Documente Academic
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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
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CONTENTS
44
52
Features
Departments
38
44
FABTECH 2013
Experience the highlights of this largest-ever exhibition
A. Cullison et al.
52
58
Editorial ............................4
Press Time News ..................6
International Update ..............8
News of the Industry ............10
Business Briefs ..................14
Stainless Q&A ....................20
RWMA Q&A ......................22
Product & Print Spotlight ......28
Coming Events....................64
Certification Schedule ..........68
Conferences ......................70
Welding Workbook ..............72
Society News ....................75
Tech Topics ......................77
Guide to AWS Services ........95
Personnel ........................96
Classifieds ......................102
Advertiser Index ................104
6-s
15-s
38
23-s
WELDING JOURNAL
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
JANUARY 2014
Officers
President Dean R. Wilson
Welldean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Vice President John R. Bray
Affiliated Machinery, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
U. Aschemeier (Dist. 7), Miami Diver
R. E. Brenner (Dist. 10), CnD Industries, Inc.
D. J. Burgess (Dist. 8), University of Tennessee
N. C. Cole (Past President), NCC Engineering
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (At Large), The Harris Products Group
J. Knapp (Dist. 17), Gas and Supply
T. J. Lienert (At Large), Los Alamos National Laboratory
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), K. A. Phy Services, Inc.
W. R. Polanin (At Large), Illinois Central College
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
R. W. Roth (At Large), RoMan Manufacturing, Inc.
N. Samanich (Dist. 21), NS Inspection and Consulting
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
J. Stoll (Dist. 18), Bohler Welding Group U.S.
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), Ford Motor Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Wright Welding Technologies
PRESS TIME
NEWS
Praxair to Fund Welding Scholarships through
AWS Program and SkillsUSA Competition
Praxair, Inc., Danbury, Conn., a leading industrial gases company, recently announced the companys global giving program will fund more than $200,000 in scholarships over the next five years for the American Welding Society (AWS) and SkillsUSA. They will support education and hands-on training for student welders in the
United States.
An applicant must be a minimum of 18 years old, at least a high school senior who
will be applying (or has applied) to a certificate welding program or to a college/university for a two- or four-year degree focused on welding. Information on additional
qualifications is available at www.aws.org/foundation.
Twenty-six awards will be made to students who reside/attend school in the areas
in which the following AWS Sections are located: Chicago, Ill. (Section 002); Cleveland, Ohio (Section 006); Dallas, Tex. (North Texas Section 053); Detroit, Mich. (Section 011); Fox Valley, Wis. (Section 074); Houston, Tex. (Section 022); Kansas City,
Mo. (Section 016); Los Angeles, Calif. (Section 008); North Dakota (Northern Plains
Section 117); Portland, Ore. (Section 052); Salt Lake City, Utah (Utah Section 059);
Tulsa, Okla. (Section 034); and North Carolina (Charlotte #140 and Triangle #151).
MEMBER
JANUARY 2014
INTERNATIONAL
UPDATE
Lincoln Electric Opens Automation
Facility in Brazil
Lincoln Electric Co. recently opened its new Automation Center of Excellence in Brazil, a 5000-sq-m facility that includes
demonstration, integration, training, and office space. The newly
built facility, located in the city of Indaiatuba, features a training
lab with six robot systems, a station for orbital welding process
development and system instruction, and eight additional demonstration systems for robotic and mechanized applications. Two
classrooms can accommodate up to 40 students.
Lincoln held a grand opening event, where a welcome was extended by Indaiatuba Mayor Reinaldo Nogueira, who stressed
the importance of creating an environment for business to grow
and in which their employees could feel comfortable making their
home. George Blankenship, president of Lincoln Electrics North
American operations, delivered the keynote presentation. He
said, Our responsibility to our customer must be more than just
a provider of product. Their expectations of us are greater today
because they have escalated demands from their customer. When
we can improve their welding and fabrication procees, we become a partner rather than a vendor.
Leonardo Sabedot, business manager for the ASG-Brazil
group, closed out the presentation. We are excited by the opportunity that this facility represents, and look forward to forging strong partnerships with the many customers in the region,
he said.
Lincoln Electric has grown its automation offerings over the
last few years to include preengineered robotic systems, CNC
plasma cutting equipment, fixturing and tooling, engineered line
builds, robotic integration, laser systems, weld fume control, and
fire prevention.
Kemppi Oy, a manufacturer of industrial arc welding equipment, and ABB Robotics, a supplier of industrial robots and modular manufacturing systems, have established a collaboration to
develop fully equipped robotic welding packages. ABB indicated
the technologically innovative welding packages would be designed as modular, cost-effective projects for companies to easily install or upgrade into a robotic system. The joint business
covers Europe, Asia, Africa, and South America.
Kemppi equipment will be featured at all certified ABB Robotics welding lab locations, where customers will be able to conduct robotic welding trials on the latest equipment.
JANUARY 2014
Pemamek, a manufacturer of automated welding and production systems, has received another contract to supplement
continued on page 100
NEWS OF THE
INDUSTRY
Greater Waco Advanced Manufacturing Academy Awarded $2.2 Million Grant
The Waco Independent School District, Waco, Tex., has been awarded a $2.2
million grant from the U.S. Department of Education to further enhance the
Greater Waco Advanced Manufacturing Academy. The school opened its doors
in August and is now teaching welding skills to students from Waco and the surrounding area.
The grant is part of the federal governments $89.8 million in Magnet School
Assistance Program grants featuring a goal to promote courses within magnet
schools that will strengthen knowledge of academic subjects and attainment of
tangible vocational skills.
Our vision for the Greater Waco Advanced Manufacturing Academy is to prepare Waco area students for productive employment, success in postsecondary
education, or both, said Waco Independent School District Superintendent Dr.
Bonny Cain. Right now, we know that many of our local manufacturing businesses need welders, so were trying to meet that demand.
The school district plans to use the grant awarded to the academy for purchasing additional equipment and consumables, provide professional development
staff and students, plus expand the schools curriculum.
JANUARY 2014
WELDING JOURNAL
11
agery on the site, so the members will be able to really see themselves in the new design, Collins added.
Industry Notes
The Bhler Welding Group, Vienna, will become an integrated
part of the voestalpine Group, a steel-based technology and
capital goods group with about 500 group companies and locations in more than 50 countries and on five continents. Its
name now also changes to voestalpine Bhler Welding.
gas tungsten arc torch and accessory lines from Weldcraft under
its brand. The only change will be the addition of the Miller
name on products, labels, and packaging. Torch bodies have
also transitioned from red to black (excluding Redhead
series).
Aiken Technical College, Graniteville, S.C., to purchase an orbital welding machine and Bevelmaster beveling machine for
use in both advanced manufacturing and nuclear training.
continued on page 100
12
JANUARY 2014
800.545.4921
w w w. i m p a c t - n e t . o rg
BUSINESS
BRIEFS
Recent Acquisitions
At FABTECH 2013, Lincoln Electric Holdings, Inc., Cleveland, Ohio, announced the company acquired an ownership interest in Burlington Automation Corp., Hamilton, Ontario,
Canada, a designer and manufacturer of 3D robotic plasma cutting systems. Rob Tyler serves as its president. In addition, the
company has entered into a definitive agreement to acquire Robolution GmbH, based outside of Frankfurt, Germany, a European
provider of robotic arc welding systems. Wolfgang Koenig is its
managing director.
Victor Technologies, St. Louis, Mo., has acquired Gas-Arc
Group Ltd., a privately held manufacturer of gas control equipment in the United Kingdom, for approximately $40 million in
cash, subject to post-closing adjustments. Its portfolio includes
branded gas control products that meet specialty gas application
requirements as well as cutting and welding equipment for the
industrial, laboratory, and medical gas control markets. In addition, Gas-Arc will continue to operate under its own name.
Reliance Steel & Aluminum Co., Los Angeles, Calif., recently
announced that, through its wholly owned subsidiary American
Metals Corp., the company has acquired all of the capital stock
of Haskins Steel Co., Inc., Spokane, Wash. Founded in 1955,
Haskins processes and distributes carbon steel and aluminum
products of various shapes/sizes. In-house processing capabilities include shearing, sawing, burning, and forming. Haskins will
operate as a wholly owned subsidiary of American Metals Corp.,
and current management will also remain in place.
Antelope Oil Tool & Manufacturing Co., LLC, Mineral Wells,
Tex., has acquired WearSox, L.P., Houston, Tex. Founded in 2004,
WearSox is a developer of thermal spray-on casing centralizers
14
JANUARY 2014
Ford Motor Co. will invest $150 million and add approximately 350
new jobs at its Buffalo Stamping Plant. (Photo courtesy of Ford.)
I want to encourage you to submit nomination packages for those individuals whom you feel
have a history of accomplishments and contributions to our profession consistent with the standards
set by the existing Fellows. In particular, I would make a special request that you look to the most
senior members of your Section or District in considering members for nomination. In many cases,
the colleagues and peers of these individuals who are the most familiar with their contributions, and
who would normally nominate the candidate, are no longer with us. I want to be sure that we take
the extra effort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nomination process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issue
of the Welding Journal. Please remember, we all benefit in the honoring of those who have made
major contributions to our chosen profession and livelihood. The deadline for submission is July 1,
2014. The Committee looks forward to receiving numerous Fellow nominations for 2015
consideration.
Sincerely,
Thomas M. Mustaleski
Chair, AWS Fellows Selection Committee
CLASS OF 2015
Fellow Description
DEFINITION AND HISTORY
The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for
distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional
stature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of the
individual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by:
Sustained service and performance in the advancement of welding science and technology
Professional recognition
RULES
1.
2.
3.
4.
5.
6.
7.
NUMBER OF FELLOWS
Maximum of 10 Fellows selected each year.
Description of significant technical advancements. This should be a brief summary of the candidates most
significant contributions to the advancement of welding science and technology.
Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited
in (1). Where possible, papers and articles should be designated as to whether they were published in
peer-reviewed journals.
Inventions and patents.
Professional recognition including awards and honors from AWS and other professional societies.
Meaningful participation in technical committees. Indicate the number of years served on these committees and
any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.).
Contributions to handbooks and standards.
Presentations made at technical conferences and section meetings.
Consultancy particularly as it impacts technology advancement.
Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology.
Participation on organizing committees for technical programming.
Advocacy support of the society and its technical advancement through institutional, political or other means.
Note: Application packages that do not support the candidate using the metrics listed above
will have a very low probability of success.
Supporting Letters
Letters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These
letters should address the metrics listed above and provide personal insight into the contributions and stature of the
candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.
Return completed Fellow nomination package to:
Wendy S. Reeve
American Welding Society
Senior Manager
Award Programs and Administrative Support
8669 Doral Blvd., #130
Miami, FL 33166
Telephone: 800-443-9353, extension 293
SUBMISSION DEADLINE: July 1, 2014
HT Series
Head Tailstock
Locust I & II
Welding Head
Manipulators
HD Series
Gear Driven
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TR Series
Turning Rolls
Follow us on
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STAINLESS
Q&A
BY DAMIAN J. KOTECKI
20
JANUARY 2014
68 (20)
36 (241)
1.00
200 (93)
0.80
400 (204)
23 (159)
0.65
600 (316)
20 (134)
0.59
750 (399)
0.55
800 (427)
17 (114)
0.54
a bad idea, but its execution is not without risk. If you follow the guidelines
herein, I think you can be successful,
though I would not guarantee it.
WELDING JOURNAL
21
RWMA
Q&A
Q: One of our resistance welding machine operators recently lost part of his
finger when it was crushed between the
electrodes of the machine. How can we
protect our operators from similar injuries in the future?
BY TOM SNOW
22
JANUARY 2014
WE BUILD
Industry
The biggest, toughest shovels on the planet. Moving tons
of earth in a single scoop. With key components built by
Al and the team of welders at Weldall Mfg., Inc.
Together, we build industry.
However, if an operator is not properly trained in the operation of a retraction feature, or if its not properly adjusted, additional pinch point dangers can
result when the machine comes out of
retraction.
OSHA requires guarding against pinch
point injury to be passive. This means that
there can be no way to defeat the protection system and that safety of the welding
machine cannot be dependent upon operator adjustments. Since the gap between
electrodes can vary depending on the
setup, at present the only way to meet this
OSHA requirement is by use of a system
called Soft Touch.
WELDING JOURNAL
25
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The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image and
impact of the welding industry. Election as a Counselor shall be based on an individuals career of
outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in the
welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the welding
industry. The individuals organization shall have shown an ongoing commitment to the industry, as
evidenced by support of participation of its employees in industry activities.
Leadership of or within an organization that has made a substantial contribution to training and
vocational education in the welding industry. The individuals organization shall have shown an
ongoing commitment to the industry, as evidenced by support of participation of its employee in
industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this
issue of the Welding Journal. The deadline for submission is July 1, 2014. The committee looks
forward to receiving these nominations for 2015 consideration.
Sincerely,
Lee Kvidahl
Chair, Counselor Selection Committee
CLASS OF 2015
CLASS OF 2015
Spot Welding
Different Sheet Metal
Grades and Gauges
A study looks at improving the welding of automobile body parts involving joints of
mild and high-strength steels of varying thicknesses
BY E. BIRO, L. CRETTEUR, AND T. DUPUY
crostructure in the spot weld, which is sensitive to the notch effect when testing is performed in opening mode. However, most
of these observations and conclusions are based on standard
steel qualification results, i.e., tests on homogeneous welding
configurations. When these data are then applied to dissimilar
configurations, the most common approach in the automotive
industry is to consider that the fracture behavior of a dissimilar
configuration can be deduced from the corresponding two homogeneous configurations through a minimum rule, i.e., the
load-bearing capacity of the heterogeneous configuration is
supposed to be equal to the minimum strength of both homogeneous assemblies. This assumption is verified experimentally
on material combinations using thin mild steels, as illustrated
in Fig. 1. The mild steel sheet is the weakest point of the assembly and fails during the mechanical test, leading to the formation of a plug around the weld.
Dissimilar Welds
Studies on heterogeneous or dissimilar configurations are
much fewer, although several studies have been published recently (Refs. 812). However most of these studies consider
only tensile-shear testing of dissimilar welds. Only the work
from Khan et al. (Ref. 9) considers cross-tension testing of a
DP600-HSLA similar-thickness configuration, obtaining a loadbearing capacity almost equal to that of the maximum level
among the similar configurations results, i.e., almost equal to
that of DP600. This result does not agree with the minimum
rule described above, which is attributed by the authors to the
difference in microstructure and hardness of the spot weld
nugget due to the dilution effect. This article focuses on AHSS
E. BIRO (elliot.biro@arcelormittal.com), L. CRETTEUR, and T. DUPUY are with ArcelorMittal Global R&D, based in Hamilton, Ont., Canada;
Montataire, France; and Maizires-ls-Metz, France, respectively. This article is based on a paper presented at the Sheet Metal Welding
Conference XV, Livonia, Mich., Oct. 25, 2012.
38
JANUARY 2014
The materials chosen for this study are a low-carbon equivalent 980-MPa dual-phase (DP980 LCE) cold-rolled steel with
a hot-dip galvanized coating, and a 800-MPa transformationinduced plasticity (TRIP800) steel.
Each steel grade was obtained in different thicknesses. Material details are given in Table 1. It can be seen that although
there are slight differences in chemistry or mechanical properties from sample to sample, due to slightly different processing
parameters, the metallurgical concept remains the same for
each grade. Experiments were carried out on two- and threesheet stackups. Both the DP980 and TRIP800 were used for the
two-sheet stackups and only the DP980 was used for the threesheet stackups. All of the joints were made using similar grade
material of both similar and dissimilar material thickness to
focus on geometrical effects. The material thickness combinations for all of the two-sheet joints are shown in Table 2.
All three-sheet stackups were made using the 1-mm DP980
LCE. These configurations were designed to study what happens in such cases, knowing that three-sheet welding is very
common in car body manufacturing. The four configurations
tested, shown in Fig. 2, are as follows: A a square DP980
coupon (patch) is inserted between the two classical cross-tension coupons for welding (1+patch+1 mm); B two coupons
oriented the same way welded with one coupon oriented
in the transverse direction to form a cross-tension sample
(1+[1+1] mm); C same configuration as A but the external
coupon is removed by manual torsion before cross-tension
testing (1+1+0 mm); D same configuration as A, but the
two coupons oriented the same way are first spot welded together strongly (with several spots) in the extremities, before
the actual three-sheet spot weld is done ([1++++1]+1 mm).
Spot welding was carried out based on using the procedure
and parameters described in ISO 18278-2 (Ref. 13). For each
welded configuration, a welding current range test was carried
out using a pedestal spot single-phase 50-Hz welding machine,
with the welding parameters chosen to correspond to the
thinnest sheet in the assembly (Table 3).
