Professional Documents
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FEBRUARY 2016
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
For Info, go to www.aws.org/adindex
For Info, go to www.aws.org/adindex
For Info, go to www.aws.org/adindex
February 2016 • Volume 95 • Number 2 CONTENTS
FEATURES
32 LowEnergy Impact Spot Welding of HighStrength aluminum foil and high electrical current to
Aluminum Alloys launch one piece of metal toward a stationary
A novel impact welding process utilizes a thin sheet — A. Vivek et al.
C. Matricardi (Dist. 5), Welding Solutions, Inc. D. L. Doench, Chair, Hobart Brothers Co.
S. M. McDaniel (Dist. 19), Big Bend Community College S. Bartholomew, Vice Chair, ESAB Welding
W. R. Polanin (At Large), Illinois Central College & Cutting Prod.
R. L. Richwine (Dist. 14), Ivy Tech State College Lorena Cora, Secretary, American Welding Society
D. J. Roland (Dist. 12), Airgas USA, LLC, D. Brown, Weiler Brush
NorthCentral Region C. Coffey, Lincoln Electric
R. W. Roth (At Large), RoMan Manufacturing D. DeCorte, RoMan Manufacturing
M. Sebergandio (Dist. 3), CNH America S. Fyffe, Astaras, Inc.
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co. D. Levin, Airgas
M. Sherman (Dist. 10), SW&E, LLC R. Madden, Hypertherm
11” thick
1 -8 0 0 -2 6 3 -2 5 4 7
w w w .h c r s te e l.c o m
For Info, go to www.aws.org/adindex
EDITORIAL
During a past American Welding Society at a local Section meeting might be the next
(AWS) board meeting, there was a discus- AWS president, and they don’t even know it
sion about our Sections being the “grass- yet. As members of the Society, we have
roots of our Society.” This was stated by in- such a great opportunity to help grow new
coming District 10 Director Mike Sherman. members.
At the time, I did not really think about How we plant that seed of excitement in
the truth in that statement. However, re- someone to attend the local Section meet-
membering back to when I served on the ing is very important. With the younger
board of my local Houston Section for generation so in tune with technology and
twelve years made me realize that was the social media connections, this has to be our
“grassroots” of my AWS career. best path to maintain their interest and de-
Many of the volunteers who serve on our sire to join AWS.
committees, subcommittees, and the na- The staff at AWS is doing just that right
John Bray tional AWS board of directors came up now with maintaining the following web-
A W S V ic e P r e s id e n t through the Sections. That made me won- sites and accounts:
der how so many people were first intro- • AWS WeldLink, awsweldlink.org
duced to AWS. • Jobs In Welding, jobsinwelding.com
Our members attend local Section meet- • Careers In Welding, careersinwelding. com
ings and are able to meet and network with • Facebook, facebook.com/American
other members of our Society to exchange WeldingSociety
ideas and concepts. But how do members • Twitter, @AWSHQ
find their local Section meeting time and • Instagram, americanweldingsociety.
location? We need to discuss that information
All you have to do is go to the AWS web- about our new features at every meeting.
site at aws.org. Click on “About” in the So, still the question comes back to how
upper-right corner of the headings. This will do we grow those seeds into the roots of our
bring up a screen that shows “Sections” at Society? In particular, how can we reach out
the box on the right-hand side. Then click and develop in the next generation of men
on that and you will be taken to a screen and women an interest in the welding pro-
that has “Find a Section” in the box on the fession as an honorable way of life?
right. Click on that, and it will take you to Senator Marco Rubio said, “Welders
“How we plant the listing of all the Sections’ names in al- make more money than philosophers,” and
phabetical order along with what city they we have to do a better job of getting the
that seed of excite are located in. Then click on the Section message to people that you can make a very
ment in someone name you want, and the next screen gives good living by being a welder. Then the next
to attend the local you a picture of that Section’s District Direc- step is to show all of the different avenues
Section meeting is tor along with all of his or her information you can take in your welding career.
very important. and a listing of contacts for each Section. So with all of our new “AWS tools,” it is
With the younger Most Sections have websites that you our job as members to get the word out of
can click on to get all of their meeting in- how valuable being involved in your local
generation so in formation and contacts. Some even give Section really is. It goes back to being an
tune with technol you pictures of past and future meetings “AWS mentor.” The most important asset
ogy and social along with speakers and events. It is all de- we have is “people.”
media connections, signed by AWS to help you get the informa- When speaking at different engagements
this has to be our tion you need to contact with the local Sec- about AWS, I am always amazed at how 138
tions and Districts around the United AWS staff members maintain, serve, and as-
best path to main States, and it only takes a few seconds. sist more than 72,000 members worldwide.
tain their interest Information is critical to keep our “grass- With the help of our staff and volun-
and desire to join roots” fed and nurtured so we can grow our teers, the sky is the limit for what we can ac-
AWS.” membership. It can make you stop and complish with growing our seeds for the fu-
think about the fact that someone you met ture of welding and AWS. WJ
Air Liquide Announces Agreement to Maritime Administration Offers Funding for Small
Acquire Airgas U.S. Shipyards; Applications Due February 16
The U.S. Department of Transportation’s Maritime Admin-
Air Liquide, Paris, France, a world provider of gases, tech-
istration, Washington, D.C., recently announced the availabili-
nologies, and services for industry/health, is set to acquire Air-
ty of $4.9 million in federal funding to support capital im-
gas, Radnor, Pa., a supplier of industrial gases as well as associ-
provements and employee training at small U.S. shipyards.
ated products and services in the United States, which will be-
Provided through the Small Shipyard Grant Program, these
come a wholly owned subsidiary of the company.
will support efficiency improvements and modernizations
Airgas shareholders will receive $143 per share in cash for
that allow U.S. shipyards to compete more effectively in the
all outstanding shares of the company, representing a total en-
global marketplace.
terprise value of $13.4 billion on a fully diluted basis and in-
Applications are due by 5 p.m. EST on February 16. The ad-
cluding the assumption of Airgas debt.
ministration intends to award grants no later than April 18.
“This transaction is compelling for our shareholders, aris-
Additional details can be found in the Federal Register at
ing from the persistent execution of our business strategy for
http//1.usa.gov/1mG9jVj or by contacting David M. Heller, di-
more than three decades. Air Liquide’s long-term vision and
rector, Office of Shipyards and Marine Engineering, Maritime
strong heritage in the U.S. make it the right fit for our valued
Administration, Room W21-318, 1200 New Jersey Ave., S.E.,
customers, and the combination creates significant opportuni-
Washington, D.C. 20590; David.Heller@dot.gov.
ties for the talented employees of both companies,” said Peter
Grants are offered to support many projects, including cap-
McCausland, executive chairman of Airgas.
ital and related improvements, plus equipment upgrades that
He further mentioned, “We are excited about the prospects
foster ship construction, repair, and reconfiguration in small
of integrating these two businesses to create the largest indus-
shipyards across the United States. Also, the grants can be
trial gas company in the world.”
used to support maritime training programs that improve
The entity will be able to better serve users with multidis-
technical skills to enhance shipyard worker efficiency.
tribution networks in the United States and more product of-
The Small Shipyard Grants, which are limited to no more
ferings. In addition, the combined company will continue to
than 75% of the estimated improvement costs, are available to
implement an approach that blends scientific expertise, tech-
U.S. shipyards with less than 1200 production employees.
nology, and customer insight.
The venture is subject to Airgas shareholders’ approval, re-
ceipt of necessary antitrust and other regulatory approvals, Flexovit USA Begins Reconstruction Journey
plus customary conditions and provisions. Flexovit USA, Inc., an industrial abrasives manufacturer, is
in the process of starting to rebuild its manufacturing and
warehouse facilities in Angola, N.Y. A majority of the compa-
FANUC Achieves RecordBreaking 400,000 ny’s 100,000-sq-ft building collapsed due to record snowfall
Robots Sold Worldwide that hit the western New York state area in late November
2014, dumping from 5 to 7 ft of snow in 48 h.
FANUC Since that time, the company has resumed manufacturing
America Corp., resin-reinforced grinding/cutting wheels and abrasive flap
Rochester Hills, discs in undamaged sections of the property. It has also main-
Mich., a suppli- tained sales and distribution services at its four distribution
er of robotics, centers.
CNCs, and fac- Rebuilding the 62,000-sq-ft plant and warehouse will re-
tory automa- store Flexovit’s full production capabilities. This should be
tion, has recent- completed by fall 2016. As work progresses, the company ex-
ly announced pects to rehire employees laid off due to the event.
that its parent
company, Weiler Secures SWATYCOMET from Avtotehna
FANUC America Corp. demonstrates fix FANUC Corp.,
tureless welding with its ARC Mate set a new world Weiler Corp., Cresco, Pa., a provider of power brushes, abra-
100iC/12 robot, LR Mate 200iD/7L mini record for pro- sives, and maintenance products for surface conditioning, re-
robot, and iRVision® 3D area sensor. ducing more cently announced the acquisition of SWATYCOMET d.o.o.,
than 400,000 Maribor, Slovenia, a manufacturer of bonded abrasives that
robots. dates back to 1879. Through the transaction, Weiler also adds
Mike Cicco, vice president, FANUC America, stated that a range of cut-off/grinding wheels and technical fabrics.
over the last several years, there’s been an increasing global de- “It has been a pleasure to get to know some of the mem-
mand to implement the latest technologies in factories, and bers of the SWATYCOMET team during the sale process,
this has stimulated production of industrial robots in general, and I am excited to have them join the Weiler team. The
playing a major role in the company’s achievement. complementary nature of our products, geographies, and
“From a product standpoint, the recent drivers behind company cultures makes this a great fit. Additionally, Weiler
reaching this milestone have been the popularity of the customers will see immediate benefit as we expand our
FANUC R-2000iC series, the LR Mate 200iD series, and the TigerTM brand into the bonded abrasive category,” said Chris
new CR-35iA collaborative green robot,” added Cicco. Weiler, CEO, Weiler Corp. WJ
New Education Law Highlights CTE manufacturing positions by awarding grants to up to five
states and five metropolitan areas with the strongest and
The Every Student Succeeds Act (ESSA) was passed by most comprehensive proposals. Each winner would receive
Congress and signed by the President at the end of 2015. up to $10 million over a three-year period. The state or met-
ESSA is a four-year education reform law that replaces the ropolitan area receiving the grant would also be required to
No Child Left Behind Act, which was enacted in 2002. provide at least 50% of the grant’s value in matching funds.
The Every Student Succeeds Act shows unprecedented
support for career and technical education. It includes career Government Seeks to Bolster Nuclear
and technical education (CTE) in its definition of a well-
rounded education, requires coordination of ESSA and CTE Energy Industry
plans by state and local education agencies, supports the in-
tegration of academic and CTE coursework, and encourages The federal government is taking steps to support the
states to include the progress of students in attaining career U.S. nuclear industry. In the legislative arena, the recently
and technical education proficiencies on state report cards. introduced Nuclear Energy Innovation Capabilities Act
would, according to its preamble, “enable civilian research
and development of advanced nuclear energy technologies
Project Streamlining Bill Introduced by private and public institutions and...expand theoretical
and practical knowledge of nuclear physics, chemistry, and
The Federal Permitting Improvement Act of 2015 (S.280) materials science.” The bill would accomplish this by di-
is designed to streamline and improve the federal permit- recting the Department of Energy (DOE) to focus its civil-
ting process by expediting permit decision making and in- ian nuclear research and development activities toward
jecting certainty into the process by facilitating coordination programs that enable the private sector, national laborato-
and deadline setting among agencies. The bill would also im- ries, and universities to carry out such experiments as are
prove transparency and reduce unnecessary delays caused necessary to promote scientific progress and enhance prac-
by litigation. Key reforms include the following: tical knowledge of nuclear engineering.
• Creation of an interagency council to identify best prac- Recent initiatives by the White House include an an-
tices and deadlines for required reviews and approvals of nouncement that costs incurred by an eligible project as part
various types of infrastructure projects of the licensing process, such as design certification, con-
• Establishment of a formal role for a single “facilitating” struction permits, combined construction, and operating li-
or “lead” agency to set a permitting timetable for each major censes, may be eligible for Department of Energy loan guar-
capital project antees. This is in addition to the Department of Energy’s ex-
• Encouragement of greater cooperation with state and isting solicitation of $12.5 billion in loan guarantees avail-
local permitting authorities able to support innovative nuclear energy projects. Also, the
• Creation of a public, on-line “dashboard” to track agency Department of Energy has launched its Gateway for Acceler-
progress on required approvals and reviews of major capital ated Innovation in Nuclear (GAIN) program, which is de-
projects and to provide access to relevant documents signed to provide the nuclear energy community with
• Requiring agencies to reach out to accept comments single-point access to nuclear energy-related capabilities and
from stakeholders early in the approval and review process, expertise across DOE. The GAIN program also will feature
with the aim of identifying and addressing important public the DOE-published Nuclear Energy Infrastructure Database
concerns early and a small business voucher scheme.
• Requiring courts to consider potential job loss in weigh-
ing equitable considerations for injunctive relief.
OSHA Set to Issue Silica, Other Rules
“Race to the Shop” Manufacturing Grant The U.S. Occupational Safety and Health Administration
Legislation Reintroduced (OSHA) has issued its regulatory agenda for 2016, and it in-
cludes plans to issue several final and proposed rules.
Legislation has been introduced in the House and Senate Among the most anticipated concerns is increased safety
to create an annual $100 million competitive grant to pro- standards for occupational exposure to crystalline silica. An-
mote reforms in workforce education and skills training for other will address the tracking of workplace injuries and ill-
manufacturing jobs. The Manufacturing Skills Act of 2015 is nesses, in which OSHA is expected to impose new electronic
similar to legislation considered, but not adopted, by Con- reporting obligations to most employers that are required to
gress in recent years and is inspired by the successful “Race keep OSHA 300 logs. Employers with 20 or more employees
to the Top” program created by the Department of Educa- also may be required to submit annual reports to OSHA elec-
tion, which created competition among schools to improve tronically with the information provided on OSHA Form
student metrics across the country. “Race to the Shop” 300A. Perhaps most significant, OSHA plans to post the 300
would give similar incentives to states and cities to train for logs and 300A forms on its website for public review. WJ
HUGH K. WEBSTER, AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE — Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania
Ave. NW, Washington, DC 20006; email hwebster@wcb.com; FAX (202) 8350243.
German Nonprofit Research Institute Works to machine manufacturer, GSI SLV Munich, a research institute,
Solve Steel and Aluminum Joining Challenges and Helmholtz-Zentrum Geesthacht, an interdisciplinary re-
search center, the event offered young scientists from Ger-
many, Portugal, Belgium, Hungary, Australia, Brazil, China,
Lazer Zen-
and India a platform for debate and discussion.
trum Hannover
Representatives from the automotive, aviation, aero-
eV (LZH), Han-
space, and wind energy industries presented their scientific
nover, Germany,
developments. Future welding applications in these sectors
a nonprofit re-
and associated challenges were discussed.
search institute,
EWM organized an excursion to its technology center,
will work with
where international guests were able to explore welding
industry part-
processes and learn more about the company’s latest devel-
ners and scien-
opments in arc welding technology.
tists to solve the
challenges of
joining steel and AWS Launches AWS Asia Website
aluminum in
Laser welding of steel to aluminum (photo maritime con- The American Welding Society (AWS), Miami, Fla., has
courtesy of Laser Zentrum Hannover). struction. The launched an AWS Asia website, awsasia.org, to allow mem-
company’s Laser bers in China to access information in their native language
Welding of Steel as well as in English. It has been designed to provide infor-
to Aluminum for Applications in Shipbuilding project aims mation on services offered by AWS in Asia, including mem-
to develop, test, apply, and verify a laser processing head bership benefits, certifications, exposition details, online
and welding process. education, and AWS publications and technical standards.
The project also aims to replace the adapter piece currently Highlights include quick links to areas of special interest
used in shipbuilding when joining different metals, which is and search features.
a complicated and cost-intensive joining technology. Ger- “AWS is committed to the future of the welding profes-
man-based system manufacturers Precitec GmbH & Co. KG, sion in China, and the new AWS Asia website will allow us to
Scansonic MI GmbH, and TRUMPF Laser and Systemtech- better serve the welding community there and become more
nik GmbH are working with LZH to develop a laser process- accessible to our members by keeping them up-to-date on
ing head with a weld-penetration depth control. the latest news and opportunities,” said Jeff Kamentz, AWS
Using the processing head, LZH will develop a welding corporate director of global sales.
process under lab conditions to be tested in cooperation
with LASER on demand GmbH, Langenhagen, Germany.
The process will then be transferred to actual applications
WEC Group Celebrates Success of Apprentices
by semifinished product manufacturers Druckguss Service
Deutschland GmbH and Hilbig GmbH, as well as shipyards WEC Group,
Fr. Lürssen Werft GmbH & Co. KG and Meyer Werft GmbH Ltd., Lan-
& Co., all of which are based in Germany. cashire, United
The project is funded by the German Federal Ministry for Kingdom, cele-
Economics and Energy and supervised by Forschungszen- brated the suc-
trum Jülich GmbH, an interdisciplinary research center. cess of its
training acade-
my apprentices
IIW Colloquium Held in the Netherlands at its annual
WEC Group apprentices pose with their Apprentice of
awards at the company’s annual awards the Year
ceremony. Awards cere-
mony. The
awards
evening, which was held at Whitehall Hotel, Darwen, United
Kingdom, recognizes the success of the company’s welding/
fabrication, CNC machining, and new business administra-
tion apprentices.
Students were presented with awards based on their com-
mitment, academic achievements, as well as welding and ma-
Attendees of the 5th IIW Colloquium visited EWM’s technology chining excellence. “The Apprentice of the Year Awards is a
center. tribute to the amount of effort and commitment our appren-
tices put into their work,” said Kris Mercer, WEC Group’s
The 5th International Institute of Welding (IIW) Welding training and development manager. “They are an exceptionally
Research and Collaboration Colloquium was recently held in talented group of young people and it’s important to reward
Limburg, the Netherlands. Organized by EWM AG, a welding them for their efforts.” WJ
Brazosport College to Use $1 Million Award age fleet weight to meet fuel and CO2 emission goals.
for New Welding Facility • Audi and Tesla, among luxury OEMs, and Ford, among
mass-market OEMs, are expected to have aluminum prolif-
erate into models across many vehicle segments by 2025.
• Aluminum is being used more in body-in-white applica-
tions, and resistance spot along with ultrasonic welding are
expected to increase aluminum-to-aluminum/alternate ma-
terial amalgamation.
• Aluminum is expected to become the backbone of
OEMs’ multimaterial strategy by 2025 beside Gen3 steel
grades and composites.
• North America and Europe are early adopters of alu-
minum as a primary material choice in higher margin
vehicles.
For more details, visit reportlinker.com/p03421859-
summary/view-report.html.
Ford FSeries Super Duty Brings $1.3 Billion Michigan Manufacturing International
Investment, 2000 New Jobs to Kentucky Plant Expands Facility
Michigan Manufacturing International, a supplier of
manufactured to print assemblies and components to origi-
nal equipment manufacturers, recently completed a 20,000-
sq-ft addition to its headquarters in Stevensville, Md.
This expansion occurred for future growth as well as to
accommodate tenants seeking affordable, quality work-
spaces with a Chesapeake Bay view. The addition can be di-
vided into nine spaces with each suite having its own sepa-
rate 480-V electric service and many other features.
“The additional space will enable us to meet our cus-
tomers’ needs by allowing for the installation of new ma-
chinery, increasing our warehouse storage capacity, and
adding workspace for our personnel,” said CEO Jacob Prak.
This venture supports a new body shop, facility upgrades, and re Report Released on U.S. Welding and Soldering
tooling to build the truck. Pictured is team member Jerylann Vaden.
(Photo by Sam VarnHagen.) Equipment Market
U.S. Welding and Soldering Equipment Market – Analysis
Ford Motor Co. will create 2000 new jobs and invest $1.3 and Forecast to 2020 presents current data of the market size
billion in its Kentucky Truck Plant to support launching the and volume, domestic production, exports and imports,
new 2017 F-Series Super Duty truck. A body shop along price dynamics, and turnover.
with facility upgrades and retooling will help build this alu- In addition, the report has industry information, includ-
minum-bodied truck at the facility. ing life cycle, business locations, productivity, and employ-
Add to that the $80 million invested in 2014 to meet ment divisions. There’s company profiles, too.
growing demand for Super Duty trucks, as well as the $129 Product coverage includes arc welding machines, compo-
million to support Lincoln MKC production at the Louisville nents, and accessories (excluding electrodes and stud weld-
Assembly Plant, and Ford has invested more than $1.5 bil- ing equipment); arc welding metal electrodes; resistance
lion in the commonwealth of Kentucky and the city of welding machines; gas welding and cutting equipment; and
Louisville in the past two years. welding and soldering equipment manufacturing.
“Adding new jobs and more investment at Kentucky For more information, visit researchandmarkets.com.
