. 4 Gonzalez performs gas metal arc welding on another work of
sculptures to be made with it. art, a little girl modeled after his granddaughter.
MARCH 2009
THE AMERICAN WELD
made its bottom base with Vi-in. steel. is the sole inspiration behind this memori- Bright Outlook
All together, these two towers along al, has a positive can-and-will-do spirit, and
with the other sculptures will provide a credits him with making it all possible. "I think I want people to be moved,
statement about the events of 9/11 and as Menasche further provided motivation and but also get a sense of our humanity, how
a nation what is represented. "The whole encouragement to Gonzalez. close we are to one another," Gonzalez
idea is to make you feel like you were This four-sided figure shows the fol- said of the whole memorial. He wants
there," Gonzalez said. lowing types of grief: shock, realization, individuals to fully understand it and ask
acceptance, and rebuilding. Each side dis- questions like what the artist conveyed
Sources of Inspiration plays a different image. "It's a story," and the meaning of that day.
Menasche said, representing what hap- He further hopes others will be
Working on this project became chal- pened to somebody who lost something inspired to accomplish their dreams and
lenging at times. Gonzalez compared the and the stages of trying to understand. goals after viewing the display. "I want it
creation process to a game of chess. "The A steel girder donated from New to be a total experience," he added.
hardest part is how you're going to pres- York's WTC remains will go on top of this After all, when Gonzalez set out to
ent the artwork," he said. As pieces get piece. "I'm putting this girder onto some- make his firefighter he was told it could
put together, details come, and then it thing white," Menasche said, adding he not be done with steel, yet he pushed
turns into movement and shapes. did not want the marble base to over- ahead anyway with this transformation. "I
Getting welds tight and clean required power the girder but did want to show a like creating the impossible," he said.
tedious attention. "My welding had to be concept of dark vs. light. For the viewer, In the future, he would like to contin-
accurate," he said. the whole figure will be at eye level; its ue using his welding and artistic skills for
Despite all this, the reward of making base will be 8 in. a good cause. "I want to do this the rest of
sculptures for many to view outweighs any Various tools used for the carving my life," he said.
difficulties. "I like monumental art, creat- include air compressors, hammers and Eventually, Gonzalez would like to
ing big pieces," Gonzalez said, because chisels, grinders, die grinders, and dia- create sculptures in honor of the
everybody sees different things. Also, when mond bits. "It's very, very hard marble," Holocaust survivors as well as for Cubans
he thinks of those who passed away on Menasche said. He works on the images because his father served as a tank cap-
9/11, this drives him to do the best he can. when time permits and shares the con- tain/soldier in the Bay of Pigs Invasion. "I
Gonzalez finds it gratifying to create verted fire station with Gonzalez. It is like public art," he said, noting its incred-
something totally different from other expected to be done later this year. ible ability to touch so many lives.
items. "I never make the same things
twice. If you're not extending yourself,
how are you going to grow?" he said.
WELDING JOURNAL
. AmericanWeldng Society'
Depending on the level of experience, individuals who pass a written exam and performance test can be
certified as either Robotic Arc Welding Technicians or Operators.
For more information regarding this program, including those companies interested in becoming an
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To schedule training and testing to become Certified in Robotic Arc Welding, contact one of these
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ding is the most vital and
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Keeping in tune with the progress of new innovative
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THE AMERICAN WELD
Optimizing Tiingsten
Electrode Performance
Proper preparation can lead to an increase in
electrode life and better welds
BY MIKE FLETCHER
It can be argued that the electrode is the weakest link in the drive for
gas tungsten arc weld quality. Poor electrode choice and preparation
invariably lead to defective joints.
While hand grinding can be tolerated in 3. Choose the best electrode compo-
some circumstances, producing welds for sition.
safety-critical applications and where For many years, manufacturers have
weld properties must meet stringent been adding residual compounds to offer
inspection criteria needs a more con- improved performance. Additions of sta-
trolled approach. Following are some tips ble oxides such as thoria, ceria, and lan-
for optimizing electrode preparation, thana provide the same level of emission
which can lead to a significant increase in as pure tungsten at lower temperatures,
electrode life. while improving arc time and stability.
1. Choose the right diameter. Pure tungsten has a high work func-
Table 1 can be used to determine the tion, i.e., it takes a great deal of energy to
electrode diameter best suited to the operate. This makes it difficult to start
welding current you are using. This guide and maintain a stable arc. It also has a
to the optimum diameter is based on high burn-off rate and thus a shorter serv-
decades of welding practice. ice life.
2. Choose a reputable supplier. Thoria stablized. It is now clear that
Fig. 1 Precision mechanized tungsten Superficially, electrodes from differ- thoria, although promoting better weld-
grinder with dust extraction. (Photo cour- ent companies look much the same, but ing, is low-level radioactive and many
tesy ofHuntingdon Fusion Techniques Ltd., do consider that, in general, cost means manufacturers and welders have stopped
UK.) quality. The better electrodes have been using it because of the health concerns
manufactured to ensure a small grain (Refs. 1, 2).
structure that allows for better migration Zirconia stabilized. Zirconia is used
of oxides to the tip, easier arc starting, for radiographic-quality welding where
improved arc time, and better weld quali- tungsten contamination must be mini-
ty with minimized contamination. mized. It balls up easily in AC applica-
Electrode
Diameter (mm)
MARCH 2009
THE AMERICAN WELD
tions, but has good arc starting and cur- duce a poorly shaped electrode tip.
rent-carrying capacity. Choose a grinding machine that has
Ceria stabilized. Ceria electrodes are been designed specifically for electrode
good for low-current, DC, orbital tube, preparation and use it only for this pur-
pipe, and thin-sheet applications. This pose Fig. 1. Select one with robust per-
formula has low current capacity but formance to cover the entire range of
offers low arc ignition and good arc diameters to be used. A diamond wheel is
stability. preferred and the operation should
Lanthana stabilized. These electrodes ensure that any grinding marks are paral-
are a nontoxic alternative to thoria-stabi- lel to the length: electrons flow along a
lized products. They offer excellent igni- surface and become erratic if they
tion and re-ignition properties and good encounter cross-grinding marks Fig. 2.
service life. Ensure that an angle-setting jig is pro-
Fig. 2 Grinding should be done so that
Combination stabilized. Some compa- vided (0-90 deg) and extraction facilities
grinding marks run along the electrode
nies manufacture electrodes with com- are available to remove any radioactive
length and not normal to it.
plex oxide stabilization. These advanced dust safely.
nonradioactive formulas combine three Repeatability is a must if consistency
oxides with tungsten to produce excellent of weld deposition is to be realized and Vertex Angle
all-purpose electrodes. They offer long this is where the advantages of employing
life, repeatable performance, and reliable a tungsten tip grinding machine start to
arc starting even after numerous ignitions
(Ref. 3). An example of this type of elec-
be appreciated. The alternative of manu-
al preparation by the welder brings with it
>fCr'
trode is Multi-Strike from Huntingdon the probability not only of inconsistent
Fusion Techniques. geometry from electrode to electrode but Truncation
Color coding is used on some elec- the introduction of significant deviations
trodes but this practice is not standardized from the optimum. Table 2 compares
for all mixes and varieties from Europe, machine grinding to manual grinding.
Fig. 3 Geometry of electrode tip showing
Japan, and the United States. See AWS 5. Choose the proper tip grinding
vertex angle and truncation.
standard A5.12/A5.12M, Specification for procedure.
Tungsten and Tungsten-Alloy Electrodes The geometry and surface finish of the
for Arc Welding and Cutting for U.S. electrode point are crucial to good weld-
designations. ing Fig. 3. for DC polarity can be used as a valuable
Classification is undertaken on the Taper. Only experience taking into guide.
basis of chemical compositions, as fol- consideration the arc current, welding In general, larger angles offer longer
lows: power supply, welding torch, material to life, better penetration, a narrower arc,
be welded and its thickness, and joint and the capability to sustain more current
E: Electrode preparation will define the truly opti- without erosion. Smaller angles result in
mum electrode configuration, but Table 3 less tendency for arc wander, give a wider
W: Tungsten
P: Pure tungsten
Table 2 Recommended Vertex Angle for Different Electrode Diameters and Currents
Zr: Zirconia stabilized Diameter (mm) Current (Amp) Vertex Angle
(Deg)
Th: Thoria stabilized
0.5 5-20 10
Ce: Ceria stabilized 1.0 15-80 10
1.6 70-150 15
La: Lanthana stabilized 2.4 150-250 30
3.2 250^100 40
G: Unspecified oxide stabilization. 4.0 400-500 45
WELDING JOURNAL
^IHE AMERICAN WELDER
and more stable arc, and can be used at Table 4 Recommended Truncation
lower currents. Dimensions for Different Electrode
Electrode tip finish. Current transfer Diameters
takes place predominantly through the
flow of electrons along the electrode sur- Electrode Diameter Recommended
face and is influenced by the surface fin- (mm) Truncation
ish. Free flow of electrons is inhibited by 0.5 0.1
scratches or grinding marks that do not 1.0 0.5
run parallel to the axis, and for this rea- 1.5 0.75
son, it is important that grinding should 2.5 0.85
be longitudinal and concentric. For opti- 3 1
mum operation, a typical surface finish of 4 1.25
0.5 Ra is essential. Electrodes that have 4.75 1.5
been ground normal to the axis or that 6 1.75
have a surface finish much coarser than
0.5 Ra will produce instability in current References
flow. This may result in the following: arc
initiation away from the tip, arc wander, 1. Thoriated tungsten electrodes stud-
thermal shock at the tip, and reduced ied for effects on welders' health. 1994.
electrode life. Welding Journal 73(5): 88, 89.
Truncation. For some specific applica- 2. Statement of Commission VIII on
tions, the use of a truncated tip is benefi- health aspects in the use of thoriated
cial. A truncated cone of specified includ- tungsten electrodes. 1994. Soudage dans
ed angle, obtained by grinding, is often le Monde 33(4): 276.
preferred for DCEN. Table 4 shows rec- 3. Performance of TIG Electrodes.
ommended truncation dimensions for dif- June 1993. Welding Institute Ref
ferent electrode diameters.^ 220177/1/93.
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MARCH 2009
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THE AMERICAN WELD
How to Choose
Ergonomic Hand
Tools
These tips will tell you what makes a hand tool ergonomic,
and help you choose the right one for your body and the job
BY PAUL HOLSTEIN
But what exactly does that mean for con- from the raised groove edges can cause
sumers? Simply put, ergonomics is the discomfort and injury.
science of designing and producing tools, Choose tools with handles that are
furniture, and other work-related imple- covered in a soft material, like foam or
ments that improve a worker's efficiency flexible plastic. Cushioned handles are
while reducing discomfort, fatigue, and not only comfortable for long hours of
risk of injury. use, but they provide a much firmer grip
Ergonomically enhanced tools can and cut down on slippage Fig. 1. Hard-
include helpful features like angled han- handled tools can be quickly and inexpen-
dles, padded handgrips, and nonslip coat- sively converted by adding a sleeve.
ings. However, no matter how impressive Ensure tool handles are free from
a tool's design is, it's almost impossible sharp edges and seams that might irritate
for it to be universally ergonomic since or cut the hands.
human physiques and project applica- When selecting double-handed grip-
tions vary greatly from one to the next. ping and cutting tools, opt for ones
Whether you're shopping for with spring-loaded handles that will
ergonomic tools or just trying to select the automatically return to the open
Fig. 1 Tools such as these screwdrivers, right one for the job from an existing col- position.
which feature a cushioned handle, provide lection, the key things to consider are If you need to forcefully pinch or
a firmer grip, cut down on slippage, and are whether or not the tool fits your hand, grip an object for an extended amount of
more comfortable for longer periods of how well it suits the job being done, and time, prevent muscle strain by switching
time. whether or not it eases your work and from standard pliers to a clamp or grip.
prevents you from straining in ways that Only use tools that allow you to
could lead to injury. Regardless of how work with your wrist in a straight position.
user-friendly a tool is built to be, the most For tasks that require force, such as
important factor in what makes a tool torquing screws and nuts, hammering,
ergonomic is, ultimately, you. and heavy chiseling, choose single-
To make the decision process a little handle tools with handle diameters that
easier, here are some guidelines for range from IVi to 2 in. Larger handles
choosing the right ergonomic hand tool allow fingers to wrap comfortably around
for your body type and the job at hand. the tool in a power grip, which prevents
Because finger size and placement slippage and reduces stress and impact on
differs from person to person, avoid using hands, fingers, and wrists.