Each three-specimen cross-tension test was welded at the
multiple current levels using 38- 125-mm coupons as specified by ISO 18278-2. Cross-tension testing was then carried out
with a tensile machine equipped with a special hydraulic clamping system, allowing the cross-tension specimens to be held without sliding. After testing, the maximum load was recorded, and
the weld diameter was measured according ISO 14329 (Ref.
14), using a caliper gauge for button diameters and a magnifying glass for weld diameters in case of partial or full interfacial
failures. Only welds without expulsion are considered in the following analysis.
Cross-tension strength is strongly dependent on weld diameter Fig. 3. In spite of the scatter, the CTS for the dissimilar configuration is clearly above that of the similar 1-mm configuration,
rather in the trend of the thicker similar 2-mm configuration.
WELDING JOURNAL
39
Coating
Sample #
Thickness
(mm)
YS (MPa)
DP980
LCE
Hot Dip
Galvanized
AR1084
AS160
AN2157
1
1.25
2
650
833
704
TRIP
800
Electrogalvanized
AL761
Bare
AL351
UTS (MPa)
C (%)
Mn (%)
Si (%)
Cr (%)
Al (%)
995
1076
1037
0.08
0.08
0.07
2.49
2.44
2.54
0.27
0.26
0.25
0.28
0.29
0.31
0.14
0.15
0.14
520
828
0.19
1.67
1.63
0.02
0.03
546
832
0.19
1.71
1.68
0.03
0.04
Thickness
(mm)
1
DP980
LCE
1.25
1
AR1084/
AR1084
TRIP800
1
2
Analysis of Results
Several hypotheses can be proposed to explain the positive
deviation:
1. Dilution Effect: when spot welding an AHSS sheet to a lowcarbon sheet, the dilution (mixing of both chemistries) reduces
40
JANUARY 2014
DP980 LCE
1.25
AR1084/
AS160
AS160/
AS160
TRIP800
AR1084/
AN2157
AS160/
AN2157
AN2157/
AN2157
AL761/
AL761
AL761/
AT351
AT351/
AT351
the carbon content of the molten nugget, which may improve its
mechanical behavior. Although this explanation is probably true,
it cannot explain the results of the present study, since they were
obtained with similar grades joined together (Ref. 9).
2. Thermal Effect: when comparing 1+2-mm to 1+1-mm configuration, the overall assembly thickness is increased, leading
logically to increased thermal mass slowing the cooling rate. Reducing the cooling rate can, in turn, reduce the brittleness of the
microstructures formed during welding (bainite may be tougher
than autotempered martensite, which may be tougher than
quenched martensite).
3. Notch Effect: in the case of dissimilar thickness spot welds,
the solidification plane, where the columnar grains in the weld
nugget meet, is assumed to be roughly at the midthickness of
the whole assembly, which is away from the notch end at the faying surface. As the solidification plane may be weaker than the
bulk of the molten nugget, a dissimilar thickness joint may be
stronger in opening mode than a similar thickness joint.
4. Mechanical Effect: in the case of dissimilar thickness spot
welds, the stress concentration at the notch will be different than
in a similar thickness joint due to uneven loading. This will in
turn influence the cross-tension strength. As this effect is not
obvious it will be shown further in the discussion. The analysis
of three-sheet configurations results helps in understanding the
relative importance of these effects Fig. 8.
The 1+1+0-mm configuration is especially interesting as the
loading conditions during cross-tension are strictly identical to
the reference 1-mm similar configuration, but its CTS performance is greater than the strength of the similar gauge joint
Fig. 6. This positive deviation can only be attributed to the thermal (since overall thickness during welding was 3 mm instead of
2) and notch effects. However, the positive deviation for this
1+1+0-mm configuration is limited compared to the 1+2,
3.5
4
5
260
320
720 (four 180 ms
pulses separated by
40 ms cold times)
260
320
400
WELDING JOURNAL
41
Fig. 8 Schematic view of the thermal, notch and mechanical effects for the main configurations.
from Equation 52
from Equation 54
These computed ratios can be directly compared with the
average experimental ratios obtained from Table 4; all the data
being plotted in the same graph Fig. 10.
Clearly, the order of magnitude of the mechanical effect, as
computed through the elastic analysis from Ref. 15, appears
very consistent with the experimental data. Further work by
Dancette et al. (Ref. 16) also supports the evidence of a strong
mechanical effect explaining the positive deviation. This study
used finite element modeling to predict the failure of the
TRIP800 spot welds presented here. In that study, two different numerical approaches are considered for failure prediction
1. Similar to the above analysis from Radaj and Zhang (Ref.
15), the onset of fracture is predicted through a critical fracture mechanics parameter, but in this case the J-integral, computed through finite element analysis. A critical J-integral level
of 22.5 kJ/m is found to be appropriate for the TRIP800 spot
weld molten zone. This critical level is reached for a cross-tensile load of 3.3 kN in the case of a 5-mm-diameter weld in 1+1mm configuration, and for a cross-tensile load of 5.1 kN in the
42
JANUARY 2014
Conguration
TRIP800 1+1 mm
TRIP800 2+2 mm
TRIP800 1+2 mm
DP980 LCE 1+1 mm
DP980 LCE 1.25+1.25 mm
DP980 LCE 2+2 mm
DP980 LCE 1+1.25 mm
DP980 LCE 1+2 mm
DP980 LCE 1.25+2 mm
DP980 LCE 1+patch+1 mm
DP980 LCE 1+[1+1] mm
DP980 LCE 1+1+0 mm
DP980 LCE [1+++1]+1 mm
747
639
1146
929
823
913
1014
1220
1180
1179
1004
1039
1277
Conclusions
While material qualification tests are frequently based on
similar welding configurations, real car body applications are
quite systematically dissimilar configurations. For spot welds
failing in plug mode, the strength of the assembly only depends
on the weakest material strength. In the case of AHSS+AHSS
welded combinations, however, things turn out differently. Similar-grade but dissimilar-thickness high-strength-steel configurations have been spot welded and tested in cross-tension.
The following main conclusions can be highlighted:
1. For dissimilar-thickness configurations, the cross-tensile
strength is above the standard minimum rule assumptions,
this phenomenon being called a positive deviation.
2. Limited thermal and notch location effects can explain
part of this positive deviation, but the main reason is
mechanical.
3. As evidenced through several analytical and numerical
studies, this mechanical effect is due to the less severe local
stresses at the notch in case of uneven thickness, and improves
the positive deviation when the thickness ratio increases.
Although widely used for material qualification and scientific purposes, similar configurations appear as the worst case
in terms of cross-tension performance for high-strength steels.
Actual vehicle design should consider positive deviation in dissimilar configurations to maximize the potential strength of
spot welds in high-strength steels.
Acknowledgments
The authors would like to thank Savine Henrion, Sylvain
Dancette and Florent Krajcarz for their help in this study and
ArcelorMittal for granting us permission to publish this work.
References
1. Seeger, F., Feucht, M., Frank, Th., Keding, B., and Haufe,
A. 2005. An investigation on spot weld modeling for crash simulation with LS-DYNA. LS-DYNA Anwenderforum, Bamberg.
2. ISO 14272:2000, Specimen dimensions and procedure for
cross tension testing resistance spot and embossed projection welds.
3. ISO 14273:2000, Specimen dimensions and procedure for
shear testing resistance spot, seam and embossed projection welds.
4. Pouranvari, M., and Marashi, S. P. H. 2010. Key factors
influencing mechanical performance of dual phase steel resist-
Dear Readers:
The Welding Journal encourages an exchange of ideas
through letters to the editor. Please send your letters to
the Welding Journal Dept., 8669 NW 36th St., #130,
Miami, FL 33166. You can also reach us by FAX at (305)
443-7404 or by sending an e-mail to Kristin Campbell
at kcampbell@aws.org.
WELDING JOURNAL
43
FABTECH 2013
This years show set marks as the biggest ever, both in terms of
square footage of exhibit space and in the number of attendees
FABTECH 2013 will take a place
in history as the most successful
metal forming, fabricating, finishing, and welding exhibition ever in
North America. A record 650,000
sq ft total of exhibition space was
utilized by a total 1573 exhibitors.
Also, a record 40,667 visitors
JANUARY 2014
Fig. 1 Dean Wilson, 2014 AWS president, talks of the exciting future of the
Society.
Fig. 2 Professor DuPont details his research into welding high-alloy Ni steels.
Adams Lecture
Fig. 3 Dr. Rick Polanin gave the Plummer Memorial Education Lecture.
Plummer Lecture
Dr. Rick Polanin, professor and program chair of the manufacturing engineering technology and welding technology programs at Illinois Central College,
presented this years Plummer Memorial
Education Lecture Fig. 3.
Polanins topic, The Future of Welding Education, focused on looking to
the past for guidance and inspiration for
the future; understanding what welding
education is about; describing the development of effective welding courses; considering the role of technology both in
equipment and teaching; why manufacturing is vitally important to the United
States; and attempting to predict the future of welding education.
With welding, you can individualize
instruction and achieve life-long learning, Polanin said.
Also included during his talk was the
complexity of issues affecting American
education for which there are no easy
WELDING JOURNAL
45
Product News
Following are just a few of the products that drew the attention of the Welding Journal editors at this years show.
Ensitech demonstrated its TIG Brush
(Fig. 4) for removing heat tint stains on
stainless steel. The system combines electricity, chemistry, and heat to clean the
weld surface. A conductive brush attached to a 40-A electrical motor applies
a cleaning fluid that is heated up to
200C. The electrochemical reaction that
occurs cleans and passivates the stainless
steel. The company offers a choice of fluids depending on whether a satin or mirror finish is desired as well as whether a
heavy or medium stain must be removed.
The company exports to 12 different
countries, but this is the first introduc-
ting operations Fig. 7. This 5-kW solidstate laser is touted to produce cut quality very similar to a CO 2 laser with the
speed of a fiber laser. It reaches maximum efficiency when cutting thin material, but can cut mild steel up to 25 mm
thick. The unit can handle nonferrous
metals such as copper and brass, as well
as stainless steel and aluminum. It has a
working range of 3000 mm, X axis; 1500
mm, Y axis; and 115 mm, Z axis.
TRUMPF, www.us.trumpf.com
JANUARY 2014
TRUMPF used FABTECH to introduce its TruLaser 5030 fiber laser for cut-
flame-resistant cotton, provides less restriction for better movement and increases safety with a tailored fit. The
GMA and GTA gloves are available in Xsmall and small. In particular, the GMA
glove (lined) has a dual-padded palm;
fleece-insulated palm, foam-insulated
back; and original wraparound keystone
thumb design. The GTA glove is unlined
for heightened feel and dexterity; has a
triple-padded palm; and contains goat
grain leather. Miller Electric Mfg. Co.,
millerwelds.com/arcarmor
47
Women in Welding
Girls dont take off their tiaras for a welding helmet, but they do want a rewarding career, said AWS President Nancy Cole during the Women in Welding
reception held Nov. 19 at the FABTECH Theatre.
She discussed how she had been traveling across the United States throughout
her presidential year talking about welding and brazing, and had seen the excitement women she spoke to had regarding manufacturing and the opportunities
available in the welding field. We need to encourage those women to be the manufacturing workforce of tomorrow, she said.
Speaking first was Brenda Ryan, owner and president of Ryan Industries,
Wixom, Mich., and a partner of SME, who noted that the number of women in
manufacturing has declined in recent years. We need to offer recommendations
for change to bring more women into manufacturing, she said. It is important
that we speak with one voice. Women represent 48% of the working population,
but only 24% of manufacturing jobs.
It is expected that there will be an additional 5 million manufacturing jobs
available by 2020, Ryan said. Women offer the biggest opportunity to fill these
jobs.
The statistics (Ryan) talked about should be a loud call to industry, Cole
said.
Gretchen Zierick of Zierick Manufacturing and a past president of the Precision Metalforming Association said the only areas at her company where the number of women have not declined is customer service and general office. She
lamented the elimination of classes such as high school shop that gave students
an introduction to manufacturing and the trades.
She noted that hers is a third-generation family business. My company could
go out of business just because the workers wont exist.
ful for any type of metal-to-earth engagement tool, the 155FC wire was designed
for multipass operations where cross
checking is undesirable and to offer
greater resistance to spalling. It exhibits
a matrix hardness range of 3545 HRC.
Applications include process screw flight
edges, drill bit and stabilizer buildup, and
hardbanding. The 160FC was designed
for use as an overlay, and its matrix hardness range is 4050 HRC. It is well suited
for upstream oil and gas production applications such as drill bit holders, kicker
pads, stabilizers, and mud motors. Victor Technologies, www.victortechnologies.com
The Lincoln Electric Weld Sequencer
software shows a picture of a workpiece
and then explains to the welder step by
step where to place each weld Fig. 13.
It is especially useful for applications
where there is a large number of parts,
but not necessarily high volume. It eliminates the need for the welding operator
to rely on his/her memory of where each
weld is needed and the parameters for
each weld. The system on display at the
show was set up for 140 different welds.
The software automatically sets welding
power source parameters such as voltage
and wire feed speed. It also can be set to
48
JANUARY 2014
automatically make changes to weld parameters and to track the operators actions to confirm each weld was performed. The software can also be tied
into other equipment such as positioners. The Lincoln Electric Co., www.lincolnelectric.com
shoulder bag, pipe saw, four pipe supports, saw blade, Allen wrenches for
changing the blade and adjusting the saw,
operating instructions, and a DVD with
demonstrations and instructions. Model
220E retails for approximately $1500 and
the 280E for $2500. Exact Tools Oy,
www.exacttools.com
Fig. 16 The 2013 Image of Welding Award winners (from left) are Ned Lane (Distributor, Cee Kay Supply); Nanette Samanich (Educator); Levi Crusmire and Bob Richwine (AWS Section, Ivy Tech Community College Student Chapter); Dennis A. Wright
(Individual); Woody Cook (Large Business, SME Steel); and Rick McCartney (Small
Business, Bay State Industrial Welding & Fabrication, Inc.). Not pictured: Dr. Patricio
Mendez (Educational Facility, Canadian Centre for Welding and Joining, University of
Alberta).
at the Nevada State Skills-USA Competition 20112013; volunteered at Boy
Scout Welding Merit Badge clinics; and
is currently the AWS District 21 director.
Educational Facility, Canadian
Centre for Welding and Joining, University of Alberta, Alb., Canada. This facility opened in 2010 at the University of
Alberta and currently operates under the
supervision of Dr. Patricio Mendez. A
graduate-level research center, the
school also offers undergraduate and
graduate students a fundamental to welding course. Graduate students also work
with high school students to educate
them on robotic welding. The facility is
home of an AWS Student Chapter, too.
Small Business, Bay State Industrial Welding & Fabrication, Inc., Hudson, N.H. This company was founded in
1992 by Rick McCartney after years of
working as a welder. With 23 employees,
Bay State has donated time and materials to construct the Benson Park 9/11 Memorial, plus teamed up with Building
Dreams for Marines to renovate homes
for local Marines who need improved accommodations after war-related injuries.
In the near future, it is looking to welcome apprentice and internship opportunities for individuals in local welding
classes.
Large Business, SME Steel, West
Valley City, Utah. Since 1992, this company has provided comprehensive struc-
49
Welding Wars
Groups battled it out during the first
Welding Wars Competition (Fig. 17) held
at FABTECH Nov. 19 and 20.
First place went to Jeff Anderson,
Garrett Harris, and Austin Raetz with
Kankakee Community College, Kankakee, Ill Fig. 18. They prepared for this
competition before coming to the show
and were excited to win. It was tough,
Anderson said. It looks easy but was
hard, Harris added.
Second place was awarded to Anthony
Godinez, Ryan Crandal, and Brad
Williamson with Ferris State University,
Big Rapids, Mich.
Third place was earned by Jeffrey
Kubic, Matthew Zohfeld, and Robert
Stephens with Moraine Valley Community College, Palos Hills, Ill.
Prizes included welder backpacks with
supplies from BSX; gas metal arc, gas
tungsten arc/shielded metal arc, and
plasma cutting machines from Lincoln
Electric; and three-in-one gas metal arc,
shielded metal arc, and gas tungsten arc
machines from Tweco.
Given a 2-h time limit in which to
work, the three-member teams were
given a project drawing to interpret and
materials for creating it. Gas metal arc
and gas tungsten arc welding with plasma
arc cutting were used. Among the additional sponsors were NI Steel for donating steel and Bessey Tools for providing
clamps.
A panel of AWS Certified Welding Inspectors evaluated all weldments to the
requirements of the current AWS D1.1,
Structural Welding Code Steel, based
on project accuracy to print specifications, weld size and overall weldment appearance, craftsmanship, professionalism, and safety.
Professional Welders
Contest
A record number of welders, 206 to
be exact, put their skills to the test to see
who would earn the bragging rights as
Americas best welder by winning the
Professional Welders Contest at
FABTECH. The two-day event attracted
50
JANUARY 2014
Fig. 17 Students from Moraine Valley Community College display teamwork while
competing at the Welding Wars event.