Truck Plant not only secures a solid foundation for our UAW
members, but also strengthens the communities in which Recent Acquisitions
they live, work, and play,” said Jimmy Settles, UAW vice
president, National Ford Department. • Alaska Governor Bill Walker recently announced the
The 2017 pickup and chassis cab lineup will have a high- state’s acquisition of TransCanada’s share of the Alaska LNG
strength steel frame; military-grade, aluminum-alloy body; project. Department of Natural Resources Commissioner
16 class-exclusive new features and up to seven cameras; Mark Myers finalized the termination of the formal agree-
adaptive steering; plus Ford engineered/built gasoline and ment that established and guided the participation of Tran-
diesel engines and transmissions. sCanada Alaska Midstream LP in the project. “Today is a his-
toric day. As Alaska faces a $3.5 billion budget deficit, this
gasoline project is our number-one get-well card. By gaining
Bilton Welding Reveals Record Earnings an equal seat at the negotiating table, we are taking control
of our destiny and making significant progress in our effort
Bilton Welding and Manufacturing, Ltd., Calgary, Cana- to deliver Alaska gas to the global market,” Walker said.
da, a designer, engineer, and manufacturer of custom energy
equipment for the oil and gas market, has achieved a 116% • Reliance Steel & Aluminum Co., Los Angeles, Calif., has
five-year growth rate at its fiscal year end on September 30, reached an agreement to purchase all the outstanding capi-
2015. The company also witnessed a 21% sales growth with tal stock of Tubular Steel, Inc., St. Louis, Mo., a distributor
a sustainable bottom line. and processor of carbon/alloy/stainless steel pipe, tubing,
“Based on our market outlook, we expect a continued and bar products. It is expected to close early this year.
strong sales performance over the next year,” said Jason
Greene, vice president of sales and marketing. “We’ve suc- • Schaefer Ventilation Equipment, Sauk Rapids, Minn., has
cessfully improved our efficiencies and supply chain...more- been acquired by Pinnacle Products International, Inc., Yard-
over, we’ve created new opportunities by employing new ley, Pa., a provider of portable heating and ventilation equip-
products and technology.” ment. The addition of distribution in Europe, Asia, and
President and CEO Robert Bilton added: “Operational in- South America will speed global market development strate-
novation, diversification, and continued investment in our gies. Schaefer will continue operating from its headquarters,
team will be at the forefront of our strategic plan.” and the management/sales leadership structure will remain. WJ
Q: I have been informed that there Table 1 — Aluminum Base Metal Strengths Before and After Arc Welding
is a reduction of strength in an alu
minum weld heataffected zone NonheatTreatable Base Metals – Strengths Before and After Arc Welding
(HAZ) after arc welding and that Base Metal *Typical **Minimum Reduction in
this can be particularly pro and Temper Ultimate Tensile Ultimate Tensile Strength %
nounced when arc welding the Strength Before Strength After
heattreatable base metals. What I Welding ksi Welding ksi
would like to know is how signifi 3004H32 31 ksi 22 ksi 29%
cant is this reduction in base metal 3004H38 41 ksi 22 ksi 46%
strength, does it differ in its extent 5052H32 33 ksi 25 ksi 24%
between the heattreatable and 5052H38 42 ksi 25 ksi 40%
5086H32 42 ksi 35 ksi 16%
the nonheattreatable base met 5086H38 52 ksi 35 ksi 33%
als, and what, if anything, can be 5083H116 46 ksi 40 ksi 13%
done after welding to recover this
HeatTreatable Base Metals – Strengths Before and After Arc Welding
lost strength and return the base
metal to its original condition? Base Metal *Typical **Minimum Reduction in
and Temper Ultimate Tensile Ultimate Tensile Strength %
Strength Before Strength After
Reduction in Strength in the Welding ksi Welding ksi
Conclusion
So in answer to the questions: the
reduction of strength in an aluminum
weld heat-affected zone can be signifi-
cant, and it will typically occur in
both the heat-treatable and nonheat-
treatable base metals. In general, the
reduction tends to be more pro-
nounced in the heat-treatable base
metals than it is in the nonheat
treatable.
What can be done after arc welding
to regain this lost strength and return
aluminum base metals to their original
unwelded condition? For the nonheat-
treatable base metals, no practical
Fig. 2 — This chart shows four examples of strength levels: 6061T4 and 6061T6 in the method of postweld processing is
aswelded condition, and both materials in the postweld aged only condition. The 6061
T4 postweld aged condition exhibits an improved recovery of strength within the HAZ
available. For the heat-treatable base
along with typical T6 properties throughout the structure. The benefits associated with metals, variations of postweld thermal
this processing are related to the fact that no hightemperature solution heat treatment treatments are available for considera-
and quenching are required, only more moderate lower temperature artificial aging. tion. However, after explaining these
methods, I feel it is reasonable to say
NonheatTreatable Base Metals – ened and deformed crystals are re- that in reality, the majority of the
3xxx and 5xxx Series placed by new strain-free crystals. In heat-treatable alloys used for structur-
the case of the nonheat-treatable base al welding applications are used in the
The strength of these base metals is metals, the HAZ is transformed into same way as the nonheat-treatable
initially produced by alloying the alu- the annealed (dead soft) condition. alloys and that is in the as-welded
minum with additions of other ele- This transformation effect is unavoid- condition. WJ
ments. These alloying elements in- able in all alloys; regardless of the orig-
clude manganese for the 3xxx series inal prewelded temper, the strength-
and magnesium for the 5xxx series. ening effect of the strain hardening
A further increase in strength of condition will always be removed in TONY ANDERSON is director of aluminum
these alloys is obtained through vari- the base metal HAZ. technology, ITW Welding North America. He
ous degrees of cold working or strain Figure 1 shows a 5083-H321 welded is a Fellow of the British Welding Institute
hardening. Strain hardening is a with a high heat input, and the (TWI), a Registered Chartered Engineer with
the British Engineering Council, and holds
process that is used to increase the reduction of strength in the HAZ is numerous positions on AWS technical com
strength of aluminum alloys that are minimal when compared with the mittees. He is chairman of the Aluminum As
both heat treatable and nonheat treat- other examples of the 6061-T6 heat- sociation Technical Advisory Committee for
able. Strain hardening is accomplished treatable base metal. However, as can Welding and author of the book Welding
through change of shape by the appli- be seen in Table 1, the degree of Aluminum Questions and Answers currently
available from the AWS. Questions may be
cation of mechanical energy. strength loss can be more pronounced sent to Mr. Anderson c/o Welding Journal,
Most commercial available strain when welding the nonheat-treatable 8669 NW 36th St., #130, Miami, FL 33166
hardened alloys are available in the base metals that are in the higher 6672; tony.anderson@millerwelds.com.
nonheat-treatable alloys and tempers. strength tempers. In practice, it is of-
As this physical deformation progress- ten the case that the nonheat-treatable
es (typically through rolling or draw- base metals are used in tempers that
ing), it produces an elongation of the are less severely affected when com- Change of Address?
material’s grain structure in the direc- pared to the heat-treatable base metals Moving?
tion of working that provides a pre- and their commonly used tempers.
ferred grain orientation, high level Make sure delivery of your Welding
of internal stress, and resultant in- Options Available for Postweld Heat Journal is not interrupted. Contact
crease in strength. When these strain- Treatment of NonheatTreatable Base Maria Trujillo in the Membership
hardened base metals are heated dur- Metals Department with your new address in-
ing arc welding, recrystallization takes formation — (800) 443-9353, ext. 204;
place in the HAZ, and the work-hard- Unfortunately, in the case of the mtrujillo@aws.org.
contain Cu, Ni, and Zr, and B) titani- size of chamfers, you minimize the
Q: We braze Titanium Grade 2 um forms a number of intermetallic volume of liquid filler metal in fillet
parts in a vacuum using a standard phases in contact with liquid filler areas, and subsequently limit the
BTi5 filler metal. The brazing tem metals. Brittle intermetallic phases growth of brittle intermetallic layers.
perature is 900°C, according to (such as TiCu2, TiAl3, TiNi2, Ti3Cu4, (Ti, Figure 2 presents the microstruc-
AWS A5.8, Specification for Filler Zr)2Cu, etc.) are formed in practically ture of a joint brazed at a 5-min dwell
Metals for Brazing and Braze all titanium brazed joints. For exam- time. There is no intermetallic layer at
Welding. When we set up the ple, brittle intermetallic phases are the interface, but we observe many
process, we tested different dwell found in a titanium-to-steel joint structural constituents, including an
times and found the strength of shown in Fig. 1. Mostly, the fracture of eutectic layer in the middle of the joint
the joints was very sensitive to the brazed joints is caused by an inter- metal, the solid solution areas around
dwell time value — even when metallic layer formed at the interface the eutectic, recrystallized, needle-like
changed in 5min increments. Our of the base metal, or at least inter- grains of the diffusion zones, and fine
first intention was to minimize metallic phases initiate the nucleation crystals of intermetallic phases (as de-
dwell time in order to minimize of microcracks in the joint metal. This termined by EDX analysis) distributed
the growth of brittle intermetallic may result in a significant decrease in everywhere. This unstable and irregu-
layers at the interface. However, the strength of brazed joints. lar microstructure comprised of com-
even 1min dwell time resulted in If the thickness of the joint metal is ponents with different hardness and
low joint shear strength. While the <50 microns (0.002 in.), the amount crystal structures — in other words,
joint had low strength at 5 min, of reaction occurring in components many phase boundaries — causes low
10–12 min showed strength al such as copper or nickel is insufficient strength of the brazed joint. The mi-
most double that at the short to form a thick intermetallic layer at crostructure of titanium brazed joints
dwell time. Hoping to further im the interface of the base metal. But can be improved by adjusting the braz-
prove the strength, we switched to the volume of liquid filler metal (as a ing thermal cycle.
a 20–22min dwell time. However, source of copper and nickel) is much Thermal cycle plays an important
the strength of the brazed joints larger in fillet areas, where a thick, role in optimizing the microstructure
dropped again. Can you explain brittle layer is always formed at the ti- and in decreasing the presence of in-
this brazing quality volatility? The tanium base interface. This layer may termetallic phases in the joint metal.
second question we have is how to initiate the first crack that is further There are two approaches to changing
optimize timing to provide stable propagated into the joint. If titanium the thermal cycle for these purposes.
strength values of brazed joints. is brazed to steel, the (Ti, Zr)Fe2 inter- The first approach is an additional dif-
metallic layer formed at the steel in- fusion and aging heat treatment of a
A: Titanium brazing filler metals of terface can also cause fracture of the brazed structure. This method re-
the Ti-Cu-Ni and Ti-Zr-Cu-Ni families brazed joint — Fig. 1. quires separate consideration; we shall
are characterized by high reaction abil- Therefore, the first recommenda- not discuss it here.
ity and intense diffusion exchange tion for keeping stable quality and reli- The second approach lies in the lim-
during interaction with base metals, ability of titanium brazed joints is to itation of reaction time between the
because A) the base metal does not avoid large fillets. If you minimize the base and filler metal in order to pre-
Fig. 1 — A crack propagated along the interface between carbon Fig. 2 — Microstructure of Ti Grade 2 joint <50 microns thick
steel and BTi5 joint metal due to the formation of a brittle (Ti, brazed by BTi5 filler metal at 890°C for 5 min.
Zr)Fe2 intermetallic layer.
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C
onventional welding by means of
high heat input, fusion, and so-
lidification greatly alters the mi-
crostructure in the welded region and
can be detrimental to the weld’s
mechanical properties, especially in
the case of highly engineered, high
strength-to-weight ratio materials.
The strength of the heat-affected zone
(HAZ) can be reduced to as little as
one third the original strength of the
base material. Additionally, suscepti-
bility to corrosion is greatly increased
after welding certain alloys such as
6xxx and 7xxx series aluminum alloys.
Fasteners and structural adhesives
offer nonwelding joining solutions.
Solid-state welding techniques, such as
impact welding, friction stir welding,
Fig. 1 — Schematics of the VFAW process. A — Before and after experiment condi-
ultrasonic welding, and roll bonding
tions of the foil actuator; B — stackup of a typical VFAW assembly; C — closeup of
are some alternatives to fusion-based the welding operation.
welding and have undergone a certain
degree of industrial adoption so far.
Impact welding is of particular interest scouring of the colliding surfaces and tive industries. Vaporizing foil actua-
due to the potentially short cycle time subsequent bonding under high pres- tor welding currently operates at the
of the process, the possibility to join a sure — Fig. 1. Explosive welding same size scale as MPW while having
wide variety of metal combinations, (EXW) and magnetic pulse welding certain advantages over it. Longevity
and the ability to perform the process (MPW) are previously known and of the solenoid actuator used for MPW
over varying length scales. practiced methods of impact welding. is a major concern, whereas VFAW is
Vaporizing foil actuator welding Implementation of EXW in a designed to have a low-cost
(VFAW) is a novel impact welding traditional factory environment is not consumable for each cycle. With
technique that utilizes the force gener- possible due to safety regulations in VFAW, generated pressures and
ated by a thin aluminum foil vaporized transportation, storage, and handling achievable flyer sheet velocities are
by high electric current to launch one of explosives, and because of the much higher as compared to MPW;
piece of metal toward one or more sta- inability to automate such a process. therefore, a wider variety of materials
tionary target sheets (Ref. 1). At high Explosion welding is mostly used for can be effectively welded with VFAW.
speed, oblique impact between the welding thick plates for the shipbuild- This article illustrates VFAW of alu-
flyer sheet and target plate(s) leads to ing, nuclear, oil and gas, and locomo- minum Alloys A5052 and A7075. This
BY ANUPAM VIVEK, SCOTT M. WRIGHT, TAESEON LEE, GEOFFREY A. TABER, AND GLENN S. DAEHN
material combination is germane to high temperature gas that can push on rent was measured by a 50-kA:1-V
the effort in the automotive industry the 2-mm-thick A5052-H32 flyer Rogowski coil.
toward vehicle weight reduction. sheet. Some degree of confinement is Figure 2A shows an impact spot
While 5xxx-series aluminum alloys are essential; accordingly, the other side of welded specimen before and after
increasingly being applied for inner the foil was backed by a block of steel lap shear testing. The load vs. displace-
components of automotive structural approximately 2 cm thick. The flyer ment data for each sample is plotted in
assembly, 7xxx-series alloys have been sheet was separated from the 2.3-mm- Fig. 2B. The samples failed outside the
scarcely utilized. This is despite the thick A7075-T6 target plate by a 2.5- weld nugget at an average load of 14.5
superior mechanical properties offered mm-thick neoprene washer with an in- kN. The average nugget diameter was
by 7xxx-series alloys as compared to side diameter of 19 mm and outside 10 mm. As compared to friction spot
6xxx and 5xxx-series alloys. Forming diameter of 37 mm. The target plate welds and resistance spot welds
and joining are considered two major was backed by another block of steel between similar materials, the welds
barriers to the widespread implemen- about 2 cm thick. The in-plane dimen- created by VFAW are roughly twice as
tation of 7xxx-series alloy as a sions of the flyer as well as the target strong. This can be attributed to three
lightweight alternative. Although plates were 40 mm ¥ 120 mm. The two factors: 1) negligible thinning around
there are certain drawbacks with the were overlapped by 40 mm along the the welded area, 2) no HAZ, and 3)
method, it is possible to use hot length and the welding experiment very effective metallurgical joining at
stamping to form 7xxx series into was conducted to create lap-joint spec- the bond line. The weld cross-section
components such as B-pillar outers imens. Due to the low strength of the image in Fig. 3A depicts the character-
(Ref. 2). In this work, VFAW will be neoprene washer, it breaks and gets istic wavy morphology of an impact
presented as a promising technique for ejected from between the flyer sheet welded interface in some parts of the
solving the joining problem. and target plate. Six welded samples weld. The figure also shows the flyer
were created this way and subjected to sheet retained its original thickness in
lap shear testing, microhardness test- and around the weld. The microhard-
Experimental Procedure, ing, and imaging. ness data (Fig. 3B) also reveals that
Results, and Discussion In a separate experiment, the veloc- the Vicker’s hardness on both sides of
ity of the flyer sheet was measured the weld interface and around the
A 0.0762-mm-thick aluminum foil, using a device called the photonic weld nugget was held constant at the
with a shape as shown in Fig. 1, was Doppler velocimeter (Ref. 3). In this base material level, which is 90 HV for
connected across the terminals of a experiment, the target plate had a A5052 and 205 HV for A7075. This is
Maxwell-Magneform capacitor bank, through hole, which provided a line of due to the low external input energy
which has a short circuit current rise sight to the laser focusing probe. With to the weld. It turns out that the input
time of 12 ms. While the capacitor this technique, the evolution of the energy for VFAW is not only an order
bank can be charged up to 16 kJ, for flyer sheet velocity can be measured of magnitude smaller than that for re-
these experiments it was operated at a with a submicrosecond temporal reso- sistance spot welding, but is also
4-kJ energy level. Once this energy lution. Voltage was measured using a merely a fraction of the energy
was discharged through the foil, the 1000:1 probe connected across the ter- required for friction spot welding or
latter vaporized rapidly and formed a minals of the capacitor bank, and cur- self-pierced riveting processes (Ref. 4).
T
he run-out phenomenon occurs
when a significant portion of the A
molten filler metal exits the gap
region and accumulates on an exterior,
base material surface. It can cause ex-
cessive void formation, plus wastes
filler metal and generates residual
stresses that crack brittle base materi-
als. This behavior was observed in ac-
tive braze joints made with 97Ag-1Cu-
2Zr (wt-%) filler metal when joining B
alumina (Al2O3) ceramic to Kovar™ (a
trademark of Carpenter Technologies,
Reading, Pa.).
The proposed mechanism for run-
out is an instability in the wetting and
spreading of molten filler metal. The
driving force for run-out was the reac-
tion between the Fe, Ni, and Co con-
stituents of Kovar™ with elemental Al
released by the reduction-oxidation re-
action between Zr and Al2O3.
Based on this study, a modification
to the filler metal composition, or use
of a barrier coating on the Kovar™ sur-
face, provide the most promising miti-
gation strategies against run-out.
Run-Out Phenomenon
Braze joint optimization requires
that the amount of filler metal sup-
plied to the gap be closely controlled.
Too little filler metal results in voids
and nonfilled regions in the braze- Fig. 1 — A — This photo shows run-out by an Ag-Cu-Zr active braze alloy being used to join
ment that jeopardize both strength two Al2O3 base materials to a Kovar™ spacer; B — a SEM photo shows run-out by means of
a metallographic cross section.
and hermeticity. On the other hand,
an excessive quantity of molten braze
alloy can be rejected from the gap, fitup or mechanical functions. ing to surfaces, is the generation of
only to collect on an exterior surface The run-out filler metal may wet to residual stresses in the base material.
as run-out; this not only causes un- ancillary structures, as shown in Fig. This phenomenon is illustrated in Fig.
sightly cosmetic defects and impedes 1, or simply freeze to nonwettable sur- 2. The run-out of an Au-Cu-Ni-Ti filler
visual as well as x-ray inspection, it faces. A particularly problematic con- metal caused cracking in the ceramic
may also interfere with next-assembly sequence, whether by wetting or freez- member of the assembly.
Fig. 2 — Optical micrograph shows cracking in the ceramic member Fig. 3 — This photo shows the tensile button assembly. There are two
caused by run-out of the Au-Cu-Ti-Ni filler metal. Al2O3 ceramic buttons brazed to either side of the Kovar™ spacer.
Characterization of
A Run-Out for the Target
Application
The Ag-Cu-Zr active braze alloy was
considered for an application that
joined Kovar™ to Al2O3 ceramic. The
tensile button configuration was used
to assess braze joint performance (Ref.
1). A photo of the tensile button as-
Fig. 5 — Photograph shows run-out (ar- sembly is shown in Fig. 3.
rows) experienced by the Kovar™ Two Al2O3 “buttons” were brazed to
spacer/Ag-Cu-Zr/Al2O3 joint that was a Kovar™ “spacer.” The spacer had
brazed with a reduced amount of filler 0.038-mm (0.0015-in.) dimples that
B metal. The process conditions were controlled the thicknesses of both
985°C (1805°F) for 5 min in a 600-torr Ar gaps. The Ag-Cu-Zr filler metal was
atmosphere. preplaced in the gap with the form of
an annular ring. Its footprint was the
• Reduce the peak brazing tempera- same as that of the Al2O3 faying sur-
ture to increase the viscosity of the face with a 10.2-mm (0.400-in.) inner
molten filler metal. Unfortunately, diameter and 15.9-mm (0.625-in.)
filler metal viscosity is relatively insen- outer diameter. The preform was
sitive to peak temperature (except in 0.051 mm (0.002 in.) thick.
the presence of a pasty range). Two varieties of Al2O3 ceramic were
• In light of the previous point, a used in this study; however, the slight
second approach is to add one or more compositional variations responsible
Fig. 4 — A, B — Photographs show run- alloying elements to the filler metal to for their different colors had a negligi-
out experienced by the Kovar™ spacer/Ag- create a wider pasty range. ble effect on wetting or mechanical
Cu-Zr/Al2O3 braze joint. The tensile button • Modify the geometry of the base properties.
assemblies were brazed at 965°C (1769°F) material surface by adding corners Shown in each of Fig. 4A and B
for 20 min in 600-torr Ar prior to being that would be expected to slow or halt are two, post-pull tested tensile but-
pulled apart. The ceramic faying surfaces the flow of molten filler metal. tons taken from different assemblies.
are between the dashed circles. Both samples were brazed at 965°C
All of these measures have been
met with little or no success. The lack (1769°F) for 20 min in a 600-torr Ar
The detrimental effects of run-out of effectiveness implies that run-out is atmosphere. The yellow dashed circles
have long been recognized by the braz- not simply a physical displacement or indicate the boundaries of the ceramic
ing industry. Several mitigation ap- “squishing-out” of molten filler metal. faying surface area. The specimens ex-
proaches have been explored to con- Rather, there are other driving forces hibited significant filler metal run-out.
trol it, which include the following: responsible for this phenomenon. Although two run-out “lobes” formed
Fig. 6 — SEM photo shows the general microstructure of the braze Fig. 7 — High-magnification SEM image shows the immediate
joint formed between the Kovar™ and Al2O3 ceramic base materials Ag-Cu-Zr/Al2O3 interface and formation of the ZrO2 particles.
using the Ag-Cu-Zr active filler metal. The process conditions were
985°C (1805°F), 5 min, and 600-torr Ar atmosphere.
in Fig. 4A, most often, there is only a gate this hypothesis and to develop Fig. 6. Besides the filler metal and base
single lobe per side of the Kovar™ potential mitigation steps that will materials, the brazements were char-
spacer, as shown in Fig. 4B. prevent it in the future. acterized by distinct reaction struc-
An experiment was performed to tures at the two interfaces.
confirm that run-out was not simply Review of the Material
the squishing-out of excess filler metal
Systems Interface Reactions
from the joint. A smaller footprint of
filler metal was placed in the same ten-
sile button braze joint by reducing the The materials system is the same as Cross-Section Microstructure
outer diameter of the Ag-Cu-Zr pre- that previously exemplified.