PAUL HOLSTEIN is the cofounder and
chief operating officer of tools whose handles have built-in finger For tasks that call for more preci-
CableOrganizer.com, grooves. When fingers don't naturally sion and delicacy (like fine chiseling and
www.CableOrganizer.com. align with grooves, excessive pressure driving miniature screws), opt for single-
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WELDING JOURNAL
THE AMERICAN WELD
\imm
Understanding Edge Shapes
Edge shape refers to the shape of the a type of bevel edge shape that has one shape that has two prepared surfaces
edge of the joint member. The figure prepared surface, while a double-bevel adjacent to opposite sides of the materi-
shows the seven edge shapes and the edge shape (Fig. 1C) has two prepared al. A flanged edge shape, such as shown
types of welds for which they are appli- surfaces adjacent to opposite sides of the in Fig. IF, is produced by forming the
cable. With a square edge shape (Fig. material. Figure ID shows a single-J member, and a round edge shape (Fig.
1A), the prepared surface lies perpendi- edge shape, a type of J-edge shape that 1G) is one in which the surface is curved.
cular to the material surface. has one prepared surface; Fig. IE shows
A single-bevel edge shape (Fig. IB) is a double-J edge shape, a type of edge
APPLICABLE WELDS
DOUBLE-BEVEL-GROOVE SINGLE-J-
GROOVE
DOUBLE-BEVEL-FLARE-GROOVE SQUARE-GROOVE
DOUBLE-J-GROOVE EDGE
SINGLE-BEVEL-GROOVE FILLET
(A) SQUARE EDGE SHAPE SINGLE-FLARE-BEVEL-GROOVE BRAZE
APPLICABLE WELDS
SINGLE-BEVEL-GROOVE
SINGLE-V-GROOVE
(B) SINGLE-BEVEL EDGE SHAPE BRAZE
APPLICABLE WELDS
DOUBLE-BEVEL-GROOVE
DOUBLE-V-GROOVE
(C) DOUBLE-BEVEL EDGE SHAPE
APPLICABLE WELDS
SINGLE-J-GROOVE
SINGLE-U-GROOVE
(D) SINGLE-J EDGE SHAPE
APPLICABLE WELDS
DOUBLE-J-GROOVE
DOUBLE-U-GROOVE
APPLICABLE WELDS
APPLICABLE WELDS
OR
DOUBLE-FLARE-BEVEL GROOVE
DOUBLE-FLARE-V-GROOVE
BRAZE
(G) ROUND EDGE SHAPE
MARCH 2009
4th International
Register Today At: www.aws.org/eaucation/ibsc or call 800-443-9353, ext. 213 (outside North America 305-443-9353)
or for more information, call 800-443-9353, ext. 455. Email: sharon@aws.org
Registration includes lunch (Monday & Tuesday), refreshment breaks, conference proceedings, and an optional Tuesday
evening networking dinner.
Reserve Exhibit Space and Sponsorship - For more information or to reserve exhibit space and sponsorship
at the IBSC call 440-338-1733. Email: keUy.thomas@asminternMonal.org. To download a complete Exhibit/Sponsor
Information Packet, visit the web at www.aws.org/educMonAbsc/tabletop.html.
Earn PDH's toward your AWS recertification or renewal when vou attend the conference!
NEW PRODUCTS Replacement Laser Optics
continued from page 27 Come In Range of Sizes
Cylinder's Valve Reduces
Gas Leaks
TRUMPF Inc.
www.us.trumpf.com
(860) 255-6000
KM*
L, ' 'M
Shaft Collars Suitable for
The SMARTOP compressed gas cylin- Ovens, Conveyors Laser Research CO2 beam delivery op-
der completes the lines of MINITOP and tics include focusing lenses and mirrors
ALTOP products. This user-friendly item that meet or exceed OEM and ISO-10110
providers users with benefits in terms of specifications for lower-power lasers used
safety and ease of operation, and responds in laser beam cutting, marking, and en-
to the needs expressed by professionals graving applications. Focusing lenses are
and occasional welders who use it for available inVitoVA in. diameter sizes with
argon. The cylinder features a residual 1 to 25 in. focal lengths, in lA-m. incre-
pressure valve equipped with an on/off ments, and mirrors are offered in silicon
lever that can be turned in a single mo- and molybdenum. They are suitable for
tion along with a high-pressure gauge that Amada, Coherent, Cincinnati, Contin-
indicates the volume of gas in it at all uum, Epilog, Lambda Physik, Mazak, Syn-
times. Additionally, users can determine rad, and similar lasers. They are optimized
whether the valve is open or closed at a for 10.6 |im as well.
glance by checking the position of the
lever. The cylinder is further equipped Laser Research Optics
with a guard that remains in place at all www.laserresearch.net
times to protect the valve. To use, the user (888) 239-5545
connects an extension line, selects the ap-
propriate pressure, and moves the lever.
NEW LITERATURE
Air Liquide Canada Inc.
www.ca.airliquide.com
(514) 933-0303 Stafford high-temperature shaft col- continued from page 74
lars are designed for applications where
they might be subjected to extreme tem-
peratures up to 2200oF such as ovens, fur- overviews, instructors' names and quali-
Station Contains Electronic fications, student prerequisites, registra-
naces, and conveyors. Machined from
Stereomlcroscope Type 330 stainless steel and other cus- tion fees, and training location details.
tomer-specified high-temperature alloys, The courses presented in the 16-page,
The TruLaser Station 5004 is a com- the collars are offered in bore sizes from full-color brochure are laser safety offi-
pact, comfortable workstation accommo- l
A up to 10 in. ID and a variety of configu- cer (LSO), LSO with hazard analysis, ad-
dating manual and semiautomatic laser rations. They feature one- and two-piece vanced LSO, medical LSO, and advanced
beam welding in even the smallest of clamp-style and hinged construction, and medical LSO. The online courses de-
spaces. It comes equipped with an inte- can be modified with special hexagonal, scribed are LSO, industrial laser safety,
grated protective hood, inert gas feeder, square, or threaded bores and mounting medical LSO, and laser safety for physi-
welding fume exhaust system, and safety holes on the face or OD. Applications in- cians. Also described are courses avail-
features. Plus, it offers an electronic stere- clude drive systems, mixing equipment, able for presentation at the customer's
omlcroscope that has been separated from and structural components. facility, and laser safety audit services.
the laser optics; the user adjusts the
monocular of the microscope to the job's Stafford Manufacturing Corp. Laser Institute of America
needs and no longer has to orient it to the www.staffordmfg.com www.laserinstitute.org
part's size. The two cameras of the micro- (800) 695-5551 (800) 345-2737
MARCH 2009
NEWS OF THE INDUSTRY COMING EVENTS
continued from page 11 continued from page 47
Craig P. Eddy, past chairman of The Aluminum Association, Motorsports Welding School Advanced Materials Courses.
represented the organization's board of directors at the 2008 Cleveland, Ohio. April 27-May 1, June 15-19, Sept. 14-18, Oct.
China Aluminum Forum. 12-16, Dec. 7-11. Contact The Lincoln Electric Co.,
www. lincolnelectric. com.
Western Enterprises, Westlake, Ohio, partnered with Lorain
County Community College as the supplier of shielding gas Motorsports Welding School Basic Materials Courses.
regulators, flashback arrestors, and hose quick disconnects for Cleveland, Ohio. March 9-13, April 20-24, May 11-15, June
the new National Center for Welding Education and Training. 8-12, July 27-31, Sept. 8-11, Sept. 21-25, Oct. 5-9, Nov. 9-13,
Nov. 30-Dec. 4. Contact The Lincoln Electric Co.,
The acquisition of Gordon Woods Industrial Welding Supply, www. lincolnelectric. com.
Inc., Accu Air Gases & Equipment, LP, Summit Gas & Gear,
LP, and Great Lakes Oxygen has been completed by Alrgas, NACE Int'l Training and Certification Courses. Contact
Inc., Radnor, Pa. National Assoc. of Corrosion Engineers, (281) 228-6223,
A new Web site unveiled by Weldcraft, Appleton, Wis., at www.nace.org.
www.weldcraft.com displays convenient product selection in-
formation as well as valuable educational resources. NDE and CWI/CWE Courses and Exams. Allentown, Pa., and
at customers' locations. Contact Welder Training and Testing
At the recent Rend Lake College, Ina, 111., board of trustees Institute, (800) 223-9884, www.wtti.edu.
meeting, a $35,389.48 bid from ILMO Products Co., Mt. Ver-
non. 111., was accepted for 14 welding machines and accessories. Pipe Welding. Cleveland, Ohio. Three-week-long courses begin-
ning March 30, May 11, June 22, Aug. 3, Sept. 14, and Oct. 26.
The Texas Workforce Commission chose Lauren Engineers Contact The Lincoln Electric Co., www.lincolnelectric.com.
Constructors, Abilene, Tex., as the 2008 Current Workforce
Award recipient. Plastics Welding School. A two-day, hands-on course for certifi-
cation to European DVS-approved plastics welding standards
Smith Equipment, Watertown, S.Dak., received an Overall Per- for hot gas and extrusion techniques. Contact Malcom Hot Air
formance Achievement Award from Goodrich Corp.'s Sensors Systems, www.plasticweldingtools. com.
and Integrated Systems business.
Shielded Metal Arc Welding of 2-ln. Pipe In the 6G Position
FARO, Lake Mary, Fla., a provider of portable 3-D measure-
Uphill. Troy, Ohio. Contact Hobart Institute of Welding Tech-
ment and imaging technology, won the Defense Manufactur-
nology, (800) 332-9448, www.welding.org.
ing Excellence Award from the National Center for Advanced
Technologies.
Structural Welding: Design and Specification Seminars and
The welding program offered at Northeast Community Col- AWS Dl.l, Structural Welding Code Steel. Contact Steel
lege, Norfolk, Neb., will also be given by the school in South Structures Technology Center, www.steelstructures.com, (248)
Sioux City. The 36-credit-hour program will begin this fall. 893-0132.
Rockford Toolcraft Inc., Rockford, 111., has been recognized by Tool and Die Welding Courses. Troy, Ohio. Contact Hobart
Daimler Trucks North America, Portland, Ore., as a Masters Institute of Welding Technology, (800) 332-9448,
of Quality Supplier. www. welding, org.
A FocalSpot FSX-075, high definition X-ray system has been Unltek Mlyachl Corp. Training Services. Offers personalized
added to the Selective Soldering Process Development Lab at training services on resistance and laser beam welding and laser
ACE Production Technologies, Inc., Spokane Valley, Wash. marking. Call (626) 303-5676; visit www.unitekmiyachi.com.
Hypertherm, Hanover, N.H., has acquired the core assets of Victor Training Seminars. Programs for gas apparatus and serv-
MTC Software, Lockport, N.Y., a developer of computer-aided ice repair technicians, end users, and sales personnel. Visit
manufacturing software. www. victorequip. com.
Affiliated Distributors, Wayne, Pa., recently named PFERD
Advance, Leominster, Mass., as its Supplier of the Year. Welding Courses. A wide range of specialized courses pre-
sented throughout the year. Contact Lincoln Electric Co., visit
Hobart Institute of Welding Technology, Troy, Ohio, launched a www.lincolnelectric.com/knowledge/training/weldschool/courses.
revised Web site dXwww.welding.org with features including drop- asp, or call (216) 486-1751.
down menus, training information, and promotional materials
ordering, its library collection, and job bank for its students. Welding Introduction for Robot Operators and Programmers.
This one-week course is presented in Troy, Ohio, or at customers'
An OPTIMO 3-D laser cutting system has been delivered by locations. Contact Hobart Institute of Welding Technology, (800)
PRIMA North America, Inc., Chicopee, Mass., to Northern 332-9448, ext. 5603; www.welding.org.
Manufacturing Co., Oak Harbor, Ohio.
Welding Skills Training Courses. Courses include weldability of
The hand-held line of Niton XL3t Series XRF analyzers from ferrous and nonferrous metals, arc welding inspection and qual-
Thermo Fisher Scientific Inc., Billerica, Mass., has been rec- ity control, preparation for recertification of CWIs, and others.
ognized with a GOOD DESIGN Award by the Chicago Contact: Hobart Institute of Welding Technology, (800) 332-
Athenaeum Museum. 9448, visit www.welding.org.
WELDING JOURNAL
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WELDING JOURNAL
FIRST ANNOUNCEMENT
and
CALL FOR PAPERS
DV5
GERMAN WELDING SOCIETY
The American Welding Society, DVS - German Welding Society and The International Institute of Welding are
organizing their first International Electron Beam Welding Conference. This Two-day event will be held in conjunction
with the FABTECH International and AWS Welding Show, it will include a two-day Technical Program and a half day
Tutorial sponsored by the Pro-beam foundation. IEBW brings together scientists, engineers and technical personnel
from around the globe involved in the research, development, and application of Electron Beam Welding processes.
IEBW 2009 Program Organizers invite to submit your work for consideration of inclusion in the technical program.
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capture these high-quality technical presentations for later reference. Presentations focused on practical applications
of Electron Beam Welding will also be included in the conference proceedings.
To submit your work for consideration, visit our website at www.aws.org/iebw then follow the instructions at "Click
here to submit your abstract." All abstracts submissions must be completed by close-of-business on Wednesdav.
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This premiere event is truly one that anyone involved in the electron beam welding community
should plan to attend.
