WJ 2016 07

Cover JULY 2016.
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JULY 2016
WELDING JOURNAL VOLUME 95 NUMBER 7 JULY 2016
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
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For Info, go to aws.org/adindex

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July 2016 Volume 95 Number 7 CONTENTS

FEATURES 32 38
32 Selecting Filler Metals for Stainless Steel
This guide to consumables will make your choices
a lot easier J. Coubrough and K. Ivarsson
38 Sunny Economics: Using Solar Power to Save Money

A new solar field puts an industrial manufacturer
on the map as the first fully solar-powered
operation in the state R. Steffensmeier and
A. Van Beek
42
42 Variables Affecting the Mechanical Properties of
Carbon Steel Welds
Get to know the welding variables that impact
the properties of the finished weld B. Guy
46 International Thermal Spray Association Holds Its

Annual Conference
Technical presentations attract a diverse thermal
spray audience A. Cullison 50 56
50 Equipment Furthers Welding Research Discoveries
Researchers explain some of their favorite and
most effective equipment M. R. Johnsen
56 Thermal Spray The Misunderstood Process

Step-by-step rundown of thermal spray technology
R. MCDemus
WELDING RESEARCH SUPPLEMENT

229s Solidification Cracking Susceptibility of 257s Constitutional Liquation of the Laves Phase in
Ni30Cr Weld Metals with Variable Niobium Virgin FB2 Steel
and Molybdenum Large particles of Laves phase were observed in a
An investigation on the effect of Nb and Mo additions new 9% Cr martensitic stainless steel, which under
to Alloy 690s susceptibility to cracking was performed certain conditions might lead to liquation cracking
R. A. Wheeling and J. C. Lippold K. Li et al.
239s Pulsed UltrasonicWaveAssisted GMAW of 7A52 264s UltrasonicInduced Rising and Wetting of a SnZn
Aluminum Alloy Filler in an Aluminum Joint
Three groups of comparative experiments were The wetting of a Sn-Zn solder in a vertical
conducted to assess the effect of ultrasonic treatment aluminum joint under ultrasonic agitation was
on molten metal W. F. Xie et al. investigated Z. Xu et al.
248s Characterization of Constitutive Behavior of

Dissimilar Aluminum Alloy Resistance Spot Welds
The weld nuggets and heat-affected zones for three
dissimilar aluminum alloy stack-ups were evaluated
J. Kang et al.
JULY 2016 / WELDING JOURNAL 3

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DEPARTMENTS
6 Editorial 66 Certification Schedule
8 Press Time News 68 Welding Workbook
10 International Update 71 Society News
12 News of the Industry 73 Tech Topics
16 Business Briefs 78 Section News
18 Stainless Q&A 95 Guide to AWS Services
22 RWMA Q&A 96 Personnel
26 Product & Print Spotlight 102 Thermal Spray Profiles
60 Conferences 107 Classifieds
62 Coming Events 110 Advertiser Index On the cover: When selecting filler ma
terials, consider using a Type L filler be
cause its lower carbon content helps
reduce the risk of intergranular corro
sion. (Photo courtesy of ESAB.)
M. Skiles (Dist. 9), Consultant D. Marquard, IBEDA Superflash

W. J. Sperko (At Large), Sperko Engineering Services J. F. Saenger Jr., Consultant
J. Stoll (Dist. 18), The Bohler Welding Group U.S. S. Smith, WeldAid Products
H. W. Thompson (Dist. 2), UL, Inc. D. Wilson, Wilson and Associates
R. P. Wilcox (Dist. 11), Consultant J. N. DuPont, Ex Off., Lehigh University
OFFICERS J. A. Willard (Dist. 13), Kankakee Community College L. G. Kvidahl, Ex Off., Northrop Grumman
D. R. Wilson (Past President), Wilson and Associates Ship Systems
President David L. McQuaid
D. L. McQuaid and Associates, Inc. D. J. Landon, Ex Off., Vermeer Mfg.
WELDING JOURNAL S. P. Moran, Ex Off., Weir American Hydro
Vice President John R. Bray E. Norman, Ex Off., Southwest Area Career Center
Affiliated Machinery, Inc. Publisher Andrew Cullison R. G. Pali, Ex Off., J. P. Nissen Co.
Editorial N. Scotchmer, Ex Off., Huys Industries
Vice President Dale Flood Editorial Director Andrew Cullison R. W. Shook, Ex Off., American Welding Society
Tri Tool, Inc. Editor Mary Ruth Johnsen
Features Editor Kristin Campbell American Welding Society
Vice President Thomas J. Lienert
Los Alamos National Laboratory Assistant Editor Melissa Gomez 8669 NW 36 St., # 130, Miami, FL 331666672
Assistant Editor Annik Babinski (305) 4439353 or (800) 4439353
Treasurer Carey Chen Peer Review Coord. Sonia Aleman
Cincinnati, Inc. Publisher Emeritus Jeff Weber
Executive Director Ray W. Shook Design and Production

American Welding Society Production Manager Zaida Chavez Welding Journal (ISSN 00432296) is published monthly by
Sr. Production Coordinator Brenda Flores the American Welding Society for $120.00 per year in the United
States and possessions, $160 per year in foreign countries: $7.50
DIRECTORS Manager of International Periodicals and per single issue for domestic AWS members and $10.00 per single
Electronic Media Carlos Guzman issue for nonmembers and $14.00 single issue for international.
T. Anderson (At Large), ITW Welding North America American Welding Society is located at 8669 NW 36th St., # 130,
Miami, FL 331666672; telephone (305) 4439353. Periodicals
U. Aschemeier (Dist. 7), Subsea Global Solutions Advertising postage paid in Miami, Fla., and additional mailing offices. POST
D. J. Burgess (Dist. 8), Alstom Power Sr. Advertising Sales Exec. Sandra Jorgensen MASTER: Send address changes to Welding Journal, 8669 NW
D. A. Desrochers (Dist. 1), Old Colony RVTHS 36th St., # 130, Miami, FL 331666672. Canada Post: Publications
Sr. Advertising Sales Exec. Annette Delagrange Mail Agreement #40612608 Canada Returns to be sent to
D. L. Doench (At Large), Hobart Bros. Co. Manager of Sales Operations Lea Paneca Bleuchip International, P.O. Box 25542, London, ON N6C 6B2,
D. K. Eck (At Large), Praxair Distribution, Inc. Canada.
Sr. Advertising Production Manager Frank Wilson Readers of Welding Journal may make copies of articles for
K. Fogleman (Dist. 16), Consultant personal, archival, educational or research purposes, and which
P. H. Gorman (Dist. 20), Sandia National Laboratories Subscriptions are not for sale or resale. Permission is granted to quote from arti
Subscriptions Representative Evelyn Andino cles, provided customary acknowledgment of authors and sources
S. A. Harris (Dist. 4), Altec Industries is made. Starred (*) items excluded from copyright.
J. Knapp (Dist. 17), Consultant eandino@aws.org Copyright 2016 by American Welding Society in both
M. Krupnicki (Dist. 6), Mahany Welding Supply printed and electronic formats. The Society is not responsible for
any statement made or opinion expressed herein. Data and infor
D. J. Landon (Past President), Vermeer Mfg. Co. MARKETING ADVISORY COUNCIL mation developed by the authors of specific articles are for infor
S. Lindsey (Dist. 21), City of San Diego mational purposes only and are not intended for use without inde
D. E. Lynnes (Dist. 15), Lynnes Welding Training
(MAC) pendent, substantiating investigation on the part of potential users.
C. Matricardi (Dist. 5), Welding Solutions, Inc. D. L. Doench, Chair, Hobart Brothers Co.
S. M. McDaniel (Dist. 19), Big Bend Community College S. Bartholomew, Vice Chair, ESAB Welding
W. R. Polanin (At Large), Illinois Central College & Cutting Prod.
R. L. Richwine (Dist. 14), Ivy Tech State College Lorena Cora, Secretary, American Welding Society
D. J. Roland (Dist. 12), Airgas USA, LLC, D. Brown, Weiler Brush
NorthCentral Region C. Coffey, Lincoln Electric
R. W. Roth (At Large), RoMan Manufacturing D. DeCorte, RoMan Manufacturing
M. Sebergandio (Dist. 3), CNH America S. Fyffe, Astaras, Inc.
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co. D. Levin, Airgas
M. Sherman (Dist. 10), SW&E, LLC R. Madden, Hypertherm
4 WELDING JOURNAL / JULY 2016

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EDITORIAL JULY 2016_Layout 1 6/9/16 4:24 PM Page 6
EDITORIAL
Embracing Diversity
Would you like your work environment diverse groups are more innovative than ho-
to be more rewarding, or your company to mogeneous groups (Refs. 1, 2). Many sur-
be more innovative and profitable? Adopt- veys have consistently demonstrated corre-
ing a diversity and inclusion program may lations between financial success and mem-
provide the answer to these questions. We bership of women in top management and
would like to take this opportunity to upon corporate boards. Moreover, similar rela-
date members on diversity benefits and re- tionships exist for companies that endorse
cent initiatives at the American Welding So- racial diversity.
ciety (AWS) on this subject. The results of controlled experiments
One of the greatest AWS strengths is show the same beneficial outcomes for cul-
membership diversity. Accordingly, one of tural diversity in terms of cause and effect
our biggest challenges is to promote initia- (Ref. 1). Findings indicate cultural diversity
Thomas J. Lienert tives that embrace and promote diversity within a team makes members uncomfort-
AWS Vice President more effectively. Diversity is a valued asset able. It can cause uneasiness, strained inter-
and Member of the that enriches the Society and the welding actions, lack of trust, poorer communica-
Diversity and industry; efforts that endorse inclusion tion, and less unity at least initially
Inclusion Committee make us more innovative and successful. until these barriers are broken by success.
First, what does diversity involve? One This discomfort is the driving force that
definition of the term is the inclusion of dif- provides the benefits of diversity. Interact-
ferent types of people within a group or or- ing with people of diverse backgrounds
ganization. In addition, different types of compels team members to prepare more
diversity can be identified. Diversity of thoroughly, expect unfamiliar opinions, and
expertise involves inclusion of specialists anticipate reaching concurrence will require
from different disciplines on a problem solv- greater work.
ing team (Ref. 1). A good example is the de- Given the enormous benefits of diversity
sign and construction of a new car model. outlined above, the AWS Board of Directors
No reasonable automobile manufacturer (BOD) has recently enacted a formal initia-
would undertake these tasks without in- tive on diversity and inclusion for the Socie-
cluding scientists, engineers, and other spe- ty. The BOD agreed that the diversity initia-
cialists from a variety of disciplines. In com- tive will be included in future strategic plan
Pierrette H. Gorman parison, social or cultural diversity relates to revisions, and it should involve promoting
AWS District 20 involvement by people from different demo- diversity to all AWS stakeholders. The objec-
Director and Chair of graphic groups within a larger group. tive of the effort is to advocate greater di-
the Diversity and The crucial point in appreciating the ben- versity of participation in member activi-
Inclusion Committee efits of diversity is the concept of informa- ties, sections, committees, and the BOD by
tional diversity. Members of different demo- under-represented groups, including partici-
graphic groups carry distinct information pation in leadership positions.
and perspectives to the pertinent task. This So far, the most tangible outcome from
concept is readily understood for diversity this program is the official formation of the
of expertise, such as with the new car model Diversity and Inclusion Committee. Its lead-
example. Interestingly, identical principles ers have been identified, and a draft of the
hold for cultural diversity. mission and duties statement has been writ-
The AWS Board of So, just what are the benefits of diversity ten and approved. The committees first
(Ref. 2)? All humans understand intuitively gathering took place recently at the BOD
Directors (BOD) has that employees are more satisfied and hap- meeting at AWS headquarters in May.
recently enacted a py when they work for organizations that While efforts are just starting and there
formal initiative on accept and value their ideas and views. In is much work to be done, these steps repre-
diversity and inclu turn, numerous studies have repeatedly sent an important move by AWS toward em-
sion for the Society... shown that satisfied employees are more bracing diversity. Contact the AWS Mem-
productive, innovative, and engaged, as well bership Department if you would like to
so far, the most tan as less likely to take sick days or quit (Ref. contribute in this effort. WJ
gible outcome from 2). Given the shortage of welding profes-
this program is the sionals and competition for talent within References
official formation of the welding industry, it makes sense that
the Diversity and In companies embracing diversity in the work- 1. scientificamerican.com/article/
clusion Committee. place will enjoy greater financial success. how-diversity-makes-us-smarter/
The overwhelming consensus from many 2. saharconsulting.wordpress.com/
years of research by various types of scien- 2010/03/26/6-advantages-of-workplace-diversity/
tists and business experts shows culturally

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PRESS TIME NEWS
Air Liquide Completes Acquisition of Airgas with the Citys Human Rights Department as well as Detroit
Employment Solutions Corp.
Air Liquide, The Michigan Strategic Fund board has approved a $3.5-
Paris, France, a million Business Development Program grant to incentivize
world provider of the auto supplier to expand its Michigan operations. The
gases, technolo- Economic Development Corp. of the City of Detroit has also
gies, and servic- approved the sale of 30 acres in the I-94 Industrial Park.
es, has complet- Our news today from Detroit is further evidence that
ed the acquisi- the United States auto industry is strong, promising, and
tion of Airgas, experiencing exceptional growth, said Khan. Building a
Inc., Radnor, Pa., new plant from the ground up within the Detroit city limits
a supplier of in- will be a milestone moment...we couldnt do this alone.
dustrial gases
Benot Potier (left), Air Liquide chairman and associated General Dynamics Electric Boat to Help
and CEO, shakes hands with Peter Mc products/ser- Rhode Island Students by Backing Career
Causland, Airgas founder and former vices in the Unit- Technical Instruction for Future Employment
executive chairman. ed States.
Globally, the Rhode Island Governor Gina M. Raimondo has recently
combined com- revealed, through a partnership with General Dynamics
panies will generate annual sales of more than $22 billion (at Electric Boat, six career and technical schools will be able to
press time exchange rates), employ approximately 68,000 peo- offer training to prepare for marine industry occupations.
ple worldwide, and serve more than three million customers This includes the Chariho, Coventry, Cranston, and War-
and patients. wick school districts, the Providence Career and Technical
The two businesses are highly complementary, and the Academy, and the William M. Davies, Jr. Career and Techni-
transaction extends our customer base through a unique, mul- cal High School for a total enrollment over the next two
tichannel distribution network and a nationwide presence in years of about 180 students. It is also anticipated about 350
the U.S., said Benot Potier, chairman and CEO of Air Liquide. students will graduate annually from career-technical pro-
Since founding Airgas some 30 years ago, Peter McCausland grams in marine industries as the programs expand to all
has successfully grown the business...it is an exciting day for career-technical centers and schools in Rhode Island.
the group as we welcome our Airgas colleagues and together This initiative will lead students directly into careers in
begin a new chapter in our history. welding and electrical services, which will prepare them for
Under the agreement terms, first announced and unani- jobs in shipfitting and advanced marine manufacturing,
mously approved by each companys board of directors in No- Raimondo said. She added Electric Boat will support in-
vember 2015, Airgas shareholders receive $143 in cash for struction in career-technical centers and schools, provide
each share of common stock. paid student internships on site, and work with partners
Airgas will also operate as a subsidiary of Air Liquide within seeking qualified workers to offer students jobs at the ship-
the companys U.S. operations and, commercially, go to market builder upon graduation.
as Airgas, an Air Liquide company. A sector partnership led by Electric Boat, the Pipelines to
Additional benefits include allowing Air Liquide to expand Manufacturing Careers in Ship Building, obtained $369,500
in the United States, extending its customer base by more through Real Jobs Rhode Island. With that funding, plus
than one million, and permitting potential volume growth us- partner input, the shipbuilder and Rhode Island Depart-
ing Airgas footprint; identifying more than $300 million of ment of Labor and Training are embarking on one of the
pretax industrial, administrative, and volume growth syner- biggest planned hiring efforts in state history. This consists
gies; and together delivering more value with service to users of more than 10,000 skilled maritime-manufacturing indus-
in North America and around the world. try workers over the next 10 years.
FlexNGate to Build Nearly $100Million Facility Large Commercial Vacuum Furnace

to Supply Ford Vehicles, Create Up to 650 Jobs Construction Nearly Complete
Flex-N-Gate Owner Shahid Khan has stated his company, Solar Atmospheres of Western Pennsylvania and Solar
a global auto supplier in Urbana, Ill., offering exterior trim Manufacturing, Inc., have been building what they claim is
components, plus aluminum/steel modular stamped body- the largest vacuum furnace in the world.
in-white and chassis assemblies, will invest $95 million in The working hot zone of this high-vacuum furnace is 80
construction and capital costs for a facility that will supply in. diameter 48 ft long with a maximum operating temper-
parts to Ford Motor Co. Potential additional investment ature of 2400F. In addition, 35 points of temperature will
could push it to at least $100 million. be surveyed to within 10F per the AMS 2750E specifica-
In addition, Khan noted the project will create at least tion. The U.S. patented, dual-load car design will have the
400 and up to 650 new jobs in Detroit, Mich., over the next capacity to transfer up to 150,000 lb of material in and out
three years. At capacity, up to 750 total jobs could be added. of the furnace.
Flex-N-Gate has committed to meeting Detroit-based hir- The commissioning of the furnace into production is ex-
ing and contracting thresholds, and developing a hiring plan pected this month. WJ

ASTARAS.qxp_FP_TEMP 6/7/16 10:50 AM Page 9
Tungsten Ele
ectrodes
Your Best Choice To Replace 2% Thoriated
The new tungsten electrode that outperforms other electtrode types in most
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orkplace environment.
Thoriated Tungsten
Tu should be avoided!
Global Industry newss from iiW - International Institute of Welding
We
( Countries from 5 Continents are members of The International Institute of Welding (iiW)
(56
a global body for science and joining technology) Doc. IIW-2509, recommended for publicatioon by
Commission VIII Health, Safety and Environment states in part: The experts recommend that use of
thoriated electrodes ceases as soon as is practicable and that, until that change is completedd, special
care is taken to inform workers of the hazards and to implement all the other protective measures
which are detailed in the report. http://link.springer.com/article/10.1007/s40194-014-0197--9
AWS
WS S - The American W Weelding Societys s Safety and Health FACT Sheet No. 27 states in part:
HOW TO REDUCE EXPOSURE Choose thorium-free tungsten n electrodes such as those
containing cerium, lanthanum, yttrium, or zirconium.
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International Update July_Layout 1 6/9/16 4:25 PM Page 10
INTERNATIONAL UPDATE
Women Building Futures Celebrates First

Graduating Class
Architects from Landmarken AG and KPF (right) officially handed

the keys to the new Photonics Cluster over to Fraunhofer ILT. From
left: Jens Kreiterling, Landmarken AG; Jens Hardvendel, KPF Archi
tects; Norbert Hermanns, Landmarken AG; Aachens City Manager
Annekathrin Grehling; Chair of Additive Manufacturing Johannes
Women Building Futuress first Ironworker Readiness class re Henrich Schleifenbaum; Ernst Schmachtenberg, RWTHAachen Uni
cently graduated and entered Albertas workforce at North West versity; and Reinhart Poprawe, director of the Photonics Cluster.
Redwater Partnerships Sturgeon Refinery. ( Photo Fraunhofer ILT/Andreas Steindl.)
Women Building Futures (WBF), a trades training organi- Photonics Cluster on the RWTH Aachen Campus. This cen-
zation for women in Alberta, Canada, recently celebrated ter specializes in researching and developing techniques de-
the graduation of its first Ironworker Readiness class. Along signed to generate, shape, and harness light in particular
with its partners, North West Redwater Partnership (NWR) as an industrial manufacturing tool.
and the Alberta Ironworkers Apprenticeship and Training Guests were present to see property developers Land-
Plan (Local 720), the new program was launched in late marken AG and KPF architects officially hand Fraunhofer
2015 to meet the need for motivated, skilled tradespeople in ILT the keys to the center. Following the Photonics Cluster
the construction and maintenance of the NWR Sturgeon Re- Tailored Light talk, they had the opportunity to visit the
finery, located near Edmonton, Alberta. new building and take a look at its research facilities and of-
The program partners joined together to recognize the fices.
Ironworker graduates now entering Albertas workforce at With the addition of the Photonics Cluster on RWTH
NWRs Sturgeon Refinery. Currently in Phase 1 construc- Aachen Campus, our international reputation for laser tech-
tion, the refinery now stands to benefit from the proactive nology will expand even further, said Reinhart Poprawe, di-
recruitment, training, and apprenticeship of these women. rector of the Photonics Cluster. Now the Fraunhofer Institute
These highly skilled women represent the strength, de- for Laser Technology ILT and RWTH institutes can work to-
termination, and diversity of this great province. Not only gether with companies under one roof to explore the future of
will they build the energy infrastructure of Albertas future, lasers and their versatile applications.
they have chosen to take hold of their own futures, to do
what they love, and to prove any and all nay-sayers wrong, EWI Extends Manufacturing Services to
said Margaret McCuaig-Boyd, Minister of Energy.
Tuition for the program was provided by NWR, and work Australia
experience and employment at NWRs Sturgeon Refinery
was provided in conjuction with its contractors, Fluor Cana- EWI, Columbus, Ohio, an engineering and technology or-
da and PCL Industrial Constructors, Inc. Participants were ganization dedicated to developing, testing, and implement-
also indentured as Ironworking apprentices with the Alberta ing manufacturing technologies, is now offering its services
Ironworker Apprenticeship and Training Plan, who provided in Australia to help manufacturers with technology chal-
the hands-on skill building. lenges. Marc Purslow, who is based in Sydney, will represent
The WBF Ironworkers training program is an important EWIs technology capabilities throughout the country with a
next step in a wider effort to help open doors for women in focus on the defense, rail, heavy manufacturing, and aero-
trades. We are pleased to welcome these recent graduates as space industries.
they join us at PCL on the NWR project site, said Gary EWIs global network of technical centers, industrial part-
Truhn, vice president and general manager, PCL Industrial nerships, and team of applied engineers will support
Constructors, Inc. Purslows efforts.
The Australian government, through the development
of the National Innovation and Science Agenda, has demon-
Photonics Cluster Opens in Aachen, strated a strong commitment to innovation and progress on
Germany a national scale, said EWI President and CEO Henry
Cialone. With our technological expertise and strong histo-
The International Laser Technology Congress AKL16, or- ry of manufacturing innovation, EWI can help advance this
ganized by Fraunhofer ILT, Aachen, Germany, welcomed ambitious plan in the same way we have worked to enhance
more than 500 laser technology experts and 100 scientists, the competitiveness of U.S. manufacturers for over 30
business leaders, and politicians to the opening of the new years. WJ

DIAMOND GROUND.qxp_FP_TEMP 6/7/16 2:53 PM Page 11
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NI JULY 2016.qxp_Layout 1 6/9/16 9:44 AM Page 12
NEWS OF THE INDUSTRY
Pipeline Inspection Certification Program

Could Prove a Benefit to AWS Certified
Welding Inspectors
This graphic displays the structure of inspector certification

programs. (Courtesy of INGAA.)
American Welding Society (AWS) Certified Welding In-

spectors (CWIs) could potentially benefit from a new Pictured with shovels at the mobility companys ceremony for its
pipeline inspection certification program jointly developed new development are (from left) Tom Wessner, VP of global sup
by the Interstate Natural Gas Association of America (IN- ply chain at Faraday Future; Ding Lei, cofounder, global vice
GAA), INGAA Foundation, and Canadian Energy Pipeline chairman at SEE Plan at LeEco; Nevada Governor Brian Sandoval;
and Dag Reckhorn, VP of global manufacturing at Faraday
Association along with its foundation. Future. (Courtesy of Bizuayehu Tesfaye/AP Images for Faraday
These pipeline trade associations in the United States Future.)
and Canada have voted to endorse a program to ensure all
pipeline inspectors doing work for their member companies
are certified by 2018. vanced manufacturing equipment to produce its vehicles, in-
The new certification program uses, as its base require- cluding robotic automation, laser measurement and vision
ment, the American Petroleum Institute (API) 1169 Pipeline systems, autonomous material delivery, and aluminum join-
Inspector Certification test. This certification has also been ing along with coating technologies.
revised to meet industry requirements in Canada. Operations will cover body, powertrain/battery pack, and
Additional certifications are required for specialty inspec- final vehicle assembly as well as paint operations.
tors, such as AWS CWI and Canadian Welding Bureau (CWB) We are moving extremely quickly for a project of this
Level 2 for welding, plus National Association of Corrosion size, said Dag Reckhorn, VP of global manufacturing at
Engineers (NACE) Level 2 for coating. Faraday Future. Our aim is to complete a program that
The program developed by INGAA and its partners will would normally take four years and do it in half the time,
not allow grandfathering into certification from other pro- while still doing it right.
grams. All inspectors will be required individually to obtain The ceremony was attended by Nevada Governor Brian
the certifications required by the program. There is no abili- Sandoval, North Las Vegas Mayor John Lee, Clark County
ty to apply for equivalent certifications. Commission Chairman Steve Sisolak, and many officials.
Training for the appropriate certifications is available We are thrilled to have chosen Nevada for the home of
from AWS (aws.org) as well as CWB, API, and NACE. our first manufacturing facility and are deeply committed to
This new program could prove beneficial to AWS CWIs as bringing our investment to the state, added Reckhorn.
more companies and regulatory bodies adopt these guide-
lines. Where fully adopted, this will require that all weld in- International Thermal Spray Association Offers
spection be done by an AWS CWI or a CWB Level 2 Inspec- Scholarship Opportunities
tor. The program is expected to be fully implemented over
the next two years. The International Thermal Spray Association, a Standing
In addition, AWS CWIs now doing inspection on Committee of the American Welding Society, has up to three
pipelines will need to obtain the additional API 1169 certifi- graduate scholarships worth $2000 each to be awarded each
cation to continue working where the new guidelines are calendar year. Applications will be accepted through July 15.
adopted. For more details, including criteria requirements, visit
the scholarship section at thermalspray.org.
Faraday Future Breaks Ground on $1Billion
Electric Vehicle Manufacturing Facility Mechanized Unit Construction Process to
Save More Than $1 Million Annually at Ingalls
Faraday Future recently hosted a ground breaking for its
manufacturing facility, where electric and technologically The Navy Metalworking Center, Johnstown, Pa., is lead-
advanced vehicles will be built, at Apex Industrial Park in ing a Navy ManTech Integrated Project Team to improve
North Las Vegas, Nev. unit assembly, preoutfitting, and kitting of components
This $1-billion, 3-million-sq-ft, 900-acre development within the Ingalls Shipbuilding unit construction areas.
will create approximately 4500 direct jobs over a 10-year pe- Mechanizing unit construction processes, currently done
riod. The production facility will be connected, futuristic manually, can save more than $1 million per year for the
looking, and environmentally conscious. ships constructed by Ingalls.
The mobility company intends to use up-to-date ad- The Integrated Project Team will focus on improvements

A more efficient unit construction will increase shipbuilding

throughput while reducing production costs and labor. (Courtesy
of Ingalls.)
to leveling structures, handling/setting bulkhead structures,

and transporting structures among stations. Also, the team
will evaluate processes and compile data to identify unit
For info, go to aws.org/adindex

families and focus areas to target for mechanization.
The Navy Metalworking Center will work with Ingalls to
identify prototype technology requirements and develop
concepts. Once selected, the center will develop prototype
hardware for demonstration and pilot testing at Ingalls.
The total projected five-year process savings for all hulls
is $7.2 million. Implementation will occur on the first avail-
able hull at Ingalls starting in January 2018.
continued on page 15

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continued from page 13
GAWDAs Spring Conference Draws

Record Attendance
At GAWDAs spring conference, Disruption: Recognize It, Under

stand It, Mitigate It, Thrive Through It attracted (from left) Mike
Masha, Buzz Campbell, Jim Earlbeck, Ken Thompson (modera
tor), and Dave Manthey. (Courtesy of GAWDA/GAWDA Media.)
Distributor and supplier member attendance at the

Spring Management Conference of the Gases and Welding
Distributors Association (GAWDA), Hollywood, Fla., result-

ed in the highest participation level since 2010, according to
John Ospina, the organizations executive director.
The event, held in Savannah, Ga., from April 2 to 5, drew
651 attendees. That included 199 gases and welding distrib-
utor company representatives, 363 participants from indus-
try supplier companies, and 89 others.
Participants heard from experts about the state of the in-
dustry and from distributors and suppliers on the impact of

BB JULY 2016.qxp_Layout 1 6/9/16 12:53 PM Page 16
BUSINESS BRIEFS
Amada Miyachi America Opens New Headquarters flat-pack integrated circuits for surface mounting was devel-
oped for Hughes Aircraft and Timex.
Today, Manncorp has two 18,000-sq-ft facilities. Its
headquarters is in Huntingdon Valley, Pa., and there is a
new San Diego, Calif., location. Offices are also in Mexico,
Brazil, and China. The company employs more than 30 full-
time employees.
Essex Weld Solutions to Establish Cherokee

President/CEO of Amada Miyachi Co., Ltd. Toshiyasu Tsuijoka
County Operations, Create 70 Jobs
holds the scissors at a ribbon cutting ceremony for Amada Miy
achi Americas new building with enhanced facilities. Essex Weld Solutions, an international manufacturer of
automotive racking products, is starting operations in
Cherokee County, S.C., with Essex Weld USA, Inc.
Amada Miyachi America, Inc., Monrovia, Calif., a manu- This move will bring a capital investment of $2.6 million
facturer of resistance/laser welding, marking, cutting, and to the Upstate region and create 70 new jobs.
micromachining equipment, recently celebrated the opening A subsidiary of the company, Essex Weld USA, also manu-
of its new headquarters. factures custom and standard automotive racking products,
This $13.5 million, 85,000-sq-foot facility includes a new plus provides professional engineering services and certifica-
technical center with 11 application-specific product tions for shipping/storage containers to comply with Occupa-
demonstration labs, a training room, and a technology tional Safety and Health Administration requirements.
showroom. To create operations in the county, the company is mov-
In addition, there is a manufacturing facility with a ing into a 15,000-sq-ft industrial warehouse in Gaffney, S.C.
1400-sq-ft, Class 10,000 clean room and six customer Hiring is underway for new positions.
test labs.
The event kicked off with a Taiko drum performance by Airgas Reorganizes Its South Distribution Region
TAIKOPROJECT, accompanied by a Kagami biraki, a tradi-
tional Japanese ceremony where a sake barrel is opened. Airgas, Inc., Radnor, Pa., has recently reorganized its
More than 100 guests attended the ceremony, which was south distribution region. A redefined south region, head-
followed by a reception and open house. Attendees included quartered in Tampa, Fla., covers Florida along with southern
top management from its parent company, Amada Miyachi Georgia, Alabama, and Mississippi. It is led by Edwin
Japan, Hidehisa Horinouchi, the Consul General from the Robertson, who has served as an area vice president in the
Consulate-General of Japan in Los Angeles, officials from south region since 2007. In addition, a new southeast re-
Los Angeles County and City of Monrovia, and customer gion, headquartered in Kennesaw, Ga., covers northern
representatives. Georgia and Alabama, Mississippi, and southern Tennessee.
We are very proud of our new headquarters, especially It is led by Kevin McBride, who has led the south regions
the many features we included to make it a great work envi- growth as president since 2014.
ronment for employees, said David Fawcett, president and
CEO of Amada Miyachi America. We also focused the build-
ing design efforts on enhancing our ability to meet the Recent Acquisitions
needs of customers and were gratified to hear that our ef-
forts really paid off. Lincoln Electric Holdings, Inc., Cleveland, Ohio, has acquired
Vizient Manufacturing Solutions, Bettendorf, Iowa. The
Manncorp Celebrates 50th Anniversary privately held robotic integrator, which specializes in custom-
engineered tooling and automated arc welding systems for
Manncorp has achieved 50 years of service to the elec- general and heavy-fabrication applications, also has operations
tronics industry. Founder and CEO Henry Mann started the in Brazil. Annual sales are approximately $40 million.
company from his parents home in Philadelphia in 1966. Praxair, Inc., Danbury, Conn., has acquired five industrial
In the late 60s and early 70s, every industrial park in gas businesses. In the United States, it bought three inde-
the country was full of companies building their own circuit pendent distributors of industrial and specialty packaged
boards, Mann said. However, he noticed that not only were gases The Welding Center in Illinois, Welder Services in
companies in need of equipment and supplies, but they also Indiana, and A&B Electric Motors and Supplies in Arizona.
needed them quickly and efficiently. These observations led In Panama, it secured Geneva Industrial Gases. Also, its Ital-
him to develop a customer-focused business model. Mann ian subsidiary, Rivoira, acquired Ossigas S.r.l. Combined,
created catalogs that published pricing for everything from these had 2015 annual sales of more than $40 million.
hand tools to high-end capital equipment. In addition, the Novaria Group, Fort Worth, Tex., has acquired substantial-
company started designing and manufacturing its own ly all the assets of Ferco Tech, L&E Engineering, and GGF
brand of equipment. Manufacturing. These three business units, collectively op-
Delco and Motorola sought Manns assistance in develop- erating as Ferco Aerospace, supply aircraft engine manufac-
ing systems for applications like high-volume processing of turers with high-strength, temperature-resistant brackets,
transistors, while some of the earliest equipment to form tube assemblies, and other exotic metal fabrications. WJ

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Stainless Q&A July.qxp_Layout 1 6/10/16 12:56 PM Page 18
STAINLESS Q&A
BY DAMIAN J. KOTECKI
making a butt joint with a square very typical of good quality commer-
Q: We have been trying to qualify
preparation, the welder adds filler cial products.
welders for complete joint penetra
metal only to keep from having a con- The calculations of Table 1 are
tion gas tungsten arc welding
cave bead shape, and when the joint shown on the WRC-1992 diagram
(GTAW) butt joints of 304 stainless
closes, less filler metal is required so (Ref. 1) with extended axes and the
to carbon steel according to the
that dilution increases. As a result, di- 1% martensite boundary in Fig. 1. A
AWS D1.6/D1.6M:2007, Structural
lution (percent of base metal incorpo- first tie-line is drawn from the carbon
Welding Code Stainless Steel.
rated into the fused metal) can range steel composition to the 304 composi-
The steels are 18 in. thick. Although
from near 0 to 100% in GTAW. A root tion. The midpoint of this tie-line rep-
D1.6 does not provide for prequali
opening of 116 in. maximum will result resents the equal mix of the two base
fied welding procedures of stainless
in high dilution for complete joint metals, which can be considered as a
to carbon steel, we thought that
penetration, and dilution will increase synthetic base metal. Then a second
the AWS B2.11/8010:2015, Stan
as the root opening closes. tie-line is drawn from this synthetic
dard Welding Procedure Specifica
To understand this effect on GTAW base metal to the ER309/309L filler
tion (SWPS) for Gas Tungsten Arc
of a dissimilar metal joint, it is helpful metal composition. All possible dilu-
Welding of Carbon Steel (M1/P1)
to consider Table 1, which shows a tions of the synthetic base metal with
to Austenitic Stainless Steel (M8/P
typical carbon steel composition, a the ER309/309L filler metal must lie
8) through 10 Gauge, in the As
typical 304 stainless steel composi- along this second tie-line. The point
Welded Condition, with or without
tion, a typical ER309/309L composi- labeled Weld Metal corresponds to
Backing, would be a logical starting
tion, and calculated fusion zone com- 80% dilution. It lies along the second
point. We are using ER309/309L
positions at several dilution levels. tie-line at 80% of the distance from
filler metal as in the SWPS. The
Table 1 assumes that there is equal the ER309/309L filler metal to the
joint design has been a square butt
contribution to the dilution from each point labeled Mix of Base Metals.
with a maximum root opening of 116
of the two base metals. This weld metal composition lies be-
in. (the root often closes partially
One might think, since the low and to the left of the 1% Mn
between tacks), as shown as joint
ER309/309L composition is quite a bit Martensite Boundary on the diagram,
type 1 in Fig. 1 of the SWPS.
lower in Cr than midrange (the range predicting that the weld metal mi-
D1.6/D1.6M: 2007, Table 4.3, re
is 23.0 to 25.0% Cr in AWS A5.9), I crostructure will be martensite and
quires a face bend and a root bend
have deliberately chosen an odd com- the weld metal therefore will be brit-
for welder qualification. We have
position, but that is not the case. Sup- tle. Such a composition would be ex-
failed these tests with virtually
pliers of 309(L) rod for drawing into pected to develop transverse cracks
every welder. The welds typically
welding wire very commonly target during a longitudinal face bend or root
develop a number of transverse
the low end of the chromium range to bend test, as were often observed by
cracks during bending, and there is
keep the ferrite content of the wire the inquirer.
an occasional longitudinal crack.
low for ease of reducing the ingot or It can be appreciated that the com-
What is wrong?
billet to rod. Likewise, suppliers of position indicated as 60% Dilution in
309(L) rod commonly keep the nickel Table 1 will lie along the second tie-
A: The root of the problem lies in the content to the high end of the nickel line of Fig. 1 at 60% of the distance
fact that, unlike in SMAW, GMAW, range (the range is 12.0 to 14.0% Ni in from the ER309/309L filler metal to
FCAW, and SAW, in GTAW there is no AWS A5.9), again to keep the ferrite the point labeled Mix of Base Metals.
relationship between filler metal depo- content of the rod low. The ER309/ That point will lie inside the grey
sition rate and welding current. In 309L composition shown in Table 1 is shaded 1% Mn Martensite Bound-
Table 1 Dilution Calculations in Joining Carbon Steel to 304 with ER309/309L
Typical Chemical Composition, wt%
Component C Mn Si Cr Ni Mo Nb Cu N
Carbon Steel 0.15 0.90 0.10 0 0 0 0 0 0.005

304 0.04 1.20 0.40 18.5 9.8 0.1 0 0.2 0.04
Equal Mix of 0.095 1.05 0.25 9.25 4.90 0.05 0 0.1 0.023
Base Metals
ER309/309L 0.02 1.5 0.40 23.5 13.5 0.1 0 0.2 0.04
20% Dilution 0.035 1.41 0.37 20.65 11.78 0.09 0 0.18 0.037
40% Dilution 0.05 1.32 0.34 17.8 10.06 0.08 0 0.16 0.033
60% Dilution 0.065 1.23 0.31 14.95 8.34 0.07 0 0.14 0.030
80% Dilution 0.08 1.14 0.28 12.10 6.62 0.06 0 0.12 0.026

Fig. 1 WRC1992 diagram including typical compositions of car

bon steel, 304 stainless steel, and ER309/309L stainless steel filler
metal. Fig. 2 Joint type 1 from AWS B2.11/8010:2015.
ary. Compositions within this grey examples of Table 1 would shift the comfortably within the region of com-
shaded boundary area may or may not sweet spot slightly, but the general positions that solidify as primary fer-
be martensitic and may or may not fail trend will be the same. rite. It is well within the sweet spot.
a bend test there is a degree of un- The 20% dilution composition in So the remedy for the problem de-
certainty when compositions lie inside Table 1 would be found at 20% of the scribed by the inquirer is to ensure
this boundary area. distance along the second tie-line pro- that the weld metal composition will
However, weld metal composition ceeding from the ER309/309L compo- lie in the sweet spot of less than 40%
corresponding to 60% dilution lies to sition towards the point labeled Mix dilution. That can be accomplished by
the left of an extrapolation of the light of Base Metals. This lies comfortably expanding the root opening the in-
green dashed boundary that separates above the martensite boundary and quirer indicated a root opening of 116
primary austenite solidification mode
(region labeled AF in Fig. 1) from pri-
mary ferrite solidification mode (re-
gion labeled FA in Fig. 1). This
means that, even if the 60% dilution
composition does not form marten-
site, it is likely to be susceptible to so-
lidification cracking. Solidification
cracking is usually longitudinal to the
welding direction. Note that the in-
quirer also reported occasional longi-
tudinal cracks.
The composition labeled 40% Dilu-
tion in Table 1 lies 40% of the dis-
tance along the second tie-line from
the ER309/309L filler metal to the
point labeled Mix of Base Metals.
This is almost exactly at the point
where the second tie-line crosses the
light green dashed boundary between
the AF and FA regions. The 40% dilu-
tion composition will not form
martensite and may or may not be
susceptible to solidification cracking.
Any composition of less than 40%
dilution will lie in the FA region and
therefore not be susceptible to solidifi-
cation cracking and not form marten-
site. Such compositions should be con-
sidered to be in the highly desirable
sweet spot. Of course, somewhat dif-
ferent compositions for the base met-
als and filler metal illustrated in the

in. maximum, and that it often closes

during welding. Figure 1 from AWS
B2.1-1/8-010:2015 (Fig. 2) allows for a
root opening of up to the maximum
thickness of the two members of the
joint. Since the base metals are about 18
in. thick, a 18-in. root opening would be
within the limits of this SWPS. The
root opening would need to be main-
tained by frequent tacks to prevent
closing that results in higher dilution.
Another approach would be to grind or
machine a single V-groove or single
bevel joint preparation so that more
filler metal would be required to fill
the joint. If a single bevel is used, I
would recommend putting the bevel
on the carbon steel side so that more
dilution comes from the 304 side than
from the carbon steel side that
would move the point labeled Mix of
Base Metals to the right in Fig. 1 and
would thereby increase tolerance for
dilution in the joint. I note that a
V-groove or bevel groove joint prepa-
ration is not within the SWPS men-
tioned, so the inquirer would need to
write a new WPS.
The inquirers experience demon-
strates a limitation of simply following
a SWPS. As stated in the clause titled
Users Responsibility in AWS
B2.1-1/8-010:2015, The ability to
produce production welds having
properties suitable for the application
depends upon supplementing the
SWPS with appropriate performance
qualification tests and sound engi-
neering judgment. Sound engineering
judgment would certainly entail
limitation of dilution as described
above. WJ
Reference
1. Kotecki, D. J. 2000. A martensite

boundary on the WRC-1992
diagram Part 2: The effect of
manganese. Welding Journal 79(12):
346-s to 354-s.
DAMIAN J. KOTECKI is president, Damian

Kotecki Welding Consultants, Inc. He is treas
urer of the IIW and a member of the A5D
Subcommittee on Stainless Steel Filler Met
als, D1K Subcommittee on Stainless Steel
Structural Welding; and WRC Subcommittee
on Welding Stainless Steels and NickelBased
Alloys. He is a past chair of the A5 Commit
tee on Filler Metals and Allied Materials, and
served as AWS president (20052006). Ques
tions may be sent to Damian J. Kotecki c/o
Welding Journal, 8669 NW 36 St., # 130,
Miami, FL 33166, or via email at
damian@damiankotecki.com.