Fig. 18 The Welding Wars winners present at the awards gala were (from left)
Matthew Zohfeld, Jeffrey Kubic, and Robert Stephens (third place, Moraine Valley
Community College); Anthony Godinez (second place, Ferris State University); and
Jeff Anderson, Austin Raetz, and Garrett Harris (first place, Kankakee Community
College).
WELDING JOURNAL
51
Methodology
A single valve body was chosen for the
study because of its mass and its similar
configuration to valves typically used in
the oil and gas industry. The valve was
preheated to an industry minimum of
500F using typical industry practices for
all three methods. Throughout each test,
the temperatures on the inside and outside of the valve were monitored and
recorded on a data recorder. The ther-
52
JANUARY 2014
Test Procedures
Induction
The induction heater uses watercooled cables to conduct high-frequency
electric current to electromagnetically
induce eddy currents within the material.
The electromagnetic currents in the material cause the molecules to excite which
generates the heat. As such, the heat is
generated within the material compared
to the other two methods where the heating sources are applied to the external
surface and the heat must then be conducted through the part. This results in
BY J. WALKER, D. HEBBLE,
AND R. HOLDREN
J. WALKER, D. HEBBLE, and
R. HOLDREN are with Arc Specialties
Engineering & Consulting,
Houston, Tex.
Resistance
53
Direct Flame
A 100-lb cylinder of propane was used
with a Belchfire fuel gas and compressed air torch. The valve was rotated
on a turntable while the flame impinged
on the exterior surface of the valve
Fig. 3.
The valve was not insulated at all,
which is in accordance with typical industry practices. The data recorder was
placed on top of a piece of pipe tacked
to the valve so as to not tangle the thermocouple leads. Only the two data
recorder thermocouple leads were used
for this test.
The data recorder was turned on and
the flame and rotation were started.
Once both thermocouples reached 500F,
the time was noted and the maintenance
time started. Preheat maintenance was
determined by monitoring the temperature and cycling the torch on and off manually. This human element can add some
degree of inconsistency. After one hour
of preheat maintenance, no additional
heat was applied and the temperatures
were recorded for one hour after making note of the time on the data recorder.
Throughout the test, the amount of time
required to set up and tear down was
recorded.
Experimental Results
Fig. 4 Comparison between the temperature rise on the inside and outside vs. the en
ergy used. A Propane heating; B resistance heating; C induction heating.
Time
Time was evaluated based on time to
preheat to 500F, time difference between inside and outside reaching 500F,
time to set up, and time to tear down.
Preheat Time
When analyzing preheat time, induction produced the best results with both
the inside and outside of the valve reaching the minimum 500F in 0.6 h. The outside of the valve reached the minimum
54
JANUARY 2014
Fig. 5 Cost per part while paying off the preheat equipment (1.5 years).
Fig 6. Cost per part after the preheat equipment is paid off.
only taking 0.25 h for each. The induction method was next with 0.58 h to set
up and 0.6 h to tear down. Resistance required the longest time with 1.5 h to set
up and 0.37 h to tear down. Ease of setup
and tear-down was also considered, and
direct flame was the easiest. The direct
flame method only required the valve to
be rotated with a torch pointed at it, while
the other methods required more complicated preparation. The only constraint
with the propane method is if the part is
too heavy for a turntable. The most difficult method was the resistance; with the
reality that the operator must wire tie the
pads to each other and in the desired position, as well as deal with hot pads once
the part is preheated. Induction was significantly easier than resistance to set up,
with the self-supporting coils and the additional advantage that the coil does not
Energy Efficiency
Each methods efficiency was analyzed based on energy (generated and
consumed) as well as total energy used.
For resistance and induction, the kilowatt-hours (kWh) were recorded. For the
flame test, the pounds of propane used
were recorded for the preheat and preheat maintenance stages. In order to
compare all three methods, the pounds
of propane were converted to BTU1 and
then to kWh2. The amounts of electricity used in the other tests were converted
to BTU2 so that all three tests have kWh
and BTU as values in relation to the temperature increase.
Flame preheating was the least efficient, using 171 kWh and 585,000 BTU.
Flame also had the quickest temperature
drop once heat was removed, with a 12F
difference between the inside and the
outside. The quick temperature drop was
easily predicted because there was no insulation used for the propane test. The
induction method was the most efficient,
using 21.5 kWh and 73,000 BTU and had
the smallest temperature drop once heat
was removed, with only a 4F difference.
The resistance used 24.5 kWh and 84,000
BTU. The outside temperature dropped
34F more than the inside. The difference can be linked to the requirement
that the outside needed to be heated to
550F in order for the inside to reach
500F. Once the heat was removed, the
outside and inside temperatures were
still equalizing, and once the temperatures were the same they both started
dropping. One of the most significant differences was the observation that the
propane used 585,000 BTU compared to
73,000 BTU for induction. Therefore,
512,000 BTU (87.5%) of energy was
wasted. Also, theoretically all 512,000
BTU went into heating the environment,
meaning that in production situations,
the wasted energy resulted in greater
heat exposure to welders and other workers in the area. Induction proved to be
the most efficient, using the least energy
and having the slowest temperature drop
Fig. 4AC.
Safety
Each method was analyzed to determine its level of safety based on the
amount of handling and potential hazards. Safety was evaluated because it is
one of the primary concerns in shop environments. Induction is the safest
method out of the three. The part does
not need to be on a turntable, which eliminated one part-handling operation.
Also, the induction coils remain at room
temperature at all times and with the part
wrapped in an insulating blanket, the
user has a very small chance of getting
burned by the 500 F part.
Resistance and propane are hazardous for multiple reasons, but propane
is slightly more dangerous. With resistance and propane, the heating elements
and torch are extremely hot during and
immediately after preheating, and are
only cooled by the air. With resistance,
the pads are covered with an insulating
blanket, but once the part is preheated
it is difficult to move the hot pads. With
WELDING JOURNAL
55
Induction
Miller Pro Heat 35
N/A
21.6
73,000
36/4
Resistance
PDS Bartech
N/A
24.6
84,000
56/34
Flame
Belchre torch
27
N/A
585,000
76/12
0.60
0.58
0.60
1.78
$150.34
1.75
1.50
0.37
3.62
$287.57
1.10
0.25
0.25
1.60
$187.69
*Costs based on the following values: labor @ $65/h; electricity @ $0.064/kWh; propane @ $0.652/lb.
Cost
The cost of each method was analyzed
based on cost of labor, electricity,
propane, and personnel usage. An analysis using $65/h for labor, $0.064/kWh for
electricity, and $0.652/lb of propane revealed that resistance preheating costs
the most to preheat a valve, costing
$287.57. That breaks down to $164.67 in
labor to preheat the valve, $121.33 in
labor to set up and tear down, and $1.57
in electricity. Direct flame preheating
was the next most expensive, costing
$187.68; $137.58 in labor to preheat the
valve, $32.50 in labor to set up and tear
down, and $17.60 in propane. Finally, induction preheating was the cheapest,
costing $150.34. That breaks down to
$72.04 in labor to preheat the valve,
$76.92 in labor to set up and tear down,
and $1.38 in electricity.
If the shop is air conditioned, there
will be extra electricity used to dissipate
56
JANUARY 2014
References
1. www.flameengineering.com
2. Google calculator
Conclusions and
Recommendations
Based on this study, the induction
method was the best in most categories
(Table 1). Induction heating required the
least amount of time to preheat, was the
most energy efficient, safest, and most
cost-effective. It used less energy than
the resistance and the electricity cost less
than the propane used. Induction heated
the valve the fastest and was quicker to
set up than the resistance. The induction
method also was the safest for the user,
with the whole valve being insulated and
heating coils that do not get hot.
If offline heating is employed,
propane is the cheapest, but with an open
Change of Address?
Moving?
Make sure delivery of your Welding
Journal is not interrupted. Contact
Maria Trujillo in the Membership
Department with your new address information (800) 443-9353, ext. 204;
mtrujillo@aws.org.
In-Line Inspection of
Resistance Spot Welds
for Sheet Metal Assembly
Chryslers Windsor Assembly Plant tries
out an ultrasonic real-time monitoring
system to track expulsion, electrode life,
and weld problems
the use of a nondestructive automatic inspection system is necessary for the sheet
assembly industry to stay competitive and
provide quality products at a low cost.
Real-Time Inspection
Technology
R. Gr. MAEV, A. M. CHERTOV, W. PEREZ REGALADO, and A. KARLOFF are with Institute for Diagnostic Imaging Research, University of Windsor, Windsor, Ont., Canada. A. TCHIPILKO is with Tessonics, Inc., Windsor, Ont., Canada. P. LICHAA, D. CLEMENT, and T. PHAN are with Chrysler Windsor Assembly Plant, Windsor, Ont., Canada.
This article is based on a paper presented at the Sheet Metal Welding Conference XV, Livonia, Mich., Oct. 25, 2012.
58
JANUARY 2014
59
Expulsion Detection
60
JANUARY 2014
part. Each part has nine welds. As welding through the part progresses, welds
are scanned and automatically characterized. At a certain part, the purpose failures were made by dropping the welding
current. The system has successfully recognized undersized welds and stopped
the robot.
At its current state, the system performs unsupervised testing of weld quality and qualifies the results using a threelevel grading: acceptable, marginal, and
unacceptable. Processing time of a single M-scan is about 150250 ms for a 3
GHz Pentium D processor. It depends
on the stack thickness and welding time,
which determine the width and height of
the M-scan. Special algorithms for efficient M-scan processing have been applied (Refs. 12, 13). The processing time
requirements are strict since average
cycle time is around 1.52.5 s/weld. The
Fig. 10 Weld quality dynamics over 24 h with cooling water tube failure at around 22 h.
WELDING JOURNAL
61
Conclusions
Ultrasonic in-process characterization of resistance spot welds has many
advantages over off-line methods, particularly adding the ability to inspect
more than 99% of the parts that would
otherwise go unchecked. In addition,
real-time monitoring of the process can
identify problems that occur and allow
control engineers to correct these problems before additional bad parts are produced. An example of a damaged watercooling pipe is illustrated in this article.
Use of the RIWA system provides an
opportunity to automatically correct bad
welds and prevent them in the future
product.
The inline ultrasound inspection system installed in the Windsor Assembly
Plant provides the capability to observe
the process of weld formation as well as
identify expulsion. Parameters such as
the moment of melting, liquid metal penetration depth, solidification, and cooling rates are used for quality characterization of every weld done at the installed
unit. In addition, statistics of weld quality over time are monitored from which
data regarding electrode wear and
process degradation can be inferred.
Such a tool is proving to be effective in
the harsh industrial environments of the
automotive assembly plant, and the benefits of such thorough quality inspection
are immediately clear.
Acknowledgments
The authors would like to thank the
Natural Sciences and Engineering Research Council of Canada (NSERC) for
support of this research together with
Chrysler
Canada,
through
the
NSERC/Chrysler Canada, Inc./ University of Windsor Industrial Research Chair
IRCPJ 260901-07 in Applied Physics and
Material Characterization.
References
1. Gould, J. E. 2012. Joining aluminum sheet in the automotive industry
A 30 year history. Welding Journal 91(1):
23-s to 34-s.
2. Sutter, J. E. 2004. In-process ultrasonic weld inspection and adaptive control. Sheet Metal Welding Conf. XI, Sterling Heights, Mich.
3. Rokhlin, S. I., Meng, S., and Adler,
L. 1989. In-process ultrasonic evaluation
62
JANUARY 2014
Bring
Brand Awareness
to Your
Your Company
By Placing YYour
our Product
Product Video
Video
on the AWS
AWS
W Website
Website
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salty@aws.org / (800) 443-9353, ext. 243
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lea@aws.org / (800) 443-9353, ext. 220
Sandra Jorgensen
sjorgensen@aws.org / (800) 443-9353, ext. 254
COMING
EVENTS
Metal & Steel Saudi Arabia 2014. April 710. Riyadh, Saudi Arabia. Visit www.metalsteelsaudi.com.
Pipelines Conference. March 4, 5. Sheraton Houston Brookhollow, Houston, Tex. Sponsored by the American Welding Society.
Topics to include current and future pipeline welding trends. Contact P. Henry, phenry@aws.org; (800) 443-9353, ext. 215.
ABB Robotics Technology Days and Open House. March 13, 14.
1250 Brown Rd., Auburn Hills, Mich. Offering workshops, training, and demonstrations. To register, visit www.abb.com/robotics;
call (800) 435-7365.
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Feb. 15
Feb. 15
Mar. 1
Mar. 1
Mar. 8
Mar. 8
Mar. 8
Mar. 8
Mar. 8
Mar. 15
Mar. 15
Mar. 15
Mar. 15
Mar. 22
Mar. 22
Mar. 29
Mar. 29
Mar. 29
Mar. 29
Apr. 5
Apr. 5
Apr. 5
Apr. 12
Apr. 12
Apr. 12
Apr. 12
Apr. 17
Apr. 19
May 3
May 3
May 3
May 3
May 10
May 10
May 10
May 10
May 31
June 7
June 7
June 7
June 14
June 14
June 14
June 19
June 28
June 28
June 28
EXAM DATE
Apr. 5
July 19
JANUARY 2014
www.aws.org
www
w.aws.org
.
AWS
A
W
WS International
Internationa Scholarship
"Thank you selecting me as a
2013-2014 recipient of a A
W
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AWS
International Scholarship. This
scholarship not only provides financial
support, it is also a source of
encouragement because of the
irreplaceable role A
W
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AWS
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will use this scholarship to continue my education as
every semester I am one step closer to making my
career aspirations a reality
reality.. Thank you for your
generosity
."
generosity."
Isira U. Abeyagunawardana
Ferris State University
W
eelding Engineering T
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Technology
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James A. T
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It is truly an honor to be chosen as
the 2013-2014 recipient for the James
A. Turner,
Turner
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, Jr
Catrina Fox
University of South Alabama
Business Administration
William
W
illiam H. Harrison
Jr.,
Scholarship (Mobile)
Jrr.,. Memorial Sch
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Zackery Br
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Ferris State University
Welding
Technology
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James W
Ozark Section Scholarship
"Being selected as a recipient for the
- Ozark Scholarship
James W.
W. Gardner
Ga
is an honor
honor.. I really appreciate this
award and will continue to work hard
in my pursuit of the Associate of
Applied Science Welding
Welding
e
T
echnology
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Technology
degree and the Associate of Applied
Science Drafting and Design degree, from Ozarks
Community College,
to prove my
Technical
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e
Coll
appreciation. This will all help me someday achieve
my long term goal of a career in the industry of
engineering."
Brie H. Jenkins
Community
Ozark Technical
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Weelding T
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Welding
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CONFERENCES
U.S./European Welding Standards
January 2628
Miami, Fla.
The American Welding Society (AWS) and Germanys
Gesellschaft fr Schweitechnik International (GSI) have partnered to deliver a unique conference at which U.S. and European
welding standards will be presented, compared, and discussed.
This conference will benefit engineers, inspectors, supervisors,
and quality control personnel who are familiar with only one set
of standards. Topics include welding standards covering structural
fabrication, pressure vessels, railway vehicles, and company certification. The format of the conference will be one expert presentation on the U.S. standards followed by an expert presentation
on the comparable European standards for each topic. There will
be open discussion allotted for each topic period.
Energy Conference
February 5, 6
New Orleans, La.
The demand for new and improved welding technology from
the expanding energy markets is starting to pay off in the development of superior hybrid welding processes, new filler metals,
and hosts of cladding procedures. The technologies are showing
up in nuclear power plants, coal-fired utilities, and especially in
the new 1700-mile-long pipelines designed to bring oil and natural gas to American markets.
Pipelines Conference
March 4, 5
Houston, Tex.
Welding has always been an integral part of pipeline construction, going all the way back to the days when hand-held oxyacetylene torches were used to connect pipes in the field. Current and
future pipeline welding trends will be discussed.
Aluminum Conference
May 28, 29
New Orleans, La.
The 17th Aluminum Welding Conference will feature a distinguished panel of aluminum-industry experts who will survey
the state of the art in aluminum welding technology and practice. This conference also provides several opportunities for you
to network informally with speakers and other participants, as
well as to visit an exhibition showcasing products and services
available to the aluminum welding industry.
For more information, please contact the AWS Conferences and Seminars Business Unit at (800) 443-9353, ext. 223, or e-mail
ablanco@aws.org. You can also visit the Conference Department website at www.aws.org/conferences for upcoming conferences
and registration information.
70
JANUARY 2014
www.aws.org
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WELDING
WORKBOOK
Datasheet 345
Excerpted from ANSI Z49.1: 2012, Safety in Welding, Cutting, and Allied Processes.
72
JANUARY 2014
Pipelines Conference
Mar
W
back to the days when hand-held oxyacetylene torches wer
r
re pipeline welding trends will be
AWS-sponsored confer
Highlights
Learn about the progress of new and innovative developments
in pipeline welding.
business growth.