Mark your calendar now, and if you are interested in presenting your work at the conference,
submit your abstract no later than April 1. 2009.
prolbeam
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SUPPLEMENT TO THE WELDING JOURNAL, MARCH 2009
Sponsored by the American Welding Society and the Welding Research Council M
Welding Gun Inclination Detection and
Curved Fillet Weld Joint Tracking
An investigation was conducted to detect the welding gun deviation and inclination
simultaneously based on the welding current for the control of a mobile robot to
track curved fillet welds
distance (CTWD) cause variations in the developed that fits the arc currents to a
arc currents, these arc current variations plane in three dimensions using a least-
ABSTRACT can be used to detect the welding gun de- squares fitting method. The deviation of
viation. Due to its compact structure, re- the welding gun was obtained through cal-
It is important to adjust the welding sistance to arc light disturbance, and real- culating the intersection line slope of the
gun's inclination during automatic time capabilities, rotational arc sensing is fitting plane with the Y-Z plane, and the
curved-joint tracking of arc welding. In
this paper, a novel method is proposed
widely employed in automatic joint track-
ing (Refs. 5, 6). In the manufacturing of
inclination was calculated through the in-
tersection line slope of the fitting plane
o
to detect the deviation and inclination large ships and oil containers, there are with the X-Z plane.
of the welding gun based on the arc cur- many curved and broken-lined joints that A wheeled mobile robot consisting of a <
rents acquired by a high-speed rota- need to be welded. Since these workpieces differential driving vehicle and a cross- LU
tional arc sensor. It uses a least-squares are usually not welded in a workshop, the slider manipulator was developed. A rota- (/)
method to fit the arc currents to a plane welding paths are not easily prepro- tional arc sensor was used for measuring LU
in three dimensions. The deviation and grammed. When these joints are tracked the deviation and inclination of the weld- OC
inclination of the welding gun are pro- automatically in robotic welding, the incli- ing gun. A fuzzy controller was designed to
jected to two orthogonal planes so that
they can be decoupled and thus can be
nation errors of the welding gun are prob-
ably very great. Therefore, it is essential to
control the robot path and to extend the
horizontal slider based on the
O
calculated separately. A mobile welding adjust the inclination of the welding gun measurements.
robotic system was developed, which dynamically in order to achieve high-
consists of a differential driving vehicle quality welding. Dynamic Model of the Rotational
and a cross-slider manipulator. A fuzzy Kim and Na (Ref. 7) established a Arc Sensor
controller was designed to control the mathematical model for gas metal arc
LU
robot wheels and the horizontal slider
in the curved fillet weld tracking. Ex-
welding with rotational arc sensors, and
Yoo and Na (Ref. 8) improved the model
Figure 1 shows the equivalent circuit of
a gas metal arc welding (GMAW) system.
5
periment results show that the detec- for joint tracking and endpoint detection. The output voltage of the welding power
tion errors of welding gun inclination Shi and Yoo (Ref. 9) proposed a signal source can be calculated by
and deviation are approximately 7.85 pattern for joint tracking and endpoint de-
deg and 0.42 mm, respectively. tection after E. Halmoy (Ref. 10) simu- U(t) = Ue(t) + Ua(t) (1)
lated the joint tracking signals from a high-
speed, rotating electrode in gas metal arc where Ue and Ua are the voltages of the
welding of carbon steels. Their experi- wire extension and the welding arc, re-
ments were very close to the results of spectively. The arc voltage can be ex-
Introduction other researchers. pressed as
In this research, a novel method was
Real-time joint tracking is very impor- UJO = kaHa(t) + kpI(t) + Uc (2)
tant in robotic arc welding. Devices such
as arc and vision sensors have been em- where ka is the potential gradient across
ployed to detect the precise position of the KEYWORDS the arc column, kp is the equivalent resist-
joint (Refs. 1-4). In rotational arc sensing, ance of the cathode and anode spots, and
the welding electrode rotates as it moves Fuzzy Control Uc is a constant in the welding model.
along a V-joint or a fillet weld. Because the Gas Metal Arc Welding The voltage of the wire extension Ue(t)
variations of the contact tip-to-workpiece Mobile Robot can be written as
Rotational Arc Sensor
Weld Joint Tracking Ue(t) = keHe(t)I(t) (3)
Y. F. GAO (gyf_2672@hotmail.com), H. Curved Fillet Weld
ZHANG, cindZ. W. MAO are with School ofMe-
where ke is the electrical resistance per
chanical & Electrical Engineering, NanChang
University, China. unit length of the wire extension, and
WELDING JOURNAL
Assuming I(t) in the quiescent point is /Q
and He(t) is HeQ, we have fy = kgHgQ, k^
= kglQ, kc = km +7k^HeQ, and kr = fc^/g
C^ and C2 are constants.
The relationship of wire feed rate and
the wire-melting rate is
-^ + V (t)-Vf(t) = ^-
dt \/ n/ ^ (7)
where Vf(t) is the wire feed rate.
From Equations 1, 2, 5, and 6, we can
get
clu(t)_dUe(t) dUa(t)
d d (8)
Fig. 1 Equivalent circuit of gas metal arc welding (GMAW) system.
^H *,. 4)
P d (9)
(2) j y -^ y- s^ i y r^
^M=k ^W 1
k.
d d d (10)
ioiJj^f
Cl ^^] ^|^S dV it dl
(')
W\^ d d (11)
(1) Electrically conducting tube (2) Uppa aligning bearings (3) Optical
Using Laplace transform for Equations
encode (4) Hollow shaft motor (5) Trachea (6) Shell (7) Slider (8) 7-11, we have
Under aligning bearings (9) Chamber (10) Hollow shaft (11)
Watercourse (12) Balance block (13) Cooling water room U(s) = Us(s)+Ua(s) (12)
-*#*F%%.
i|
slot
Vm(s) = kcI(s) + kjHfs) (15)
Optical encode P s
,(s)
Deep slot optocoupler
Based on Equations 12-17, Pan (Ref. 12)
developed the transfer function from H(s)
to I(s) as
Fig. 2 The construction of rotational arc sensor. A Cutaway view of rotational sensor; B the en-
I{s\ k s+k P s
coder of the rotational sensor. G\s\
H\s\ l-kNPls\\s + k P{s\ + k
r
(18)
where kN = kpki ,kq = kfa - k^ -
He(t) is the length of the wire extension. sensor is within a small area around the kak^jkm. When the welding power source
For GMAW, a melting model was de- quiescent point, the small-signal theory is has the hard output characteristic, its
veloped by Lesnewich (Ref. 11) in which justifiable for analysis, and He(t)I(t) and transform function can be written as
the wire-melting rate is He(t)I2(t) can be linearized according to a
first-order Taylor series. Based on the as- P(s) = PQ (19)
Vm(t) = kmI(t) +k^He(t)P(t) +Cm (4) sumption. Equations 3 and 4 can be lin-
earized as So the transfer function of the arc sensor
where fcp can be regarded as the influence becomes a first-order model and can be
of resistance heating on the melting rate, Ue(t) = kfi^+kflgit) +C1 (5) written as
km is the influence of arc heating on the
melting rate, and Cm is a constant. If we Vm(t) = kJitj+kjHgit) + C2 (6)
assume that the working range of the arc
22
J
111
a i ^
y1
Jr
i? /
16 y
!S r*f
14 ^s^!Z>
r
13
12
n
i&
i 2 3 4 S ? S 910 ^0 30
Frequency/Hz
WELDING JOURNAL
Table 1 Welding Conditions for Experiments
foriginal signals)
Items Parameters
,r Welding machine Miller DeltaWeld 450
Shielding gas 85%Ar + 15%C02
Mean filtering Welding wire Real core wire, 1.2-mm diameter
Welding speed 36 cm/min
,r Welding voltage 28 V
Rotational radius 3 mm
Space neighborhood Welding wire feed rate 200 mm/s
median filtering Gas flow rate 15 L/min
,r
Mean filtering Table 2 Experimental Results of Dynamic Character Identification
. ^.i. ..
4
aCi-1,0) *
a(i,0) - 'f ' r .
aCi+1,0) # n - V* f/A ' '
m 1
J fe
i?" C
I A i o
i
a(n;0) * 64 128 192 256 320 384
Time direction k Sample points
Fig. 6 The principle of the space neighborhood median filtering method. Fig. 7 Welding current signals acquired by rotational arc sensor.
While the heights in interval [0,32] are not to fit the heights into a Welding-torch Welding-torch
symmetrical when e = -1.5 and 9 = 0, but plane, the plane will re-
flect the deviation and in-
N
the heights in [0, 64] are symmetrical. So
the symmetry of heights in interval [0, 32] clination of the welding
reflects the deviation of the welding gun gun. For the sake of clar-
ity, the graph of Fig. 11B Welding direction
and the symmetry of heights in interval [0,
64] reflects the inclination. This method is
and Fig. 11C is projected
into the X-Z and the Y-Z
o
called the interval integral method. Work-piece
surfaces, and shown as
Although the interval integral method <
Fig. 12.
is simple and easy, the symmetry of heights
The lines aa and a'a' LU
is destroyed when bothe 7^0 and 9 7^0 due
to the coupling of welding gun deviations
in Fig. 12 are the inter- CO
and inclinations (such as Fig. 9D), so it
section lines of the fitting LU
plane with the X-Z plane, /^N 0C
cannot detect the deviation and inclina-
tion simultaneously.
and the lines bb and b'b'
are the intersection lines
of the fitting plane with
e-
N^- O
the Y-Z plane. It can be
Welding Gun Deviations and
seen that the slopes of
Inclinations Detection Method
lines aa and a'a' are only Fig. Welding gun space attitude sketch.
related to the deviations,
The Construct of Character Plane
and the slopes of lines bb
LU
Taking the welding of a V-groove as an
and b'b' are only related
to the inclinations. By
5
example, a Cartesian frame as shown in
Fig. 10 is constructed. The frame [X Y Z
O] is linked to the welding gun, and the co-
ordinate origin is the center of the arc ro- Table 3 Experimental Results of Welding Gun Inclination Detection
tation, the Z axis is parallel with the axis of Actu; il values (deg) Detection values (radi Variances (radian)
the welding gun, and the X axis is parallel -45 -0.9079 0.1027
with the direction of welding. -34 -0.6215 0.1219
Because the welding velocity is far less -22 -0.4416 0.1217
than the arc rotation velocity, the height of -11 -0.3136 0.1637
welding gun H(t) can be computed as 0 0.0136 0.1860
11 0.0930 0.1243
Equation 24 in one rotation cycle, and
22 0.3601 0.1085
X(t) and Y(t) can be written as 34 0.4701 0.1122
45 0.6046 0.1105
x (| = roos(ot + ;z72|
\y(tyr^(m + nl2] ^
Based on Equations 24 and 25, the graph
Table 4 Experimental Results of Welding Gun Deviation Detection
of heights in one rotation cycle is plotted
in three dimensions in Fig. 11.
Actual values (mm) Detection values Variances
From Fig. 11, it can be seen that the 3 mm 0.7733 0.0843
heights of the welding gun show different 0 mm 0.0515 0.1670
three-dimensional characteristics in space -3 mm -0.7812 0.0723
with the change of deviations and inclina-
tions. If we use the least-squares method
WELDING JOURNAL
Experimental Study
o i=\ (29)
Using the differential method to solve
(e<0). Because the shape of the welded
fillet joint is in an arc, the inclination of the
gun changes from forward incline to back-
projecting the deviations and inclinations Equation 29, we have
to two orthogonal planes, they can be de- ward incline. Thus, the detection results
coupled and calculated. representing the deviation and inclination
H.-Yx.p ^ = 0(i = 0,l,2) will be a time-variable function. The de-
The Mathematical Method for tection results are shown in Fig. 15.
y=o (30)
Solving Fitting Plane From Fig. 15, we can see that the de-
Changing Equation 30 to tection results of deviation and inclination
Suppose Hi, Xp and_y;- are the discrete n n 2 are in accord with the actual ones, which
points of H(t),x(t), andy(t), respectively. TH.X, =yy x..xnB verifies that the proposed method can cor-
Based on the analytic geometry theory, a ;=1 /=iy=o rectly detect the deviation and inclination
space plane equation can be shown as 2 of the welding gun simultaneously.
Z = Ax + By +C (26)
=1 t-i ijs ik
n Curved Fillet Joint Tracking by
7=0 i=\ (31) Mobile Robot
Expressed by matrix, the above equation
In order to facilitate discussion. Equation can be written as
26 is changed to Design of Mobile Welding Robot
r r
X H=(X X)$ (32) Figure 16 shows the mobile welding
Z = p0 + (3F1 + (3^2 (27)
robot. The robotic welding system consists
By analyzing, we know that the matrix of a main controller, a robot body, driving
Vector and matrix marks are introduced XTX is a positive matrix, therefore it has actuator parts, and a rotational arc sensor.
an inverse matrix (^X)-1. So (3 can be An industrial computer is used as the main
computed as controller. The welding current is meas-
ured by a Hall-effect current sensor and is
p = (jKrr1. (33) acquired by a plug-in DAQ board (Ad-
-60
-0.8-0.6-0.4-0,2 0 0.2 0.4 0.6 0.8
-; Detection values of inclination
> 28
Fig. 13 The relationship between real values
*' /-\ and measured values of welding gun inclination.