VOESTALPINE BOHLER.qxp_FP_TEMP 6/7/16 1:37 PM Page 21

RWMA Q&A July 2016.qxp_Layout 1 6/9/16 9:53 AM Page 22
RWMA Q&A
BY ROGER HIRSCH
tion in the welding machine secondary

Q: We are welding 14gauge steel making about 25 welds a minute. (exposed copper components at the
We can get very good welds for the first 50 or so pieces, then the welds front of the welding machine) that has
start to weaken. If we stop welding for about a half hour, the welds high resistance will heat up during
start off well and then again become weaker after about 50 pieces. welding and increase this resistance.
Does this sound like a problem with the welding control? Another person contacted me recently
with this exact problem on a 250-kVA
A: While it is always possible that a aircraft welding machine. I suggested
welding control can have a problem, I he check the secondary connections
doubt this is the case here. There are and he found the lower arm connec-
two things to look for. tion to the weld transformer second-
1. Water problems. If cooling water ary pad was loose and had arched as
flow is low, or water temperature is too shown in Fig. 1. Because the connec-
high, heat will build up in the election was so badly pitted, the surfaces
trodes, holders, and other water-cooled had to be machined and silvered. Once
components in the welding machine this was done and the bolts tightened,
secondary. This raises the resistance of the welding machine produced the
these components and lowers the cur- same current over the entire shift.
rent in the weld. The most common
problem I see is that a water tube in the Q: I weld stainless steel cross
electrode holder is missing, or the cool- wires Fig. 2. Just by accident,
Fig. 1 Badly arched lower welding we discovered we can increase the
ing tube does not go all the way to the machine arm where it attached to the
bottom of the hollow of the electrode. strength of a weld by lowering the
machines secondary pad. Loose bolts
In this case, the electrode will get hot caused this damage.
welding pressure regulator. Will
enough to turn purple, and the resist- this cause a problem?
ance goes quite high. Letting the weld-
ing machine rest allows this hot cop- 2. Welding machine secondary A: First, lets see what is causing the
per to cool down and lowers resistance. component problems. Any connec- increased strength. If you lower the

the chart, and adjust the weld current pushed into the throat of the
only until you reach good stable re- welding machine (between the
sults. You can find a good chart in the machines arms) and then weld a
RWMA Resistance Welding Manual, 4th front reinforcement channel when
edition, available from the American the door panel is pulled almost
Welding Society at pubs.aws.org/p/ out of the welding machines
323/rwma-resistance-welding-manual- throat, the welds are different in
revised-4th-ed. The chart is in Table appearance and strength. We try
6.1. This chart is for welding steel to make our setups in the middle
rods. For stainless steel rods, increase position of the door, but the re
the electrode force about 10%. Using sults are not reliable. This also
this chart, you can even adjust the per- makes production of strong welds
cent setdown (final height of complet- that do not mar the outer show
ed joint). surface very difficult.
Fig. 2 Stainless steel wires being cross
welded. Q: My company is a threeshift op A: Modern welding controls can easily
eration. We weld large coldrolled solve these problems.
steel door panels on deep throat 1. Line voltage variation. In an-
force between the rods, the resistance welding machines. This includes swer to your first problem, the voltage
at the contact point will increase. The welding of stiffeners as well as going into your welding machine from
energy produced at this joint is cov- hinge plates and latch brackets. the power company is not constant. It
ered by the following formula: There are two problems that we will rise and fall during the day and
have observed. evening in response to the amount of
Joules of energy = I2 r t First, the welds produced dur power being used by others on the
ing the third shift seem to be line. Typically, voltage at night is the
where I = current, r = resistance, and stronger than those from the highest when most industrial use is
t = time. other two shifts even though the low and, in the summer, air condition-
If you reduce the force at the weld welding programs are locked into ing use is minimized.
joint area, you increase the resistance all of our welding machines. The voltage available between the
and therefore increase the energy ex- The second is that if we set up a electrodes on the welding machine sec-
pended on that joint. weld when the door panel is ondary is directly proportional to the
Thats the good news. But you have
to be careful when lowering electrode
force. One of the purposes of electrode
force is to forge the parts together.
Lower force will reduce the amount of
forging and reduce the reliability of
the weld.
Another purpose of the force is to
keep metal within the nugget area
during the weld process. Low force will
start to produce metal expulsion. This
removes some of the metal at the joint
and the flying sparks of hot metal can
be a danger to the operator and others
in that area. Extremely low force will
cause voids inside the weld nugget to
lower the total joint area and reduce
weld strength, and metal expulsion be-
tween the wires at the nugget area
might need to be ground down as an
expensive and unnecessary secondary
process.
Additionally, if you lower the elec-
trode force, you also lower the force
where the electrodes contact the out-
side of the parts being welded. This
heats up the area under the electrodes
more than needed and will rapidly de-
grade the electrode. The result will be
greatly lowered electrode life.
Consult a good cross-wire welding
chart to get starting values to use.
Take the weld force and weld time on
Fig. 3 Large panel pushed all the way into the throat of the Fig. 4 Large panel pulled all the way out of the throat of the
welding machine. welding machine.
line voltage. Therefore, lower voltage compensation systems. These sys- should be able to hold the RMS (effec-
going into the welding machine will re- tems, called AVC or LVC, will electroni- tive) voltage going into the welding
sult in proportionally lower secondary cally increase or decrease the voltage transformer to no worse than 1%
voltage and lower weld current. This on the secondary of the welding trans- variation with a line voltage variation
leaves two choices. First, you can ad- former to produce a reasonably con- of 10%. On a 460-V line, welding
just your welding program settings for stant voltage for each of your heat set- machine output voltage should be
each shift. That is not a great fix but tings. All quality modern resistance within this 1% window for line volt-
can help. The second is to use welding welding controls should have this fea- ages as low as 414 V and as high as
controls that have automatic voltage ture available for your use. They 506 V.
2. Metal into welding machine
throat. As you push the metal panel
back onto the welding machine, the
steel increases the impedance (AC re-
sistance) of the machine secondary.
This means that for the same voltage
at the machines secondary, a lower
current is produced. This lower
current reduces the weld strength
considerably.
I worked on a welding machine that
had a 40-in. throat. The parts being
produced were, at times, pushed pret-
ty much the full depth of the arms
(Fig. 3) and at other times only 4 in.
into the area between the arms
(Fig. 4). With no change to the welding
program, the current produced at
when the part was pulled almost out
of the throat was 12,640 A. When the
part was pushed fully into the throat,
the amperage dropped to 10,690 A.
The welds produced at these two loca-
tions were very different.
One solution is to rotate the part so
that it does not go as deep into the
throat. This means handling large
heavy sheets and requires a really good
support system and a strong operator.
This also reduces production output
by adding a lot of wasted material
handling.
The best solution is to use a weld-

at both extremes of part position by welds. This can cause these joints to
electronically changing the welding fir- fail as the steel sheet is processed
ing and using feedback to target a de- through rollers under high stress on
sired welding current. Some controls the way to the coiler.
are more successful than others at Ironically, many companies own
reaching rock-solid current values be- modern resistance welding machines
tween the electrodes. The best will that have the ability to operate in the
hold the welding current variation to a constant current mode but do not
range of about 1% with parts fully know it exists Fig. 5. They paid for
into and out of the throat. a quality control and are not taking
This becomes even more challeng- full advantage of the controls ability.
ing when you are seam welding with Check your control to see if it includes
rolling electrodes. One process I have a constant current mode. If not, it is
worked on over the years is the joining probably time to upgrade your welding
of steel coil ends during the processing machine if you want consistent weld
of sheet steel into coils. When one bil- quality on large parts. WJ
let has been rolled out, the end of the
steel strip has to be joined to the start
of the next rolled sheet. This is often
done by having a seam weld wheel as-
sembly move over this splice while the ROGER HIRSCH is a past chair of the Re
metal stays still. sistance Welding Manufacturing Al
The sheets can be 8 ft or wider and liance (RWMA), a standing committee
Fig. 5 Setting a weld program in
this changes the secondary impedance of the American Welding Society. He is
constant current mode using direct
also president of Unitrol Electronics,
amps. dramatically as the wheels travel deep-
Inc., Northbrook, Ill. Send your com
er into the steel sheet. Without some ments and questions to Roger Hirsch
form of constant current ability from c/o Welding Journal, 8669 NW 36 St.,
ing control that provides some form of the welding control, the welds pro- # 130, Miami, FL 33166, or via email at
constant current function. This func- duced at the end of a joint would be roger@unitrolelectronics.com.
tion can maintain the welding current considerably weaker than the starting
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Coubrough Feature July 2016.qxp_Layout 1 6/10/16 12:57 PM Page 32
Selecting Filler Metals

for Stainless Steel
BY JAY COUBROUGH AND
Here are answers to your questions on KARIN IVARSSON
how to choose the right filler metal for
your stainless steel application
T
he capabilities that make stainless
steel so attractive the ability to
tailor its mechanical properties
and resistance to corrosion and oxida-
tion also increase the complexity of
selecting an appropriate filler metal.
For any given base material combina-
tion, any one of several types of elec-
trodes may be appropriate depending
on cost issues, service conditions, de-
sired mechanical properties, and a host
of welding-related issues.
This article provides the necessary
technical background to give the read-
er an appreciation for the complexity
of the topic and then answers some of
the most common questions filler met-
al suppliers receive. It establishes gen-
eral guidelines for selecting appropri-
ate stainless steel filler metals and
then explains all the exceptions to
those guidelines. The article does not
cover welding procedures, as that is a
topic for another article.
Four Grades, Many

Alloying Elements
There are four principal categories
of stainless steels: austenitic, marten-
sitic, ferritic, and duplex (Table 1). The
names are derived from the crystalline
structure of the steel as it is normally
found at room temperature. When
low-carbon steel is heated above
1550F, its atoms are rearranged from
the structure called ferrite at room
temperatures to the crystal structure
called austenite. On cooling, the low-
carbon steel atoms return to their
original structure, ferrite. The high-
temperature structure, austenite, is
Fig. 1 To reduce the risk of intergranular corrosion issues, consider using a Type L
filler material. nonmagnetic and has lower strength

Coubrough Feature July 2016.qxp_Layout 1 6/10/16 12:58 PM Page 33
joints produced in austenitic stainless

Table 1 Stainless Steel Types and Their Chromium and Nickel Content
steels are strong, ductile, and tough in
their as-welded condition. They do not
Type % Chromium % Nickel Types
normally require preheat or postweld
heat treatment. Austenitic grades ac-
Austenitic 1630% 840% 200, 300
count for approximately 80% of the
Martensitic 1118% 05% 403, 410, 416, 420
Ferritic 1130% 04% 405, 409, 430, 422, 446
stainless steel welded, and this article
Duplex 1828% 48% 2205
focuses heavily on them.
How do I choose the correct

and greater ductility than the room- referred to as the chrome-nickel stainless filler metal?
temperature form of ferrite. type, and martensitic and ferritic
When more than 16% chromium steels are commonly called the If the base material in both plates is
is added to the steel, the room- straight chrome types. Certain alloy- the same, the original guiding princi-
temperature crystalline structure, fer- ing elements used in stainless steels ple used to be, Start by matching the
rite, is stabilized and the steel remains and weld metals behave as austenite base material. That works well in
in the ferritic condition at all tempera- stabilizers and others as ferrite stabi- some cases; to join Type 310 or 316,
tures. Hence the name ferritic stain- lizers. The most important austenite choose the corresponding filler type.
less steel is applied to this alloy base. stabilizers are nickel, carbon, man- To join dissimilar materials, follow
When more than 17% chromium and ganese, and nitrogen. The ferrite sta- this guiding principle: choose a filler to
7% nickel are added to the steel, the bilizers are chromium, silicon, molyb- match the more highly alloyed materi-
high-temperature crystalline structure denum, and niobium. Balancing the al- al. To join 304 to 316, choose a 316
of the steel, austenite, is stabilized so loying elements controls the quantity filler.
that it persists at all temperatures of ferrite in the weld metal. Unfortunately, the match rule has
from the very lowest to almost Austenitic grades are more readily so many exceptions that a better prin-
melting. and satisfactorily welded than those ciple is, Consult a filler metal selec-
Austenitic stainless is commonly that contain less than 5% nickel. Weld tion table. For example, Type 304 is
Fig. 2 To improve wet out in GMAW applications, consider using a welding wire with silicon, such as 308LSi or 316LSi.

Coubrough Feature July 2016.qxp_Layout 1 6/8/16 10:01 AM Page 34
Table 2 The High Alloy Content of Type 309L and 312 Makes Them Suitable for Joining Stainless Steel to Carbon Steel
Ni Si C Mn Cr FN WRC-92 N Mo
309L 13.4% 0.4% 0.02% 1.8% 23.2% 10% 0.05% 0.10%

312 8.8% 0.4% 0.10% 1.6% 30.7%
the most common stainless steel base ments to a base material with alloying For joining carbon steel to Type
material, but no one offers a Type 304 elements, use an overalloyed filler so 304 or 316, as well as for joining dis-
electrode. that the dilution within the weld metal similar stainless steels (Table 2), con-
balances or is more highly alloyed than sider a Type 309L electrode for most
If I am supposed to match the stainless base metal. applications. If a higher Cr content is
the filler metal to the base
metal, what do I use to weld
Type 304 stainless?
To weld Type 304 stainless, use
Type 308 filler, as the additional alloy-
ing elements in Type 308 will better
stabilize the weld area.
However, 308L is also an acceptable
filler. The L designation after any
type indicates low carbon content. A
Type 3XXL stainless has a carbon con-
tent 0.03%, where standard Type
3XX stainless can have a maximum
carbon content of 0.08%.
Because a Type L filler falls within
the same classification as the non-L
product, fabricators can, and should
strongly consider, using a Type L filler
because lower carbon content reduces Fig. 3 Because of different expansion rates, distortion from warping must be com-
the risk of intergranular corrosion is- pensated for to a greater extent when welding carbon steel to austenitic stainless.
sues Fig. 1. In fact, the authors con-
tend Type L filler would be more wide-
ly used if fabricators simply updated
their procedures.
Fabricators using the gas metal arc
welding (GMAW) process may also
want to consider using a Type 3XXSi
filler, as the addition of silicon im-
proves wet out Fig. 2. In situations
where the weld has a high or rough
crown, or where the weld pool does
not tie in well at the toes of a fillet
weld or lap joint, using an Si-type
GMAW electrode can smooth the weld
bead and promote better fusion.
If carbide precipitation is a concern,
consider a Type 347 filler (see next to
last question), which contains a small
amount of niobium.
How do you weld stainless

steel to carbon steel?
This situation occurs in applica-
tions where one portion of a structure
requires a corrosion-resistant exterior
face joined to a carbon steel structural Fig. 4 To avoid hot cracking, most standard austenitic filler metals are designed to
element to lower cost. When joining a solidify with a small amount of ferrite. This picture shows 309L weld metal with a
base material with no alloying ele- small amount of ferrite (dark color) in an austenitic matrix.

Fig. 6 Intergranular corrosion takes place in the heat-affected zone on the inside
of a tank storing corrosive media. Using low-carbon and specially alloyed electrodes
can mitigate the risk of carbide precipitation and the resulting corrosion.
chromium with oxygen to form a pro- perature of the application. For exam-
Fig. 5 Duplex steels combine the tective layer of chromium oxide on the ple, too much ferrite causes the weld
best properties of austenite and fer- surface of the material. Stainless rusts to lose its toughness at low tempera-
rite. This micrograph shows a duplex because of carbide precipitation (see tures. Thus, Type 308 filler for an LNG
weld with austenite (light color) in a next to last question) and because the piping application has a ferrite num-
ferrite matrix. welding process heats the weld metal ber between 3 and 6, compared to a
to the point where ferritic oxide can ferrite number of 8 for standard Type
desired, consider Type 312. form on the surface of the weld. Left 308 filler. In short, filler metals may
As a cautionary note, austenitic in the as-welded condition, a perfectly seem similar at first, but small differ-
stainless steels exhibit a rate of expan- sound weld might show wagon ences in composition are important.
sion that is about 50% greater than tracks of rust at the boundaries of the
that of carbon steel. When joined, the heat-affected zone in less than 24 Is there an easy way to weld
different rates of expansion can cause hours. duplex stainless steels?
cracking due to internal stresses un- So that a new layer of pure chromi-
less the proper electrode and welding um oxide can properly reform, stain- Typically, duplex stainless steels
procedure are used Fig. 3. less steel requires postweld cleaning by have a microstructure consisting of ap-
polishing, pickling, grinding, or brush- proximately 50% ferrite and 50%
What are proper weld ing. Again, use grinders and brushes austenite. In simple terms, the ferrite
dedicated to the task.
preparation cleaning provides high strength and some re-
procedures? sistance to stress corrosion cracking
Why is my stainless steel while the austenite provides good
As with other metals, first remove welding wire magnetic? toughness. The two phases in combi-
oil, grease, markings, and dirt with a nation give the duplex steels their at-
nonchlorinated solvent. After that, the Fully austenitic stainless steel is tractive properties Fig. 5. A wide
primary rule of stainless weld prepara- nonmagnetic. However, welding tem- range of duplex stainless steels is
tion is avoid contamination from car- peratures create a relatively large grain available, with the most common be-
bon steel to prevent corrosion. Some in the microstructure, which results in ing Type 2205; it contains 22%
companies use separate buildings for the weld being crack sensitive. To miti- chromium, 5% nickel, 3% molybde-
their stainless shop and carbon gate sensitivity to hot cracking, elec- num, and 0.15% nitrogen.
shop to prevent cross contamination. trode manufacturers add alloying ele- When welding duplex stainless
Designate grinding wheels and stain- ments, including ferrite Fig. 4. The steel, problems could arise if the weld
less brushes as stainless only when ferrite phase causes the austenitic metal has too much ferrite (the heat
preparing edges for welding. Some pro- grains to be much finer, so the weld from the arc causes the atoms to
cedures call for cleaning 2 in. back from becomes more crack resistant. arrange themselves in a ferrite ma-
the joint. Joint preparation is also more A magnet will not stick to a spool of trix). To compensate, filler metals
critical, as compensating for inconsis- austenitic stainless filler metal, but a need to promote the austenitic struc-
tencies with electrode manipulation is person holding a magnet might feel a ture with higher alloy content, typical-
harder than with carbon steel. slight pull because of the retained fer- ly 2 to 4% more nickel than in the base
rite. Unfortunately, this causes some metal. For example, flux-cored wire for
What is the proper postweld users to think their product has been welding Type 2205 may have 8.85%
cleaning procedure, or why mislabeled or they are using the wrong nickel.
filler metal (especially if they tore the Desired ferrite content can range
does my stainless weld rust? label off the wire basket). from 25 to 55% after welding (but can
To start, remember what makes a The correct amount of ferrite in an be higher). Note that the cooling rate
stainless steel stainless: the reaction of electrode depends on the service tem- must be slow enough to allow the

austenite to reform, but not so slow as How do I control carbide How should I prepare for a
to create intermetallic phases, nor too precipitation in austenitic discussion on filler metal
fast as to create excess ferrite in the
heat-affected zone. Follow the manu-
stainless steel? selection?
facturers recommended procedures
At temperatures in the range of At a minimum, gather information
for the weld process and filler metal
8001600F, carbon content in excess on the end use of the welded part, in-
selected.
of 0.02% migrates to the grain bound- cluding service environment (especial-
aries of the austenitic structure, where ly operating temperatures, exposure to
Why do I keep adjusting the it reacts with chromium to form corrosive elements, and degree of ex-
parameters when welding chromium carbide. If the chromium is pected corrosion resistance) and de-
stainless steel? tied up with the carbon, it is not avail- sired service life. Information on re-
able for corrosion resistance. When ex- quired mechanical properties at oper-
For fabricators who constantly ad- posed to a corrosive environment, in- ating conditions helps greatly, includ-
just parameters (voltage, amperage, arc tergranular corrosion results, allowing ing strength, toughness, ductility, and
length, inductance, pulse width, etc.) the grain boundaries to be eaten away fatigue.
when welding stainless steel, the typical Fig. 6. Most of the leading electrode man-
culprit is inconsistent filler metal com- To control carbide precipitation, ufacturers provide guidebooks for
position. Given the importance of alloy- keep the carbon content as low as pos- filler metal selection, and the authors
ing elements, lot-to-lot variations in sible (0.04% maximum) by welding cannot overemphasize this point: con-
chemical composition can have a notice- with low-carbon electrodes. Carbon sult a filler metal applications guide or
able affect on weld performance, such can also be tied up by niobium (for- contact their technical experts. They
as poor wet out or difficult slag release. merly columbium) and titanium, are there to help with selecting the
Variations in electrode diameter, sur- which have a stronger affinity for car- correct stainless steel electrode. WJ
face cleanliness, cast, and helix also af- bon than does chromium. Type 347
fect performance in GMAW and FCAW electrodes are made for this purpose.
applications.
JAY COUBROUGH (JCoubrough@esab.com) is global product manager, Stainless Steel & Nickel Solid Wires, ESAB, Mississauga, ON,
Canada, and KARIN IVARSSON (karin.ivarsson@esab.se) is global project manager, Filler Metals, ESAB, Gothenburg, Sweden.
WELLDIING EDUCCATTION,
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SELECT ARC 2.qxp_FP_TEMP 6/7/16 1:35 PM Page 37

STEFF ARTICLE JULY 2016.qxp_Layout 1 6/7/16 5:46 PM Page 38
Sunny Economics:
Using Solar
Power to
Save Money
BY RACHEL STEFFENSMEIER
AND AMY VAN BEEK
Detailed are the

A
t Steffensmeier Welding and Manufacturing, Inc., Pilot Grove, Iowa
(steffweld.com), a new solar field is putting the company on the map as the
many reasons first industrial manufacturing operation to be fully solar powered in the
state. The solar field has 430.66-kW DC power and is located on 3 acres adjacent
why a welding to the headquarters on an open property the business already owned Fig. 1.
This move will save an estimated $92,000 per year in electrical costs, with a
business serving 5 to 6 year return on total project costs. Over 25 years, its projected to save about
$2.5 million in utility costs.
the Heartland Another bonus is running an operation thats more sustainable.
A carbon emission reduction equivalent of about 8917 metric tons of CO2 will
installed a be seen over the next 25 years. In energy terms, this translates to avoided
9,599,356 lb of coal burned, 228,614 trees planted and grown for 10 years, or
430-kW solar field 1227 homes energy use for one year.
Follow the story of this sunlit shift.

Fig. 1 This aerial shot shows the costs. He took what he learned to Jen-
312-acre Steffensmeier solar field in ny, then she assembled a team to in-
Pilot Grove, Iowa. It powers the vestigate its feasibility.
welding companys entire operations After meeting with multiple ven-
and offers 430-kW DC power. dors, Steffensmeier decided to collabo-
rate with the Iowa-based solar design
and installation firm, Ideal Energy,
who shared the companys values.
The welding company announced
the project in July 2015. Iowa Gover-
nor Terry Branstad was present at that
presentation Fig. 2.
Its important to remember that
80% of the new jobs in our state come
from existing businesses, Branstad
said. The more I can be knowledge-
able and helpful to eliminate some of
the barriers, the better the Iowa econ-
omy and the opportunities in the
state.
Making a Cost-Effective
Choice
The system was installed at a total
cost of $973,233. However, the net
cost of Steffensmeier Weldings system
after tax incentives and depreciation
for all years will be $322,257.
Once construction began, the proj-
ect was completed in six weeks to ac-
commodate using 2015 tax credits.
The following incentives were bene-
ficial: the Federal Investment Tax
Credit, covering 30% of the system
costs as a dollar-for-dollar reduction in
income taxes, the Modified Accelerat-
ed Cost Recovery System, an incentive
that applies to solar to help capture
the depreciation value faster than nor-
mal, and the Iowa Solar Tax Credit.
Installation Impact
The solar installation was not in a
simple rectangle, even though the pre-
liminary design started out that way.
During the value-based engineering
phase of the project, on-the-ground
Clean-Energy tristate area within a 200-mile radius site assessments revealed potential
(see sidebar). shading issues from the buildings dur-
Transformation To continue spurring growth and ing winter months. Taking this into ac-
increasing efficiency, she adopted new count along with the property avail-
Last year, Jenny Steffensmeier as- strategies, including pioneering the able and solar production goals, a key-
sumed management of the family solar field. shaped layout was adopted Fig. 3.
business when her husband Ben The inspiration for this project
passed away. He founded the company came when the companys former pro- Advanced Technology Details
in 1982 by opening a repair shop from duction engineer, Glenn Steffensmeier
his small garage to assist Iowas farm (Bens brother), was looking into solar The solar field is constructed of
and agricultural industries. Since then, power at his own homestead. He heard 1412 solar panels with 21 inverters to
it has become an industrial operation about Iowa farmers and agricultural generate an annual production of
with 22 employees, occupying a operations transitioning to this energy 548,981 kWh Fig. 4. Thats enough
24,000-sq-ft facility, and serving the form and saving money on utility to cover Steffensmeier Weldings com-

Fig. 2 Iowa Governor Terry Branstad (far left) spoke at

Steffensmeier Welding last year. Pictured next to him are
former Production Engineer Glenn Steffensmeier, Owner Fig. 3 This overhead picture, taken during the installation
Jenny Steffensmeier, and Ideal Energys Founder and CEO phase, reflects the key-shaped layout chosen for the solar
Troy Van Beek. field.
Fig. 4 An Ideal Energy worker carries a solar panel, one of Fig. 5 A grid of panels, shown at sunset, capture the days
more than 1400 that make up the field, to be placed in its spot. last sunshine to generate electricity.
plete electrical needs on a net-annual frequency to the utility grid using a ergy transfers down the lines and the
basis. local oscillator and limit the voltage inverters stay disconnected until the
Using net metering, the array is de- for a high-quality match with grid power grid returns to normal.
signed to overproduce in electricity voltage. The inverters on-board com- With no moving parts and solid-
during the summer, allowing credit to puters sense the grids waveform and state technology, the solar installation
build with the serving utility. The adjust the output voltage to match on is a minimal maintenance, passive
credit is then drawn upon during win- the fly. The inverters output voltage energy-generation system, which is
ter months when production is lower and current are aligned within 1 deg one of the reasons the company was
due to shorter daylight periods and with the grid. attracted to the technology.
more cloudy days. Steffensmeier Weldings industrial
electrical equipment cannot tell the Linking the Inverters
The Importance of Inverters difference if energy is coming from the
grid or on-site solar installation. With Iowas seasonal weather, any
At the heart of the solar installa- The inverters are also equipped with significant dust buildup on the solar
tion are American-made, SMA Sunny built-in safety features meant to pro- panels is washed away with the next
Tripower inverters, turning the up-to- tect utility line workers who are sent rainstorm. Theres not much to do but
800 V of raw DC energy generated out to fix the power grid in case of an watch the sunshine and generate elec-
from the solar panels into familiar, outage. If the inverters on-board com- tricity, though it can be important and
clean, and workable 480-V AC energy. puter detects that the utility grid has useful to know exactly how the solar
The transformerless grid-tie- gone down, the inverters automatically installation is performing Fig. 5.
inverters synchronize their output disconnect from the grid so that no en- For this purpose, the solar inverters

are linked together using an RJ45 Cat5e

ethernet cable, and connected to the
SMA cluster controller, a monitoring Facts at a Glance
device.
In particular, the monitoring device
provides on-site readouts for solar pro-
Steffensmeier Welding
duction performance and is also con-
nected to the Internet via an RJ45
and Manufacturing
Cat5e ethernet cable so information is
also available online in more detail. As a custom-order fabricator that 12-ft shear, 38-in. mild steel capacity;
The company can view live solar pro- services the Midwest, Steffensmeier oxyfuel cutting table, 6 16 ft;
duction performance by computer, Welding and Manufacturing, Inc., Pi- and three auto band saws, 10 14,
tablet, or smartphone. lot Grove, Iowa, has handled various 15 20, and 16 16 in.
The system is also outfitted with an- jobs over its 34-year history. From the Forming, Bending Two, 230-
alytic tools that show, in detail, how the design phase to final production, it fo- ton 12-ft press brakes; tube bender,
solar system is performing on a daily or cuses on fine craftsmanship; some of up to 2-in. pipe; plate roller, 10 ft
yearly basis to ensure expected per- the companys welders are certified by long, up to 516-in.-sheet thickness; and
formance and assist in any necessary the American Welding Society. angle roller, rounds 1316 in. and
maintenance. In addition to in-house service, a squares 214 in.
mobile repair unit is deployed for on- Welding Robots; gas metal arc/
Additional Advantages site farm and industry repairs. Also, gas tungsten arc welding equipment;
it serves some of the largest enter- steel, aluminum, and stainless capa-
Theres an economic multiplier ef- prises in the region, including bilities; and braze welding.
fect we see with solar, said Troy Van Siemens Wind, Hawkeye Steel, ICI Machining Manual lathes,
Beek, CEO of Ideal Energy. Steffens- Iowa Fertilizer, and Cryotec, yet takes 1400 rev/min; four CNC mills (two
meier will use these savings to grow a no job is too small attitude. with pallet changers); and two CNC
their company, ultimately benefiting Here is a look at the fabricators lathes (one with a bar feeder).
Lee County. range of capabilities. Painting Powder coating sys-
This installation is also contributing Laser, Cutting 2500-W laser, tem and manual wet spray painting.
to the growth of Iowas new solar econo- 5 10 ft; 4000-W laser, 6 12 ft;
my, which has expanded from two in-
stallation companies in 2009 to 45 com-
panies that employ nearly 1000 people
across the state today.
When businesses like Steffensmeier
Welding and Manufacturing decide to
switch to solar energy, theyre saving on
their operating budget, creating jobs in
our state, and contributing to a healthi-
er environment, Van Beek added.
Bright Future
Jenny Steffensmeier hopes her weld-
ing companys solar panel project will
inspire other businesses.
There has been a strong history of
development and growth at Steffens-
meier, which will only get stronger as
were able to use the savings to provide
more classes, training, and benefits to
our employees, she said.
This change could not have hap-
pened without the people who make the
company what it is today, she
concluded. WJ
RACHEL STEFFENSMEIER
(rachels@steffweld.com) is the marketing
director at Steffensmeier Welding and Manu-
facturing, Inc., Pilot Grove, Iowa. AMY VAN Jeremy Marshall, an employee at Steffensmeier Welding, gas metal arc welds
BEEK (amy@idealenergyinc.com) is the co-
a project.
founder of Ideal Energy, Inc., Fairfield, Iowa.

Guy Feature (Hobart).qxp_Layout 1 6/8/16 2:09 PM Page 42
Variables Affecting the

Mechanical Properties
of Carbon Steel Welds
BY BLAINE GUY
Variables such as heat input and shielding gas can

impact the finished weld, even when using the same
classification of filler metal. Mechanical properties
such as tensile strength, ductility, and yield strength
can vary greatly from weld to weld as a result.
Understand how
heat input and
shielding gas
impact weld
deposit properties
W
hen engineers design a struc-
ture whether it is a bridge,
building, or vehicle they
do so according to the strength of the
base material. Every finished product
must meet certain requirements, in-
cluding how much weight it can with-
stand and the amount of force it can
resist. During welding, it is usually im-
portant the filler metal match or
slightly overmatch the base materials
mechanical properties to achieve
those requirements and prevent weld
failures that could be potentially
catastrophic.
To that end, filler metal manufac-
turers rigorously test products to guar-
antee they meet minimum specifica-
tions, based on American Welding So-
ciety (AWS) and other industry stan-
dards. Filler metals typical mechanical
values are some degrees higher than
the AWS minimums.
There are welding variables, howev-
er, that can impact the finished weld
properties, even when using the same
filler metal. Mechanical properties
such as tensile strength, ductility, and
yield strength (see sidebar) can vary
greatly from weld to weld as a result.
Consider this example: An AWS
E71T-1 gas-shielded carbon steel flux-
cored wire typically provides 74,000-
lb/in.2 tensile strength. Changing the
shielding gas and welding parameters
can make the weld possess over
90,000-lb/in.2 tensile strength with
that same filler metal.
Understanding the ways in which
variations in heat input and shielding
gases, in particular, affect weld deposit
properties is important. It helps
ensure the weld stands up to the
necessary strength and quality
requirements.

input will also reduce ductility, which similar to those regarding heat input
Mechanical Properties can make the finished weld more sus- variations, with the same relationship
Defined ceptible to cracking. between strength and ductility.
On the other hand, completing a Shielding gas with higher argon
Tensile strength is the maximum weld with higher heat input results in content results in welds with higher
force required to produce failure. larger weld deposits and requires few- tensile and yield strengths and lower
er passes to fill a joint. This improves ductility. Again, the higher strength
Ductility refers to how much ductility and resistance to cracking but may or may not be needed for the
the material can stretch before it lowers tensile and yield strength a application, and the disadvantage is
fractures. disadvantage if the reduction is that the weld is more susceptible to
enough to cause the weld to fall below cracking.
Yield strength is the force re- minimum requirements. Conversely, higher CO2 content in a
quired to cause a material to plasti- As an example, an AWS E71T-1C or shielding gas mixture improves ductili-
cally deform or yield. E71T-1M carbon steel wire, when used ty and crack resistance but lowers the
with a low heat input of 30 kJ/in., pro- tensile and yield strengths. As a result,
Heat input (kJ/in.) = [amps duces a tensile strength of 93,800 the weld may fail minimum require-
volts 60] /[1000 (travel speed lb/in.2, a yield strength of 89,300 ment standards if the numbers drop
in in./min)] lb/in.2, and an elongation of 24%. below necessary levels.
Compare that to the same wire used Consider the different variances
Elongation is a measurement of a with a high heat input of 80 kJ/in., produced in this example: The same
materials ductility expressed in a which produces a tensile strength of E71T-1C or E71T-1M wire mentioned
percentage. 81,500 lb/in.2, a yield strength of previously used with 100% CO2 gas
70,200 lb/in.2, and elongation of 29% provides a tensile strength of 84,000
Table 1. lb/in.2, a yield strength of 77,000
Features of the Heat There are pros and cons with each lb/in.2, and 28% elongation. The same
of the heat input options; the optimal wire used with a gas mixture of 75%
Input and Mechanical choice depends on the applications re- argon/25% CO2 results in a tensile
Properties quirements. For the best results, con- strength of 90,000 lb/in.2, a yield
sult the filler metal manufacturers strength of 83,000 lb/in.2, and elonga-
Changes in heat input can cause recommended parameters for a specif- tion of 26% Table 2.
significant variances in the ductility of ic product to help avoid issues caused There is more to consider when se-
a weld, as well as its tensile and yield by excessively high or low heat inputs. lecting shielding gas. Shielding gas se-
strengths. A materials strength and These recommendations suggest heat lection factors in weldability, fume re-
its ductility are related. As strength in- input ranges to produce the desired quirements, arc qualities, and more.
creases, ductility decreases, and vice strength and ductility results. The change in mechanical properties
versa. The general rule is that higher that shielding gas can cause, however,
strength equals increased brittleness; should always be considered, as it di-
however, higher strengths may be re- Shielding Gas Impact rectly affects the weld quality.
quired in certain applications.
The strength of the weld deposit in- In addition to heat input, shielding
creases with lower heat inputs. Using a gas selection affects the mechanical The Combination of Heat
lower heat input will generally result properties of a weld. There are some Input and Shielding Gas
in smaller welds and requires more general factors to consider when using
weld passes to fill the joint. As well as argon mixtures versus straight CO2 Because high heat input and CO2
the changes in strength, lowering heat shielding gas. The scenarios are very can have a similar effect on mechani-
Table 1 Changes in Heat Input can Cause Signicant Variances in the Ductility, Tensile, and Yield Strengths of a Weld
Low Heat Input (30 kJ/in.) High Heat Input (80 kJ/in.) Dierence
Tensile 93,800 lb/in.2 81,500 lb/in.2 12,300 lb/in.2

Yield 89,300 lb/in.2 70,200 lb/in.2 19,100 lb/in.2
Elongation 24% 29% 5%
Table 2 Shielding Gas Selection Aects the Mechanical Properties of a Weld
100% CO2 75% Argon/25% CO2 Dierence
Tensile 84,000 lb/in.2 90,000 lb/in.2 6000 lb/in.2

Yield 77,000 lb/in.2 83,000 lb/in.2 6000 lb/in.2

Table 3 Varying Heat Input and Shielding Gases can Compound or Oset Eects on Mechanical Properties
High Heat Input with 100% CO2 Low Heat Input with 75% Argon/25% CO2 Dierence
Tensile 81,500 lb/in.2 104,400 lb/in.2 22,900 lb/in.2

Yield 70,200 lb/in.2 98,600 lb/in.2 28,400 lb/in.2
cal properties (reducing strength and elongation. That compares to a low using an argon or CO2 shielding gas
increasing ductility), and lower heat heat input with 75% argon gas, which which option is the better choice all
inputs and high argon content gas will results in 104,400 lb/in.2 tensile depends on the needs and require-
do the opposite (push strength up and strength, 98,600 lb/in.2 yield strength, ments of the specific application and
ductility down), these variables can be and 22% elongation (which is the min- wire. That makes it especially impor-
used together to compound these ef- imum requirement) Table 3. tant to understand the relationship
fects or to offset each other. Whether or not combining these between these variables and the im-
For example, in an application factors to work together is the right pact each has on the mechanical prop-
where a high heat input is causing solution depends upon the filler metal, erties of the weld. Knowing how to ad-
strength to drop, selecting a gas with a as some are more or less affected than just heat and the impact of shielding
higher argon content can help increase others. Also, certain filler metals are gas to help produce the desired effect
strength levels. Conversely, lower heat formulated for dual gas usage, while can help welding operators refine their
input may cause a lack of ductility and others can only be used with a single process and ultimately improve their
CO2 shielding gas can be used to mini- gas. results. WJ
mize that effect.
Using the same carbon steel gas-
shielded wire as in the previous exam-
Understanding the
ples, a high heat input with 100% CO2 Dynamics
combination results in a tensile BLAINE GUY is welding engineer/CWI,
welding engineering and applications,
strength of 81,500 lb/in.2, a yield There are no absolutes regarding Hobart Filler Metals, Troy, Ohio.
strength of 70,200 lb/in.2, and 29% the choice of high heat or low heat, or
For info, go to aws.org/adindex For info, go to aws.org/adindex

Cullison 7-16.qxp_Layout 1 6/8/16 11:36 AM Page 46
International Thermal
Spray Association Holds
Its Annual Conference
BY ANDREW CULLISON
A variety of technical presentations
attracted an audience of researchers,
end users, and manufacturers
B
ill Mosier, executive officer, In-
ternational Thermal Spray Asso-
ciation (ITSA), welcomed atten-
dees (Fig. 1) from 33 member compa-
nies to its annual technical conference
and business meeting, April 2022.
The conference, held at the Opryland
Hotel, Nashville, Tenn., had a full day
of technical presentations. Below is a
brief review of some.
Additive Manufacturing
Advances
The day was started with a presen-

tation from Mark Smith, deputy direc-
tor for Additive Manufacturing, San-
dia National Laboratories, on the chal- Fig. 1 Attendees listened intently to presentations at the International Thermal
lenges and world of opportunities of Spray Associations annual technical conference.
additive manufacturing (AM). Addi-
tive manufacturing (aka, 3D printing) duction of waste or material cost, and configured to handle many different
is basically making parts using data weight and energy savings. It also is a shapes. Half of the construction of the
from a 3D model that directs a layer- process that can produce engineered hand was additive manufactured. Be-
upon-layer deposition of material in materials that may have need for spe- cause of the many iterations allowed
the form of the object. There are vari- cial properties, as well as inexpensive in the design process by AM, it was es-
ous processing technologies for de- prototype objects, jigs, and fixtures. timated the design phase cost only
positing plastics, metals, ceramics, and Smith spoke of its commercial use $10,000, whereas normally it would
multimaterials. The commercialization in aerospace with an example of a part have cost in the area of $250,000.
of 3D printing plastic parts is relative- that was redesigned with an internal Although new applications for AM
ly mature, while metal material is rela- geometry that could only be built with are growing, the process does have
tively immature but growing. At pres- AM. The part was 84% lighter than the limitations. It is still an evolving man-
ent, ceramic use is limited and multi- previous part produced with tradition- ufacturing field, and there is a lack of
material shows potential, but requires al manufacturing, and performed well engineering data to establish design
further development. in load testing. standards. There are software limita-
He noted the potential advantages Another example is a unique prod- tions, and material properties, toler-
of AM include the production of uct designed at Sandia. It is a robotic ances, and residual stresses are still is-
shapes that previously might have hand operated remotely for bomb dis- sues that have to be defined. Postfin-
been impractical or unachievable, re- ablement. The fingers can be quickly ishing equipment is needed, adding

another stage of production. There are tions that offer guides and specifica- erant coatings being researched at the
also inspection and metrology chal- tions for thermal spraying, with three university was to take a lesson from
lenges, and depending on the applica- new guides in the works on powders, nature, specifically the mollusk shell.
tion, AM is not always faster and less masking, and equipment selection. Many shells are composed of two lay-
costly than traditional manufacturing. The committee is composed of 20 ers: a nacreous layer that is damage
Still in its formative stages, there members and 10 advisors representing tolerant, and above it, a hard, thick
are possibilities for thermal spray in producers, end users, educators, and layer that blunts stresses from outside
AM. In the medical field, thermal consultants. forces. Using a rod flame spray
spraying might be the final stage of a Also in the planning stages by AWS process, a layer was deposited followed
custom 3D-printed body implant. Ad- Learning is an online learning module by a polymer infiltration. Then a dense
ditive manufactured plastic parts that that will present the fundamentals of ceramic layer was deposited with the
require conductivity and wear proper- thermal spraying, which will include high-velocity oxygen fuel (HVOF)
ties can rely on thermal spraying to its science, equipment, materials, vari- process. Subsequent bending tests
provide them. There is development ables, and safety. showed the outer layer provided good
being done on spray forming rocket strength. On its fracture, the load was
nozzles, and most interesting, re- Damage-Tolerant Thermal redistributed to the more flexible un-
search is being conducted on direct Spray Coatings der layer. Experiments are continuing
writing of thermocouples, strain with this concept.
gauges, integrated wiring, and sensors
Greg Smith (Fig. 2), an ITSA schol-
using thermal spray. The History of Thermal Spray
arship recipient, spoke of the research
being conducted at Stony Brook Uni-
C2 Thermal Spray versity on damage-tolerant thermal James Weber, Sulzer Chemtech
Committee Update spray coatings. Tower Field Service, gave an interest-
Understanding how to stop a crack ing historical perspective on thermal
David Lee, proxy committee chair, from happening or progressing re- spraying.
gave the audience an update on the quires an extensive study of failure He claimed thermal spraying got its
American Welding Societys C2 Com- modes and experiments in arresting start from a method patented by Oer-
mittee on Thermal Spray. This com- cracks. With thermal spraying, the real likon in 1882 of spraying lead powders
mittee establishes standards on ther- challenge is trying to measure an in- against a fixed surface. The process
mal spray design, manufacture, inspec- herently unstable process. Torch, oper- was developed to make lead plates for
tion, and test methods, as well as ating parameters, kinetic energy, sur- batteries. As this process was refined,
develops guides. It also works on stan- face preparation, cooling, and plume more patents followed, and lead was
dardizing thermal spray symbols and character are just some of the factors the material for early coatings.
definitions. that enter into reproducibility. Thermal spraying really got its
Presently, AWS has seven publica- One approach for the design of tol- boost from the work of Ulrich Schoop,
who is considered the Father of ther-
mal spraying. In 1909, he patented the
first commercially viable thermal
spray plant for delivering metal coat-
ings. In 1912, he developed the first
practical flame spray wire gun (or pis-
tol, as it was called then), and in 1914,
he patented a twin wire arc spray gun.
He continued his research into materi-
als and methods of thermal spraying,
including plasma spraying, and by the
1930s thermal spraying was consid-
ered an accepted process for applying
coatings, especially in corrosion
prevention.
Thermal Spray: Rules of

Thumb
Daryl Crawmer, Fisher Barton
Technology Center, made an interest-
ing presentation on rules of thumb for
thermal spraying.
He started with his first law, The
only absolute in thermal spray is that
Fig. 2 Greg Smith talked about research being conducted at the State University there are no absolutes. Then went on
of New York at Stony Brook on nature-inspired, damage-tolerant thermal spray to his second law, There are no small
coatings. carrier gas leaks, and All carrier gas

leaks are bad. He explained any leak

can lead to contamination, significant
drops in control pressure, and plasma
gun restrike instability, making leaks a
condition not to be ignored.
On the equipment side, he noted
power supplies for plasma and electric
arc spraying only pretend to be DC. Ac-
tually they are really noisy AC super-
imposed on really dirty DC. On arc
starting, he commented most high-
frequency starters are essentially a
spark-gap transmitter, similar to what
was used in the early days of Morse
Code transmission.
If your arc start takes more than
100 ms, you have a problem. It could
be any number of things, including
water-cooled cables, bad gas, moisture,
high-frequency components, point
gap, or dirt and oil.
With surface preparation, he noted
that to increase surface roughness, it
is more effective to increase grit size
rather than increasing pressure or
dwell times.
Wires for electric arc spraying
should not have a cast of more than 30
in. Powder size and mass affect splat
cooling rate the most. His presenta-
tion closed with the statement, Han-
For info, go to aws.org/adindex dles do not belong on high-energy de-
vices such as plasma guns, HVOF
guns, and cold spray guns. They just
encourage people to grab them and
create an unsafe situation.
Four new member companies, De-
Wal, Kermetico, Lincoln Electric, and
Mason Global Management, were also
given a chance to speak about their
products and services.
Upcoming Events
At FABTECH 2016 in Las Vegas,
Nev., Nov. 1618, there will be a free
half-day class on Thermal Spray Ba-
sics: Putting Coatings to Work. Next
year, the annual ITSA conference
is scheduled to be in Albuquerque,
N. Mex. If you are interested in be-
coming an ITSA member company or
want to find out more about the or-
ganization, go to thermalspray.org. WJ
ANDREW CULLISON (cullison@aws.org) is

publisher, Welding Journal.