A reaction zone developed near the
form from 15.9 mm (0.625 in.) to 12.7 The filler metal is the active braze
Ag-Cu-Zr/Al2O3 interface — Fig. 6.
mm (0.500 in.). The tensile button was alloy, 97Ag-1Cu-2Zr (wt-%, abbreviat-
The high-magnification, SEM image in
assembled with a single such preform, ed Ag-Cu-Zr). The Ts is 940°–950°C
Fig. 7 shows the ZrO2 particles that
thereby reducing the filler metal vol- (1724°–1742°F) and Tl is 960°–970°C
ume by a total of 60%. The buttons (1760°–1778°F). The filler metal pre- developed at the immediate Ag-Cu-
were brazed at 985°C for 5 min (600- forms had these dimensions: 10.2-mm Zr/Al2O3 interface and then migrated a
short distance into the filler metal.
torr Ar). (0.400-in.) inner diameter, 15.9-mm
The ZrO2 particles were a product
Figure 5 shows a photograph of the (0.625-in.) outer diameter, and 0.051
of this reduction-oxidation (redox) re-
post-pull tested sample. The run-out mm (0.002 in.) thickness.
action between Zr and Al2O3 ceramic:
still occurred as identified by the ar- The base materials were Kovar™
rows. The lobes confirmed that this and 94% Al2O3 ceramic. The nominal
phenomenon is a result of an instabili- braze process had a peak temperature 3Zr + 2Al2O3 = 4Al + 3ZrO2 (1)
ty in the wetting and spreading behav- of 985°C (1805°F), time duration of 5
However, this reaction is not spon-
ior of molten Ag-Cu-Zr on the Kovar™ min at peak temperature, and a 600-
taneous as determined by a balance of
base material. torr Ar atmosphere.
equilibrium free energies. There are
This report describes a study with The braze joint microstructure is
three other mechanisms that could
the objective being to further investi- exemplified by the SEM image in
drive the Zr/Al2O3 redox reaction into
spontaneity, including the following:
1. Zr/SiO2 (grain boundary phase)
redox reaction
2. Free energy of solution as ele-
mental Al enters the molten Ag-Cu-Zr
filler metal
3. Aluminide reactions at the
Kovar™/Ag-Cu-Zr interface.
Fig. 8 — SEM image shows the reaction sublayers that form at the Kovar™/Ag-Cu-Zr The first mechanism would not
interface. pose a significant effect given the lim-
A B
Fig. 14 — SEM image shows the cross section of the expected fillet that formed at the red
dot of the inset photo for the all-Kovar™ test sample.
Fig. 12 — Schematic shows the four vari-
ants of individual tensile button and
spacer material based on Kovar™ or Wetting Front Microstructure Fe, Ni, Al, Ag, and Zr are provided in
Al2O3. Fig. 10B.
The interface reactions were inves- The Ag map confirmed that these
tigated with respect to their roles in images pertained to the edge of the fil-
the wetting and spreading of molten let, not a precursor foot phenomenon.
Ag-Cu-Zr filler metal on the Kovar™ The EDX maps show that particles
surface. composed of Fe, Ni, Al, and Zr formed
Shown in Fig. 9A is a tensile button at the very edge of the fillet.
having run-out (yellow box). The SEM The fillet edge location indicated by
image in Fig. 9B shows a precursor the yellow box in Fig. 10B is shown at
“foot” that extended approximately 40 high magnification in Fig. 11. There
mm from the edge of the Ag-Cu-Zr fil- were two particle phases that corre-
let. The composition of the precursor sponded to the high Al (Fe, Ni, Co)x(Al,
foot was analyzed, qualitatively, by the Zr)y and high Zr (Zr, Al)y(Fe, Ni, Co)x
energy dispersive x-ray (EDX) tech- compositions noted in the previous
Fig. 13 — Schematic shows the observa- nique. The Fe, Ni, and Al elemental cross sections. It was conjectured that
tions of run-out for the four variants of maps are also shown in Fig. 9B. The re- the formation of these particles im-
spacer and button base materials. gion “A” exhibited a very strong pres- peded the further wetting and spread-
ence of Al, Ni, and Fe that indicated ing action of the Ag-Cu-Zr filler metal
the (Fe, Ni)-Al reaction. There is an en- by acting as a sink for Al, thus prevent-
cent to the Kovar‘ base material. The richment of Ni vs. Fe when compared ing formation of the precursor foot.
presence and morphologies of the sub- to unreacted Kovar™ at the lower,
layers varied sample to sample as well right-hand region. Region “B” shows
as location to location along the same the same reaction, albeit, with a lesser Base Material Geometry
interface. presence of Al. Zirconium and Ag were
The Cu constituent of the Ag-Cu-Zr absent from the precursor foot. The previous analysis suggests that
braze alloy did not have a detectable The edge of the Ag-Cu-Zr fillet was the reaction between the released Al
presence in any of the interface reac- similarly analyzed where run-out was and Fe plus Ni constituents of Kovar™
tions. The filler metal retained its 2 absent. The tensile button and loca- underlie the wetting and spreading in-
wt-% Cu and became, effectively, an tion (yellow box) are shown in Fig. stability responsible for run-out. The
Ag-Cu alloy. Also, both Zr and Al were 10A. The corresponding SEM (BSE) next analysis examined the role of
absent from the filler metal. image, together with the EDX maps of molten Ag-Cu-Zr surface tension.
concentration of elemental Al in the between Kovar™ and Al2O3 ceramic us- as follows: braze joint geometry that
filler metal was in the range of 0.7–0.9 ing the active filler metal, 97Ag-2Zr- takes advantage of the molten filler
wt-% Al. 1Cu (wt-%). The phenomenon did not metal’s surface tension, filler metal
Such a relatively small quantity of respond to mitigation strategies, the modifications that inhibit the alu-
elemental Al was responsible for the cause being “squishing out” of exces- minide reaction at the Kovar™ surface,
aluminide reactions and run-out phe- sive filler metal. or coatings on the Kovar™ surface that
nomenon observed in this brazement. 2. At the Ag-Cu-Zr/Al2O3 interface, prevent the aluminide reactions. WJ
Last, this sample also provided evi- the redox reaction between Zr and the
dence that identified the likely driving Al2O3 released elemental Al into the Acknowledgments
force behind the Zr/Al2O3 redox reac- molten filler metal. The Al reacted
tion. The absence of the Kovar™ base with the Kovar™ constituents, creating The authors wish to thank Lisa
material eliminated the aluminide re- the aluminide reaction layer responsi- Deibler for her careful review of the
actions as the primary driving force. ble for the wetting and spreading in- original IBSC 2015 proceedings manu-
Therefore, it was concluded that the stability that generated run-out. script. Sandia is a multiprogram labo-
free energy of solution generated by 3. It was also learned that the free ratory operated by Sandia Corp., a
elemental Al entering the molten filler energy of solution generated by ele- Lockheed Martin Co., for the United
metal drove the spontaneity of the mental Al entering the molten filler States Department of Energy’s Na-
Zr/Al2O3 redox reaction. metal drove the spontaneity of the tional Nuclear Security Administration
Zr/Al2O3 redox reaction. under contract DE-AC04-94AL85000.
Conclusions 4. Most important, however, the
References
findings of this study indicate that the
1. The run-out behavior degraded strategies having the greatest promise
of successfully mitigating run-out are 1. ASTM F19-11, Standard Test
the performance of braze joints made Method for Tension and Vacuum Testing
Metallized Ceramic Seals.
2. The Ag-Al (Silver-Aluminum)
System. 1987. Ed. by A. McAlister.
Bull. of Alloy Phase Diagrams 8(6): 526.
3. Yue, T., Yang, H., Li, T., and
Huang, K. 2009. The synthesis of
graded thermal barrier coatings on
nickel substrates by laser induced
thermite reactions. Mater. Trans. Jap.
Inst. of Metals 50(1): 219–221.
P. T. VIANCO (ptvianc@sandia.gov), C. A.
WALKER, D. DE SMET, A. KILGO, B. M.
MCKENZIE, P. M. KOTULA, and R. L. GRANT
are with Sandia National Laboratories,
Albuquerque, N.Mex.
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Hobart had the solution.
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oday, the demand for higher
thermal and mechanical per-
formance in aluminum assem-
blies used in numerous applications —
from cold plates to heat exchangers to
chassis — requires a higher level of
precision, increased joint strength and
integrity, and tighter mechanical de-
sign tolerances. Consequently, the
joining methods used to fabricate alu-
minum assemblies need to promote
clean interior surfaces and avoid con-
tamination by flux, salts, or filling ma-
terials that can cause corrosion, poros-
ity, and weak metallurgical bonds.
Several methods may be used for
joining aluminum assemblies. Many of
these methods — dip brazing, weld-
ing, soldering, epoxying, and friction
stir welding — have cleanliness and
repeatability issues.
In contrast, vacuum brazing has nu- In vacuum brazing, a vacuum furnace allows the joint paths to be purged of gases while the
merous advantages, which include furnace chamber is being evacuated.
• No need for brazing flux1, which
reduces the risk of corrosion and cre-
ates cleaner parts • Ability to join large surfaces and the unique characteristics of the
• Avoids oxidization of sensitive highly complex internal geometries process. In general, brazing is a
materials • Ensures uniform material proper- process of joining materials by heating
• No potential for salt contamina- ties during and after brazing. metal surfaces to the liquidus temper-
tion compared to dip brazing ature of a filler metal, which forms a
• High repeatability and controlla- metallurgical bond with the mating
bility for batch processing Understanding the surfaces — Fig. 1. Typically, the filler
• Produces joints with strength ap- Process metal is a braze foil of thickness rang-
proaching the base metal, resulting in ing from 0.001 to 0.005 in. The
leak-free parts with high proof pres- The advantages that aluminum vac- molten filler metal is drawn through
sures uum brazing brings are the result of the joint by capillary action.
1. In atmospheric brazing as opposed to vacuum brazing, a chemical compound applied to the joint surfaces before brazing, called “flux,” is used
to shield the surfaces from oxygen in the air that causes oxide formation. Heating a metal surface accelerates the formation of oxides, the result
of chemical combination between the hot metal and oxygen in the air. These oxides must be prevented from forming or the oxides will inhibit
the brazing filler metal from wetting and bonding to the surfaces. The flux helps wetting of the joint surface in the presence of air and oxidation
and absorbs any oxides that form during heating or that were not completely removed in the cleaning process.
In vacuum brazing, a vacuum fur- mine the precise levels and timing of decreasing pressure of time. Helium
nace allows the joint paths to be both heating and vacuum levels. leak checking requires sophisticated
purged of gases while the furnace Although brazing in a vacuum re- helium mass spectrometer equipment
chamber is being evacuated. The dy- quires additional time compared with to sense for helium molecules that are
namic vacuum prevents oxidation of other methods, the technique greatly able to permeate through extremely
the surfaces and, consequently, braz- reduces the risk of metal oxidation or small holes that bubble testing will
ing flux is not needed. contamination. The vacuum furnace never uncover.
During preparation of the compo- cycle also facilitates temperature uni- Unlike some forms of controlled at-
nents to be brazed, a cleaning process formity. At the braze temperature, the mosphere brazing (CAB), vacuum
removes the oxide layer and any resid- molten filler metal is distributed by brazing is not typically a high-volume
ual machining oils. A filler metal pre- capillary action and pressure, making a process due to batch cycle time. A fur-
form (typically Al-Si alloys for base thin and strong joint. nace load typically consists from one
metal compatibility) is then placed be- After the brazing process is com- to 100 parts depending on size of the
tween the aluminum parts to be pleted, the parts are typically heat furnace and the parts.
joined. Foil preforms are most com- treated to restore temper (a degree of Equipment controls and brazing
mon in aluminum vacuum brazing; metal hardness and elasticity), which conditions are typically dictated by ap-
however, aluminum filler directly ap- allows machining at feeds and speeds plicable industry standards. What dif-
plied to the mating surfaces, called similar to unbrazed aluminum. If ferentiates vendors is their under-
“cladding,” can be used. After assembly there is internal geometry in the com- standing of the process and their
of the components, closely spaced ponent, such as cooling passages, a philosophies regarding braze compo-
clamps are applied to the components leak test is performed. Depending on nent and fixture design. These factors
to provide uniform pressure during the test requirement, a leak test can be play a significant role in consistency,
the brazing operation. a simple bubble test, a pressure decay repeatability, and overall performance.
During the braze cycle, the vacuum test, or a more stringent helium leak
furnace is heated to a point above the test. A bubble test involves submerg- Factors for Success
melting temperature of the braze foil ing the component in a fluid, typically
(>450°C). Thermocouples are attached water, pressurizing the flow passage, Typically, the part of the vacuum
to the component to monitor temper- and looking for signs of bubbles. Soap brazing process that end users focus
ature to ensure the proper braze tem- and water can be used too. The pres- on is the design of the finished part.
perature is achieved. Digital program- sure decay test involves pressurizing In reality, a successful vacuum-brazed
mable logic controllers (PLC) deter- the internal passage and checking for assembly is the result of integrating all
Fig. 2 — An experienced vacuum-brazed cold plate designer can quickly identify jobs that would benefit from using clad aluminum, rather
than the conventional braze foil. (Pictured here is a CAD design of a cold plate completed.)
the manufacturing steps: rough ma- machined “blank” assembly made with are often advisable to ensure success,
chined prebraze component design, oversized prebrazed components that especially on challenging assemblies.
assembly and fixturing, vacuum braz- include external features for adequate Not every project has the budget for
ing, heat treatment, final machining, clamping and fixturing during vacuum braze trials, and so as a result, careful-
and testing. brazing. In other words, allow excess ly designing the rough-machined
material in the rough-machined blank design with the final assembly
brazed-blank design to allow machin- design is a must. Best design practices
Prebraze Component ing of intricate external features of the include
Design final assembly during the final ma- • Minimize the number of braze
chining stage. joints. It’s important to evaluate
To start with, it’s critical to consid- Another important consideration strength requirements and machining
er the design of the prebraze compo- in the brazed blank design is to avoid issues on a case-by-case basis.
nents. That’s because the prebraze creating unnecessary joints. Stacking • Avoid elements protruding out of
component design determines how up generic, off-the-shelf plates merely the external surfaces — they can often
the assembly is going to behave to save the raw material costs of buy- interfere with appropriate clamping.
through the heat treat and aging ing a properly sized piece of aluminum • Design with a strong preference
process that takes place after brazing. is short-sighted. Additional and un- for joints or bond lines that are in the
The heat treat process involves a rapid necessary joints can lead to increased horizontal plane, which enable imme-
quench that causes distortion. The ob- risk of braze joint failures. For this diate success and high repeatability.
jective is to minimize this distortion reason, it is typically more cost effec- • Avoid vacuum brazing very broad,
via prebraze component design. tive to invest in properly designed pre- featureless surfaces together. Better
The first step in the prebraze com- brazed components and assembly integrity of the finished component is
ponent design process is to consider rather than risk poor yield at the com- achieved if thick, solid areas are not
the nature of the features that need to pletion of the brazing stage. comprised of a series of thin plates
be brazed. Due to postbrazing distor- stacked together. Large featureless ar-
tion, attempting to braze components Best Practices eas tend to exhibit a higher occurrence
machined to their final assembly di- of voids — especially in heavy parts.
mensions creates difficulties when try- Complex final assembly design fea- • Where possible, avoid brazing
ing to meet final assembly tolerances. tures can be accommodated in the vac- tubes into sockets. This cylindrical
A better practice is to braze a rough- uum brazing process, but braze trials geometry violates the design of a bond
line in the horizontal plane. While tive to the lower cost braze foil filler through air quenching in air. Air
possible, trial and error is required to metal approach. A common clad alu- quenching will cause some oxidization;
achieve success and ensure consisten- minum alloy used in vacuum brazing is therefore, a skin or coating treatment
cy; however, it adds cost. comprised of a 6000 series aluminum may be required where a clean appear-
• Ensure distributed and even core with a thin layer of 4000 series ance is desired. An alternative to air
clamping pressure is applied over the braze filler metal bonded to it. Using quenching is liquid submersion
entire joint being brazed, especially on clad aluminum reduces part count and quenching. We do this before machin-
thin components that do not translate assembly labor time, and it can be ing to final shape.
pressure well when they become soft more forgiving than braze foil. In high
at elevated temperatures. volumes, clad aluminum can be ob- Integrating the Process
Consult over blank design early in tained in many sizes; however, low-
the process. To ensure a successful alu- volume jobs require the use of stock- Integrating the process from pre-
minum vacuum-brazed cold plate, heat sized material. An experienced vacu- braze component design to finished
exchanger, or chassis assembly, collab- um-brazed assembly designer can machining is critical. To ensure a suc-
orate with a brazing partner that has quickly identify jobs that would bene- cessful aluminum vacuum-brazed as-
demonstrated thermal and mechanical fit from using clad aluminum — Fig. 2. sembly outcome, the best practices
engineering design, fabrication, and and design rules identified previously
material process and testing expertise. must be applied at the beginning of
A partner with demonstrated prebraze Postbraze Machining the project. When the process is fully
component design and prebraze as- integrated from prebraze component
The aluminum vacuum brazing
sembly experience on numerous de- design to postbraze machining and
process inherently thermally cycles the
sign configurations is highly recom- testing, a repeatable, high product
blank assembly. Thermal cycling ma-
mended. Early consultation and col- yield manufacturing process is estab-
chined components that get joined to-
laboration with an expert will save on lished. More importantly, a well-inte-
gether can result in distortion or
braze cycle costs and postbraze yield. grated design and manufacturing
warpage of the postbraze blank. As a
result, the postbraze assembly typical- process assures the best thermally and
Design for Manufacture ly requires some postbraze or final ma- mechanically performing and most re-
and Assembly chining to eliminate minor distortions liable aluminum vacuum-brazed as-
that would cause an out-of-tolerance semblies. Typical contract aluminum
condition on the final assembly. vacuum brazing houses do not have
Applying “design for manufacturing
Postbraze machining to allow for the integration of design and manu-
and assembly (DFMA)” methodologies
correcting mechanical distortion and facturing process capabilities. An expe-
and experience is equally important. It
other minor surface imperfections rienced, integrated firm can determine
is the combination of two methodolo-
should be considered in the early de- brazing and finishing parameters
gies, namely, design for manufacture,
sign stages of the prebraze compo- based on application, desired thermal
which means the design for ease of
nents, prebrazed assembly, and post- and mechanical performance, geome-
manufacture of the parts that will
brazed blank. tries, and features.
form a product, and design for assem-
By combining vertically integrated
bly, which means the design of the
engineering and manufacturing capa-
product for ease of assembly. The Machining Process bilities, coupled with the identified
The DFMA process captures poten-
best practices and stringent quality
tial manufacturability design flaws in Postbraze machining is done after control steps, Thermacore produces
prebrazed and postbrazed compo- the brazed part is stable. Machining aluminum vacuum-brazed cold plates,
nents, and makes it easy to discuss can be accomplished down to five heat exchangers, and chassis that en-
and implement possible improve- thousandths of an inch. Additional sure high levels of performance and
ments. For example, a design may re- tooling is often incorporated into the reliability for demanding customer ap-
quire large amounts of material to be braze clamps and fixtures to protect plications — maintaining near-perfect
removed after brazing in a final ma- the parts from being damaged when at yields on assemblies that utilize estab-
chining operation. Depending on braze temperature. Using plates or fix- lished design principles. WJ
geometry, a slight compromise in the tures may cause some discoloring or
design for braze performance may rough spots. Furthermore, some braze
positively impact postbraze machining may squeeze out of the joints, requir-
and potentially lead to a part that is ing cleanup in order to meet surface
more efficient to produce. finish or cosmetic requirements. DR. ROBERT CARACCIOLO is engineering group
leader, Vacuum Braze and High Temperature,
TIMOTHY DELAHANTY is light metals project
Other Filler Metal Heat Treating manager, Materials Technology Division,
Considerations JOSEPH GIGLIO is vice president, Customer De-
Heat treating: Heat treating is con- velopment, Materials Technology Division, and
GREGG BALDASSARRE is vice president, Sales
Some aluminum vacuum braze de- ducted after machining to achieve the and Marketing, at Thermacore, Inc. (therma-
signs also lend themselves toward clad design-specified metal hardness. Solu- core.com), Lancaster, Pa.