N 24 V
- "A{ '^- -^ y a'
/^ N 24
/^Cx
^^
22
- V yS
2!
N^
""" ^ ^v.
-2 D ;
v
B Theproject graphofFig.il (c)( e^l ^ ^0)
30 40 50 60 70 80
Sample points
o
30
r\"*-*-%.<.- <
LU
a 10
*f
(/)
o
* % LU
Fig. 14 The experiment of curved fillet welding.
1o -10
v-V-'A- .' -.. OC
30
O
C 10 20 30 50 SO 70 80 I
ventech PCI-1713). The control value is ear velocity of the welding gun's front-end ^ Sample points
sent to driving actuator parts by a plug-in point, and vr is the reference linear veloc- Fig. 15 The measured results of curved fillet ^"
data output card (Adventech PCI-1723). ity. We then know that the angular error is welding. A Detection results of deviations; B lU
The robot body consists of a differential a. The inclination of the welding gun de- detection results of inclinations. ^^
driving vehicle and a cross-slider manipu- tected by the rotational arc sensor is 6, and
lator. The right and left wheels are driving apparently 6 is equal to a. So the control
wheels and the front and back wheels are The Design of Multisegment
process is described as follows: when Controller
omnidirectional. The mass center of the
tracking the curved fillet joints, the devia-
mobile robot is in the middle of the axis of
the driving wheels, and the cross-slider is tions are used to control horizontal slider For controlling the horizontal slider, a
over the axis of the driving wheels and can extension, and the inclination is used to multisegment controller was proposed
move horizontally and vertically. In order control the wheels moving and turning and the key idea is shown in Fig. 19. The
to avoid skidding, four magnets are at- along the joints. controller is composed of a proportion
tached in four corners under the body. The fuzzy controller used to control the controller and a fuzzy controller. When
The driving part is composed of four welding gun was described in Hu (Ref. 13), the deviation is large, the proportion con-
Maxon RE35 DC servo motors, and they Wang (Ref. 14), and Liang (Ref. 15). In troller will be used to quickly reduce the
drive two wheels and the cross-slider, re- this project, a fuzzy controller was devel- deviation, otherwise the fuzzy controller
spectively. The rotational arc sensor is at- oped to deal with the disturbance of the will be used to avoid overshoot and
tached to the cross-slider to detect the de- welding processing and the dynamic un- achieve smooth tracking. In view of that, a
viation and inclination, and it is used as a certainties of mobile robots. The control fuzzy controller cannot eliminate static er-
welding gun as well. scheme is shown in Fig. 18. rors. An integral operation was intro-
It is composed of two fuzzy controllers. duced, and its principle is described as fol-
The Design of the Controller for Tracking One is a multisegment controller that is lows: the deviation change rate is used as
Curved Fillet Welds used to control horizontal slider extension, a switch threshold, and when it is small,
for eliminating the deviations, and the other the deviations will be integrated and then
For the curved fillet joint tracking, as is a traditional fuzzy controller that is used are put into the fuzzy controller, otherwise
shown in Fig. 17, vc and a)c are the robot's to control the moving and turning wheels, the deviations will not be integrated.
current center linear velocity and angular for the elimination of inclinations. The con- The two inputs of the fuzzy controller
velocity, respectively. Suppose vt is the lin- trol cycle of the two controllers is equal. are the welding gun deviations e and its
WELDING JOURNAL
Welding seam
Welding-torch
CO
Robot 1 -
Fig. 16 Structure of mobile welding robot. Fig. 17 The sketch of curved fillet weld joint tracking.
Miilti-segiiient
< Honanttel slida-
contiolla'
3"f
t
-*$- adjustment
Fuzzy contiollei'
Rotational aix;
m saisoi
ivg. i5 Controller frame of tracking curved fillet welds. Fig. 19 The principle frame of horizontal slider.
O
NB NM NS ZE
m
0) -0.4 0 0.4 0.9
Membership Funclion of e
m
>
33 B 1,0 -0,75 -0.4 0 0.4 0,75 1.0 ec(mm)
O Membership Function of ec
NM NS ZE
f/g. 20 Membership function of fuzzy controller for horizontal slider. Fig. 21 The tracked curved weld joint shape.
(Positive Big), PM(Positive Middle), PS fleets the different weights of e and ec, so
(Positive Small), ZE (Zero), NS (Negative the parameters of the fuzzy controller can
Table 5 Measuring Results of Tracking Errors Small), NM (Negative Middle), NB (Neg- be changed by adjusting a. Usually e
ative Big)}, The membership functions of should be eliminated when it is big, so a
Number LI (mm) L2 (mm) e (mm) inputs and output are shown in Fig, 20, should be augmented. On the contrast, a
Section 1 6.3 6.5 0.141 For fuzzy control, the mathematical should be reduced. In view of the real-time
Section 2 6.5 6.3 -0,141
Section 3 6.7 6.0 -0.495 model of adjusting the modifying gene can application of welding joint tracking, a
Section 4 6.6 6.1 -0.354 be written as function is used to modify a and it is writ-
Section 5 6.2 6.5 0.212 ten as
A
2
iments were Miller DeltaWeld 450 weld-
ing machine, 85% Ai+15%C02 shielding
gas, 17 L/min gas flow rate, 24 cm/min 1
J
fV> fr AA
J\JV
g 0.4
s
/\
WELDING JOURNAL
Heat Transfer and Fluid Flow during Electron
Beam Welding of 304L Stainless Steel Alloy
Models were used to calculate the three-dimensional temperature field and fluid
velocities for electron beam welding of 304L stainless steel
Fig. 1 Beam shape for 0.17-mm beam radius Fig. 2 Fluid flow pattern in electron beam weld for focal spot radius of the following: A 0.13 mm;
produced at sharp focus settings for 1000-W power B 0.28 mm. Labels 1, 2, and 3 represent 1697, 1900, and 2200 K, respectively,
at a work distance of 229 mm.
process is the power density distribution. The stainless steel workpiece had a com- at 1/e2 of the peak intensity (FWe2) are
In this work, the model was applied to position of 18.2%Cr, 8.16%Ni, 1.71%Mn, measured. The beam radius was taken to
welds made on 304L stainless steel with 0.02%C, 0.082%N, 0.47%Mo, 0.44%Si, be Vi of the FWe2 value measured by the
fixed input power and welding speed but 0.14%Co, 0.35%Cu, 0.0004%S, 0.03%P, EMFC. Figure 1 shows the beam shape for
different power density distributions. The and balance Fe. Six welds were made using the case of a 0.17-mm focal spot radius,
power density distribution was varied by
changing the work distance and then refo-
a sharply focused beam at different work
distances (Table 1). The resulting weld
from EB welding machine model number
SN/175 manufactured by Hamilton Stan-
o
cusing the electron beam to a sharp spot pool cross sections were polished and dard at a 229-mm work distance (Ref. 28).
on the workpiece surface. The increase in etched with electrolytic oxalic acid solu- Since the beam has an elliptical shape, the <
the focal spot diameter with increasing tion to provide the outline of the fusion effective value of the beam radius was LU
work distance also affects the geometry of zone boundary. Image Pro, Version 4.1 taken as the radius of a circle with an area if)
the weld pool shape (Ref. 28). The calcu- was then used to measure the weld di- equal to the actual beam spot (Ref. 28). LU
lated and the experimental weld geome- mensions (Ref. 28). The beam shape and radius may vary with
tries were compared for each case and the The sharp focus condition was deter- distance from the focal plane, which can
0C
effect of variation of power density distri-
bution on the weld geometry was investi-
mined by using an enhanced modified
Faraday cup (EMFC) device to ensure a
affect the weld geometry. However, due to
a lack of data on the divergence of the
O
gated. The resulting fluid flow circulation more consistent and quantified beam beam near the focal plane, its effect has
patterns in the 304L stainless steel elec- focus than is manually possible (Ref. 28). been neglected in this work.
tron beam weld pools were studied. The The EMFC device samples the electron
nail-head-shaped weld cross section of beam through 17 linear slits placed radi- Mathematical Model
electron beam welds observed in this study ally around a tungsten slit disk and con- LU
was explained in terms of the fluid flow
and resulting convective heat transfer.
verts them into voltage drops across the
known resistor. A computer-assisted to-
Calculation of Keyhole Profile
5
mographic (CT) imaging algorithm is then Quasi-steady state and flat top surface
Experiments used to reconstruct the power density dis- outside the keyhole region are assumed.
tribution of the beam using the data from The fluctuations of the keyhole shape and
Autogenous electron beam welds were the 17 linear slits. From the reconstructed size have been neglected. Energy balance
made on 9.5-mm-thick 304L stainless steel beam, the peak power density, full width is performed on the liquid-vapor interface
samples with a power of 1000 W (100 kV, of the beam at half of its peak intensity to calculate the keyhole geometry using a
10 mA) and a welding speed of 17 mm/s. (FWHM), and the full width of the beam model that is available in literature (Refs.
Table 1 Experimental and Calculated Weld Dimensions for Welds Made at 1000-W Input Power and 17 mm/s Welding Speed Using Electron
Beam Welding Machine S/N 175
WD Rf PPD dm dc % w
m w
c % MA AR
mm mm kW/mm2 mm mm error mm mm error mm2
127 0.131 34.9 4.46 4.20 -6.19 1.27 1.38 7.97 2.40 3.52
184 0.166 21.6 4.21 3.87 -8.79 1.29 1.52 15.13 2.55 3.27
229 0.173 20.0 3.97 3.80 -4.47 1.48 1.58 6.33 2.63 2.65
305 0.207 14.1 3.69 3.56 -3.65 1.48 1.68 11.90 2.58 2.49
381 0.243 10.2 3.39 3.33 -1.80 1.55 1.76 11.93 2.56 2.19
457 0.279 7.79 2.96 2.97 0.34 1.71 1.90 10.00 2.62 1.73
WD; work-distance, Rj: radius of focal spot; PPD: peak power density; d; depth; w: width; subscripts m and c stand for measured and calculated; MA: melted cross-sectional
area; AR: aspect ratio.
WELDING JOURNAL
9.0
E 8.0
E
N
7.0
100 mm/s
6.0
2.0 3.0 4.0 5.0 6.0
X , mm
-1.0 o.o 1.0 '-1.0 o.o i.o ' :i.o o.o i.o
A Y, mm B Y, mm C Y, mm
7.0-
100 mm/s
6.0
2.0 3.0 4.0 5.0 6.0
X , mm
9.0-
-1.0 0.0 1.0 -1.0 0.0 1.0 1.0 0.0 1.0
D
Y, mm E Y, mm F Y, mm
E 8.0-
m Fig. 3 Fluid flow in the weld made with 0.28-mm beam radius in transverse planes at the following
E
N
locations behind the electron beam: A 0.11 mm; B 0.28 mm; C 0.45 mm; D 0.62 mm; E 7.0-
ft 78 mm; and F 0.95 mm. Only the top 3.5 mm of the total plate thickness of 9.5 mm is shown. 100 mm/s
6.0
o 12, 19-23). The temperature gradient in p = pgz + Y(T)/r(z) (1)
2.0 3.0 4.0
X , mm
5.0 6.0
:T:T:t
^^^
".--1 1
E
E
3.0- m
0) Measured Calculated
^^^
Q
Linear (Measured) - - - Linear (Calculated)
on
0. 13 0.18 0.23 0. 28
Focal radius, mm
9 A
B
- - - -1 0 1
Y, mm
1.6-
r ~ " ' -
9 :-
f
E
E 8
. 0.8-
4-1
o Measured Calculated 7 1
V
- - - Linear (Calculated) Linear (Measured) 6
0. 13 0.18 0.23 0.28 5^
-1 0 1
O
Focal radius, mm
Y, mm
<
Fig. 5 A Variation of weld depth with spot radius; B variation of weld width with spot radius. Kg. 6 Comparison of experimental and calcu- LU
TTT
lated weld geometries for focal spot radii: A \Ji
0.131 mm; B 0.173 mm; C 0.207 mm; D III
0.243 mm; E 0.279 mm. Input power: 1000 W. ff
Welding speed: 17 mmls. "
o
verge. During calculation of the asymmet- values for the solid phase were tempera- metal flow in the weld pool can be repre- ~~
ric keyhole geometry, all temperatures in- ture dependent and the thermal conduc- sented by the following momentum con- ^J
side the keyhole were assigned the wall tivity data were available up to a tempera- servation equation (Refs. 33, 34): ^J
temperature at that depth, for the identi-
fication of the keyhole. At each horizontal
ture of 1273 K. Approximate thermal
conductivity values above this tempera-
m
xy plane, where x is the direction of weld- ture were estimated based on linear ex- du dlu.u. du
ing, the keyhole boundary was identified trapolation of the experimental data for (2)
by both minimum and maximum x values 304L stainless steel (Ref. 31). Thermal dt etc. ar.
for any given}1 value. conductivity for liquid was calculated
The attenuation of the beam due to ab- based on the Wiedemann-Franz relation,
sorption and scattering, as it traverses a which states that the ratio of thermal con- where p is the density, t is the time, J:;- is the
unit distance in the plasma, is estimated by ductivity to the product of temperature distance along the ;'"' (i = 1, 2, and 3) or-
using attenuation coefficients (Ref. 12). and electrical conductivity is a constant thogonal direction, u; is the velocity com-
The beam attenuation affects the amount (Ref. 32). The electrical conductivity of ponent along the j direction, |i is the ef-
of electron beam energy incident on key- liquid stainless steel was taken as the elec- fective viscosity, and S: is the source term
hole walls below the workpiece surface. It trical conductivity of liquid iron at its the- for the /* momentum equation and is
is assumed that the energy loss due to oretical melting point, which was close to given as {
large angle backscattering of electrons by the value obtained by extrapolating the
dp | 9 du?