HOBART BROTHERS.qxp_FP_TEMP 6/7/16 11:16 AM Page 49

Johnsen Feature July 2016.qxp_Layout 1 6/10/16 1:02 PM Page 50
Equipment Furthers Welding

Research Discoveries
BY MARY RUTH JOHNSEN
Adding to the body of knowledge
about welding requires a variety
of specialized equipment
T
he work welding researchers do ence Foundation Manufacturing and beam instrument, and an electron mi-
requires the use of a variety of Materials Joining Innovation Center croprobe, DuPont said. The pride of
specialized equipment in addition (M2aJIC), for which DuPont is the the facility is a JEOL JEM-ARM200CF
to power sources, wire feeders, filler Lehigh site Director. aberration-corrected STEM, a state-of-
metals, shielding gases, lasers, robots, The universitys welding-related fa- the-art instrument purchased through
computer numerical controls, and oth- cilities and infrastructure are concen- a National Science Foundation MRI
er more or less commonplace types of trated in six areas: microstructural grant Fig. 1. This atomic resolution
welding equipment and consumables. characterization; thermal analysis, electron microscope has among the
Depending on their areas of interest, heat treating, high-temperature corro- best resolution in the world.
researchers need equipment that can, sion; mechanical testing; additive The university also houses a mod-
among other things, simulate the con- manufacturing; and microstructural ern light optical microscopy lab with a
ditions that occur during welding, see modeling. full range of reflection, transmission,
into the welds and base metals, moni- The Electron Microscopy Labora- polarized light, dark field, bright field,
tor the welding process, and test the tory at Lehigh University houses one and Nomarski optical microscopes, as
welds for a variety of conditions. of the most advanced suites of elec- well as a Leco 2001 quantitative image
The goal of these researchers work tron microscopes in the world and in- analyzer.
is to not only add to the body of cludes four scanning electron micro- DuPont manages a complete welding
knowledge about welding in general, scopes (see boxed item, page 52), two laboratory with equipment for arc and
but also discover solutions to prob- transmission electron microscopes, laser welding, preparation of experi-
lems and develop methodologies that two scanning transmission electron mental alloys, weldability testing, and
will eventually find their way out of ac- microscopes (STEMs), one focused ion welding simulation. The lab also houses
ademia or government laboratories a Gleeble 3500 high-temperature
and into the private sector. thermo-mechanical simulator for a wide
The Welding Journal asked some range of welding simulation and phase-
prominent researchers to detail some transformation studies (see boxed
of the special equipment they use and item). In addition, DuPont said, The
why they are useful, outline break- Gleeble system has a high-speed
throughs accomplished, and for their dilatometer that is ideally suited to de-
equipment wish list. tect and measure phase transformation
temperatures under the high heating
Lehigh University and cooling rates associated with weld-
ing. Also available is a varestraint tester
The research at Lehigh University, for solidification cracking studies and
Lehigh, Pa., addresses fundamental a Thermonetics welding calorimeter
issues of weldability and properties for conducting transfer efficiency
mechanical properties and corrosion measurements.
resistance of fusion welds in ad- According to DuPont, the universi-
vanced engineering alloys, explained ty has made a significant investment
John N. DuPont, the R. D. Stout in developing a state-of-the-art Addi-
Distinguished Professor of Materials tive Manufacturing (AM) laboratory.
Science & Engineering and Students, faculty researchers, and staff
Associate Director of Lehighs Energy have access to this centralized facility.
Research Center. Our group also The facility has capabilities for all
conducts research in additive Fig. 1 This atomic resolution elec- major forms of additive processes,
manufacturing. Much of our research tron microscope offers some of the DuPont explained. As a central cam-
is conducted through the National Sci- highest resolutions in the world. pus facility for AM, the laboratory also
serves as a site for industry partners

to learn about applications for AM lenges. The university also has the processes. Zhang is the James R. Boyd
technologies. The LU AML has facili- MatCalc, Sysweld, and SOAR programs Professor in Electrical Engineering and
ties for vat polymerization, direct met- for conducting kinetic and heat flow director of the Welding Research Labo-
al deposition, powder bed fusion, simulations. ratory, Institute for Sustainable Manu-
binder jetting, material jetting, and di- Breakthroughs. Significant discov- facturing and Dept. of Electrical and
rect metal deposition. eries have recently been made in two Computer Engineering, University of
DuPont emphasized the increasing- areas that explained why premature Kentucky, Lexington.
ly important role microstructural failures occur in two types of high- For the work he and his colleagues
modeling plays in welding and AM re- temperature materials: dissimilar perform, they need welding power
search, stating it is used in nearly welds involving 9Cr alloys, and prema- sources and wire feeders that can re-
every project. ture creep rupture failure in the new ceive analog signals to control their out-
The modeling results are critical nickel-based Alloy IN740H. These puts, high-speed cameras, and welding
for more efficient design of experi- breakthroughs would not have been robots whose motion/trajectory can be
ments, interpreting experimental re- possible without Lehighs advanced controlled/adjusted in real time rather
sults, and designing new alloys with electron microscopy laboratory and than being preprogrammed.
improved microstructures and proper- modeling capabilities, according to Easy adjustment is key, Zhang ex-
ties. Through its current membership DuPont. plained. With regard to the power
at the Lehigh M2aJIC site, ThermoCalc Wish List. Lehigh University cur- sources and wire feeders, We need to
(Canonsburg, Pa.) provides Lehigh rently collaborates with Northwestern easily adjust the welding parameters
with the full suite of ThermoCalc and University (NU) where NU conducts lo- to adaptively control the welding
DICTRA software tools for conducting cal electrode atom probe (LEAP) tomog- process based on the feedback from
thermodynamic and kinetic simula- raphy. Lehigh would very much like to the process. For the robot, parame-
tions in multicomponent systems. In have a LEAP instrument of its own. ters such as speed, torch orientation,
addition, ThermoCalc provides updat- and torch position must be adjusted.
ed databases as they become available University of Kentucky High-speed cameras allow them to
and provides technical assistance and observe and analyze the welding
mentoring of graduate students as Dr. YuMing Zhangs work focuses process at the speeds they need.
they encounter new modeling chal- on sensing and control of arc welding Breakthroughs. We have devel-
What Is a Gleeble? The systems can perform a wide variety of simulations

and tests to develop, characterize, and test welding materi-
Gleeble systems, developed by Dynamic Systems, Inc., als and processes, including the following:
Poestenkill, N.Y., exactly replicate in a laboratory the ther- Heat-affected zone simulation
mal and mechanical processes a material is subjected to Nil-strength temperature determination
during the manufacturing process or while in its end use. On-heating hot ductility test to determine nil ductility
Available systems include the Gleeble Welding Simula- temperature
tor (GWS) (Figs. 2, 3) and the larger 3500 and 3800 mod- On-cooling hot ductility test to determine ductility
els. Features of the Welding Simulator system include high- recovery temperature and brittle temperature range
speed direct resistance heating up to 10,000C/second and Strain-induced crack opening test for hot crack
controlled cooling or accelerated cooling with optional susceptibility
quench (air/gas/water/mist), at up to 3000C/second. Upset welding.
Fig. 2 The Gleeble Welding Simulator. Fig. 3 A closeup of the GWS tank.

sponds to that to analyze how the In the case of the LeTourneau

What Is a Scanning welder operates, Zhang explained. group, they did compressive loading
Electron Microscope? and measured the deformation rates
LeTourneau University at different temperatures, then fed the
A scanning electron microscope data into a high-frequency (forge)
(SEM) uses electrons instead of The lab at LeTourneau University, weld model. Similarly, they found
light to form images. Since their Longview, Tex., contains a variety of changes in the Curie temperature (the
development in the early 1950s, specialized equipment such as a temperature at which ferromagnetic
SEMs have developed new areas of microwave welding machine, short- materials lose their magnetic proper-
study in the medical and physical circuit detector, high-speed cameras, ties on heating vs. cooling) as a func-
science communities. and infrared cameras. However, the tion of heating rates.
The advantages of an SEM are schools modified DSI Gleeble 1500 Recently, a U.S. patent was issued
that it has a large depth of field, thermal-mechanical simulator plays an to Adonyi, Baylor University Prof. Se-
which allows more of a specimen important role in much of the work as ung Kim, and former students Ithamar
to be in focus at one time, and it does varestraint testing equipment. Glumac and Allen Worcester for a
also has much higher resolution, Professor Yoni Adonyi holds the closed-loop controlled standing-wave,
so closely spaced specimens can be Omer Blodgett Chair of Welding & 3-kW microwave welding machine.
magnified at much higher levels. Materials Joining Engineering at Le- This type of research equipment was
Because the SEM uses electromag- Tourneau and is also Materials Joining not available commercially, so the Le-
nets rather than lenses, re- Engineering Program Coordinator. Ac- Tourneau group designed and fabricat-
searchers have much more control cording to Adonyi, The main focus of ed one.
over the degree of magnification. our research has always been simulat- Breakthroughs. Dynamic recrystal-
The disadvantages of SEMs are ing welding and other manufacturing lization conditions for high-frequency
that they are expensive, large, and processes by deconstructing the ther- weld optimization, plus dissimilar
must be housed in an area free of mal and mechanical processes involved sold-liquid interface simulations for
any possible electric, magnetic, or using the Gleeble. After collecting real centrifugal casting and weld cladding.
vibration interference. They are data from welding processes, we feed Wish list. A Gleeble 3500.
also limited to solid, inorganic them into the Gleeble software and
samples small enough to fit inside simulate different processes by recon- Canadian Centre for
the vacuum chamber that can han- structing them, using different heat
dle moderate vacuum pressure. inputs, etc., without making any Welding and Joining
welds. They focus their energies on
finding mechanical, physical, and oth- The Canadian Centre for Welding
oped a human-robot collaborative sys- er properties under dynamic condi- and Joining (CCWJ), associated with
tem where the robot follows the mo- tions such as high heating and cooling the Dept. of Chemical and Materials
tion of a torch operated by a human rates, or strain rates. Engineering at the University of Alber-
welder, Zhang explained. In this Adonyi desribes physical simula- ta, Edmonton, is located right at the
case, the motion of the human welder tions as the missing link between epicenter of manufacturing for the oil
is not planned in advance. We use a numerical simulations and real life. To sands operations, and is the central
sensor to track the torchs motion and illustrate what he means, he said, point for weld-related issues in the oil
command the robot to follow the mo- Most computer models are inaccurate sands, related Prof. Patricio Mendez,
tion in real time. The robot Zhangs because they use static or not time- the centers director, and Program
group uses is a UR 5 from Universal dependent material properties from Manager Dr. Goetz Dapp.
Robots USA, Inc., East Setauket, N.Y. handbooks (for example, slowly heating The CCWJ holds a preeminent
He prefers this robot because most in- samples to high temperatures and then place in Canada in carrying out weld-
dustrial robots do not allow their mo- measuring their strength by slowly ing research in direct interaction and
tion to be changed in real time, but pulling on them). In reality, in welding collaboration with the industry, Dapp
Universal Robots do. and forging processes, heating rates of said. The center functions as a liaison
Using this human-robot collabora- hundreds of degrees per second and between the industry, equipment
tive system, we can allow the robot to strain rates of many feet/second occur manufacturers, consumable manufac-
carry sensors to see the welding and properties change dramatically. turers, and the global research com-
process. The measurement from the To illustrate this difference, a steel munity, and plays a key role in intro-
sensors can be displayed to the human heated to 1000F can elongate like ducing technological advances and
welder and the human welder can ad- chewing gum when slowly pulled, new technologies to the industry to
just the welding parameters per the reaching almost 100% elongation and drive innovation, increase productivi-
display. The adjustment will be real- no strength. On the other hand, if ty, and optimizing process and proce-
ized by the robot. As such, the human pulled at 3 ft/s, the same steel breaks dures. We offer the unique ability
welder will not carry sensors such that like glass with no elongation or close to combine fundamental research
he can operate freely to adjust the to 0% and considerable strength. The with practical, industry-related and
welding speed and torch orientation Gleeble is able to produce these dy- industry-driven applications, and with
per the feedback of the welding namic properties, and if we feed those our excellent connections in the inter-
process. We will be able to record what results into computer models, they be- national welding and research commu-
the welder sees and how the torch re- come more accurate. nities ensure that the industry can

benefit from developments that reach ment for all arc welding processes, a cumstances has been possible because
far into the future. Fanuc GMAW robot, and a friction stir of the donation of welding machines
The connection to Canadas oil welding machine has been established. and consumables, the understanding
sands region has resulted in a research Our Lincoln S500 with advanced of metal transfer in wire-based
specialization in wear protection over- waveform module, as well as a Miller processes would not have been possi-
lays. Our high-speed videography of XMT 450 make it possible to work ble without the high-speed cameras,
welding processes is being used in complex waveforms, Dapp said. In and the understanding of overlays
welding education by institutions addition, we have highly specialized would not be complete without the
around the world, and recently re- characterization equipment in our lab hardness mapper. Our creative contri-
ceived a lot of attention when we start- such as a Linseis dilatomer that allows butions to the theory of measurement
ed to lead a renewed effort in high- us to study phase transformations; a of phase transformations is based on
speed videography of submerged arc Bruker G8 Galileo oxygen/nitrogen/ our dilatometer, Mendez related.
welding, Mendez said. (See Mendez, hydrogen gas chromatographer that Wishlist. As research progresses
et al. 2015. High-speed video of metal gives us precise readings of O/N/H there are always new tools that can
transfer in submerged arc welding. content in steels and other metals; help to gain insights into areas previ-
Welding Journal 94(10): 325-s to hardness mappers for accurate hard- ously impossible and to take research
332-s.) ness readings even in complex configu- projects to new levels, Dapp noted.
The center also conducts research rations, a Tukon 2500 automated hard- Following is the centers current
into metal transfer and effects of ness tester; a cryogen Instron CEAST wish list:
shield gases, analysis of welding arc 9350 impact tester with up to 1800 J High-speed cool-sensor thermal
plasma, laser cladding, metallurgy and that allows us to do full-size Charpy imaging camera that would help to
failure mechanisms of creep-resistant, samples; and servo-hydraulic testing understand weld temperature
high-alloyed steels (X80, X90), and equipment for dynamic (fatigue) and distributions
dilatometry. The CCWJ also works on fracture toughness testing. We also High-temperature confocal laser
the development of predictive tools have two very high-precision Alicat scanning microscope that would allow
for procedure development. This in- flow meter systems that are synchro- for true metallurgical undestanding of
terdisciplinary research uses a scaling nized with our data-acquisition sys- welding processes, particularly over-
approach and complex mathematics to tems and allow us to mix up to four dif- lays and precipitation in steels
create relatively simple tools an engi- ferent gases on the fly. The capability A lighting system to improve
neer can use in procedure develop- to do high-resolution data acquisition high-speed video of the laser
ment to calculate the effects of weld- is essential for any welding-related re- cladding/welding process
ing parameters within a small error search, and we have multiple systems Laser beam profiler to get accurate
margin without having to rely on com- operating at any given time, including measurements for power density in
plex and expensive simulations on a several National Instruments USB the beam for modeling purposes
computer, Mendez explained. The 6351-X series. The data we obtain in Image analysis software
fundamental nature of this research our experiments is then synchronized Offline programming for welding
creates a large applicability to a wide with our high-speed video cameras, a robots
range of industrial applications. Phantom V210 and a Miro eX4, and Laser profilometer for surface
Donations from welding equipment forms an invaluable tool to understand textures. WJ
manufacturers and suppliers com- weld-stability and metal transfer.
bined with government grants and lo- Breakthroughs. The centers ability
cal industry support, a lab with equip- to perform welds under controlled cir- MARY RUTH JOHNSEN (mjohnsen@aws.org)
is editor of the Welding Journal.
In-Situ Synchrotron and Neutron Radiation

Advanced Welding Research
BY JOHN W. ELMER AND AMANDA S. WU
Over the past century, the principal kinetics, postweld visual observations crostructural evolution of welds are
method for understanding the effects have provided the framework for in- possible. For these reasons, new meth-
of welding on the mechanical and terpreting the events that lead to the ods are being developed for the direct
physical integrity of the final joint has final weld microstructure. However, observation of phase transformations
been postweld microstructure analy- without direct and confirming evi- that occur both during and post weld-
sis, and its the interpretation of these dence of the actual phases that exist ing, using modern synchrotron and
microstructures that sets welding met- during welding, or measurement of neutron user research facilities
allurgy apart from other related scien- invisible weld properties such as (Ref. 1).
tific fields. In conjunction with heat crystal structure and residual stress, Synchrotron radiation provides an
flow analysis, thermodynamics, and multiple interpretations for mi- intense and tunable source of x-rays

Fig. A APS weld neutron radiation. Hence, through-

simulation setup thickness measurements of texture,
showing synchro- dislocation density, and more rele-
tron-based TRXRD vant residual stress, become acces-
experiments being
sible in geometrically complex parts.
performed in an
environmental Aside from their ability to pene-
chamber to prevent trate thick, high atomic number weld-
oxidation of the ed metals, neutrons can be used to de-
heated sample. tect nonmetallic impurities (e.g., ox-
ides and carbides), as these can have
coherent neutron-scattering cross sec-
tions comparable to the metallic ma-
trix, remarked Donald W. Brown,
Team Leader and Instrument Scientist
at Los Alamos National Laboratory.
Further, engineering beamlines at
neutron sources can map residual
stresses near and through weldments,
which is essential for model validation
and refinement, noted Thomas R.
Watkins, Senior Research Staff and the
Scattering and Thermophysics Group
Leader, Oak Ridge National Laboratory
(ORNL).
A schematic of a neutron beam line
is shown in Fig. B, where data have
been collected to help understand
residual stress formation in welds as
well as to provide verification of weld
modeling efforts (Ref. 3). WJ
Auspices
This work was performed under the

Fig. B A schematic of the experimental setup at the VULCAN neutron beam line at auspices of the U.S. Department of En-
ORNLs Spallation Neutron Source. The specimen (blue rectangle) is translated relative ergy by Lawrence Livermore National
to the gauge volume, allowing for mapping studies. The two detector banks can collect
Laboratory under Contract DE-AC52-
signals in two orthogonal directions (LD & ND) simultaneously from the gauge volume
(red square), which is defined by the incident beam slits and radial collimators. (Cour- 07NA27344 and has been assigned the
tesy of Dr. Ke An, ORNL.) document release LLNL-JRNL-
691945.
from the infrared to hard x-ray portions mations in steels, stainless steels, and References
of the electromagnetic spectrum, which titanium alloys (Ref. 2).
has enabled it to become one of the Neutron radiation interacts with 1. Spooner, S. 1992. Using federal
most important research tools for the matter differently than x-rays, and is x-ray, electron and neutron facilities.
study of matter in all its various forms. particularly relevant to welding re- Journal of The Minerals, Metals & Mate-
The intense x-rays penetrate up to tens search where it can spatially probe rials Society 44(10): 7276.
of um in most metals and can be used as residual stresses within bulk welded 2. Elmer, J. W. 2008. A new path
Spatially Resolved (SRXRD) or Time Re- components. Unlike x-rays that inter- forward for understanding microstruc-
solved (TRXRD) x-ray diffraction non- act with electrons, neutrons interact tural evolution during welding. Weld-
contact probes to monitor real-time mi- with atomic nuclei and can be cap- ing Journal 87(6): 149-s to 166-s.
crostructural evolution under the ex- tured or scattered depending upon the 3. Spooner, S. 2003. Neutron resid-
treme temperatures and harsh condi- kinetic energy of the neutron and in- ual stress measurement in welds, in
tions that surround welds (Ref. 2). trinsic characteristics of the samples Analysis of Residual Stress by Diffraction
Figure A shows a schematic of one nuclei. Because of this and in general, Using Neutron and Synchrotron Radia-
type of experiment for simulating neutrons travel further into the crys- tion. New York, N.Y.: Taylor & Francis,
welding that is used at the Advanced tal lattice than x-rays, penetrating up Inc., pp. 296318.
Photon Source (APS), which is situated to tens of mm in typical metals. While
at Argonne National Laboratory. This neutron diffraction measurements
technique probes the surface of a met- cannot currently compete with high
JOHN W. ELMER (elmer1@llnl.gov) is the Group
al alloy in real time at 50-ms resolu- energy x-rays in time or spatial resolu- Leader for Materials Processes, and AMANDA
tion as the sample is heated and tion, the ability to probe the interior S. WU is a Materials Scientist, Materials Engi-
cooled under controlled conditions, to of application-sized components on neering Division, Lawrence Livermore National
study welding-related phase transfor- multiple length scales is unique to Laboratory, Livermore, Calif.

OERLIKON METCO.qxp_FP_TEMP 6/7/16 1:34 PM Page 55

McDemus Feature July 2016.qxp_Layout 1 6/9/16 7:46 AM Page 56
Thermal Spray
The Misunderstood Process
BY ROBERT MCDEMUS
Six thermal spray processes are detailed
along with a common application
The combustion powder/wire and

HVOF along with cold spray processes
use propane, propylene, hydrogen,
natural gas, or vaporized kerosene.
Combined with oxygen in the correct
ratio, a combustion flame is created
that melts the feedstock material. In
cold spray and HVOF, the powder par-
ticles are not fully melted until impact.
Material Source
All the materials in thermal spray
are either a powder or a wire. The
most common wire sizes are 116, 18,
and 316 in. depending on the material,
Twin wire electric arc thermal spray is shown here on stainless steel.
equipment selected, and end applica-
tion.
T
hermal spray is often a misunder- combustion wire, twin wire electric An additional source of material is
stood technology. This process arc, plasma spray, high-velocity oxygen available. Cored wire is a hollow wire
melts the feedstock, atomizes it, fuel (HVOF), and cold spray. filled with powder. If a material can be
and sprays the molten material. All of these processes require three made into a powder or a wire, there is
Molten particles then hit the part be- main components an energy a thermal spray process that can be
ing sprayed, splat, and solidify rapidly. source, a material source, and an at- used to spray it.
On the flip side, welding melts the omizing gas. Figure 1 illustrates how Thermal spray processes can build
feedstock as well as the base material. they work together. up at a rate of 0.0005 to 0.008 in. per
In the past, spray welding was pass depending on the material and
used to describe this process. For clari- Three Main Components process. The surface speed of the ther-
fication, the industry has shifted away mal spray torch over the part being
from using that term.
Both thermal spray and welding are
Energy Source sprayed is in the range of 150 to 300
ft/min. Thus, the time it takes to coat
similar in that they melt the feedstock. Similar to welding, the energy in a part with thermal spray is often sig-
The fundamental difference is thermal thermal spray processes can be from nificantly faster than welding. Addi-
spray does not melt the base material one of three sources electric arc, tionally, the surface temperature of
whereas welding does. The sprayed combustion gases, and plasma arc. the part being coated is kept below
material sticks because of a mechani- An additional source of energy not 300F.
cal bond. used in welding is the velocity of the
This article not only details the dif-
ference between welding and thermal
feedstock material. In HVOF and cold Atomization
spray processes, powder is accelerated
spray but also reviews a typical appli- to high velocities, and the final melt- In welding, the feedstock is melted
cation where thermal spray is useful. ing occurs when the particle impacts from wire or powder, and the droplets
the surface being sprayed. are transferred to a melted base mate-
The twin wire electric arc process rial using low-velocity techniques. In
Identifying Various and the plasma process both use large thermal spray, as the material is being
Thermal Spray Processes power supplies, similar to what you melted, it is subjected to a relatively
would use for welding. Manufacturers high pressure and velocity atomizing
Six common thermal spray process- supply the DC power to melt the feed- gas.
es are as follows: combustion powder, stock material. Sometimes, this atomizing gas is a

result of the expanding gases from the

torch. Other times, compressed gases
are added to the process for atomiza-
tion. In either case, the droplets are
reduced to a smaller size and acceler-
ated, thus atomized.
Table 1 features a comparison of
the common thermal spray processes.
Where Thermal Spray

is Useful
Thermal spray is used to change
the surface properties of components,
Fig. 1 Thermal spray processes melt, atomize, and spray molten droplets. including dimensional control, wear
resistance, corrosion resistance, elec-
trical properties, thermal barrier, and
traction/antiskid.
Table 1 Thermal Spray System Comparisons
Combustion Powder One Common Application

Melting energy is from fuel gas/oxygen. Because the part being sprayed is
Material source is powder, metals, alloys, and some ceramics. normally kept below 300F, thermal
Atomization is from compressed air, plus expanding combustion gases. spray is extremely useful where keep-
Low purchase cost and low operating cost ing heat to a minimum is required.
Useful entry-level technology An example of a common applica-
tion for thermal spray is repairing a
Combustion Wire
damaged shaft. Smaller shafts can dis-
Melting energy is from fuel gas/oxygen. tort with applying heat sufficient
Material source is wire, metals, and alloys. enough to melt the base material. In
Atomization is from compressed air, plus expanding combustion gases. this case, the repaired area does not
Low purchase cost and low operating cost require a metallurgical bond, but it re-
Useful entry-level technology quires a bond strong enough to with-
stand shear forces from postcoat
Twin Wire Electric Arc machining.
In addition to dimensional restora-
Melting energy is electric arc, typically a DC welding power supply.
tion, a material can be selected that
Material source is wire.
Atomization is from compressed air. improves the wear resistance. The ba-
Medium purchase cost and low operating cost sic thermal spray process for this type
Highest spray rates for thermal spray of repair includes machine undersize,
surface cleaning, mask, surface textur-
Plasma Spray ing, thermal spray, clean, and finish
machine.
Melting energy is from ionized plasma gas.
Material source is powder, metals, alloys, carbides, and ceramic.
Atomization is from inert gases used in the process.
Surface Preparation
High purchase cost and high operating cost
Best for ceramics When a shaft is damaged due to a
spun bearing or a worn bearing seal
High-Velocity Oxygen Fuel area, the damaged material must be
removed. This is typically done by ma-
Melting energy is from fuel gas/oxygen and particle velocity. chining the damaged area undersize
Material source is powder, metals, alloys, and carbides. deep enough to create a uniform di-
Atomization is from compressed air, plus expanding combustion gases. ameter and clean up any damaged
Medium purchase cost and high operating cost areas.
Best for carbides
All oil and grease on the part must
Cold Spray be removed before spraying. Some
common methods include degreasing
Melting energy is from particle velocity. with solvents, alkaline water-based
Material source is soft metal powders. washes, and baking in an oven. Extra
Atomization is from compressed gases. care should be taken with castings to
High purchase cost and high operating cost ensure there is no trapped grease or
This is a relatively new and developing technology. oil in the casting porosity.

Fig. 2 Before and after repair using thermal spray: A The pump sleeve before
repair; B the pump sleeve after spray with chrome oxide and grind to finish.
Even though we are keeping the nificant damage to the surface; it was
temperature below 300F, grease and machined undersized down to a uni-
oil will weep out during thermal spray form surface, grit blasted with 24-grit
and cause bonding issues. aluminum oxide, and sprayed. The ap-
plication required an inert and hard
Surface Profile surface. A chrome oxide was selected
and a plasma spray process was used
The bonding of standard thermal to spray the ceramic. The final finish
spray processes is a mechanical bond. was achieved using aluminum oxide
The molten droplets of the material grinding wheels.
being sprayed hit the surface being
coated and splat. The molten materi- Conclusion
al quenches rapidly and attaches to the
surface being sprayed as it solidifies. If Thermal spray is an important, of-
it is a smooth surface, there is not ten misunderstood technology that is
much for it to attach to. If there are used in many industries today. And
jagged peaks and valleys, the molten even though it shares many of the
material will surround those peaks same technologies used in welding, it
and grip it. is not a welding process. As with all
A raised angular profile of 1 to 3 special methods, it has certain niches
mils is optimal for the bond strength where it is the best process to choose
of a thermal-sprayed coating. This is from. WJ
referred to as a white metal finish. It
can be achieved using 24- to 36-grit
aluminum oxide or steel grit as the ROBERT MCDEMUS

(bob@thermalspraydepot.com) is
blast media. the founder of Thermal Spray Depot,
Other alternatives to grit blast are Washington, Pa.
knurling and cutting threads. Howev-
er, the bond strength is inferior to that
from grit blast.
Figure 2A, B shows an example of a
pump shaft repair. This part had sig-

WEILER CORP..qxp_FP_TEMP 6/7/16 1:38 PM Page 59

Conferences July 2016.qxp_Layout 1 6/10/16 1:05 PM Page 60
CONFERENCES
3rd Welding Education, Skills & 19th Annual Aluminum Conference

Certification Conference September 20, 21
August 1012 AWS Headquarters, Miami, Fla.
Houston, Tex.
Aluminum is one of the most versatile and widely used
The impending skills gap in manufacturing continues to metals in manufacturing, but its unique chemical and physi-
be a hot-button topic. In its third year, the Welding Educa- cal properties can also make it one of the most challenging
tion, Skills & Certification Conference aims to address the to weld. During this popular, annual conference, a distin-
welding industry piece of the puzzle. How do we ensure guished panel of aluminum industry experts will survey the
were doing our part to deliver new, skilled professionals current landscape of aluminum welding technology and
into this booming sector? Attend this conference to gain practice. This year also features a new seminar format. The
new insights, share best practices, exchange ideas, and be first day will continue to emphasize core aluminum joining
part of the solution. technologies, while the second day will focus on new joining
technologies and new aluminum applications. The confer-
ence will also provide several opportunities to network in-
formally with speakers and other participants.
Lasers Conference
August 29, 30
San Francisco, Calif. 10th International Conference on
Lasers never seem to quit. Users have found ways to hook Trends in Welding Research & 9th
lasers up with other technologies like hybrid laser arc weld- International Welding Symposium of
ing and additive manufacturing. Those two technologies will Japan Welding Society
be emphasized in the AWS Conference on Lasers. There will
also be presentations on laser cutting, cladding, heat treat-
October 1114
ing, and peening. Tokyo, Japan
The 10th International Conference on Trends in Welding
Research will be held for the first time outside of the United
States. The conference covers not only the fundamental sci-
ence of welding and joining but a wide variety of applica-
tions of welding and joining different materials in different
industries, which include various approaches of theoretical
analysis, experiments, and numerical simulations. The con-
ference will also provide an opportunity for technical discus-
sions, since leading welding and joining scientists and engi-
neers from all over the world will be in attendance. The 9th
International Welding Symposium of Japan Welding Society
will be held jointly with the conference. WJ
For more information, please contact the AWS Conferences and

Seminars Business Unit at (800) 4439353, ext. 218, or email
ablanco@aws.org. You can also visit the Conference
Department website at aws.org/conferences for upcoming
conferences and registration information.
An Important Event
on Its Way?
Send information on upcoming events to the Welding
Journal Dept., 8669 NW 36 St., #130, Miami, FL 33166.
Items can also be sent via FAX to (305) 443-7404 or by
e-mail to ababinski@aws.org.

SOUTHWIRE.qxp_FP_TEMP 6/7/16 1:36 PM Page 61

Coming Events July.qxp_Layout 1 6/10/16 1:19 PM Page 62
COMING EVENTS
10th International Conference on Trends in Welding

AWS-SPONSORED EVENTS Research & 9th International Welding Symposium of Japan
Welding Society. Oct. 1114. Hitotsubashi Hall, Tokyo,
Japan. The conference will cover the fundamental science of
For more information on AWS conferences: welding and joining as well as a wide variety of applications
aws.org/w/a/conferences/index of welding and joining different materials in different indus-
(800/305) 4439353, ext. 455 tries. Visit trends2016.org, or e-mail twr2016@issjp.com.
FABTECH 2016. Nov. 1618. Las Vegas Convention Center,

3rd Welding Education, Skills & Certification Conference. Las Vegas, Nev. Contact American Welding Society, (800)
Aug. 1012. Houston, Tex. This conference aims to address 443-9353, or fabtechexpo.com.
the welding industry piece of the impending skills gap
puzzle. Surface Technologies in the Oil and Gas Industries. Feb. 8, 9,
2017. International Thermal Spray Association. Contact
Lasers Conference. Aug. 29, 30. Crowne Plaza Hotel San Kathy Dusa at kathydusa@thermalspray.org or visit
Francisco Airport, San Francisco, Calif. Lasers are forging re- thermalspray.org.
markable paths, appearing in hosts of new applications such
as hybrid laser arc welding, additive manufacturing,
cladding, and heat treatment. U.S., CANADA, MEXICO EVENTS
19th Annual Aluminum Conference. Sept. 20, 21. American
Welding Society Headquarters, Miami, Fla. A distinguished QNDE (Review of Progress in Quantitative Nondestructive
panel of aluminum industry experts will survey the current Evaluation). July 1622. Georgia Tech Hotel and Conference
landscape of aluminum welding technology and practice. Center, Atlanta, Ga. Contact Iowa State University Center
The first day will emphasize core aluminum joining tech- for Nondestructive Evaluation, (515) 294-8152;
nologies, and the second day will focus on new joining tech- cnde@cnde.iastate.edu or qndeprograms.org.
nologies and applications.

Coming Events July.qxp_Layout 1 6/9/16 9:38 AM Page 63
Digital Imaging 2016. July 25, 26. Foxwoods Resort,

Mashantucket, Conn. Contact American Society for Nonde-
structive Testing, (800) 222-2768 or asnt.org.
Ultrasonics for NDT 2016. July 2729. Foxwoods Resort,

Mashantucket, Conn. Contact American Society for Nonde-
structive Testing, (800) 222-2768 or asnt.org.
Next Generation Collaborative Robots & Automation Tech

nologies Automotive Manufacturing 2016. Aug. 1718. De-
troit, Mich. Assess the commercial benefits of implementing
new robotics and automation technologies. Contact
aman.sandhu@lbcg.com or visit next-generation-automotive-
automation.com.
5th Annual Global Automotive Lightweight Materials

(GALM) Detroit Congress. Aug. 2325. COBO Center,
Detroit, Mich. Drive overall vehicle weight reduction
cost effectively. Contact ash.robins@ibcg.com or visit
global-automotive-lightweight-materials-detroit.com.

NDE/NDT for Highway and Bridges: Structural Materials
Technology 2016. Aug. 29Sept. 1. DoubleTree by Hilton
Hotel Portland, Portland, Ore. Contact American Society for
Nondestructive Testing, (800) 222-2768 or asnt.org.
International Automotive Body Congress 2016. Sept. 2829.

Ford Motor Co. Conference and Event Center, Dearborn,
Mich. Visit gamcinc.com.

aws.org
Want access
ess to reliable,
re
accurate welding
ngg information
in
any timee you
y needeed it?
The AW
AWS
W Weldin
e ing Handbookk
pu it at yourr fingertips.
puts
go.aws.org/awshandbo
w book

ASNT Annual Conference 2016. Oct. 2427. Long Beach CAD/CAM software development, 3D laser engraving, and
Convention & Entertainment Center, Long Beach, Calif. 3D printers, the fair will be held concurrently with Asiamold
Contact (800) 222-2768 or visit asnt.org/annual. 2016. Visit 3dprintingasiaexpo.com or e-mail 3dprintingasia@
hongkong.messefrankfurt.com.
4th Annual Assembly Show. Oct. 2527. Donald E.
Stephens Convention Center, Rosemont, Ill. A trade show EuroBLECH 2016. Oct. 2529. Hanover Exhibition Grounds,
focused exclusively on assembly manufacturing processes Hanover, Germany. The 24th International Sheet Metal
featuring workshops on collaborative robotics and mixed Working Technology Exhibition is an international trade ex-
model assembly lines. Contact (978) 4754441 or visit hibition for the sheet metal working industry and will serve
theassemblyshow.com. as a platform for interlinked sheet metal working produc-
Additive Manufacturing Americas 2016. Dec. 79. Pasadena tion. Call +44 (0)1727 814400 or visit euroblech.com.
Convention Center, Pasadena, Calif. This is the business-to-
business show for additive manufacturing/3D printing. This BLECH India. April 2729, 2017. Bombay Exhibition Center,
years show will incorporate a 3D print show. Visit amshow- Mumbai, India. Business platform for Indias sheet metal
americas.com. working industry. Visit blechindia.com.
INTERNATIONAL EVENTS EDUCATIONAL OPPORTUNITIES
2016 International Conference on Material Science and Civil Advanced Blueprint Reading. Troy, Ohio. Learn design pro-
Engineering. Aug. 57. Guilin, Guangxi, China. Contact +86 cedure, blueprint interpretation, shop drawings, the use of
15919704498 or msce2016@126.com. measuring tools in layout and assembly, and more. Two-
week, 70-hour class. Classes begin July 11, Aug. 8, Sept. 5,
21 IAS Steel Conference 2016. Sept. 1316. Rosario, Santa Oct. 3, Nov. 7, and Dec. 19. $850. Hobart Institute of Weld-
Fe, Argentina. From raw materials to end products, only in ing Technology; (800) 332-9448; welding.org.
one event: ironmaking, steelmaking, rolling and processing,
products, and applications. Visit siderurgia.org. AWS Certified Welding Supervisor Exam. Troy, Ohio. Class
begins Oct. 10. Exam given Oct. 14. Hobart Institute of
3D Printing Asia. Sept. 2022. China Import and Export Fair Welding Technology; (800) 332-9448; welding.org.
Complex, Guangzhou, China. Covering rapid prototyping, Brazing Training Seminars. Oct. 1113, S.C. This three-day

aws.org
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Direct access to an enccyclopedia
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Coming Events July.qxp_Layout 1 6/9/16 9:38 AM Page 65
intensive program covers all essentials of brazing using fur- GE Industrial Computed Tomography (CT) Operator Course.
nace, torch, induction, or dip brazing processes, and all braz- Learn to operate the 3D technology that is becoming more
ing filler metals. Contact Dan Kay at kaybrazing.com, prominent in industrial quality control and metrology.
dan.kay@kaybrazing.com, or (860) 651-5595. Lewistown, Pa., (315) 554-2039; geinspectionacademy.com.
Certified Welding Inspector/Educator Courses. Troy, Ohio. Hypertherm Cutting Institute Online. Includes video tutori-
Classes begin July 18, Aug. 15, Sept. 19, Oct. 17, Nov. 7, and als, interactive e-learning courses, discussion forums, webi-
Dec. 5. Exams given July 1, July 29, Aug. 26, Sept. 30, Oct. nars, and blogs. Visit hypertherm.com; hyperthermcutting
28, Nov. 18, and Dec. 16. Hobart Institute of Welding Tech- institute.com.
nology; (800) 332-9448; welding.org.
Industrial Laser Training. Technical training and support
ECourses in Destructive and Nondestructive Testing of offered for users of industrial lasers in manufacturing,
Welds and Other WeldingRelated Topics. Online video education, and research. Regularly scheduled classes in laser
courses taken at ones own pace offer certificates of comple- welding and laser cutting and drilling. HDE Technologies,
tion and continuing education units. Contact Hobart Insti- Inc.; (916) 7144944; laserweldtraining.com, drilling-
tute of Welding Technology; (800) 332-9448; training.com.
welding.org/product-category/online-courses/.
INTEG Courses. Courses in NDE disciplines to meet certifica-
ESAB Welding and Cutting Distributor Instructor Lead Train tions to Canadian General Standards Board or Canadian Nu-
ing. Year-round training at Denton, Tex.; West Lebanon, clear Safety Commission. The Canadian Welding Bureau;
N.H.; Traverse City, Mich.; Hanover, Pa.; and Salt Lake (800) 844-6790; cwbgroup.org.
City, Utah. Online eLearning training available at
training.victortechnologies.com, e-mail trainingteam@esab.com. Laser Safety Online Courses. Courses include Medical Laser
Safety Officer, Laser Safety Training for Physicians, Indus-
European Brazing School. Oct. 1820. Wall Colmonoys Eu- trial Laser Safety, and Laser Safety in Educational Institu-
ropean headquarters, Pontardawe, Wales, UK. Course tions. Laser Institute of America; (800) 345-2737; lia.org.
teaches vitals of modern furnace brazing. Contact Alise
Jeremiah, +44 (0) 1792 860622 585-6400, ext. 233; Laser Safety Training Courses. Courses based on ANSI
brazingschool@wallcolmonoy.co.uk, or visit wallcolmonoy.com. Z136.1, Safe Use of Lasers. Orlando, Fla., or customers site.
Laser Institute of America; (800) 345-2737; lia.org.

916-714-4944 aws.org
Training classes and Workshops

For the past 40 years HDE has been the provider of
comprehensive technical training and support for users
of industrial lasers in manufacturing, education and
research. Regularly scheduled classes are offffered in:
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Certification Schedule July.qxp_Layout 1 6/8/16 5:01 PM Page 66
CERTIFICATION SCHEDULE Certication Seminars, Code Clinics, and Examinations
Note: The 2016 schedule for all certifications is posted online at 9Year Recertification Seminar for CWI/SCWI
aws.org/w/a/registrations/prices_schedules.html. For current CWIs and SCWIs needing to meet education re-
quirements without taking the exam. The exam can be tak-
Certified Welding Inspector (CWI) en at any site listed under Certified Welding Inspector.
Location Seminar Dates Exam Date Location Seminar Dates
Los Angeles, CA July 1015 July 16 Miami, FL July 2429
Louisville, KY July 1015 July 16 San Diego, CA July 31Aug. 5
Omaha, NE July 1015 July 16 Orlando, FL Aug. 2126
Cleveland, OH July 1015 July 16 Denver, CO Sept. 1116
Birmingham, AL July 1722 July 23 Dallas, TX Sept. 2530
Scottsdale, AZ July 1722 July 23 New Orleans, LA Oct. 2328
Denver, CO July 1722 July 23
Chicago, IL July 1722 July 23
Waco, TX July 1722 July 23 Certified Welding Educator (CWE)
Sacramento, CA July 2429 July 30 Seminar and exam are given at all sites listed under Certified
Miami, FL July 2429 July 30 Welding Inspector. Seminar attendees will not attend the Code
Helena, MT July 2429 July 30 Clinic portion of the seminar (usually the first two days).
Milwaukee, WI July 2429 July 30
Baton Rouge, LA Aug. 712 Aug. 13
Las Vegas, NV Aug. 712 Aug. 13 Certified Welding Sales Representative (CWSR)
Philadelphia, PA Aug. 712 Aug. 13 CWSR exams will be given at Prometric testing centers.
Seattle, WA Aug. 712 Aug. 13 More information is available at aws.org/certification/detail/
Miami, FL Exam only Aug. 18 certified-welding-sales-representative.
Mobile, AL Aug. 1419 Aug. 20
Portland, ME Aug. 1419 Aug. 20
Charlotte, NC Aug. 1419 Aug. 20
Fargo, ND Aug. 1419 Aug. 20 Certified Welding Supervisor (CWS)
San Diego, CA Aug. 2126 Aug. 27 CWS exams are also given at Prometric testing centers.
Minneapolis, MN Aug. 2126 Aug. 27 More information is available at aws.org/certification/detail/
Kansas City, MO Aug. 2126 Aug. 27 certified-welding-supervisor.
San Antonio, TX Aug. 2126 Aug. 27
Salt Lake City, UT Aug. 2126 Aug. 27
Miami, FL Sept. 1116 Sept. 17 Certified Radiographic Interpreter (CRI)
Nampa, ID Sept. 1116 Sept. 17 The CRI certification can be a stand-alone credential or can
St. Louis, MO Sept. 1116 Sept. 17 exempt you from your next 9-Year Recertification.
Houston, TX Sept. 1116 Sept. 17
Anchorage, AK Sept. 1823 Sept. 24 Location Seminar Dates Exam Date
Long Beach, CA Sept. 1823 Sept. 24 Dallas, TX July 1822 July 23
New Orleans, LA Sept. 1823 Sept. 24 Kansas City, MO Aug. 2226 Aug. 27
Pittsburgh, PA Sept. 1823 Sept. 24 Chicago, IL Sept. 1923 Sept. 24
Indianapolis, IN Sept. 2530 Oct. 1 Pittsburgh, PA Oct. 1721 Oct. 22
Tulsa, OK Sept. 2530 Oct. 1
Portland, OR Sept. 2530 Oct. 1
Nashville, TN Sept. 2530 Oct. 1
El Paso, TX Sept. 2530 Oct. 1 Certified Robotic Arc Welding (CRAW)
Miami, FL Exam only Oct. 13 ABB, Inc., Auburn Hills, MI; (248) 3918421
Shreveport, LA Oct. 1621 Oct. 22 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800, ext. 218
S. Plainfield, NJ Oct. 1621 Oct. 22 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Beaumont, TX Oct. 1621 Oct. 22 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Atlanta, GA Oct. 2328 Oct. 29 Wolf Robotics, Fort Collins, CO; (970) 225-7736
Des Moines, IA Oct. 2328 Oct. 29 On request at MATC, Milwaukee, WI; (414) 456-5454
Detroit, MI Oct. 2328 Oct. 29
Roanoke, VA Oct. 2328 Oct. 29
Spokane, WA Oct. 2328 Oct. 29
Cleveland, OH Oct. 30Nov. 4 Nov. 5
IMPORTANT: This schedule is subject to change. Please verify your event dates with the Certification Dept. to confirm your course status
before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received after
that time will be assessed a $350 Fast Track fee. Please verify application deadline dates by visiting our website
aws.org/certication/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit
aws.org/certification or call (800/305) 4439353, ext. 273, for Certification; or ext. 455 for Seminars.