AWS Conference attendees are awarded 1 PDH (Professional
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 223.
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
Dean R. Wilson
president
David J. Landon
vice president
David L. McQuaid
vice president
John Bray
vice president
W. Richard Polanin
director-at-large
Robert Roth
director-at-large
Harland Thompson
Dist. 2 director
Carl Matricardi
Dist. 5 director
WELDING JOURNAL
75
D. Joshua Burgess
Dist. 8 director
Robert Wilcox
Dist. 11 director
Robert Richwine
Dist. 14 director
Jerry Knapp
Dist. 17 director
John Stoll
Dist. 18 director
Pierrette Gorman
Dist. 20 director
lier, she worked as a research and applications
engineer at Optomec,
Inc.; welding engineer at
Wilson Greatbatch, Ltd.;
and a research technician
at EWI where she explored resistance welding
of dissimilar materials.
She holds two patents on
forming structures from
CAD solid models.
Shown at the Doral City Council meeting Nov. 13 are (from left) Adam Temple, Sandra Ruiz, Hidail Nuez, Jim Lankford, Mayor Luigi
Boria, Bettina Rodriguez Aguilera, Ana Maria Rodriguez, and Vice Mayor Christi Fraga.
The American Welding Societys
World Headquarters campus was voted to
receive the 2013 Keep Doral Beautiful
Award during a meeting of the Doral City
Council Nov. 13. The Society was nominated for the recognition by Adam Temple, interim director of code compliance.
76
JANUARY 2014
Tech Topics
A2 Committee Meets at EWI in Columbus
Shown during the Oct. 29, 30 A2 Committee meeting at EWI in Columbus, Ohio, are (from left) Richard Holdren, Secretary Stephen Borrero, Chris Lander, Chuck Ford, Dave Beneteau, Bob Anderson, Mike Ludwig, Chris Thurow, Pat Newhouse, Ben Finney, Bryan Worley, J.
P. Christein, and Brian Galliers. The Committee members met to discuss the revisions for AWS A3.0, Standard Welding Terms and Definitions, and A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination.
Standard for Public Review
D10.17M/D10.17:201X, Guide for
Welding Tubular Steel Vehicle Structures.
$35. Review expired 12/16/2013. E-mail B.
McGrath, bmcgrath@aws.org, to order a
copy. AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute in
1979. AWS rules require that all standards
be open to public review for comment during the approval process.
New Standards Projects
Development work has begun to revise
the following standards. Affected individuals are invited to contribute to this work.
F4.2:201X, Safety Guidelines for Proper
Selection and Safe Use of Welding Cables.
This document provides guidance on the
safe and proper selection of welding cables. This includes identifying specific criteria including minimum copper content,
gauge sizing, electrical performance, and
resistance for welding cable sizes. Stakeholders: Personnel involved in welding.
Contact Steve Hedrick, steveh@aws.org.
E-mail Chelsea Lewis, clewis@aws.org,
for information on the following projects.
C4.1:201X, Criteria for Describing Oxygen-Cut Surfaces. This set consists of a
plastic gauge with samples of oxygen-cut
surfaces, and a document including descriptive terms and illustrations of surface
cuts. Stakeholders: Oxyfuel gas cutters and
inspectors as an aid to identify acceptance
levels of oxygen-cut surfaces. C4.1 is referenced in several AWS D.1 structural
welding documents.
C4.2/C4.2M:201X,
Recommended
Practices for Safe Oxyfuel Gas Cutting Torch
David Trees (left) receives his Silver Member Certificate from Lee Kvidahl, a past
AWS president, during the Membership
Committee meeting Oct. 23 at AWS World
Headquarters in Miami, Fla. The Silver
Member Certificate is presented for 25
years of service to the Society.
tion of nozzles by torch operators. Stakeholders: Members of the oxyfuel gas welding and cutting community.
C7.2M:201X, Recommended Practices
for Laser Beam Welding, Cutting and Allied
Processes. This document can be used for
welding, cutting, drilling, and transformation hardening of various materials. These
recommended practices stress the process
basics, parameters, and applications.
Stakeholders: Members of the laser beam
welding industry.
WELDING JOURNAL
77
U.S. Experts Sought to Develop ISO Standard on Micro Melting Diffusion Bonding
The U.S. TAG (Technical Advisory
Group) that serves as the United States
National Committee to ISO/TC 44/SC 10,
Unification of Requirements in the Field
of Metal Welding, seeks United States ex-
of second-generation high-temperature
superconductors.
For complete information, contact Andrew Davis, managing director, technical
services, adavis@aws.org.
Member-Get-A-Member Campaign
Listed are the members participating in the June 1Dec. 31, 2013, campaign. Members receive 5 points for each Individual and 1 point for
each Student Member recruited. Standings as of Nov. 20. See page 85 of this Welding Journal for campaign rules and prize list or visit
www.aws.org/mgm. Call (800) 443-9353, ext. 480, for more information.
20+ Points
J. Compton, San Fernando Valley 85
J. Morris, Mobile 75
M. Anderson, Indiana 57
D. Ebenhoe, Kern 50
G. Fudala, Philadelphia 45
M. Box, Mobile 42
B. Scherer, Cincinnati 40
K. Rawlins, Columbia 31
M. Pelegrino, Chicago 30
S. Siviski, Maine 29
B. Trankler, West Tennessee 27
78
JANUARY 2014
P. Kreitman, Chicago 15
S. Lathrop, Puget Sound 15
S. Lindsey, San Diego 15
F. Oravets, Pittsburgh 15
S. Schulte, Kansas City 15
J. Terry, Greater Huntsville 15
R. Riggs, Tulsa 14
H. Hughes, Mahoning Valley 13
J. Goodson, New Orleans 12
R. Poirier, Tidewater 11
J. Carney, West Michigan 11
S. Robeson, Cumberland Valley 11
SECTIONNEWS
Shown during the Boston Sections tour are (from left) Dist. 1 Director Tom Ferri, Fitz Acheson, John Hamel, Kevin Noel, Dave Aubin, and
Jeff Mannette, Section chair.
Students participating in the Philadelphia Section program are (from left) Trace Say, Nick
Parrish, Malik Downing, Jacob Doll, and Daniel Fillipelli.
District 1
District 2
BOSTON
NOVEMBER 4
Activity: The Section visited Climax
Portable Machine and Welding Systems in
Amherst, N.H. Conducting the tour were
Fitz Acheson, John Hamel, Kevin Noel,
and Dave Aubin.
PHILADELPHIA/Parkside
CTE Student Chapter
OCTOBER 9
Activity: The Section members met at
Parkside High School Career and Technical Education Center in Salisbury, Md., to
District 3
79
The York-Central Pennsylvania Section members are shown at Legacy Innovations in November.
SOUTHWEST VIRGINIA
OCTOBER 17
Speaker: David McQuaid, AWS VP
Affiliation: D. L. McQuaid & Associates
Topic: Welding repairs and heat straightening
Activity: Following the talk, the Section
members toured the Altec Industries, Inc.,
facility in Daleville, Va. Stewart Harris,
Dist. 4 director, attended the event.
Shown at the SW Virginia Section tour are (from left) David Owens, Greg McQuaid, Chair
Bill Rhodes, speaker David McQuaid, Dist. 4 Director Stewart Harris, and David Cash.
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
ATLANTA
NOVEMBER 7
Activity: The Section members toured the
Applied Technical Services facility in Marietta, Ga., to study its weld testing and
training operations. Jason Loy led the tour
assisted by Jeff George and David Mock.
Southwest Virginia Section members are shown during their tour of Altec Industries.
YORK-CENTRAL PA.
OCTOBER 17
Activity: The members visited York
County School of Technology in York, Pa.,
to compete using the VRTEX virtual reality arc welding trainer. Dave Watson,
Lincoln Electric sales engineer, conducted
the contest. Jay Covert won the event.
JANUARY 2014
OCTOBER 16
Activity: The Section members joined
members of the Society of Naval Architects and Marine Engineers, headed by
Chair Alexandra Anagnostis, to tour the
Tampa Yacht Mfg. LLC facilities in Pinellas Park, Fla. The tour was conducted by
CEO Bob Stevens and Timothy Chalfant,
chief naval architect.
NOVEMBER 14
Activity: The York-Central Pa. Section
members visited Legacy Innovations, Inc.,
in York, Pa., to study the manufacture of
custom-made automobiles.
NOVEMBER 13
Speakers: Jessica McRory, Arehna Engineering, Inc.; and John Watson, L.R.E
Ground Services, Inc.
Topic: Detection and repair of sinkholes
Activity: Al Sedory received his Life Member Certificate for 35 years of service to
the Society. This Florida West Coast Section program was held at Spaghetti Warehouse in Tampa, Fla.
District 4
District 6
Lawson State Community College Student Chapter members are shown at the November meeting.
Shown at the Atlanta Section tour are (from left) Jeff George, Dist. 5 Director Carl Matricardi, David Mock, Jason Loy, and Chair David Ennis.
NIAGARA FRONTIER
OCTOBER 24
Speaker: Michael Tracy
Affiliation: Hypertherm
Activity: The Section members met at Erie
1 BOCES Workforce Development Center in Cheektowaga, N.Y., for a talk and
demonstration of plasma cutting. Twentyseven members and students attended the
program.
Shown Oct. 16 during the Florida West Coast Section tour are (from left) Bill Machnovitz,
Ray Monson, Chair Charles Crumpton III, Bob Stevens, Alexandra Anagnostis, and Timothy Chalfant.
NOVEMBER 5
Activity: Chuck Furman, terminal manager, gave a talk then conducted the Section members on a tour of Global Terminal, Port of Albany, N.Y. The facility is a
distribution center for ethanol, gasoline,
and crude oil.
District 7
81
The Birmingham Section and Lawson State C.C. Student Chapter members are shown at the November students night program.
The incoming Lawson State C. C. Student Chapter officers are (from left) Edward Lovell,
P. J. Phillips, Chair Caroline Cotton, Ryan Duke, Roderick Jemison, and Greg Anderson.
Shown at the New Orleans Section program are (from left) Chair Aldo Duron and presenters Eddie Harper, District 17 Director J. Jones, and Todd Taranto.
Shown at the Nov. 14 Mobile Section program are (from left) Ryan Harrison, Johnny
Dedeaux, and Chair Michael Zoghby.
New Orleans Section meeting participants are (from left) Vernon Delaune, Al Theriot, Chair Aldo Duron, John Marcade, host Rickey Fabra,
Mike Eilers, Ed Dixon, and Neal Keller.
82
JANUARY 2014
COLUMBUS
OCTOBER 9
Speaker: David Cook, team leader
Affiliation: Venturi Buckeye Bullet, The
Ohio State University Center for Automotive Research
Topic: Developing high-speed electric cars
Activity: The program was held at La Scala
Restaurant in Columbus, Ohio.
District 8
BIRMINGHAM/Lawson State
C. C. Student Chapter
NOVEMBER 12
Activity: The Section held its students
night program at Lawson State C. C.,
Bessemer Campus, for 55 attendees. Recruiters David Cobb, Carlos Lett, and
Erica Fleming discussed job openings and
worker benefits at Ingalls Shipbuilding in
Pascagoula, Miss.
Lawson State C. C.
Student Chapter
OCTOBER 29
Activity: The Chapter held its election of
officers. Elected were Chair Caroline Cotton, Vice Chair P. J. Phillips, Secretary Edward Lovell, Treasurer Ryan Duke, Publicity Chair Roderick Jemison, and Program Chair Greg Anderson.
District 9
MOBILE
OCTOBER 10
Speaker: Chip Fonde, safety director
Affiliation: Taylor-Wharton Cryogenics
Topic: Welding and cutting safety
Activity: The Section, in recognition of
breast cancer awareness, presented a pair
of pink safety glasses to each attendee. The
program was held at The Original Oyster
House in Spanish Fort, Ala.
NOVEMBER 14
Speaker: Johnny Dedeaux, senior fixed
equipment engineer
Affiliation: Hargrove Engineers + Constructors, Mobile, Ala.
Topic: Engineering before the Arc
Activity: Dedeaux was assisted by
coworker Ryan Harrison in his presentation detailing a new high-pressure separator used in an oil refinery. The Mobile Section has a new presence at www.facebook.com/awsmobilesection.
Shown are Drake Well Section members (from left) front row: Robert Fugate, Ronald Lang,
Jim Shore, Erick Speer, and speaker Ron Stahura; back row: Rolf Laemmer, Ward Kiser,
Mike Owens, and Delayne Jacobs.
NEW ORLEANS
OCTOBER 15
Speakers: Eddie Harper, district manager;
Todd Taranto, local representative; and J.
Jones, district director and AWS District
17 director
Affiliation: Harris Products Group
Topic: Brazing and soldering filler metals
Activity: The program was held at
Plumbers & Steamfitters UA Local 60 in
Metairie, La., hosted by Business Manager
Rickey Fabra.
District 10
DISTRICT 10
NOVEMBER 9
Activity: The District held its third Certified Welding Inspector (CWI) roundtable
for CWIs to share their experiences and
opinions. The 17 attendees discussed welding procedure specifications, simplified
DRAKE WELL
NOVEMBER 14
Speaker: Ron Stahura, sales manager
Affiliation: ESAB
Topic: Plasma arc cutting
Activity: The program was held at The
Commons at Franklin, Pa.
MAHONING VALLEY
OCTOBER 17
Activity: The Section held an executive
committee meeting at Rachels Restaurant
in Austintown, Ohio.
WELDING JOURNAL
83
Madison-Beloit Section members and students are shown at the October event.
Shown at the Madison-Beloit event are (from left) Chair Tony Stute, Dave Gilbertson, Rob
Stinson, James Chapman, Ben Newcomb, Chris Wierschke, and Jim Maynard.
Speaker Galen White (left) is shown with
Chuck Moore, Mahoning Valley Section
chair.
NOVEMBER 7
Speaker: Will Brick, manager
Affiliation: TechShop Detroit
Topic: Introduction to TechShop
Activity: The program was held at
TechShop Detroit in Allen Park, Mich.
District 12
David Havrilla conducts an automotive laser
welding class for the Detroit Section members in November.
NOVEMBER 7
Speaker: Galen White, welding engineer
Affiliation: Hobart Brothers
Topic: Trends in welding aluminum
Activity: This Mahoning Valley Section
program was held at Columbiana County
Career Center in Columbiana, Ohio.
District 11
Robert P. Wilcox, director
(734) 721-8272
rwilcox1@ford.com
84
JANUARY 2014
DETROIT
NOVEMBER 5
Speaker: David Havrilla, manager, products and applications
Affiliation: TRUMPF, Inc.
Topic: Fundamentals of automotive laser
welding
Activity: Havrilla led this 2-h class as part
of the Sections welding education series.
Forty attendees participated in the lecture
and demonstrations held at TRUMPF,
Inc., in Plymouth, Mich.
MADISON-BELOIT
OCTOBER 16
Activity: The Section members attended
the Madison Area Technical College open
house in Madison, Wis. They toured its recently expanded welding facilities and saw
its new waterjet cutting machine demonstrated by Instructor Jon Christian. Manufacturing representatives included Rob
Stinson (Lincoln), James Maynard and
Chris Wierschke (Miller), Dave Gilbertson (Encompass Gas of Madison), Ben
Newcomb (Badger Welding Supplies), and
Jim Chapman (Airgas).
Online: www.aws.org/membership
contact information
q New Member q Renewal
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Please check each box that applies to the Membership or service youd like, and then add the cost together to get your Total Payment.
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ONLY ONE SELECTION PLEASE. For more book choices visit www.aws.org/membership
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Welding Handbook Selections: q WH (9th Ed., Vol. 4) q WH (9th Ed., Vol. 3) q WH (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1)
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Note: Hard copy option applies to students in U.S., Canada and Mexico. Digital delivery of magazine is standard benefit for all student members.
PaYmEnt information
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card.
q Check q Money Order q AMEX
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q Other
St. Louis Section members are shown during their tour of AmerenUE.
Attendees are shown at the Racine-Kenosha Section tour of Wisconsin Oven Corp.
RACINE-KENOSHA
OCTOBER 23
Activity: The Section met at Wisconsin
Oven Corp in East Troy, Wis., to study its
operations. James Stewart, shop manager,
and Diana Dalgren, head of human resources, conducted a tour. Members of
Gateway Technical College Welding,
Elkhorn Campus, participated in the
event.
District 13
John Willard, director
(815) 954-4838
kustom_bilt@msn.com
Indiana Section awardees are (from left) Jack Laudig, Martina Miller, Erin Fromson, Gary
Dugger, and Steve Gillig.