1
the plasma in a deep, narrow keyhole is data for electrical resistivity of 18Cr-8Ni S.= I1
small (Ref. 30). Consequently, a small steel between 300 and 1273 K to the liq- doc. dx. dx.
value of attenuation coefficient has been uidus temperature (Ref. 29).
J ' v 1J
u +
1 *sAT-T*t)
beam plasma here, 99% and 96% of the V J
electron beam passes through lengths of 1 After calculating the keyhole profile, du.
and 4 mm, respectively, through the the fluid flow and heat transfer in the weld
pi J '
(3)
plasma. Table 2 lists the values of material pool are modeled by solving the equations dx
properties and process parameters used of conservation of mass, momentum, and
for the calculations. Thermal conductivity energy in three dimensions. The liquid where/? represents pressure, f/is the weld-
WELDING JOURNAL
tions were solved for the complete work-
A0.28mm 0.13 mm | - V II ; - II II piece. For the region inside the keyhole,
|o.6-
3 0,4-
9
A\: 9 - i the coefficients and source terms in the
discretized algebraic equations were ad-
8 8 justed to obtain zero fluid velocities and
E E
5 0.2- E temperature equal to the wall tempera-
E
> 7
N
7 - ture at that depth. The methodology for
N
the implementation of known values of
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 40 6 6
z, mm
variables in any specified location of the
:
5_ Jx 5_ Y solution domain is well documented in the
1 0 1 1 0 1 literature (Ref. 34).
Fig. 7 Variation of vapor pressure in the keyhole A Y, mm Y, mm B
with depth for radius of 0.13 and 0.28 mm. z = 0 at Boundary Conditions
the surface of the workpiece. ^ w
y
9 - \ i
3000 -
4 0 28 mm 0 13 mm I ,"
9
8
rVY 8 -
i i
I)
A 3-D Cartesian coordinate system is
used in the calculation, and only half of the
^ E E workpiece is considered since the weld is
<D
" E E symmetrical about the weld centerline.
.-l
^ 2800 - V N
7
N
7
The boundary conditions are discussed as
E follows.
0)
O. 2600 - 6 - 6 -
E .A4*
; :
u
5_
Top Surface
5
1 0 - 1 o -
^ 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 Y, mm Y, mm Outside the region of vapor cavity, the
z, mm c D weld top surface is assumed to be flat. The
velocity boundary conditions are given as
^^ Fig. 8 Variation of keyhole wall temperature with Fig. 9 Weld pool cross sections for focal spot (Refs. 40-43)
^0 depth for radius of 0.13 and 0.28 mm. z = Oat the radius of 0.13 mm: A With convection and B
^" surface of the workpiece. without convection; and 0.28 mm: C with du _ rfy_9r
convection and D without convection. Input
L
power: 1000 W, welding speed: 17 mm/s. dz dT dx
dy dT
= /L
o dz
w=0
dT dy
(8)
ing velocity, (3 is the coefficient of volume heat of fusion. The liquid fraction/^ is as-
expansion, and TWis a reference temper- sumed to vary linearly with temperature
m ature taken here as the solidus tempera- for simplicity (Ref. 37):
where u, v, and w are the velocity compo-
nents along the x, y, and z directions, re-
(/) ture. The third term represents the fric- spectively, and dy/dT is the temperature
m tional dissipation in the mushy zone
according to the Carman-Kozeny equa-
coefficient of surface tension. As shown in
> T>T, this equation, the u and v velocities are de-
tion for flow through a porous media termined from the Marangoni effect
33 (Refs. 35, 36), where/^ is the liquid frac- T-T
o tion, fi is a very small computational con-
stant introduced to avoid division by zero,
T
L- ST
T <T<T (5) (Refs. 40-43). The w velocity is equal to
zero since the outward flow at the top sur-
face is assumed to be negligible.
and C is a constant accounting for the r<r The heat flux at the top surface is given
mushy zone morphology (a value of 1.6 x
104 was used in the present study) (Ref.
36). The fourth term is the buoyancy where 7^ and Tg are the liquidus and
source term (Refs. 37-41). The last term
accounts for the relative motion between
solidus temperatures, respectively. Thus,
the transport of thermal energy in the
f[x2+y2]
the electron beam and the workpiece weld workpiece can be expressed by the 92 2
tap TVb
(Ref. 37). following modified energy equation:
The following continuity equation is
solved in conjunction with the momentum
-oel TA-TA\-h{T-T\
_k_dh_ + S
equation to obtain the pressure field. p+P^'-=
dt cbc. dx. C dx
(6) -Th J .
^^ V,l V,l (9)
V P ' ;=1
WELDING JOURNAL
distance of the transverse section from the comes narrower and deeper as the beam at the top surface of the workpiece. The
heat source increases, fluid gradually radius is decreased. The narrower key- differences in shape and size of the cal-
starts to come downward and the reversal hole for lower focal spot radius requires culated weld pools in absence of and in
of the direction of fluid velocity from up- a larger vapor pressure to balance the the presence of convection indicate the
ward to downward happens at shorter dis- surface tension force that tends to close significance of convective heat transfer
tances from the top surface. the keyhole. Therefore, vapor pressures under the conditions considered.
In the longitudinal sections shown in are higher for the higher peak power den-
Fig. 4, the fluid moves upward near the sities obtained with the smaller focal spot Summary and Conclusions
heat source location and circulates back- radii. In accordance with higher vapor
ward near the top surface resulting in en- pressures in the keyhole for the smaller The geometry of the keyhole formed
hanced heat transfer toward the rear of beam radius, equilibrium wall tempera- during electron beam welding was calcu-
the weld pool and an elongated weld pool. tures at the keyhole walls are higher for lated through an energy balance at the
The circulation pattern is similar in all of the beam radius of 0.13 mm as compared keyhole walls considering the variation of
the longitudinal sections shown in Fig. 4 to the larger beam radius of 0.28 mm as vapor pressure and keyhole wall tempera-
located at different distances from the shown in Fig. 8. The higher keyhole wall ture with depth. A numerical heat transfer
weld centerline. temperatures calculated for the smaller and fluid flow model was used to calculate
As shown in Table 1, an increase in focal spot radius are consistent with more the three-dimensional temperature field
work distance from 127 to 457 mm re- intense heating. The average tempera- and fluid velocities for electron beam
sulted in more than a twofold increase in ture gradient in the perpendicular-to- welding of 304L stainless steel. A turbu-
the beam focal spot radius (Rf). With a welding direction was always significantly lence model based on Prandtl's mixing
larger focal spot radius, the beam is more higher than that along the keyhole wall in length hypothesis was used to estimate the
diffuse and the peak power density is the vertical direction. For example, for effective viscosities and thermal conduc-
lower, decreasing from 34.9 kW/mm2 for the weld made with the beam radius of tivities in the weld pool. The vapor pres-
127-mm work distance (focal radius = 0.28 mm, the average temperature gradi- sure in the keyhole was calculated through
0.13 mm) to 7.79 kW/mm2 for 457-mm ent in the weld pool at mid-height of the a force balance on the keyhole wall con-
work distance (focal radius = 0.28 mm) keyhole in the horizontal direction was sidering the surface tension force, the hy-
(Ref. 28). As a result, the weld character- about 26 times that in the vertical direc- drostatic force, and the force due to vapor
m istics are likely to be strongly affected by
the variation in beam radius. Figure 5A, B
tion. Thus, the assumption that the tem-
perature gradient in the vertical direction
pressure. The wall temperatures were cal-
culated from equilibrium temperature-
shows the variation of weld pool depth and is small compared to that in the horizon- pressure relations for the alloy.
g width at the top surface, respectively, with tal plane is justified. Since the variation The calculated weld pool depth and
z the variation in the focal spot radius. The of vapor pressure from the bottom to the width were compared with experimen-
tally observed values for a set of experi-
o calculated weld width and depth display
trends similar to the measured values.
With an increase in beam radius, the input
top of the keyhole results in less than a
15% variation in the wall temperature,
any errors in vapor pressure calculation
ments where the power density distribu-
tion was varied by changing the focal spot
energy distribution is more diffuse and the are likely to result in much smaller errors radius at a fixed input power. As the focal
m peak power density decreases, thus de- in the computed wall temperatures. spot size increased and the power distri-
(/) creasing the weld penetration. However, a The significance of convective heat bution became progressively diffuse, the
m larger focal spot radius increases melting
on the top surface, resulting in a wider
transfer relative to conductive heat trans-
fer is given by the Peclet number,
penetration depth decreased and the
weld width increased proportionally in
> weld pool. Thus, the ratio of weld pool Pe=pMCp(viV2)/&:,where p is the density, u order to maintain the total weld cross-
33 depth to width decreases with increasing is the characteristic velocity, is the spe- sectional area for the fixed input power.
o beam radii, as shown in Table 1. The area
of calculated weld cross section is nearly
cific heat, w is the weld pool width, and k
is the thermal conductivity. Using p =
Higher peak power density with the same
input power resulted in higher peak tem-
constant with variation in the beam radius. 7000 kg/m3, u = 0.1 m/s (the value of ref- perature and vapor pressure at the key-
Figure 6 shows the comparison of cal- erence velocity vector in Fig. 2), Cp = 800 hole bottom. Fluid circulation in the weld
culated and experimental weld cross sec- J/kg-K, w/2 = 8.0 x 10-4 m, andlc = 30 pool was studied for transverse sections
tions for different focal spot radii. The W/m-K, Pe = 14.9. Therefore, convective located at different distances from the
dashed lines show the calculated keyhole heat transfer is very important for the electron beam. Convective heat transfer
profile. The calculated keyhole radius at welding conditions studied here. was very significant in determining the
the top surface of the weld is closely related To further illustrate the significance of weld geometry, as shown by Peclet num-
to the electron beam radius. The calculated convection on the weld pool geometry, ber calculations. In the absence of con-
weld cross sections are similar to the ex- the temperature field in the workpiece vection, the calculated nail head shape of
perimentally observed weld cross sections. was calculated by considering only con- the weld pool was not obtained. The re-
The experimentally observed nail-head ductive heat transfer and ignoring fluid duced heat transfer near the top surface
shape of the weld cross section is predicted flow. Figure 9A, C shows the calculated in the absence of convection resulted in a
by calculations as well. Even though the weld pool cross sections for the case of much narrower calculated weld pool, fur-
beam divergence may contribute to the 0.13- and 0.28-mm focal spot radius, re- ther illustrating the significance of con-
nail-head shape, this characteristic shape of spectively, with convection, and Fig. 9B, vective heat transfer for the conditions of
electron beam welds can also be explained D shows the corresponding weld cross welding considered.
in terms of Marangoni convection. sections in the absence of any convection.
The keyhole and weld geometry de- In the absence of convection, heat trans- Acknowledgment
pends on the keyhole wall temperatures, fer is significantly reduced, which results
which in turn depend on the vapor pres- in much narrower weld pools. The calcu- The work was supported by a grant
sure in the keyhole. Figure 7 shows the lated weld pool in absence of convection from the U.S. Department of Energy, Of-
variation of vapor pressure with depth for also lacks the nail head shape usually ob- fice of Basic Energy Sciences, Division of
beam radii of 0.13 and 0.28 mm. For the served in experiments because of the ab- Materials Sciences, under grant number
welds shown in Fig. 6, the keyhole be- sence of enhanced outward heat transfer DE-FGO2-01ER45900.