AMERICAN TORCH TIP.qxp_FP_TEMP 6/7/16 10:47 AM Page 67
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Welding Workbook July 2016_Layout 1 6/9/16 5:36 PM Page 68
WELDING WORKBOOK
DATASHEET 366
Thermal Spraying Safety

Thermal spraying processes use electric arc, plasma, and Fumes, Vapors, and Gases Use ventilation and safe
combustion energy sources to produce a high-temperature practices according to ANSI Z49.1, the material supplier's
and high-velocity gas stream. Powder or wire material is in- Safety Data Sheet (SDS), and AWS Safety and Health Fact
troduced to this gas stream. Particles of this material are Sheet No. 1. Most spray and abrasive blasting operations re-
heated and propelled onto a surface to produce a coating. quire the operator to use an approved respirator that com-
The noise, heat, dust, fumes, and mechanical operations of plies with requirements of ANSI Z88.2. Also, precautions
the spraying processes create a unique set of safety hazards should be taken to avoid the presence of chlorinated hydro-
for the operator and those nearby. carbon solvent vapor in the area of the arc or plasma spray-
ing. Hazardous phosgene gas can be produced when hydro-
Definitions/Process Descriptions carbon vapors are exposed to ultraviolet radiation from
these processes.
According to ANSI/AWS A3.0, Standard Welding Terms Noise Thermal spray processes generate noise levels
and Definitions, thermal spraying is a group of processes that that require hearing protection by the operator. Earmuffs
deposit molten metallic or nonmetallic surfacing materials and noise control procedures should be provided to conform
onto a prepared substrate. to the standard limits of OSHA 29 CFR 1910.95.
All thermal spraying processes introduce a feedstock Radiation Intense ultraviolet (UV) and infrared (IR)
(usually a powder or wire) into a spraying device (combus- radiation occurs with these processes. They require total
tion or electrical). protection of the eyes and all exposed skin to avoid eye dam-
The spraying device is generally referred to as a thermal age and burns.
spray gun. The material is heated at the gun , blended into a Eye shades of No. 36 for combustion and 912 for
hot gas stream, and sprayed onto a prepared substrate. The electrical processes are recommended. See AWS Safety and
heated particles strike the surface, where they flatten and Health Fact Sheet No. 2.
adhere to the surface. As this process continues, a coating is Electric Shock Arc, plasma arc, and plasma induction
formed from the spray material. The coating process is spraying utilize electrical voltages in excess of 100 V. Take
stopped when the desired thickness of coating is formed. precautionary measures according to ANSI Z49.1 and AWS
Thermal spray processes include Safety and Health Fact Sheet No. 5.
Combustion processes Fire The gas stream from a thermal spray gun is in
LVOF: Low-velocity oxyfuel excess of 3000F. Use care when handling thermal spray
HVOF: High-velocity oxyfuel guns during operation to avoid personal injury or fire (see
Electrical processes: AWS Safety and Health Fact Sheet No. 6).
Arc (twin-wire) Mechanical Hazards The substrate surface prepara-
Plasma arc tion, spraying, finishing, and posttreatment operations in-
Typical operating conditions for the various processes are volved with thermal spraying processes present a variety of
shown in Table 1. mechanical hazards. Consult the equipment manufacturers
manuals and material suppliers Material Safety Data Sheets
for their recommended safe practices.
Potential Hazards and Hazardous Effects Compressed Gases Use and handle compressed gas-
es as specified in ANSI-Z49.1. WJ
Dust The finely divided airborne dust and fume
should be treated as an explosion and inhalation hazard. Adapted from AWS Fact Sheet No. 20. All of the AWS Safety and
Adequate ventilation, proper electrical system design, and Health Facts Sheets are available through the AWS website by visit
appropriately designed dry collection systems should be ing aws.org, then clicking on Standards at the top of the home
provided. page, then Safety and Health on the righthand side of the Stan
dards page.
Table 1 Operating Conditions for the Various Thermal Spray Processes

LVOF HVOF Arc Plasma Arc
Temperature To 5000F To 6000F 400015,000F 400015,000F
Velocity 200700 ft/s 25004000 ft/s 8001800 ft/s 8001800 ft/s
(<Mach 1) (to Mach 5) (to Mach 2) (to Mach 2)
dBA (Sound Level) 110 150 115 132
Spray Distance 410 in. 618 in. 2126 in. 2126 in.
AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, con
sequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this information. AWS also makes no
guaranty or warranty as to the accuracy or completeness of any information published herein.
American Welding Society, 8669 NW 36th St., #130, Miami, FL 33166, email info@aws.org; website aws.org.
68 WELDING JOURNAL / JULY 2O16

LACO INDUSTRIES.qxp_FP_TEMP 6/7/16 11:17 AM Page 69

andy's trends circular ad.qxp_FP_TEMP 6/8/16 7:42 AM Page 70
ORGANIZING SOCIETIES KEYNOTE SPEAKERS

American Welding Society (AWWS)
Prof. Sudarsanam Suresh Babu, The Universitty of Te ennessee, USA

Japan We
elding Society (JWS)
Prof. Amitava De, Indian Institute of technologgy, India

Prof. Yo
oshinori Hirata, Osaka University, Japaan
CONFERENCE CO-CHAIRS
Prof. Hiroyuki Kokawa, To ohoku University, Jaapan

Tooshihiko Koseki, The University of Tookyo, Japan
Prof. Yu
u-Ming Zhang, University of Kentucky, USA

Stan David, Oak Ridge National Laboratory, USA
Prof. Norman Zhou, University of Wa aterloo, Canada
C

Tarasankar DebRoy, Penn State University, USA

Thomas J. Lienert, Los Alamos National Laboratory, USA
U REGISTRAT TION

Akio Hirose, Osaka University, Japan Online registration is now open at the following website.
w
http://trends2016 org/registration html
http://trends2016.org/registration.html
WELCOME TO TOKYO IN 2016
The 10th International Conference on Trends in Welding Research
R REGISTRAT TION FEES
will be held from October 11 to 14, 2016, in Tookyo, Japan n, for the Regular Participant: 90,000 JPY
first time outside of USA. The conference covers not only y the Student: 50,000 JPY

fundamental science of welding and joining but a wide vaariety of Accompanying Person: 15,000 JPY

applications of welding and joining diffferent materials in diffferent Invitation Letter for Visa Application: 10,000 JP
PY
industries, which include various approaches of theoreticaal analysis,
experiments and numerical simulations. Also, the conferennce aims to The registration fee for Regular Participants and S
Student includes:
provide a wonderful opportunity of technical discussions, having Session Participation, Conference Kit, Reception P Party, Cofffee Break,
leading welding and joining scientists and engineers from m all over the and Banquet.
world. The 9th International Weelding
d g Symposium
Sy pos u oof Japan
J p n Weeelding
d g Thee registration
eg s o fee
ee for
o Accompanying
cco p y g Persons
e so s in
ncludes:
c udes: Reception
ecep o
Society will be jointly held during the conference. So, we cordially Party, Cofffee Break, and Banquet.
invite you to the conference and hope that you will enjoy the technical
discussions at the conference and also the best season of Japan.
J IMPORTA ANT DAT TES
September 2, 2016 Pre-registration (Regular)
TOPICS TO BE COVERED

Fundamentals and applications of welding and joining processes
p MORE INFORMAT TION

Microstructure and metallurgical behaviors in welds Visit the following website: http://trends2016.orgg

Weeldability of diffferent materials
CONTAACT

Weeld properties and performances
Trends2016 Secretariat

Residual stress and distortion in weldments
Mita MT Bldg. 8F, 3-13-12 Mita, Minato-ku, Tokyyo 108-0073, Japan

Monitoring,
Monitoring sensing and controls of welding E-mail: twr20166@issjp.com

Te
esting and inspections for weld integrity

Weelding practices in industries

Modeling and simulation of weld behaviors
July Society News.qxp_Layout 1 6/9/16 1:16 PM Page 71
BY MELISSA GOMEZ mgomez@aws.org

SOCIETY NEWS
National and District Officers Nominated for 2017
The 20152016 Nominating Com- Dist. 5; Joshua Burgess, Dist. 8; Phillip as chairman of the AWS New Mexico
mittee has announced its slate of candi- Temple, Dist. 11; Tony Brosio, Dist. 14; Section, and is currently a member of
dates who will stand for election to Jerry Knapp, Dist. 17; and Pierrette the Executive Committee of that Sec-
AWS national offices for the 2017 term, Gorman, Dist. 20. tion. He is also currently serving as vice
which begins Jan. 1, 2017. John Bray is nominated to serve as president-nominee and is in the last
Nominated are the following candi- president. He served four years as vice year of his term as director-at-large.
dates: John R. Bray for president; Dale president of AWS and six years as Dis- Robert Roth is nominated to serve
A. Flood, Thomas J. Lienert, and trict 18 director. He is currently presi- as vice president. He currently serves as
Robert W. Roth for vice presidents; and dent of Affiliated Machinery, Inc. For a director-at-large, member of the Exec-
Richard L. Holdren and Duane K. Miller 12 years, he served on the Houston Sec- utive Committee, and member of the
for directors-at-large. One president, tion Board and is a past chairman of Finance Committee. He is president
three vice presidents, and two direc- the Section. He is a 27-year AWS and CEO of RoMan Manufacturing,
tors-at-large are to be elected. Member, an AWS Distinguished Mem- Inc., which is an AWS sustaining mem-
The National Nominating Commit- ber, and a Certified Welding Sales ber, as well as a member of WEMCO
tee was chaired by Past President Dean Representative. and the RWMA.
R. Wilson. Serving on the committee Dale Flood is nominated to serve a Richard Holdren is nominated to
with Wilson were Bruce P. Albrecht, third term as vice president. He is proj- serve as a director-at-large. He is presi-
Uwe W. Aschemeier, Robert E. Brenner, ect manager, R&D, at Tri Tool, Inc. He dent and principal welding engineer of
Josh D. Burgess, Nancy C. Cole, Tom A. served as Dist. 22 director and chaired Welding Consultants, LLC, and a senior
Ferri, Karl R. Fogleman, Pierrette H. the Sacramento Valley Section. He is an welding engineer with Arc Specialties
Gorman, Stewart A. Harris, Bob G. Pali, active member of the Membership Technical Services. He has served as a
Kerry Shatell, Jerry L. Warren, and Committee, Education Scholarship member, and in several cases chair, of
John A. Willard. Alex L. Diaz served as Committee, Professional Welders Com- various AWS certification, education,
secretary. petition Committee, and D10 Commit- and technical committees.
The Nominating Committees for tee on Piping and Tubing. Duane Miller is nominated to serve
Districts 2, 5, 8, 11, 14, 17, and 20 have Thomas Lienert is nominated to as a director-at-large. He is currently
selected the following candidates for serve as vice president. He is a technical manager of engineering services and a
election/reelection as district directors staff member, R&D Engineer 4, at Los welding design consultant with Lincoln
for the three-year term Jan. 1, 2017 Alamos National Laboratory. He is an Electric. He is an active member of sev-
Dec. 31, 2019. The nominees are Ken- active member and/or officer of several eral technical committees and a chapter
neth Temme, Dist. 2; Carl Matricardi, national level committees, has served chair of the AWS Handbook Commit-
John Bray Dale Flood Thomas Lienert Robert Roth Richard Holdren
president vice president vice president vice president directoratlarge
Duane Miller Kenneth Temme Carl Matricardi Joshua Burgess Phillip Temple
directoratlarge Dist. 2 director Dist. 5 director Dist. 8 director Dist. 11 director

SOCIETY NEWS
teaches welding at Ivy Tech Communi-
ty College. He has worked in the weld-
ing and fabrication industry for 26
years, and been involved with the AWS
Indiana Section for 10 years, serving
as chairman and Dist. 14 deputy
director. He has also been involved
with the SkillsUSA regional and state
welding competitions, as well as the
Midwest Welding Competition for the
past 10 years, and served as chairman
Tony Brosio Jerry Knapp Pierrette Gorman
of the 2015 Professional Welding
Dist. 14 director Dist. 17 director Dist. 20 director
Competition Committee.
Jerry Knapp is nominated to serve
his second term as Dist. 17 director.
tee. He recently completed his second tor. He is a metallurgical/welding engi- An AWS member for more than 38
three-year term as chair of the AWS neer with General Electric. He has years, he has served as chairman for
D1 Committee. served on the Executive Committee the Tulsa Section, and as a board advi-
Kenneth Temme is nominated to Board and as chairman for the NE Ten- sor. He has extensive experience as a
serve as Dist. 2 director. He currently nessee Section, as well as Dist. 8 salesman in the gas and welding sup-
works as a contract QA/QC inspector, deputy director and director. He ply industry, and currently works as a
recently serving with Kawasaki Heavy earned a PhD in Materials Science and consultant. He has worked for Gas and
Industries in Kobe, Japan. He has Engineering with a concentration in Supply, Alloy Welding Supply,
served as chairman of the Philadelphia Welding Metallurgy from the Universi- Arkansas Specialty Co., Jimmie Jones,
Section, of which he is still a member. ty of Tennessee and has more than 13 National Welding Supply, Bell Helicop-
He also worked as the assistant school years of experience in the welding and ter, Adair Sheet Metal, and American
director for Divers Academy Interna- metallurgical industry. Mfg. of Texas. He has also worked as a
tional and as a journeyman for UA Lo- Phillip Temple is nominated as grinder, welders helper, and in sheet
cal 322 Plumbers and Pipe Fitters Dist. 11 director. He is president of metal welding.
Union. eNergy Wise Consulting, LLC, and re- Pierrette Gorman is nominated to
Carl Matricardi is nominated to tired from the Detroit Edison Co. He serve her second term as Dist. 20 di-
continue serving as Dist. 5 director. served two terms as chairman of the rector. She has chaired the New Mexi-
An AWS Certified Welding Inspector Welding Handbook Committee, and co Section and received the Section
and Certified Welding Educator, he continues to serve as an advisor. He and District Meritorious Awards. She
has worked in the welding industry for served as Section chair and Executive currently works at Sandia National
35 years and is founder and president Committee member in several Sec- Laboratories. Earlier, she worked as a
of Welding Solutions, Inc. He has tions. He has been the recipient of the research and applications engineer at
taught welding and manufacturing Samuel Wylie Miller Memorial Medal Optomec, Inc.; welding engineer at
processes at technical colleges and Award, National Meritorious Award, Wilson Greatbatch, Ltd.; and a re-
state universities in Georgia, and Distinguished Service Award, and an search technician at Edison Welding
served as an expert witness. AWS Distinguished Member. Institute. She holds patents on form-
Joshua Burgess is nominated to Tony Brosio is nominated to serve ing structures from CAD solid models.
serve his second term as Dist. 8 direc- as Dist. 14 director. He currently
AWS Bylaws Article IX, Section 3

Section 3. Nominations. also be published in this issue of the with the petition. Any such nominee
Nominations, except for Executive Welding Journal, along with a copy of shall be included in the election for
Director and Secretary, shall proceed this Article IX, Section 3. such office. A District Director may
as follows: (b) Any person with the required be nominated by written petitions
(a) Nominations for District Direc- qualifications may be nominated for signed by at least ten members each
tors shall be made by the District any national office by written peti- from a majority of the Sections in the
Nominating Committees [see Article tions signed by not less than 200 District, provided such petitions are
III, Section 2(c)]. The National Nomi- members other than Student Mem- delivered to the Executive Director
nating Committee shall select nomi- bers, with signatures of at least 20 and Secretary before August 26 for
nees for the other offices falling va- members from each of five Districts, the elections to be held that year. A
cant. The names of the nominees for provided such petitions are delivered biographical sketch and acceptance
each office, with a brief biographical to the Executive Director and Secre- letter of the nominee shall be provid-
sketch of each, shall be published in tary before August 26 for the elec- ed with the petition. Any such nomi-
the July issue of the Welding Journal. tions to be held that year. A biograph- nee shall be included in the election.
The names of the members of the Na- ical sketch of the nominee (and ac-
tional Nominating Committee shall ceptance letter) shall be provided

SOCIETY NEWS
Nominations Sought for National Officers
American Welding Society members 2. Present their nominations in per- ingness and ability to serve if nomi-
who wish to nominate candidates son at the open session of the Nation- nated and elected, letters of support,
for President, Vice President, and al Nominating Committee meeting, and a 5 7-in. head-and-shoulders
Director-at-Large on the AWS Board of scheduled for 2:00 to 3:00 P.M., Tues- color photograph.
Directors for the term starting Jan. 1, day, Nov. 17, 2016, at the Las Vegas Note: Persons who present their
2018, may either: Convention Center, Las Vegas, Nev., nominations at FABTECH must pro-
1. Send their nominations electron- during the 2016 FABTECH Expo. vide 20 copies of the biographical ma-
ically by September 30, 2016, to Alex Nominations must be accompanied terials and written statement.
Diaz at adiaz@aws.org, c/o D. J. Lan- by biographical material on each can-
don, chairman, National Nominating didate and include a written statement
Committee, or by the candidate as to his or her will-
TECH TOPICS
Technical Committee Meetings the gas tungsten arc and gas metal arc es, 8669 NW 36 St., #130, Miami, FL
welding processes. Stakeholders: Own- 33166-6672; (800/305) 443-9353.
All AWS technical committee meet- ers, fabricators, and inspectors associ- A4.4M:2001 (R2016), Standard Pro-
ings are open to the public. Contact ated with the fabrication of aluminum cedures for Determination of Moisture
staff members listed below or call piping. Revised Standard. Contact: A. Content of Welding Fluxes and Welding
(800/305) 443-9353 for information. Naumann, anaumann@aws.org, ext. Electrode Flux Coverings. Reaffirmed
Aug. 10. International Standards 313. Standard. $36.50. ANSI public review
Activities Committee. Charlotte, N.C. D10.14M/D10.14:20XX, Guide for expires 7/11/16. Contact: R. Gupta,
Contact: A. Davis, adavis@aws.org, ext. Multipass Orbital Machine Pipe Groove ext. 301, rgupta@aws.org.
466. Welding. Presents several aspects of A5.10/A5.10M:201X ISO
Aug. 10, 11. Technical Activities multipass orbital machine pipe groove 18273:2004 (MOD), Welding Consum-
Committee. Charlotte, N.C. Contact: welding. Among the aspects presented ables Wire Electrodes, Wires and
A. Alonso, aalonso@aws.org, ext. 299. are arc welding processes, pipe bevel- Rods for Welding of Aluminum and
ing, pipe line up, welding equipment, Aluminum Alloys Classification. Re-
New Standards Projects nondestructive examination, consum- vised Standard. $36.50. ANSI public
able estimation, maximum repair review expires 7/11/16. Contact: R.
Development work has begun on length, and preparation for welding. Gupta, ext. 301, rgupta@aws.org.
the following new or revised stan- Multipass orbital machine pipe groove D16.1M/D16.1:2004 (R201X),
dards. Affected individuals are invited welding of both plant pipe welding and Specification for Robotic Arc Welding
to contribute to their development. transmission pipe welding are dis- Safety. Reaffirmed Standard. $64.00.
Participation on AWS Technical com- cussed. Stakeholders: Pipeline-owning ANSI public review expired 6/27/16.
mittees is open to all persons. and pipeline construction companies, Contact: P. Portela, ext. 311,
A5.35/A5.35M:2015-AMD1, Speci- power-plant and petrochemical plant pportela@aws.org.
fication for Covered Electrodes for Under- owning and piping construction com-
water Wet Shielded Metal Arc Welding. panies. Revised Standard. Contact: A. ISO Draft Standards for Public Review
This specification establishes the re- Naumann, anaumann@aws.org, ext.
quirements for classification of cov- 313. Copies of the following Draft Inter-
ered electrodes for underwater wet national Standards are available for re-
shielded metal arc welding. Stakehold- Standards for Public Review view and comment through your na-
ers: Underwater welding and construc- tional standards body, which in the
tion industry. Addenda to a current AWS was approved as an accredited United States is ANSI, 25 West 43rd
Standard. Contact: J. Douglass, ext. standards-preparing organization by Street, Fourth Floor, New York, NY
306, jdouglass@aws.org. the American National Standards In- 10036; telephone (212) 642-4900. Any
D10.7M/D10.7:20XX, Guide for the stitute (ANSI) in 1979. AWS rules, as comments regarding ISO documents
Gas Shielded Arc Welding of Aluminum approved by ANSI, require that all should be sent to your national stan-
and Aluminum Alloy Pipe. This docu- standards be open to public review for dards body.
ment presents information concerning comment during the approval process. In the United States, if you wish to
those properties of aluminum that af- This column also advises of ANSI ap- participate in the development of In-
fect its weldability and that cause spe- proval of documents. ternational Standards for welding,
cific problems in the fabrication of alu- The following standards are sub- contact Andrew Davis at AWS, 8669
minum pipe. Recommendations are mitted for public review. A draft copy NW 36 St., #130, Miami, FL 33166-
made for solving these problems and may be obtained by contacting the 6672; (305) 443-9353, ext. 466,
suggested procedures are presented staff secretary of the committee as e-mail: adavis@aws.org. Otherwise,
for welding aluminum pipe joints with listed below at AWS, Technical Servic- contact your national standards body.
SOCIETY NEWS
ISO/DIS 9455-13, Soft soldering als responsible for the WPSs should D1.1:2010, clause 5.3.1.2.
fluxes Test methods Part 13: De- make certain that the stored WPSs 3) No. clause 3.2.1 permits the use of
termination of flux spattering. meet the applicable requirements of all modes of GMAW, except for
D1.1, including compliance with GMAW-S, which is precluded from
Revised Standard Approved by ANSI D1.1:2015, clause 5.3.1.2. prequalification.
3) No. Clause 3.2.1 permits the use of 4) No. clause 3.2.4 was developed to
A5.36/A5.36M-2016, Specification all modes of GMAW, except for preclude the use of constant current
for Carbon and Low-Alloy Steel Flux GMAW-S, which is precluded from power supplies for FCAW and GMAW
Cored Electrodes for Flux Cored Arc prequalification. when using prequalified WPSs; this
Welding and Metal Cored Electrodes for 4) No. Clause 3.2.4 was developed to provision was developed without any
Gas Metal Arc Welding. Approval Date: preclude the use of constant current intention of imposing requirements
5/6/2016. power supplies for FCAW and GMAW on GMAW-P.
when using prequalified WPSs; this 5) Yes, providing all the requirements
Reaffirmed Standard Approved provision was developed without any of Clause 3 are met.
by ANSI intention of imposing requirements
on GMAW-P. A3.0M/A3.0:2010
A5.15-1990 (R2016), Specification 5) Yes, providing all the requirements
for Welding Electrodes and Rods for Cast of Clause 3 are met. Subject: Definition for Heat Input
Iron. Approval Date: 5/4/2016. Code Edition: A3.0M/A3.0:2010
Subject: Waveform Power Supplies Code Provision: Glossary
Interpretations Code Edition: D1:1:2010 AWSLog: A3.0-10-I02
D1.1 Code Provision: Subclauses 5.11, 3.2.1, Inquiry: Can you please clarify
and 3.2.4 whether this definition refers to the
Subject: Waveform Power Supplies AWSLog: D1.1-10-I21 total energy of the arc applied to the
Code Edition: D1:1:2015 Inquiry: workpiece during welding, or does it
Code Provision: Subclauses 5.10, 3.2.1, 1) Does AWS D1.1:2010, clause 5.11 refer only to the amount of heat actu-
and 3.2.4 preclude the use of waveform power ally absorbed into the workpieces dur-
AWSLog: D1.1-15-I01 supplies? ing welding (the total energy of the arc
Inquiry: 2) Does AWS D1.1:2010, clause 5.11 minus the heat losses)?
1) Does AWS D1.1:2015, clause 5.10 preclude the use of waveform power Interpretation: The definition refers to
preclude the use of waveform power supplies where the welding procedure the input energy applied to the work-
supplies? is preprogrammed into the welding piece during welding. There is no at-
2) Does AWS D1.1:2015, clause 5.10 machine, and the welding personnel tempt to differentiate the amount of
preclude the use of waveform power call up the welding procedure from the energy absorbed, reflected, miscalcu-
supplies where the welding procedure welding machines memory? lated, misdirected, lost, etc. as this is
is preprogrammed into the welding 3) Does AWS D1.1:2010, clause 3.2.1 considered beyond the scope of the
machine, and the welding personnel preclude the use of GMAW-P from use definition. It is important to realize
call up the welding procedure from the with prequalified WPSs? that this definition applies to all types
welding machines memory? 4) Does AWS D1.1:2010, clause of welding processes, not just arc
3) Does AWS D1.1:2015, clause 3.2.1 3.2.4 preclude the use of waveform- welding.
preclude the use of GMAW-P from use controlled power supplies from being
with prequalified WPSs? used with prequalified WPSs? Errata
4) Does AWS D1.1:2015, clause 5) Does AWS D1.1:2010, clause 3 per-
3.2.4 preclude the use of waveform- mit the use of prequalified WPSs that The following Errata have been
controlled power supplies from being use GMAW-P? identified for AWS D1.1/D1.1M:2000,
used with prequalified WPSs? Response: Structural Welding Code Steel.
5) Does AWS D1.1:2015, clause 3 per- 1) No. Any type of power supply is ac- Pages 80, 83, Figure 3.4, Detail B-
mit the use of prequalified WPSs that ceptable, providing the equipment is U3a-S, B-U5b and TC-U5a. Change 3
use GMAW-P? so designed and manufactured...as X R to 18 X R and 6 X R to 14 X R.
Response: to enable designated personnel to fol- Pages 139, 141, Table 4.9, under (1)
1) No. Any type of power supply is ac- low the procedures and attain the re- Test on Plate, Type of Test Weld (Ap-
ceptable, providing the equipment is sults described elsewhere in this code. plicable Figures): Change Groove (Fig.
so designed and manufactured...as 2) No. Any type of power supply con- 4.30 or 4.31) for 38 < T < 1 to Groove
to enable designated personnel to fol- trol is acceptable, so long as the con- (Fig. 4.21, 4.22 or 4.29).
low the procedures and attain the re- trols are such that designated person- Page 176, Table 6.1 under (6) Un-
sults described elsewhere in this code. nel are enabled to follow the proce- dersized welds. Change In all cases,
2) No. Any type of power supply con- dures and attain the results described the undersize portion of the shall to
trol is acceptable, so long as the con- elsewhere in this code. The individu- In all cases, the undersize portion of
trols are such that designated person- als responsible for the WPSs should the weld shall
nel are enabled to ...follow the proce- make certain that the stored WPSs Page 226, Clause 7.5.5.7, change
dures and attain the results described meet the applicable requirements of reference to subclause 6.6.1 to sub-
elsewhere in this code. The individu- D1.1, including compliance with clause 6.9.
SOCIETY NEWS
Annex M, page 342 Bottom Row, Brazing and soldering, C3 Commit- pportela@aws.org. Highenergy beam
under Electrode Classification. tee (G, E, C, U). Welding in marine welding and cutting, C7 Committee.
Change E10018- X to E11018-X. construction, D3 Committee (G, E, C, Robotic and automatic welding, D16
U). Welding of machinery and Committee (C, E, G). Hybrid welding,
Opportunities to Contribute to equipment, D14 Committee (G, E, C, C7D Subcommittee (G).
AWS Technical Committees U). J. Rosario, ext. 308,
A. Naumann, ext. 313, jrosario@aws.org. Procedure and per
The following committees welcome anaumann@aws.org. Oxyfuel gas welding formance qualification, B2 Committee
new members. Some committees are and cutting, C4 Committee (C, E, G, (E). Thermal spraying, C2 Committee
recruiting members with specific in- U). Friction welding, C6 Committee. (C, E, G, U). Welding iron castings, D11
terests in regard to the committees Welding practices and procedures for Committee (C, E, G, P, U). Railroad
scope, as marked below: Producers (P), austenitic steels, D10C Subcommittee. welding, D15 Committee (E, G).
General Interest (G), Educators (E), Aluminum piping, D10H Subcommit- J. Molin, ext. 304, jmolin@aws.org.
Consultants (C), and Users (U). For tee. Chromium molybdenum steel pip Welding sheet metal, D9 Committee
more information, contact the staff ing, D10I Subcommittee. Welding of ti (G, P).
member listed or visit aws.org/ tanium piping, D10K Subcommittee. S. Hedrick, ext. 305, steveh@aws.org.
w/a/technical/comm_stand.html. Purging and root pass welding, D10S Joining of plastics and composites, G1
M. E. Rodriguez, ext. 310, Subcommittee. Lowcarbon steel pipe, Committee. Safety and Health Com-
mrodriguez@aws.org. Automotive, D8 D10T Subcommittee. Orbital pipe mittee (E, U, G, C). Mechanical testing
Committee (C, E, G, U). Resistance welding, D10U Subcommittee. Duplex of welds, B4 Committee. Metric prac
welding, C1 Committee (C, E, G, U). pipe welding, D10Y Subcommittee. Re tice, A1 Committee.
Resistance welding equipment, J1 active alloys, G2D Subcommittee (G). R. Gupta, ext. 301, gupta@aws.org.
Committee (E, G, U). Titanium and zirconium filler metals, Magnesium alloy filler metals, A5L
J. Douglass, ext. 306, A5K Subcommittee. Aircraft and Aero Subcommittee.
jdouglass@aws.org. Methods of weld space, D17 Committee (G, E, C, U).
inspection, B1 Committee (E, C, U). P. Portela, ext. 311,
C3 Committee Meets at AWSHeadquarters
The C3 Committee on Brazing and Soldering recently held meetings at AWSHeadquarters in Miami, Fla. From left: Vice Chair Grayson
Alexy, Jonathan Longabucco, Sunder Rajan, Michael Pohlman, Constantino Volpe, James Bush, Chuck Walker, Joe Bassindale, David
Budinger, Chair Ron Smith, Hui Zhao, Martin Stroiczek, Terence Profughi, Steve Feldbauer, William Coughlan, Ray Xu, Justin Liguori, Ray
McKinney, Juan Carlos Madeni, Michael Paponetti, Secretary John Douglass, and Richaad Reed.
MEMBERSHIP ACTIVITIES
New AWS Supporters Colorado Ornamental Iron, Inc. Facility Makers, Inc.
1155 S. Platte River Dr. P.O. Box 60066
Denver, CO 80223 Irvine, CA 92602
Affiliate Companies
DARLSCO Inspection Services Qari Steel
CFS Inspections Unit No. 307, Bait Al Nahda Bldg.
932 N. Garland Al Madina Rd Beside Al Mazalim Ct.
Al Nahda 2, Dubai 231941 Al Salama Jeddah, Makkah Al
Fayetteville, AR 72703 United Arab Emirates Mukarrama 21352 Saudi Arabia

SOCIETY NEWS
Schupan Aluminum & Plastic Sales Lynnes Welding Training, Inc. Doneth, and Andre Young, Detroit
4200 Davis Creek Ct. 4329 Centurion Dr., Unit 9 Section; Bruce Faccio, Saginaw Valley
Kalamazoo, MI 49001 Bismarck, ND 58504 Section; and Jeff Carney, Kris Post,
Matt Post, and James Koster, West
Simufact Engineering MecostaOsceila Career Ctr. Michigan Section.
201 Depot St., Ste. 100 15830 190 Ave. District 7 Director Uwe Aschemeier
Ann Arbor, MI 48104 Big Rapids, MI 49639 has nominated Bruce Scherer, Cincin-
nati Section; Jim Worman, Columbus
Morgan Community College Section; Larry Barley, Dayton Section;
Superior Steel Fabrication 920 Barlow Rd. Brian Barnes, Johnny Appleseed Sec-
3451 West St. Ave. Ft. Morgan, CO 80701 tion; J. Bart Sickles, Johnstown-
Eugene, OR 97402 Altoona Section; George Kirk, Pitts-
Multicare Safety &Industries burgh Section; George Bodnar, Tri-
PO 121089 State Section; Michael Pawelczyk,
Dubai 121089 Wheeling Section; and Edison Welding
United Arab Emirates Institute (Randy Dull), Columbus
Sustaining Members Section.
Safe Systems for Advanced
Dynetics, Inc. Technology
P.O. Box 5500 4045 Ash Shefaa, Unit No. 1
Huntsville, AL 35814 Jeddah Makkah 22451
dynetics.com Student Chapter Member
Saudi Arabia
Award Presented
St. Joseph CountyCareer &Technical
62445 Shimmel Rd. The AWS Beaver Valley Student
Centreville, MI 49032 Chapter, Pittsburgh Section, Dist. 7,
Supporting Company has selected Eli D. Seibel to receive the
Supreme Welding Academy Student Chapter Member Award.
Members 11980 Proctor St., Ste. 11 Seibel was selected by AWS Beaver
Houston, TX 77038 Valley Student Chapter Advisor Tom
ProMachine, Inc. Geisler. Seibel, who has served as the
6150 Edgewater Dr., Ste. H University of Arkansas Chapters secretary this past year, was
Orlando, FL 32810 2005 White Dr. an honor roll student throughout high
Batesville, AR 72503 school, and is also a member of the PA
Farm Bureau. He received a PA Skills
Certificate for NOCTI.
This award was established with the
Educational Institutions purpose of recognizing AWS Student
District Director Awards
Members whose Student Chapter
Carbon County Higher Education Ctr. Presented activities have produced outstanding
812 E. Murray St. school, community, and/or industry
Rawlins, WY 82301 The District Director Award pro- achievements.
vides a means for District Directors to
I AM A QC, LLC recognize individuals and corporations
315 N. Shary Rd., Ste. 1032 who have contributed their time and
Mission, TX 78572 effort to the affairs of their local Sec-
tion and/or District.
Indian River State College District 9 Director Michael Skiles
3209 Virginia Ave. has nominated Tom Reynolds, Barry AWS Member Counts
Ft. Pierce, FL 34981 Bernard, and Marcie Jacquet, Acadi- June 1, 2016
ana Section; Steve Moore and Shin
Lakeshore High School Horikawa, Auburn-Opelika Section; Sustaining.................................603
5771 Cleveland Ave. Thomas Shelton and George Fair- Supporting ...............................357
Stevensville, MI 49127 banks, Baton Rouge Section; Dustin Educational...............................763
Wright and Roy L. Ledford, Birming- Affiliate.....................................666
Lamar Community College ham Section; Don Sanders, Central Welding Distributor ...................61
2401 S. Main Louisiana Section; Aldo Duron, D. J. Total Corporate .......................2450
Lamar, CO 81052 Berger, and Travis Moore, New Or- Individual ...........................61,318
leans Section; and Brenda Amos and Student + Transitional ...........11,739
Lincolnland Technical Education Ctr. Clay Byron, Mobile Section. Total Members ..................73,057
1000 Railer Way District 11 Director Robert Wilcox
Lincoln, IL 62656 has nominated Robin Michon, Wesley

July Society News.qxp_Layout 1 6/10/16 9:46 AM Page 77
SOCIETY NEWS
MemberGetaMember Campaign AWSAttends Mecnica Fair in Brazil
Listed here are the members participating in the 2016
Member-Get-a-Member campaign. The campaign runs from
Jan. 1 to Dec. 31, 2016. Members receive 5 points for each In-
dividual Member and 1 point for every Student Member
recruited.
For campaign rules and a prize list, please see page 81 of
this Welding Journal. Standings as of May 22. Call the AWS
Membership Dept. at (800) 443-9353, ext. 480, for more
information.
J. W. Morris, Mobile 105

G. Bieniecki, Cleveland 52
D. J. Ebenhoe, Kern 45
M. Krupnicki, Rochester 35
D. A. Saunders, Lakeshore 32
J. J. Russell, Fox Valley 26
B. M. Scherer, Cincinnati 22
G. L. Gammill, N.E. Mississippi 20
C. A. Renfro, Chattanooga 17
C. J. Bridwell, Ozark 15
T. A. Harris, Johnstown-Altoona 15
Y. Lopez, International 15
R. F. Purvis, Sacramento 15
J. D. Schlarb, Portland 15
M. D. Stein, Detroit 15
J. Upton, Houston 15
R. D. Zabel, S.E. Nebraska 14
T. E. Buckler Sr., Columbus 13 AWS Staff Members Joe Krall (left) and Matt Rubin
(right) recently attended Mecnica, a machinery trade
M. J. Haggard, Inland Empire 13 fair in So Paulo, Brazil. They are pictured here with
L. M. Roat, Sacramento 13 Donizette Miranda, director of ConAn, a member of
T. Geisler, Pittsburgh 12 AWS and RWMA.
A. I. Duron, New Orleans 12
AWS International Agents Come Together in Panama
AWSstaff and representatives, along with representatives from 15 AWSInternational Agencies, recently met in Panama City, Panama, to
discuss the promotion and administration of AWScertification exams throughout the world. Pictured visiting the Atlantic Ocean side of the
Panama Canal expansion project are (back row, from left): Lorena Garza, Erick Jurgensen, John Gayler, Fubao Ding, Arley Gonzalis, Mad
havan Krishnamurthy, Rigoberto Carrin, Michael Walsh, Horacio Navarro, Mauricio Ibarra, Jeff Kamentz, and AWSPresident David
McQuaid; (front row, standing, from left) Pabitra Das, Le Hoang Son, Neville Cornish, Edgard Vera, Juan Guardia, Dacheng Feng, Yoanne
Lau, Daniel Almeida, Adnan AlAwwami, Eduardo Rojas, Kamal Gupta, Daniel Rojas, Terry Perez, Vanessa Gonzlez, and Sara Lpez; and
(front row, kneeling, from left) Carlos Gomez, Mohsen Hassanein, and Carlos Posligua.

July 2016 Layout Section News final.qxp_Layout 1 6/9/16 2:39 PM Page 78
SECTION NEWS BY ANNIK BABINSKI ababinski@aws.org
Blackstone Valley Regional Vocational processes the company uses. Students

District 1 High School, United State Representa- had a chance to see orbital welding,
Douglas Desrochers, director tive and WorldSkills 2015 fth place purge welding, CNC laser jet cutting,
(508) 763-8011 nisher automated press brake applications,
dadaws@comcast.net Summary: Cardin discussed his experi- and waterjet cutting. Students were
ence and presented his journey from treated to t-shirts and dinner by Lord.
BOSTON SkillsUSA to WorldSkills to the Old The following were present: Instruc-
April 25
Colony welding students. tor Chris Baker, Owner Kenneth Lord,
Location: New England Institute of
Tyler Kimmey, Nathaniel Lowe, Will
Technology, Lawrence, Mass.
Watkins, Gavin Mowery, Kobi Ruark,
Summary: Section Chairman Tom Ferri
presented the 25-Year Silver Member- District 2 Cole Willey, Jake Morris, Biazzio
Giordano, Hunter Hughes, Austin
ship Award to Section Secretary Rick Harland W. Thompson, director
Nichols, Wyatt Barnes, Micah Brooks,
Moody. Moodys niece Carolyn Holden, (631) 546-2903
Donavan Mundy, and Jody Jackson.
who has an interest in welding technol- harland.w.thompson@us.ul.com
ogy, attended the meeting with him.
Dorchester Career and North Montgomery County
CENTRAL MASSACHUSETTS/ Technical Center S.C. Technical Career Center S.C.
RHODE ISLAND April 19 May 13
April 5 Location: C K Lord, Inc., Cambridge, Location: Lansdale, Pa.
Location: Old Colony Regional Voca- Md. Activities: Student chapter meetings, a
tional Technical High School, Event: Kenneth Lord, owner, gave WEMCO video, and a presentation
Rochester, Ma. student chapter members a tour of about being an AWS member were
Presenter: Andrew Cardin, graduate of the facility, and discussed the welding reviewed.
BOSTON Section Chairman Tom Ferri

(from left) presented Section Secretary
Rick Moody with his 25Year Silver Mem CENTRAL MASSACHUSETTS/RHODE ISLAND Andrew Cardin (left), WorldSkills winner,
bership Award while Moodys niece Car spoke to students, welding instructors, and Jacqueline Machamer, vocational coordinator,
olyn Holden cheered him on. Old Colony RVTHS.
NORTH MONTGOMERY COUNTY TECHNICAL CAREER CENTER (First row, from left) Austin Diaz, Tyler Scheponik, Josiah Shimko, Caitlin
Turner, Vincent Dilenno, Andrew Ascher, Dakota Brown, and Dist. 2 Director Harland Thompson; (second row, from left) Quest Moore,
Steven LaBella, William Snyder, Amir Thompson, Joe Karg, Connor Moyer, Adam Scialdone, and Matt McClean.

SECTION NEWS
District 3
Michael Sebergandio, director
(717) 471-2065
drweld13@gmail.com
LANCASTER/YORK
April 26
Location: CNH Industrial America, LEHIGH VALLEY Student winners of the high school welding competition posed with
New Holland Agriculture Manufactur- Dist. 3 Director Michael Sebergandio (middle left) and AWS President David McQuaid.
ing Operations, New Holland, Pa.
Presenters: Jake Fisher, advanced man-
ufacturing engineer, Derek Oberlin, ad-
vanced quality engineer, and Ryan Alle-
man, operations manager
Summary: For this joint meeting be-
tween the Lancaster, Pa., and York, Pa.,
Sections, members of the company con-
ducted tours through its manufacturing
facility. Section members learned the
history of the company, as well as de-
tails about the design and fabrication of
various agricultural equipment and at-
tachments made in the facility.
LEHIGH VALLEY LEHIGH VALLEY Students prepared for the Sections Student Welding Competition.
March 2
Location: Monroe County Career and
Technical Institute, Bartonsville, Pa.
Event: 49th Lehigh Valley Section Stu-
dent Welding Contest
Summary: Students from Bethlehem
Area Vocational School, Monroe Ca-
reer and Technical Institute, Upper
Bucks County Vocational Institute,
Middle Bucks County Vocational Insti-
tute, Warren County Vocational Insti-
tute, and Lehigh Career and Technical
Institute competed in a day-long event
that demanded the reading of blue-
prints and completion of projects with
various welding processes and posi- NORTH MONTGOMERY COUNTY TECHNICAL CAREER CENTER (Front row, from left)
tions. Dino Fourst organized the com- Dik Getz, Michael Cardimone, Eric Nelson, Zaheer Razi, McKaila Conway, Chris Green,
petition and Mike Rizzo, Joe Feranti, Joshua Seitzer, and Dist. 2 Director Harland Thompson; (back row, from left) Karl Schafer,
and Joe Diltilia were judges. Ed Devlin, Bob McSain, David DeGideo, Lexi Virgilio, Matt Emmett, and Jud Munsell.
LANCASTER/YORK Section members toured CNH Industrial with tour guides Jake Fisher, Derek Oberlin, and Ryan Alleman.

SECTION NEWS
March 29
Location: The Meadows, Hellertown,
Pa.
Presenter: AWS President David
McQuaid
Topic: Weld defects repaired while in
service
Summary: Sixty-six people attended
the presidents report on eld repairs
while in service. After, the student
awards were given to Nick Baer
(Lehigh Career and Technical Insti- SOUTHWEST VIRGINIA (From left) Bob Campbell, Banker Steel; Ron Stahura, ESAB;
tute), rst place; Brandon Bergen Mark Newman, CVCC welding instructor; Jewel Newman, CVCC welding instructor; Jay
(Lehigh Career and Technical Insti- Coubrough, ESAB; E. Roger Cobb, CVCC welding instructor; David Owens, Altec Indus
tute) second place; and Jack Daniels tries/Section chairman; and Bob Fitch, Arc3/Section programming chairman.
(Bethlehem Area Vocational and Tech-
nical School) oxyfuel cutting contest
winner.
District 4
Stewart A. Harris, director
(919) 824-0520
stewart.harris@altec.com
CAROLINA
April 14 CAROLINA Section Chair Sergey Ko CAROLINA Section Chair Sergey Ko
Summary: The Section held a joint belev (right) handed out a Section Meri belev (right) awarded a Section Meritori
meeting with the Carolina ASME Sec- torious Award for many years of work in ous Award to Samuel Glass (Isometrics,
tion for networking purposes, and to the society to Donald Ellington (GTCC). Inc.).
discuss welder training. Staff from three
local community colleges were present:
Forsyth Tech (FTCC, Winston-Salem),
Guilford Tech (GTCC, Greensboro), and
Surry Community College (SCC). Mark
Jeffries, Rick Ward, and their colleagues
from Arc3 Gases, as well as Kevin Shaf-
fer and Lincoln Electric helped coordi-
nate the meeting. Joel D. Welch, VP
FTCC, J. Woods, welding technology de-
partment chair, and L. Kiser, dean, engi- CAROLINA The Section held a joint meeting with the local ASME chapter that involved
neering technologies division also students, faculty, engineers, and industry consultants.
helped.
LEHIGH VALLEY President McQuaid (center) stood with participants of the Sections Student Welding Competition.