aluminum braze sheets as an alterna- tion heat treating is typically done
Effect of SiC Nanoparticles on doped with “nano” SiC powder, is melting temperature in comparison to
Shear Strength, Microstructure equal to or even exceeding 50% of that the corresponding bulk material. After
of pure Mo. The microstructure of the melting or sintering of the nanoparti-
of Molybdenum Brazed Joints doped samples depends strongly on cles, the material behaves like the bulk
the concentration of the SiC power. material. Therefore, high-strength and
A doping of the microsized eutectic Both metalloids, Si and C, are dis- temperature-resistant joints can be
alloy Mo.40-Ni.653 powder by SiC solved upon filler metal melting, and produced at low temperatures.
nanoparticles applied in order to de- found as solid solution components in The investigations made at Chem-
crease the liquid alloy spreading over Mo- and Ni-based intermetallic eutec- nitz Technical University, Germany,
pure Mo was studied at the Harbin In- tic joint phase components. proved that silver nanopaste offers a
stitute of Technology, China, and the The major beneficial changes of the great potential for joining copper and
University of Kentucky. brazed joint’s morphology due to alloy- other metals at temperatures below
The addition of SiC nanoparticles ing with SiC takes place in the joint mi- 500°C (Ref. 2).
to the eutectic Mo-Ni brazing filler crostructure. These changes are ex- The study showed that the organic
metal changes both the microstructure pressed in transformation, replace- shell of silver nanoparticles decompos-
of the solidified Mo/Mo-Ni joints and ment of typical eutectic morphology es at ~410°C, followed by a sintering
mechanical properties of the material consisting of dendrites embedded process. The sintered structure pos-
(Ref. 1). within a mixture of lamellae into a new sesses thermal properties of bulk sil-
The Mo-Ni powder was doped with type of refined microstructure consist- ver. Joints can be produced even at
1, 3, and 5 wt-% of nano-SiC powder. ing of a mixture with very small, evenly lower temperatures, ~300°C, with the
The maximum joint fracture stress lev- distributed eutectic crystals having satisfied strength ~95 MPa and high
el was observed in the specimen con- cuboidal and trapezoidal forms. temperature stability. The variation of
taining 3 wt-% SiC additive. For the the process parameters reveals that the
first time, nano-indentation experi- LowTemperature Bonding of joining pressure varied from 5 to 80
ments were carried out using atomic MPa exerts an essential positive effect
force microscopy to measure the hard- Copper Using Silver on the achievable strengths increased
ness of submicrometer joint phases Nanoparticles from 20 to 95 MPa, and also on de-
with a resolution of <50 nm. The creasing porosity from ~45 to ~10%.
strength of brazements, which are Nanoparticles exhibit a decrease in The change of joining temperature
in the range of 300°–400°C did not af- ous reaction layers without compro- continuous reaction layer on the fay-
fect the strength of the joints, while mising tensile strength or promoting ing surface it was positioned adjacent
increasing the holding time from 5 to excess filler metal wetting/flow. Tita- to during the prebrazing fixturing
30 min improved the strength of cop- nium or zirconium thin film, 0.5 mi- process.
per joints from ~45 to ~80 MPa. crons thick, as active components
were deposited on conventional silver Metal Leaching of Brazed
Evaluation of Brazing Filler and gold brazing foils by PVD tech-
niques (Ref. 3). Stainless Steel Joints into
Metals with a Reduced Content Drinking Water
SEM/EDS analysis confirmed the
of Active Elements for Joining reaction layers formed were not con-
Alumina Ceramic tinuous on either of the surfaces, as Stainless steel is replacing copper
compared to samples fabricated with alloys in heat exchangers and plumb-
Active braze filler metals are widely commercially manufactured active ing systems for drinking water instal-
used to join nonmetals to metals and brazing filler metals containing 2 wt-% lations due to hygienic considerations
nonmetals without metallization coat- of titanium or zirconium. The average and improved corrosion resistance.
ings. Because active filler metal com- tensile strengths of the samples The hygienic suitability of stainless
positions are limited and designed to brazed using the 2 wt-% active ele- steel for drinking water applications is
work with various materials systems, ment were superior to the strengths of well investigated, documented, and
the amount of active element is often those fabricated using the modified approved. However, hygienic aspects
more than required resulting in thick, filler metals having reduced active ele- of brazed joints made on stainless
brittle reaction layers or reactions with ment percentages. steel components, such as heat ex-
base materials that lead to excessive Future test samples should include changers, was not studied enough.
braze filler metal flow. greater concentrations of active ele- Leaching metals from brazed joints
Reduced quantities of the active el- ment and also amended filler metal of 316L stainless steel made by using
ements titanium and zirconium added preparation methods, because the copper-, nickel-, and iron-based braz-
to standard braze filler metals were analysis of the metallographic cross ing alloys in the form of amorphous
tested at Sandia Laboratories, Albu- sections also showed the tendency of foils was examined by Vacuum-
querque, N.Mex., to determine the the sputter-deposited active element schmelze, Hanau, Germany (Ref. 4).
quantities required to form continu- to preferentially form a thicker, more The obtained results confirmed it is
(860) 283-07
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FEBRUARY 2016 / WELDING JOURNAL 49
BRAZING & SOLDERING TODAY TECHNOLOGY NEWS
not possible to characterize corrosive heat exchanger (HE) samples were molten alloy In-Na at a small addition
or hygienic aspects of a braze joint by brazed using an industrial controlled- of sodium that resulted in significant
studying individual materials. It is im- atmosphere brazing furnace, and the deviations of the surface tension val-
perative to analyze the metallurgical dissolution was examined. ues for some compositions of this alloy.
bond and activities of the involved ma- The metallographic study of the
terials with respect to their thermal dissolution shows the baseline group
processing. of the HE experienced an average dis-
New Brazing Concept for
It was found that not all nickel solution up to 64%, which is consis- Joining Stainless Steels
brazing alloys are comparably suitable tent with the results monitored for
for drinking water applications. In par- mass production development sam- A new method of brazing stainless
ticular, the nickel brazing alloys con- ples. In contrast, the group of HE with steel parts that aims to reduce the
taining a high boron content, about 3 altered Si content in the clad experi- process steps and production costs
wt-%, are not applicable because they enced a very low level of dissolution. was disclosed by Alfa Laval Corp.,
release high values of nickel into the Therefore, the results show the base Lund, Sweden.
water. The Ni-Cr brazing alloys with metal dissolution can be largely im- The method proved that it is possi-
lower boron content of ≤1.5 wt-% ex- pacted by controlling the potential of ble to create a melted alloy of the par-
hibit the lowest metal leaching rates capillary molten clad flow, which sup- ent material by using a Mn3P2 or NiP
and show much more convenience for ports the concept in the proposed and pure silicon powder mixture as a
drinking water applications. model. melting point depressant on the plate
The copper-brazed 316L joints re- surface in vacuum or in a hydrogen at-
lease a significant amount of Ni in ad- Effects of Alkali and mosphere. No additional brazing filler
dition to copper and iron. Brazed spec- metal is used. The composition of the
AlkaliEarth Elements on formed joint alloy after cooling has a
imens using the Ni-Cr-Si-B brazing
foils showed a significantly lower nick-
Surface Tension of Lead, Tin, composition similar to the base metal.
el leaching rate than that of the copper and Indium Wetting of the facing surface is provid-
brazed specimen. The general leaching ed with a contact angle of <90 deg,
of metal ions (Cu + Ni + Fe) for the Cu- Development and testing of new, and a smooth joint is formed (Ref. 7).
brazed steel is orders of magnitude effective solders is still a problem in the For example, the Mn3P2 and pure
higher than that of the specimens industry. Therefore, knowledge of silicon powders are mixed at the
brazed with the previously mentioned fundamental physical properties of weight ratio 2.46:1, and a water-based
Ni-Cr and Fe/Ni-Cr brazing foils. low-temperature molten alloys is polymer binder is added. The paste is
important. placed onto the flat surface of a 316
The effects of alkali and alkali-earth stainless steel part and covered by a
Capillary Enhanced Dissolution elements on the surface tension of 254SMO steel part. The assembly is
in Brazing lead, tin, and indium that constitute heat treated for 2 h in vacuum at
the major portion of solders were 1120°–1140°C. The joint metal com-
During a brazing process, dissolu- studied by the North-Caucasus position is C 2.86, Si 2.40, P 1.43, Cr
tion (erosion) of the solid base metal Mining and Metallurgy University, 18, Ni 18, Mo 5.6, Mn 1.63, and Fe
into the liquid filler metal is an in- Vladikavkaz, Russia, using the method 50.54 wt-%.
evitable phenomenon, which can be of large droplet on graphite substrates. A similar joining procedure is car-
enhanced by surface-tension-driven The polythermic diagrams of sur- ried out if the stainless steel is coated
molten metal flow. Severe dissolution face tensions and density of such bina- by a NiP layer 50 microns thick and a
associated with base metal thickness ry alloy melts as Sn-0.1Ba, Sn-0.59Sr, pure silicon powder is placed onto this
reduction can be detrimental for Sn-1.93Sr, In-(0.1-0.5)Na, Pb-0.3Li, coating. After heat treatment for 2 h
brazed products. and Pb-0.2Ca (all in atomic %) were at 1120°C, the steel parts are brazed,
An analytical model was established determined based on experimental and the joint metal has the composi-
by Delphi Thermal Systems, Lockport, data in the wide range of temperatures tion O 1.20, P 14.41, Cr 18, Ni 40.95,
N.Y., that combines the mechanism of 200°–700°C (Ref. 6). Mo 4.77, Mn 0.51, and Fe 10.17 wt-%.
both dissolution and surface-tension Diagrams of surface tensions and
driven molten metal flow. The model density in the systems Sn-Ba, Pb-Li,
explains the underlying physics of dis- and In-Na liquid alloys are well repre- Aluminum Brazing of Hollow
solution for a brazing process and as- sented by linear equations with nega- Titanium Fan Blades
sociated impacts caused by the capil- tive temperature coefficients. In other
lary action (Ref. 5). words, small additions of alkali and A method of brazing titanium fan
The model suggests that with low- alkali-earth elements decrease surface blades at the temperature below the
ering the Si content in the Al-Si alloy tension of the solder base metals. annealing temperature of Ti-6Al-4V al-
cladding towards a reduced surface Nonlinear diagrams were found in the loy of thin-wall parts was disclosed by
tension to viscosity ratio at elevated systems of liquid Sn-Sr and Pb-Ca al- United Technology Corp., South
temperatures, the capillary action can loys that were explained by a specific Windsor, Conn.
be weakened, thus achieving a sup- temperature effect on surface tension. Brazing below the annealing tem-
pressed dissolution. To validate that A repeatable process of ordering perature allows for the maintenance of
concept, two groups of aluminum surface structure was observed in the certified mechanical properties of the
base metal. An aluminum alloy of the 1175°F (solidus of the aluminum braz- 4. Hartmann, T. Metal leaching of
Al-Cu-Mn system containing <3 wt-% ing alloy) on heating and 1175°F on brazed stainless steel joints into drinking
of copper and <5 wt-% of manganese cooling would be controlled to produce water. Paper #26.
and having a solidus-liquidus range a braze microstructure that satisfies 5. Liu, W., and Barten, B. L. Capillary
enhanced dissolution in brazing. Paper
within 1175°–1225°F (635°–663°C) is the required testing characteristic of
#60.
deposited at least on one of the forged brazed joints. WJ 6. Kashezhev, A. Z., Kutuiev, P. A.,
and machined titanium parts to be Ponezhev, M. K., and Sozaev, V. A. 2013.
brazed (Ref. 8). References Effects of alkali- and alkali-earth elements
The assembled fan blade is inserted on surface tension of lead, tin, and indium.
into a metallic foil bag constructed Refs. 1–5 are Proceedings of the 6th Inter- Melts, Journal of Russian Academy of Sci-
from stainless steel or nickel alloy foils national Brazing and Soldering Conference, ences No. 5: 66–77.
that can be sealed. The sealed, bagged April 19–22, 2015, Long Beach, Calif. 7. Sjödin, P., Walter, K., and Falkenberg,
fan blade is loaded into a vacuum com- F. 2015. A novel brazing concept. World
1. Sekulic, D. P., Fu, H., Rabinkin, A., Patent WO 2014/099067. Publication date
pression brazing furnace. Oxygen and Busbaher, D., Leone, E., and Preuss, T. Me- April 2, 2015.
nitrogen within the bag are evacuated, chanical properties of Mo-Ni brazing filler 8. Bales, D. A., and Watson, T. J. 2014.
and the bag is backfilled with dry ar- metal caused by additions of SiC nanopar- Aluminum brazing of hollow titanium fan
gon, then a negative atmosphere pres- ticle powder. Paper #59. blades. World Patent WO 2015/043977.
sure is maintained with the sealed bag. 2. Hausner, S., Weis, S., Wielage, B., and Publication date June 26, 2014.
Brazing could occur in a vacuum Wagner, G. Joining of copper at low tem-
furnace capable of maintaining a par- perature using Ag nanoparticles: Influence
tial pressure of argon to provide a pos- of process parameters on mechanical
strength. Paper #103.
itive pressure that will compress 3. Walker, C. A., Bishop, G., DeSmet,
brazed parts during the brazing cycle. D. J., and Brumbach, M. Single and double Information provided by ALEXANDER E.
Heating is carried out in the range of SHAPIRO (ashapiro@titaniumbrazing.com)
reaction layer formation using reduced ac-
1225°–1290°F (663°–699°C) followed and LEO A. SHAPIRO, Titanium Brazing, Inc.,
tive element containing brazing filler met- Columbus, Ohio.
by immediate cooling. Time between als. Paper #56.
$6450. Independ
L ocal
dence.
3&13*/54 Perform
m.
This is
Thi i H o
ow I
INTERNATIONAL EVENTS
— continued on page 55
FEBRUARY 2016 / WELDING JOURNAL 53
COMING EVENTS Lewistown, Pa., (315) 554-2039; geinspectionacademy.com.
— continued from page 53 Hypertherm Cutting Institute Online. Includes video tutori-
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Institute of Welding Technology; (800) 332-9448; Laser Safety Training Courses. Courses based on ANSI
welding.org. Z136.1, Safe Use of Lasers. Orlando, Fla., or customer’s site.
Laser Institute of America; (800) 345-2737; lia.org.
ECourses in Destructive and Nondestructive Testing of
Welds and Other WeldingRelated Topics. Online video Laser U — Online Education Portal. Offers practical infor-
courses taken at one’s own pace offer certificates of comple- mation to use on the job. Topics range from 3D printing to
tion and continuing education units. For information, con- drilling, welding, wireless and optical product requirements,
tact Hobart Institute of Welding Technology; welding.org/ and many others. Visit website for complete information
product-category/online-courses/. and to sign up for modules. Laser Institute of America;
lia.org/laseru.
GE Industrial Computed Tomography (CT) Operator Course.
Learn to operate the 3D technology that is becoming more Laser Vision Seminars. Two-day classes, offered monthly
prominent in industrial quality control and metrology.
— continued on page 112
PERFO
ORM
YOUR OWN WA
WAY!
Note: The 2016 schedule for all certifications are posted online at 9Year Recertification Seminar for CWI/SCWI
aws.org/w/a/registrations/prices_schedules.html. For current CWIs and SCWIs needing to meet education re-
quirements without taking the exam. The exam can be tak-
en at any site listed under Certified Welding Inspector.
Certified Welding Inspector (CWI)
Location Seminar Dates
Location Seminar Dates Exam Date
Denver, CO Feb. 21–26
Miami, FL Exam only Feb. 18
Dallas, TX Mar. 6–11
New Orleans, LA Feb. 21–26 Feb. 27
Miami, FL Mar. 13–18
Milwaukee, WI Feb. 21–26 Feb. 27
Sacramento, CA Apr. 10–15
San Diego, CA Feb. 28–Mar. 4 Mar. 5
Boston, MA Apr. 17–22
Kansas City, MO Feb. 28–Mar. 4 Mar. 5
Charlotte, NC May 1–6
Houston, TX Feb. 28–Mar. 4 Mar. 5
Pittsburgh, PA May 15–20
Norfolk, VA Feb. 28–Mar. 4 Mar. 5
Scottsdale, AZ Mar. 6–11 Mar. 12
Indianapolis, IN Mar. 6–11 Mar. 12
Boston, MA Mar. 6–11 Mar. 12
Certified Welding Educator (CWE)
Perrysburg, OH Exam only Mar. 12 Seminar and exam are given at all sites listed under Certified
Miami, FL Mar. 13–18 Mar. 19 Welding Inspector. Seminar attendees will not attend the Code
Birmingham, AL Mar. 13–18 Mar. 19 Clinic portion of the seminar (usually the first two days).
Chicago, IL Mar. 13–18 Mar. 19
Springfield, MO Mar. 13–18 Mar. 19
Dallas, TX Mar. 13–18 Mar. 19 Certified Welding Sales Representative (CWSR)
Miami, FL Exam only Apr. 7 CWSR exams will be given at CWI exam sites.
Minneapolis, MN Apr. 3–8 Apr. 9
Las Vegas, NV Apr. 3–8 Apr. 9
Portland, OR Apr. 3–8 Apr. 9
St. Louis, MO Exam only Apr. 9 Certified Welding Supervisor (CWS)
San Francisco, CA Apr. 10–15 Apr. 16 CWS exams are also given at all CWI exam sites.
Annapolis, MD Apr. 10–15 Apr. 16
Nashville, TN Apr. 10–15 Apr. 16 Location Seminar Dates Exam Date
Detroit, MI Apr. 17–22 Apr. 23 New Orleans, LA Apr. 4–8 Apr. 9
Corpus Christi, TX Apr. 17–22 Apr. 23 Cleveland, OH Sept. 19–23 Sept. 24
Fresno, CA May 1–6 May 7 Norfolk, VA Oct. 17–21 Oct. 22
Miami, FL May 1–6 May 7
Albuquerque, NM May 1–6 May 7
Syracuse, NY May 1–6 May 7
Oklahoma City, OK May 1–6 May 7 Certified Radiographic Interpreter (CRI)
Rapid City, SD May 1–6 May 7 The CRI certification can be a stand-alone credential or can
Knoxville, TX Exam only May 21 exempt you from your next 9-Year Recertification.
Jacksonville, FL May 15–20 May 21
Hutchinson, KS May 15–20 May 21 Location Seminar Dates Exam Date
Houston, TX May 15–20 May 21 Seattle, WA Feb. 22–26 Feb. 27
Spokane, WA May 15–20 May 21 Houston, TX Mar. 14–18 Mar. 19
Bakersfield, CA June 5–10 June 11 San Francisco, CA Apr. 11–15 Apr. 16
New Orleans, LA June 5–10 June 11 Las Vegas, NV May 2–6 May 7
Duluth, MN June 5–10 June 11 Cleveland, OH June 6–10 June 11
Pittsburgh, PA June 5–10 June 11
Miami, FL Exam only June 16
Hartford, CT June 12–17 June 18 Certified Robotic Arc Welding (CRAW)
Orlando, FL June 12–17 June 18 ABB, Inc., Auburn Hills, MI; (248) 391–8421
Memphis, TX June 12–17 June 18 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800, ext. 218
Beaumont, TX June 12–17 June 18 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Los Angeles, CA July 10–15 July 16 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Louisville, KY July 10–15 July 16 Wolf Robotics, Fort Collins, CO; (970) 225-7736
Omaha, NE July 10–15 July 16 On request at MATC, Milwaukee, WI; (414) 456-5454
Cleveland, OH July 10–15 July 16
IMPORTANT: This schedule is subject to change. Please verify your event dates with the Certification Dept. to confirm your course status
before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received
after that time will be assessed a $350 Fast Track fee. Please verify application deadline dates by visiting our website
aws.org/certification/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit
aws.org/certification or call (800/305) 4439353, ext. 273, for Certification; or ext. 455 for Seminars.
From left are Counselors John C. Bruskotter, William F. Newell Jr., André Odermatt, William A. Rice Jr., Carolyn K. Russell, Phillip I. Temple;
and Fellows Norman Y. Zhou, Yoni B. Adonyi, Duane K. Miller, Pingsha Dong, and Boain T. Alexandrov.
Charles V. Robino Todd A. Palmer Jeffrey L. Mitchell YuMing Zhang Yan Shao
Comfort A. Adams Lecture Award tations. Robino has held adjunct facul- ence and engineering. Before joining
This award is presented to an outstand- ty appointments at Lehigh University the university, Palmer was a metallur-
ing scientist or engineer for a lecture de- and the Colorado School of Mines, is gist at Lawrence Livermore National
scribing a new or distinctive development recent past chairman of the New Mexi- Laboratory. His current research fo-
in the field of welding. The lecture is pre- co Tech Materials Dept. External Advi- cuses on the laser and electron beam
sented during FABTECH. sory Board, and a member of ASM joining and additive manufacturing of
“Engineering Approximations in International. metallic materials.