WELDING JOURNAL
Metallurgical Investigation into Ductility Dip
Cracking in Ni-Based Alloys: Part II
Microstructural and microchemical development is characterized during simulated
weld reheat thermal cycle and correlated to ductility dip cracking susceptibility
80
80 \
\
70 70
"
60 I 60
f
50
i : 50
40 "^ ^A600 minimum
ductility
40 on-heating
on-hea ting
cooling rate
on-coo ing
on-cooling 30
30 1000 1200 1400 1600 1800 2000 2200 2400
1000 1200 1400 1600 1800 2000 2200 2400
Temperature: 0F
Temperature: "F
C 100
FM82H 100
S 90 FM52
90
80 80
70 70
60 60
50 50
on-heating on-heating
FM82H minimum
40 on-cooling 40 on-cooling
o
A on-cooling from M7C3 soivus ductility A on-cooling from M23C6 soivus
60s hold, on-cooling 60s hold, on-cooling
30 I 30
1000 1200 1400 1600 1800 2000 2200 2400 1000 1200 1400 1600 1800 2000 2200 2400
Ni Cr Fe C Mn Si Cu Nb Ti Al Ti +Al Mo Other
WELDING JOURNAL
'free-cooling' in the Gleeble, select samples
B migrated boundary were rapidly quenched from their test tem-
/ perature for subsequent microstructural
Cr rich ppt and microchemical characterization.
Cr rich ppt The objective of this work is to charac-
terize the microstructural and micro-
chemical development of A600, A690,
FM82H, and FM52 during both heating
and cooling portions of a simulated weld
Cr rich matrix thermal cycle, and to correlate these mi-
crostructural changes to DDC susceptibil-
o
s l600 Fon-heat 2421 peak T ESSAJLCD gsjjm saas stm ity. As a first step, the majority of this char-
acterization work was carried out on
samples that were exposed to the weld
thermal cycle, but without being strained.
This approach captures the microstruc-
Cr rich ppt ture present immediately before strain
was applied in the form of a Gleeble hot
ductility test as described in the first
paper. The microstructural evolution in
these unstrained samples will be com-
pared to the DDC susceptibility of the al-
loys, which was determined in previous
18590F on-cool 1600oF on-cool work (Ref. 1.) This work will provide fur-
CESSoSaim %$WS& f^sfc ana
ther insight into the metallurgical mecha-
nism(s)ofDDC.
m Experimental Procedure
Cr rich ppts- Sample Preparation
g
z A total of four alloys were investigated
as part of this work: A600 (UNS: N06600),
o A690 (UNS: N06690), FM82H (AWS: ER-
NiCr-3), and FM52 (AWS: ERNiCrFe-7).
Cr rich ppts A600 and A690 were the two wrought al-
m o
1600 F on-cool 1100oF on-cool 5iiasnaisa SSolstS? sse&
loys. FM82H and FM52 are the companion
weld filler metals for A600 and A690, re-
m Fig. 2 ^4600 water-quenched SEM micrographs. A 160(fF on-heating; B 24210Fpeak tempera-
spectively. Nominal compositions for each
alloy are given in Table 1. A600 and A690
> ture; C ISSQ'F on-cooling; D and E 1600oF on-cooling; and F 1100oF on-cooling. EDS used to
form the base metal material in multipass
J3 identify composition of various regions and precipitates indicated on micrographs.
weldments of many industrial applications
O and were therefore tested in the wrought
condition as part of this work. The weld
are not expected. The exact role of inter- ond limiting factor in previous work since filler metals were tested in the as-solidified
granular precipitates on DDC remains un- reheated weld metal experiences both condition, which allowed the DDC suscep-
clear. Specifically, IV^Cg may be the heating and cooling. To determine when tibility and microstructural evolution during
cause of DDC, contribute to it, or be the reheated weld metal is metallurgically the first weld thermal cycle to be studied.
merely coincidental. most susceptible to form DDC, both the Details of the specimen design are pre-
Previous investigations into DDC have heating and cooling portions of the thermal sented elsewhere (Ref. 1).
had several limitations in their experimen- cycle must be evaluated. There is a poten-
tal approach. Multipass weld mock-ups tial limitation of performing microstruc- Testing Parameters and Design
have been used to assess the DDC suscep- tural characterization on Gleeble speci-
tibility of candidate filler metals (Refs. 20- mens that are allowed to 'free cool' in the The heating rate for the on-heating
22). However, these samples experience Gleeble vacuum jaws from their testing tests was 200oF/s (lll0C/s), while the cool-
complex and multiple thermal- temperature. Preliminary testing showed ing rate for all on-cooling tests was 90oF/s
mechanical cycles that prevent accurate de- that this method of cooling would result in (50oC/s). He gas quench was used to aug-
termination of microstructures, and/or mi- cooling rates as low as 150F/s in the sample ment the cooling rate in the "on-cooling"
crosegregants that cause ductility dip design used for this work. This may allow samples because the maximum "free cool"
cracks to form. This problem can be re- enough time for diffusive processes to cooling rate that could be obtained in the
solved by using a hot tensile/Gleeble- occur that can change segregation profiles Gleeble was so low (150F/s). The heating
based test that exposes single-pass samples and/or form secondary phases that may not and cooling rates were based upon ther-
in the as-solidified condition to a simulated have been present at the elevated temper- mocouple measurements taken from a
weld thermal cycle. Gleeble-based test- ature where the cracking susceptibility of standard weld joint during typical multi-
ing has been used by several investigators, the alloy was determined. Therefore, to pass welding conditions. Samples were hot
but only the heating or cooling portion of minimize the potential for diffusional mi- ductility tested at 1250F (510C) intervals
the weld thermal cycle has been investi- crostructural changes (e.g., precipitation, between HOOT (5930C) and the peak
gated (Refs. 4, 19, 23-26). This is the sec- Sulfur segregation) that may occur during temperature for each alloy. Smaller tem-
c 4000
3
8 3000 Cr rich ppt
>>
? 2000
X Cr rich
1000
matrix
0
0 3 4 5 6
Energy: keV
1600oFon-heat \55gs0[fe3 m^&sfi EMS 24220F peak T
Fig. 3 Two EDS spectra from A600 2421Fpeak
temperature superimposed on one another. The
Ti rich ppt
"dark matrix" refers to the "Cr-rich matrix" region
in Fig. 25. Sample was water quenched.
Table 2 Grain diameter data as a function of temperature along first reheat thermal cycle.
A600 A690
Temp (0F) Grain diam. (urn) Std dev. (|a,m) Temp (0F) Grain diam. (|a.m) Std. dev. (urn)
BM 41 7 BM 29 7
1100 on-heat 41 5 1100 on-heat 30 2
1600 on-heat 42 7 1600 on-heat 25 3
1859 on-heat 41 4 1972 on-heat 35 20
2422 peak T 50 8 2422 peak T 52 10
1859 on-cool 57 8 1972 on-cool 86 11
1600 on-cool 98 27 1600 on-cool 93 13
1100 on-cool 196 54 1100 on-cool 101 11
Table 2 (continued)
EN82H EN52
Temp (0F) Grain diam. (|xm) Std. dev. (Urn) Temp(0F) Grain diam. Om) Std. dev. (|j.m)
As-solidified 153 36 As-Solidified 294 40
1600 on-cool from 1967 158 38 1600 on-cool from 2077 269 51
1600 on-cool 142 34 1600 on-cool 263 50
1600 on-cool 158 38 1600 on-cool 2077 269 51
60-s hold @ 1600 144 38 60-s hold @ 1600 293 50
WELDING JOURNAL
B
Nb rich ppts
Nb rich ppts
/
^Ti rich Ti
rich /
/
ppt PP. /
^
WELDING JOURNAL^
chromium-carbide dissolution in A600
1600oF on-cool from FM82H B 60 sec hold at 1600oF FM82H
was incomplete. In FM82H there was no
19670F on-cool discernable dissolution of the NbC pre-
cipitates throughout the thermal cycle.
^Nb rich ppts Qualitatively, it appeared that there may
be a slight increase in intergranuiar NbC
Cr rich ppts precipitates at the peak temperature as
seen in Fig. 5B. The FM82H microstruc-
ture remains very stable, as can be seen in
Nb rich ppts the micrographs at 1600oF (8710C) and
SUB HOOT (5930C) on-cooling.
The microstructural results from mod-
ifying the thermal cycle in FM82H and
FM52 FM52 FM52 are shown in Fig. 7. Increased in-
tergranuiar carbide coverage was ob-
Tl rich ppts served when the peak temperature was
Tl rich ppt
lowered to the respective carbide solvus
for each alloy. The time at the solvus tem-
\ perature was short (less than 0.25 s) and
insufficient to cause any carbide dissolu-
tion. An isothermal hold at the on-cooling
Cr rich ppts ductility minimum temperature (1600oF
(8710C)) for 60 s also produces increased
Cr rich ppts intergranuiar carbides in both alloys. Ad-
on-cool from 2077oF 60 sec hold at 1600oF on-cool ditionally, some of the grain boundaries in
FM52 become more serrated as a result of
the isothermal hold.
m Fig. 7 SEM micrographs of FM82H (A and B) and FM52 (C and D) that were water quenched at Microstructural and Microchemical
1600F on-cooling from the carbide solvus temperature (A and C), and water quenched after a 60-s hold Characterization: AEM
at IdOff'F on-cooling from NST-25F.
The experimentally determined Cliff-
Lorimer sensitivity factors and associated
2/ matrix remained where intergranuiar car- age is much greater on-heating than it is standard deviation were found to be kpe^i
^^ bides were once located, similar to A600. on-cooling. = 0.913 + 0.0068 and kCrNi = 0.861 +
^0 These chromium-rich regions traced out The carbide dissolution behavior in 0.0044. The thin foils prepared using the
^0 the former location of grain boundaries, A600 is distinctly different than in A690 FIB technique were first examined using a
f/> which had all migrated away from their and FM52. In A600 there are regions of TEM to determine that they were suitable
^H original locations. The only second phases grain boundaries where the intergranuiar for subsequent analysis. This examination
> existent at the peak temperature of both carbides never fully dissolve during the involved using electron diffraction to con-
A690 and FM52 were Ti(C,N). There is no super solvus portion of the thermal cycle. firm the location of grain boundaries prior
JU discernable microstructural change in This is shown in Fig. 2C, which is taken on- to analysis in the AEM. All of the bound-
(") A690 and FM52 at the on-cooling IV^Cg cooling at the MyC3 solvus for A600 aries are oriented vertically in the follow-
^p solvus temperature (Figs. 4C and 6C), (18590F (1015oC)). As the alloy cools ing AEM maps. Figure 8 displays the
^ which is 19720F (1078oC) and 2077oF these carbides coarsen, as shown in Fig. AEM results from an FM52 1600oF on-
(11360C), respectively. Extensive interro- 2D, which is taken at 1600oF (8710C) on- heating. The dotted line in the HAADF
gation of precipitates using EDS revealed cooling. The carbide content may also in- image denotes the grain boundary.
that only Ti(C,N) precipitates remain over crease due to precipitation below the car- Chromium-rich precipitates are observed
this temperature range. For example, all bide solvus temperature. However, this adjacent to a titanium-rich precipitate. No
the second phases present in Fig. 6C con- intergranuiar carbide coverage is not uni- sulfur or phosphorous were detected in
tain titanium, thereby precluding them form, as some boundaries contain very few the AEM maps collected from this condi-
from being M^Cg. However, at 1600oF precipitates, as seen in Fig. 2E, which is at tion, nor were they detected in any spot
(8710C) on-cooling there are intergranu- 1600oF (8710C) on-cooling. In this region analysis performed on the boundary or in
iar chromium-rich carbides in A690 that the carbides fully dissolved and have yet to the matrix. Table 4 contains quantified
are not present in FM52 at the same tem- reprecipitate. Additionally, both the inter- point analyses data collected from the
perature. These chromium-rich intergran- granuiar carbide morphology and grain grain boundaries and matrix. It was found
uiar precipitates are found to be inhomo- boundary carbide coverage for both A600 that the grain boundaries in FM52 at
geneously precipitated on A690 grain and A690 at 1600oF (8710C) on-cooling is 1600oF on-heating were depleted in Cr
boundaries that intersect the chromium- significantly different than at 1600oF on- (21.4 vs. 29.8 wt-%) and enriched in Ni
rich regions of the matrix that remain after heating. The micrographs shown in Figs. (66.3 vs. 58.9 wt-%) as compared to the
the dissolution of blocky IV^Cg inter- 2D and 4D represent the greatest amount matrix, while there was no difference in Fe
granular carbides. Figure 4D shows a re- of intergranuiar precipitation observed in concentration (10 wt-%) given the ex-
gion where the grain boundary carbide both A600 and A690 at 1600oF on-cooling. perimental error.
coverage is relatively high for this alloy There were three different levels of in- The AEM mapping results for FM52
and temperature; however, much of the tergranuiar carbide dissolution observed 1600oF (8710C) on-cooling from the NST-
grain boundary length was free of with the four alloys. A690 and FM52 ex- 250F temperature are presented in Fig. 9.
chromium-rich carbides. In both A600 perienced complete intergranuiar The dotted line in the HAADF image de-
and A690 the intergranuiar carbide cover- chromium-carbide dissolution, while the notes the grain boundary. No chromium-
o
<
Fig. 8AEM results from FM5 21600F on-heat- Fig. 9AEM results from FM521600oF on-cool- Fig. 10 AEM results from FM52 60-s hold at LU
ing, water-quenched sample. Dotted line in ing from NST-250F, water-quenched sample. Dot- 160(fF on-cooling from NST-250F, water-quenched
HAADF image delineates grain boundary. ted line in HAADF image delineates grain bound- sample. Dotted line in HAADF image delineates if)
Grayscale bar indicates number of integrated x-ray ary. Grayscale bar indicates number of integrated grain boundary. Grayscale bar indicates number of LU
peak counts above background. x-ray peak counts above background. integrated x-ray peak counts above background. OC
O
rich precipitates were observed in this AEM map, nor in any point analysis in the This summed EDS spectrum had a total
condition; however, titanium precipitates 60-s hold condition. Like the 1600oF on- live time of 76 min. No sulfur or phospho-
are observed along the grain boundary. heating condition, there is chromium de- rous were detected. Similarly, EDS spec-
The smallest precipitate that was resolved pletion (21.2 vs. 29.6 wt-%) and nickel en- tra from multiple 120-s live time point LU
in all of the AEM work was a seven-nm-
diameter titanium precipitate in this ther-
mal condition. The concentrations of iron,
richment (65.9 vs. 58.7 wt-%) along the
grain boundaries as compared to the ma-
trix. The chromium concentration adja-
analyses were summed to produce Fig.