AWS MEMBERSHIP APPLICATION
Join or Renew: Mail: Form with your payment, to AWS Call: Membership Department at (800) 443-9353, ext. 480
Fax: Completed form to (305) 443-5647 Online: www.aws.org/membership 8669 NW 36 St, # 130
Miami, FL 33166-6672
CONTACT INFORMATION Telephone (800) 443-9353
FAX (305) 443-5647
q New Member q Renewal Visit our website: www.aws.org
q Mr. q Ms. q Mrs. q Dr. Please print Duplicate this page as needed Type of Business (Check ONE only)
A q Contract construction
Last Name:_______________________________________________________________________________
B q Chemicals & allied products
C q Petroleum & coal industries
First Name:___________________________________________________________________ M.I:_______
D q Primary metal industries
E q Fabricated metal products
Birthdate: _____________________________ E-Mail:____________________________________________
F q Machinery except elect. (incl. gas welding)
G q Electrical equip., supplies, electrodes
Cell Phone ( )__________________________ Secondary Phone ( )______________________
H q Transportation equip. air, aerospace
Were you ever an AWS Member? q YES q NO If YES, give year________ and Member #:____________________ I q Transportation equip. automotive
J q Transportation equip. boats, ships
Company (if applicable):___________________________________________________________________ K q Transportation equip. railroad
L q Utilities
Address:________________________________________________________________________________ M q Welding distributors & retail trade
N q Misc. repair services (incl. welding shops)
_______________________________________________________________________________________ O q Educational Services (univ., libraries, schools)
P q Engineering & architectural services (incl. assns.)
City:_____________________________________State/Province:__________________________________ Q q Misc. business services (incl. commercial labs)
R q Government (federal, state, local)
Zip/PostalCode:_____________________Country:______________________________________________ S q Other
Who pays your dues?: q Company q Self-paid Sex: q Male q Female Job Classification (Check ONE only)
01 q President, owner, partner, officer
Education level: q High school diploma q Associates q Bachelors q Masters q Doctoral
02 q Manager, director, superintendent (or assistant)
q Check here if you learned of the Society through an AWS Member? Members name:_______________________Members # (if known):________ 03 q Sales
04 q Purchasing
q Check here if you would prefer not to receive email updates on AWS programs, new Member benefits, savings opportunities and events.
05 q Engineer welding
20 q Engineer design
INDIVIDUAL MEMBERSHIP 21 q Engineer manufacturing
06 q Engineer other
Please check each box that applies to the Membership or service youd like, and then add the cost together to get your Total Payment. 10 q Architect designer
q AWS INDIVIDUAL MEMBERSHIP (One Year)......................................................................................................$87 12 q Metallurgist
13 q Research & development
AWS INDIVIDUAL MEMBERSHIP (Two Years) SAVE $25 New Members Only....................................$149 22 q Quality control
07 q Inspector, tester
q New Member Initiation Fee ...........................................................................................................................................$12
08 q Supervisor, foreman
OPTIONS AVAILABLE TO AWS INDIVIDUAL MEMBERS ONLY: 14 q Technician
09 q Welder, welding or cutting operator
A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling) 11 q Consultant
q Individual Members in the U.S..................................................................................................................................$35 15 q Educator
17 q Librarian
q Individual Members outside the U.S (includes International shipping)...........................................................................$85 16 q Student
ONLY ONESELECTION PLEASE. For more book choices visit https://app.aws.org/membership/books 18 q Customer Service
q Jeffersons Welding Encyc.(CD-ROM only) q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy q Welding Inspection Handbook 19 q Other
Welding Handbook Selections: q WHB (9th Ed., Vol. 5) q WHB (9th Ed., Vol. 4) q WHB (9th Ed., Vol. 3) q WHB (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1) Technical Interests (Check all that apply)
Pocket Handbook Selections: q PHB-1 (Arc Welding Steel) q PHB-2 (Visual Inspection) q PHB-4 (GMAW / FCAW) A q Ferrous metals
B q Aluminum
B.) OPTIONAL Welding Journal Hard Copy (for Members outside North America) C q Nonferrous metals except aluminum
q Individual Members outside North America (note: digital delivery of WJ is standard)..............................................$50 D q Advanced materials/Intermetallics
E q Ceramics
INDIVIDUAL MEMBERSHIP TOTAL PAYMENT..................................................................................$_____________ F q High energy beam processes
NOTE: Dues include $17.30 for Welding Journal subscription and $4.00 for the AWS Foundation. G q Arcwelding
H q Brazing and soldering
I q Resistance welding
STUDENT MEMBERSHIP J q Thermal spray
K q Cutting
q AWS STUDENT MEMBERSHIP (with digital Welding Journal magazine)................................................$15 L q NDT
M q Safety and health
q AWS STUDENT MEMBERSHIP (with hard copy Welding Journal magazine)..............................................$35
N q Bending and shearing
Option available only to students in U.S., Canada & Mexico.
O q Roll forming
P q Stamping and punching
PAYMENT INFORMATION Q q Aerospace
R q Automotive
Payment can be made (in U.S. dollars) by check or money order (international or foreign), payable to the American Welding Society, or by charge card. S q Machinery
q Check q Money Order q AMEX q Diners Club q MasterCard q Visa q Discover q Other T q Marine
U q Piping and tubing
CC#:____________ / ____________ / ____________ / ____________ Expiration Date (mm/yy) ________ / ________ V q Pressure vessels and tanks
W q Sheet metal
X q Structures
Signature of Applicant:_________________________________________ Application Date:_______________________
Y q Other
Z q Automation
OFFICE USE ONLY Check #:_______________________________ Account #____________________________________ 1 q Robotics
Source Code: WJ Date:_________________________________ Amount:_____________________________________ 2 q Computerization of Welding
REV. 11/15
SECTION NEWS
SOUTHWESTVIRGINIA bot, and plasma cutting devices used in
April 28 the Advanced Manufacturing Center. District 6
Michael Krupnicki, director
Location: Central Virginia Community
SOUTH FLORIDA (585) 705-1764
College Welding Facility, Lynchburg, Va.
February 10 mkrup@mahanyweld.com
Presenter: Jay Coubrough, global prod-
uct manager, stainless steel and nickel Location: McFatter Tech, Davie, Fla.
solid wires, and Ron Stahura, CWI/ Presenter: Bill Gardner, senior product
CWE, strategic account manager, pres- manager of safety and health, Miller
Electric
District 7
sure vessel and pipe mill segment Uwe Aschemeier, director
Company Affiliation: ESAB welding and Topic: Welding safety and practices (786) 473-9540
cutting Summary: Gardner provided valuable uwe@sgsdiving.com
Topic: Welding stainless steel information pertaining to codes for the
safety of a welding facility.
District 5 April 20
Location: McFatter Tech, Davie, Fla.,
Carl Matricardi, director
(770) 356-2107 and Robert Morgan Tech, Miami, Fla.
cmatricardi@aol.com Presenters: Steve Voight, Magne Gas,
and Justin Mango, Norton Abrasives
FLORIDA WEST COAST Topic: Introduction to alternative fuel,
May 7 and explanation on polishing mill nish
Location: The Bloomingdale Golfers stainless steel
Club, Bloomingdale, Fla. Summary: Voight spoke about a hydro-
Event: The Sections 24th Annual Schol- gen-based alternative fuel that he sug-
arship Fundraiser Golf Tournament gested will replace acetylene. Mango SOUTH FLORIDA Bill Gardner, senior
Summary: Forty golfers participated in gave a hands-on presentation on polish- product manager of safety and health,
ing mill-nish stainless steel. Miller Electric, spoke to members.
the four-person scramble event, which,
along with donations from the hole
sponsors, helped the Section raise more
than $2000 for the welding student
scholarship fund. The Section would
like to extend its thanks to all partici-
pants and hole sponsors that made the
event a success: Crumpton Welding
Supply, KTA Steel Group, Tampa Steel
Erecting Co., Rapid Metals, Pinellas
Technical Education Center, Interna-
tional Ship Repair, Lincoln Electric,
Norton Saint-Gobain Abrasives, Miller
Electric, Erwin Technical College, and
Uniweld Products, Inc. NORTHCENTRAL FLORIDA Jason NORTHCENTRAL FLORIDA Past Presi
Becker, senior welding instructor, Valen dent Bill Myers presented outgoing
NORTHCENTRAL FLORIDA cia College, Kissimmee, Fla., explained Chairman Chris Owens with his Chair
May 10 the colleges welding program. man Appreciation plaque.
Location: Valencia College Advanced
Manufacturing Center, Kissimmee, Fla.
Summary: The Sections annual election
of officers was called to order by Chair-
man Chris Owen. Secretary Bill Myers
gave the list of nominees for the offi-
cers: Howard Record, chairman; Josh
Esposito, rst vice chairman; Ed Mis-
zczak, second vice chairman; Bill Myers,
secretary; Chris Utman, treasurer; Chris
Owen, past chairman; and Mark Geiger,
member-at-large. Thirty-one members
and students attended the event. J. T.
Mahoney gave a presentation on why
you should be an AWS member. Jason
Becker described and demonstrated FLORIDA WEST COAST The firstplace team won with a score of 65 for 18 holes. From
some of the machine tools, welding ro- left are Mike Gates, Walt Arnold, Donny Chadwell, Nick Gates, and Jack Garrison.

SECTION NEWS
Beaver County CTC Student Science and Technology
Chapter Topic: Sustainability in manufacturing
May 17 Summary: Product transparency has
Location: Beaver County Career and become a megatrend in the consumer
Technical Center, Monaca, Pa. products industry. Thomas highlight-
Summary: Tom Geisler, welding in- ed trends in corporate sustainability
structor, awarded Eli Seibel with the from a manufacturing perspective, in-
Student Chapter Student of the Year cluding marketplace expectations, life
Award. Seibel has been enrolled in the cycle thinking, and an overview of sus-
welding program for two years with- tainability in manufacturing.
out missing or being late for a class.
He works full time at his family farm
and recently passed his all-position,
limited-thickness welding District 8
certication. D. Joshua Burgess, director
BEAVERCOUNTY CAREER AND TECH (931) 260-7039
NOLOGY CENTER Tom Geisler (left), COLUMBUS djoshuaburgess@gmail.com
welding instructor at Beaver County April 26
CTC, awarded Eli Seibel, a senior en Location: Old Worthington Library, NORTHEAST TENNESSEE
rolled in the welding program, with the Worthington, Ohio April 12
Student Chapter Student of the Year Presenter: Dr. Richelle Thomas, ad- Location: Knoxville, Tenn.
Award. vanced engineer, R&D, Owens Corning Presenter: David McQuaid, AWS presi-
dent, D. L. McQuaid & Associates
Topics: Common problems and their
solutions
Activities: President McQuaid gave an
interesting presentation that covered
several problems he has encountered
in his career. He also explained the so-
lutions that were used to solve these
problems.
April 12
Location: Tennessee College of Applied
Technology (TCAT), Knoxville, Tenn.
Presenter: Jeff Hankins
Topics: Student Day, Education and Ca-
COLUMBUS Jim Worman (left), Sec reers in Welding
tion chairman, thanked Dr. Richelle NORTHEAST TENNESSEE President Summary: Hankins was master of cere-
Thomas, advanced engineer, R&D, McQuaid (right) presented a chairmans
mony for the proceedings at TCAT,
Owens Corning Science and Technology, certificate to current District 8 Director
for speaking to the group. Josh Burgess. Knoxville. About 170 high school stu-
dents attended the presentation on ca-
NORTHEAST TENNESSEE AWS President David McQuaid (middle front) spoke with welding students from Oak Ridge High School at the
Sections student day.

SECTION NEWS
reers and training available in welding.
Presenters represented the U.S. Navy,
April 1820
Location: Chattanooga, Tenn. District 9
union apprentice programs, Tulsa Topic: SkillsUSA State Championship Michael Skiles, director
School of Welding, and others. The Sec- Summary: Abbie Allison won a gold (337) 501-0304
tion provided lunch and local distribu- medal in welding sculpture, Peyton michaelskiles@cox.net
tors provided door prizes. Ooten won a bronze medal in action
skills, and Evan Eschenberg won a gold ACADIANA
medal in welding. All three will repre- April 19
sent Tennessee at the national champi- Location: Gator Cove Restaurant,
onship. Jeff Hankins was their Lafayette, La.
instructor. Summary: Shane Searels, ESAB, pre-
sented on the companys new ICE SAW
welding process, and Section Chair Tom
Reynolds presented him with a Jamba-
laya Paddle in thanks.
AUBURN/OPELIKA
April 6
Location: South Union State Commu-
nity College, Opelika, Ala.
Presenter: Darin Baldwin, dean of
Technical Education
Topic: Program of study and tour of
NORTHEAST TENNESSEE Abbie Alli
son (from left) won a gold medal in technical facility
welding sculpture, Peyton Ooten won a Summary: The Section toured the col-
ACADIANA Section Chair Tom bronze medal in action skills, and Evan leges new technical facility and en-
Reynolds (left) presented Speaker Shane Eschenberg won a gold medal in weld joyed Baldwins presentation about the
Searels, ESAB, with a Jambalaya Paddle ing at the SkillsUSA State Competition. welding program.
as thanks for speaking to the Section. Jeff Hankins (right) is their instructor.
May 2
Location: Hyundai Power Transform-
ers USA, Inc., Mongomery, Ala.
Presenter: Jaehun Kim
Summary: The Section held a joint
meeting with the IEEE Alabama Sec-
tion, and toured the companys facility
together. Kim spoke about the compa-
nys transformer products and ex-
plained how they made power trans-
formers.
MOBILE
April 30
Location: T. L. Faulkner CTC, Prichard,
Ala.
AUBURN/OPELIKA Section members toured the new technical facility at South Union Presenter: Tim DeVargas, welding in-
State Community College, Opelika, Ala. structor, and Jerry Betts, Section schol-
arship chair
AUBURN/OPELIKA Speaker Jaehun Kim spoke to Section members and IEEE Alabama Section members about how Hyundai makes
power transformers.

SECTION NEWS
Topic: Boy Scouts Merit Badge Training NEWORLEANS
Summary: DeVargas and Betts conduct- May 17
ed training for Troops 3 and 143, Mo- Location: Best Western Landmark Ho-
bile, Ala., to earn their welding merit tel, Metairie, La.
badges. The instructors were assisted by Presenter: Tony DeMarco, DeMarco
students Thor Broadhead and Zach Welding Services
Manderson. Topic: The Art of Lead Welding
Summary: The Sections annual stu-
April 14 dent appreciation night meeting was
Location: The Original Oyster House, well attended. DeMarco gave an in-
Spanish Fort, Ala. formative presentation on the art of
Presenter: Thomas B. Bender Jr., re- lead welding, and a 50/50 raffle was
tired president and CEO, Bender Ship- held, with proceeds donated to stu-
building & Repair dent Section activity.
Topic: History of shipbuilding on the
MOBILE Thomas (Tom) B. Bender Jr.
Mobile River
(left), retired president and CEO, Bender
Shipbuilding & Repair, was presented
Summary: Clay Byron welcomed mem-
bers and introduced the speaker. Ben- District 10
der spoke about the history of ship- Mike Sherman, director
with a Plaque of Appreciation by Clay
building in the area dating back to the (216) 570-9348
Byron at the Original Oyster House,
Spanish Fort, Ala. late 1800s. A split the pot draw and mike@shermanswelding.com
door prizes raised $110 for the Sec-
tion. Forty people were in attendance. MAHONINGVALLEY
April 20
Location: Columbiana County Techni-
cal and Career Center, Lisbon, Ohio
Speaker: Jim Hannahs, P. E., CMfgE,
CWI
Topic: Welding and driving NASCAR
racing cars
Summary: More than 50 people were
in attendance.
NEWORLEANS Speaker Tony De

District 11
Robert P. Wilcox, director
Marco (from left), DeMarco Welding (734) 721-8272
Services; Chad Calliuet, Section student
MAHONING VALLEY Speaker Jim rmwilcox@wowway.com
liason; DJ Berger, Section vice chairman;
and Bruce Hallila, Section awards chair Hannahs presented to more than 50
man, enjoyed the student appreciation guests about his time welding and driv
night. ing NASCAR racing cars.
MOBILE Section members helped Boy Scouts Troops 3 and 143 in Mobile, Ala., complete their welding merit badges. (From left) Thor
Broadhead, Zach Manderson, Joey Westerfield, Daniel Newbill, Thad Arthur, Christopher Hites, Marcelo Washington, Sharon Westerfield,
Mauricio Washington, William Poirier, Andrew Bolton, Joshua Washington, Andrew Simpson, David Hantouche, Jerry Betts, Joseph Han
touche, and Tim DeVargas.

SECTION NEWS
DETROIT had more than 35 participants from achievements of our industry. Most
April 13 nine different high schools from across importantly, funds raised from the
Location: Addison Iron Fabricators, De- Michigan. More than $9000 in prizes, evening gala are used to support the
troit, Mich. including three power sources for the Section Scholarship program. Since its
Topic: Women Who Weld top three nishers, was awarded. Ian inception, the Section has contributed
Summary: Wes Doneth visited the facil- Schwenke, South & West Washtenaw close to $800,000 to scholarships for
ity to see the lastest Women Who Weld Consortium, won rst place and $2500; students pursuing a career in welding.
class in action. Samantha Farr and James Bedzyk, William D. Ford Career First Vice Chairman Tyler Alexander
Ralph Taylor were teaching the funda- Technical Center, won second place and acted as host and Past Chair Don
mentals to seven students over three $2000; Jared Lambrix, Flat Rock Com- Maatz was MC. They were joined by
weeks. The Section donated protective munity High School, won third place David L. McQuaid, AWS president,
equipment such as helmets, jackets, and $2000; Matt Nyrkkanen, South & and almost 400 other likeminded
gloves, and other essential tools to the West Washtenaw Consotrium, won welding professionals who added
class. Tom Viggiano, Roy Smith Co., and fourth place and $1500; and Christo- more than $8000 to its scholarship
Steve Smith, Weld-Aid, also assisted pher Flores, Oakland Schools Technical fund. The event also highlighted the
with supplies. Doneth was impressed Campus Northeast, won fth place and other aspects of the Section,
with Farr and Taylor engaging on a $1500. including Women Who Weld, a unique
grassroots level with the community on program that uses welding to help
behalf of AWS. April 30 women in need.
Location: MGM Grand, Detroit, Mich.
April 15 Presenter: Tyler Alexander, B.A. Sc., May 12
Location: Washtenaw Community Col- weld engineering supervisor, Center- Location: Casadei Steel, Sterling
lege, Ann Arbor, Mich. Line (Windsor), Ltd. Heights, Mich.
Presenter: Glenn Kay II, CWI/CWE, in- Event: 76th Annual Section Ladies Presenter: Robert Casadei, vice presi-
structor and department chair, welding Night Celebration dent, Casadei Steel
and fabrication department Summary: This annual event has been Topics: Section awards night, Old
Topic: The Sections high school welding an important activity for the Section Timers Night
contest for 76 years and affords a unique op- Summary: Casadei provided his insight
Summary: The Section held its 43rd an- portunity for the welding community into the current state of industry with a
nual high school welding contest, which to come together and celebrate the presentation on structural steel fabrica-
tion challenges. The presentation was
followed by a tour of the Casadei Steel
fabrication facility. The night was also
the Sections annual Old-Timers Night.
Two individuals were recognized:
Michael Poss with his 25-year service
certicate and two-time Section Chair-
man Thomas Sparschu with his 50-year
Gold Service Award. The event was also
the Sections awards night. The follow-
DETROIT Winners of the high school welding contest stood with AWS Learning Sales ing were honored at the meeting: Indus-
Rep. Efram Abrams (from left), Section Chair Wes Doneth, and Welding Contest Chair try Sponsor Recognition Award, KUKA
Glenn Kay II, including first place winner Ian Schwenke, second place winner James Systems North America, LLC; Section
Bedzyk, third place winner Jared Lambrix, fourth place winner Matt Nyrkkanen (not pic Appreciation Award, Jeffry Hill, ARO
tured, instructor Steve Hasselbach standing in for Nyrkkanen), fifth place winner Christo Technologies; and Section Educator
pher Flores, and Welding Contest Chair Glen Knight. Award, Juan Whiting, Golightly VoTech.
DETROIT The Sections high school welding competition contestants showed their pride alongside Section Chair Wes Doneth and Weld
ing Contest Chair Glenn Kay II (lower right hand).

SECTION NEWS
DETROIT Dolly (left) and David L. DETROIT Robert Casadei (left), vice
McQuaid, AWS president, at the AWS president of Casadei Steel, received a DETROIT Tom Sparschu (left) received
Detroit Sections 76th annual Ladies speakers gift from Section Chairman his 50year Gold Service Award from
Night party. Wes Doneth. Section Chairman Wes Doneth.
ANNOUNCE YOUR
SECTIONS ACTIVITIES
If you would like to submit a calen-
dar listing, send along the following
information: Section name; activity
name, date, time, and location; and
speaker name, title, affiliation, and
subject. If some of your meeting
plans are pending, include the name
and e-mail or phone number of a
contact person for the event.
Please keep in mind the Journal

publication cut-off is usually the
20th of the month, for 2 months
ahead. For example, if you want to
have your October meeting in the
September Journal calendar, the
deadline is July 20.
Send your calendar event listing to

Annik Babinski, assistant editor, by
DETROIT Women Who Weld (from left) Samantha Farr, Jazmond Ravarra, Tiffany e-mail, ababinski@aws.org, or fax,
Collins, Maria Cantin, Daniela Hagen, Ralph Taylor, Brittany Shepherd, and Sandra (305) 443-7404.
DeBoard, completed a threeweek class to learn welding and fabrication basics.
SECTIONEVENTS New Orleans North Texas Holston Valley

CALENDAR Meetings are the third Tues-
Meetings are usually the Contact Jon J. Cookson for
Please note events are subject to third Tuesday of each of the day of each month: dinner at more information about
change. Reach out to the listed following months: Sept., 6:30 pm, program at 7 pm Holston Valley events at (757)
contact to conrm. Oct., Nov., Jan., Feb., Mar., Humperdinks, 700 Six Flags, 897-3748, or by e-mail at
April, and May. Arlington, Tex. Bring three jjcookson@northeast
Student Welder Competition, canned goods for the North state.edu.
Colorado Nov. 12. Texas Food Bank and receive
a door prize ticket.
Contact Bob Teuscher for more Contact D. J. Berger for more
information about Colorado information about New Or- Contact Paul Stanglin for
events at (303) 893-3602 or leans events at (504) 415- more information about
by e-mail at 9165, or by e-mail at North Texas events by
bobteuscher@hotmail.com. dj@nationalitc.com. e-mail at pstangli@
cityofirving.org.

SECTION NEWS
Ferris State Student Chapter William D. Ford CTC Student Ky. Welding processes used for the com-
April 16 Chapter petition included: GMAW on steel,
Location: Big Rapids, Mich. April 21 FCAW using a shielding gas, SMAW, and
Summary: Ten members of the Student Location: R & H Ornamental Ironworks, GTAW on aluminum.
Chapter participated in the colleges Big Westland, Mich.
Event, a day dedicated to volunteering Summary: Owner Richard Heinicke NEW JERSEY
around town to help clean up communi- showed students blacksmithing skills April 20
ty members yards. Associate professor and techniques, and offered his tongs Location: Snuffys Pantagis
Jeffrey Carney is the chapter academic and hammer to student Rick Laurence, Presenter: Nagesh Goel, AEIS, Atlas
advisor. who found blacksmithing much harder Evaluation and Inspection Service
than hed expected. Seventeen students Topics: Phased array ultrasonic testing
were in attendance. in lieu of radiographic testing
Summary: Goel gave a presentation on
the present state of phased array ultra-
sonic testing and how it is becoming
District 12 more cost-effective and a better alterna-
tive to radiographic testing. Jim Dolan
Daniel J. Roland, director
(920) 241-1542 received a belated District Meritorious
daniel.roland@airgas.com Award.
LAKESHORE RACINE/KENOSHA
April 14 April 8
Location: Manitowoc, Wis. Location: Putzmeister America, Inc.,
WILLIAM D. FORD CTC Richard Sturtevant, Wis.
Heinicke (left) stood with Danny Thacker,
Presenter: Donald Wensink, chairman,
Manitowoc Cranes Presenter: Don Gerou, product per-
who presented Heinicke with a plaque of
appreciation. Summary: The Section awarded its an- formance manager
nual scholarships to current or future Summary: District 12 held its annual
welding students. meeting at the company, where they
were treated to a tour, followed by a
MADISON/BELOIT banquet and awards ceremony at the
April 27 Roma Lodge. Bill Dawson was awarded
Location: Blackhawk Technical College, the District Meritorious Award, Rich
Milton, Wis. Hemler was awarded Instructor of the
Topic: SkillsUSA welding competition, Year Award, and Shaun Walker was
postsecondary level awarded CWI of the Year.
Summary: The colleges Advisors Jere-
miah Johnson and Mark Prosser over-
saw this years event, which hosted 29
students from eight different technical
District 13
John Willard, director
colleges. The Section would like to (815) 954-4838
WILLIAM D. FORD CTC Richard thank Technical Chair Chad Hendzel, kustom_bilt@msn.com
Heinicke taught students about black Robinson Metals, for prepping all metal
smithing in his shop, R & H Ornamental used for the competition. Congratula-
Ironworks, Westland, Mich. tions to Isaac Vania from NWTC, who
advanced to the Nationals in Louisville,
WILLIAM D. FORD CAREER AND TECHNICAL CENTER Student Chapter members enjoyed their visit with Richard Heinicke at his studio:
(from left) Kevin Sienko, Umar Black, Wesley Pringle, Jake Longuski, Ryan Sherman, Chase Larsen, Tyler Braun, Instructor Richard Randall,
Daniel Humphrey, Joe Fox, James Bedzyk (holding banner), Eric Cassidy, Rick Laurence, Owner Richard Heinicke, Dakota Clisch, Crystal Till
man, Danny Thacker, and Marshal Dotson.

SECTION NEWS
NEW JERSEY James Dolan (left) re RACINE/KENOSHA Bill Dawson (left) RACINE/KENOSHA Rich Hemier
ceived his District Meritorious Award was awarded the District Meritorious (right) was awarded the Instructor of the
from Bob Petrone. Award at the annual District Meeting. Year Award at the Roma Lodge.
NEW JERSEY Section Chairman Vince CHICAGO Section members gathered for the monthly board meeting: (sitting, from
Murray (left) thanked speaker Nagesh left) Anghelina and Cliff Iftimie, Bob Zimny, and John Hesseltine; (standing, from left) Jeff
Goel at Snuffys Pantagis. Stanczank, Tyler Anderson, Marty Vondra, and Craig Tichelar.
PEORIA Welding contest participants gathered for a photo together.
MADISON/BELOIT The SkillsUSA Welding Competition, college/postsecondary level, was held at Blackhawk Technical College in Milton,
Wis.

SECTION NEWS
CHICAGO INDIANA ST. LOUIS
April 20 April 27, 28 April 21
Location: Prime Time Restaurant, Hick- Location: J. Everett Light C. C., Indi- Location: Southwestern Illinois College,
ory Hills, Ill. anapolis, Ind. Granite City, Ill.
Topics: Section board meeting, plus the Topic: Mid-west Team welding Presenters: Rick Suria and Mike Kamp
online scholarship selection and deci- tournament Summary: The Section held its 2016
sion process. Summary: The Section hosted 130 con- Student Night and awarded Outstand-
testants, who competed for ve team ing Student Awards along with a new
PEORIA trophies, 25 individual trophies, schol- grinder to each recipient. Scholarships
March 24 arships, and $10,000 in door prizes at ranging from $750 to 1500 and total-
Location: Illinois Central College, East its 38th annual welding tournament. ing $13,500 were awarded. Pizza and
Peoria, Ill. Teams came from Indiana, Kentucky, drinks were served, and door prizes
Activity: The Sections annual student Missouri, and Illinois. The keynote and AWS student memberships were
and apprentice welding contest speaker was AWS Vice President John raffled off.
Bray, and the winning team was from
April 19 Pike Central High School, Petersburg,
Location: Illinois Central College, East
Peoria, Ill.
Ind. Individual winners were Eli Love-
land (SMAW), Pike Central, Petersburg,
District 15
David Lynnes, director
Speaker: Ethan Labowitz, Miller Electric Ind.; Travis Jacob (GTAW), Pike Central, (701) 893-2295
Activity: Labowitz demonstrated the Petersburg, Ind.; Josh Moore (GMAW), dave@learntoweld.com
LiveArc and the Section held its annual Whitewater Tech, Connersville, Ind.;
student night. Trevor Harlan (FCAW), Impact Insti-
tute, Kendallville, Ind.; and Jacob Dils
(Theory), Whitewater Tech, Con-
District 14 nersville, Ind.
Robert L. Richwine, director
(765) 606-7970
rlrichwine2@aol.com
PEORIA Luke Barnes (left), first prize INDIANA Section members gathered for a photo after the welding tournament: (front
winner, and Curt Rippey, ICC Instructor, row, from left) Larry Gibson, Bob Richwine, Pat Richwine, and Luanne Bray; (back row,
as Barnes accepted the welding machine from left) Eric Cooper, Tony Brosio, Sam Chance, John Bray, Richard Alley, Dave Jackson,
he won. and Bennie Flynn. Missing are Garry Dugger, Gary Tucker, and Mike Anderson.
PEORIA District 13 Director John

Willard (from left), Director at Large
Rick Polanin, and Miller Electric Repre
sentative Ethan Labowitz at the Sec INDIANA One hundred and thirty students and instructors attended the Sections 38th
tions annual student night. annual welding tournament and awards banquet.

SECTION NEWS
NORTHERN PLAINS longest drive, longest putt, closest to SOUTHEAST NEBRASKA
April 7 the pin, and course winners. April 12
Location: Alexandria Technical College, Location: Southeast Community Col-
Alexandria, Minn. NEBRASKA lege, Lincoln, Neb.
Event: The Sections Annual Behind the April 14 Topic: Education night meeting and
Mask welding contest Location: Camaco, Columbus, Neb. dinner
Summary: The contest consisted of Speaker: Tim Tucker, maintenance engi- Summary: Dan Zabel presented Pat
GMAW on 14-gauge steel sheet and neer/tour guide Wagner with a plaque in appreciation of
tubing, and SMAW on 14 -in. plate. Both Topic: Welding process for production his years of service. The new Pat Wagn-
processes required welding in all posi- of automotive seats er Student Scholarship Award was also
tions. Alexandria Technical and Com- Summary: Section members toured a unveiled. Two $500 Pat Wagner Schol-
munity College swept rst place. car seat manufacturer facility. The arships were awarded to Michael Adams
Thanks to the host, Lincoln Electric, group got to see what it takes to weld and Kiersten Wegner. District 16 Direc-
Praxair, Central McGowan, American 35,000 seats a day and meet stringent tor Karl Fogleman spoke to the group
Welding & Gas, A-OX, and many others WPS criteria. about welding qualications while
that supported the contest through do- everyone enjoyed a BBQ dinner.
nations and/or personnel.
District 16
Karl Fogleman, director
(402) 677-2490
fogleman3@cox.net
IOWA
April 12, 19
Location: DMACC Southridge Center
Summary: The Section held two meet-
ings to introduce attendees to the IOWA The Section hosted its annual social golf outing at the Prairie Knolls Country
AWS D1.1 code (April 12 free semi- Club in New Sharon, Iowa, in early May.
nar), and a full-day (April 19) technical
seminar presented by Past President
Dave Landon that took a deeper dive
into six different AWS codes/stan-
dards and how they apply to different
industries.
May 7
Location: Prairie Knolls Country Club,
New Sharon, Iowa
Topic: Annual social golf outing
Summary: The Section held its annual
two-person best ball golf tournament
in early May. With a shotgun start, the ST. LOUIS The 2016 Section Scholarship winners gathered for a photo after the Section
Student Night.
competitors aimed for the best ball af-
ter 18 holes. Prizes were given for the
NORTHERN PLAINS The Sections Be

hind the Mask welding contest GMAW
winners: (from left) Justin Simon
NORTHERN PLAINS The Sections Behind the Mask welding contest SMAW winners:
(NDSCSFargo), 2nd; Mike Kluver (ATCC),
(from left) Travis Hieserich (ATCC), 2nd; Mike Kluver (ATCC), 1st; Gunnar Kimber (ATCC),
1st; Andrew Johnson (NCTCTRF), 3rd;
3rd; and Andrew Johnson (NCTCTRF), 4th.
and Josh Christen (ATCC), 4th.

SECTION NEWS
AWS codes. They even have a fully func-
District 17 tional steel building mock up they erect
Jerry Knapp, director and disassemble during training. Sec-
(918) 813-0541 tion 167 officers for the 2016/2017 year
jgknapp@cox.net were presented and approved by the
members. A total of 25 members and
students attended the meeting.
District 18
John Stoll, director
(713) 724-2350
John.Stoll@voestalpine.com
District 20
SOUTHEAST NEBRASKA Michael Pierrette H. Gorman, director
Adams (from left), Dan Zabel, and Kier (505) 284-9644
sten Wegner celebrated Adamss and phgorma@sandia.gov
Wegners $500 Pat Wagner Scholarship
Awards.
District 19
Shawn McDaniel, director
(509) 793-5182
shawnm@bigbend.edu
District 21
Sam Lindsey, director
(858) 740-1917
SPOKANE slindsey@sandiego.gov
May 18
Location: Ironworkers Local #14,
Spokane, Wash.
Summary: As training director and ap- District 22
prentice coordinator with the Ironwork- Kerry E. Shatell, director
ers #14, Ethan LeGrand covered high- (925) 866-5434
lights of all Ironworker apprentice edu- kesi@pge.com
SOUTHEAST NEBRASKA Dan Zabel cation, training, and testing provided at
the facility. These include every aspect SACRAMENTO VALLEY
(left) awards Pat Wagner with a plaque April 27
in appreciation of his years of service to of a professional Ironworkers job, from
welding, bolting, rigging, reinforcing Location: Sierra College, Rocklin, Calif.
the Section.
steel, safety, and certication to seven Presenter: Chris Messier, Section chair-
SPOKANE Phil Zammit (left), section

chairman, presented a thank you gift to
Speaker Ethan LeGrand. SAN ANTONIO AWS Vice President John Bray visited the Section in 2015.
NEBRASKA Second Vice Chair Greg

Schroeter (right) presented the AWS
welding hood of appreciation to tour NEBRASKA Section members toured Camaco, Columbus, Neb., a facility that makes
guide Tim Tucker. 35,000 car seats a day.

SECTION NEWS
man, GNB Valves, American River Col- Norske Veritas (U.S.A.), Inc. (now DNV Summary: Thirty-ve members and
lege instructor GL), Dublin, Ohio guests attended the banquet
Topic: Officers meeting Topic: Industry response to pipeline presentation.
Summary: The Section officers met for construction quality issues identied by
a planning and organizational business federal regulators
meeting prior to the Section meeting.
The primary focus of this meeting was
preparing for the Section Clay Shoot
Fundraiser.
April 27
Location: Sierra College, Rocklin, Calif.
Presenter: Jared Ware, Builtware
Fabrication
Topics: Fabrication, starting a welding
business, advice for welding students
Summary: The Sierra College Student
Chapter hosted a barbeque and Ware,
an alumni, spoke about how he grew his
business and offered details about dif-
ferent fabrication projects his company
completed.
SAN FRANCISCO
April 6
Location: Spengers Restaurant, Berke- SACRAMENTO VALLEY Student members from Sierra College and Section members
ley, Calif. won prizes from Jared Ware, owner of Builtware Fabrication, at the colleges barbeque.
Presenter: William A. (Bill) Bruce, Det
SACRAMENTO VALLEY Officers Bob Baker, Chairman Chris Messier, Apolo Salazar, Sec
SAN FRANCISCO Guest Speaker Bill retary Bruce Tanner, Education Chairman Alex Taddei, Ray Atnip, Membership Chairman
Bruce (left) and Section Chairman Mike Bill Wenzel, AWS Vice President Dale Flood, Svetlana Meshkova, Past Chair Rob Purvis,
Zinser at Spengers Restaurant. and First Vice Chairman Jerry Wentland gathered for an officers meeting.
SACRAMENTO VALLEY Members and students from the Section and Sierra College Student Chapter enjoyed a barbeque.

Guide to AWS Services

American Welding Society Corporate Director, Global Sales Director International Activities
8669 NW 36th St., #130 Jeff Kamentz..jkamentz@aws.org . . . . . . . . . . . . .(233) Andrew Davis.. adavis@aws.org . . . . . . . . . . . . . . .(466)
Miami, FL 33166-6672 Oversees international business activities; cer- International Standards Activities, American
(800/305) 443-9353; Fax: (305) 443-7559 tification, publications, and membership. Council of the International Institute of Welding
Phone extensions are in parentheses.
PUBLICATION SERVICES Manager, Safety and Health
AWS PRESIDENT Dept. information . . . . . . . . . . . . . . . . . . . . . . . . .(275) Stephen Hedrick.. steveh@aws.org . . . . . . . . . . . .(305)
David McQuaid . . . . . . . .davidlmcquaid@comcast.net Metric Practice, Safety and Health, Joining of
D. L. McQuaid and Associates, Inc. Managing Director Plastics and Composites, Personnel and Facilities
519 Gala Drive, Canonsburg, PA 15317 Andrew Cullison.. cullison@aws.org . . . . . . . . . . .(249) Qualification, Mechanical Testing of Welds
ADMINISTRATION Welding Journal Program Managers II

Executive Director Publisher Stephen Borrero... sborrero@aws.org . . . . . . . . . .(334)
Ray Shook.. rshook@aws.org . . . . . . . . . . . . . . . . .(210) Andrew Cullison.. cullison@aws.org . . . . . . . . . . .(249) Definitions and Symbols, Structural Subcommit-
tees on Reinforcing Steel, Bridge Welding, Stainless
Senior Associate Executive Directors Editor Steel, Brazing and Soldering Manufacturers Commit-
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . . .(253) Mary Ruth Johnsen.. mjohnsen@aws.org . . . . . .(238) tee
John Gayler.. gayler@aws.org . . . . . . . . . . . . . . . .(472) Society News Editor Rakesh Gupta.. gupta@aws.org . . . . . . . . . . . . . .(301)
Melissa Gomez..mgomez@aws.org . . . . . . . . . . . .(275) Filler Metals and Allied Materials, International
Chief Financial Officer Filler Metals, UNS Numbers Assignment, Arc Weld-
Gesana Villegas.. gvillegas@aws.org . . . . . . . . . . .(252) Section News Editor ing and Cutting Processes, Computerization of Weld-
Annik Babinski..ababinski@aws.org . . . . . . . . . . .(256) ing Information
Chief Information Officer
Emilio Del Riego..edelriego@aws.org . . . . . . . . . .(247) Welding Handbook Editor Jennifer Molin.. jmolin@aws.org . . . . . . . . . . . . .(304)
Kathy Sinnes.. ksinnes@aws.org . . . . . . . . . . . . .(255) Structural Welding, Sheet Metal Welding
Board and Executive Director Services
Associate Director MARKETING COMMUNICATIONS Program Managers
Alex Diaz.. adiaz@aws.org . . . . . . . . . . . . . . . . . . .(294) Director John Douglass..jdouglass@aws.org . . . . . . . . . . . .(306)
Lorena Cora.. lcora@aws.org . . . . . . . . . . . . . . . . .(417) Brazing and Soldering, Methods of Weld Inspec-
AWS Awards, Fellows, Counselors tion, Welding in Marine Construction, Welding of
Board and Executive Director Services Public Relations Manager Machinery and Equipment
Program Manager Cindy Weihl..cweihl@aws.org . . . . . . . . . . . . . . . .(416)
Chelsea Lewis.. clewis@aws.org . . . . . . . . . . . . . .(293) Andre Naumann.. anaumann@aws.org . . . . . . . .(313)
Coordinates AWS awards and Fellow and Webmaster Welding and Brazing in Aerospace, Joining of
Counselor nominations. Jose Salgado..jsalgado@aws.org . . . . . . . . . . . . . .(456) Metals and Alloys, Piping and Tubing, Ti and Zr Filler
Metals, Oxyfuel Gas Welding and Cutting
Administrative Services Section Web Editor
Corporate Director Henry Chinea...hchinea@aws.org . . . . . . . . . . . . .(452) Peter Portela.. pportela@aws.org . . . . . . . . . . . . .(311)
Hidail Nuez..hidail@aws.org . . . . . . . . . . . . . . . .(287) High-Energy Beam Welding, Robotics Welding,
MEMBER SERVICES Welding in Sanitary Applications, Additive Manufac-
HUMAN RESOURCES Dept. information . . . . . . . . . . . . . . . . . . . . . . . . .(480) turing, Structural Welding Subcommittee on
Director Titanium
Gricelda Manalich.. gricelda@aws.org . . . . . . . . .(208) Senior Associate Executive Director
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . . .(253) Maria Elena Rodriguez..mrodriguez@aws.org . . ..(310)
INTERNATIONAL INSTITUTE OF WELDING Automotive, Friction Welding, Resistance Weld-
Senior Coordinator Corporate Director ing, Resistance Welding Equipment
Sissibeth Lopez . . sissi@aws.org . . . . . . . . . . . . . .(319) Rhenda Kenny... rhenda@aws.org . . . . . . . . . . . . .(260)
Liaison services with other national and interna- Serves as a liaison between members and AWS Jennifer Rosario.. jrosario@aws.org . . . . . . . . . . .(308)
tional societies and standards organizations. headquarters. Railroad Welding, Thermal Spraying, Welding
Iron Castings, Welding Qualification
GOVERNMENT LIAISON SERVICES CERTIFICATION SERVICES
Hugh Webster . . . . . . . . . . . . . . . . .hwebster@wc-b.com Dept. information . . . . . . . . . . . . . . . . . . . . . . . . .(273) CUSTOMEROPERATIONS
Webster, Chamberlain & Bean, Washington, D.C. Program Specialists
(202) 785-9500; F: (202) 835-0243. Managing Director Vivian Pupo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(362)
Monitors federal issues of importance to the Judy Manso..jmanso@aws.org . . . . . . . . . . . . . . .(281) Danielle Garcia . . . . . . . . . . . . . . . . . . . . . . . . . . . .(361)
industry. Answer customer questions about AWS.
Director of Agency Representation
CONVENTION AND EXPOSITIONS Terry Perez..tperez@aws.org . . . . . . . . . . . . . . . . .(470) AWS FOUNDATION, INC.
Director, Convention and Meeting Services aws.org/w/a/foundation
Matthew Rubin.....mrubin@aws.org . . . . . . . . . . .(239) EDUCATION SERVICES General Information
Corporate Director (800/305) 443-9353, ext. 212, vpinsky@aws.org
ITSA INTERNATIONAL THERMAL Patrick Henry..phenry@aws.org . . . . . . . . . . . . . .(226)
SPRAY ASSOCIATION Chairman, Board of Trustees
Senior Manager and Editor Director, Operations William A. Rice.. brice@oki-bering.com
Kathy Dusa....kathydusa@thermalspray.org . . . . .(232) Martica Ventura.. mventura@aws.org . . . . . . . . .(224)
Executive Director, Foundation
RWMA RESISTANCE WELDING MANUFACTURING Director, Development and Systems Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . . . . . (331)
ALLIANCE David Hernandez.. dhernandez@aws.org . . . . . . .(219)
Committee Specialist Corporate Director, Workforce Development
Adrian Bustillo....abustillo@aws.org. . . . .. . . .. . . .(295) TECHNICAL STANDARDS SALES Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . . .. . (461)
Managing Director
WEMCO ASSOCIATION OF WELDING Michael Walsh...mwalsh@aws.org . . . . . . . . . . . .(350) Associate Director of Scholarships
MANUFACTURERS AWS Bookstore, Subscription Sales, and AWS Re- Vicki Pinsky.. vpinsky@aws.org. . . . . . . . . . . . . . . .. . . . (212)
Program Manager seller Management
Keila DeMoraes....kdemoraes@aws.org . . . . . . . .(444) Customer Service...customer.service@awspubs.org(280) The AWS Foundation is a not-for-profit 501(c)(3)
charitable organization established to provide support for
INTERNATIONAL SALES TECHNICAL SERVICES the educational and scientific endeavors of the American
Managing Director of North American Sales Dept. information . . . . . . . . . . . . . . . . . . . . . . . . .(340) Welding Society. Promote the Foundations work with your
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . . . . . .(297) financial support.
Managing Director Technical Services
Learning Sales Representative Annette Alonso.. aalonso@aws.org . . . . . . . . . . . .(299)
Efram Abrams.. eabrams@aws.org . . . . . . . . . . . .(307) Technical Committee Activities, Additive Manufac-
turing, Welding Qualification