Welding — Bridging the Gap Be-
tween Speculation and Simulation” Adams Memorial Membership Award Howard E. Adkins Memorial
Charles V. Robino, an AWS Fellow, This award recognizes educators for Instructor Membership Award
holds a PhD in materials engineering outstanding teaching activities in under- This award recognizes instructors for
from Lehigh University. He joined graduate and postgraduate engineering their outstanding teaching accomplish-
Sandia National Laboratories in 1988 institutions. ments at the high school, trade school,
and is a Distinguished Member of the Todd A. Palmer holds a PhD in ma- technical institute and community college
Technical Staff in the Metallurgy and terials science and engineering from levels.
Materials Dept. He has authored more Pennsylvania State University, where Jeffrey L. Mitchell, an AWS CWI
than 100 technical publications and he is a research senior associate and an and CWE, is dean of Industrial Tech-
made more than 100 technical presen- associate professor of materials sci- nologies at Kirkwood Community Col-
Jose E. Ramirez David R. Sigler Sampath K. Vanimisetti David Elsloo Jeffrey S. Noruk
lege, Cedar Rapids, Iowa. Prior to be- in materials, welding, and corrosion predecessor, A.O. Smith Automotive.
coming dean, he served as program di- technologies. Noruk holds two patents for improv-
rector of industrial education for 25 Structure Design ing overall performance of automotive
years. He has also owned and operated “Improving Fatigue Performance of structures.
a stainless steel and aluminum manu- Spot Welds in Advanced High-
facturing company specializing in gov- Strength Steels” W. H. Hobart Memorial Award
ernment contracts. David R. Sigler received his PhD in This award is presented to the authors
metallurgical engineering from Wayne of the paper published in the Welding
Robert J. Conkling Memorial Award State University, Detroit, Mich., and Journal during the previous calendar
This award is presented to the schools has since worked at the General Mo- year that describes the best contribution
that trained the two first-place winners tors Research Laboratory. As a Nation- to pipe welding, the structural use of
in the SkillsUSA welding competition. al Science Foundation Fellow at WSU, pipe, or similar applications, excluding
2015 SkillsUSA Championships his research focused on understanding the manufacture of pipe.
Gold Medalist FirstPlace Schools the fatigue behavior of aluminum “Weldability of Niobium-Containing
High School: S&W Washtenaw Consor- alloys. High-Strength Steel for Pipelines”
tium, Saline, Mich. Sampath K. Vanimisetti works as a Alexander Bortsov graduated from
Postsecondary School: Penn College of senior technical lead and optimization Moscow Engineering-Physical Insti-
Technology, Williamsport, Penn. engineer in the Vehicle Engineering tute with a focus in physics of metals
Dept. of General Motors. He has pub- and metallurgical science. His research
A. F. Davis Silver Medal Award lished 11 scientific papers and general focuses on dual-phase automotive
This award recognizes authors of pa- articles and holds four patents. steels, materials mechanics, low-alloy
pers published in the Welding Journal and carbon steels, cladding metal,
during the previous calendar year that Distinguished Welder Award weld metal, hot rolling, pipe produc-
represent the best contributions to the This award recognizes individuals tion, and quality of metal products.
progress of welding in the categories of who have exceptional welding skills and Igor I. Frantov received his PhD
Machine Design, Maintenance and Sur- experiences related to all aspects of the from Moscow Metallurgical Institute
facing, and Structure Design. art of welding. with a focus in physical and chemical
Machine Design David Elsloo, an AWS CWI, CWE, welding processes. He is the head of
“Gas Metal Arc Welding Enhanced by and CWS, is the senior training and laboratory at I.P. Bardin Central Re-
Using a Pulsed Laser” development specialist for welding in- search Institute for Ferrous Metallur-
YuMing Zhang, an AWS Fellow, struction at Vermeer Corp., Pella, gy Laboratory of Pipe-rolling, Technol-
holds the James R. Boyd Professorship Iowa. During his 29 years with the ogy, Weldability, and Heat Treatment
in Electrical Engineering at the Uni- company, he has served as a welding in Moscow, Russia.
versity of Kentucky, and is the founder technician, group leader, welder, engi- A. A. Velichko is with Izorsky Pipe
and president of Adaptive Intelligent neering technician, job shop foreman, Plant, Kolpino, Russia.
Systems, LLC, Lexington, Ky. and sales representative. I. Y. Utkin is with I.P. Bardin Cen-
Yan Shao received his PhD from the tral Research Center for Ferrous Met-
University of Kentucky in electrical Excellence in Robotic and Automated allurgy, Moscow, Russia.
engineering. He is currently a welding Arc Welding Award
engineer at Caterpillar, Inc., Mossville, This award recognizes significant in- Honorary Membership Award
Ill. dividual achievements in the area of ro- This award is presented to a person of
botic arc welding. acknowledged eminence in the welding
Maintenance and Surfacing Jeffrey S. Noruk, an AWS CWI and profession or to an individual who is cred-
“Characterization of CSC-GMAW Tita- Counselor, has a master of science in ited with exceptional accomplishments in
nium-Rich Weld Overlays” engineering management from Mil- the industry.
Jose E. Ramirez received his PhD in waukee School of Engineering. He is Zhili Feng, an AWS Fellow, is group
metallurgical and materials engineer- president of Servo Robot Corp., and leader of materials processing and
ing from Colorado School of Mines. He was previously the manager of R&D joining at Oak Ridge National Labora-
has more than 25 years of experience for both Tower Automotive and its tory. Additionally, Feng is joint faculty
Alexander Bortsov Igor I. Frantov Zhili Feng Thomas J. White Ajit K. Mukherjee
David J. Landon Xiao Huang Jeffrey A. Badger Daryush K. Aidun Alireza Bahrami
professor at The Univeristy of Ten- since 1993 and served as chair for six Jeffrey A. Badger received his PhD
nessee, Knoxville, and guest professor years. He chaired the Technical Activi- in mechanical engineering from Trini-
at Tsinghua University, China. ties Committee for three years, served ty College in Dublin, Ireland. He works
Thomas J. White, an AWS CWI and on the board of directors from 2007 as an independent expert consultant,
Silver Member, is a maintenance engi- to 2011, was vice president from 2012 visiting companies around the world
neer and welder at the Beaver Valley to 2014, and was the 2015 AWS and helping them improve their grind-
Power Station Duquesne Light/ president. ing operations, set up research pro-
FirstEnergy, Hookstown, Pa. grams, and perform research into
Charles H. Jennings Memorial Award grinding and abrasives.
International Meritorious Certificate This award recognizes the authors of
Award the most valuable paper written by a col- McKayHelm Award
This certificate recognizes an individ- lege student or faculty representative This award is presented for best con-
ual who has made significant contribu- published in the Welding Journal during tribution to the advancement of knowl-
tions or services to benefit the worldwide the previous calendar year. edge of low-alloy steel, stainless steel, or
welding industry. “Brazing of CMSX-4 with a Boron- and surfacing welding metals, involving the
Ajit K. Mukherjee is the executive Silicon-Free Ni-Co-Zr-Hf-Cr-Ti-Al use, development, or testing of these ma-
director of technical at Techno Electric Brazing Alloy” terials, as represented by articles pub-
and Engineering Co., Ltd., Kolkata, In- Xiao Huang is a professor at Car- lished in the Welding Journal during the
dia. He is a founding member of the leton University, Ottawa, Canada, previous calendar year.
Indian Institute of Welding, and where she teaches materials- and man- “Interaction of Gravity Forces in Spot
served as its president from ufacturing-related courses. She holds GTA Weld Pool”
2005–2008. two U.S. patents and has published Daryush K. Aidun received his PhD
one book and more than 130 peer-re- in material science and engineering
William Irrgang Memorial Award viewed journal and conference papers. from Rensselaer Polytechnic Institute.
This award recognizes the individual He is a professor and chair of the Me-
who has done the most to enhance the James F. Lincoln Gold Medal Award chanical and Aeronautical Engineering
American Welding Society’s goal of ad- This award is presented for the paper Department at Clarkson University.
vancing the science and technology of with a single author that represents the Alireza Bahrami is a research and
welding over the past five years. best original contribution to the advance- development engineer at The Fulton
David J. Landon, an AWS CW, CWS, ment and use of welding published in the Companies, Pulaski, N.Y. He obtained
CWI, and Counselor, is the manager of Welding Journal during the previous cal- his PhD from Clarkson University in
welding engineering for Vermeer endar year. mechanical engineering with a focus
Corp., Pella, Iowa. He has been a mem- “Evaluation of Triangular, Engineered- on heat and mass transfer in welding
ber of the AWS D14 technical commit- Shape Ceramic Abrasive in process.
tee for Machinery and Equipment Cutting Discs” Daniel T. Valentine earned his PhD
Daniel T. Valentine Yoshiaki Morisada Dennis D. Crockett Thomas J. Lienert Dean C. Phillips
Ali Ekrami Amir H. Kokabi Majid Pouranvari Richard T. Stone Eric J. Cox
in fluid dynamics from The Catholic 1993 to 2003. Crockett also serves on Ali Ekrami received his PhD in ma-
University of America. He is the affili- several AWS technical committees. terials science at the University of
ate director of the Clarkson Space Leeds in the United Kingdom. He has
Grant Program, which is part of the National Meritorious Award been an academic member of the Ma-
New York NASA Space Grant This award is given in recognition of terials Science and Engineering De-
Consortium. good counsel, loyalty, and devotion to the partment at the Sharif University of
affairs of the Society, and for promoting Technology, Tehran, Iran, since 1979.
Professor Koichi Masubuchi Award cordial relations with industry and other Amir H. Kokabi is a professor at
This award is presented to an individ- organizations. Sharif University of Technology,
ual who has made significant contribu- Thomas J. Lienert, an AWS Fellow Tehran, Iran, where he has taught for
tions to the advancement of science and and CWI, earned his PhD in materials more than 40 years. He currently
technology of materials joining through science and engineering from The teaches in the Department of Mathe-
research and development. Ohio State University. He is a technical matics and Science.
Yoshiaki Morisada received his PhD staff member for R&D at Los Alamos Majid Pouranvari received his PhD
in environmental engineering from National Laboratory. Lienert is cur- in materials science and engineering
Osaka University in Japan, where he rently an AWS vice president, holds from Sharif University of Technology
serves as a specially appointed associ- various positions throughout AWS in Iran, where he is currently an assis-
ate professor at its Joining and Weld- committees, and serves as lead princi- tant professor in the Dept. of Materi-
ing Research Institute. pal reviewer for the Welding Journal. als Science and Engineering.
Dean C. Phillips graduated from
Samuel Wylie Miller Memorial Medal LeTorneau University and has more Plummer Memorial Education
Award than 40 years of experience in the Lecture Award
This medal is awarded for meritorious welding industry. He is the manager of The award honors outstanding contri-
achievements that have contributed con- welding engineering for ITW, Hobart butions to the national education lectures
spicuously to the advancement of the art Bros. Co. in Troy, Ohio. presented at the AWS FABTECH conven-
and science of welding and cutting. tion.
Dennis D. Crockett earned a bache- Robert L. Peaslee “The Physiological and Cognitive
lor of science degree in physics from Memorial Brazing Award Effects of Virtual Reality Training in
John Carroll University and a bachelor This award recognizes the paper con- Welding”
of science degree in metallurgical engi- sidered to be the best contribution to the Richard T. Stone received his PhD
neering from Cleveland State Universi- science or technology of brazing pub- in industrial engineering from the
ty. While working for The Lincoln lished in the Welding Journal during the State University of New York. He is an
Electric Co., he was awarded nine previous calendar year. associate professor in the Dept. of In-
welded-related patents and was vice “Diffusion Brazing Metallurgy of dustrial and Manufacturing Systems
president of consumable R&D from IN718/Ni-Cr-Si-B-Fe/IN718” Engineering at Iowa State University.
Joseph Bundy Adrian Gerlich Hossein Izadi Patricio F. Mendez Eric W. Fusner
Adam T. Hope John C. Lippold Jerry E. Gould Donald B. Decorte Robert E. Shaw Jr.
His research focuses on human per- Joseph Bundy received his bachelor William Spraragen Memorial Award
formance engineering, particularly ap- of science degree in metallurgical engi- This award recognizes the best paper
plied biomedical, biomechanical, and neering from The Ohio State Universi- published in the Welding Journal Re-
cognitive engineering. ty. He has been employed by Hobart search Supplement during the previous
Bros. Co. for almost 30 years, where he calendar year.
Private Sector Instructor is currently the director of advanced “Development of High-Cr, Ni-
Membership Award engineering for tubular wires, oversee- Based Filler Metals Using Combined
This award honors educators in the ing product and process R&D. Computational and Experimental
welding community who teach in private Adrian Gerlich obtained his PhD in Techniques”
facilities and have, in the opinion of the materials science and engineering at Eric W. Fusner received his master
AWS Education Committee, advanced the the University of Toronto. He has been of science degree in welding engineer-
knowledge of welding to their students an associate professor at the Universi- ing from The Ohio State University.
through apprenticeship programs, inter- ty of Waterloo since 2012, and has He is a metallurgist at Cummins Emis-
nal corporate training programs, and been appointed the NSERC/Trans- sion Solutions where he built the ma-
similar nonpublic education activities. Canada Industrial Research Chair in terials engineering function within
Eric J. Cox, an AWS CWE, CWI, and Welding for Energy Infrastructure CES and developed an ISO-16949-
CWS, is a full-time welding instructor since 2014. compliant materials laboratory at the
at the Des Moines Area Community Hossein Izadi earned his master of technical facility in Stoughton, Wis.
College. Previously, he worked at science in materials science and engi- Adam T. Hope is currently finishing
Johnson Machine Works as a group neering from Ferdowsi University of his PhD in welding engineering at The
leader and area manager, and at Ver- Mashhad in Mashhad-Iran. He joined Ohio State University. His work in-
meer Corp. as a welder and group the Canadian Center of Welding and volves optimizing a new alloy compo-
leader. Joining at the Dept. of Chemical and sition for construction and repair of
Materials Engineering at University of nuclear reactor components.
Warren F. Savage Memorial Award Alberta as a graduate student, where John C. Lippold, an AWS Fellow,
This award recognizes the paper pub- he mainly worked on welding metal- has served on the faculty of the Weld-
lished in the Welding Journal Research lurgy of ferrous and nonferrous alloys. ing Engineering Program at The Ohio
Supplement during the previous calendar Patricio F. Mendez, an AWS Fellow, State University since 1995. He re-
year that best represents innovative re- is the Weldco/Industry chair in Weld- ceived his PhD at Rensselaer Polytech-
search resulting in a better understand- ing and Joining and director of the nic Institute, and has coauthored three
ing of the metallurgical principles related Canadian Centre for Welding and textbooks and published more than
to welding. Joining, University of Alberta. He 250 papers.
“Characterization of High-Strength holds a PhD in materials engineering R. D. Thomas Memorial Award
Weld Metal Containing Mg-Bearing for the Massachusetts Institute of This award recognizes a member of
Inclusions” Technology. the American Council of the Internation-
q Mr. q Ms. q Mrs. q Dr. Please print • Duplicate this page as needed Type of Business (Check ONE only)
A q Contract construction
Last Name:_______________________________________________________________________________
B q Chemicals & allied products
C q Petroleum & coal industries
First Name:___________________________________________________________________ M.I:_______
D q Primary metal industries
E q Fabricated metal products
Birthdate: _____________________________ E-Mail:____________________________________________
F q Machinery except elect. (incl. gas welding)
G q Electrical equip., supplies, electrodes
Cell Phone ( )__________________________ Secondary Phone ( )______________________
H q Transportation equip. — air, aerospace
Were you ever an AWS Member? q YES q NO If “YES,” give year________ and Member #:____________________ I q Transportation equip. — automotive
J q Transportation equip. — boats, ships
Company (if applicable):___________________________________________________________________ K q Transportation equip. — railroad
L q Utilities
Address:________________________________________________________________________________ M q Welding distributors & retail trade
N q Misc. repair services (incl. welding shops)
_______________________________________________________________________________________ O q Educational Services (univ., libraries, schools)
P q Engineering & architectural services (incl. assns.)
City:_____________________________________State/Province:__________________________________ Q q Misc. business services (incl. commercial labs)
R q Government (federal, state, local)
Zip/PostalCode:_____________________Country:______________________________________________ S q Other
Who pays your dues?: q Company q Self-paid Sex: q Male q Female Job Classification (Check ONE only)
01 q President, owner, partner, officer
Education level: q High school diploma q Associate’s q Bachelor’s q Master’s q Doctoral
02 q Manager, director, superintendent (or assistant)
q Check here if you learned of the Society through an AWS Member? Member’s name:_______________________Member’s # (if known):________ 03 q Sales
04 q Purchasing
q Check here if you would prefer not to receive email updates on AWS programs, new Member benefits, savings opportunities and events.
05 q Engineer — welding
20 q Engineer — design
INDIVIDUAL MEMBERSHIP 21 q Engineer — manufacturing
06 q Engineer — other
è Please check each box that applies to the Membership or service you’d like, and then add the cost together to get your Total Payment. 10 q Architect designer
q AWS INDIVIDUAL MEMBERSHIP (One Year)......................................................................................................$87 12 q Metallurgist
13 q Research & development
AWS INDIVIDUAL MEMBERSHIP (Two Years) SAVE $25 New Members Only....................................$149 22 q Quality control
07 q Inspector, tester
q New Member Initiation Fee ...........................................................................................................................................$12
08 q Supervisor, foreman
OPTIONS AVAILABLE TO AWS INDIVIDUAL MEMBERS ONLY: 14 q Technician
09 q Welder, welding or cutting operator
A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling) 11 q Consultant
q Individual Members in the U.S..................................................................................................................................$35 15 q Educator
17 q Librarian
q Individual Members outside the U.S (includes International shipping)...........................................................................$85 16 q Student
ONLY ONE SELECTION PLEASE. For more book choices visit https://app.aws.org/membership/books 18 q Customer Service
q Jefferson’s Welding Encyc.(CD-ROM only) q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy q Welding Inspection Handbook 19 q Other
Welding Handbook Selections: q WHB (9th Ed., Vol. 5) q WHB (9th Ed., Vol. 4) q WHB (9th Ed., Vol. 3) q WHB (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1) Technical Interests (Check all that apply)
Pocket Handbook Selections: q PHB-1 (Arc Welding Steel) q PHB-2 (Visual Inspection) q PHB-4 (GMAW / FCAW) A q Ferrous metals
B q Aluminum
B.) OPTIONAL Welding Journal Hard Copy (for Members outside North America) C q Nonferrous metals except aluminum
q Individual Members outside North America (note: digital delivery of WJ is standard)..............................................$50 D q Advanced materials/Intermetallics
E q Ceramics
INDIVIDUAL MEMBERSHIP TOTAL PAYMENT..................................................................................$_____________ F q High energy beam processes
NOTE: Dues include $17.30 for Welding Journal subscription and $4.00 for the AWS Foundation. G q Arc welding
H q Brazing and soldering
I q Resistance welding
STUDENT MEMBERSHIP J q Thermal spray
K q Cutting
q AWS STUDENT MEMBERSHIP (with digital Welding Journal magazine)................................................$15 L q NDT
M q Safety and health
q AWS STUDENT MEMBERSHIP (with hard copy Welding Journal magazine)..............................................$35
N q Bending and shearing
Option available only to students in U.S., Canada & Mexico.
O q Roll forming
P q Stamping and punching
PAYMENT INFORMATION Q q Aerospace
R q Automotive
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card. S q Machinery
q Check q Money Order q AMEX q Diners Club q MasterCard q Visa q Discover q Other T q Marine
U q Piping and tubing
CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________ V q Pressure vessels and tanks
W q Sheet metal
X q Structures
Signature of Applicant:_________________________________________ Application Date:_______________________
Y q Other
Z q Automation
OFFICE USE ONLY Check #:_______________________________ Account #____________________________________ 1 q Robotics
Source Code: WJ Date:_________________________________ Amount:_____________________________________ 2 q Computerization of Welding
REV. 11/15
SOCIETY NEWS
al Institute of Welding (IIW) or an AWS equipment innovations, unique applica- operative participation in areas such as
member who has made a substantial con- tions in production, a published paper, or technology transfer, standards rationali-
tribution to IIW activities. other activity of merit. zation, and promotion of industrial
Jerry E. Gould, an AWS Fellow, re- Donald B. DeCorte, an AWS Coun- goodwill.
ceived his PhD degree in metallurgical selor, received his degree from RETS Robert E. Shaw Jr. is a professional
engineering and materials science Electronic School and passed the first, engineer and president of Steel Struc-
from Carnegie-Mellon University. second, and third class FCC license ex- tures Technology Center, Inc. He
Since 1985, he has been on the senior aminations. He is the vice president at chairs IIW’s Select Committee on
technical staff at EWI, concentrating RoMan Mfg., and has served a number Quality Management, and serves on
on forge welding activities. of committees within the AWS Detroit IIW’s Working Group on Regional Ac-
and West Michigan Sections. tivities, Working Group on Standardi-
Elihu Thomson zation, and Commission XIII on Fa-
Resistance Welding Award George E. Willis Award tigue of Welded Components and
This award recognizes an outstanding This award is presented to an individ- Structures.
contribution to the technology and appli- ual for promoting the advancement of
cation of resistance welding, including welding internationally, by fostering co-
AWS President Dave Landon (far left) is shown with Gold Members celebrating 50 years of service to the Society — David Belforte, Jimmie
Bolton, Paul Miller, and Damian Kotecki.