12B, which had a total live time of 16 min.
Once again, there was no evidence of sul-
5
nickel, and chromium along the grain cent to the precipitate-matrix interface is fur or phosphorous.
boundary in the composition maps are in- different on each side of the precipitate, as
distinguishable from those in the matrix. seen in Fig. 11. The interface that the pre- Fractography
This similarity is quantified by use of spot cipitate has with the grain on the right ex-
measurements, which are recorded in hibits no chromium depletion (~29.5 wt- A ductility dip crack from an FM52
Table 4. This shows that not only did the % Cr), while the chromium concentration specimen tested at 1600oF on-cooling that
peak temperature portion of the thermal at the interface the same precipitate has was water quenched immediately after
cycle dissolve the chromium-rich carbides, with the other grain is only approximately fracture is shown in Fig. 13. The fracture
but it homogenized the near grain bound- 24 wt-% on one side of the precipitate. surface contains both dimpled and wavy
ary concentration profiles of nickel and The detectability of any element using regions. The wavy regions are the domi-
chromium that were existent at 1600oF EDS is a function of collection live time nant fracture surface appearance in duc-
(8710C) on-heating. (Ref. 37). Therefore, to improve the de- tility dip crack of all four alloys. The frac-
Figure 10 shows the results for FM52 tectability of sulfur and phosphorous, ture surface is decorated with chromium-
after a 60-s hold at 1600oF (8710C) on- EDS spectra collected from multiple rich precipitates, as determined by EDS,
cooling from the NST-250F temperature. AEM maps and point analyses were that are 200-300 nm in width (Fig. 13B).
Larger chromium-rich intergranular pre- summed. This was performed for data col- Intergranular precipitates with similar
cipitates are observed in this condition, lected from FM52 specimens quenched at size, morphology, and chemistry
which necessitated that the compositional the ductility minimum temperature, (chromium rich) are observed on the grain
map displayed in Fig. 10 be collected at a 1600oF (8710C) on-cooling from NST- boundary adjacent to ductility dip crack
lower magnification than for the 1600oF 250F. EDS data from nearly 23,000 pixels (Fig. 13C and D). Intergranular cavities
on-heating and 1600oF on-cooling condi- located near grain boundary region of 13 are found adjacent to these precipitates,
tions. Like these other two conditions, no different boundaries were added, which as seen in Fig. 13D.
sulfur or phosphorous was detected in any resulted in the EDS spectrum in Fig. 12A. For the purpose of comparison. Fig. 14
WELDING JOURNAL
Fig. 12 EDS spectra from FM52 water quenched at 1600oF on-cooling from NST-25F grain
boundary regions. A Sum from compositional maps; B sum from point analyses.
tensile axis is oriented in the horizontal and preventing them from migrating.
direction. This crack shares some simi- Other investigators have reported similar
lar features with those observed in the findings for A690 (Refs. 38-40). At tem-
specimen fractured at 1600oF without peratures above the carbide solvus the
any hold (Fig. 13). Additionally, in both grain size of A690 begins to increase con-
conditions the samples have intergran- siderably while that of A600 only changes
ular cavities along the grain boundary slightly. This is the result of the complete
adjacent to the ductility dip crack. The dissolution of intergranular carbides in
difference is that the precipitates in the A690 and incomplete dissolution in A600.
Fig. 11 AEM chromium concentration profiles as a
60-s hold specimen are significantly As the temperature continues to decrease
function of distance from precipitate matrix interface in
the FM52 60-s hold at 1600oF on-cooling water quenched larger and have a disc shape (Fig. 15B on-cooling the grain size in A690 stabilizes
sample. HAADF image in A is the same as that in Fig. 10; and C) compared to those observed in due to the formation of intergranular pre-
B and C are the chromium concentration profiles to the the sample without the hold. The inter- cipitates at locations where the boundary
left and right of the precipitate, respectively. precipitate cavities are also clearly seen intersects chromium-rich regions in the
between the precipitate discs on the matrix that are remnants of previously dis-
fracture surface in Fig. 15D. solved intergranular carbides. In A600 the
is a SEM fractograph of a ductility dip
grain boundaries that contain carbides re-
crack taken from a multipass weld of
Discussion main pinned, while those that do not con-
FM52 that was fabricated as part of previ-
ous work (Refs. 22, 20). The fracture sur- tain carbides continue to migrate even as
face of the multipass weld is quite similar Influence of Microstructure on Grain Size the temperature drops to HOOT (5930C)
to the DDC fracture surface in the Glee- Evolution on-cooling. It is for these reasons that the
ble hot ductility specimen (Fig. 13). grain size standard deviation for A600 at
Each fracture surface exhibits a wavy ap- The changes in grain size throughout 1600oF (8710C) and HOOT on-cooling is
pearance and is decorated with so large.
the thermal cycle are a function of the pre-
chromium-rich carbides that are approxi- While the grain size varies with temper-
cipitate dissolution behavior. In A600 and
mately 200-300 nm in size. ature in the wrought alloys it is essentially
A690 the grain size remains stable on-
Figure 15 is the fracture surface from an heating up the respective carbide solvus constant in both of the weld metal alloys,
FM52 specimen held at 1600oF (8710C) for FM82H and FM52. The stable average
temperature. This is the result of inter-
60 s before being hot ductility tested. The grain size for the two weld metals can be at-
granular carbides pinning the boundaries
WELDING JOURNAL
The interface the precipitate makes with brittlement (Refs. 14, 15). Furthermore,
the left grain is curved, while the interface this very same AEM, operated under sim-
with the grain on the right is straight. To ilar conditions, was able to detect inter-
minimize interfacial energy, an incoher- granular sulfur in Ni at concentrations less
ent interface is expected to be curved. A than 3 wt-% (Refs. 46, 47), which further
curved incoherent interface reduces the validates the approach taken in the cur-
interfacial surface area per unit volume of rent work. Furthermore, the grain bound-
precipitate, thereby decreasing the inter- aries examined in the AEM were random,
facial energy. To the contrary, to mini- and thereby most likely to experience seg-
mize interfacial strain energy a partially regation of sulfur. Still, no sulfur or phos-
coherent interface is much more likely to phorous segregation were detected in
be straight due to the orientation rela- FM52 at 1600oF (8710C) on-heating,
tionship that the precipitate shares with 1600oF on-cooling (ductility minimum), or
the matrix. The significance of this find- after a 60-s hold at 1600oF on-cooling.
ing to DDC will be discussed later in this The summed EDS spectra from the
paper in light of the precipitation-in- AEM map and point analyses in Fig. 12
duced cracking hypothesis. have a similar shape with the exception of
The precipitates and chromium deple- carbon. In the summed point analyses
tion existent at 1600oF on-heating in spectrum the carbon peak has a higher
FM52 are no longer present at 1600oF on- ratio with the other peaks than that ob-
cooling. This is distinctly different than served for the summed AEM maps. This
the dissolution and on-cooling precipita- may be the result of increased carbon con-
tion behavior of A690. In A690 some in- tamination that occurred during the point
tergranular chromium-rich carbides are analyses where the electron beam was sta-
observed at 1600oF on-cooling. These tionary on the sample for approximately
carbides form at locations where the mi- 2.5 min/measurement. During the collec-
Fig. 14 SEMfractographs taken from ductility dip grated grain boundary intersects tion of maps, the total time ("real time")
crack in FM52 multipass weldment. A Lower
m magnification revealing intergranular nature of
chromium-rich regions in the A690 ma-
trix. The difference in dissolution and
the probe dwelled at each pixel was about
240 ms. The longer collection dwell time
crack; B higher magnification that shows precipitation behavior of A690 and FM52 with the point analyses would be expected
chromium-rich carbides on a wavy fracture surface.
is related to grain boundary migration. In to result in greater carbon contamination
both alloys the peak temperature results and a larger carbon peak in the summed
bide the remainder term is actually ~5.7 in carbide dissolution, but in FM52 the EDS spectra (Fig. 12B).
O wt-%. This leads to an overestimation of grain boundaries remain fixed while they
the metallic concentration in the carbide. are found to migrate in A690. FM52's Fractography
Approximately the same degree of fixed grain boundaries provided a rapid
m chromium depletion is observed along the diffusion path for chromium as the pre- A variety of intergranular fracture sur-
(/) grain boundary, 25 nm away from the pre- cipitate dissolved. This resulted in the ho- faces have been shown for ductility dip
m cipitate (21.3 1.15 wt-%), as is observed
directly adjacent to the precipitate at the
mogenization of the near grain boundary
microchemistry in FM52. This process
cracks formed at various temperatures
(Ref. 19). However, no direct comparisons
> precipitate-matrix interface (24.4 1.15 does not happen in A690 where the have been made between the fracture sur-
33 wt-%) at 1600oF (8710C) on-heating, and boundaries migrate away from their origi- faces generated as part of Gleeble-based
o after a 60-s hold at 1600oF on-cooling.
AEM maps reveal that the grain boundary
nal location, thereby leaving chromium-
rich regions in the matrix where inter-
testing and those observed in actual mul-
tipass welds. In the current work the DDC
chromium depletion exists along the en- granular M23Cg precipitates were once fracture surface in an FM52 multipass
tire length of the boundary as seen in Figs. located. weld (Fig. 14) was found to be very similar
8 and 10. This is a result of the nearly five In preparation for the AEM analysis to that observed in an FM52 Gleeble hot
order of magnitude greater chromium dif- performed in this work. Desktop Spec- ductility specimen fractured at 1600oF
fusivity along the grain boundary as com- trum Analyzer (DTSA) (Ref. 45) was uti- (8710C) on-cooling (Fig. 13). Both frac-
pared to the matrix at 1600oF (Ref. 44). lized to estimate the minimum detectabil- ture surfaces have a wavy appearance and
The grain boundary acts as a fast diffusion ity limit (MDL) of sulfur and contain chromium-rich carbides. It has
pathway for chromium in the matrix far phosphorous. This was done using the also been suggested that the DDC suscep-
away from the precipitate, where it is rap- FM52 composition and the analytical con- tibility of FM52 is at a maximum at very
idly transported to the growing intergran- ditions of the VG 603 microscope for a high temperatures (~2400oF (13160C))
ular chromium carbide. collection live time of 120 s. Each DTSA (Ref. 21). However, the similarity between
The asymmetric chromium depletion spectrum was generated with the addition the FM52 multipass weld and the FM52
profiles adjacent to the precipitate-matrix of Poisson's noise, which occurs with EDS 1600oF on-cooling sample (Fig. 13 and 14,
interface as shown in Fig. 11 can be attrib- analysis and degrades the MDL. Assum- respectively) indicates that the DDC
uted to the growth behavior of the precip- ing a 200-nm-thick specimen, which is rea- mechanism was reproduced in the Glee-
itate. As seen in Fig. 11A, the precipitate sonable given the weld metal FIB speci- ble. It also supports the hypothesis that
is growing from the grain boundary into mens, the MDL for sulfur and ductility dip cracks in the multipass welds
the grain on the left. As the precipitate phosphorous was below 0.1 wt-%. This occur within the same on-cooling inter-
grows it preferentially depletes chromium limit applies not only to individual point mediate temperature range as the Glee-
from the left grain, thereby resulting in the analyses but to the summed EDS spectra ble on-cooling ductility dip (1475-
asymmetric chromium depletion. Not only shown in Fig. 12. This MDL is more than 17250F (802o-941oC). This hypothesis is
are the concentration profiles different on an order of magnitude lower than the ~5 further supported when combined with
either side of the precipitate, but so is the wt-% sulfur that would have to be segre- the crack count data (Fig. 14 in the Part I
shape of the precipitate matrix interface. gated to the grain boundary to cause em- article (Ref. 1)), which exhibits a peak in
WELDING JOURNAL
length. This is true at all temperatures, The on-cooling ductility between ceptibility that occur during the weld ther-
with all alloys, and with all forms of inter- 17250F (9410C) and 14750F (802oC) is sig- mal cycle.