Personnel July 2016.qxp_Layout 1 6/9/16 11:49 AM Page 96
PERSONNEL
SelectArc Announces New previously worked as a product spe- Dabney S. Lancaster Community Col-
Appointments cialist at a power tool company, and as lege (DSLCC), Clifton Forge, Va., has
district and sales territory managers been recognized as DSLCC Educator of
in the welding industry. Tyler Edwards the Year. Bryant, an AWS member and
and Michael Hare have joined the CWI, has worked at the college for 17
company as members of the applica- years. He has served as coordinator
tions/technical support team. Ed- for the regional SkillsUSA welding
wards has 10 years of welding indus- competition and has judged at the re-
try experience in onshore pipelines, gional and state levels. Before joining
petrochemical facilities, and more. DSLCC, he was owner-operator of
Hare has been working in the welding Earle S. Bryant Welding Service in
industry for a decade, primarily in Troutville, Va.
R&D and technical support for filler
metals.
Yaskawa Mexico Adds
Mike Hare Marty Caruso
General Manager
Pandjiris Sales VP Retires
Yaskawa Mo-
Jim Tainter, toman, Dayton,
vice president of Ohio, has an-
sales and market- nounced that Ger-
ing for Pandjiris, mn Villalobos
St. Louis, Mo., a has joined the
welding equip- company as gen-
ment supplier, has eral manager of
retired after 40 Yaskawa Mexico.
years of service. In this position,
Tainter has agreed Villalobos will be
Barry Power Tyler Edwards
to work on a con- responsible for
tract basis on be- Germn Villalobos the companys
Jim Tainter
half of Pandjiris strategic direc-
Select-Arc, Fort Loramie, Ohio, a doing sales train- tion, sales growth, and the operation
tubular welding electrode company, ing and participating at trade shows of its three facilities in Mexico. He
has announced four new additions to and exhibitions. Steve Candela, who brings nearly two decades of experi-
its sales and technical service teams. has worked at the company for more ence in industrial robotics to the com-
Marty Caruso has been named techni- than 25 years, will replace Tainter. pany. Most recently, Villalobos was the
cal director over engineering, R&D, head of robotics at Comau, Mexico
and quality control for Select-Arc and City, Mexico.
Arcos Industries, LLC. He brings 25 Welding Instructor Awarded
years of experience related to product Educator of the Year
and processing development. Barry International Aluminium
Power has assumed the title of region- Michael Bryant, program head of Institute Appoints Chair
al sales manager for Ga. and Fla. He the welding technology program at
The Interna-
tional Aluminium
Institute, London,
United Kingdom,
a global forum of
aluminum pro-
ducers, has ap-
pointed Hilde
Merete Aasheim
chair of its board
of directors.
Aasheim is execu-
H. M. Aasheim tive vice president
of Norsk Hydro
ASA, a Norwegian aluminum and re-
newable energy company headquar-
tered in Oslo, Norway. She succeeds
Abdulla Kalban, chief executive officer
aws educ braz symp.qxp_FP_TEMP 6/8/16 7:40 AM Page 97

EDUCAATION
T
aws.org
CALLL FO
OR P
PA
APERS
APER
RS
40TH IN
NTERNATTIO
ONAL
BRAZING AND SSOLLDERING SYMPOS
SIUM
Presented by the Am
mericcan Welding Society (A
AW
WS)
November 116, 20016 - Las Vegas, NV
WS C3 Committee on Brazing and Soldering invites yoou take part in this prestigious
The AW
program by submitting a research papeer for consideration. This is your opportunity to present
p your
research to peers and leaders in the inddustry.
The programm organizers are acceptiing 500--600-wword abstrracts describing original, previously
unpublished woork. The work may includde currentnt res
research
earch, actuual or potential applications,
ons new
developments, or an outlook into actual technical areenas. Subm missions must be receivved on or
before Septembber 3, 2016 and authors will be notifieed whetherr their papers have beenn accepted
for presentationn at the Symposium.
For more details and

a to submit abstracts electronically,
visit: go.a
g ws.org/bbrazeabstr
tracts
**Note: If you have

v any co-authors on your suubmitted paper,
please make sure to supply all name and affiliation details througgh the link above when submitting.
PERSONNEL Most recently, Davis served as director

of education for the company.
accounts manager,
a newly created,
high-profile sales
of Emirates Global Aluminium, Dubai, and management
United Arab Emirates, who steps Pemamek Chooses New CEO position. In his
down after his two-year tenure. new position,
The board of Pemamek, Liomaa, Briggs will be re-
Finland, a welding and production au- sponsible for key
EWI Promotes NDE tomation company, has named Jaakko accounts, address-
Technology Leader Heikonen as its new chief executive ing the changing
officer. Heikonen holds a master of operational needs
EWI, Columbus, Ohio, an engineer- science in engineering degree, and of large trading
Steve Briggs
ing and technology company, has pro- joined the company more than ten partners, and po-
moted Dr. Evgueni Todorov to tech- years ago. Most recently, he served as sitioning the com-
nology leader for nondestructive ex- vice president. Heikonen succeeds pany for long-term global sales growth
amination (NDE). Todorov will be longtime CEO Pekka Heikonen, who and profitability. Briggs has been with
based in Loveland, Colo., where he will will continue with the company full the company for 19 years.
oversee the technical team in setting time as chairman of the board.
up EWI Colorado, a new center for ad-
vanced process monitoring and con- Wagner Companies Hires
trol technologies. Todorov has more Alcoa Reveals Executive Shuffle Senior PE Manager
than 30 years of experience in the de-
velopment and industrial application The Wagner
of NDE and electronic measurement Companies, Mil-
technologies. He was worked at the waukee, Wis., a
company since 2004. supplier and man-
ufacturer of
handrail fittings
Gdel Selects CEO and metal prod-
ucts, has appoint-
Gdel, Inc., ed Michael
Ann Arbor, Mich., MacLeish senior
a manufacturer of product engineer-
robotic automa- Karl Tragl Tim Myers ing manager. In
tion products, sys- Michael MacLeish this role,
tems, and servic- MacLeish will be
es, has announced Alcoa, New York, N.Y., a light- responsible for the design, develop-
the appointment weight metals producer, has an- ment, implementation, and improve-
of Stuart Shep- nounced that Karl Tragl, recently ment/analysis of company products
herd as CEO. This group president of transportation and and services. MacLeish has more than
follows the retire- construction solutions (TCS), has 18 years of experience and was most
ment of Stefan been appointed group president of en- recently at SPI Lighting, Inc., where he
Stuart Shepherd Nilsson. Shepherd gineered products and solutions, suc- was business unit manager/chief
will report directly ceeding Olivier Jarrault. Prior to join- brand officer.
to President and ing the company in February, Tragl
Chairman of the Group Executive was CEO of Bosch Rexroth, an au-
Board Martin Strb. Prior to joining tomation systems company, for six Jet Edge Employee Named
the company, Shepherd was vice presi- years. Succeeding Tragl as group presi- Young Professional of the Year
dent sales, America, for KUKA USA dent of TCS is Tim Myers, recent pres-
Holdings Co. ident of Alcoa Wheel and Transporta-
tion Products (AWTP). In this new The I-94 West
role, Myers will oversee the AWTP and Chamber of Com-
Alcoa Building and Construction Sys- merce, St.
GMCA Names Vice President of Michael, Minn.,
Workforce Development tems. Myers has been with the compa-
ny for 25 years. has chosen Jet
Edge Sales and
The Greater Michigan Construction
Marketing Assis-
Academy (GMCA), Midland, Mich.,
tant Jamie Larson
has promoted Stephanie Davis to vice Dynabrade Fills as its 2016 Young
president of workforce development Management Role Professional of the
and training. In her new position,
Year. Larson, who
Davis will be responsible for directing, Dynabrade, Clarence, N.Y., a manu- performs a wide
developing, and implementing GMCA facturer of abrasive power tools, has Jamie Larson range of sales and
training and education programs. promoted Steve Briggs to global key

memb corporate.qxp_FP_TEMP 6/7/16 8:41 AM Page 99
PERSONNEL
continued from page 98 MEMBER MILESTONE
marketing duties for the waterjet sys- Andrew Kireta Jr.
tems manufacturer, was recognized
for her commitment to professional ASTM Internationals Committee on Copper and
growth and leadership development, Copper Alloys (B05) has presented its top annual
as well as for her involvement in the award, the Award of Merit, to Andrew Kireta Jr., Coop-
Chamber. This is the fourth time that er Development Association, Inc., Franklin, Ind. The
the company has been recognized by award, which includes the accompanying title of Fel-
the Chamber in four years, including low, is the organizations highest recognition for indi-
when Larson was named Chamber vidual contributions to developing standards.
Ambassador of the Year in 2013. The committee honored Kireta for outstanding con-
tributions in copper forgings, cooper and copper al-
loys, pipe and tubing, castings and ingots, and more.
Hobart Institute Adds He has been a member of ASTM since 1998, serving as
Instructors B05.92 subcommittee chairman since 2011. He re-
ceived the Arthur Cohen Memorial Award in 2007, and
the Copper Club Award in 2014.
Kireta is vice president of market development with the Copper Devel-
opment Association, Inc., where he advises in areas such as strategic devel-
opment, promotion, and support of copper and copper alloy products in
the North American market. He has been with the company since 1992,
having previously served as vice president of building construction, nation-
al program manager, technical project manager, and Midwest regional
manager.
In addition to ASTM, Kireta is a member of the American Society of
Mechanical Engineers, American Society of Plumbing Engineers, Ameri-
can Society of Sanitary Engineering, American Water Works Association,
National Association of Corrosion Engineers, International Code Council,
Brian Sheward Justin Wilson
International Association of Plumbing and Mechanical Officials (IAPMO),
NSF International, and the American Welding Society, of which he has
Hobart Institute of Welding Tech- been a member since 1993.
nology (HIWT), Troy, Ohio, has hired
Brian Sheward as an instructor for the
structural welding and the combina- sponsible for managing the field serv-
tion structural and pipe welding pro- ice team, product management of the
grams. Sheward has more than 25 companys fluid recycling product line,
years of experience, and is a 1989 and more. Milton has been promoted
graduate of HIWT. Prior to this new to manager, filtration systems,
role, Sheward worked for National Oil- Hydroflow. In this position, Milton
well Varco as a UAW journeyman mill- will assume product management re-
wright. The institute has also hired sponsibility for company filtration
Justin Wilson as a technical training products.
instructor. Wilson is an AWS Certified
Welding Instructor and has more than
ten years of welding and inspection
experience. He is a 2005 graduate of Andy Kloecker Darrell Milton Florida Governor Recognizes
HIWT. His most recent position was Bettinger Welding CEO
with Effox, Cincinnati, Ohio. tor sales, support-
ing other product During a meeting of the Florida
group sales, over- Cabinet, Tallahassee, Fla., Governor
Eriez Announces Promotions seeing company Rick Scott recognized Mike Bettinger,
material handling CEO of Bettinger Welding, Inc., Tala-
Eriez, Erie, Pa., has reorganized its products, and hassee, Fla., with the Governors Busi-
metalworking group and promoted more. Mackowski ness Ambassador Award. Since 1976,
three team members: Andy Kloecker, has been promot- the family-owned business has special-
Darrell Milton, and John Mackowski. ed to manager, ized in creating ornamental handrails,
Kloecker has been promoted to man- technical service, gates, decorative artwork, and more.
ager, distribution and material han- Hydroflow. In The company has created dozens of
dling. In this new role, Kloecker will be this role, Mack- jobs over the past 40 years. WJ
responsible for metalworking distribu- John Mackowski owski will be re-

aws educ learning.qxp_FP_TEMP 6/8/16 8:44 AM Page 101

LEARNING
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o more, visit awoo..aw
ws.orgg
2016-Thermal Spary Layout .qxp_April School Profiles 2007 6/8/16 11:11 AM Page 102
THERMAL SPRAY PROFILES (ADVERTISEMENTS)
Caml Air Pollution Control Oerlikon Metco

Founded 1963
Oerlikon Metco enhances surfaces that
Camfil APC is a leading global bring benefits to customers through
manufacturer of cartridge dust a uniquely broad range of surface
and fume collectors for the technologies, equipment, materials,
thermal spray industry. services, specialized machining
Our Farr Gold Series dust collector services and components. Technologies
is the most technologically advanced such as thermal spray, laser cladding,
available delivering greater high quality braze, and weld hardfacing
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emissions requirements and satisfy all safety concerns, including automotive, oil & gas, industrial and other specialized markets.
fire and explosion prevention. Oerlikon Metco operates a dynamically growing network of more
than 40 sites in EMEA, Americas, and Asia Pacific.
(800) 4796801
(870) 9338048 1101 Prospect Ave.
filterman@camfil.com Westbury, NY 11590
camfilapc.com
(516) 3341300
FAX: (516) 3382414
oerlikon.com/metco
CenterLine (Windsor) LTD. Polymet Corporation

Founded 1957
Polymet is a world-class
CenterLines Supersonic Spray manufacturer of high-
Technology Division (SST) performance welding,
supplies standard and custom cold hardfacing and thermal spray
spray metal coating systems to the wire. Our manufacturing
aerospace, defense, glass, and processes include a patented
automotive industries. SST provides hot extruded forged wire
an extensive range of process process, rolling, die drawing, and alloy cored wire fabrication.
development, system integration, and Polymets multiple wire processing capabilities allows it to be
job shop services to help integrate cold an innovator in problem solving. The high quality products
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Cincinnati, OH 45246
(519) 7348464 (513) 8743586
info@cntrline.com sales@polymet.us
supersonicspray.com polymet.us
Hayden Corporation SaintGobain

Founded 1919 Founded 1920
Hayden Corporation's expertise
in wear protection spans three With over 90 years of experience
generations and multiple indus- in both plasma and flame spray
tries. Our experience with the technologies, Saint-Gobain is your
strictest tolerances and standards premium solution provider for
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surfaces. In addition to the full range of thermal spray coating offices and distributors world-wide. Contact Saint-Gobain Coating
processes, Hayden also has in-house machining capability for Solutions for any PTA welding or thermal spray requirements at
preparing and finish grinding customer components. coatingsolutions@saint-gobain.com.
333 River St., 1 New Bond Street,

West Springeld, MA 010893603 Worcester, MA 01615
(413) 7344981 (800) 2430028 (508) 7952380
Fax: (413) 7855052 coatingsolutions@saintgobain.com
haydencorp.com coatingsolutions.saintgobain.com
memb individual.qxp_FP_TEMP 6/7/16 8:42 AM Page 103
aws educ conf/sem.qxp_FP_TEMP 6/8/16 1:09 PM Page 104

EDUCAATION
T
aws.org
DONTT TRUST YOUR

WELDIN
WE
ELDING
NG EDUCA
ATTION
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TO JUST ANYONE.
AWS offers worldwide conferences
co and seminars featuring the most
RELEVVA
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T , RESEARCH
RES and FIRSTT--H
-HAND KNOWLED DGE
in the welding
wel industr
stry.
When it comes to your career development, w
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AW
WS CONFERENCES
3RD WELDING EDUCA
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Houston, TX / Aug 10-12, 2016
LASERS CONFERENCE
San Francisco, CA / Aug 29-30, 2016
19TH ANNUAL ALUMINUM CONFERENCE
Miami, FL / Sep 20-21, 2016
AWS CERTIFIED WELDING INSPECTOR

OR SEMINARS
Los Angeles, CA / July 10 16, 2016 Birmingham, AL / July 17 23, 2016 Sacramento, CA / July 24 30, 2016
Louisville, KY / July 10 16, 2016 Scottsdale, AZ /July 17 23, 2016 Miami, FL / July 24 30, 2016
Omaha, NE / July 10 16, 2016 Denver, CO / July 17 23, 2016 Helena, MT / July 24 30, 2016
Cleveland, OH / July 10 16, 2016 Waco, TX / July 17 23, 2016 Milwaukee, WI / July 24 30, 2016
For a complete listi

sting please visit aws.orrg/events
g

economic/market trends. They learned from speaker Dirk

Beveridge about how disruption creates opportunity for in-
novation. Motivational speaker Steven B. Wiley discussed
how developing leadership skills can sustain success.
The association presented $20,000 in scholarships to
10 college-bound students as well.
GAWDAs Annual Meeting will take place September
2528 at The Grand Wailea in Kihei, Hawaii. More informa-
tion is at gawda.org/activities/2016-annual-convention/.
Columbus Welding Students Play a Starring

The winners from Denton LaGrone ATC constructed a total of
Role in Set Fabrication for Sweeney Todd eight benches to seat an outdoor class. Shown (from left) are
Andy Ochoa, Eve Torres, Instructor Rebecca Hendricks, Bobby
Wallace, and Daniel Teniente. (Photo by photography students
Juan Ocampo and Brianna McQuee.)
the theme of A Cut Above, describing how cutting and

welding have influenced their lives. In addition, each mem-
ber of three winning teams received $500 for their submis-
sion of a metal fabrication project.
All schools associated with the winners were given a cut-
ting, welding, and gas control package valued at $4000.
The 2015 individual winners were as follows: Adele Tan-
talo, Tennessee College of Applied Technology, Newbern,
Tenn.; Roxanne Desrosiers, SAIT Polytechnic, Calgary, Al-
berta; and Carly Loving, McMinnville High School, McMin-
nville, Ore.
The 2015 team winners included Bobby Wallace, Eve Tor-
Welding student Wilmer Escorcia uses his skills to fabricate set res, Braden King, Daniel Teniente, and Andy Ochoa, Denton
pieces for the Springer Opera Houses production of Sweeney LaGrone Advanced Technology Complex, Denton, Tex.;
Todd. (Photo courtesy of Columbus Technical College.)
Austin Erickson, Sam Moore, Pedro Rosario, and Jamison
Dimeco, Assabet Valley Regional Technical High School,
Marlborough, Mass.; and Mitchell Cutsforth, Chris Smith,
The welding department at Columbus Technical College, Nic Ostrander, and Andrew Meyer, Ferris State University,
Columbus, Ga., recently played a part in the Springer Opera Big Rapids, Mich.
House production of Sweeney Todd: The Demon Barber of In particular, the Ferris State team helped erect a 35-ft
Fleet Street. bell tower that represents three local churches joining to-
Project assistance started when adjunct welding instruc- gether. Winners from Denton LaGrone ATC constructed
tor Tim Vinson learned the opera houses technical manager eight benches, each representing different departments, to
was hospitalized and immediate set help was needed. He seat a class of 24 students outdoors. Assabet Valley Regional
called Program Director Ronnie McBride, and within a week, Technical High School students built a bulldozer to repre-
the opera house provided materials and specifications for sent the Victor legacy in building and maintaining heavy
the eight set pieces. This included a two-story staircase and equipment.
platforms. A total of 28 students participated.
It was amazing, Vinson said. It was like watching a
well-oiled machine; we blended first semester students with
some of our more advanced students. They all learned from Industry Notes
each other and now have a better understanding of what its
like to work under a firm deadline. We had three students Comau, Turin, Italy, has been awarded the 2016 NED In-
serve as quality control managers. The quality control team novation Award at the IndustryWeek Manufacturing &
even caught some mistakes and had to start parts over from Technology Conference in Rosemont, Ill. The companys
scratch just like in a real shop. Racer3, a high-speed, 6-axis articulated robot, was among
the 11 innovations selected from 2000 technologies.
ESAB Reveals A Cut Above Contest Winners
ESAB, Florence, S.C., recently announced the six winners AllTex Welding Supply, Inc., with locations in Waller
of its 2015 A Cut Above contest for students in welding/ and Navasota, Tex., along with Wilson Products Com-
cutting programs at secondary and postsecondary schools. pressed Gas Co., Inc., Easton, Pa., have joined the Inde-
Three individual winners received $250 for their essay on pendent Welding Distributors Cooperative. WJ

COMING EVENTS Plastics Welding School. A two-day course for certification

to European plastics welding standards. Malcom Hot Air
continued from page 65 Systems; plasticweldingtools.com.
Laser U Online Education Portal. Offers practical infor- Protective Coatings Training and Certification Courses. At
mation to use on the job. Topics range from 3D printing to various locations and online. The Society for Protective
drilling, welding, wireless and optical product requirements, Coatings; (877) 281-7772; sspc.org.
and many others. Visit Laser Institute of America;
lia.org/laseru. Robotics Operator Training. Presented by ABB University at
13 locations nationwide. For course titles and locations:
Laser Vision Seminars. Two-day classes, offered monthly (800) 435-7365, opt. 2, opt. 4; abb.us/abbuniversity.
and on request, include tutorials and practical training. Pre-
sented at Servo-Robot, Inc., St. Bruno, QC, Canada. For Robotic Welding Training. Offers a variety of courses to en-
schedule, cost, and availability, e-mail info@servorobot.com. hance productivity and product quality, presented at your
facility. Wolf Robotics, LLC, 4600 Innovation Dr., Fort
Laser Welding Summer Residency. Aug. 16, 17. Madison Collins, Colo.; (970) 225-7600; wolfrobotics.com.
Concourse Hotel, Madison, Wis. Earn a certification, make a
presentation, and meet other laser welding professionals. Robotic Welding Online Course. IRC5 Operations Web-
University of Wisconsin-Madisons Department of Engi- Based Training (US519) offered by ABB Robotics are self-
neering Professional Development. Contact Elaine paced online courses. Successful completion awards stu-
Andrysick at (608) 262-8708 or at embower@wisc.edu. dents with a certificate of completion and Continuing Edu-
cation Units (CEUs). Contact (800) 435-7365,
Laser Welding Technology Course. Sept. 1923, Phoenix, abbuniversity@us.abb.com, or abb.us/roboticstraining.
Ariz. Laser cutting and drilling technology courses: Dec.
58, San Diego, Calif. Call (916) 714-4944 or visit laserweld Safety Training Online. Unlimited training on myriad indus-
training.com. trial safety course titles. Visit website for complete informa-
tion and previews of several courses; safety99.com.
Liquid Penetrant & Magnetic Particle Inspection. Aug.
29Sept. 2. The course provides students with training in LP Service Manager Course. Designed for sheet metal workers
& MP theory and hands-on laboratory projects. Hobart In- and HVAC service shop owners. Various locations and dates.
stitute of Welding Technology; (800) 332-9448; welding.org. International Training Institute. (703) 739-7200;
sheetmetal-iti.org.
Machine Safeguarding Seminars. Rockford Systems, Inc.;
(800) 922-7533; rockfordsystems.com. Soldering Training Live, Interactive Online Courses.
Three courses offered: basic hand soldering, through-
Machining and Grinding Courses. TechSolve, techsolve.org. hole technology, and surface-mount technology.
Visit site for course outlines, schedules, prices,
NACE International Training and Certification Courses. Na- and to register. Soldering Training & Certification (STC);
tional Assoc. of Corrosion Engineers; (281) 228-6223; solderingtraining.com/online-soldering-training.php.
nace.org.
SSPC Training and Certification Courses. Courses in protec-
NDE Classes. Moraine Valley Community College, Palos tive coatings, abrasive blasting, paint inspector, bridge coat-
Hills, Ill., offers NDE classes in PT, MT, UT, RT, Radiation ings inspector, surface preparation, NAVSEA inspector, and
Safety, and Eddy Current, as well as API 510 exam prep many others. The Society for Protective Coatings; sspc.org.
and weld inspection. Contact (708) 9745735;
wdcs@morainevalley.edu; morainevalley.edu/NDE. Superabrasive Materials, Principles & Applications. Two-
day course offered. One day of grinding and one day of ma-
NDT Courses and Exams. Brea, Calif., and customers loca- chining is $500. Just one day costs $275. Offered by the In-
tions. Level I and II and refresher courses in PA, UT, MP, ra- dustrial Diamond Association of America (IDAA) at the YG-I
diation safety, radiography, visual, etc. Test NDT, LLC; (714) America Advanced Manufacturing Center in Charlotte, N.C.
255-1500; testndt.com. (614) 797-2265; superabrasiveseducation.com.
Offsite Resistance Welder Seminars. Presented by T. J. Snow Unitek Miyachi Corp. Training Services. Personalized train-
Co. July 20, Harrisburg, Pa.; Aug. 3, Atlanta, Ga.; Aug. 24, ing services on resistance and laser beam welding and laser
Lincoln, Neb.; Sept. 14, Chicago, Ill.; Sept. 28, St. Louis, marking; (626) 303-5676; unitekmiyachi.com.
Miss.; and Oct. 19, Columbus, Ohio. Contact (423) 894-
6234; tjsnow.com. Veterans Goodwill Weld Training Program. South Burling-
ton, Vt., and Eagle River, Wis. AWI and Veterans of
Online Education Courses. Topics include Introduction to Foreign Wars (VFW) have partnered to offer veterans
Die Casting ($99), Metal Melting and Handling ($99), complimentary two-day training at AWI facilities. Contact
Product Design ($59), Energy Training ($19), Dross Train- (802) 6600600, (715) 3370122, or awi.edu. WJ
ing ($19), Managing Dust Hazards ($19), and Safety (free).
North American Die Casting Assoc.; (847) 808-3161;
diecasting.org/education/online.

july 2016 wj classifieds.qxp_Layout 1 6/10/16 1:18 PM Page 107
CLASSIFIEDS
CAREER OPPORTUNITIES
Put your CWI exp

pertise
to work from yourr home! Business Development Manager
Southeast States
CM Industries, Lake Zurich, IL, a

manufacturer of premium robotic MIG
The AWS Educaation Department torches and peripherals, is seeking a
is looking for qualified
q writers to proven and sales oriented business
develop new educa
e tional development manager to expand its
automation related products in the
uture Certified
materials for fu Southeast states with focus in Kentucky,
Welding Inspec e tors: Tennessee and Alabama.
Must have the ability to work

Textbooks independently, communicate well and
Workbooks think strategically. Five years of welding
Practice Te
essts related sales or work experience is
required.
Please send ressume and cover Please send your resume to:
eminars@aws.org.
letter to aws.se hr@cmindustries.com.
CWI
eacherrs
Te
Needed d
The AWWS Educaation Department
is seeking quallified instructors
to lead our week-long Certified
Welding Inspe ector seminars.
Must be a CWI and able to

travel.
Please send ressume and cover

letter to aws.se
eminars@aws.org.

july 2016 wj classifieds.qxp_Layout 1 6/9/16 11:23 AM Page 108
CLASSIFIEDS
CAREER OPPORTUNITIES (contd) FOR SALE OR RENT
MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1Ton thru 60Ton
Tank Turning Rolls

POSITION FUNCTION
The American Weelding Society is seeking a Chief Operating Officeer
(COO), with Chief Executive Officer (CEO) capabilities,who can
provide the leadership, management, and vision to ensure that the
Used Equipment for Sale
induustr y is supported and the Society grows revenues, controls budgets www.mitrowskiwelding.com
and contributes to a yearly surplus. Management functions also include
operational
a controls (administrative and procedures) and people systems.
SUMMARY OF COO RESPONSIBILITIES:

Promoting the Society and managing the sales, marketing, certification,
trade show, memb bership, publishing , online programms, and seminars/confeerences in
9*;=7.;<129@2=1=1.A.,>=2?.2;.,=8;#D$;8?2-270-*B
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*7-2695.6.7==1.) )&058+*5<=;*=.0 BD<<2<=270272-.7=2/BB270*,:>2<2=287<*7-
sales@mitrowskiwelding.com
(800) 218-9620
collaborative opportunities to enable AW WS to meet growth, and market share objectivess.
(713) 943-8032
Managing the Society s business development operations in partnership with
the Executive Director (CEO).
D&9.*;1.*-270=1.-.?.5896.7= *7-2695.6.7=*=2878/0;8@=1<=;*=.02.< 27,5>-270
27=.;7*=287*5.A9*7<287*7-.->,*=287*59;80;*6<*7-<.; ?2,.<D)8 8;4270@2=1=1.
management team m to develop and implement plans designed to steward and drive
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8;6.6+.;<129<7=.;*,=270.///..,=2?.5B@2=1=1.
<=*// 8*;-6.6+.;< ?85>7=..;< 6.6+.;< *7-27-><=; B9*;=7.;< $6450.3&13*/54
Providing oversi s ght and direction to the approxim
x ately 300
AWS Committees e and nearly 2,000 active Comm mittee volunteers. 6 T F S F Q S J O U T U P
D(7-.;<=*7-270=1.2698;=*7,.8/=1.8*;-8/2;.,=8;<*7-=1.?85>7=..;< *<@.55*< N B Y JNJ[F ZPVS
=1.,;2=2,*5,86987.7=8/?85>7=..;5.*-.;<129*7-6*7*0.6.7=D8<=.;270*,87<.7<><
mindset in interacting with volunteers. Supporting continued success of AW
WS through NBSLFUJOHJOJUJBUJWFT
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POSITION QU UALIFICAT TIONS
D$;8?.7=;*,4;.,8;-276*;4.=270 /27*7,. <=;*=.02,<*5.< *7-+><27.<<-.?.5896.7=
CSBOETWBMVF
@2=1$ ;.<987<2+252=B8/ !95><D!2726>68/ B.*;<C6*7*0.6.7=.A9.;2.7,.
DA9.;2.7,.27=1.@.5-27027-><=; B2<2-.*5D$;.9*;.-7.<<=8=;*?.5>9=8
27,5>-27027=.;7*=287*5D*,1.58; <-.0;..;.:>2;.-!*<=.; <8;!9;./..;;.-
Submit your rssum with cover letter to:

Human Resources Department
American Weeldin
ng Society
")=1&=
!2*62
8;1;*@<8;0
Call 866.879.9144
or sales@fosterprinting.com

CLASSIFIEDS
FOR SALE OR RENT
JOE FULLER LLC

Put Your Products and
We manufacture tank turning rolls Services to Work in October 2016
3-ton through 120-ton rolls
www.joefuller.com
Generate new sales leads by showcasing

your full-color product photo with a
email: joe@joefuller.com product description, website, or other
Phone: (979) 277-8343 sales literature. Welding Marketplace
Fax: (281) 290-6184 reaches 80,000 qualified buyers. Its
Our products are made in the USA great exposure for just pennies per
contact.
Closing date for October issue is
Aug. 15, 2016
Call the AWS sales team at
(800) 4439353
Sandra Jorgensen, ext. 254
CERTIFICATION sjorgensen@aws.org
& TRAINING
Annette Delagrange, ext. 332
adelagrange@aws.org
BIG
ON SAVINGS Lea Paneca, ext. 220
lea@aws.org
2016 USED EQUIPMENT
An Excellent Selection of Used
Welders, Welding Positioners, Place Your
CWI PREPARATORY Welding-Related Specialty Classified Ad Here!
80+ HOUR COURSE Equipment and Generators.
MORE HANDSON/PRACTICAL APPLICATIONS Call the AWS sales team at:
Ellijay, GA Sep. 516, Oct. 31Nov. 11 (800) 443-9353
Pascagoula, MS Sep. 1930, Nov. 1425
Marksville, LA Aug. 1526 Sandra Jorgensen, ext. 254
Houston, TX Aug. 112, Oct. 121
sjorgensen@aws.org
+ Includes additional self study for weekend
FOR DETAILS, CALL OR EMAIL: Annette Delagrange, ext. 332
(800) 4892890 adelagrange@aws.org
info@realeducational.com
Lea Paneca, ext. 220
View available equipment on our lea@aws.org
Also offering: RT Film Interpretation,
website or call us toll-free.
Applications of Welding Inspection,
MT/PT/UT Thickness, CWS, SCWI, reddarc.com 1-866-733-3272
Welding Procedure Fundamentals,
and Advanced Inspection Courses

ADVERTISER INDEX
Abicor Binzel 48 LACO Industries/Markal 69

binzelabicor.com (301) 8464196 markal.com (800) 6214025
American Torch Tip 67 Lincoln Electric Co. Outside Back Cover

attc.us/plasmacool (800) 3428477 lincolnelectric.com (216) 4818100
Arcos Industries, LLC 31, Inside Back Cover Midalloy 24

arcos.us (800) 2338460 midalloy.com (800) 7763300
Astaras 9 Nippon Steel & Sumikin Welding Eo., Ltd. 14

e3tungsten.com web contact only welding.nssmc.com/en/ +81 3 6388 9000
AWS Certification Services 28 Oerlikon Metco 55

aws.org/certification (800) 4439353, ext. 273 oerlikon.com/metco (866) 8287929
AWS Education Services 26, 36, 97, 101, 104 ORSNasco 25

aws.org/education (800) 4439353, ext. 455 orsnasco.com (800) 6786577
AWS Member Services 99, 103 OTC Daihen, Inc. 17

aws.org/membership (800) 4439353, ext. 480 daihenusa.com (888) 6827626
AWS Publication Services 63, 64, 65 Postle Industries/Postalloy 15

aws.org/publications (800) 4439353, ext. 275 Email: ksmith@postle.com (216) 2659000
AWS Technical Services 30 RedDArc Weldrentals 48

aws.org/technical (800) 4439353, ext. 340 reddarc.com (866) 7333272
Camfil Air Pollution Control 2 Revco Industries 20

camfilapc.com (800) 4796801 blackstallion.com (800) 5273826
CDA Technical Institute 23 Rolled Alloys 45

commercialdivingacademy.com (888) 9742232 rolledalloys.com (800) 5210332
CorMet 58 SelectArc, Inc. Inside Front Cover, 37

cormet.com (800) 8482719 selectarc.com (937) 2955215
Diamond Ground Products, Inc. 11, 13 Southwire Co., LLC 61

diamondground.com (805) 4983837 southwire.com (800) 4441700
Divers Academy International 29 TEC Welding Products 63

diversacademy.edu (800) 2383483 tectorch.com (760) 7473700
Elco Enterprises, Inc. 60 Trends in Welding Research International Conference 2016 70

wirewizard.com (517) 7828040 trends2016.org +81 3 4212 3900
Fischer Engineering Co. 96 Triangle Engineering, Inc. 63

fischerengr.com (937) 7541754 trieng.com (781) 8781500
Fischer Technology 62 TRUMPF 5

fischertechnology.com (860) 6830781 us.trumpf.com web contact only
Fronius USA, LLC 1 Voestalpine Bohler Welding USA, Inc. 21

froniususa.com (877) 3766487 voestalpine.com/welding (800) 5270791
Gedik Welding 22 Weiler Corp. 59

gedikwelding.com +90 216 378 50 00 weilercorp.com (800) 8359999
Gullco International, Inc., U.S.A. 25 Weld Aid 13, 15

gullco.com (440) 4398333 weldaid.com (800) 9353243
HDE Technologies, Inc. 65 Weld Engineering 7

hdetechnologies.com (916) 7144944 weldengineering.com (508) 8422224
Hobart 49 Welder Training & Testing Institute 62

HobartBrothers.com/tiethatbinds (800) 4241543 wtti.com (800) 2239884
Hobart Institute of Welding Technology 45 Welding Alloys 19

welding.org (800) 3329448 weldingalloys.com (859) 5250165
Intercon Enterprises, Inc. 27 THERMAL SPRAY PROFILES 102

intercon1978.com (800) 6656655
K.I.W.O.T.O., Inc. 64
rodguard.net (269) 9441552 Visit our Interactive Ad Index: aws.org/adindex

Wheeling 7-2016_Layout 1 6/9/16 5:16 PM Page 229
WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, JULY 2016
Sponsored by the American Welding Society and the Welding Research Council
Solidification Cracking Susceptibility of

Ni30Cr Weld Metals with Variable
Niobium and Molybdenum
A crack healing effect was observed with additions of Nb above 4 wt%
BY R. A. WHEELING AND J. C. LIPPOLD
7) and 52 (ERNiCrFe-7) were devel-

ABSTRACT oped for welding these high-Cr alloys,
such as Alloy 690. Niobium and
Ni30Cr alloys such as Alloy 690 and compatible filler metals are used extensively in
molybdenum have been added to this
the nuclear power industry to avoid problems with primary water stress corrosion
cracking (PWSCC). Depending on composition, these alloys can be susceptible to both class of filler metal, in some cases to
solidification and ductilitydip cracking. In this study, the effect of niobium (Nb) and reduce susceptibility to DDC (Refs.
molybdenum (Mo) additions to a base Ni30Cr alloy (Alloy 690) on solidification cracking 27). While this approach has been
susceptibility was evaluated. Both computational and experimental techniques were quite successful in mitigating DDC, in-
used to determine the effect of composition modifications on solidification behavior and creased susceptibility to solidification
cracking susceptibility. Nb additions from 0 to 8 wt% and Mo additions from 0 to 4 wt% cracking has been reported, as the so-
were evaluated. The addition of Nb resulted in an increase in the fraction eutectic that lidification temperature range expands
forms at the end of solidification, with 8 wt% Nb resulting in over 20 vol% eutectic con and supports a eutectic reaction at the
stituents. The addition of Mo had virtually no effect on the fraction eutectic. The cast pin end of solidification (Refs. 68).
tear test (CPTT) was used to measure solidification cracking susceptibility. With this test,
It is well documented that niobium
a peak in cracking susceptibility was observed at 4 wt% Nb. The addition of Nb above
4 wt% resulted in a decrease in cracking due to a crack healing effect. The addition of additions in Ni-based alloys result in
Mo resulted in a decrease in cracking susceptibility in the higher Nb alloys. Characteriza an interdendritic eutectic reaction
tion performed using SEM/EDS verified the crack healing effect at high Nb levels and dif consisting of (fcc) and Nb-rich phas-
ferentiated the eutectic constituents that formed along the solidification grain es such as NbC and Laves (A2B) at the
boundaries. end of solidification, but little re-
search has focused on additions in Al-
loy 690, due to a greater interest in
KEYWORDS corrosion resistance of the alloy
(Refs. 912). Niobium is a common
Solidification Cracking Stress Corrosion Cracking Alloy 690 Nuclear Industry addition of choice for improving
Filler Metal Cast Pin Tear Test weldment quality in terms of increas-
ing room temperature strength as
well as increasing corrosion resist-
Introduction tions and coal-gasification units (Ref. ance, but the effect of Nb on weld-
1). In efforts to combat the observed ability has been limited to maximum
Nuclear power generation, petro- ductility dip cracking (DDC) that can additions of up to 5 wt-% (Ref. 12).
chemical, and many other industries occur when these alloys are welded, al- Reports regarding molybdenum
rely on high chromium (2530 wt-%), loying additions such as niobium and suggest that additions may increase
Ni-based alloys due to the corrosion molybdenum have been introduced, the solidification temperature range
and stress corrosion cracking resist- but may result in an increased suscep- and promote the formation of a low
ance imparted by the high chromium tibility to solidification cracking due to melting eutectic phase, similar to Nb
content, as well as good mechanical a widened solidification temperature (Refs. 7, 13). Molybdenum has been
properties at elevated temperatures. range. shown to improve resistance to DDC
Other applications include the han- Compatible high-chromium weldin Nb-bearing filler metals such as
dling of nitric/hydrofluoric acid solu- ing filler metals such as 152 (ENiCrFe- 52MSS (ERNiCrFe-13), and there is
R. A. WHEELING and J. C. LIPPOLD are with the Welding Engineering Program, The Ohio State University, Columbus, Ohio.
JULY 2016 / WELDING JOURNAL 229-s

WELDING RESEARCH
Fig. 1 Four curves that compare

cracking susceptibility or sensitivity
as a function of alloying content in Al
alloys (Ref. 36).
some evidence that it reduces suscep-

tibility to solidification cracking in
fully austenitic stainless steels (Refs.
4, 5, 14).
It has been reported that in some
materials, a large fraction of liquid of
eutectic composition present at the
end of solidification may promote a
backfilling or crack healing effect
(Refs. 7, 1517). Backfilling is defined
as a partial or entire healing of solidifi-
Fig. 2 Percentage of circumferential cracking for the Alloy 690 base composition and
cation cracks due to the flow of liquid the Nbbearing alloys. Each point and error bar represents the average of at least 4 ac
metal into newly formed cracks or ceptable pins. The red circles indicate the critical cracking threshold or longest pin at
voids (Ref. 18). Both volume fraction which no cracking was observed.
eutectic and liquid phase characteris-
tics such as viscosity, surface tension,
and wettability of eutectic films deter- creases, cracking susceptibility initially is associated with the fraction of eu-
mine whether the liquid will heal a increases to a peak value and then de- tectic liquid present at the end of so-
forming crack (Ref. 19). It is known creases, presumably due to a crack lidification at a given composition. At
that some Nb-bearing, Ni-based alloys, healing effect. The variation in the lo- the peak, the liquid completely wets
such as Alloy 625, are resistant to so- cation of the peak cracking susceptibil- the solidification grain boundary and
lidification cracking, presumably due ity in these different Al-based systems promotes cracking, while at composi-
to a backfilling (crack healing) effect
(Refs. 5, 7, 9, 2023). The amount of
Table 1 Calculated Composition (wt%) of Alloys Evaluated in this Study
eutectic constituent necessary to pro-
mote crack healing is likely alloy de-
pendent, but in one study of Alloy 625 Composition Ni Cr Fe Nb Mo C
weld metal, an increase in the fraction Alloy 690 60.51 29.45 9.13 0.0290
of Nb-rich eutectic from 7 to 11.5 2Nb0Mo 59.29 28.86 8.95 2.00 0.0284
vol-% resulted in a significant decrease 2Nb2Mo 58.09 28.27 8.76 2.00 2.00 0.0278
in cracking susceptibility (Ref. 20). 2Nb4Mo 56.87 27.68 8.58 2.00 4.00 0.0273
Cracking susceptibility curves have 4Nb0Mo 58.09 28.27 8.76 4.00 0.0278
been developed for Al alloys (Fig. 1) 4Nb2Mo 56.87 27.68 8.58 4.00 2.00 0.0273
that illustrate a reduction in cracking 4Nb4Mo 55.66 27.09 8.40 4.00 4.00 0.0267
susceptibility at high alloy content due 6Nb0Mo 56.87 27.68 8.58 6.00 0.0273
6Nb2Mo 55.66 27.09 8.40 6.00 2.00 0.0267
to the crack healing effect. All of these
6Nb4Mo 54.47 26.51 8.22 6.00 4.00 0.0261
binary (or ternary) systems exhibit a 8Nb0Mo 55.66 27.09 8.40 8.00 0.0267
eutectic reaction. As alloy content in-
230-s WELDING JOURNAL / JULY 2016, VOL. 95