District 14
INDIANA
ST. LOUIS
NOVEMBER 7
Activity: The Section held its annual
awards night hosted by Chair Bennie Flynn
of Flynn Welding Inspection in Solsberry,
Ind. Erin Fromson and Steve Gillig re-
NOVEMBER 7
Activity: The Section members toured the
AmerenUE training facilities in St. Louis,
Mo. The guides were John Baima, Laurie
Kutz, and Steve Zaitz.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
NORTHWEST
JULY 13
Activity: The Section visited the 3M facility in St. Paul, Minn., for a presentation on
new metal-removal products. Guiding the
tour were Brad Johnson, Scott Barnett,
Marv Schifsky, Nick Manor, Nate Herbst,
Jim Olson, and John Barry.
WELDING JOURNAL
87
IOWA
OCTOBER 24
Speaker: Nancy Cole, AWS president
Affiliation: NCC Engineering
Topic: Women in Welding
Activity: The program was held at Vermeer Mfg. Corp. in Pella, Iowa.
NOVEMBER 7
Activity: The Iowa Section members and
guests toured Kinze Mfg., Inc., in
Williamsburg, Iowa, for a presentation
on its planter assembly area.
AWS President Nancy Cole (center) is surrounded by the ladies attending the Northwest
Section dinner meeting.
KANSAS
OCTOBER 5
Activity: The Section and Hutchinson C.
C. personnel coached six Boy Scouts from
Troop 301 to earn their welding merit
badges. The event was held at the college
in Hutchinson, Kan.
OCTOBER 10
Activity: The Kansas Section members
toured the Caterpillar Work Tools facility in Wamego, Kan., led by Mike Jones,
plant manager.
Shown during the Northwest Section tour are (from left) Anna Wald, Traci Tapani, AWS
President Nancy Cole, and Lori Tapani.
The Iowa Section members are shown during their tour of Kinze Mfg. in Williamsburg, Iowa.
OCTOBER 14
Speaker: Nancy Cole, AWS president
Affiliation: NCC Engineering
Topic: Women in Welding
Activity: In the afternoon, Cole and the
Northwest Section members toured
Wyoming Machine in Stacy, Minn., a
company owned by two sisters, Co-Presidents Lori and Traci Tapani. CWI Anna
Wald serves as the companys QC manager. Afterward, Cole presented her talk
to more than 30 members and guests at
a dinner program held in Shoreview,
Minn.
District 16
Ric Eckstein (left), Northwest Section chair,
is shown with Brad Johnson at 3M in July.
88
JANUARY 2014
OCTOBER 19
Activity: The Section members coached
eight Boy Scouts from Arkansas City,
Kan., to earn their welding merit badges.
NOVEMBER 14
Speaker: David Landon, AWS vice president and manager of welding engineering
Affiliation: Vermeer Mfg. Co.
Topic: Virtual reality welding
Activity: Following the talk, Jamie Kappler (Lincoln Electric) demonstrated the
VRTEX360 virtual arc welding training system. Dennis Wright, Dist. 16 director, presented Diane Steadham the
District Meritorious Award. Chair Greg
Siepert presented Bob Simon his Silver
Member Certificate for 25 years of service to the Society. The meeting was held
at WATC National Center for Aviation
Training in Wichita, Kan.
KANSAS CITY
OCTOBER 22
Speaker: Nancy Cole, AWS president
Affiliation: NCC Engineering
Topic: Women in Welding
Activity: Cole and the Section members
toured the new welding facilities at
Kansas City Kansas C. C. Cole presented
Dist. 16 Director Dennis Wright the 2013
Image of Welding Award.
District 17
AWS President Nancy Cole poses with the Kansas City Section members.
Shown Oct. 19, the Kansas Section members and Boy Scouts celebrate the young welders earning their merit badges.
Diane Steadham receives the District Meritorious Award from Dennis Wright, Dist. 16
director.
Grant Von Lunen, chair, Kansas City Section, presents a speaker plaque to Nancy
Cole, AWS president.
Bob Simon (left) receives the Silver Member Certificate Award from Greg Siepert,
Kansas Section chair.
Kansas Section program helped six Boy Scouts earn their welding merit badges Oct. 5.
DISTRICT 17 Conference
Activity: Dist. 17 Director J. Jones presented Donnie Williams, North Texas Section chair, the District CWI of the Year
Award, and District Director Awards to
Caterpillar Work Tools & Services, Luminant Academy, Red Ball Oxygen, and Lincoln College of Technology for their sup-
The Kansas Section members are shown during their tour of Caterpillar Work Tools.
WELDING JOURNAL
89
OCTOBER 23
Activity: The Tulsa Section members visited Sherry Laboratories in Broken Arrow,
Okla., to tour the facility and learn about
its metallurgical and mechanical testing of
materials. Don Bunn, special projects engineer, conducted the program.
District 18
CORPUS CHRISTI
OCTOBER 17
Speaker: Jason Czajkowski, CWI, CWE
Affiliation: Applus RTD
Topic: Infrared thermographics
Activity: Czajkowski discussed and demonstrated infrared thermographic camera
technology and took room-light and thermal photos of the attendees. The meeting
was held at Craft Training Center of the
Coastal Bend in Corpus Christi, Tex.
HOUSTON
Attendees are shown at the District 17 conference in Waco, Tex.
OCTOBER 31
Activity: The Houston Section toured
Forged Components, Inc., in Humble,
Tex., to study the fabrication of ASME
pressure vessels and numerous other products. Chris Heitman and David Allen explained how forgings are made and conducted the tour.
EAST TEXAS
LAKE CHARLES
OCTOBER 24
Activity: The Section members toured
Southwest Fabrication and Coatings in
White Oak, Tex. Jerry Newman, executive
VP and general manager, conducted the
program.
AUGUST 21
Activity: Drew Fontenot shared his experiences as the Sections representative at
the Dist. 18 conference. The meeting was
held at Logans Roadhouse Restaurant in
Lake Charles, La., for 24 attendees.
Fontenot noted John Stoll was elected to
fulfill John Brays last year as Dist. 18 director effective Jan. 1 when Bray is installed as an AWS vice president.
TULSA
CWI Ryan Rummel (left) is shown with J.
Jones, Dist. 17 director.
port of AWS activities. Ryan Rummel, a
CWI and CWE, received the Section Meritorious Award for his support of the Central Texas Section and serving as advisor
to the Texas State Technical College Student Chapter. Joe Melendez received the
Central Texas Section Educator Award.
90
JANUARY 2014
OCTOBER 26
Activity: The Section held a seminar for
49 attendees at NCI Training Center. The
topics were welding procedure specifications and procedure qualification records.
The presenters were George Baldree, Ron
Theiss, Charles W. Patrick, and Scott
Witkowski. The class was arranged by
James Hansford, education chair.
OCTOBER 12
Activity: The Section sponsored a weeklong Certified Welding Inspector seminar
and weekend exams for 36 attendees. Abiodun Akinnibosun from Niger Delta Petroleum Resources, Ltd., traveled from Nigeria to take the exam. Test supervisors included Melissa Howard, Ethan Howard,
Barry Lawrence, Jim Otte, Tim Smith, and
Rich Howard. The activity was held at
DoubleTree Hotel in Tulsa, Okla.
SAN ANTONIO
OCTOBER 15
Speaker: Brian Parrish, strike construction foreman
Affiliation: Eagle Ford Shale Area
Topic: Automatic pipe welding in the field
Activity: John Bray, Dist. 18 director, presented several awards.
Shown are the Houston Section members who braved the elements Oct. 31 to tour the Forged Components plant.
Shown at the Houston Section seminar are George Baldree, Charles Patrick, Ron Theiss,
Scott Witkowski, and James Hansford.
District 19
BRITISH COLUMBIA
SEPTEMBER 25
Speaker: Scott Stanley, technical sales representative
Affiliation: The Lincoln Electric Co.
Topic: Virtual reality arc welding training
Activity: The meeting was held in Delta,
B.C., Canada.
OCTOBER 22
Speaker: Colin Stewart, senior welding inspector
Affiliation: SKC Engineering
Topic: Removing the Port Mann Bridge
Activity: At this British Columbia Section
program, the Bruce Third Memorial Welding Scholarship was awarded to Lorenzo
Webb, a welding student and a new Section member. Attending were Bruce
Thirds widow Violet, son Rob Third, and
Adriana Webb.
OLYMPIC/PUGET SOUND
NOVEMBER 5
Activity: The Sections hosted a 9-year CWI
recertification class at CK Worldwide in
Auburn, Wash. Ron Theiss taught the seminar, assisted by Sjon Delmore, Olympic
Section chair.
Colin Stewart (left) is shown with Scott Stanley at the British Columbia Section program.
WELDING JOURNAL
91
Shown at the Olympic/Puget Sound-sponsored seminar at CK Worldwide are (from left) Braidy Fernandez, Leonard Olson, John Jaques,
Eric Murray, Joseph Gallagher, Zeki Gokle, Jeffrey Rice, presenter Ron Theiss, Coby Bounds, William Gentry, Patricia Yates, Stephen Scheffle, Olympic Section Chair Sjon Delmore, David A. Vallejo, and Jeff Tuttle.
New Mexico Section members are shown during their tour of Horizon Trikes.
PUGET SOUND
Shown at the British Columbia Section are (from left) Violet Third, Rob Third, Lorenzo
Webb, Adriana Webb, and Brad Moe, Scholarship Committee chair.
92
JANUARY 2014
APRIL 4
Speaker: Nancy Cole, AWS president
Affiliation: NCC Engineering
Topic: Women in Welding
Activity: Robert J. Hollingsworth received
his Silver Member Certificate for 25 years
of service to the Society.
Shown during the Arizona Section tour are (from left) Daniel Hurst, presenter Ivan Insua, Robert James, Richard Pell, Jerry Siko, Paul
Moreno, Karl Kammerzell, Richard Moreno, Alan Gaiser, Nick Martinez, Keith Winchester, James Benjamin, Jordan Potterfield, and Fran
Johnston.
The Sacramento Valley Section members are shown during the Praxair tour.
SPOKANE
OCTOBER 24
Speakers: Phil Zammit, Brooklyn Iron
Works; and Jared Satterlund, Oxarc
Topics: Welding to AWS codes and nondestructive evaluation techniques
Activity: The program was held at Pullman
High School welding facility for more than
90 attendees including local industry members and students from North Idaho College. Equipment demonstrations were
conducted by Karl Susz (Lincoln Electric)
and Paul Stone (ESAB). Attendees participated in bending welder qualification
coupons and NDE techniques.
NOVEMBER 13
Activity: The Section members toured
Wear-Tek Foundry in Spokane, Wash. Jeff
Bailey and Bob Underhill conducted the
tour of the facility that specializes in manufacturing and heat treating parts for the
mining, power, and agriculture industries.
District 20
NEW MEXICO
OCTOBER 17
Speaker: Adolph Romero, CEO
Affiliation: Horizon Trikes
Topic: Fabrication and DOT requirements
for road-worthy vehicles
Activity: The meeting was held in Albuquerque, N.Mex.
District 21
ARIZONA
OCTOBER 11
Activity: The Section members toured Salt
River Project Kyrene Generating Station
in Tempe, Ariz. Ivan Insua, engineer, led
the tour and discussed where welding is
used in the plant.
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
SACRAMENTO VALLEY
OCTOBER 16
Activity: The Section members toured the
Praxair Gas Production Facility in Pittsburg, Calif. Bill Bright, general manager,
conducted the program.
WELDING JOURNAL
93
94
JANUARY 2014
Kimball Midwest
4800 Roberts Rd.
Columbus, OH 43228
MT Rigmat LLC
PO Box 190, Charlo, MT 59824
Hico ISD
PO Box 218, Hico, TX 76457
Jersey Village High School
7600 Solomon St., Houston, TX 77040
Joint Professionals & Support Intl, Ltd.
2 Tokunbo Alli St., Ikeja, Lagos
Nigeria
Langham Creek High School
17610 FM 529, Houston, TX 77095
Steelpipe, Ltd.
224 Neilson St., PO Box 13514
Onehunga 1643, New Zealand
INTERNATIONAL SALES
TECHNICAL SERVICES
Dean R. Wilson
deanwilsonaws@gmail.com
Welldean Enterprises
151 Oak Tree Circle
Glendora, CA 91741
PUBLICATION SERVICES
Director, Operations
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Technical Activities Committee
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
MARKETING COMMUNICATIONS
Human Resources
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
MEMBER SERVICES
GOVERNMENT LIAISON SERVICES
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors federal issues of importance to the industry.
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between members and AWS headquarters.
CERTIFICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(273)
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all international certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Accreditation Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification programs, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
WELDING JOURNAL
95
PERSONNEL
Intelligrated Hires VP
Intelligrated, Cincinnati, Ohio, an
automated material-handling solutions
provider, has named
David Erickson vice
president, software
development, for its
New York-based subsidiary
company,
Knighted. Erickson
previously held product development and
performance engineering positions for
David Erickson RedPrairie.
Aluminum Association
Makes Board Changes
The Aluminum Association, Arlington, Va., has announced the following
uct manager separation. With the company since 2006, Confer has served as a
technical sales representative and a team
leader and project
manager for the
Eriez Orange University
mobile
Bill Dudenhoefer training and education center. Since
2006, Dudenhoefer has served as separation product manager.
EB Industries Hires
Business Director
EB Industries, Farmingdale, N.Y., a
provider of electron beam and laser beam
welding services, has appointed John DeLalio director of new business development. DeLalio, with 23 years of experience in mechanical engineering and information technology positions, most recently served as senior director of enterprise architecture for NYC Health and
Hospitals.
Selective Soldering
Academy Names Director
The Selective Soldering Academy, Elk
Grove Village, Ill., has appointed Eddie
Groves director. In the soldering and selective soldering field for 25 years, Groves
worked with AT&T/Lucent Technologies
as a soldering process engineer and later
as a sales engineer for a soldering equipment manufacturer and soldering materials suppliers.
For info, go to www.aws.org/ad-index
96
JANUARY 2014
Weldcote Metals,
a supplier of welding
alloys, electrodes,
helmets, and accessories, has named
Dave Colwell midwest regional sales
representative. Colwell, with 30 years experience in the weldDave Colwell
ing, brazing, and soldering industries, is
an AWS Certified Welding Inspector who
has judged SkillsUSA contests for 15
years.
continued on page 98
PERSONNEL
continued from page 96
Caterpillar Names
Project Manager
Caterpillar, Inc.,
has assigned Jacob
Shorey to Sosnowiec,
Poland, to serve as
project manager for
the expansion of a
heavy fabrications
and welding factory.
Shorey, an AWS
member, was hired
Jacob Shorey
into
Caterpillars
Manufacturing Professional Development program in 2006 as its first welding
engineering technology graduate. Prior
to this assignment, he has held several
roles and assignments in welding engineering and manufacturing.
Obituary
James H. Walker
Member Milestones
WeiJie Zhang
WeiJie Zhang
WeiJie Zhang has received the prestigeous IIW Henry Granjon Prize in Category D,
Human-Related Topics, in recognition for his paper, Modeling of Human Welder Behavior. Zhang received his masters degree in electrical engineering/control from Harbin Institute of Technology, China, in 2007, then joined the University of Kentucky at Lexington in 2008 as a research assistant and PhD candidate in the Welding Research Laboratory. His research interests include sensors, arc welding processes, and system identification and control. He has published more than 20 papers in peer-reviewed publications
including the Welding Journal, Measurement Science and Technology, and Manufacturing
Science and Engineering Transactions of ASME. Five of his papers studying human behavior during welding operations have been published in the Welding Journal Research Supplement. The paper he submitted at 2012 IEEE Symposium on Industrial Electronics
was ranked in the top ten of more than 300 papers submitted. His biography as a promising welding researcher was featured in the May 2012 Welding Journal.
Damian J. Kotecki
Damian Kotecki
98
JANUARY 2014
Damian J. Kotecki, AWS president 20052006, has received the International Institute of Welding Yoshiaki Arata Award. This lifetime achievement award is presented to
a person who has made extraordinary achievements in fundamental research in welding
science and technology and its allied processes, which have been recognized as significant contributions to the progress of welding engineering and related fields. The award,
sponsored by the Japanese Delegation to the IIW, has been presented annually since
1994 to pay tribute to the career of Prof. Dr. Yoshiaki Arata who devoted years to the
development of ultrahigh energy density heat sources and their applications to welding,
cutting, and other thermal materials processing.
INTERNATIONAL UPDATE
continued from page 8
To highlight the introduction of a plasma cutting line for manual and mechanized plasma processes, and its evolvement into
a full line thermal cutting original equipment manufacturer,
Thermacut, Inc., Claremont, N.H., has changed its corporate
logo and the slogan to The Cutting Company.
COMING EVENTS
The Association for Manufacturing Excellence, Rolling Meadows, Ill., is honoring Bombardier Aerospace with a 2013 Manufacturing Excellence Award. When evaluating its Toronto
site, the assessment team was impressed by the use of tools
that drive continuous improvement.
Joining Technologies, East Granby, Conn., now offers capabilities in both laser beam and electron beam welding. The
company is using its expanded capabilities to take on
more welding projects in the medical device and aerospace
industries.