granular precipitates formed within those nificantly lower in A600 than it is on-heat-
alloys. However, the ductility minimum at ing. This same trend is reflected in the nor- Grain Boundary Sliding (GBS)
1600oF (8710C) corresponds to the same malized ductility dip crack length, which is
temperature at which IV^Cg precipitates significant over the same temperature Grain boundary sliding is generally
are formed when the sample is strained in range (Ref. 1). This is the same tempera- considered to be an operative deforma-
both FM52 and A690. It has been pro- ture range over which the ductility dip oc- tion mechanism at temperatures above
posed that the chromium concentration in curs in FM52 and A690; however, FM52 0.5, the homologous temperature (Tm)
the matrix can significantly affect the in- and A690 have significantly fewer inter- (Refs. 56, 57). Strain rate is equally im-
terfacial stresses at the IV^Cg-matrix in- granular precipitates over this tempera- portant to the type of failure mechanisms
terface (Ref. 20). Increasing the ture range than A600 and FM82H. Inter- caused by grain boundary sliding. It has
chromium concentration in the matrix in- granular precipitates can have a profound been shown that in commercially pure
creases the precipitate-lattice misfit, role in reducing grain boundary sliding as nickel at 700oC round intergranular cavi-
thereby increasing the localized stress will be discussed below. Additionally, ties form when the strain rate is low (10-9
along the grain boundary that may, in turn, FM82H forms ductility dip cracks both on- s'1), but as the strain rate increases the type
promote DDC. As the precipitate grows heating and on-cooling. This occurs over a of intergranular damage transitions from
the matrix chromium concentration is de- wide range of temperatures in FM82H round cavities to wedge-cracks, then to
pleted and the misfit at the interface is ex- from 14750F (802oC) to 2100oF (11490C) transgranular ductile fracture at approxi-
pected to decrease, thereby resulting in on-heating and from 2100oF to 14750F on- mately 0.1 s_1 (Ref. 58). Alloying additions
improved ductility (Ref. 20). cooling. can decrease the temperature/strain rate
There are several key observations that The second observation is that ductility regime over which wedge type cracking
are consistent with a PIC mechanism. dip cracks are observed in FM52 at 2100oF occurs if the additions promote increases
First, DDC susceptibility is highest in the both on-heating and on-cooling, as was in size and volume fraction of intergranu-
two alloys investigated in this work that shown in the first paper (Ref. 1). This spe- lar particles and/or enhance recovery
are strong M^Cg carbide formers: A690 cific sample is significant for two reasons. (Ref. 59). Both round cavities and wedge-
and FM52. The M^Cg carbide is partially First, the IV^Cg carbide solvus tempera- cracks are a result of GBS, with wedge
m coherent and some stress at the precipi-
tate/matrix interface is expected due to
ture for FM52 is 2077F (11360C), there-
fore these carbides would not be expected
cracks being observed in hot ductility
specimens tested as part of this program
lattice misfit. The second observation is to form while the test is being performed, (Ref. 1). Grain boundary sliding can result
g that the partially coherent M^Cg car- although some carbides are expected to be in intergranular cracking when the grain
z bides formed during straining at the duc- existent in the on-heating sample because interiors are stronger than the grain
WELDING JOURNAL
rous segregation was found in FM52 in References Proceedings of the 7th International Trends in
water-quenched samples from the ductil- Welding Research Conference. Eds. S. A. David,
ity minimum temperature, 1600oF (8710C) 1. Noecker II, F. E, and DuPont, J. N. 2009. et al., pp. 767-772. ASM International.
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considered. The grain size of FM52 was crack and evaluation of hot ductility of reheated steel. Transactions ofJWRIl(V): 59-70.
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2.5 times greater than that of A690, but
4. Nissley, N. E., and Eippold, J. C. 2003. pold, J. C. 2003. An investigation of ductility dip
they both experienced a ductility mini- Development of the strain-to-fracture test: A cracking in nickel-based weld metals. Part II:
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versely, the grain sizes of A600 and A690 ductility dip cracking susceptibility in austenitic phology are related to microstructure, compo-
at the same temperature were the same, alloys. Welding Journal 82(12): 355-s to 364-s. sition, and temperature. Welding Journal
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FM52 during the peak temperature por-
its rate. Metallurgical Transactions 3(7): 43-s.
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termediate temperature range [1725- on Materials Science and Technology 25: 1-19. ity in reheated weld metal. Science and Tech-
m 14750F (941o-802oC) on-cooling] in all
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22. Young, G A., Capobianco, T. E., and
fluence of zirconium additions on the ductility Etien, R. 2007. Development of a highly weld-
g lar carbide size and volume fraction ap-
pears to promote grain boundary sliding. and deformation structure of nickel over a wide
temperature range. Russian Metallurgy 5: 65-72.
able and corrosion resistant Ni-Cr filler metal.
Degradation 2007: 13th International Confer-
z 4. Cooling FM82H and FM52 from
9. Nishimoto, K., Mori, H., and Hirata, H. ence on Environmental Degradation in Nuclear
o peak temperatures that correspond to
their carbide solvus resulted in increased
intergranular carbide coverage. Similarly,
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phur on reheat cracking susceptibility in multi-
Power Systems. Eds. T. R. Allen, J. T. Busby, and
P. T. ICing, compact disc (CD). Canadian Nu-
pass weld metal of Fe-36%Ni alloy. Today and To- clear Society.
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m ductility minimum for A690 and FM52) Joining, Proceedings of the 7th Japanese Welding An investigation of ductility dip cracking in
(/) resulted in more intergranular carbides in Society International Symposium. T. Ohji, pp. nickel-based filler materials. Part I: Ehe strain-
m both FM82H and FM52. Increased inter-
granular carbide coverage reduces DDC
827-832. Japan Welding Society.
10. Matsuda, E, Nakagawa, H., Minehisa,
to-fracture test has been used to develop tem-
perature-strain relationships for ductility dip
> susceptibility regardless of carbide type. S., Sakabata, N., Ejima, A., and Nohara, K. cracking. Welding Journal 82(10): 288-s to 295-s.
33 This increase in intergranular carbide size
1984. Weldability of Fe-36% Ni alloy report II: 24. Collins, M. G, Ramirez, A. J., and Eip-
o and volume fraction would promote grain
boundary sliding.
Effect of chemical composition on reheated hot
cracking in weld metal. Trans. JWRI 13(2):
pold, J. C. 2004. An investigation of ductility-
dip cracking in nickel-based weld metals. Part
69-75. III: Ehe characteristics of weld-metal grain
5. Ductility dip cracking in these alloys 11. Ogawa, T. 1986. Weldability of Invar and boundaries associated with elevated-tempera-
appears to be caused by GBS that may be its large-diameter pipe. Welding Journal 65(8): ture fracture are investigated. Welding Journal
exacerbated by highly localized stresses. 213-s to 226-s. 83(2): 39-s to 49-s.
These stresses may develop along the ma- 12. Nishimoto, K., Saida, K., Okauchi, H., 25. Dave, V. R., Cola, M. J., Kumar, M.,
trix/precipitate interface when M^Cg and Ohta, K. 2006. Microcracking in multipass Schwartz, A. J., and Hussen, G N. A. 2004.
carbides form in the same time/tempera- weld metal of Alloy 690. Part 2: Microcracking Grain boundary character in Alloy 690 and duc-
mechanism in reheated weld metal. Science and tility-dip cracking susceptibility. Welding Jour-
ture regime as the hot ductility test.
Technology of Welding and Joining 11(4): nal 83(1): 1-s to 5-s.
462-470. 26. Nissley, N. E. 2006. Intermediate tem-
Acknowledgments 13. Nishimoto, K., Saida, K., Okauchi, H., perature grain boundary embrittlement in
and Ohta, K. 2006. Microcracking in multipass nickel-base weld metals. PhD diss., Columbus,
This work was funded by a Naval Nu- weld metal of Alloy 690. Part 3: Prevention of Ohio, Ehe Ohio State University.
clear Propulsion Program Fellowship spon- microcracking in reheated weld metal by addi- http: Ilwww.ohiolink.eduletdlview.cgi?acc _num =
sored by Naval Reactors Division of the tion of La to filler metal. Science and Technol- osull56949345
ogy of Welding and Joining 11(4): 471^179. 27. ASEM E112-96, Standard Test Methods
U.S. Department of Energy. The authors
14. Heuer, J. K, Okamoto, P. R., Lam, N. for Determining Average Grain Size. 1996. Con-
would like to thank Dr. George Young Jr. Q., and Stubbins, J. E 2002. Disorder-induced shohocken, Pa.: American Society for Eesting
and Tom Capobianco of Lockheed Martin melting in nickel: Implication to intergranular and Materials.
for their assistance in this work. The authors sulfur embrittlement. Journal of Nuclear Mate- 28. Eim, Y. S., Kim, J. S., Kim, H. P., and
also appreciate the advice of Dr. Chris rials 301(2-3): 129-141. Cho, H. D. 2004. Ehe effect of grain boundary
Kiely, Dave Ackland, and Bill Mushock of 15. Yamaguchi, M., Shiga, M., and Kabu- misorientation on the intergranular M23Cg
Lehigh University with regards to electron raki, H. 2005. Grain boundary decohesion by carbide precipitation in thermally treated Alloy
microscopy. Additionally, Noecker thanks impurity segregation in a nickel-sulfur system. 690. Journal of Nuclear Materials 335(1):
Dr. Tom Lienert of Los Alamos National Science 307(5708): 393-397. 108-114.
16. Capobianco, T. E., and Hanson, M. E. 29. Hong, H. U., Rho, B. S., and Nam, S. W
Laboratory for his continuing interest in
2006. Auger spectroscopy results from ductility 2001. Correlation of the M23Cg precipitation
this work and helpful discussions.
dip cracks opened under ultra-high vacuum. morphology with grain boundary characteris-
WELDING JOURNAL
Preparation of Manuscripts for Submission
to the Welding Journal Research Suppiement
All authors should address themselves to the fol- 6) Acknowledgment, References and Appendix.
lowing questions when writing papers for submission to Keep in mind that proper use of terms, abbrevia-
the Welding Research Supplement: tions, and symbols are important considerations in pro-
Why was the work done? cessing a manuscript for publication. For welding termi-
What was done? nology, the Welding Journal adheres to AWS A3.0:2001,
What was found? Standard Welding Terms and Definitions.
What is the significance of your results? Papers submitted for consideration in the Welding
What are your most important conclusions? Research Supplement are required to undergo Peer
With those questions in mind, most authors can log- Review before acceptance for publication. Submit an
ically organize their material along the following lines, original and one copy (double-spaced, with 1-in. margins
using suitable headings and subheadings to divide the on 8 1^ x 11-in. or A4 paper) of the manuscript. A manu-
paper. script submission form should accompany the manu-
1) Abstract. A concise summary of the major ele- script.
ments of the presentation, not exceeding 200 words, to Tables and figures should be separate from the
help the reader decide if the information is for him or her. manuscript copy and only high-quality figures will be
2) Introduction. A short statement giving relevant published. Figures should be original line art or glossy
background, purpose, and scope to help orient the read- photos. Special instructions are required if figures are
er. Do not duplicate the abstract. submitted by electronic means. To receive complete
3) Experimental Procedure, Materials, Equipment. instructions and the manuscript submission form,
4) Results, Discussion. The facts or data obtained please contact the Peer Review Coordinator, Erin
and their evaluation. Adams, at (305) 443-9353, ext. 275; FAX 305-443-
5) Conclusion. An evaluation and interpretation of 7404; or write to the American Welding Society, 550 NW
your results. Most often, this is what the readers remem- LeJeune Rd., Miami, FL 33126.
ber.
CAN WE TALK?
The Welding Journal staff encourages an exchange of ideas with you, our readers. If you'd like to ask a question, share an idea or
voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along with a guide to help you interact with
the right person.
Publisher Production Manager Peer Review Coordinator
Andrew Cullison Zaida Chavez Erin Adams
cullison@aws.org, Extension 249 zaida@aws.org. Extension 265 eadams@aws.org. Extension 275
Article Submissions Design and Production Peer Review of Research Papers
Arcos, The Standard of Excellence in as 625, 800, 801, 825 and 600.
Covered Electrodes and Bare Wire, This covered electrode is the smart
offers two outstanding welding choice for applications including
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Arcos 625 and Arcos 1N12 (625) are heat exchangers and offshore
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Arcos 625 is ideal for welding alloys 625, 601, 802
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in a wide variety of other engineering applications.
Arcos 1N12 (625) is utilized for welding alloys such
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