WELDING RESEARCH
Fig. 3 Cracking susceptibility based on CPTT results compared Fig. 4 The average circumferential cracking in pins containing
to measured and ThermoCalcpredicted fraction eutectic values. 2 or 4 wt% molybdenum along with 2, 4, or 6 wt% niobium ad
Error bars represent the standard deviation of the measured ditions is compared to that observed in pins with only niobium
fraction eutectic values. additions. Each point represents at least 4 acceptable pins.
Fig. 5 Optical micrographs of sectioned pins representative of Fig. 6 Low and highmagnification optical micrographs of
the CPTT data in Fig. 2. backfilled cracks. A 4Nb0Mo; B 8Nb0Mo pins.
tions beyond the peak, the eutectic liq- lidification cracking. Field testing in- Experimental Methods
uid has a backfilling, or crack healing, volving weldments of varying degrees
effect. The crack healing approach has of restraint and comparison to CPTT and Procedures
been shown to be quite effective with data may provide insight on the practi-
aluminum alloys (Refs. 2436), but cal significance of the test, as well as Materials and Sample
there is limited data for other alloy the backfilling effect in various Ni- Preparation
systems. based alloys.
The cast pin tear test (CPTT) was The objective of this study was to de- Alloy 690 was used as the base ma-
used in this investigation since it pro- termine the effect of variable Nb and terial for this study. The composition
vides a more effective means of ac- Mo content on the susceptibility of Ni- (wt-%) of the alloy used was Ni-
counting for the effect of backfilling 30Cr filler metals to solidification crack- 29.45Cr-9.13Fe-0.15Mn-0.32Ti-
on solidification cracking susceptibili- ing as a function of the fraction eutec- 0.24Al-0.02Mo-0.02Nb-0.029C-
ty than the Varestraint test, or other tic. The potential for a reduction in sus- 0.002S-0.0048P-0.014N. Additions of
externally loaded tests. Because it is, ceptibility due to a crack backfilling ef- Nb and Mo were made using a button
in effect, a self-restraint test, it pro- fect with increasing fraction eutectic melting technique. Niobium additions
vides a means to determine and obtain was investigated using an Alloy 690 in this study varied from 0 to 8 wt-%
cracking data at imposed strains low base alloy that contains no Nb or Mo. A and were in the form of 99.8% pure
enough as to not overwhelm the back- more fundamental understanding of Nb 1.0-mm-diameter wire. Molybdenum
filling effect. The CPTT may provide and Mo additions in terms of solidifica- additions of 2 and 4 wt-% were made
better predictions regarding cracking tion cracking will potentially influence to select niobium additions and were
susceptibility in actual practice com- filler metal development for these high- in the form of 99.94% pure, annealed
pared to the Varestraint test since the Cr alloys and allow filler metals to be de- 1.0-mm-diameter wire.
test is more effective in identifying the veloped that are resistant to both DDC The Alloy 690 and pieces of Nb and
critical strain required to produce so- and solidification cracking. Mo wire were carefully weighed and

WELDING RESEARCH
Fig. 7 Optical micrograph of a network of backfilling and some open cracks in a B

2Nb4Mo pin that exhibited surface cracking.
consolidated using a gas tungsten arc 1) determine an approximate starting

(GTA) button melting process. All melt- point for this study in terms of the
ing was conducted under an argon at- levels of niobium, 2) calculate mass
mosphere, so the introduction of impu- fraction values of eutectic phase for
rity elements (oxygen, nitrogen) was each composition, and 3) calculate the
unlikely. Each button was remelted average niobium and molybdenum lev-
three times to ensure homogeneity. The els at the end of the eutectic reaction.
buttons melted using this procedure The TTNi7 database, including liq-
showed little evidence of oxidation. The uid, FCC, NbC, and Laves phases, were C
nominal composition of Alloy 690 and used for the calculation. The Scheil sim-
resulting compositions after the Nb and ulations were run using two values of
Mo additions are shown in Table 1. fraction solidified as an end point for
Note that only the major elements are the mass fraction calculations, namely
listed in this table. The compositions of 0.95 and 0.98, in order to determine
a select number of buttons were deter- how the end point affected the calcula-
mined using SEM/EDS and showed that tions relative to solidification tempera-
the calculated compositions in Table 1 ture range and fraction eutectic. These
were a good approximation of the actual values of fraction solidified were select-
compositions. ed based on the range that is commonly
used by other investigators for deter-
Computational Modeling mining solidification temperature range
and/or fraction eutectic (Refs. 3842). Fig. 8 SEM micrographs depicting
The ThermoCalc Scheil module The mass fractions were determined by crack backfilling in cast pins at crack
(Ref. 37) was used to do the following: ing threshold. A 4Nb0Mo; B
plotting the solid phase fractions as a 6Nb0Mo; C 8Nb0Mo.
Table 2 Calculated Solidication Data for Fe30Cr Alloys with Nb and Mo Additions
Fraction Solid Fraction Solid

0.95 0.98 Measured
Alloy kNb kMo Volume Final Wt. Final Wt.
Mass STR Mass STR Fraction Fraction Fraction
Fraction (C) Fraction (C) Eutectic Nb Mo
Eutectic Eutectic
Alloy 690 0.16 65 0.0192 108 0.003 0.001

2Nb0Mo 0.17 215 0.0255 239.5 0.014 0.006 0.201
2Nb2Mo 0.17 0.66 225.5 0.0268 254 0.191 0.0656
2Nb4Mo 0.17 0.68 237.5 0.0287 264.5 0.183 0.118
4Nb0Mo 0.18 0.0659 212.3 0.0959 221.9 0.075 0.01 0.217
4Nb2Mo 0.18 0.67 0.0686 220.8 0.0986 237 0.206 0.0700
4Nb4Mo 0.18 0.69 0.0727 228 0.103 247.8 0.199 0.124
6Nb0Mo 0.19 0.152 191 0.182 199.5 0.144 0.03 0.223
6Nb2Mo 0.19 0.68 0.156 201 0.186 216.3 0.212 0.0736
6Nb4Mo 0.19 0.69 0.160 207.8 0.190 226.5 0.204 0.129
8Nb0Mo 0.20 0.253 168.3 0.283 176.3 0.239 0.018 0.227

WELDING RESEARCH
Fig. 9 SEM/EDS analysis of the region around a backfilled crack from Fig. 8. Spots 13 represent the composition of the backfilled cracks.
Fig. 10 SEM/EDS analysis of the region around a backfilled crack in a 6Nb4Mo alloy. Spots 1, 2, and 6 represent the composition of the
backfilled cracks.
function of temperature (Ref. 43). The variation of restraint levels imposed old, there tends to be more scatter in
average solute solidification profiles cal- by solidification shrinkage. It can be the cracking response, making com-
culated by the module and the resulting classified as a self-restraint test since parison among alloys more difficult.
mass fractions were compared to Im- the strain that promotes cracking re- Determination of the threshold pin
ageJ analyses of the volume fractions sults from contraction stresses that ac- length for each alloy was based on a
from metallographic analysis and to the cumulate in the pin during solidifica- minimum of four acceptable tests.
energy dispersive spectroscopy (EDS) tion. Detailed information regarding Acceptable pins were those that exhib-
composition data. the test as well as the procedure can be ited no visible casting defects. Casting
The significance of the Scheil simula- found elsewhere (Refs. 44, 45). Pins defects result from improper mold fill-
tions in this study was in the correlation ranging from 0.75 to 1.625 in. in ing and leave behind swirl-like inden-
made between the measured volume length were cast at 1460C after a 90-s tations on the pin surface and some-
fraction eutectic and the calculated purge in argon gas. The CPTT has been times visible voids. Casting defects
mass fraction eutectic, as well as the rel- previously demonstrated to effectively were minimized through extensive
ative composition changes that were rank the solidification cracking suscep- mold cleaning between casts and by
predicted during solidification based on tibility of a number of Ni-based alloys ensuring that the molten button was
compositional changes to Alloy 690. (Refs. 45, 46). heated to the appropriate casting tem-
In this study, the shortest pin perature and dropped properly into
Cast Pin Tear Test length that exhibited no visible crack- the pin mold. The judgment regarding
ing was used to quantify cracking sus- acceptable pins was based on visual
The cast pin tear test (CPTT) can be ceptibility. This value is designated the inspection only. Sectioning of multiple
used to evaluate susceptibility to solid- threshold pin length for solidification pins that were considered acceptable
ification cracking through a controlled cracking. At pin lengths above thresh- did not reveal any subsurface voids.

WELDING RESEARCH
Characterization lations, but the effect should be minor.

As both the Nb and Mo alloying addi-
The microstructure of each sample tions increase, the partition coeffi-
set was characterized using both opti- cients increase slightly (less partition-
cal (Olympus GX51) and scanning ing). The fraction eutectic was predict-
electron (Quanta 200 and Sirion) mi- ed to increase with increasing alloy
croscopy. Sections were taken both content, particularly with respect to
transverse to the pin length (across Nb. Molybdenum additions produced
the pin diameter) and longitudinally only a small change in the calculated
along the pin length. Serial sectioning fraction eutectic, but did result in a
performed by successive grinding was large change in the final calculated
used to reveal the microstructure composition of the eutectic phase
gradient from the pin surface to the since Mo partitions to the liquid
pin center. This technique was particu- during solidification.
The calculated fraction eutectic val- Fig. 11 Cracking susceptibility versus
larly useful for determining the extent solidification temperature range based
of crack backfilling in certain ues are reported as mass fraction while
on Varestraint data from DuPont et al.
compositions. the measured fraction eutectic values (Ref. 54).
All samples were then polished and are volume fraction (based on area
electrolytically etched in a 10% fraction measurements). These mass
chromic acid solution for 510 s at 5 V fraction values are reportedly compa-
and 2 A with a tungsten anode and rable to volume fraction values as the
stainless steel cathode. The area frac- densities of the phases involved are
tion eutectic was determined via im- similar (Ref. 9). Regardless, the calcu-
age analysis using ImageJ software. lated fractions correlate well with the
The procedure was developed from measured values. The calculated aver-
work by Payton et. al. (Ref. 47) and age weight fractions of niobium and
conformed to ASTM E1245-03. molybdenum were later compared to
SEM/EDS was used to determine the Nb and Mo levels measured in back-
composition of the matrix and eutectic filled regions using EDS.
constituents.
An accelerating voltage of 25 kV, Cast Pin Tear Test
spot size 6, and probe current 10 nA
were utilized at magnifications rang- The critical cracking thresholds for Fig. 12 Cracking susceptibility and
ing from 200 to 6000. EDS analysis the niobium-bearing samples are predicted solidification temperature
was performed at 800 on samples shown in Fig. 2. The base composition, range for the Nbbearing alloys at 0.95
that had all been etched in chromic Alloy 690 with no Nb, and the alloy fraction solidified.
acid in order to reveal the eutectic con- with 8 wt-% Nb exhibited the lowest
stituents and solidification structure susceptibility to solidification cracking,
in the samples. Etching prior to EDS as indicated by threshold (no cracking) lated mass fractions as a function of
analysis facilitated locating and ana- pin lengths of 1.5 and 1.375 in., respec- Nb content is shown in Fig. 3. In order
lyzing the eutectic constituents. tively. The alloy with 4 wt-% Nb addi- to be consistent with other data show-
tion showed the highest susceptibility ing the effect of composition on crack-
Results with a threshold pin length of 0.75 in. ing susceptibility in eutectic systems,
The scatter in the CPTT data tends to such as that shown in Fig. 1, suscepti-
Solidification Modeling increase with an increase in pin length bility is represented by the reciprocal
above the threshold and with increased of the critical cracking threshold (Refs.
Results from Scheil simulations for Nb content. This scatter is likely due to 29, 30, 34, 36). The larger this value,
all compositions are shown in Table 2. some variation in the amount of eutec- the more susceptible to cracking rela-
Partition coefficients were calculated tic that is present and the ability of tive to the other plotted compositions.
by dividing the composition of the cracks to heal by a backfilling mecha- This plot clearly illustrates that the
first solid to form by the initial, nomi- nism when greater stress (pin length) is highest susceptibility is exhibited by
nal composition in terms of either Nb imposed on the system. For that rea- the 4 wt-% Nb composition.
or Mo. The available literature does son, the threshold pin length at which When considering the fraction eu-
not report partition coefficients for there is no cracking is used as the most tectic, it appears that the highest
Alloy 690, but the calculated values reliable indicator of resistance to solidi- cracking susceptibility occurs at levels
used seem to be consistent with other fication cracking. just below 10%. Above 10%, cracking
studies of Nb- and Mo-bearing Ni- Samples representing the critical susceptibility decreases due to an ap-
based alloys (Refs. 8, 9, 4851). A cracking thresholds determined in Fig. parent crack healing effect, as will be
small under/over estimation of the 2 were then prepared for image analy- shown by characterization results in
partition coefficients may decrease the sis. Comparison of their measured vol- the next section. Additional data at 3
accuracy of the fraction eutectic calcu- ume fraction eutectic as well as calcu- and 5 wt-% Nb are needed to more ful-

WELDING RESEARCH
ly develop this curve and more accu- nor backfilling was only observed in atively thin with several breaks along
rately identify the peak in cracking pins containing cracks and is at such a the boundary. As Nb increases to 6
susceptibility. low level that the contribution to crack and 8 wt-%, the degree of backfilling
The effect of adding 2 and/or 4 healing is minimal. increases and the backfilled bound-
wt-% molybdenum to alloys with 2, 4, The backfilled cracks in the aries are much wider. While the back-
or 6 wt-% Nb at the same pin length is 8Nb0Mo pins appeared to contain filling network in the 8Nb0Mo sample
shown in Fig. 4. The pin length, 1.375 fewer voids (cracks) and are more con- is quite extensive, some small voids
in., selected for comparison of the Mo tinuous than in the 4Nb0Mo sample. are still present internally, even
effect was one in which all three niobi- The backfilled cracks in the 8Nb0Mo though no cracking was observed on
um compositions exhibited cracking sample run almost continuously the surface. Based on prior research,
prior to molybdenum addition. At the through the sample, indicating an ex- cracks initiate at the surface and prop-
2 and 4 wt-% Nb levels, there appears tensive crack healing effect in this al- agate toward the center and pins that
to be little effect from the Mo addi- loy. In the 4Nb0Mo alloy, many open are at or below the threshold do not
tion, and it may actually increase sus- cracks are evident, indicating that in- contain internal cracks (Refs. 52, 53).
ceptibility in the 2% Nb alloy. A signif- sufficient liquid of eutectic composi- Thus, for the 8Nb0Mo material, the
icant effect of the Mo addition can be tion is available to heal the cracks that crack that formed at the surface was
seen in the 6Nb samples. The 6Nb4Mo form. nearly completely healed by
composition results included pins that Backfilled cracks were difficult to backfilling.
did not crack compared to 6Nb0Mo find in the lower niobium, 2 wt-% This backfilling results in the sub-
pins, which exhibited significant compositions, although some were ob- stantial drop in cracking susceptibility
cracking. Thus, there appears to be a served in the 2Nb4Mo alloy, as shown in the 6 and 8 wt-% Nb alloys relative
clear beneficial effect of Mo additions in Fig. 7. While the beginnings of a to the 4 wt-% alloy, as shown in Fig. 2.
at the higher Nb level. The large error small network of backfilled cracks ap- Based on the data in Table 2, maxi-
among circumferential cracking values pear, many voids remain, and the pin mum cracking at 4 wt-% Nb occurs
in pins of the same composition exhibited surface cracking. The addi- when there is ~7.5 vol-% eutectic pres-
makes it difficult to make definitive tion of 4 wt-% Nb to this alloy increas- ent. By increasing the fraction eutectic
comparisons where small trends may es the fraction eutectic from 1.4 to 7.5 above 15 vol-%, a significant reduction
appear, as for the 2Nb and 4Nb com- vol-% (Table 2), leading to an increase in cracking occurs, as shown in Fig. 2.
positions. The data suggest that the in cracking susceptibility, as shown SEM/EDS spot analyses were per-
4Mo samples experienced less cracking previously in Fig. 4. formed to determine the composition
regardless of niobium composition, Crack healing via a backfilling in the backfilled cracks for 4Nb0Mo,
but the error in the data will require mechanism is clearly dependent on 6Nb0Mo, 8Nb0Mo, 2Nb2Mo,
more testing before definitive conclu- the Nb content. While some crack 2Nb4Mo, 6Nb2Mo, and 6Nb4Mo com-
sions can be made. healing may occur in the lower 2Nb positions. SEM micrographs and the
and even 4Nb compositions, the level location of the spot analysis for the
Characterization of backfilling is not sufficient to have a 8Nb0Mo and 6Nb4Mo alloys are
beneficial effect. In fact, the effect shown in Figs. 9 and 10, respectively.
As shown in Fig. 5, there is a clear may actually be detrimental in that The nominal composition refers to
increase in the fraction eutectic as the the solidification temperature range of the composition of the Alloy 690 base
Nb content is increased in the Alloy the 2Nb and 4Nb alloys has increased, alloy used in this study prior to niobi-
690 base alloy. In the base alloy mi- but the amount of eutectic formed is um and molybdenum additions, and
crostructure, virtually no eutectic not enough to adequately fill voids and the adjusted composition is the cal-
phase is detectable, and only a slight cracks to prevent cracking. Again, it is culated composition of the new alloys
increase is observed when 2 wt-% Nb important to point out that crack heal- taking the additions of Nb and Mo
is added, as evidenced by the dark par- ing is a phenomenon that may not al- into account.
ticles at the solidification subgrain ways increase resistance to solidifica- The partially backfilled crack (spots
boundaries. At 4 wt-% Nb, consider- tion cracking during welding. High lev- 13) is enriched in Nb to an average of
able eutectic constituent is evident, els of restraint may overwhelm any 24.34 wt-% while the matrix (fcc gam-
and at 8 wt-% Nb, the eutectic con- crack healing effects, even if the frac- ma phase) is depleted to an average of
stituent is almost continuous. tion eutectic is high. This is shown in 3.56 wt-% Nb. These matrix values
Evidence of crack backfilling was Fig. 2, where at the longest pin lengths represent locations away from the so-
detected in the 4, 6, and 8 wt-% niobi- significant cracking is observed in the lidification boundary where no eutec-
um pins as well as in the Nb + Mo al- 6Nb0Mo and 8Nb0Mo alloys. tic constituent is present. Thermo-
loys. Optical and SEM micrographs The SEM micrographs in Fig. 8 bet- Calc predicted an average niobium
that demonstrate the backfilling effect ter illustrate the difference in crack concentration of 23 wt-% for the eu-
are shown in Figs. 68. With the ex- backfilling observed based on differ- tectic reaction that occurs in this alloy,
ception of the 2 wt-% Nb alloys, all mi- ences in Nb. In all cases, the backfilling so the EDS data is in good agreement
crographs shown are from pin lengths occurs along solidification grain with the computed value. It is impor-
at the cracking threshold, where no boundaries where preexisting cracks tant to point out that the measured
surface cracking was observed. In the were present. In the 4Nb0Mo sample, values are average values.
2 wt-% Nb alloy, evidence of very mi- the width of the backfilled liquid is rel- The EDS spot collected data from

WELDING RESEARCH
an ~1 m diameter. It was determined loys measured using the Varestraint Conclusions

that the eutectic lamellae in the back- test, as shown in Fig. 11. While this
filled regions is much less than 1 m, data may be relevant, it should be point- 1) The fraction eutectic in Ni-30Cr
so EDS measurements taken in this reed out that at the strains used in gener- weld metals increases dramatically with
gion are likely to more closely repre- ating this data, crack healing is probably increasing niobium content based on
sent the average Nb level. Near the not possible. both the measured fraction eutectic and
edges, an average representation is When the cracking susceptibility values calculated with ThermoCalc.
less likely, as lamellae spacing appears curve from Fig. 2 is plotted with the 2) Additions of Nb up to 4 wt-% re-
to increase. As such, differences from corresponding predicted STR for each sult in an increase in cracking suscep-
predicted values were encountered in composition, it is apparent that STR is tibility associated with an increase in
some samples, especially those with a not the dominating factor affecting solidification temperature range and
thinner backfilled region to collect susceptibility at high-alloy additions, the presence of continuous liquid
data from. Depletion of the other ma- as shown in Fig. 12. Note that cracking films along the solidification grain
jor elements, Ni, Cr, and Fe coincides susceptibility and solidification tem- boundaries.
with the Nb enrichment. Similar perature range correlate well with 3) Niobium additions above 4 wt-%
trends were seen with the other com- small additions of Nb, with increased result in a decrease in cracking suscep-
positions tested. solidification temperature range re- tibility due to an increase in the frac-
As with the 8Nb0Mo sample, the sulting in increased susceptibility. tion eutectic, which promotes crack
backfilled crack for the 6Nb4Mo pin However, as alloying addition increas- healing.
also exhibited a large Nb enrichment, es, a relatively small decrease in STR is 4) The peak in cracking susceptibili-
but to a lesser extent with spots 1, 2, predicted compared to the dramatic ty corresponds to a fraction eutectic of
and 6 averaging at 21.2 wt-% Nb. decrease in susceptibility and the cor- ~7.5 vol-%. At levels above ~15 vol-%,
Molybdenum enrichment of an aver- relation is much weaker. This is be- crack healing by eutectic backfilling is
age of 7.11 wt-% was measured for the cause of the following: 1) the liquid significant.
same spots. ThermoCalc predicted a composition has reached the terminal 5) Additions of Mo to alloys con-
niobium level around 20 wt-% and a eutectic point, so further increase in taining 6 wt-% Nb resulted in a de-
molybdenum level around 13 wt-% for STR is not possible, and 2) the amount crease in cracking susceptibility. This
this alloy. of eutectic increases allowing for crack effect was not observed at lower Nb
While the niobium prediction is healing to occur. As a result, higher levels.
consistent with the measurement, the strains (longer pins) are required to 6) There was a good correlation be-
molybdenum prediction is overesti- promote solidification cracking. It tween cracking susceptibility and so-
mated. This may indicate several should be noted that the STR values in lidification temperature range at lower
things: 1) the calculated partition coef- Fig. 12 are predicted, not measured. Nb levels. At higher Nb levels (> 4
ficient is too low, 2) the Scheil simula- Ongoing work will determine the wt-%), the correlation is not good be-
tion predicted a phase with a higher actual STR values using the single cause of crack healing effects.
stoichiometric ratio of molybdenum sensor differential thermal analysis 7) The cast pin tear test appears to
than actually occurs, and 3) the EDS (SS DTA) technique (Ref. 55). be an effective method to evaluate the
analysis may be inaccurate. Sulfur K- The specific effect of Mo on crack- influence of backfilling on cracking
alpha lines overlap molybdenum L ing susceptibility remains unclear. It susceptibility in materials where suffi-
lines, but since sulfur levels in the Al- has little influence on either expand- cient liquid of eutectic composition
loy 690 base composition were less ing the solidification temperature forms at the end of solidification.
than 0.002 wt-%, such a sulfur K-alpha range or increasing the fraction eutec-
contribution should be minimal. Coin- tic. It does segregate to the liquid and
ciding depletion of Ni, Cr, and Fe is is present in higher than nominal con- Acknowledgments
again observed in the backfilled region centration in the eutectic liquid. As
of this alloy. shown in Fig. 4, it seems to have no in- The lead author (RW) would like to
fluence in the 2 and 4 wt-% Nb alloys, thank the Graduate School at The
but its effect is dramatic in reducing
Discussion cracking susceptibility in the 6Nb4Mo
Ohio State University for providing a
fellowship during the first year of
alloy. One possibility is that the pres- graduate studies and to the Depart-
The results presented here indicate ence of Mo somehow affects the wet- ment of Energy (DOE) Nuclear Engi-
for Ni-based alloys that form eutectic ting characteristics of the eutectic liq- neering University Program (NEUP)
constituents at the end of solidification, uid and helps promote crack healing. for providing continuing support
the backfilling effect makes predictions It should be noted that filler metal through an NEUP Fellowship. Our
of cracking susceptibility difficult to de- 625, which has good solidification thanks to Paul Mason from Thermo-
termine simply as a function of the so- cracking resistance despite a wide solidi- Calc for his prompt and helpful re-
lidification temperature range. Previous fication temperature range, contains on sponses regarding the computational
data from DuPont et al. (Ref. 54) have the order of 4 wt-% Nb and 10 wt-% work performed in this study. Fellow
shown a correlation between the solidi- Mo. Further work is underway to better graduate students Adam Hope, David
fication temperature range (STR) and understand the effect of Mo in high-Cr, Tung, and Daniel Tung are recognized
cracking susceptibility in Ni-based al- Nb-bearing Ni-based alloys. for their instruction and guidance

WELDING RESEARCH
with experimental and computational joint with various Nb addition. Metallurgical cracking in 5083-O aluminum alloy weld-
techniques. The authors also thank and Materials Transactions 34A: 1097. ments. Welding Journal 56(6): 171-s to
Ken Copley and Ed Pfeiffer, support 13. Nelson, D. E., Baeslack, W. A., III, and 178-s.
staff in the Welding Engineering Pro- Lippold, J. C. 1987. An investigation of weld 29. Lippold, J. C. 2015. Welding Metallur-
hot cracking in duplex stainless steels. Weld- gy and Weldability, p. 107, Hoboken, N.J.,
gram at OSU, for their dedication and
ing Journal 66(8): 241-s to 250-s. John Wiley & Sons, Inc.
commitment to the development of a 14. Lundin, C. D., Chou, C. P. D., and Sul- 30. Anderson, T. 2009. Finding an ally al-
safe and sustainable research environ- livan, C. J. 1980. Hot cracking resistance of loy. Practical Welding Today 12(3).
ment. austenitic stainless steel weld metals. Weld- 31. Davis, J. R., ed. 1993. ASM Specialty
ing Journal 59(8): 226-s to 232-s. Handbook: Aluminum and Aluminum Alloys,
15. Huang, C., Cao, G., and Kou, S. 2004. p. 379, ASM International.
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lidification microstructures of Fe-Ni-Cr al- Weld Solidification Cracking. Hot Cracking Phe- 43. Private communication with Paul
loys. Scripta Materialia 41(4): 449454. nomena in Welds. Eds. T. Bllinger and H. Mason, ThermoCalc.
12. Lee, H. T., Jeng, S. L., and Kuo T. Y. Herald. Springer, pp. 318. 44. Kreuter, V., and Verner, C. 2015. Op-
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ior of the dissimilar Alloy 690-SUS 304L age, W. F. 1977. An investigation of hot fracture test. M.S. thesis. The Ohio State

WELDING RESEARCH
University, Columbus, Ohio.

45. Alexandrov, B. T., and Lippold, J. C.
2013. Use of the cast pin tear test to study
solidification cracking. Weld World 57:
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B. J., Sowards, J. W., Lippold, J. C., and Mc- If youd like to ask a question, share an idea or voice an opinion, you can call, write,
Cracken, S. S. 2012. Susceptibility to solidifi- e-mail, or fax. Staff e-mail addresses are listed below, along with a guide to help you
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2015121_Layout 1 6/10/16 3:28 PM Page 239
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Pulsed UltrasonicWaveAssisted
GMAW of 7A52 Aluminum Alloy
A comparative study was conducted on pulsed and continuous
ultrasonicwaveassisted gas metal arc welding
BY W. F. XIE, C. L. FAN, C. L. YANG, AND S. B. LIN
Dai (Ref. 2) imposed ultrasonic fre-

ABSTRACT quency vibration to the side surface of
a workpiece to be welded in the gas
As a new welding process, pulsed ultrasonicwaveassisted gas metal arc welding
tungsten arc welding (GTAW) of 7075-
(PUGMAW) was first proposed. The peak power output of pulsed ultrasonic is higher
than that of continuous ultrasonic. In theory, the effect of ultrasonic treatment on the T7 aluminum alloy and found that the
molten metal should be more pronounced during the welding process. To prove the fea grain size in the overheated and heat-
sibility of this idea, three groups of comparative experiments, including gas metal arc affected zones decreases. By exerting
(GMA), continuous ultrasonicwaveassisted GMAW (UGMAW), and PUGMAW of 7A52 ultrasonic to the back of the workpiece
aluminum alloy were conducted. A highspeed camera and a spectrometer were of AL-6XN austenitic stainless steel,
employed to detect the welding process in real time. The weldments were evaluated by Cui et al. (Ref. 3) discovered that the
performing a variety of testing methods. In PUGMAW, when the smallest droplet size corrosion resistance was improved. In
and the largest metal transfer frequency were obtained, the weld area increased signifi conventional gas metal arc welding
cantly. The grains rened by pulsed ultrasonic were much finer than those rened by (GMAW), Watanabe et al. (Ref. 4) in-
continuous ultrasonic. The microhardness tests revealed the degree of softening of the
troduced into the weld pool by the ul-
joint decreased. The microstructure and element analysis showed the presence of the
coarse secondphase particles, which was a cause of softening in the fusion zone, and trasonic frequency oscillation of filler
due to enhanced ultrasonic agitation there was a significant inhibitory effect to the Zn el metal and found that the elongation of
ement gasication loss. Compared with the ultimate tensile strength (UTS) and the stainless steel joint increased by
elongation of the GMA joint, those of the PUGMA joint increased 23 and 62%, more than 40% compared to those ob-
respectively. The UTS and elongation of the UGMA joint were 8.34 and 15.43% lower tained in conventional GMAW. Wu et
than those of PUGMA joint, respectively. al. (Ref. 5) reported this arc ultrasonic
as the result of excitation of arc by
high-frequency current. He et al. (Ref.
KEYWORDS 6) and Morisada et al. (Ref. 7) also
Pulsed UltrasonicWaveAssisted Gas Metal Arc Welding (PUGMAW)
demonstrated the effectiveness of this
7A52 Aluminum Alloy Microstructure Mechanical Properties method in improving the performance
of the joint.
Yang et al. (Refs. 8, 9) proposed the
Introduction ern industry and the variation in the continuous ultrasonic-wave-assisted
diversity of products, materials, and arc welding method, where the non-
Arc welding, characterized by ad- their service conditions, the require- contact ultrasonic vibration is im-
vantages such as simple operation, ments for welding quality become posed along the coaxial direction of
high production efficiency, and being more strict. Excellent welding technol- the arc to form an acoustic radiation
prone to automation, has been exten- ogy of high efficiency and low con- field in the arc zone. The ultrasonic
sively applied in welding manufactur- sumption is an inevitable development field acted on the arc and the weld
ing, including in the automobile, avia- trend in the field. Considering the ad- pool. Under the action of ultrasonic ra-
tion, shipbuilding, national defense, vantages of ultrasonic, such as me- diation force, both GTA and GMA
petroleum, and electron industries. As chanical effect, acoustic streaming, welding arcs can be compressed and
the technology and the theory devel- and cavitation effect, many re- therefore generate certain arc acoustic
op, arc welding has become a system- searchers have done some distinctive binding effects (Refs. 10, 11). During
atic discipline (Ref. 1). However, with work to introduce it into the process the continuous ultrasonic-wave-assist-
the continuous development of mod- of arc welding. ed GMAW (U-GMAW) process, it was
W. F. XIE, C. L. FAN (fclwh@hit.edu.cn), C. L. YANG, and S. B. LIN are with the State Key Laboratory of Advanced Welding and Joining, Harbin
Institute of Technology, Harbin, China.

2015121_Layout 1 6/9/16 4:35 PM Page 240
WELDING RESEARCH
Fig. 1 Schematic of the welding setup. Fig. 2 Schematic of the realtime monitoring system.
sonic wave to the GMAW process to

better achieve welding the 7A52 alu-
minum alloy. Compared to continuous
ultrasonic, pulsed ultrasonic in pulsed
ultrasonic-wave-assisted GMAW (PU-
GMAW) has the characteristic of high-
er peak power output. The objective of
Fig. 3 Dimensions of the flat tensile specimens (in mm). this study is to prove the concept and
feasibility of PU-GMAW of the 7A52
found that the droplet transfer fre- acoustic cavitation and streaming in aluminum alloy.
quency increased (Ref. 12). Compared the liquid metal (Refs. 16, 17). Increas-
with conventional GTAW, the weld ing the applied ultrasonic power gen- Experimental Procedure
penetration increased by more than erally resulted in smaller, more round-
one time (Ref. 13), and the welding ef- ed, and better distributed grains and Material
ficiency was higher. Additionally, the intermetallic particles (Ref. 18).
weld grains were refined (Ref. 14), and The Al-Zn-Mg alloys (7XXX series) Table 1 shows the chemical compo-
the strength of the joint could be im- with high strength and low density are sitions of the commercial 7A52 alu-
proved by more than 8% (Ref. 8). widely used in the aerospace eld and minum alloy and consumable ER5356
Therefore, its application potential is other engineering applications (Refs. (1.2 mm) with yield strength of 120
as wide as to cover many arc welding 19, 20). In all cases, arc welding is the MPa and ultimate tensile strength
processes. It may find the most attrac- primary joining method. The final (UTS) of 260 MPa. The sheet was
tive applications in welding other posi- properties of the joint are attributed sheared into sample sizes of 200 100
tions except for flat with the small to the welding procedures, welding 8 mm3. Single V-groove angles (30
welding gun and few process methods, and welding wire. Aluminum deg) were cut using an abrasive water-
parameters. Alloy 7A52 is a medium-strength alloy jet cutting machine in the plates with
Another effective but less practiced of the 7XXX series alloys, which gains 2-mm root faces for a total 60-deg in-
application of ultrasonic is ultrasonic strength from MgZn2 precipitates and cluded angle between two plates. Be-
treatment of cast alloys. The idea of can be fusion welded with few difcul- fore welding, all of the plates were
improving the quality of cast alloys by ties arising from melting and solidi- cleaned with acetone in order to make
means of elastic oscillations produced cation. The microstructure in the fu- sure the surface was free from contam-
by mechanical vibration or shaking ap- sion zone is related to the fusion ratio, inants. Experimental samples were
plied to solidifying steel was rst sug- and there are many problems remain- xed tightly into a xture to ensure a
gested by Chernov in 1878 (Ref. 15). ing to be solved, such as coarse grains, zero root opening.
The effects of ultrasonic on rening joint softening, and element loss
the cast microstructure and removal of (Refs. 21, 22). PUGMAW Procedure
gases and oxides from the melt have In this paper, the authors propose
been associated with the occurrence of the idea of applying the pulsed ultra- The welding setup schematic is
Table 1 Chemical Compositions of Base Metal (Al 7A52) and Welding Wire (ER5356), (wt%)
Compositions Zn Mg Cu Fe Mn Cr Si Ti Al
7A52 4.04.8 2.02.8 0.050.2 0.3 0.20.5 0.150.25 0.25 0.050.18 Bal.
ER5356 0.1 4.55.5 0.1 0.4 0.050.2 0.050.2 0.25 0.060.2 Bal.

2015121_Layout 1 6/10/16 3:30 PM Page 241
WELDING RESEARCH
B C
Fig. 4 Arc shape and droplets under different welding conditions: A

GMAW; B UGMAW; C PUGMAW. Fig. 5 Electron temperature for three welding processes.
sonic power and ultrasonic transducer.

Synchronous mechanical vibration
generated by the ultrasonic transducer
A was radiated to surrounding space in
the form of ultrasonic waves by the ul-
trasonic radiator after being amplified
by the amplitude transformer and sub-
sequently ultrasonic energy acted on
the arc. With reasonable structure de-
sign, the vibration reached maximum
amplitude when the transducer was
resonant (Ref. 23). Different reso-
nance modes could be obtained by ad-
justing the distance between the radia-
tor and workpiece. The periodic cycle
of pulsed ultrasound consists of three
B parts: the establishment, stability, and
disappearance of the ultrasonic field.
The ultrasonic, with the same exci-
tation frequency of 19.5 kHz, includ-
ing continuous ultrasonic and pulsed
ultrasonic, was generated by the ultra-
sonic transducer using a concave
spherical surface ultrasonic radiator
with a height of 14 mm. The height of
the ultrasonic radiator was determined
by the experiment; the specific
method can be found in Ref. 24. These
C geometric parameters of the ultrasonic
radiator were designed to be optimal
by the boundary element method (Ref.
25). For pulsed ultrasonic, the pulsed
current frequency (pulsed frequency)
was 5 Hz. The input power of the ul-
trasonic power source was regulated to
2000 W for both the U-GMAW and the
PU-GMAW. The welding parameters
are listed as follows: the constant volt-
Fig. 6 Macroscopic appearances of the weld and EBSD maps of the weld joint center: age power supply was used during the
A GMAW; B UGMAW; C PUGMAW. experiments, and the welding process
was performed under direct current
shown in Fig. 1. The welding gun was piece was 90 deg. It consisted of two electrode positive conditions. The noz-
fixed, and the workpiece moved at a parts, the welding system and ultra- zle height was 11 mm. Argon with a
constant speed. The angle between the sonic radiation system.The ultrasonic purity of 99.99% was utilized as the
axis of the welding gun and the work- radiation system included the ultra- shielding gas and the flow rate

2015121_Layout 1 6/10/16 3:32 PM Page 242
WELDING RESEARCH
A B C
Fig. 7 Distribution of the secondphase particles for different welding processes: A

GMAW; B UGMAW; C PUGMAW.
Fig. 8 XRD analysis of the second

phase particles for different welding
processes: A GMAW; B UGMAW;
C PUGMAW.
time monitoring system is shown in

Fig. 2.
In this experiment, the ber head
was accurately parallel with the work-
piece and all the spectrum data were
gained under the same acquiring con-
dition. The electron temperature dur-
ing the welding process was calculated
based on the spectral emission of ele-
mental aluminum detected within the
Fig. 9 EDS results of the weld joint obtained with GMAW. arc. Under the welding conditions, the
local thermodynamic equilibrium
could be satisfied and the electron
through the nozzle was 15 L/min. Ex- vertically to the welding direction to temperature was approximately equal
periments were performed at a weld- simultaneously acquire the shape of to the excitation temperature (Ref.
ing speed of 0.4 m/min, wire feed the arc and droplet. To characterize 26). Therefore, the same kinds of
speed of 11 m/min, and welding volt- the arc temperature, a spectrograph atoms or ions met the Boltzmann dis-
age of 25.5 V. was used to acquire the spectrum of tribution on two levels (Em and En). For
the arc plasma. A computer was used two close spectral lines of the same
RealTime Monitoring System to simultaneously control the high- kind of atom or ion, the following rela-
speed camera and the spectrograph, tionship could be obtained:
A high-speed camera was posi- and manage the information ac-
tioned toward the welding arc and quired. The schematic of the real- I n An g n m E E
= exp n m (1)
I m Am g m n kTe
Table 2 Mg and Zn Contents (wt%) in Dierent Welding Processes and Dierent where I and are the emission line rel-
Locations to the Same Weldment ative intensity and wavelength, respec-
tively, A is the transition probability of
Processes Locations Mg Zn electron from upper level m to lower
Upper 03.53 00.98 level n, k is the Boltzmann constant, E
is the emitted energy, and Te and g are
GMAW Middle 03.56 01.02 the electron temperature and the sta-
Lower 03.86 01.60 tistical weight of the upper transition
level, respectively. In order to improve
Upper 03.54 02.24 the estimation accuracy, the spectral
lines used for calculation should be
UGMAW Middle 03.51 02.48 carefully chosen.
Lower 03.50 02.62
Weld Quality Analysis and
Upper 03.54 03.23
Mechanical Property Testing
PUGMAW Middle 03.95 03.79
To evaluate weld quality, the weld
Lower 03.60 04.10 samples were sectioned, mounted,

2015121_Layout 1 6/9/16 4:36 PM Page 243
WELDING RESEARCH
Fig. 10 Schematic of the test sections of element distribution by Fig. 11 UTS, yield strength, and elongation of the base plate
EDS analysis. and the joints obtained with different conditions.
A B Experimental Results
and Analysis
Arc and Metal Transfer Process
There are three basic metal transfer
modes: short-circuiting, globular, and
spray (Ref. 28). At low current and low
voltage levels, short-circuiting transfer
occurs. At a slightly higher voltage lev-
el, globular transfer occurs. The drop
C D size is greater than the diameter of the
welding wire, and the detachment is
mainly controlled by gravity.
When the welding current further
increases to a higher level that is above
a critical value, called the transition
current, transfer occurs in the form of
relatively small drops that are trans-
ferred at the rate of hundreds per sec-
ond. This spray transfer becomes the
predominant mechanism. These metal
transfer modes show different arc sta-
bilities, weld formation, spatter levels,
Fig. 12 A Fracture surface of BM and welding joints; B GMAW; C UGMAW; and so on.
D PUGMAW.
Figure 4 shows the arc and a typical
globular transfer process under differ-
and polished applying standard met- hardness tests were performed. The ent welding conditions. The first im-
allographic techniques to provide a tensile test coupons were cut from age shows the end of the last transfer
cross-sectional view, and subsequent- the metal sheets using an abrasive cycle, at the moment prior to the
ly etched using a 2% nital etchant for waterjet cutting machine. The tensile droplet detachment, and the last im-
metallographic study. Microstructur- specimens comprising the welded age shows the droplet prior to detach-
al and composition analysis of the joints were machined to the required ment in the current transfer cycle.
weld metal were performed using op- dimensions (Fig. 3) as per ASTM When the experiment was carried
tical microscopy (OM), electron E8M-04 guidelines (Ref. 27). Micro- out without ultrasonic, the detaching
backscatter diffraction (EBSD), scan- hardness testing was carried out by force, mainly the gravitational force,
ning electron microscope (SEM), x- applying a 200-g load and a dwell was not large enough to balance out
ray diffraction (XRD), and energy dif- time of 10 s followed by optical the retaining force for rapid detach-
fraction x-ray spectrum (EDS) ana- measurements of the resulting in- ment, so the droplet size gradually
lyzers. To test the mechanical proper- dentation. grew, and the diameters of the
ties of the welds, tensile and micro- droplets prior to detachment were

2015121_Layout 1 6/10/16 3:33 PM Page 244
WELDING RESEARCH
A B
Fig. 14 A Film model of weld pool; B stress analysis of

liquid film.
Fig. 13 Microhardness distribution of the weld joint obtained with

different welding processes. Fig. 15 Schematic of the metal composition of the weld pool.
about three times the diameter of the for the PU-GMAW arc could reach joints obtained under different weld-
welding wire Fig. 4A. As a result, 17,000 K and was the highest in the ing conditions. For the weld grain of
the metal transfer cycle lasted a long three welding processes. For this rea- the PU-GMAW joint, the refinement
time, 203 ms. When the continuous son, it was primarily the result of the effect was most obvious in the three
ultrasonic was used, the diameters of plasma particle agglomeration. It joints. The size of the grains decreased
the droplets in U-GMAW were small- shows that PU-GMAW was an efficient by the ultrasonic treatment, which
er than their respective counterparts and stable welding process. The stabil- should produce complicated heat flows
in GMAW Fig. 4B. The metal ity could also reduce the spatter and and increase the nucleus number by
transfer cycle lasted a short time, ejection from the molten metal. This the cavitation effect.
144 ms. Under the action of pulsed caused a higher concentration of
ultrasonic, the most characteristic molten metal in the plasma region, Microstructure
feature was the deformation of the which led to an elevated electron tem-
droplet. At first, the droplet size was perature in turn. The weld center zone was mainly
small, and the droplet shape was ap- composed of an aluminum matrix sol-
proximately spherical. Weld Properties id solution, but also the composition
When the droplet diameter exceed- of the wire. The remarkable character-
ed the wire diameter, the droplet start- With the help of analysis and meas- istic in the microstructures at the
ed to burst spontaneously Fig. 4C. urement of photographs, compared vicinity of the weld area is shown in
The explosion process lasted until the with the GMA weld, it could be ob- Fig. 7. The number density of the pre-
end of the transfer cycle. The resultant served that when ultrasonic was ap- cipitated phase particles in the PU-
droplet shape was approximately plied, the weld areas were increased, as GMAW joint obviously decreased com-
columnar. Although the droplet size shown in the left side of Fig. 6. Ultra- pared to that of the conventional
could not be directly measured due to sonic could change the arc pressure GMAW joint.
explosion, the droplet size in PU- distribution (Ref. 13), while the pulsed To identify the variation of the
GMAW was apparently smaller than ultrasonic further enhanced the force identities and intensity of the precipi-
that in U-GMAW. Since the wire feed acted on the the arc and droplet. That tated phases at different processes,
speeds were constant in three welding was the reason why the application of XRD characterization of the welded
processes, the decrease of the droplet pulsed ultrasonic could increase the joint was performed, and the results
size resulted in a decrease of metal weld area much more severely, while are shown in Fig. 8. The phase parti-
transfer time and an increase in metal the dispersion of the arc and the low cles mainly consisted of MgZn2 ()
transfer frequency. The cycle time was additional force acting on the droplet and Al2CuMg (S) phases. The intensity
reduced from 144 to 64 ms, while the could not bring a larger melt zone. of the peak of the phase decreased
metal transfer frequency increased Selected portions of EBSD maps with the addition of the ultrasonic, in-
from about 8 to about 20 Hz. taken from the center of different fu- dicating that the -phase particles
From Fig. 4, it can also be seen that sion zones are given in the right side were dissolved into the matrix. Simi-
there is the shortest arc length and the of Fig. 6. The typical solidication larly, the intensity of the peak of the S
brightest arc to PU-GMAW. According structure consisting of an equiaxed phase reached the maximum for the
to this calculation result from the structure was conrmed for the 7A52 GMA weld. It was also suggested that
spectrum experiment, as shown in Fig. aluminum weld. The signicant differ- the S phase particles did not dissolve
5, the average electron temperature ence in grain size was observed for the into the matrix of the GMA weld.