Educational Opportunities
LAM Laser Additive Manufacturing Workshop. March 12, 13.
Houston, Tex. Laser Institute of America; (800) 345-2737;
www.lia.org/lam.
Hypertherm Cutting Institute Online. Includes video tutorials,
interactive e-learning courses, discussion forums, and blogs. Visit
www.hyperthermcuttinginstitute.com.
E-Courses in Destructive and Nondestructive Testing of Welds.
Online video courses taken at ones own pace offer certificates of
100 JANUARY 2014
INTEG Courses. Courses in NDE disciplines to meet certifications to Canadian General Standards Board or Canadian
Nuclear Safety Commission. The Canadian Welding Bureau;
(800) 844-6790; www.cwbgroup.org.
Laser Safety Online Courses. Courses include Medical Laser
Safety Officer, Laser Safety Training for Physicians, Industrial
Laser Safety, and Laser Safety in Educational Institutions. Laser
Institute of America; (800) 345-2737; www.lia.org.
Laser Safety Training Courses. Courses based on ANSI Z136.1,
Safe Use of Lasers, Orlando, Fla., or customers site. Laser
Institute of America; (800) 345-2737; www.lia.org.
AWS Conference on
Energy
The demand for new and improved welding technology from expanding and established
energy marketsis
off
tsis starting to pay of
ff in the development of superior hybrid welding processes,
new filler metals, and cladding procedures. The technologies are showing up in nuclear power
plants, in coal-fired utilities, renewable sources, and especially in the new 1,700-mile-long
pipelines designed to bring oil and natural gas to world markets.
CLASSIFIEDS
CERTIFICATION
& TRAINING
MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1-Ton thru 60-Ton
Tank Turning Rolls
2014
CWI PREPARATORY
Guarantee Pass or Repeat FREE!
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184
Our products are made in the USA
CERTIFICATION
& TRAINING
SERVICES
Closing date is
February 14, 2014
Call the AWS sales team at:
(800) 443-9353
Rob Saltzstein at ext. 243
salty@aws.org
Lea Paneca at ext. 220
lea@aws.org
Sandra Jorgensen @ ext. 254
sjorgensen@aws.org
Lea Paneca
lea@aws.org
(800) 443-9353, ext. 220
Sandra Jorgensen
sjorgensen@aws.org
(800) 443-9353, ext. 254
ADVERTISER
INDEX
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460
Midalloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
www.midalloy.com . . . . . . . . . . . . . . . . . . . . . . . .(800) 776-3300
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
www.cor-met.com . . . . . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
www.us.trumpf.com . . . . . . . . . . . . . . . . . . . . . .web contact only
Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
www.greinerindustries.com . . . . . . . . . . . . . . . . .(800) 782-2110
Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
www.weldengineering.com . . . . . . . . . . . . . . . . . .(508) 842-2224
Hypertherm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
www.hypertherm.com . . . . . . . . . . . . . . . . . . . . . .(800) 643-0030
ABSTRACT
Gas flows in and around welding arcs have a strong influence on the welding process.
Atmospheric gases reach the arc due to turbulences and diffusion mechanisms and this affects the arc and the weld pool. Using optical analysis of the gas flow during welding with
and without the arc present reveals possible mixing and thus the causes of contamination
can be determined. The Schlieren method offers a simple way to do this. In this paper, the
setup of a Schlieren measuring system and the influence of the most relevant setting parameters are described as well as their influence on the Schlieren images.
Introduction
In gas tungsten arc welding (GTAW)
the arc and the weld pool are protected
against the influence of atmospheric gases
by a shielding gas. Contamination of the
shielding gas leads, among other things, to
arc instability, oxidation, porosity, and
spatter. Furthermore, atmospheric gases
such as oxygen, carbon dioxide, or nitrogen affect the characteristics of the plasma
and influence the arc spots at the cathode
and anode. Therefore, one important goal
of welding torch development is to generate an optimal gas flow through the welding torch in order to guarantee a stable
and protective shielding gas coverage. To
achieve this, it is most important to avoid
flow separation and turbulence in the
shielding gas nozzle.
In order to minimize the experimental
effort by performing numerous welding
experiments, computational fluid dynamics and gas flow diagnostics can be used.
Dipl.-Ing. E. SIEWERT, Dr.-Ing. G. WILHELM,
M. HSSLER, Prof. Dr.-Ing. J. SCHEIN, and Dr.
T. HANSON are with Center of Excellence AAP
(advanced arc processes), a coop of Linde AG Co.
and the Lab of Plasma Technology, University of the
German Federal Armed Forces, Munich, Germany.
Dipl.-Ing. M. SCHNICK and Prof. Dr.-Ing. U.
FSSEL are with the Department of Joining Engineering and Assembly Technology, University of
Technology, Dresden, Germany.
KEYWORDS
Shielding Gas
Gas Contamination
Gas Flow Dynamics
Gas Tungsten Arc
Gas Metal Arc
Plasma Arc
WELDING RESEARCH
means of the generated intensity of illumination dispersion E, which is proportional to the second derivation of the
density along path y (Equation 2).
2
2 y
(2)
y
(3)
In contrast to the interference method, the
Schlieren technique is a simple and robust
measuring system. However, an exact
identification of gas flow characteristics is
not possible.
The experimental setup is carried out
as a Toeplers Z-Schlieren assembly with
two concave mirrors Fig. 2. This assembly is compact and avoids errors due
to chromatic aberration caused by the optical lenses.
The concave mirrors are axially parabolic mirrors with a diameter of 150 mm
and a focal length of 1200 mm. The diameter lies in the recommended area from D
= f/6 to f/12 (Ref. 6). In the region between both mirrors, parallel light is generated. In this optical path, different welding
arcs (Schliere) are inserted, influencing
the propagation of the parallel light. In the
focus of the first mirror, an aperture is
placed to produce a point light source enabling the production of parallel light by
mirror 1.
The knife edge is placed in the focus of
mirror 2. The knife edge is used to improve the contrast by blocking the deflected light. Images of the Schlieren are
generated by a high-speed camera with a
200-mm objective with a macrolens.
The exact position in which the
Schliere is arranged between the two mirrors has no influence on the measurement
outcome. The deflection level of the light
a in the Schlieren aperture depends only
upon the angle of deflection and the focal
length f of the mirror.
E
Fig. 3 Schlieren images, used filter pairs: blue/yellow (left) and red/green (right) with a shielding gas
flow of 30 L/min of argon.
WELDING RESEARCH
scribed the necessity for a gas flow analysis. However, their work contained no corresponding results or Schlieren images.
Allemand and Schroeder (Ref. 12) used
the Shadowgraph method (Ref. 6) in order
to visualize the drop transfer during gas
metal arc welding. For illumination, a HeNe laser was used. The photographs are,
however, overexposed due to the presence
of the arc and the drop transfer was difficult to observe.
This paper describes an attempt to use
the Schlieren technique to visualize the
shielding gas flow in different arc welding
processes. The principle of operation and
the experimental setup of the Schlieren
technique are described. The most important settings and their influence on the
quality of the Schlieren images of GTA are
described so that the range of application
and the limit of the Schlieren technique
can be specified. The results of the gas
flow analysis for GTA, GMA, and plasma
arc welding (PAW) are presented, where
the influences of typical welding parameters on the gas flow are displayed.
Experimental Procedure
Physical Principle and Measuring System
2-s
ity c and in the direction of light propagation direction, can be visualized in transparent media. The angle of refrac-tion
relates itself to the incident angle
sin c2 n2
=
=
sin c1 n1
(1)
a = f
(4)
Fig. 4 Schlieren image of a 100-A gas tungsten arc with vertical (top)
and horizontal (middle) apertures, and an iris (bottom).
Fig. 6 Schlieren images made by using 50-W automobile headlight (top, left), 150W tungsten coiled filament lamp (top, right), 250-W tungsten coiled filament lamp
(bottom, left), and 150-W halogen lamp (bottom, right).
WELDING RESEARCH
Fig. 5 Images of Schlieren setups with a 3 6 mm focus slit and a Schlieren aperture slit of 2 6 mm (left), 3 6 mm (middle), and 5 6 mm (right).
WELDING RESEARCH
Fig. 7 Schlieren images made by using 250-A plasma arc (left) and 20-mW continuous wave laser (=
532 nm) (right).
Fig. 8 Schlieren images of GTAW as a function of current, shielding gas, and flow rate.
PAW
Fig. 9 Schlieren image of a pilot arc (3 L/min plasma gas flow) where the hot plasma jet is clearly observable. The impinging hot gas on the workpiece and the effluent hot gas on the surface of the workpiece are visible by a dark plateau. Stalls in the periphery are detected by means of eddies.
4-s
Investigating plasma arc keyhole welding was carried out by bead-on-plate welds
(6-mm-thick, mild-steel plates). To ignite
the main arc between the tungsten cathode and the workpiece, a pilot arc between
the cathode and the copper nozzle
(anode) must be initialized. The pilot arc
serves as preionization of the arc gap between the electrode and the workpiece
Fig. 9. The Schlieren method is excellently
suited to image the gas flow of the pilot
arc. An advantage is the low radiation
emission of this plasma jet.
The Schlieren images of real keyhole
welding trials were correlated with the respective welding results Fig. 10.
Clearly visible at low shielding gas flow
rates is that the fluid flow above the hot
weld joint (left of the torch) is dominated
by thermal buoyancy. In contrast, above
the cold steel sheet (right of the torch) an
equal and laminar outflow can be seen.
With higher shielding gas flow rates, the
differences between the gas flows over the
hot and the cold steel sheet are less pronounced. It is assumed that the high
shielding gas flow counteracts the thermal
buoyancy as well as causing the outflowing
tion enables
cost-efficient
and time-resolved gas flow
Fig. 10 Schlieren images of plasma arc welding (S235, 6 mm; welding speed, 20 analysis.
2) It was ascm/min; PG-flow, 3 L/min; plasma gas three-hole-nozzle, 3 mm; torch distance, 5
certained that a
mm; shielding gas flow 5 L/min (top); 15 L/min (bottom).
powerful tungsten filament
gas to deviate from laminar flow. Using
lamp and arcs were especially appropriate
low shielding gas flows, a considerable foras light sources. In contrast, inferior immation of oxides can be determined, which
ages were obtained with widened laser
is due to contamination of the protective
beams.
cover. It must be concluded that the for3) It is possible to detect the transition
mation of a turbulent gas flow (15 L/min
from a laminar to a turbulent gas flow in a
shielding gas) does not always lead to bad
process gas-free jet in GTAW by increasgas protection cover of the weld pool. A
ing the shielding gas flow from 10 to 30 L/
sufficient gas flow is necessary in order to
min.
counteract the thermal buoyancy above
4) Through the Schlieren method, the
the hot workpiece.
gas flow of a nontransfer pilot arc can be
excellently visualized. During studies on a
GMAW
plasma arc keyhole welding process, it was
shown that high shielding flow rates, deGas metal arc welding is characterized
spite intensive turbulences, provide a betby a high radiation emission of the metal
ter protection of the process and
vapor plasma. Schlieren images of gas
counteract diffusions effects.
metal arc welding processes are therefore
5) First investigation on GMAW
especially difficult to create at high curprocesses showed that high torch temperrents. As part of the investigations,
ature principally abets the Schlieren analySchlieren images were taken of a short arc
sis of the process gas-free jets. Due to the
Fig. 11. In the images, gas flow separahigh radiation emission of the arc, powertions at the shielding gas nozzle and the
ful illuminants in combination with optical
contact tip are, in contrast to GTAW,
filters are necessary, especially in the
clearly visible. A reason for that is the
analysis of spray and pulsed arcs.
high, very hot contact tip located inside
the shielding gas nozzle caused heating of
References
the shielding gas.
For the analysis of a pulsed arc or a
1. Schnick, M., Fssel, U., and Zschetzsche,
spray arc, it is necessary to use powerful
J. 2006. Simulation and measurement of plasma
light sources or to mitigate wavelengths
and gas flows in plasma arc welding and cutting.
with special intensive radiation emission
8th International Seminar Numerical Analysis
of the arc by filters.
of Weldability, Graz, Austria.
Conclusions
The Schlieren method was used to visualize gas flows in welding processes. The
main conclusions are as follows:
1) The Topler Z-Schlieren configura-
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
Detailed investigations, including wetting studies by liquid metals and metal coatings deposition onto ceramic surfaces and brazing processes, were carried out for
semiconducting and ferroelectric perovskite ceramic states of barium titanate
(BaTiO3). Pure metals (Cu, Ag, Au, Ge, Sn, Pb, Ga, In, Al, Si, Ni, Co, Fe, Pd) and
Ti-containing alloys based on In and binary Cu-Sn, Cu-Ga, and Cu-Ag systems were
investigated under high vacuum for the semiconducting BaTiO3-x surface. The degree of wettability correlates approximately with the chemical affinity of the liquid
metal phase to oxygen (wetting increases when the liquid metal affinity to oxygen increases). Addition of Ti to the liquid metal phase increases capillary properties and
adhesion in the system under investigation. Investigations of the wettability of ferroelectric BaTiO3 ceramics were performed in air gaseous media by alloys Ag-Cu-O.
Oxygen in the gaseous media preserves stoichiometric composition of barium titanate and being dissolved in Ag-Cu alloys promotes BaTiO3 wetting. For the first
time, wettability experiments in liquid metal/ceramic material systems (BaTiO3 in
this case) were carried out when the gaseous phase was pure oxygen. At greater oxygen partial pressure (1 atm for O2 comparing to 1/5 atm for air), wettability further
increases significantly. Vacuum brazing technology for semiconducting materials and
joining processes in air or pure oxygen atmosphere for ferroelectric ceramic materials based on BaTiO3 have been developed. Various detailed brazing models of
BaTiO3 and BaTiO3-x were created.
Introduction
The perovskite-type structure ceramic
materials, such as barium titanate, play a
major role in modern electronics and electrical engineering. Barium titanate (BTO)
is widely used for creating multilayer ceramic capacitors (MLCCs), embedded decoupling capacitors (EDC), electrical ceramic filters, and other piezoelectric and
ferroelectric components (Refs. 13). Ferroelectric ceramics are ideal for use in supersonic equipment.
On the base of these materials, a ferroelectric memory device was created (Refs.
4, 5). Barium titanate is also an excellent
photorefractive material (Ref. 6).
Oxygen release that occurs during the
annealing of BaTiO3 in high vacuum and
T. V. SYDORENKO and YU. V. NAIDICH
(tvsid@ukr.net) are with the I.M. Frantsevich Institute of Problems of Materials Science NAS of
Ukraine, Kyiv, Ukraine.
6-s
KEYWORDS
Wetting
Metalization
Brazing
Barium Titanate Ceramics
and semiconducting with molten metals that will allow doing further steps in
understanding metal-perovskite ceramics
interaction and elaboration of some brazing alloys and technological processes for
joining (brazing) of BaTiO3 materials.
Semiconducting BaTiO3-x
Nonstoichiometric semiconducting
BaTiO3-x can be obtained by means of annealing in high vacuum, as is mentioned
above. It is believed that BaTiO3-x nonstoichiometry is insignificant and will not exceed such parameters for pure titanium
oxide TiO2-x. For this oxide, the x value is
between 0.04 and 0.07 (Ref. 12). Such deviation only has a minor effect on mechanical and thermodynamic properties of
the compound, except for the electrophysical characteristics.
Such nonstoichiometry variation can
be attributed to oxygen vacancies compensated mostly by background and/or intrinsic acceptors within higher oxygen partial pressure (p(O2)) regions and by
electrons within lower p(O2) regions (Ref.
13). Semiconducting BTO has specific resistivity value near 300 cm (compared to
about 10610 cm for ferroelectric
BaTiO3).
The technology of vacuum metalization and brazing by melts containing titanium as a chemically active element was
Experimental and
Discussion
WELDING RESEARCH
Cu-Sn-Ti
transition zone
BaTiO3
WELDING RESEARCH
C-1
C-2
C-3
C-4
Fig. 4 Microstructure of (Cu-8.6 Sn) 25 Ti-BaTiO3 interface. A 1000; B distribution of elements at interface, % (at.); and C characteristic emission of elements at BaTiO3 molten metal interface (top part ceramics, bottom part alloy) with barium (1), titanium (2), tin (3), and copper (4).
8-s
Table 1 The Results of Wetting of Semiconducting Barium Titanate by Some Pure Metals
Metal
Temperature,
Cu
1373
1223
102 [9]
610
Ag
1253
1273
1373
1363
1321
1292
90 [10]
139 [9]
134 [9]
260
310
345
Au
1353
1271
445
1423
1242
114 [10];
124 [9]
119 [9]
Ge
1273
1133
375
Sn
873
973
1201
1152
138 [9]
285
330
In
673
773
873
1521
1322
1172
70
195
325
Pb
673
773
873
973
1452
1344
1183
1094
143 [9]
138 [9]
80
140
250
320
Pd
1860
1163
845
Ni
1743
1131
1030
Fe
1823
962
1350
Si
1733
841
830
Al
1073
1173
1273
1373
1423
1473
1401
1362
1293
931
852
782
210
250
340
880
1015
1140
Co
1793
1082
1245
Work of Adhesion,
MJ/M2
490
WELDING RESEARCH
Fig. 5 X-ray diffraction patterns of the BaTiO3 (Cu-28 Ti) system. A 1280 K; B 1370 K.