Life Members, with 35 years of service to the Society, included Mark Anderson, James Appledorn, Craig Case, Frank Cichocki, Randall Coun
selman, Donald DeCorte, Carl Dichler, Jerry Dutton, Thomas Ferri, Dave Fischer, Karl Fogleman, William Herdman, Timothy Hirthe, Paul
Huffman, Douglass Juhl (accepting posthumously for their father were Tim Juhl and Colleen Johnson), William Komlos, Joseph Laughlin,
Vernon Lewis, Thomas McCormack, William Overshiner, Mark Peterson, Michael Rebenack, Ronald Ruch, Larry Schweinegruber, Harland
Thompson, Philip Torchio III, Robert Walker, Jerry Warren, and Dan Zabel. Everyone is not pictured.
Silver Members celebrating 25 years of membership are Akira Baba, Stephen Bruno, Chris Chwala, Robert Cohen, Dennis Eck, Alan Freder
ick, Viji Kuruvilla, Scott Lord, Clyde Martin, Robert Richwine, Marvin Rozendaal, and Douglas Steyer. Everyone is not pictured.
Representing the Sections sponsoring new scholarships are Monty Rodgers, Darin Owens, and Karl Fogleman (Nebraska); Bill Rice and
Alexyia Paige (New Mexico); Nancy Cole (North Central Florida); and Michael Sebergandio (Reading).
TECH TOPICS
Technical Committee Meetings Contact: S. P. Hedrick, ext. 305, Welding. Miami, Fla. Contact:
steveh@aws.org. S. P. Hedrick, ext. 305, steveh@aws.org.
All AWS technical committee
meetings are open to the public. Con- February 9–11. D15 Committee and February 24–26. J1F-Task Group 6 of
tact the staff member listed at Subcommittees on Railroad Welding. the J1 Committee on Resistance Weld-
(800/305) 443-9353 for information. Dallas, Tex. Contact: J. Rosario, ing Equipment. St. Petersburg, Fla.
ext. 308, jrosario@aws.org. Contact: M. E. Rodriguez, ext. 310,
February 8, 9. D20 Committee on Ad- mrodriguez@aws.org.
ditive Manufacturing. Park City, Utah. February 17. B2F Subcommittee on
Contact: P. Portela, ext. 311, Plastic Welding Qualification. Miami, February 24–26. J1G-Task Group 7 of
pportela@aws.org. Fla. Contact: S. P. Hedrick, ext. 305, the J1 Committee on Resistance Weld-
steveh@aws.org. ing Equipment. St. Petersburg, Fla.
February 9. Committee on Personnel Contact: M. E. Rodriguez, ext. 310,
& Facilities Qualification. Miami, Fla. February 17. G1A Subcommittee mrodriguez@aws.org.
on Hot Gas Welding and Extrusion
C3.4M/C3.4-2016, Specification for Page 105, Figure 3.5: replace “ALL Page 596, Index-Skewed T-joints:
Torch Brazing. Approval Date: DIMENSIONS IN mm” with “ALL DI- replace “Figure 3.44” with “Figure 3.4.”
12/15/2015. MENSIONS IN inches.”
C3.5M/C3.5-2016, Specification for Page 596, Index-Statically Loaded
Induction Brazing. Approval Date: Page 105, Figure 3.5: replace weld- Structures, backing: replace “2.6.4.1”
12/15/2015. ing process “FMAW” with “GMAW.” with “5.9.1.5.”
C3.6M/C3.6-2016, Specification for
Furnace Brazing. Approval Date: Page 106, Figure 3.5: replace weld- Opportunities to Contribute to
12/15/2015. ing process “FMAW” with “GMAW.” AWS Technical Committees
Page 135, Table 4.10: replace title
The following committees welcome
“Welder and Welding Operator Quali-
new members. Some committees are
fication-Production Welding Positions
ISO Draft Standards for Public Review recruiting members with specific in-
Qualified by Plate, Pipe, and Box Tube
terests in regard to the committee’s
Tests (see 4.15.1)” with “Welder and
Copies of Draft International Stan- scope, as marked below: Producers (P),
Welding Operator Qualification-Pro-
dards are available for review and com- General Interest (G), Educators (E),
duction Welding Positions Qualified
ments through your national stan- Consultants (C), and Users (U). For
by Plate Tests (see 4.15.1).”
dards body, which in the United States more information, contact the staff
is ANSI, 25 West 43rd Street, Fourth Page 139, Table 4.14: add a vertical member listed or visit aws.org/
Floor, New York, NY 10036; (212) line between Welding Process and Test w/a/technical/comm_stand.html.
642-4900. Any comments regarding Location.
ISO documents should be sent to your M. E. Rodriguez, ext. 310, mrodriguez@
national standards body. Page 198, 6.17.7: add an additional aws.org
In the United States, if you wish to sentence to the clause “Steel backing Automotive, D8 Committee (C,
participate in the development of In- shall not be considered part of the E, G, U). Resistance welding, C1
ternational Standards for welding, weld or weld reinforcement in IQI Committee (C, E, G, U). Resistance
contact Andrew Davis at AWS, 8669 selection.” welding equipment, J1 Committee
NW 36 St., #130, Miami, FL 33166- (E, G, U).
6672; (305) 443-9353 ext. 466, e-mail: Page 245, 7.2.6: replace “ASTM A29,
adavis@aws.org. Otherwise, contact Standard Specification for Steel Bars, J. Douglass, ext. 306, jdouglass@aws.org
your national standards body. Carbon and Alloy, Hot-Wrought, General Methods of weld inspection, B1
Requirements for Grades 1010 through Committee (E, C, U). Brazing and
ISO/DIS 15296, Gas welding equipment 1020” with “ASTM A29/A29M-12e1, soldering, C3 Committee (G, E, C, U).
— Vocabulary — Terms used for gas Standard Specification for General Re- Welding in marine construction,
welding equipment. quirements for Steel Bars, Carbon and D3 Committee (G, E, C, U). Welding
Alloy, Hot-Wrought, Grades 1010 of machinery and equipment, D14
ISO/DIS 5175-1, Gas welding equip- through 1020.” Committee (G, E, C, U).
MEMBERSHIP ACTIVITIES
New AWS Supporters Future of Basra Company for QHSE QA/QC Inspecciones Tecnicas
Training Ricardo Lyon 988
Sustaining Members P.O. Box 2131 Providencia
Basra, Iraq 42001 Santiago, Santiago Metropolitana
Arc Training and Consultation Services Region Chile
2756 Transit Rd. Goad Co.
West Seneca, NY 14224 144 S. Kentucky Ave. Sea Box, Inc.
arctraining4u.com Independence, MO 64053 1 Sea Box Dr.
Arc Training and Consultation Servies Cinnaminson, NJ 08077
is a full-service weld training, weld H & H Resistance Welders
consultation, and weld testing compa- 28701 S. Hwy. 125 Educational Institutions
ny, offering training in all welding Afton, OK 74331
processes on all materials, of all levels. Ben Franklin Career Center
IPG Photonics 500 28 St.
Affiliate Companies 46695 Magellan Dunbar, WV 25064
Novi, MI 48377
All Tech Machine & Tool, Inc. Harper Independent School District
2700 W. Center St. Iron Fab, LLC 23122 W. Hwy. 290
Greenwood, AR 72936 1771 Progress Ave. Harper, TX 78631
Columbus, OH 43207
Ally Equipment Solutions HiTech Aerospace Aviation Academy
3035 S. Dye Rd. Maxweld HC03 BOX 13545
Flint, MI 48507 Cra 39 39 D 59 Yuaco, PR 00698
Medellin Antioquia 050016633
Andre's Welding Services Colombia Horry Georgetown Technical College
13221 Lakeland Rd. 2050 Hwy. 501 E.
Santa Fe Springs, CA 90670 Modern Piping, Inc. Conway, SC 29526
500 Walford Rd. SW
CP Industries Cedar Rapid, IA 52404 Institute of Technical Trades
2214 Walnut St. 749 Warden Ave.
Mckeesport, PA 15132 Parhoon Toos Toronto, ON Canada, M1L 4A8
No. 318, Parvin Etesami St., Between
Clamptek USA, Inc. 24th and 26th, Mashhad S. Khorasan Tyler ISD Career and Technical Ctr.
2913-I Saturn St. Brea 9164867148 Iran 3013 Earol Campbell Pky.
Los Angeles, CA 92821 Tyler, TX 75702
Pearl Harbor Naval Shipyard & IMF
Dakota Ironworks, LLC 667 Safeguard St., Ste. 100 Western Area Career & Tech Ctr.
715 4th St. Code 134-2 Material Science & Eng Br 688 Western Ave.
Edgeley, ND 58433 JBPHH, HI 96860 Canonsburg, PA 15317
AWS personnel are shown with international representatives at Weld India in Navi Mumbai, India, held December 10–12, 2015. From left
are Jeff Kamentz, AWS, Jagjeet Singh, BSB Edge, Jugal Desai, Eurotech, Amey Salvi, Intertek, Sajesh Bhoir, BSB, and Mike Walsh, AWS.
The A2 Committee on Defintions and Symbols (subcommittees A2B Definitions AWS A3.0 and A2C Symbols A2.4) held their Fall 2015
meeting in Columbus, Ohio, at the Edison Welding Institute. In attendance were (from left) Bill Beckman, Bryan Worley, JP Christein, John
Gullotti, Dave Beneteau, Chris Lander, Chuck Ford, Richard Holdren, Pat Newhouse, Ben Finney, Steve Borrero, Mike Ludwig, Nancy Porter,
Ben Grimmett, Johnny Dingler, and Larry Barley.
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
District Conference
June 5
Location: Heritage Hills Golf Resort,
York, Pa.
Event: The District held its annual
conference in the summer. It was a
great opportunity for all of the Sec-
tions to come together and discuss the
past year’s successes, areas for im-
provement, ideas, and more. Lorena District 3 Conference — District Conference attendees are seen together: (from left) Front
Cora visited as the AWS National rep- row: Justin Heistand, Richard Heisey, Merilyn McLaughlin, and AWS Representative
resentative and briefed attendees on Lorena Cora. Back row: Mike Sebergandio, Dean Whitmer, Jason Deiter, Bradley Brand
the latest from AWS headquarters. meir, Tom Jacobs, David Watson, Marc Malone, and Sharon Bally.
Parkside CTE Student Chapter — Student members pose for a photo with the cans they collected for the Red Men food basket program.
ATLANTA
October 13, 15
Location: Cumming, Ga., and Ac-
worth, Ga.
Speaker: Greg Engeron, president, Gas
& Supply – Georgia/South Carolina ATLANTA — Gas & Supply employees cut the opening ribbon with the Mayor of Acworth.
Division
Company Affiliation: EAS, Gas &
Supply
Topic: Open house at both locations
Activities: The Section was invited to
participate in an educational meeting
at Gas & Supply, where vendors and
AWS committee members were pres-
ent to answer questions and perform
live demonstrations of welding prod-
ucts. The Cumming location had 3
Lanier Technical Colleges participate
and 52 students attend. The Acworth
location had 3 technical colleges (For- ATLANTA — Left — (From left) Rene Engeron, Section chairman, Wayne Engeron, Life
tis, Chatahochee, and Georgia Trade Member, and Greg Engeron, president, Gas and Supply – Georgia/South Carolina Divi
School) attend with 50 students. The sion, at the AWS table. Right — (On right) Doug Rouner (Lucas Milhaupt) performs a
Section raffled off 18 student member- demonstration for students at the Gas & Supply opening.
ships and welding bags with necessary
class equipment. Committee members
discussed benefits of and opportuni-
ties in the welding industry.
District 6
Michael Krupnicki, director
(585) 705-1764
mkrup@mahanyweld.com
District 7 PITTSBURGH — Posing after the plant tour are (from left) Kent Beedon, manager of
Uwe Aschemeier, director
(786) 473-9540 welding fabrication, Elliott Co., George Kirk, AWS Pittsburgh chairman, Mike Storms, di
rector of operations, Elliot Co., Doug Richards, senior welding engineer, Elliott Co., Tim
uwe@sgsdiving.com Hayden, pipe shop welder, Elliott Co, and unknown person.
District 8
D. Joshua Burgess, director
(931) 260-7039
djoshuaburgess@gmail.com
NORTHEAST TENNESSEE
October 27
Location: Maryville, Tenn.
Presenter: Greg Wagner, PhD
Company Affiliation: Advanced Cata-
lyst Systems, LLC (ACS)
Topic: Products and Fabrication at ACS
Activities: Dr. Greg Wagner, ACS, gave
an overview of catalysis and fabrication
at the company. Steve Frana then led a
tour of the fabrication facilities with NORTHEAST TENNESSEE — Section members and Advanced Catalyst Systems employees
demonstrations of some processes. are seen after Dr. Greg Wagner’s presentation on catalysis and fabrication.
District 9
Michael Skiles, director
(337) 501-0304
michaelskiles@cox.net
AUBURNOPELIKA
December 7
Location: Samlip Alabama Co., Alexan-
der, Ala.
Event: Joint meeting with IEEE, Ala-
bama Section and plant tour
Activities: The Section met at Samlip MOBILE — Left — Clay Byron (left) presents Jackie Morris with his AWS Silver Certificate
Alabama Co., a producer of automotive in recognition of his 25year AWS membership. Middle — Jack Sparkers is seen with his
lighting. The company speaker showed Silver Certificate in recognition of 25 years of AWS membership. Right — Robert (Bob)
members and guests some of the Bjorensen celebrates his Life Membership award.
MAHONING VALLEY
November 19
Location: Rachel’s Restaurant, Austin-
town, Ohio
Event: Executive Committee meeting
Topic: Planning session for 2015–2016
and recruitment session for new
2016–2017 volunteers
NORTHWEST PENNSYLVANIA
November 10
Location: FABTECH, Chicago, Ill. MAHONING VALLEY — The Section’s Executive Committee members are seen with guests
Presenter: Marty Sidall and District Director Mike Sherman.
NORTHWEST PENNSYLVANIA — Marty Sidall (left) presents Donna Bastien and Central Tech High School with $1000 for its students to at
tend the FABTECH convention.
NORTHWEST PENNSYLVANIA — Left — Bryan Parker (right) receives the CWI of the Year
Award from Eric Speer. Middle Left — Delayne Jacobs receives the Instructor of the Year NORTHWEST PENNSYLVANIA — Steve
Award. Middle Right — Robert Ward receives the 25year Member Award. Right — Ben Sherman (left) receives a speaker gift
Tresler receives the Instructor of the Year Award. from Jason Neff.
District 12
Daniel J. Roland, director
(920) 241-1542
daniel.roland@airgas.com
University of Toledo Student Chapter — Student chapter members are seen after their
pizza dinner and first meeting of the 2015–2016 year.
District 14
Robert L. Richwine, director
(765) 606-7970
rlrichwine2@aol.com
INDIANA
December 12
Location: Turkey Run State Park, Ind.
Activity: The Section held its annual
Christmas party at Turkey Run State
Park in west central Indiana. A high-
light of the event includes the presen-
tation of Section and District Director
Awards. Five ladies who support the
Section’s activities were presented
with District Director Awards from
District Director Bob Richwine. INDIANA — Recipients of the District Director’s Award (front row) Feather Brosio, (back
Samuel Chance was presented the Sec- row) La Donna Dugger, Vicki Tucker, Amy Flynn, and Patti Richwine pose with District
tion Meritorious Award from Section Director Bob Richwine.
Chair Dave Jackson.
William D. Ford CTC Student Chapter — Student Chapter members pose after a lecture on careers in welding: (back row from left) Daw
son Bargenser, Treasurer Jake Longuski, Secretary Ryan Sherman, Nick Caderet, James Benzyk, Vice Chairman Umar Black, Anthony Virjan,
and Marshall Dotson (front row from left) Chase Larson, Nikki Owens, Advisor Richard Randall, Rick Lawrence, Chairman Danny Thacker,
Guest Speaker Coley McLean, Advisor Assistant Wesley Pringle, and Michael Fowler.
ST. LOUIS — Section members stand with Host Dan Kania and Victor Technologies Guest Speaker Kevin Showers.
EAST TEXAS — Section members show the toys they collected for Toys for Tots.
ST. LOUIS — Award recipients are seen after the Section holiday party: (from left) Chair
INDIANA — Sam Chance receives the man Mike Kamp, Treasurer Vic Shorkey, Richard Freezor, Travis Jumper, Jim Cashdollar,
Section Meritorious Award. Ray Connolly, Richard Kemlage, and a representative for Titannova Laser.
OKLAHOMA CITY — Section members gathered after the tour of Trinity Industries.
LeTourneau University Student Chapter — Dr. Tom Siewert (center) poses for a photo with LeTourneau University engineering students
and Kilgore Jr. welding students after his speech on failures and how we can learn from them.
November 6
Location: Berkeley, Mo.
Topic: 50/50 raffle to raise funds for the
Chapter’s future goals Vatterott College Student Chapter — Vatterott College Student Chapter —
Students collected clothing and coats for Chapter Chair Katie Phelan presents
Event: Students held a 50/50 raffle to
infants, children, and adults in need Charles Woodard (right) with his 50/50
cover administrative costs and to be during the month of October. raffle prize.
—continued on page 82
80 WELDING JOURNAL / FEBRUARY 2016
SECTION NEWS
SPOKANE
November 18
Location: AccraFab, Liberty Lake, Wash.
Presenter: Barry Stewart, AccraFab
Event: Barry Stewart gave Section
members a tour of the company’s facil-
ity. A record windstorm had left most
of the region without power and inter-
net/phone communication. In spite
of this, six members and students
attended. COLORADO — AWS 2014–2015 President David Landon visited the Section and encour
aged members to mentor the next generation: (from left) Chairman Steve Unrein, Presi
dent Landon, Past President and Vice Chairman Bob Teuscher, and Treasurer Tom
Kienbaum present a speaker gift to President Landon.
October 14
Location: Kevin Caron Studios,
Phoenix, Ariz.
Presenter: Kevin Caron, sculptor/fabri-
cator
ARIZONA — Fran Johnston snapped this photo of Section members and guests after their open meeting.
ARIZONA — Students from East Valley Institute of Technology and Mesa Community College pose with Section Members at Kevin Caron’s
sculpture and fabrication studio.
SAN DIEGO — Professor Samuel Colton took this photo of the nondestructive examination lecture attendees.
SAN DIEGO — Arizona Western College welding program supporters celebrate completion of the renovations to the automotive and weld
ing departments.
WOORK
RK
DA’s executive committee. among 38 welders.
SSM
MART
M ART
RT
Jay Timmons, CEO and president,
The Nuts, Bolts & Thingamajigs National Association of Manufactur-
(NBT) Foundation, Rockford, Ill., the ers (NAM), Washington, D.C., was
charitable foundation of the Fabrica- named the TRENDS 2016 Association
tors & Manufacturers Association, In- Executive of the Year by Association
ternational, elected Franklin Mac- TRENDS, a news and information
cotan to serve as director for a two- source for association leaders. Tim-
year term. Maccotan is director and mons was honored for his work and
industry leader of manufacturing for leadership at NAM, where, prior to his
CNA, a commercial insurance writer, appointment as president, he was ex-
where he oversees management of the ecutive vice president and senior vice
fabricated metals and industrial ma- president of policy and government
chinery subsegments. Maccotan has relations.
been a strong fundraising advocate for
the NBT summer manufacturing camp
program. FEMCO Welder Celebrates
45 Years
Jamie Hamilton walks on the aerial installation, Amor Fati (2015, steel, aluminum, nylon, neoprene, 70 x 260 x 150 ft), located outside of
Santa Fe, N.Mex. Photo courtesy of Hannah Hughes.
H
ow confident are you in your makes the safety nets that catch him He started learning about welding
work? Would you bet your life in case he falls. and fabrication in high school. Hamil-
on it? That’s what aerial artist For most people, the height alone ton said he enjoyed building with met-
and welder Jamie Hamilton does every would be blindingly intimidating, but al. “I was fascinated by this material
single day. He builds the support Hamilton has been rock climbing since that could become liquid, but was also
structures for tight ropes that are sev- he was eight years old. Since then, he’s strong and ductile. I fell in love with
eral hundred feet above the ground, climbed summits in the Himalayas, the material and the forgery of it.”
which he then walks across. He also Alps, Canadian Rockies, and Yosemite. He built many practical structures
Fig. 1 — Image from a solo show at The Center for Contemporary Arts, Santa Fe, N.Mex. Photo courtesy of Nick Merrick, Hedrich Blessing.
while working as an apprentice for an three of his passions: athletics, fabri- Once he determines which support
architectural blacksmith and found cating, and art. Soon after, he started system he is using, Hamilton heads to
that most of them were like works of working on his first tightrope. “An ex- his shop in Santa Fe to begin fabrica-
art. “When structures become totally ploration of possibility and structure tion. “I have to start engineering the
pragmatic, like a bridge, they become has always been a staple in my work, dimensions and determine what will
beautiful. They’re not designed to be but it becomes much more serious be needed to support the load,” he ex-
that way, but in their purpose they when building aerial structures upon plained. In the example of a self-
have a sense of artistry and grace,” he which my life depends. I take a stance supporting rig, he essentially makes
said. of total responsibility when I become two columns, anchored to the ground,
That beauty motivated him to con- engineer, designer, fabricator, and per- that are supported by lattice trusses
tinue his fabrication work, but with an former,” he explained. that support each end of the
eye toward the arts. He studied sculp- The first thing he does before each tightrope.
ture at Bard College in New York and project is think about the scale of the Hamilton uses a Hypertherm Pow-
recently graduated with a masters in build. “I try to figure out how tall it’s ermax85 plasma cutting machine to
fine arts from Transart University in going to be. How will it be supported build many of the customized steel
Germany — Fig. 1. or installed? Will it be across a gorge, components that are anywhere from
Once in his 30s, he decided he natural setting, or supported by truss- ¼ to 1 in. thick. “When building a steel
wanted to find a way to combine all es?” — Fig. 2. structure like this, you can’t go to a
Fig. 2 — High-wire crossing a canyon outside of Santa Fe, N.Mex. Photo courtesy of Charles Calef.
A
s companies seek to improve
quality and productivity, and to
reduce costs in their welding
operations, many turn to new equip-
ment or technologies to gain efficien-
cies to meet these goals. Welding in-
formation management systems can
help. These systems electronically
gather real-time data that empower
companies to drive positive change
throughout the welding operation.
There are several levels of welding
information management systems
available in the marketplace today —
from basic to advanced. These systems
can eliminate time-consuming manual
weld data collection and can be used
for semiautomatic or robotic welding.
They help ensure the correct welding
parameters are followed and can aug-
ment training efforts. In addition, the
systems make it easier to benchmark
continuous improvement efforts.
Basic systems often deliver welding
information via Web-based browsers,
and gauge high-level factors contribut-
ing to quality and productivity by
monitoring:
• Arc-on time and total deposition
rates
• Out-of-parameter welds.
Advanced systems expand on these
benefits by offering varying levels of
As companies seek to improve quality and productivity, and to reduce costs in their welding
control over key facets of the welding
operations, many turn to new equipment or technologies to gain efficiencies to meet these
operation. They operate via an Ether- goals. Welding information management systems can help.
net connection between the power
source and a PC-based application.
Benefits include, but are not limited
to, the following: as over- and underwelding management to engineers and welding
• Weld sequence control • Operator identification and per- operators — along with a commitment
• Monitoring of weld cell downtime formance metrics. to use the data to improve the welding
or arc-off time Successful implementation of any operation — Fig. 1.
• Workflow management and part welding information management sys- To gain the best results, consider
tracking tems requires careful planning. It also some important “do’s” and “don’ts” of
• Identification and reduction of entails collaboration between all stake- adding this technology into the weld-
missed and/or defective welds, as well holders — from business owners and ing operation.
welding operators in additional train- ing targeted and achieved. Encourage improve the welding operation. Man-
ing to gain the best results. ongoing involvement and partnership agement may find an employee in one
Ultimately, the internal project to work toward and reach operation weld cell has discovered a way to
champion’s goal is to identify and ad- goals. streamline an activity that could be
dress the opportunities revealed by The data shared with stakeholders added to other weld cells.
the welding information solution. He and the changes being made in the
or she holds the responsibility and au- welding operation will vary according Don’t be afraid of internal
thority to drive the process of continu- to the audience. Top management will pushback.
ous improvement and deliver results. likely want to focus on the cost-saving
element of the systems; they want to It is not uncommon for any type of
Do have a clear plan of attack. understand how changes generate a change to be met with resistance.
positive ROI and drive better prof- Every company has its own culture
Generate a baseline for improve- itability. Welding supervisors and that is determined by the personalities
ment as a first step when implement- welding operators should be made of the employees — not everyone will
ing a welding information manage- aware of the results of changes on the respond the same to the presence of a
ment system. Doing so helps establish plant floor, including the successes, as welding information management
expectations for success. The baseline well as ongoing challenges. system.
can include an assessment of current Position this technology appropri-
arc-on time and deposition rates, as ately from the start and involve every-
well as part cycle time and weld quality The Don’ts one. Top management should be aware
defects. From this baseline, the they can receive ongoing updates on
company can determine goals for As with any change in the welding the improvements in the welding op-
improvements. operation, the introduction of welding eration. This can happen even if the
Moving forward from the baseline, information technology can disrupt leadership team is remote (via a secure
stakeholders should use the available the daily and long-term functioning of Internet connection). The progress
information to monitor trends and the process if employed without prop- and success they see will help foster
challenge status quo. For example: er precautions. Here are two key items ongoing support and confidence in the
• Where is the company compared to minimize trouble. long-term benefits, including a better
to the baseline after a given period of bottom line.
time? Don’t try to do too much Pushback from the plant floor may
• How can the company use insight too quickly. also happen, but it doesn’t mean the
from the weld data to make improve- technology can’t be successful or that
ments? These systems best serve compa- the welding operators will never em-
• What procedural changes will help nies by delivering incremental im- brace it. Internal project champions
increase productivity or achieve better provements. Trials should start out should help show the ways in which
quality? small, with the technology in only a the systems can improve and expedite
• How can the company improve few welding cells. Additionally, compa- training, and help everyone do a better
operations upstream or downstream nies should look for the “low-hanging job.
from the welding cell? fruit” — they can target the easiest is-
Commit enough resources to the sues to resolve or those that are most Conclusion
process and take a disciplined ap- beneficial. The focus often depends on
proach to the plan. Make sure there where the company is experiencing the As with most changes to a welding
are enough people to help implement most pain. operation, implementing a welding in-
and sustain the improvements made As a best practice, companies formation management solution
visible by the welding information. should first address changes that do should be executed with careful con-
Additionally, focus on logistics to fur- not require large amounts of re- sideration and planning. It is an in-
ther ensure success, such as establish- sources. Doing so creates momentum vestment. As such, the technology
ing the appropriate network capabili- with quick wins, helps avoid changes needs to position the welding opera-
ties so there is minimal downtime for that are too complex to handle early in tion for success by delivering results.
troubleshooting IT issues. There the proces,s and minimizes the risk of Keep open lines of communication
should also be a plan for the frequency employees abandoning the project. In- with all stakeholders as a best practice.
of data review and reporting, and im- volve all stakeholders to make sure the Ultimately, the end goal is to generate
provement progress. improvements being sought are rele- collective interest in making the weld-
vant. For example, if improving work- ing operation more productive, pro-
Do share the results with flow is a goal, involve a manufacturing ducing higher quality parts, and in-
all stakeholders. engineer, as well as the welding opera- creasing profitability. WJ
tors, to learn the exact process of mov-
The success of these systems is the ing parts from pre- to postweld opera-
result of collaboration among all tions. This insight prevents any mis-
stakeholders. Keep everyone involved conceptions that could hinder results. RYAN LINDEMAN is product specialist —
apprised of the information being Regularly engaging welding operators Insight Systems, Miller Electric Mfg. Co.,
Appleton, Wis., millerwelds.com.
monitored, and the improvements be- can help identify additional ways to
R
A B A
C D
E F
G H
I J K
Aluminum joints require smaller root openings and larg- welding positions. The abutting sections are designed so
er groove angles than those generally used for steel. This is that complete joint penetration is possible with the first
because aluminum weld metal is more fluid and the welding weld pass. This design has a large groove area and requires a
gun nozzles are larger. Figure 1 shows typical joint geome- relatively large amount of filler metal to fill the joint. The
tries for arc welds in aluminum. principal application is for circumferential joints in alu-
Figure 2 shows a special joint geometry that is recom- minum pipe.
mended for gas tungsten arc welding or gas metal arc weld- For thick plate, U-groove or double V-groove welds are
ing when only one side of the joint is accessible and a preferred over the V-groove design to minimize the amount
smooth root surface is required. The effectiveness of this de- of deposited metal and to permit access to the weld root.
sign for complete joint penetration depends on the surface Special joint geometries, as shown in Fig. 3, may be needed
tension of the weld metal. This design can be used with sec- to minimize porosity caused by entrapment of hydrogen
tion thicknesses greater than 3.2 mm (0.125 in.) and in all while welding in the horizontal position. WJ
Excerpted from the Welding Handbook, Ninth Edition, Volume 5, Materials and Applications, Part 2.
Schoolcraft College, Livonia, Mich., end of the 2015–2016 academic year. to the program facility. She put in five
is located in the northwest part of McLean is certified as an AWS more workstations, and acquired new
Wayne County, a large suburb of De- CWI/CWE, and she is an OSHA-autho- equipment that resembles what stu-
troit. The college recently gained na- rized instructor for general industry dents will see in the industry, so they
tional recognition when it won the and construction, as well as an NCCER are prepared once they join the work-
2015 Clips & Clamps Industries Edu- instructor. She has certified more than force — Fig. 2.
cational Institution Award of Excel- 300 welders. McLean has also brought an appre-
lence in Metalforming from the Preci- ciation for digital technologies to the
sion Metalforming Association. Com- New Leadership program. She meets her students
plementing Schoolcraft’s machining/ where they are, on their phones, and
CNC program is a newly revamped In just one year, McLean has imple- “gently forces” them to explore weld-
welding program, under the leadership mented changes to Schoolcraft’s pro- ing applications for extra credit. She
of Coley McLean, who joined the col- gram that have resulted in credit hours also uses Blackboard, an online teach-
lege’s full-time faculty a year ago. rising 120% and enrollment increasing ing platform, to post course informa-
McLean and five part-time instructors more than 100%. Some of these tion and stay connected with students.
provide training for 250 welding stu- changes include making the program a Another innovation for the pro-
dents, with individual class sizes of 15 SENSE-authorized facility for Levels 1 gram is McLean’s introduction of
students — Fig. 1. and 2, and accrediting the facility for video into the classroom. She uses
McLean started her career as a full- testing. In April 2015, the program cameras to film instructors demon-
time welding instructor at Washtenaw completed its first batch of in-house strating the techniques they use for
Community College, Ann Arbor, Mich., certifications for its students, who various processes and posts them on
but she had spent six years teaching must now pass two certifications in YouTube so that students can see
technology before that, and so will fin- order to graduate. equally good welds can be achieved in
ish her 18th year of teaching at the McLean also made physical changes different ways. The program was re-
cently awarded a grant to purchase a
professional-grade camera to capture
videos of the actual welding process,
and McLean hopes the video replays
will help learners.
Moving forward, McLean is work-
ing on setting up an articulation pro-
gram for four-year colleges so that she
can push her students to go on and
complete bachelor’s degrees in weld-
ing. That is where the money is, she
said, and so she encourages her stu-
dents to pursue higher education. She
is also forging connections with the lo-
cal Ironworkers Union and making in-
dustry partnerships to help her stu-
dents find employment once they
leave the program. For McLean, it’s all
about the one on one with students.
She enjoys watching her students
learn and grow, and giving her stu-
dents a head start in the industry.
Welding students at work in the shop.
Fig. 1 — Department Head Coley McLean speaks with a student Fig. 2 — The welding program recently acquired five more work
during a laboratory class. stations and new equipment.
Instructors welding courses, which also includes AWS-certified welder and welding in-
blueprint reading. Donald Neilson is structor at Flat Rock High School. He
Schoolcraft’s part-time instructors an AWS-certified welder and owner of has more than 12 years of industry ex-
include Christopher Olsen, an GT Fabrication. He has more than 25 perience and teaches all levels of weld-
AWS/ASME certified welder and own- years of industry experience and in- ing courses. Clyde Hall is a CWI/CWE
er of Exact Fabrication, LLC, who has structs basic and advanced welding welding instructor and has been for
more than 12 years of industry experi- courses, including fabrication and more than 30 years. Hall instructs
ence. He teaches basic and advanced blueprint reading. Jim Fowler is an AWS certification preparation courses,
among others. Dan Ondrus works for Machnee came to sculptural welding coating one of his lamps in Fig. 4. Kel-
the Ford Motor Co. and instructs in on a unique path. She completed her ly O’Neill (Fig. 5) and Doug Cannell,
adhesive joining, and Melissa Mach- bachelor of fine arts at Wayne State in both graduates of the program, exhibit
nee, an AWS-certified welder, CWE, Detroit, Mich., and began welding in and sell their art locally.
and CAWI, teaches GMAW and two college to make sculptures. She later
metal sculpture classes that she devel- went on to complete her master of fine Program Offerings
oped (see lead photo). arts in sculpture at Eastern Michigan
University, Ypsilanti, Mich., where she
primarily used welding and metal cast- Welding Fabrication Certificate
Sculpture Certificate
ing for her work.
Machnee is a graduate of School- This 33-credit certificate prepares
In 2010, Machnee developed the
craft’s program, having earned its students for jobs involving shielded
sculptural welding certificate program
welding fabrication certificate in 2007, metal arc (SMA), gas metal arc (GMA),
at Schoolcraft and ran it out of the
and she has welded in the industry for and gas tungsten arc (GTA) welding
continuing education program. The
automotive prototype and production processes, and knowledge of plasma
courses caught on, and were incorpo-
welding custom fabrications. arc and oxyfuel cutting technologies is
rated as a certificate into the program. offered. Students acquire skills in
Machnee found that entering a weld- welding and fabrication processes with
ing class under the guise of art was an
easy in for some students who might
Encouraging an emphasis on technical support sub-
Entrepreneurship jects such as mathematics and science
be intimidated to enter the industry. courses, blueprint reading classes, and
Today, the program is available to courses to prepare for welder certifica-
welding students as an elective, and Schoolcraft was open to developing tion exams.
also to graphic design and art majors. the sculpture program, Machnee said,
The result is that most classes have a because it promotes entrepreneurship.
combination of welding and art stu- The sculpture class gives students Joining Technology AAS Degree
dents, creating a great atmosphere for many ways to take the skills they’ve
creative problem solving. Welding stu- learned and go forward with their own This 67-credit associate’s degree
dents are exposed to different equip- business. The class entered and won covers the hands-on welding courses
ment in the sculpture classes, because an art competition to celebrate Henry found in the fabrication certificate,
they use fabrication equipment. Stu- Ford’s 150th birthday, which familiar- and also provides an emphasis on met-
dents in the welding sculpture class use ized students with designing for a allurgy and business operations. Be-
gas metal arc welding (GMAW), gas client — Fig. 3. Student Sasha Bennett side the courses listed under the weld-
tungsten arc welding (GTAW), oxyfuel started his own lamp business, Dan- ing fabrication certificate, the associ-
cutting, and plasma arc cutting (PAC). gerous Lamps. He can be seen powder ate’s degree offers classes like business
English, human relations, communica- project planning, layout, fabrication, placed on thinking and working cre-
tion skills, introduction to art and mu- safety, and math. Students who suc- atively, and on the ability to discuss
sic, and a few different welding cours- cessfully complete coursework will also one’s work conceptually and objective-
es. This degree prepares graduates for earn AWS certification in at least one ly. The certificate opens the student
jobs in industrial, prototype, and ma- procedure. This certificate creates an to the possibility of completing the
chine tool building, heavy equipment, option for entry into the welding fab- welding fabrication certificate or the
construction, and emerging green and rication certificate and the welding welding joining technology associate
sustainable technologies. joining technology associate degree. degree. It is a good choice for the pro-
fessional sculptor or the aspiring
PreApprenticeship Certificate Welding Sculptural Skills welder. WJ
Certificate
In order to qualify as a welding
journeyman, one must complete ap- This 19-credit certificate helps stu- For More Information
prenticeship training. Schoolcraft has dents learn basic and advanced skills
partnerships with local trade unions, in welding with the GMAW and GTAW To learn more about Schoolcraft
and trains students for union appren- processes, as well as fabrication tech- College’s welding program, contact Co-
ticeship with this 24-credit certificate niques to give students an under- ley McLean at (734) 462-4683 or e-
by providing instruction in fundamen- standing of how to problem solve in mail admissions@schoolcraft.edu.
tal welding equipment and techniques, unique situations. An emphasis is
welding program director spoke to the most up-to-date machines I have yet student is having difficulty. The in-
students one day. Cummings liked to come across in industry. The in- structors and training are top notch…
that Schoolcraft allowed its students structors are always willing to give you They will do whatever it takes to help
to study a trade at the same time as input on what to do differently and out a student who is willing and eager
they earned an associate’s degree. will even come into the booth with you to learn, whether it’s staying later
“There is so much that I enjoyed and give you dedicated one-on-one after class or opening a lab on a
about Schoolcraft’s welding program time during class. It blew me away that weekend.”
that it’s hard to say what my favorite they are willing to do that. Another Since finishing his degree, Cum-
part was,” Cummings said. “The shop thing I enjoyed is classmates will try to mings has started the OSHA safety
is clean, well organized, and has the work together to solve an issue if a course and he is planning to continue
taking classes at Schoolcraft to im-
prove his craft. He found the job hunt
in Michigan very easy after gradua-
tion. At the time of production, he was
performing a weld test and had inter-
viewed with a company that rebuilds
aircraft engines. He would ultimately
like to work in the aerospace or rail-
road industries.
LucasMilhaupt, SaintGobain
Global Brazing Solutions Founded 1920
Jimmy Jordan
(843) 3497319 4160 Washington Rd Suite 230
McMurray, PA 15317
Metglas@metglas.com (724) 7310074
www.metglas.com paul@thermocalc.com
www.thermocalc.com
The Ameriican Welding Society established the honor of Coun nselor of the Society to recognize
members for
f a career of distinguisheed leadership contributionss in the advancement of welding
science andd technology. Election as a Counselor is based upon an individual’s career of
outstandingg achievements and accommpplishments. The selection
o committee is seeking qualified
individuals who can demonstrate their leadership in the weldinng industry as evidenced by:
Sincerely,
Lee Kvidahl
Chair, Counselor Committee
I want to encourage you to submit nomination packages for those individuals whom you feel have a
history of accomplishments and contributions to our proffession consistent with the standards set by
the existing Fellows. In particular, I would make uest that you look in to the most senior
k a special requ
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 faam miliar with their contributions, and w
whho
would normally nominate the candidate, are no longer with us. I waant to be sure that we take the
extra efffort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nominating process.
For specifics on nomination requirements, please contact Chelsea Lewis at clewis@aws.org at AWS
headquarters in Miami, or simply fol
o low the instructions on the
h Fellow nomination for
o m located at
go.aws.org/appffellow. Please remember, we all benefit in the honor
h ing of those who have made
maajor contributions to our chosen profession and livelihood. The deadline for submission is August
1, 2016. The Fellows Committee looks forward to receiving numerous Fellow nominations for 2017
consideration.
Sincerely,
Dr. John Elmer
Chair, AWS Fellows Committee
NEWS OF THE INDUSTRY Water is pumped to an oversized main where it is distrib-
uted via electronic valves to three radio frequency-con-
— continued from page 17 trolled monitors; in this configuration, the vessel delivers
water flow of up to 10,000 gal/min.
will feature the company’s up-to-date technologies. Addi- With below-decks quarters offering enclosed head, galley,
tionally, the facility will combine an automation center with and bunking capacity for a crew of four, the 55 Defiant is
research and development, driving toward “one piece flow” equipped to stay on station for extended periods and accom-
sheet metal production capabilities. modate crews during lengthy patrols.
The technology center will be about 50,000 sq ft, based A product of Metal Shark’s Franklin, La., shipyard, the
on recent plans. Worldwide visitors will see system and ma- vessel can be custom-configured to suit a range of mission
chine demonstrations as well as observe and be part of live profiles. It’s also offered with many power and propulsion
sheet metal production with automated and flexible ma- systems to meet various performance requirements.
chine tools and processes.
Industry Notes
Innovative Fuel Selected to be Part of
$100 Million Kennedy Space Center Project • Austin Community College, Austin, Tex., has finished
its previously contracted purchase of about 124 acres in
MagneGas Corp., Tampa, Fla., a technology company that southeast Travis County. The college plans to use the site
counts among its inventions a patented process that con- for a career-technical training center that will provide space
verts liquid waste into MagneGas2® fuel, recently an- for many programs, including welding. The $10.5 million
nounced a lead subcontractor for a Kennedy Space Center purchase is financed through bonds approved by voters in
build-out project has placed its first order for this fuel. It November 2014.
will be used for metal cutting.
S&R Enterprises LLC, a lead subcontractor for the $100+
million Kennedy Space Center project that will last approxi- • California Brazing, Newark, Calif., has purchased its
mately 2 years, was introduced to MagneGas® during a third vacuum aluminum brazing furnace from Ipsen, Cher-
demonstration arranged by Suwannee Ironworks. As a re- ry Valley, Ill. It features a 38 ¥ 40 ¥ 62 in. all-metal hot
sult, the company chose to switch to the gas. zone with a 1500-lb load capacity and operates at 500° to
1200°F with ±5°F temperature uniformity.
Metal Shark Delivers 55ft Port Security Fireboat • WFW Industries, San Diego, Calif., a U.S. veteran-run
provider of manufacturing, welding/fabrication, machinery
repair, and customized training, has received the San Diego
Business Journal’s 2015 Manufacturing Award for best com-
munity service. Profits support Workshops for Warriors,
a nonprofit that provides veterans and injured vets with
skilled training. Also, Workshops for Warriors has re-
ceived a $37,000 donation from tooling manufacturer Core
Powered, Inc. The company contributed a vending ma-
chine for students and launched 70 Veterans at the
Table, a fundraising challenge to provide students with a
meal daily.