WELDING RESEARCH
Fig. 6 The samples of the semiconducting BaTiO3 ceramics metalized and brazed in vacuum using the following: A In-Ti alloys; B Ag-Cu-Ti paste.
be accounted for the explanation of a wetting-in system studied at high temperatures. The same data were published, for
example, in Ref. 24 for Al2O3 systems.
Varying wetting effects of titanium in different systems studied Cu-Ag, Cu-Ga,
Cu-Sn (Fig. 3) can be explained by several reasons, in particular by various thermodynamic activity of titanium in alloys.
Ag-Cu-Ti alloys demonstrate some peculiarity. A eutectic system with about
60% (at.) of silver can dissolve in about
2% (at.) of titanium at 1270 K. A titanium
content increase leads to arising the second equilibrium liquid phase that contains
64% (at.) of Cu, 28% (at.) of Ti, and 8%
(at.) of Ag (Ref. 14). The mechanism details of such interface processes in a complex BaTiO3 (AgCuTi)phase I (Ag
CuTi)phase II system requires special
consideration. It is possible now to note
only that this process can be useful for improving adhesive bonding of BaTiO3 to
Table 2 The Result of Measurements of the Shear Strength of Brazing Barium Titanate
Ceramic Samples
Shear Strength of Brazing Ceramic Samples, MPa
AgCuO
464
10-s
AgCuPtO
283
InTi
202
CuSnTi
423
AgCuPbTi
412
faces by such metal is required. Theoretically (Ref. 14), for producing continuous
film of liquid metal, spreading factor (K)
has to be positive (Equation 1).
K = WA WC
(1)
Fig. 7 Scheme of the shear strength test for the brazed ceramic samples.
Fig. 9 Scheme of the apparatus for determining the contact angle of metal
melts in the air (oxygen) atmosphere. The labeled numbers represent the following: silica tube (1); furnace (2); heat transparent screen (3); digital camera (4); metal refractory wire (5); and metal sample on the BaTiO3 ceramic
substrate (6).
thermal expansion mismatch can considerably lower the strength of the joint. Applying indium-based alloys having high
plasticity is especially expedient for metalization and joining BaTiO3 ceramics.
Additionally, the technology of brazing and metalization BTO was realized
using capillary impregnation of low-melting braze alloys through titanium powder. For such alloy cleanliness, titanium
powder was obtained from TiH dissociating into titanium and hydrogen during
heating. The indium was deposition on
the titanic powder layer onto a BaTiO3
ceramics surface. During heating up to
970 K, indium spread well over the whole
BaTiO3 surface and filling brazing gap.
The thin film of In-Ti is easily formed on
the surface of perovskite ceramic in such
conditions Fig. 6B.
Ferroelectric BaTiO3
Barium titanate with a stoichiometric
structure having high ferro- and piezoelectric characteristics can be heated up
without any changes only within a oxygencontaining environment (in air). For such
materials joining, special braze alloys and
technological processes are required.
Oxygen being dissolved in some metals
leads to a substantial increase of wetting
degree and adhesion of these metals to ceramics. The oxygen effect on wetting and
also on interface and surface tension of
metal melts was investigated earlier in our
works (Refs. 14, 2528). It has been shown
that oxygen effectively increases the adhesion of Cu, Ag, Ni, and some other metals
to ionic compounds,
for example, to oxides. Several systems
(Cu-O-Al2O3, Cu-OMgO, Ni-O-Al2O3,
Ag-O-Al2O3, Ag-CuO-Al2O3) were studied in detail. The AgCu-O system is
especially interesting. We have made
the assumption that
the oxygen technology will work for
Fig. 10 Dependence of contact angle for the ferroelectric BaTiO ceramic
ferroelectric barium by Ag-Cu-O melt in air environment and oxygen on concentration 3of copper
titanate as well. Ac- at 1250 K.
cording to Refs. 14,
15, oxygen that has
Experimental Data and
sufficient affinity to an electron, being disDiscussion
solved in liquid metal, will increase the
wettability of a surface for ionic or ionFor ferroelectric BTO ceramic, expericovalent substances.
ments and technological processes were
Up to now, there are only solitary works
carried out per method in air media and, for
concerning the possibility of a perovskite
the first time, under pure oxygen atmoscompound (Pb (Mg0.33Nb0.67) O3) for wetphere using the sessile drop method as well.
ting and joining by Ag-CuO alloys (Ref. 29).
For this purpose, a special device was creScientific background of this process is not
ated Fig. 9. Experiments were carried out
developed; the reasons for oxygen influence
in oxygen flow with the partial pressure of
on wetting are not explained in this work.
oxygen about 1 atm at 1250, 1320, and 1370
Thus, the investigation of wetting ceK. Technical pure oxygen was used. But the
ramic ferroelectric materials based on
oxygen is reactive. Pure oxygen at high presBTO, elaboration of braze compositions
sure, such as from a cylinder, can react vioand technological conditions for brazed
lently with common materials such as oil
BTO ceramic joints, and creation of
and grease. Take all reasonably practicable
strongly adherent metal coatings on the ferprecautions to ensure safety to prevent oxyroelectric perovskite ceramic surfaces were
gen enrichment by keeping oxygen equipthe main purpose of the present work. The
ment in good condition and taking care
Ag-Cu-O system alloys were used as a braze
when using it. Good ventilation will also realloys base.
WELDING JOURNAL 11-s
WELDING RESEARCH
WELDING RESEARCH
tion for metal-oxygen complex surface activity. Adsorption of metal ions on the
negative charged oxide surface results in
high adhesion.
The temperature increase intensifies
the wetting process; contact angle decreases to 2530 deg in air (with 10 % (at.)
of Cu in liquid Ag). For pure oxygen, full
spreading can be reached with Cu content
at about 67% (at.).
The high capillary activity of alloys in a
pure oxygen atmosphere is caused by a
high equilibrium concentration of oxygen
in melt under high oxygen partial pressure
(1 atm). Oxygen partial pressure for the
air is 0.21 atm. Concentration of oxygen
that saturates metal melt is described by
Sivertss law (in many cases) (Refs. 31, 32),
O liquid
2
metal
=k
p (O )
2
(2)
(3)
Transitive zone
Fig. 12 Cross section of Ag-Cu-O drop (top part) on surface of the ferroelectric BaTiO3. A In air; B in oxygen.
Conclusion
(4)
WELDING RESEARCH
Ag
12. Tretyakov, YuD. 1974. Chemistry of Nonstoichiometric Oxides. Moscow University Publishing Co., Moscow, Russia.
13. Lee, D.-K., and Yoo, H.-I. 2001. Oxygen
nonstoichiometry of undoped BaTiO3. Solid
State Ionics 144(1-2): 8797.
14. Naidich, Yu. V. 1981. Eds. Cadenhead,
D. A., and Danielli, J. F. Progress in Surface
Membrane Science, 14. Academic Press, Inc.,
New York.
15. Naidich, Yu. V. 1972. The Contact Phenomena in Metal Melts. Naukova Dumka, Kiev.
16. Eustathopoulos, N., Sobczak, N.,
Passerone, A., and Nogi, K. 2005. Measurements of contact angle and work of adhesion at
high temperature. J. Mater. Sci. 40: 22712280.
17. Shimbo, M., Naka, M., and Okamoto, I.
1989. Wettability of silicon carbide by aluminum, copper and silver. J. of Mat. Sci. Lett. 24:
663669.
18. Fujii, H., and Nakae, H. 1996. Equilibrium contact angle in the magnesium oxide/aluminum system. Acta. Mater. 44: 35673573.
WELDING RESEARCH
14-s
ABSTRACT
Weld metal deposited by flux cored arc welding that exhibited a combination of high
strength and toughness was studied. Microstructural characterization revealed it contained primarily bainitic ferrite with a fine packet size in the as-deposited metal and
mainly nonaligned ferrite in the reheated zones, which were concentrated near the root
of the weld. A new type of spherical inclusion is reported with an average size of 311
nm in diameter that exhibits a shelled structure mainly rich in Al, Mg, and O in the
core, and Mg, O in the outer shell. It is suggested the good properties stem from a
combination of fine inclusion size, low content of interstitials, and small ferrite packet
size. Instrumented impact testing indicates that grain refinement in reheated zones
near the root of the weld improve the Charpy impact energy; however, fracture initiation energy is similar to the top of the weld.
Introduction
This research focuses on the use of a
novel flux-cored arc welding wire formulation, which appears to depart from the
typical mechanisms of microstructural development, resulting in outstanding weld
metal strength and toughness. The traditional strategy for achieving a combination
of high strength along with good lowtemperature toughness in high-strength
weld metals is to promote an acicular ferrite microstructure (Refs. 14). This microstructure consists of fine interlocking
ferrite needles, with high grain boundary
misorientations to promote grain boundary strengthening together with crack deviation during cleavage fracture at low
temperatures (Refs. 5, 6). The nucleation
of acicular ferrite occurs intragranularly in
austenite on inclusions, and commercial
weld consumables rely on Ti and Al additions to form inclusions such as TiOx, TiN,
and MnO. Al2O3 (Refs. 79). The nucleation of acicular ferrite depends on achieving a large volume fraction of inclusions
A. P. GERLICH is with University of Waterloo,
Mechanical and Mechatronics Engineering, Waterloo, Ontario, Canada, H. IZADI and P. F.
MENDEZ are with University of Alberta, Chemical and Materials Engineering, Edmonton, Alberta, Canada, J. BUNDY is with Hobart Brothers, Troy, Ohio.
KEYWORDS
Flux Cored
Microstructure
Phase Formation
Oxide Inclusions
Instrumented Charpy
Magnesium
WELDING RESEARCH
WELDING RESEARCH
Experimental
The weld metal chemistry is summarized
in Table 1, and has a calculated CEIIW carbon equivalent of 0.62, and Pcm value of
0.21 (Ref. 26). The welds were completed
using a flux cored arc welding (FCAW)
consumable that conforms to AWS specification A5.29, with CO2 shielding gas, using
a current of 200 A,
voltage of 24 V in direct current electrode
negative
(DCEN) polarity,
and 0.0625-in. (1.6
mm) wire with a
feeding rate of 200
in./min (84 mm/s).
The details of the
consumable design
and flux chemistry
have been reported
elsewhere; however,
it should be noted that the flux contains
MgO, which provides an opportunity to introduce Mg content into the weld metal
(Ref. 27). Welding was conducted in the flat
(1G) position on a 0.75-in.-thick ASTM
A514 steel plate with a 45-deg bevel angle,
a 0.5-in. root opening and a backing plate,
similar to other studies (Ref. 28). The travel
speed was approximately 8 in./min during
each welding pass, and the heat input was
an average of 1.8 kJ/mm. During welding,
the preheat or interpass temperature was
350F (177C), and no postweld heat treatment was applied.
Charpy impact testing was conducted
between 73 to 20C on material ex-
tracted from the middle of the weld region. Additional welds were produced on a
75-mm-thick plate using the same conditions as above in order to facilitate extraction of 10 10 mm Charpy coupons along
the transverse direction of the weld. These
were obtained from approximately 2 mm
below the surface of the root, as well as 2
mm below the surface of the crown of the
weld, in order to obtain mainly reheated
or as-deposited weld metal, respectively,
from these two regions. These top and
bottom portions of the weld were also
tested by instrumented impact testing in
which the force and displacement were
recorded during impact. Instrumented impact testing was used in order to provide a
comparison of the relative fracture initiation energy values in these top and bottom
regions of the weld.
The microstructures were analyzed using
a combination of optical and SEM microscopy after etching with 2% nital. Microhardness indentation was used to
determine the hardness of the reheated and
as-deposited material. In order to determine the chemistry of fine inclusions, Auger
electron spectroscopy (AES) was used to
map elemental distributions. Further analysis of the inclusions was also conducted by
Mn
1.219
P
0.006
S
0.003
Si
0.123
Cu
0.044
Cr
0.264
V
0.005
Ni
3.511
Mo
0.212
Al
0.557
Ti
0.002
Nb
0.003
Co
0.005
B
0.0005
W
0.005
Sn
0.005
Pb
0.001
Zr
0.028
Ce
0.001
As
0.0034
O
0.012
N
0.0064
Mg
0.03
16-s
Results
Optical Microscopy
The macroscopic
section of the joint in
the 0.75-in. plate is
shown in Fig. 1A, and
the typical microstructures observed in the
as-deposited and reheated regions of the
weld are shown in Fig.
1B and C. The root
Fig. 3 XRD spectrum of weld metal indicating presence of ferrite () and and fill passes of the
weld metal contain a
retained austenite ().
significant fraction of
reheated weld metal,
dissolving the weld metal in a 25% HCl and
while the upper region capping passes
25% HNO3 mixture, followed by collection
comprise mainly as-deposited material.
of the dissolved metal residue on filter
The weld metal mainly consisted of
paper. The residue as well as the bulk weld
upper bainite, referred to as FS(A) mimetal was examined by XRD analysis. The
crostructures in the as-deposited material,
weld metal solidification was also simulated
and bainitic ferrite or an FS(NA) miby calculating the Scheil diagram using
crostructure in the reheated zones conThermoCalc version S with the TCFE6
taining fine-grained material. These
database. The ThermoCalc investigations
microstructures were identified using the
examined the chemistry shown in Table 1 for
modified IIW classification scheme (Ref.
only elements >0.1 wt-% as well as oxygen
29) as either ferrite with aligned second
and carbon, and the stability of all phases
phase (FS(A)), ferrite with nonaligned
within the TCFE6 database. The algorithm
second phases (FS(NA)), and polygonal
for this is included within ThermoCalc,
ferrite (PF). Both the as-deposited and rewhere the equilibrium composition of solid
heated weld metals were examined, and
phases are calculated, assuming negligible
the area fractions of each of the ferrite
diffusion in the solid and perfect mixing in
morphologies or microconstituents were
the liquid.
quantified by image analysis, summarized
in Table 2. Within the fill passes, the asdeposited regions had an average hardness of about 285 (6.7) HV1kgf, which
was comparable to the reheated material
with a hardness of 281 (6.0) HV1kgf. It
should be noted that the capping pass weld
metal had a higher hardness of 332 (2.0)
HV1kgf as a result of the higher cooling
rates. Weld metal testing indicated that
the yield point was 763 MPa with an ultimate tensile strength of 866 MPa, and
elongation to failure of 17.8%, which is
consistent with the expected minimum ultimate tensile strength (UTS) of 825 MPa.
Electron Microscopy and XRD Results
RA % =
FS(A)
FS(NA)
PF
82.4
4.6
17.2
92.5
0.4
2.9
I
1 + 0.65 1
I2
(1)
which indicated that the weld metal contained approximately 2.9% retained
austenite.
WELDING JOURNAL 17-s
WELDING RESEARCH
Fig. 4 Weight fraction of Mg (A) and Al (B) in the halite phase vs. temperature during solidification of the weld metal, calculated using ThermoCalc.
WELDING RESEARCH
Test Temperature,
C
Dynamic Fracture
Toughness J1d, kJ/m2
Total
Energy, J
Top
Top
Top
Bottom
Bottom
Bottom
20
18
62
20
18
62
246
245
280
303
279
294
94
87
67
137
139
118
18-s
Inclusion Analysis
Spherical oxide inclusions could be observed in the steel, and measurements indicated they have an average size of 311
120 nm (n = 69). These fine inclusions
were found to contain aluminum and magnesium Fig. 5. Auger electron spectroscopy (AES) was used to map the
elemental distribution in these oxides, and
a core/shell structure can be observed containing mainly Al oxide in the core, and a
shell with Mg oxide Fig. 6. These observations support the thermodynamic calculations in Fig. 4, which suggest that the
inclusions are initially nucleated with a
core that is rich in magnesium, aluminum,
and oxygen, and then following growth,
the outer shell only contains magnesium
and oxygen. Some prior research has also
shown that halite particles with a MgO
stoichiometry are predicted by ThermoCalc in steels containing low oxygen content and trace amounts of Mg (Ref. 31)
However, to the authors knowledge, such
Mg-Al-O-rich inclusions have never been
reported in weld metal and no correlation
could be observed between nucleation of
ferrite phases and these inclusions.