Metal Shark, Jeanerette, La., has delivered a 55-ft multi- Do You Have Some News to Tell Us?
purpose port security vessel to the Plaquemines Port Harbor
and Terminal District in Louisiana. If you have a news item that might interest the readers of
Based on the company’s Defiant-class monohull pilot- the Welding Journal, send it to the following address:
Welding Journal Dept.
house design, this welded aluminum vessel is meant to sup-
Attn: Kristin Campbell
port port security efforts and firefighting missions at the 8669 NW 36th St., #130
port district located 20 miles south of New Orleans at the Miami, FL 33166.
mouth of the Mississippi River. Items can also be sent via FAX to (305) 443-7404 or by
Additionally, to meet the customer’s fire fighting require- e-mail to kcampbell@aws.org.
ments, the shipbuilder employed twin Darley fire pumps.
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AWS Education Services 58, 106 Lincoln Electric Co. Outside Back Cover
aws.org/education (800) 4439353, ext. 455 lincolnelectric.com (216) 4818100
Camfil Air Pollution Control 2 Nippon Steel & Sumikin Welding Co., Ltd. 9
camfilapc.com (800) 4796801 welding.nssmc.com/en/ +81 3 6388 9000
CDA Technical Institute 21 North Orange County Community College District 102
commercialdivingacademy.com (888) 9742232 apptrkr.com/719738 web contact only
Gullco International, Inc., U.S.A. 15 Voestalpine Bohler Welding USA, Inc. 49, 51, 53, 55
gullco.com (440) 4398333 voestalpine.com/welding (800) 5270791
and on request, include tutorials and practical training. Pre- Protective Coatings Training and Certification Courses. At
sented at Servo-Robot, Inc., St. Bruno, QC, Canada. For various locations and online. The Society for Protective
schedule, cost, and availability, send your request to Coatings; (877) 281-7772; sspc.org.
info@servorobot.com.
Robotics Operator Training. Presented by ABB University at
Machine Safeguarding Seminars. Rockford Systems, Inc.; 13 locations nationwide. For course titles and locations:
(800) 922-7533; rockfordsystems.com. (800) 435-7365, opt. 2, opt. 4; abb.us/abbuniversity.
Robotic Welding Training. Offers a variety of courses to en-
Machining and Grinding Courses. TechSolve, techsolve.org. hance productivity and product quality, presented on site at
your facility or at the address shown below. Wolf Robotics,
NACE International Training and Certification Courses. Na-
LLC, 4600 Innovation Dr., Fort Collins, Colo.; (970) 225-
tional Assoc. of Corrosion Engineers; (281) 228-6223;
7600; wolfrobotics.com.
nace.org.
Safety Training Online. Unlimited training on myriad indus-
NDT Courses and Exams. Brea, Calif., and customers’ loca- trial safety course titles. Visit website for complete informa-
tions. Level I and II and refresher courses in PA, UT, MP, ra- tion and previews of several courses; safety99.com.
diation safety, radiography, visual, etc. Test NDT, LLC; (714)
255-1500; testndt.com. Service Manager Course. Designed for sheet metal workers
and HVAC service shop owners. Various locations and dates.
Online Education Courses. Topics include Introduction to International Training Institute. (703) 739-7200;
Die Casting ($99), Metal Melting and Handling ($99), Prod- sheetmetal-iti.org.
uct Design ($59), Energy Training ($19), Dross Training
($19), Managing Dust Hazards ($19), Safety (free). North Shielded Metal Arc Welding of 2in. Pipe in the 6G Position
American Die Casting Assoc.; (847) 808-3161; — Uphill. Troy, Ohio. Hobart Institute of Welding Technolo-
diecasting.org/education/online. gy; (800) 332-9448; welding.org.
S. J. CHEN (sjchen@bjut.edu.cn), L. ZHANG, G. Q. MEN, Y. X. SONG, S. SU, and L. W. WANG are with the Engineering Research Center of Advanced Manufac
turing Technology for Automotive Components, Ministry of Education, Beijing University of Technology, Beijing, China. L. ZHANG is with Hebei Key Laboratory
of Material NearNet Forming Technology, Hebei University of Science and Technology, Shijiazhuang, Hebei, China.
ArcingWire GTAW
There were three experiments con-
ducted using the arcing-wire GTAW. The
distance between the tungsten and wire
was fixed at 3 mm. The main arc was a
GTA and the second arc was a GMA.
The GTA current (IGTA) was fixed at 100
A. The major difference in the parame-
ters was the torch height, which de-
creased from 10 mm in Experiment 4 to
6 mm in Experiments 5 and 6. The wire
feed speed decreased from 2.3 to 1.3
Fig. 13 — Voltage waveforms of arcingwire GTAW in Experiment 5. m/min in Experiment 6.
For Experiment 4, the high-speed
images are shown in Fig. 10. The GTA
(main arc) was established between
the tungsten electrode and the work-
piece. The GMA (the second arc) was
established between the tungsten and
the wire. In Fig. 10, the droplet grew
uniformly when the wire was fed into
Fig. 14 — Highspeed images of arcingwire GTAW in Experiment 6. the GTA. It was similar to the cold wire
GTAW, except there was a second arc.
The current flowing into the tungsten
electrode was the sum of the GTA cur-
rent and GMA current. The tip of the
tungsten was the common cathode
where the arc divided into two arcs.
The directions of the two currents
were approximately the same. In theo-
ry, the GTA and GMA (the second arc)
should attract each other. However, it
was observed that the GTA deviated to
the left rather than toward the GMA
on the right. To explain this phenome-
non, we begin with the positive ions
emitted from the wire that must flow
to the tungsten at high speeds
through the GMA. These ions weighed
much more than the electrons and col-
Fig. 15 — Voltage waveforms of arcingwire GTAW in Experiment 6. lided with the particles in the GTA. As
such, the ions in the GMA are impact-
ed. In the meantime, any area in the
as in the last image in Fig. 8. The GMA Figure 9 is the voltage waveforms entire workpiece could be the anode
extinguished during the short circuit- in Experiment 3. The significant dif- for the GTA and the additional energy
ing time, during which the deviation ferences were that the waveforms were consumption is less sensitive to the
of GTA was serious. In Figs. 4, 6, and never smooth compared with Fig. 5. change of the anode position on the
8, there is a common phenomenon: The GMA voltage waveform was a typ- flat workpiece surface. The GTA thus
the GTA was not a straight arc, but a ical short circuiting transfer voltage tended to deviate to the left as can be
curved arc that bent toward the work- waveform. The voltage was almost 0 V seen in the macroscopic phenomenon
piece. The stability of the GTA must during the short circuiting time and observed in Fig. 10.
determine the stability of DE-GMAW. near 20 V in the open-circuiting time. From the high-speed images in Fig.
How to obtain/maintain a desirable The GTA voltage waveform was also 10, there was no evidence that GMA
bypass arc is the key to ensuring a suc- unstable. GMA experienced reestab- could be established between the wire
cessful arc dividing to maintain a sta- lishment and the cycle started over and workpiece, even when the droplet
ble process. again periodically. As such, the at- transferred to the workpiece, and even
The droplet was still transferred into cates the physical process. The droplet Conclusion
the workpiece after touching, but the needs to be detached from the wire tip
droplet was reduced. It appeared that by a sufficient electromagnetic force. This experiment studied and ana-
the reduced distance from the wire to When the wire feed speed is relatively lyzed the effect of the torch height on
the workpiece, due to the increased ex- small, the current is relatively small. the stability in two innovative divided-
tension of the wire, which was fed with The electromagnetic force that con- arc processes: DE-GMAW and arcing-
an angle, reduced the gap for the tributes to detaching the droplet is rel- wire GTAW. The authors found the fol-
droplet to grow before touching the atively small and would be insufficient lowing:
workpiece. As a result, the droplet to effectively detach the droplet by it- 1) The torch height has a signifi-
transferred into the workpiece at re- self. As a result, the droplet grows. If cant impact on the arc behavior in DE-
duced sizes as can be seen from Fig. 14 the distance between the contact tip GMAW. Maintaining a stable (bypass)
in comparison with the droplets in Fig. and the workpiece is relatively small, GTA means a successful arc dividing and
10 and Fig. 12. The waveforms for the the droplet may touch the workpiece, stable welding process. When the torch
voltages as shown in Fig. 15 also indi- forming the short circuiting. This can height is sufficient, the droplet may
cated the stability of the arcs. be seen by comparing Fig. 16A with B. transfer in globular transfer mode. The
In this case, the main arc extinguishes bypass arc can be established stably be-
Analysis and Discussion and the condition for the arc dividing tween the bypass tungsten electrode
is no longer maintained. As a result, and the main wire. Decreasing the torch
The major conclusion from this the workpiece becomes the anode to height may cause the short circuiting
study on the sensitivity of the arc di- establish the arc with the tungsten. transfer for the main GMA such that
viding stability to the torch height is The arc no longer divides at the wire the condition to divide the arc at the
that the DE-GMAW is sensitive while tip. The process deviates from the de- wire tip is no longer maintained. The
the arcing-wire GTAW is not. DE- sired DE-GMAW. process would switch between the suc-
GMAW and arcing-wire GTAW are Of course, the occurrence of the cessful arc dividing (desired DE-GMAW)
both based on the arc dividing. How- short circuiting is the only cause that and unsuccessful arc dividing (deviating
ever, while the arc is divided at a con- affects the arc dividing. If the arc from the DE-GMAW), which would be
sumable (wire) in DE-GTAW, the arc- length of the main GMA is too short, unstable.
ing dividing occurs at a nonconsum- the GMA would contract (image 5 in 2) The torch height has less impact
able (tungsten electrode) in the arcing- Fig. 6) such that it would not be able on the stability of the arcing-wire
wire GTAW. This difference causes the to immerse the bypass tungsten elec- GTAW. The stationary position of the
difference in their sensitivity to the trode. The DE-GMAW would still not arc dividing root in relation to the
variation in the torch height. be maintained. As such, maintaining a wire, and the CV mode for the added
In DE-GMAW, the position of the arc sufficient torch height and a sufficient GMA that tend to maintain a con-
dividing root (wire tip) changes in rela- arc length is needed to maintain the stant distance between the arc divid-
tion to the GMAW torch due to the con- arc dividing in the DE-GMAW. ing “root” and “destination,” are
sumable nature of the wire. The bypass For the arcing-wire GTAW, the case largely responsible for this desirable
electrode/GTA torch is attached/fixed to is simpler. The “root” where the arc is stability. The independence of the
the GMAW torch. The relative position- divided is stationary in relation to the main GTA from possible short circuit-
ing between the root and destination wire where the “destination” resides. ing between the wire and workpiece
thus changes. When the torch height re- The length of the added arc is main- also contributes to this desirable sta-
duces, the root would tend to move to- tained constant by the CV mode used. bility and insensitivity to the varia-
ward the tip because the tip of the wire The relative position between the tion in the arc length.
is supposed to keep a constant distance “root” and “destination” thus tends to
from the workpiece in the constant volt- be maintained stationary — Fig. 17.
age (CV) mode. (A synergic control de- The droplet formed on the wire would Acknowledgments
termines the voltage setting based on no longer extinguish the main arc or
the wire feed speed but the current is break the condition to maintain the
still adjusted to maintain this voltage. needed conductive channel for the This work is supported by the Nation-
The arc voltage, thus the arc length, is added arc, despite possibly touching al Science Foundation of China
still controlled similarly as in CV mode.) the workpiece. Changing the torch (51375021) and the National Science
The main arc that provides the needed height appears to have limited affect and Technology Major Project
conductive channel to maintain the de- on the successful maintainance of the (20142x04001171).
sired arc dividing at the wire tip would arc dividing as long as the torch is not
move toward the wire tip. The destina- extremely low such that the wire
References
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better immerse the needed conductive immerse into the GTA. The stability of
channel. In this case, reducing the torch the arcing-wire GTAW can thus be eas-
in a certain range may benefit the stabi- ily maintained and is much less sensi- 1. Pan, J. L. 2000. Prospects for welding
research in 21st century. China Mechanical
lization of the arc dividing. tive to the variation in the torch
Engineering 11(1): 21–25, 35.
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industry. Proceedings of 2nd Conference of 13. Li, K. H., Zhang, Y. M, and Su, P., et 20. Li, K. H., and Zhang. Y. M. 2008.
New Manufacturing Trends, Bilboa, Spain. al. 2008. High-strength steel welding with Consumable double-electrode GMAW part
5. Li, X. L., Huang, S. S., and Wu, K. Y. consumable double-electrode gas metal arc 2: Monitoring, modeling, and control.
2008. Research of the high-speed double welding. Welding Journal 87(3): 57–64. Welding Journal 87(2): 44–50.
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X. CHAI is graduate student and S. KOU is professor, Department of Materials Science and Engineering, the University of Wisconsin, Madison, Wis. T. YUAN is
graduate student, School of Materials Science and Engineering, Tianjin University, Tianjin, China.
Fraction 2.10 10–2 5.5 10–3 3.87 10–3 3.20 10–4 9.66 10–4 1.19 10–5 5.65 10–6
Conclusions
Fig. 10 — AZ91 Mg welded with AZ92 Mg welding wire: A — TfS curves predicting no
crack susceptibility; B — verification of predicted no crack susceptibility. TfS curves calcu 1. The crack susceptibility of Mg
lated using Pandat (Ref. 38) and PanMagnesium (Ref. 39) of CompuTherm, LLC. welds can be predicted by comparing
the T-fS curves of the weld and the
on the weld transverse cross section. is significantly greater than the work- workpiece, that is, susceptible if weld
Since weld (S+L) and workpiece piece fS up to about fS = 0.92 as indicat- fS > workpiece fS. The susceptibility is
(S+L) are in intimate contact with each ed by the region encircled by the dot- significant if the difference is signifi-
other along the weld edge, at any given ted oval. For instance, when the AZ91 cant, e.g., 0.05 and above.
point along the weld edge the thermal Mg workpiece fS reaches 0.70 (at about 2. This simple criterion can be used
cycles (temperature T vs. time t) they 525°C), the weld fS is about 0.86, that as a useful guide to selecting a proper
experience are identical. Thus, when a is, higher by about 0.16. Thus, the Mg filler metal and dilution level to
different heat input or travel speed is curves suggest a significant suscepti- avoid liquation cracking.
used, the thermal cycles both change bility to cracking. Beyond 0.92, the 3. As-cast AZ91Mg can be highly
but are still identical to each other. In weld fS becomes slightly lower than the susceptible to liquation during welding
fact, the thermal cycles of the two workpiece fS, but this is too late to due to the presence of numerous
semisolids are still identical even if the keep cracking from occurring. The coarse (Mg17Al12) particles in the Mg-
cooling rate becomes slow enough to crack susceptibility predicted by the rich matrix , causing liquation by +
cause significant solid-state diffusion, T-fS curves in Fig. 9A is verified by the LE at a eutectic temperature as low
which can be considered by using a so- cracks visible in the transverse cross- as 437°C. The large amount of liquid
lidification model that includes solid- section of the weld in Fig. 9B. formed separates grains and causes
state diffusion. Consequently, compar- Figure 10 shows the weld made cracking under the tension induced by
ing the T-fS curves of the two semi- with AZ91 Mg as the workpiece and the solidifying and contracting weld
solids is equivalent to comparing their AZ92 Mg as the welding wire. The T-fS metal nearby. The use of a proper filler
t-fS curves. curves in Fig. 10A show the weld fS is metal and dilution is essential for
Figure 9 shows the weld made with less than the workpiece fS at any time avoiding cracking in AZ91 Mg.
AZ91 Mg as the workpiece and the during solidification. Thus, the curves 4. Wrought AZ31 Mg alloy is much
AZ31 Mg as welding wire. The T-fS suggest no significant susceptibility to less susceptible to liquation due to its
curves in Fig. 9A show that the weld fS cracking. No crack can be observed on solution heat treatment during produc-
B. ABBASIKHAZAEI (b.abbasi@razi.ac.ir), G. ASGHARI, and R. BAKHTIARI are assistant professors, Department of Materials Engineering, Razi University,
Kermanshah, Iran.
Table 1 — Chemical Composition of the IN738 and FSX414 Superalloys and MBF80 Interlayer
wt%
Ni Co Cr Mo W Nb Al Ti Fe Ta C B Zr S Si Mn
IN738 Bal. 8.5 15.84 1.88 2.48 0.92 3.46 3.47 0.07 1.69 0.11 0.009 0.04 0.001 — —
FSX414 10.32 Bal. 30.25 0.03 6.76 — — — 0.52 0.14 0.15 0.006 — — 0.72 0.59
MBF80 Bal. — 15.2 — — — — — — — 0.06 4 — — — —
A B
Fig. 3 — Light micrographs taken from joints bonded at 1050°C for holding times of A — 1 min; B — 10 min.
A B
Fig. 4 — Light micrographs taken from joints bonded at 1100°C for holding times of A — 1 min; B — 5 min.
joints. A schematic diagram of the This could limit the diffusion of melting creased after a holding time of 10 min,
shear test fixture is shown in Fig. 2. point depressant (MPD) elements from which can be indicative of isothermal
The fracture surfaces were studied us- the interlayer into the base metal and solidification progression. Therefore,
ing a stereo microscope and SEM. cause the isothermal solidification rate occurrence of isothermal solidification
to be reduced. was possible at 1050°C, with no super-
Results and Discussion Isolated centerline eutectics were vis- heating in the interlayer.
ible at the joints made at 1050°C for 10
min — Fig. 3B. With increasing bonding Bonding at 1100°C
Bonding at 1050°C time, more effective diffusion of MPD
elements of the interlayer into the base Micrographs of joints made at
The microstructure of joints made at metal occurred. Therefore, isothermal 1100°C for bonding times of 1 and 5
1050°C for 1 and 10 min are shown in solidification was developed, and the min are shown in Fig. 4. At the joints
Fig. 3. At the joint of this figure, contin- amount of eutectic constituents de- made for 1 min, isolated eutectic con-
uous centerline eutectic compounds are
visible, which formed due to incomplete
Table 2 — Comparison of DAZ Width for Joints Made at Various Bonding Conditions
isothermal solidification. 1050°C is low-
er than the liquidus temperature of the
Bonding Temperature (C) 1050 1100 1150
interlayer (1054°C); therefore, there was
no superheating (temperature differ- Bonding Time (min) 1 10 1 5 1 5
ence higher than the melting point) DAZ Width in IN738 half (m) 40.19 50.97 44.24 54.33 70.45 85.04
during melting of the interlayer, espe-
DAZ Width in FSX414 Half (m) 23.53 27.68 26.62 30.61 40.72 42.50
cially at a short bonding time of 1 min.
A B
Fig. 5 — Micrographs taken from joints bonded at 1150°C for holding times of A — 1 min; B — 5 min.
A B
Fig. 7 — Light micrographs taken from joints bonded at A — 1050°C for 10 min; B — 1200°C for 10 min.
Fig. 9 — Hardness profile across the joints made at 1050°C Fig. 10 — Comparison of maximum hardness of DAZ and aver
for 1 and 10 min. age hardness of ISZ for different bonding temperatures.
A1 A2
B1 B2
C1 C2
Fig. 12 — Stereomicrographs of shear tested samples bonded at A — 1100°C; B — 1150°C; C — 1200°C for 10 min.
A B C
Fig. 13 — SEM micrographs of sheartested samples bonded at A — 1100°C for 1 min; B — 1100°C for 10 min; C — 1200°C for 10 min.
the DAZ and base metal at higher tem- the joints made at various tempera- FSX-414 base metals, respectively. This
peratures, which reduced the formation tures for 10 min in comparison with shows that the joint should be homoge-
of DAZ constituents as well as the DAZ those of the base metals. As can be nized in order to remove the deleterious
hardness. According to Fig. 10, the ISZ seen, the shear strength increased DAZ phases and enhance the shear
hardness increased with increasing with rising bonding temperature. The strength. The effect of homogenizing
bonding temperature. Because diffusion same trend was seen for the variation procedure (at 1150°, 1175°, 1200°, and
of the alloying elements (such as Co, Cr of ISZ hardness with increasing bond- 1225°C) on the mechanical properties
and Ti) into the joint was more effective ing temperature — Fig. 10. This could of the same system (IN738/MBF-
at higher temperatures, which caused be related to more effective diffusion 80/FSX-414) was studied in an unpub-
higher strengthening of the joint due to of alloying elements from the base lished work. The results showed carbide
the solid solution strengthening. Solid metal into the joint at higher tempera- dissolving, recrystallization, partial
solution strengthening as well as car- tures and therefore more effective melting, and precipitation coarsening
bides strengthening is the effective solid-solution strengthening. Simulta- occurred in the base metal and at the
strengthening mechanism for FSX-414 neous increase of ISZ hardness and joints during homogenizing at 1225°C.
superalloy, as reported by Saha et al. the joint’s shear strength has been re- However, maximum shear strength of
(Ref. 4). ported for similar TLP joints of FSX- the joints was obtained at the homoge-
414 superalloy (Ref. 12). nizing temperature of 1200°C, about
Shear Test The highest shear strength of the twice in respect to the as-bonded sam-
joints (1200°C/10 min) was obtained by ple (Ref. 19).
Figure 11 shows shear strength of about 59 and 58% of the IN-738 and Figure 12 shows stereomicrographs
282 superalloy. Materials Characterization rate during transient liquid phase bonding of isothermal solidification during tran-
62(1): 1–7. of Inconel 738LC superalloy. Materials Sci- sient liquid phase (TLP) bonding. Journal
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turvedi, M. C. 2004. Effect of gap size and 11. Jalilvand, V., Omidvar, H., 16. Bakhtiari, R., and Ekrami, A. 2012.
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