The carbides in the steel were also extracted by dissolving the weld metal in a
mixture of HCl and HNO3 acid. The dissolved solution was screened through filter paper in order to capture the solid
particles. XRD analysis was used to determine the solid phases recovered following
dissolution and filtering. The XRD peaks
observed in the residue recovered were
identified as ZrC carbide (Ref. 32), and
the particles were extracted from the filter
paper onto double-sided copper tape for
SEM microscopy. This residue is shown in
Fig. 7, and consisted mainly of cuboidal
particles; however, a small fraction of
spherical particles could also be observed,
which may correspond with the oxide in-
Fig. 6 AES analysis of element distributions of the Mg- and Al-rich oxide in weld metal, with A Fe;
B O; C Mg; D Al maps shown.
(2)
Discussion
In prior investigations, Koseki and
Thewlis have shown that toughness and
strength degrades when the weld metal
Al/O ratio exceeds 1.0 (Ref. 4), since these
will promote a spinel structure that does
not favor acicular ferrite nucleation (Ref.
WELDING JOURNAL 19-s
WELDING RESEARCH
Fig. 7 SEM micrograph of particles extracted from the weld metal following dissolution in acid.
Fig. 8 Charpy impact energy values for material extracted from the middle region of the fusion zone.
WELDING RESEARCH
Fig. 9 Fracture surfaces from central region of the Charpy sample for tests. A 18C; B 62C.
Fig. 12 Instrumented Charpy impact data showing force and displacement during impact from the A Top region of weld; B bottom region.
matically. The premise is that nickel improves the cohesive strength of the ferrite
lattice itself, which contributes to the enhanced fracture properties (Ref. 48). The
present work suggests that an additional enhancement may occur due to a change in
the distribution of microconstituents as well,
since nickel is an austenite stabilizer. For example, when MA phase does not contain
martensite but rather is dominated by
austenite, this may also enhance toughness
properties (Ref. 49).
The high fracture toughness values obtained at low temperatures are also promoted by the fine-grained ferrite
microstructures produced in the welds in
combination with small-diameter oxide inclusions. The fine ferrite sizes with fewer
aligned microstructures in reheated zones
contributed to the higher fracture energy
values. Aligned ferrite grains are typically
separated by boundaries with low-angle
misorientation (Ref. 50), and do not promote crack deviation during cleavage frac-
WELDING RESEARCH
WELDING RESEARCH
Conclusions
Fine Mg-bearing inclusions with a
core/shell structure have been observed in a
carbon steel weld metal. Flux cored arc
welding was used to produce a weld metal
that contained primarily bainitic ferrite with
a fine packet size in the as-deposited metal
and mainly nonaligned ferrite in the reheated zones. Spherical inclusions with an
average diameter of 311 nm were observed
with a shelled structure that was mainly rich
in aluminum, magnesium, and oxygen in the
core, vs. magnesium and oxygen in the outer
shell, which was suggested to be halite based
on thermodynamic calculations for the weld
metal chemistry. The combination of a fine
inclusion size, nickel in solution, a low content of interstitials (such as [O] and [N]),
along with a fine ferrite packet size, were
suggested to provide an excellent combination of toughness and strength. Instrumented impact testing showed the slight
increase in grain refinement in reheated
zones around the root of the weld improved
impact properties, although fracture initiation energies were comparable to the top of
the weld.
Acknowledgments
Financial support was provided from
Hobart Brothers and Natural Sciences and
Engineering Research Council of Canada
(NSERC). Discussions with Mario Amata
of Hobart Brothers, and Graham Thewlis
are also greatly appreciated.
22-s
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30. Zhang, H., Zhang, L., Cheng, X. L., and
Weldability of Niobium-Containing
High-Strength Steel for Pipelines
The investigated steels showed no tendency to cold cracking in the heat-affected
zone, even with low heat input
ABSTRACT
The presented study contains an assessment of weldability based on careful investigation of two niobium-containing industrial steel grades X70 and X80, with 0.056
and 0.094% Nb, respectively. Characteristics of their resistance to brittle fracture in
the heat-affected zone (HAZ) were evaluated on simulated samples after rapid heating to high temperature followed by cooling at various rates corresponding to different heat inputs. As shown, the HAZ of both investigated steels ensure performance
down to 30C in submerged arc welded thick-walled pipes welded with high heat
input. Investigations of phase transformations at cooling from 1300C and microhardness measurements have shown that investigated steels with Nb content up to
~0.1% do not have a tendency for cold cracking in the HAZ during welding, even
with very low heat input.
Introduction
The high working pressure of modern
gas pipelines up to 100120 MPa require
high-impact toughness [Charpy V-notch
(CVN)] of the material (at least 180250
J/cm2) at relatively low temperatures
down to 20 to 40C, depending on the
specifications for the pipelines. Designed
steel grades actually have higher CVN values; however, the most critical area of
pipelines is the weld heat-affected zone
(HAZ). The HAZ undergoes recrystallization, grain growth, followed by (at
cooling) a large scope of austenite transformation, thus destroying the attractive
thermomechanical-controlled processing
(TMCP) microstructure, and often is the
site of the lowest fracture resistance.
The microstructure of high-strength
low-alloy (HSLA) steels depends on the
steel composition and thermomechanical
processing route. With the recent trend toward lower carbon (C) contents, niobiums (Nb) effect on transformation behavior has been noted with the emergence
of acicular or bainitic steels. Under certain
conditions, such as utilizing low interstitial
contents and high austenitizing temperaI. I. FRANTOV (ifrantov@mail.ru), A. N.
BORTSOV (alnicbortsov@gmail.com), and I.
Y. UTKIN are with I. P. Bardin Central Research
Center for Ferrous Metallurgy, Moscow, Russia.
A. A. VELICHKO is with Izorsky Pipe Plant,
Kolpino, Russia.
tures, small Nb additions increase hardenability by depressing the Ar3 transformation temperature.
Microalloying with Nb is an integral part
of the composition of modern high-strength
steels for pipelines because of its significant
and simultaneous effects on retardation of
recrystallizaton, precipitation hardening,
and hardenability of austenite facilitating
the formation of a grain-refined structure of
favorable acicular ferrite/bainitic ferrite and
contributing substantially to the strength of
low-C steels (Ref. 1).
At the same time, there is considerable
disagreement on the effect of Nb on HAZ
toughness. Some controversy exists in the
literature concerning the influence of Nb
on HAZ properties under certain conditions that is discussed by pipeline construction companies and steel producers.
In the study of the effect of Nb in the
presence of nickel (Ni), chromium (Cr),
KEYWORDS
Weld Process Simulation
Weldability Testing
High-Strength Steels
Piping/Tubing
C-Mn Steels
Submerged Arc Welding
Shielded Metal Arc Welding
WELDING RESEARCH
WELDING RESEARCH
Fig. 3 The temperature dependence of the impact toughness in the HAZ of the following: A X70; B X80 grade steels depending on the cooling rate
(shown on the curves), corresponding to a different heat input at welding.
X-70
X-80
Si
0.33
Mn
1.73
S
0.0005
P
0.006
Al
0.033
Ti
0.013
Nb
0.056
V
0.001
Mo
0.002
Cr
0.17
Ni
0.012
Cu
0.014
B
0.0002
C
0.06
Si
0.30
Mn
1.56
S
0.002
P
0.014
Al
0.037
Ti
0.014
Nb
0.094
V
0.002
Mo
0.01
Cr
0.23
Ni
0.13
Cu
0.24
N2
0.0051
N2
0.004
Ca
0.0002
Ca
0.0026
Notes: H70 (HSLA) is the steel for offshore application in accordance with Standards Det Norske Veritas
(DNV) Offshore Standard OS-F101, Submarine Pipeline Systems.
X80 (HSLA) is the steel for the Cheyenne Plains Pipeline, U.S.A.
24-s
bainitic packet in the HAZ leading to an improvement in impact toughness (Ref. 9).
Some researchers found that a small
addition of Nb decreases toughness (Ref.
10), while others found either no significant effect of Nb addition in the case of
low-C steels (Ref. 11) or increased toughness in very low C (~0.03%) steel (Ref.
12). The importance of very low C to ensure high HAZ toughness in two-pass submerged arc welds is emphasized in a few
studies together with confirmation of the
fact that without microalloying by Nb the
strength of X80 cannot be achieved (Ref.
13). An investigation of coarse-grained
HAZ of X80 grade steel with ~0.1% Nb
using simulation of a single welding thermal cycle came to the conclusion that the
heat input should be less than 30 kJ/cm to
ensure good Charpy impact toughness
(Ref. 14).
As is well known, all properties including impact toughness are defined by the
microstructure. Therefore, all discussions
and differences of opinion about the role
of Nb, which was often overshadowed or
mixed with the dominating roles of C and
Mn or Mo content, should be related to
the role of Nb in specific steel compositions on parameters of phase transformation of overheated austenite at specified
cooling conditions, defined by specific
heat input. In fact, there is a lack of data
correlating the thermal conditions of the
HAZ, in particular for multipass welding,
with Nb effect on phase transformation at
corresponding cooling rate.
Thus, the presented study of two highNb-containing pipeline steels aims to characterize not only the impact toughness of
the simulated HAZ as a function of temperature and a wide range of heat inputs, including two-pass and multipass welding, but
also to investigate phase transformations of
coarse-grained austenite at various cooling
rates as well as the type/microhardness of
the obtained structure.
Tensile Properties
YS0.5
(MPa)
UTS
(MPa)
TE
(%)
YS0.5/UTS
x-70*
x-80*
551
614
631
715
32.2
33
0.87
0.86
WELDING RESEARCH
Fig. 4 The impact of toughness of steel in the HAZ of A X70; B X80 at different temperatures of testing vs. the applied cooling rate (W800/500): 2
the line of the average brittleness threshold (T50 CVN); 3 the line of specified minimum toughness (here 70 J/cm2).
WELDING RESEARCH
Table 3 shows the symbols and designations for Equations 1 and 2. The charts as
presented in Fig. 9, which are based on
corresponding calculations and experi-
Units of Measure
t8/5
E
U
I
V
To
d
seconds
Dimensionless factor
J/sm
Volt
Amperage
sm/s
C
sm
26-s
Parameter
Time of cooling from 800 to 500C
Parameter of the process effciency
Heat-input (E = U*I/V)
Electric voltage of a welding arc
Electric current of a welding arc
Speed of welding
Temperature of preheating
Thickness of pipe wall
20C
60C
100C
WELDING RESEARCH
Fig. 8 CCT diagrams of A X70; B X80 steel grades, built at cooling from 1300C.
WELDING RESEARCH
cooling rates are presented in Fig. 7. Figure 7A corresponds to the HAZ at very
slow cooling and contains 50% bainite and
50% polygonal ferrite with the sizes of the
bainite packet and ferrite grain of 30 and
35 microns, respectively. Figure 7B presents the microstructure of the SAW HAZ
with a hot pass (preliminary temperature 100C): 5% polygonal ferrite and
95% bainite, average bainite packet size is
15 microns, and prior austenite grain size
(PAGS) is 70 microns. Microstructure of
HAZ at SAW with a cold pass (20C) is
presented in Fig. 7C and contains 100%
bainite of lath and globular morphology,
and the bainite packet size is 10 microns
and the PAGS is 60 microns. The microstructure that can ensure the highest
low-temperature toughness is presented
in Fig. 7D. It is 100% lath bainite with a
packet size of 10 microns and PAGS of 45
microns.
Effect of Nb on the Kinetics of Austenite
Transformations
Conclusions
1. Weldability assessment was performed based on careful investigations of
two Nb-containing industrial steel grades
of X70 and X80, respectively, with 0.056
and 0.094% Nb.
2. The resistance of the two steels to
brittle fracture in the HAZ was evaluated
on samples of the steels after high-temperature heating and cooling to simulate
the weld thermal cycle of welded joints at
different heat inputs.
3. Use of different criteria of resistance
to brittle fracture including the tempera-
WELDING RESEARCH
Fig. 9 The cooling rate, depending on the heat input at multipass welding
of butt joints (figures show the temperature before the next weld pass, C), independent of pipe wall thickness.
K. Hollis
T. Hong
B. Horn
W. Hou
J. Hu
Y. Huang
J. Hutchins
D. L. Isenhour
J. R. Jachna
D. A. Javernick
N. T. Jenkins
C. Jiang
M. Q. Johnson
J. E. Jones
A. Kar
L. Karlsson
A. Kasapo lu
S. Katayama
D. D. Kautz
F. Kavanara
S. C. Kelley
C. Kelly
S. Kelly
R. K. Kersey
I. Khan
D. S. Kim
J. K. Kim
Y. S. Kim
M. Kimchi
D. Klingman
D. B. Knorr
H. Koike
F. Kong
S. Kore
T. Kostrivas
R. Kovacevic
L. Kramer
A. Kumar
M. Kuntz
J. J. Kwiatkowski
M. Labbe
K. Lachenberg
C. R. LaMorte
A. Landau
B. Leister
L. Li
M. V. Li
T. Li
W. Li
D. Liang
E. Liguo
S. Lillard
C. C. Lu
W. Lu
Y. Lu
D. Ludwig
N. Ma
X. Ma
D. Maatz
D. MacCallum
M. Manohar
I. Maroef
B. Marschke
F. Martinez Diez
R. P. Martukanitz
M. P. Marya
S. Massey
K. Masubuchi
V. Matthews
M. Mayer
A. Maynard
J. Mazumder
M. McAninch
S. McCracken
A. McDonald
A. Mengel
R. Menon
M. P. Miles
J. O. Milewski
D. Miller
R. Mishra
T. Morrissett
P. E. Murray
S. J. Na
X. Na
B. Narayanan
A. M. Nasiri
T. V. Natale
T. C. Nguyen
N. E. Nissley
J. T. Norris
Y. Ogawa
T. Oyama
A. Pandey
J. Peng
J. A. Penso
F. Perez
E. C. Pessoa
W. Peterson
C. Pettersson
A. Peusc
F. Pfefferkorn
S. Pilli
M. Piltch
J. P. Planckaert
A. Polar
N. Porter
M. Prager
P. Prangnell
M. Prime
J. D. Puskar
J. Querin
T. P. Quinn
A. Rabinkin
J. Ram
A. Raraz
S. Ream
C. B. Reed
R. Ress
A. P. Reynolds
D. Richards
B. Ridgway
J. R. Roper
G. Roy
D. Rudland
F. Rumiche
D. J. Rybicki
E. F. Rybicki
S. Sadagopan
M. Santella
S. Santhanakrishnan
D. Schick
J. Scott
K. Scott
O. Semenov
D. Sen
A. Shapiro
A. Shukla
M. Siddens
M. S. Sierdzinski
T. Siewert
M. Sinfield
H. B. Smartt
C. Smith
B. R. Somers
R. Somers
H. Song
W. H. Song
G. Sonnenberg
C. D. Sorensen
V. Soundararajan
W. J. Sperko
J. E. Stallmeyer
R. J. Steele
A. W. Stockdale
T. Stotler
J. Sutliff
E. Taban
H. Tang
M. Teague
K. Tello
D. J. Tillack
W. Tong
D. W. Trees
C. L. Tsai
J. Tucker
G. D. Uttrachi
D. M. Vandergriff
P. T. Vianco
B. Victor
C. A. Walker
G. Wang
H. P. Wang
W. Wang
Y. Y. Wang
B. Warke
D. C. Weckman
P. S. Wei
M. M. Weir
E. M. Westin
T. C. Wheeler
T. Wong
P. Woollin
C. Wu
C. Y. Wu
L. Xiao
J. Xie
R. Xu
S. Xu
Z. Xu
Z. Yang
L. Yepez
G. Young
X. Yu
T. Zacharia
C. Zhang
P. Zhang
R. Zhang
W. Zhang
Principal Reviewers
Y. Adonyi
B. Alexandrov
S. S. Babu
M. Balmforth
D. Barborak
J. L. Caron
H. R. Castner
B. A. Chin
C. E. Cross
C. B. Dallam
T. DebRoy
X. Deng
J. N. DuPont
T. W. Eagar
J. W. Elmer
D. F. Farson
Z. Feng
R. W. Fonda
P. W. Fuerschbach
A. Gerlich
J. E. Gould
M. Harris
D. Hartman
P. Hochanadel
T. Holverson
F. M. Hosking
Y. Huang
R. Hutchison
J. E. Indacochea
G. A. Knorovsky
P. J. Konkol
D. J. Kotecki
S. Kou
S. H. La Lam
D. Landon
K. Li
L. Li
T. W. Liao
T. J. Lienert
D. Lin
W. Lin
S. Liu
W. Liu
R. B. Madigan
M. C. Maguire
P. F. Mendez
R. Menon
D. W. Meyer
P. Michaleris
W. Mohr
P. B. Nagy
R. Nandan
T. W. Nelson
R. Noecker
D. L. Olson
T. A. Palmer
J. J. Perdomo
M. J. Perricone
R. Polanin
M. Posada
A. J. Ramirez
J. Ramirez
G. W. Ritter
J. Rodelas
J. Schneider
D. R. Sigler
X. Sun
D. Susan
M. Tumuluru
P. C. Wang
Y. P. Yang
H. Zhang
W. Zhang
Y. M. Zhang
Y. N. Zhou
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