2015121_Layout 1 6/10/16 3:34 PM Page 245
WELDING RESEARCH
Figure 9 shows the microstructure gasication burning of the Al element showed few elongated dimples of vary-
of the weld joint obtained with the was relatively small. The gasication ing size and shape uniformly distrib-
GMAW process under SEM. The distri- burning of Zn and Mg elements main- uted over the surface along with sec-
bution of the main compositional ly occurred under the welding heat ondary cracks Fig. 12C. Dimples
phases in the microstructure could be source. According to experimental re- were shallow and more. The mode of
identied. Region 1 was chosen to test sults, it can be speculated that the fracture was ductile as evident from
the chemical composition of intra- GMAW sample produced a more in- the dimpled fracture surface. These
granular coarse bulky particles, Region tense gasication burning of the Zn el- observations are in agreement with
2 for the intragranular elliptical parti- ement, while the pulsed ultrasonic had high elongation efciency of the joint
cle, Region 3 for the matrix phase, and a significant inhibition in the gasica- (7.4%). Similar behavior was observed
Region 4 for the chemical composition tion burning. for PU-GMAW joints, which also ex-
of discontinuous intergranular strip. hibited a dimpled fracture surface.
The SEM/EDS revealed that the coarse Tensile Properties The fracture surfaces were covered
bulky particles in Region 1 contained with deeper and larger dimples, as well
Al, Cu, Mg, and trace Zn, and their In order to evaluate the effect of ul- as a few flat regions Fig. 12D. More-
weight percentages corresponded to trasonic on the mechanical properties over, some deep pits with relatively
51.95, 25.86, 11.59, and 10.60%, re- of the welds, tensile testing was per- featureless surfaces can be seen on the
spectively. The composition was close formed, including base metal (BM) fractured surface, which showed the
to the stoichiometric of the Al2CuMg and the welded sample. All welded highest elongation efficiency (8.75%)
phase (S phase). Thus, it was believed samples broke in the weld location. in the as-welded condition.
that the coarse second-phase particles Figure 11 shows the experimental
were S phase, consistent with the re- average strength value. The UTS, yield Microhardness
sults of XRD. strength, and elongation efficiency of
the BM were 525 MPa, 471 MPa, and Results of the microhardness test
Element Loss 13.2%, respectively, in the as-welded for the joints obtained with GMAW, U-
condition. The UTS, yield strength, GMAW, and PU-GMAW were plotted
It is known that the 7XXX series and elongation efficiency of 375.5 in Fig. 13. The average microhardness
aluminum alloy achieves its high MPa, 322 MPa, and 8.75% as-welded was evidently lower in the fusion zone
strength from a series of precipitates condition were obtained in PU-GMAW and higher in the heat-affected zone
such as typical (MgZn2) and T condition. The GMAW joints showed than that in the BM. Hardness of the
(Al2Mg3Zn) (Ref. 29). The content and the lowest tensile strength (305.9 fusion zone was the highest when the
gradient of the alloying elements dis- MPa), yield strength (277.6 MPa), and pulsed ultrasonic was used. Thus, cor-
tinctly change in welds and play a pri- elongation efficiency (5.4%). Com- responding to the three kinds of joint
mary role in the microstructure and pared to the UTS, yield strength, and hardness values over the fusion zone
resulting properties. Few studies have elongation of the GMAW joint, those were three groups, which ranged from
examined the softening mechanism of the PU-GMAW joint increased 23, HV118 to HV125, HV100 to HV115,
from the elemental perspective. There- 16, and 62%, respectively, while those and HV90 to HV100, respectively. The
fore, the alloying elements distribu- of the U-GMAW joint only increased hardness of the BM was within HV140
tion was focused. 13, 7, and 37%, respectively. and HV160. So the hardness of the fu-
Figure 10 is the schematic of the Fracture surfaces of the BM (rolling sion zones was about 80, 70, and 65%
test section. From the top to bottom state without recrystallization) and of the BM, respectively. After PU-
of the weld axis at intervals of 3 mm, a the different welding joints can be GMAW, the average microhardness in
region was selected to analyze element seen in Fig. 12. A scanning electron the weld obviously increased by 7.4
content by EDS. microscope study of the tensile frac- HV compared with that of the U-
Table 2 shows the distribution of ture surfaces was done to investigate GMAW sample. The variation of the
the major Mg and Zn strengthening el- the mode of fracture and to under- hardness values also approximately
ements. It can be seen that, in general, stand the effect of ultrasonic treat- reected the precipitation and dissolu-
the weld of the PU-GMAW sample has ment on the mode of failure of weld- tion of the second-phase particles dur-
a higher percentage content of Zn ele- ing joints Fig. 12BD. ing welding.
ment than the weld of GMAW and U- Tensile fractured surface of the BM The precipitation of the coarse
GMAW. The primary metallic ele- was mainly composed of cleavage second-phase particles from the weld
ments of 7A52 aluminum alloy were Al steps and tearing edges that were of the aluminum alloy under the ac-
and Zn, while ER5356 welding wire characteristic of transgranular fracture tion of large heat input without ultra-
was Al and Mg. On the premise of the Fig. 12A. The mode of fracture was sonic agitation reduced the lattice dis-
initial alloying elements content being brittle or locally ductile and in agree- tortion of aluminum crystal and was
constant, if some elements were re- ment with low (5.4%) elongation effi- favorable for the movement of the dis-
duced, it was mainly due to the effect ciency of the GMAW condition. The locations, resulting in the decreased
of strong gasication burning. As the fracture surfaces were covered with hardness and producing a wider soft-
boiling point of Zn and Mg were 1180 ne dimples and large tearing ridges ening region. In contrary, the dissolu-
and 1380 K, respectively, well below Fig. 12B. Comparatively, fracture tion of the coarse second phase in-
the boiling point of 2740 K of Al the surface of U-GMAW joints invariably creased the lattice distortion of alu-

2015121_Layout 1 6/10/16 3:35 PM Page 246
WELDING RESEARCH
minum crystal and hence the where J0(ka) and J2(ka) are the zero- sonic is applied to deal with the weld
hardness. order and second-order cylindrical pool, acoustic streaming induced by the
bessel function, respectively. pA is the ultrasonic field is the major form of liq-
resultant force, including the arc pres- uid flow (Refs. 3133). According to
Analysis of the sure and the droplet impact force. Darcys law, the differential form of liq-
Ultrasonic Effect As the determining factor of the uid flow velocity (U) is then given by
weld pool boundary, S-Acan be obtained
K
Ultrasonic Effect on the Weld the amplitude maxima when ka = Mn U=
L
(P +L g ) (7)
(Mn is a series of root values about
The weld pool was assumed to be a J0(ka)), the resonant of weld
- pool may
multilayer film, and stress analysis of be considered to occur. SA is proportion- where K is the liquid penetration coef-
the liquid film on the surface was con- al to pA, the greater the increase degree ficient, g is the acceleration, P is the
-
ducted. Under the action of the exter- of SA is, the larger the weld. When the pressure, L is the liquid density, is
nal force, the film was forced to vi- ultrasonic is applied to the GMAW dynamic viscosity, and L is volume
brate. The surface microelement was process, the increase of the arc pressure fraction for liquid phase. From Equa-
extracted, as shown in Fig. 14. The and droplet impact force will result in tion 7, it can be seen the size of veloci-
tension in the unit length of film is re- an increase in pA. The arc pressure is as- ty is determined by the input power of
garded as a constant force (T), p repre- sociated with the degree of compression the ultrasonic wave. If the velocity is
sents the axial pressure. The arc axial of the welding arc, the droplet impact large enough so that the time of the
force acting on surface microelement force is closely related to the droplet vol- arc directly acting on the elements
can be obtained that ume and the droplet transfer frequency, could be shortened, it can also effec-
while the arc and the droplet are ulti- tively reduce the element loss from the
FF = pdxdy (2) mately controlled by the ultrasonic gasication burning.
power, as shown in Fig. 4.
This surface microelement consists
of several line microelements with the Ultrasonic Effect on Grain
length of dx and the width of 1. S is Ultrasonic Effect on Refinement
the displacement in the vertical direc- Element Loss
tion. The corresponding resultant The acoustic pressure characteris-
force of film in the vertical direction is Through EDS analysis, we found tics of pulsed ultrasonic is different
then given by that the pulsed ultrasonic had a signif- from that of continuous ultrasonic,
icant inhibition in the gasication the pulse power supply can output
2 S 2 S burning of the Zn element. Although higher peak power, there is the higher
Fz = T 2 + 2 dxdy (3) the electron temperature of the PU- ultrasonic power input weld pool, and
x y GMAW arc is the highest compared the stronger cavitation can be ob-
with that of the GMAW and PU- tained in the PU-GMA weld pool. The
According to Newtons second law, the GMAW arcs, this experimental result cavitation can reduce the freezing
forced vibration equation of the weld could not just be simply attributed to point of the melt, increase mobility,
pool can be obtained (Ref. 30): the fact that PU-GMAW produced a and better refine grain structure.
more constrained arc and reduced sig-
2 S 2 S nificantly weld spatter whereas the
T 2 + 2 dxdy pdxdy conventional GMAW process did not. Conclusion
x y From Fig. 6, it can be seen that the
largest weld area is obtained in PU- The mechanical behavior and the
2 S
= dxdy (4) GMAW. The total welding heat input is mechanism were comparatively stud-
t 2 consistent in three welding processes, ied for arc shape, droplet transfer, and
so this means that the heat input per welds obtained with PU-GMAW in this
where is the mass per unit area. unit volume is reduced. Additionally, paper. The following conclusions may
Equation 4 is integrated into polar welding parameters are constant in be obtained:
form, and when the boundary condi- three experiments. They are the same 1. Under three welding conditions,
tions meet r = a, S(t,a) = 0 is substitut- for the melting volume of welding wire the arc length, droplet size, and elec-
ed into the equation in three weld pools and the most metal tron temperature in PU-GMAW were
from BM entering the welding pool of the shortest, smallest, and highest, re-
S(t,r) = SAejwt (5) PU-GMAW, while the Zn element is spectively. The cycle time of droplet
mainly from the BM of 7A52 aluminum transfer was reduced from 203 ms in
where SA is the vibration amplitude. By alloy. The schematic of the metal com- GMAW to 64 ms in PU-GMAW, while
integrating the displacement ampli- position of the weld pool is shown in the metal transfer frequency increased
tude, we can obtain the average ampli- Fig. 15. from about 3 to about 20 Hz.
-
tude of the entire film (SA): At last, the effect of ultrasonic 2. By the analysis of weld proper-
p A J2 ( ka ) streaming within the weld pool should ties, it could be found that when ultra-
SA = i (6) also be considered except the mechani- sonic was applied, the fusion zone area
k 2T J0 ( ka ) cal effect of ultrasonic. When the ultra- of the 7A52 aluminum alloy joint in-

2015121_Layout 1 6/10/16 3:37 PM Page 247
WELDING RESEARCH
creased. The typical solidication 5. Wu, M. S., He, L. B., Li, L. M., and paradigm in the design of aluminium al-
structure consisted of equiaxed grains Hao, H. W. 2005. Study on arc-ultrasonic loys for aerospace applications. Materials
in the center of welds and the grains welding technology. Transactions of the Chi- Science Forum 331: 127142.
were significantly refined by the na Welding Institution 26(6): 4044. 20. Heinz, A., Haszler, A., Keidel, C.,
6. He, L. B., Wu, M. S., Li, L. M., and Moldenhauer, S., Benedictus, R., and
pulsed ultrasonic treatment.
Hao, H. W. 2006. Ultrasonic generation by Miller, W. S. 2000. Recent development in
3. Welding with a more constrained exciting electric arc: A tool for grain refine- aluminium alloys for aerospace applica-
arc and stronger acoustic field could ment in welding process. Applied Physics tions. Materials Science and Engineering A
reduce the number density of coarse Letters 89(13): 131504. 280(1): 102107.
second-phase particles (S-phase) and 7. Morisada, Y., Fujii, H., Inagaki, F., 21. Yang, C., Guo, W. M., Zhang, H. X.,
produce a higher energy density distri- and Kamai, M. 2013. Development of high Qiu, R., Hou, J., and Fu, Y. B. 2013. Study
bution of electron beam acting on alu- frequency tungsten inert gas welding on the corrosion behavior of 7A52 Al alloy
minum alloys, but would not result in method. Materials & Design 44: 1216. welded joint by electrochemical method.
stronger gasication burning of the Zn 8. Sun, Q. J., Lin, S. B., Yang, C. L., and International Journal of Electrochemical Sci-
element than with the conventional Zhao, G. Q. 2009. Penetration increase of ence 8: 93089316.
AISI 304 using ultrasonic assisted tung- 22. Huang, J., Yin, Z., and Lei, X. 2008.
arc. It is generally thought that the ul-
sten inert gas welding. Science and Technol- Microstructure and properties of 7A52 Al
trasonic streaming plays a pronounced ogy of Welding & Joining 14(8): 765767. alloy welded joint. Transactions of Nonfer-
effect on the redistribution of 9. Fan, Y. Y., Yang, C. L., Lin, S. B., and rous Metals Society of China 18(4):
strengthening elements. Liu, W. G. 2012. Ultrasonic wave assisted 804808.
4. The joint properties of PU-GMAW GMAW. Welding Journal 91(3): 91-s to 23. Fan, Y. Y. 2011. Research on ultra-
were better than that of the other two 99-s. sonic assisted gas metal arc welding and
welding processes, and tensile proper- 10. Fan, C. L., Yang, C. L., Lin, S. B., and metal transfer behaviour. PhD disserta-
ties ranking was PU-GMAW > U-GMAW Fan, Y. Y. 2013. Arc characteristics of ultra- tion, Harbin Institute of Technology.
> GMAW, which was attributed to the sonic wave-assisted GMAW. Welding Jour- 24. Xie, W. F., Fan, C. L., Yang, C. L.,
deeper and larger dimples. The average nal 92(12): 375-s to 380-s. Lin, S. B., and Tao, B. 2015. Influences of
11. Xie, W. F., Fan, C. L., Yang, C. L., sound field parameters on welding arc be-
microhardness of the fusion zones cor-
Lin, S. B., and Zhang, Y. Q. 2015. Charac- havior in ultrasonic-MIG welding. China
responded to GMAW, U-GMAW, and teristics of acoustic-controlled arc in ultra- Welding 24(3): 2935.
PU-GMAW were about 65, 70, and 80% sonic wave-assisted arc. Acta Physica Sinica 25. Xie, W., Fan, C., Yang, C., and Lin, S.
of the BM, respectively. With the help of 64(9): 95201. 2016. Effect of acoustic field parameters
pulsed ultrasonic, the weld softening 12. Fan, Y. Y., Fan, C. L., Yang, C. L., and on arc acoustic binding during ultrasonic
phenomenon was obviously improved. Liu, W G. 2012. Research on short circuit- wave-assisted arc welding. Ultrasonics Sono-
ing transfer mode of ultrasonic assisted chemistry 29: 476484.
GMAW method. Science and Technology of 26. Sabbaghzadeh, J., Dadras, S., and
Acknowledgments Welding and Joining 17(3): 186191. Torkamany, M. J. 2007. Comparison of
13. Sun, Q. J., Lin, S. B., Yang, C. L., pulsed Nd:YAG laser welding qualitative
Fan, C. L., and Zhao, G. Q. 2008. The arc features with plasma plume thermal char-
This work was supported by the
characteristic of ultrasonic assisted TIG acteristics. Journal of Physics D: Applied
Key Program of the National Natural welding. China Welding 17(4): 5257. Physics 40(4): 10471051.
Science Foundation of China (Grant 14. Yuan, H. R., Lin, S. B., Yang, C. L., 27. ASTM E8 M-04. 2006. Standard Test
No. 51435004) and the National Natu- Fan, C. L., and Wang, S. 2011. Microstruc- Methods for Tension Testing of Metallic Ma-
ral Science Foundation of China ture and porosity analysis in ultrasonic as- terials. ASTM International.
(Grant No. 51275134). sisted TIG welding of 2014 aluminum al- 28. Lancaster, J. F. 1984. The Physics of
loy. China Welding 20(1): 3943. Welding. Pergamon Press, Oxford, UK.
15. Eskin, G. I., and Lutrasonic, L. 29. Davis, J. R. 1993. ASM Specialty
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3 Cui, Y., Xu, C. L., and Han, Q. 2006. bration on the microstructure and me- Microstructure improvement in weld metal
Effect of ultrasonic vibration on unmixed chanical behavior of AlSiCu alloy. Mate- using ultrasonic vibrations. Advanced Engi-
zone formation. Scripta Materialia 55(11): rials Science and Engineering A 560: neering Materials 9(3): 161163.
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WELDING RESEARCH
Characterization of Constitutive Behavior of

Dissimilar Aluminum Alloy Resistance Spot Welds
All of the weld nuggets produced during testing proved to have a higher yield strength
than the base metal due to grain refinement that occurs during resistance spot welding
BY J. KANG, B. SHALCHI-AMIRKHIZ, Y. CHEN, D. R. SIGLER, AND B. E. CARLSON
ed zone (HAZ) material given the fact

ABSTRACT that the actual area of the weld nugget
is unknown and because of the com-
The constitutive behavior of resistance spot weld nuggets and heataffected zones was
plex stress state of the weld nugget.
directly measured in samples made from three different dissimilar aluminum alloy stackups
that included die cast Aural2T7 to Aural2T7, Aural2T7 to AA5754O, and Aural2T7 to The actual stress state of the weld
AA6022T4 using modified shear testing coupled with digital image correlation. The results nugget is much more complex than
show that all of the weld nuggets produced with the Aural2T7 die cast material have those applied during simple tensile
higher yield strength than the base Aural2T7 substrate due to grain refinement that occurs tests and depends on the base materi-
during the resistance spot welding process. Further strengthening is obtained in the Aural2 als, nugget size, loading condition, and
T7 to AA5754O and Aural2T7 to AA6022T4 dissimilar spot welds due to the formation of failure mode (Refs. 7, 8).
intermetallic particles at grain boundaries as revealed by TEM observations. What is desired is a general method
to evaluate the material properties of
the weld nugget and/or surrounding
KEYWORDS heat-affected zone HAZ that could then
be used to extrapolate joint behavior in
Constitutive Behavior Shear Test Resistance Spot Welding Aluminum Alloys both simple tensile tests and, eventual-
Mechanical Properties Transmission Electron Microscopy ly, vehicle structures. A new shear test
specimen and test procedure coupled
Introduction in obtaining consistent spot welding with digital image correlation was re-
processes. This problem has been ad- cently developed by Kang et al. (Refs. 9,
Resistance spot welding (RSW) has dressed with the invention of the mul- 10) and have been included in the latest
been the dominant welding process tiring domed (MRD) electrode (Refs. ASTM Standard B831-14 (Ref. 11).
employed by the automotive industry 35). This process is currently used to Compared to the previous versions of
for joining of steel sheet for body weld automotive structures and clo- ASTM B831, a pair of notches were
structures because of its inherently sures including the 2014 Corvette added in the shear zone in the thickness
low cost and high speed. Facing in- Stingray (Ref. 5) and 2017 Cadillac direction ensuring a simple shear state
creasing demand from the automotive CT6, as well as numerous hoods, in the shear zone in the new shear test
industry to utilize aluminum alloy doors, and liftgates. specimen (Ref. 10) and digital image
sheets for mass reduction and in- Quantitative determination of the correlation was introduced to directly
creased fuel economy, it is thus desir- performance of aluminum alloy spot measure the shear strain in the shear
able to continue using RSW as the welds is critical to safety and structural zone. This new shear test specimen and
joining process to save considerable life prediction (Ref. 6). Traditional ten- test procedure have been used to suc-
costs in capital investment and facility sile tests such as lap shear, cross- cessfully measure the constitutive be-
upgrades that would be required with tension, and peel tests can report the havior of aluminum sheet materials
the introduction of other possible maximum load and load-displacement (Ref. 9) and resistance spot weld
joining techniques in existing RSW- curves for the tested nugget size and nuggets of aluminum alloy wrought
based body shops (Refs. 1, 2). Howev- weld schedule. However, such load- sheets at large strains (Refs. 12, 13).
er, the presence of insulating oxide displacement curves cannot be directly In this contribution, a newly devel-
layers on the aluminum alloy material converted into stress-strain curves of oped shear test and test procedure was
surface presents significant problems the specific weld nugget or heat-affect- used to directly measure the constitu-
J. KANG (jidong.kang@canada.ca), B. SHALCHIAMIRKHIZ, and Y. CHEN are with CanmetMATERIALS, Hamilton, ON, Canada. D. R. SIGLER and
B. E. CARLSON are with General Motors Global R&D Center, Warren, Mich.

WELDING RESEARCH
A B
tive behavior of large strains of resist- ment speed of 1

ance spot weld nuggets produced in mm/min to obtain
dissimilar aluminum alloy combina- the baseline tensile
tions. The dissimilar alloy combina- stress-strain curves
tions included die cast Aural-2-T7 to of the base alloy
die cast Aural-2-T7, die cast Aural-2-T7 sheets.
to AA5754-O, and die cast Aural-2-T7 General Motorss
to AA6022-T4. Also included were the proprietary MRD
heat-affected zones (HAZs) for the Au- resistance spot
ral-2-T7 and AA6022-T4 combination. welding process was
In addition to microhardness testing used to weld three C
and metallography, advanced material types of aluminum
characterization tools such as focused dissimilar spot
ion beam (FIB), transmission electron welds, namely, Au- Fig. 1 Shear specimen design for the following: A Aural2
microscopy (TEM), and associated ral-2-T7 to Aural-2- T7 to Aural2T7 and Aural2T7 to AA5754O spot welds; B
techniques, e.g., energy-dispersive T7, Aural-2-T7 to Aural2T7 to AA6022T4 spot welds where the AA6022T4 side
spectroscopy (EDS) were used to char- AA5754-O, and Au- was removed; C HAZ at the Aural2T7 or AA6022T4 side
acterize and understand the measured ral-2-T7 to AA6022- where the other pieces were removed.
constitutive behavior of the weld T4. Weld coupons
nuggets and HAZ. were 150 mm long simulation are denoted as baked sam-
and 38 mm wide. Spot welding was ples, whereas those not subjected to
Experimental done using a medium-frequency DC the bake simulation are denoted as
(MFDC) weld control and transformer. as-welded samples.
The materials used in the present The MRD electrode is made from Some of the spot weld specimens
study are typical for automotive body C15000 copper alloy and has a 12-mm were sectioned through the cross sec-
applications and were 3-mm-thick face diameter with a 25-mm radius of tion perpendicular to the length direc-
Aural-2-T7 (AlSi10Mg-T7) high- curvature and 5 upstanding rings. The tion and mounted for microhardness
pressure die cast sheets, 2-mm-thick spot welding schedules are shown in measurements and macrostructure ob-
AA5754-O (Al-Mg3 solid-solution hard- Table 3. Some of the aluminum spot servations following standard metallo-
ened alloy), and AA6022-T4 (Al-Si-Mg welds underwent baking to simulate graphic procedures.
precipitation-hardened alloy) wrought the thermal history experienced dur- Shear specimens (Fig. 1) were made
alloy rolled sheets. The chemical compo- ing the electrophoretic painting with the shear zone located at the cen-
sition and nominal mechanical proper- process, i.e., e-coat employed within ter of the weld nugget for weld nugget
ties, respectively, of these materials are the assembly plant paint shop, i.e., a shear test specimens, or 6 mm away
shown in Tables 1 and 2. Tensile tests thermal cycle of 30 min in total at from the center of the weld nugget for
were carried out per ASTM E557-10 177C. For the sake of simplicity, spec- the HAZ shear test specimens. The
(Ref. 14) at a nominal cross-head move- imens subjected to the e-coat bake depth of the shear zone shown in
Table 1 Nominal Chemical Composition of Aural2T7, AA5754O, and AA6022T4 (wt%)
Element Si Mn Mg Fe Ti Sr Cu Cr Zn Al
Aural2T7 9.511.5 0.30.6 0.10.4 0.25 0.1 0.010.018 Bal.
AA5754O 0.4 1.0 2.63.6 0.4 0.15 0.1 0.30 0.20 Bal.
AA6022T4 0.71.5 0.35 0.250.75 0.30 0.15 0.25 0.10 0.20 Bal.

WELDING RESEARCH
gle. The von Mises yield criterion was

used to convert the shear stress-shear
strain curves into effective stress-
effective strain curves, i.e., s = 3 ,
e = /3, where s is the effective stress
and ethe effective strain.
The TEM samples were prepared
using ion milling (Gatan PIPS) or FIB
(FEI Helios Nanolab DualBeam). All
TEM studies were carried out using
FEIs Tecnai Osiris TEM equipped with
an X-FEG gun at 200 keV. Convention-
al bright-field/dark-field imaging,
SAD, and CBED techniques were used
for phase identification and crystallog-
raphy. STEM mode using bright field
(BF) and high angle annular dark field
(HAADF) detectors were used in com-
bination with EDS point detection and
elemental mapping. The HAADF im-
ages contain chemical information as
at higher angles, scattering is related
to atomic Z-number.
A B
Results and Discussion
Fig. 2 An example of the random pattern used on the shear specimens for digital
Macrostructures along with micro-
image correlation: A Before testing; B after testing. The shear deformation is evi
dent in the shear zone (highlighted in boxes in red color). hardness line scans of all the spot
welds are shown in Figs. 35.
From Figs. 35, it is seen that the
Table 2 Nominal Main Mechanical Properties of Aural2T7, AA5754O, and AA6022T4 penetration is much greater into the
Aural-2-T7 side of the stack-up in both
Material Yield Strength, MPa Ultimate Tensile Strength, MPa Elongation, % the Aural-2-T7 to AA5754-O welds and
Aural-2-T7 to AA6022-T4 welds. Fig-
Aural2T7 150165 180220 1420
ure 5 exhibits the unusual microstruc-
AA5754O 90130 Minimum 250 23
ture formed with very little penetra-
AA6022T4 100150 Minimum 200 24
tion into the AA6022-T4 side for the
Aural-2-T7 to AA6022-T4 spot welds.
Fig. 1 for the weld nuggets was deter- the integral part of the full-field strain The bonded area between the two
mined based on weld nugget macro- measurements during the shear tests sheets is difficult to discern in the mi-
graphs to ensure the entire shear zone (Refs. 11, 15). A random ink pattern crostructure since wetting between
was within the corresponding weld was placed on the sample surface us- the two sheets occurs beyond the area
nugget. Wire electric discharge ma- ing an airbrush prior to testing for where shallow penetration can be
chining (EDM) was used to machine shear specimens. The DIC measure- seen. The weld nugget size is easily re-
the specimen contour while the notch ments were made from a set of speci- vealed during peel testing and was
of the shear zone was machined using men surface images collected automat- found to meet the target. It is also in-
sink EDM with a specially designed ically at 1-s intervals during the shear teresting to note in Fig. 4 that the di-
electrode to ensure the notch edges at tests. After the tests, the captured im- ameter of the weld nugget is notice-
the bottom were at 90 deg to the shear ages were processed to obtain full-field ably smaller at the AA5754-O side
zone on both sides of the sample. strain maps using the DIC system soft- (e.g., 6.5 mm) than the Aural-2-T7 side
More details on shear test specimen ware (Aramis). A set of ink pattern im- (e.g., 8.0 mm).
preparation and shear test procedure ages before and after testing are It can be concluded from the micro-
for aluminum resistance spot welds shown in Fig. 2. hardness data presented in Figs. 35
are described in Ref. 12. The instantaneous shear stress () that all the weld nuggets have signifi-
A commercially available optical was calculated using = F/A0 where F cantly higher microhardness than the
digital image correlation (DIC) strain is the instantaneous force and A0 the base alloy sheet. In addition, for the
mapping system, Aramis, was used to initial shear area. The instantaneous baked welds shown in Figs. 4 and 5,
follow the shear strain development average shear angle over the shear the nugget hardness remains un-
during the shear tests. In the present zone was calculated and converted to changed after the e-coat, i.e., the ther-
study, the DIC system was used to di- shear strain using = tan (), where mal cycle does not impact the hard-
rectly measure shear angles as they are is the shear strain and the shear an- ness of the weld nuggets. No apparent

WELDING RESEARCH
A B
Fig. 3 Macrostructure and microhardness of Aural2T7 to Aural2T7 spot weld: A Aswelded sample for welding schedule 1; B
aswelded sample for welding schedule 2.
A B
Fig. 4 Macrostructure and microhardness of Aural2T7 to AA5754O spot weld: A Aswelded sample; B baked sample.
A B
Fig. 5 Macrostructure and microhardness of Aural2T7 to AA6022T4 spot weld: A Aswelded sample; B baked sample.
microhardness change was seen in weld nugget. This is the area of inter- were all obtained in-situ during the
the AA5754-O, Aural-2-T7 sides be- est chosen for the shear test of the shear tests. For the sake of simplicity,
fore and after the e-coat. However, in HAZ. only the shear angle maps at maxi-
the Aural-2-T7 to AA6022-T4 spot Shear angle measurements from mum load for the weld nuggets and
welds shown in Fig. 5, an increase of the shear tests of the three types of HAZ in the as-welded condition are
10 Hv is observed after the e-coat at a dissimilar aluminum alloy spot welds shown in Figs. 6 and 7. Based on these
spot 6 mm away from the center of the under as-welded and baked conditions measurements, the shear strains over

WELDING RESEARCH
the shear zone were calculated and

converted to effective strains. Togeth-
er with effective stresses obtained
from shear stress measurements, the
measured effective stress-effective
strain curves of all three types of weld
nuggets and their HAZ are shown in
Figs. 810. Also shown in Figs. 810
are the corresponding true stress-
true strain tensile curves of the base
metals.
Figures 810 illustrate that the ten-
sile strength of all three weld nuggets
(triangular data) are higher than the
base metal substrate shown by the sol-
A B C id line. Figure 8 shows data for the Au-
ral-2-T7 to Aural-2-T7 alloy combina-
Fig. 6 Shear strain maps at maximum load for weld nuggets in aswelded samples.: tion, where no change in alloying oc-
A Aural2T7 to Aural2 for welding schedule 1; B Aural2T7 to AA5754; C Aural curs between the two welded sheets.
2T7 to AA6022. In this case, the nugget still shows sig-
A B C D
Fig. 7 Shear strain maps at maximum load for the heataffected zone in aswelded samples: A Aural2T7 to Aural2T7 spot
weld; B Aural side in an Aural2T7 to AA5754O spot weld; C Aural2T7 side in an Aural2T7 to AA6022T4 spot weld; D
AA6022T4 side in an Aural2T7 to AA6022T4 spot weld.
Table 3 Resistance Spot Welding Schedules(a)
Spot Weld Force, kN Preheat Preheat Cool Weld Weld rms(b)

Time, ms Current, kA Time, ms Time, ms Current, kA
Aural2T7 4.9 30 ~10.0 10 156 33.3
+ AA5754O
Aural2T7 5.3 30 ~10.0 10 156 32.5
+ AA6022T4
Aural2T7 6.7 50 ~6.0 10 267 27.0
+ Aural2T7
(welding schedule 1)
Aural2T7 + Aural2T7 5.8 50 ~10.0 10 247 29.5
(welding schedule 2)
(a) No post heat was used for any of the weld schedules.
(b) Pulsating DC current was used during the welding step and is given as rms current.

WELDING RESEARCH
Fig. 8 Measured effective stresseffective strain of Aural2T7 Fig. 9 Measured effective stresseffective strain of Aural2T7 to
to Aural2T7 spot welds. AA5754O spot welds.
crease in work hard- three weld nuggets are much finer

ening of the HAZ compared to the die cast Aural-2-T7
compared to the base metal where typical spher-
base material. This oidized and isolated globules of Si are
is attributed to the present, indicating the addition of Sr
heat input of the as a modifier in its chemistry (Ref.
welding operation. 18). The presence of Sr is confirmed
After the paint bake in the EDS elemental maps of Aural-
cycle, an apprecia- 2-T7 alloy by TEM Fig. 12. Never-
ble increase in yield theless, the rapid cooling and solidifi-
strength is ob- cation produced by resistance spot
served although the welding leads to grain refinement in
work hardening re- the weld nugget. This is postulated
mains similar to as the main strengthening mecha-
Fig. 10 Measured effective stresseffective strain of Aural2 that observed in the nism responsible for the observed in-
T7 to AA6022T4 spot welds. as-welded condi- crease in strength of the weld
tion. This was likely nuggets.
due to age harden- All three weld nuggets were ana-
nificantly greater strength than that ing as the bake temperature of 177C lyzed by TEM and the results are pre-
found for the base metal substrate.
Figures 9 and 10 also reveal that the is close to the solution aging tempera- sented in Figs. 1316. From the TEM
effect of paint bake cycles on the ten- ture of 180C for AA6022-T4 (Refs. results of the Aural-2-T7 to Aural-2-
sile stress-strain curves for the Aural- 12, 16). These observations are consis- T7 weld nugget (Fig. 13), it is seen
2-T7 to AA5754 and Aural-2-T7 to tent with those from the microhard- that the structure consists of pri-
AA6022 weld nuggets is indeed negli- ness testing but quantitative tensile mary aluminum surrounded by an
gible, as the differences are within the stress-strain curves were directly aluminum-silicon eutectic containing
measurement error. measured from the areas of interest magnesium, manganese, and iron.
Tensile stress-strain curves for the within the corresponding spot welds. The grain boundaries for this weld
HAZ are also shown in Figs. 810. For The microhardness measurements nugget are free of intermetallic parti-
all three stack-up combinations, the in the current work for the AA5754-O cles, but the grain size is much finer
measured tensile stress-strain curves in as-welded and as-baked conditions compared to the Aural-2-T7 base
in the Aural-2-T7 HAZ are slightly low- indicate no HAZ, although metallo- metal alloy.
er compared to that of Aural-2-T7 base graphic analysis of AA5754 welds by The TEM results for the Aural-2-
metal regardless of testing conditions, Zhang and Senkara does indicate a re- T7 to AA5754-O weld nuggets are
i.e., whether as-welded or baked. This gion adjacent to the weld having dark- shown in Fig. 14. These weld nuggets
means the HAZ in the Aural-2-T7 side ened and widened grain boundaries in- are primarily composed of material
is indeed insensitive to the paint bake dicative of a HAZ (Ref. 17). from the Aural-2-T7 substrate Fig.
simulation. Figure 11 shows the FIB images of 4. Figure 14 reveals primary alu-
It is interesting, however, to note the microstructure near the faying minum surrounded by a more com-
that one sees a significant increase in interface of the Aural-2-T7 and weld plex eutectic structure. Intermetallic
yield strength of the HAZ in AA6022- nugget for all three spot welds. From particles are clearly seen in the alu-
T4 (Fig. 10) compared to the base met- Fig. 11, it is seen that the primary minum-silicon-rich eutectic regions,
al substrate, but a corresponding de- aluminum grains and pure Si for all e.g., AlMgSi phase (Al0.45Mg1.55Si)

WELDING RESEARCH
A B
Fig. 11 FIB images of spot welds obtained from FIB. A

Aural2T7 to Aural2T7 for welding schedule 1; B Aural
C 2/T7 to AA5754; C Aural2T7 to AA6022T4. Red dash lines
in each image guide the boundaries of the weld nugget and
Aural2T7.
B
was seen in two morphologies (Fig. gions surrounding
15), one with a MgSiSr core (Fig. primary aluminum.
15C) and one without (Fig. 15D).
Dendritic Si was seen in grain bound- Conclusions
aries, and AlMnFeSi phase
(Al19Fe4Mn1Si2) within the Si den- Three types of
dritic region was observed as well. spot welds between
The TEM results for the Aural-2- dissimilar alu-
T7 to AA6022-T4 weld nuggets are minum alloys,
shown in Fig. 16. These weld nuggets namely, Aural-2-T7
are composed almost entirely of ma- to Aural-2-T7, Au- Fig. 12 A STEM HAADF and corresponding EDS combination
terial from the Aural-2-T7 substrate ral-2-T7 to AA5754- map; B corresponding EDS elemental maps of Aural2T7 .
Fig. 5. Figure 16 also reveals pri- O, and Aural-2-T7
mary aluminum surrounded by a to AA6022-T4, were
more complex aluminum-silicon eu- successfully produced using General used as input to multiscale modeling
tectic structure. The needle-like Motorss proprietary MRD resistance of macroscale joints, an example of
phase -Al5FeSi was seen in the eutec- spot welding process. The constitu- which shall be published in a separate
tic region Fig. 16C. tive behavior of these three resistance body of work.
In summary, further strengthen- spot weld nuggets as well as that of All the weld nuggets were found to
ing in the Aural-2-T7 to AA5754-O the HAZ for the Aural-2-T7 and have higher yield strength than the
and Aural-2-T7 to AA6022-T4 spot AA6022-T4 side were determined us- base Aural-2-T7 material. This was
weld nugget as shown in Figs. 9 and ing modified shear testing coupled found to be a result of grain refine-
10 are the direct result of the forma- with digital image correlation. This ment that occurs during the resist-
tion of various forms of intermetallic local-scale data of the specific weld ance spot welding process and would
particles within the Al-Si eutectic re- nugget and HAZ properties can be be typical for any combination of Al

WELDING RESEARCH
A
A
B
B
Fig. 13 A STEM bright field and corresponding EDS combina Fig. 14 A STEM bright field and corresponding EDS combi
tion map; B corresponding elemental maps of Aural2T7 to nation map; B corresponding elemental maps of Aural2T7 to
Aural2T7 spot weld for welding schedule 1. AA5754O spot weld.
alloy stack-ups containing at least one help from Prof. In-Ho Jung (McGill spot welding in automotive structures. Weld-
cast alloy because of the relatively University) on phase diagram analysis, ing Journal 92(6): 6472.
fast solidification rates inherent in re- and Jie Liang and Cathy Bibby (Can- 6. Yang, Y. P., Gould, J., Peterson, W.,
sistance spot welding. Further metMATERIALS) on mechanical test- Orth, F., Zelenak, P., and Al-Fakir, W. 2013.
Development of spot failure parameters for
strengthening due to the formation ing and TEM work.
full vehicle crash modeling. Science and Tech-
of intermetallic particles within the nology of Welding and Joining 18(3):
aluminum-silicon eutectic region was 222231.
found in the Aural-2-T7 to AA5754-O References
7. Zhou, M., Hu, S. J., and Zhang, H.
and Aural-2-T7 to AA6022-T4 dissim- 1999. Critical specimen sizes for tensile-
ilar spot welds. The formation of the shear testing of steel sheets. Welding Journal
1. Patrick, E. P., and Sharp, M. L. 1992.
intermetallic particles was caused by 78(9): 305-s to 313-s.
Joining aluminum auto body structure, SAE
the alloying between the dissimilar 8. Chao, Y. J. 2003. Ultimate strength
paper 920282, SAE International, Warren-
metal substrate materials; thus, the and failure mechanism of resistance spot
dale, Pa.
extent of strengthening is a function weld subjected to tensile, shear, or com-
2. Meschut, G., Janzen, V., and Olfer-
bined tensile/shear loads. J. Eng. Mater.
of the weld nugget diameter and rela- mann, T. 2014. Innovative and highly pro-
Technol. :125125132.
tive amounts of penetration, as well ductive joining technologies for multi-mate-
9. Kang, J., Wilkinson, D. S., Wu, P. D.,
as the alloy composition of the base rial lightweight car body structures. Journal
Bruhis, M., Jain, M., Embury, J. D., and
materials. of Materials Engineering and Performance
Mishra, R. K. 2008. Constitutive behavior
23(5): 15151523.
of AA5754 sheet materials at large strains.
3. Sigler, D. R., Schroth, J. G., and
Acknowledgments ASME J. Eng. Mater. Technol. 130(3):
Karagoulis, M. J. 2012. Weld electrode for
031004-1-5.
attractive weld appearance. U.S. Patent
10. Kang, J., and Shen, G. 2014. A novel
8,222,560. July 17, 2012.
The authors gratefully acknowledge shear test procedure for determination of
4. Sigler, D. R., Schroth, J. G., Karagoulis,
the financial support from the Canadi- constitutive behavior of automotive alu-
M. J., and Zuo, D. New electrode weld face
minum alloy sheets. ASTM Selected Tech-
an Federal Government Inter-depart- geometries for spot welding aluminum. Con-
nical Papers, STP 1571: Application of Au-
mental Program for Energy R&D, Gen- ference Proceedings, AWS Sheet Metal Welding
tomation Technology in Fatigue and Fracture
eral Motors Canada, and Canmet- Conference XIV, May 1114, 2010, Livonia,
Testing and Analysis, pp. 5062.
MATERIALS, and Natural Resources Mich., pp. 119.
11. ASTM Standard B831-14, Standard
Canada. The authors are grateful for 5. Sigler, D. R., Carlson, B. E., and Janiak,
Test Method for Shear Testing of Thin Alu-
P. 2013. Improving aluminum resistance

WELDING RESEARCH
A A
B B
C
C
Fig. 16 A STEM bright field and corresponding EDS combination

map; B corresponding elemental maps of Aural2T7 to AA6022
T4 spot weld; C the needleshaped phase in the grain boundary
area is Al5FeSi shown in higher magnification.
95100. ASTM, West Conshohocken, Pa., Vol.

Fig. 15 A STEM HAADF image and corresponding composi 13. Kang, J., Mc- 02.02.
tion EDS map; B corresponding EDS elemental maps of the Dermid, J. R., and 15. GOM mbH. 2008. Aramis-Deforma-
grain boundary region in Aural2T7 to AA5754O spot weld Bruhis, M. 2012. tion Measurement Using the Grating Method,
zone showing two different morphologies of AlMgSi phase Measuring the me- Users Manual. V6.02, Braunschweig, Ger-
shown in C and D along with corresponding electron diffraction chanical properties many.
patterns showing Al0.45Mg1.55Si phase. The morphology of aluminum sheets 16. Kaufman, J. G. 2000. Introduction to
shown in C has a core of MgSiSr. and their resistance Aluminum Alloys and Tempers, ASM Inter-
spot welds at large national, Materials Park, Ohio.
minum Alloy Products. 2014. Annual Book of strains using digital 17. Zhang, H., and Senkara, J. 2011. Re-
ASTM Standards. ASTM, West Con- image correlation coupled with a modified sistance Welding: Fundamentals and Applica-
shohocken, Pa, Vol. 02.02. shear test. 2012 SAE World Congress, pa- tions, Second Edition, CRC Press.
12. Kang, J., McDermid, J. R., and per number 2012-01-0181. 18. North American Die Casting Associa-
Bruhis, M. 2013. Determination of the 14. ASTM B557-14, Standard Test Meth- tion: High Integrity Die Castings. 2008. Ar-
constitutive behavior of AA6022-T4 alu- ods for Tension Testing Wrought and Cast lington Heights, Ill.: North American Die
minum alloy spot welds at large strains. Aluminum- and Magnesium-Alloy Products. Casting Association.
Materials Science and Engineering A A567: 2014 Annual Book of ASTM Standards.

LI ET AL SUPP 2015107_Layout 1 6/9/16 4:26 PM Page 257
WELDING RESEARCH
Constitutional Liquation of the

Laves Phase in Virgin FB2 Steel
The evolutionary behavior of the Laves phase during welding was examined
BY K. LI, Z. CAI, Y. LI, AND J. PAN
tionary behavior on weld joints of

ABSTRACT 912% Cr martensitic stainless steels
have not been clarified in published
In 912% Crcontaining martensitic stainless steel, the Laves phase usually occurs
articles.
after longterm, hightemperature exposure. However, in the present work, some sparse,
relatively large particles of the Laves phase were observed in virgin FB2 steel (a new 9% In the present work, some (Fe,
Cr martensitic stainless steel). It is concluded that the large Laves phase particles formed Cr)2Mo-type Laves phase was also
during casting due to dendritic segregation. Then constitutional liquation resulting from found in virgin FB2 steel, which led
a eutectic reaction between the Laves phase and (Fe) during welding was found, to constitutional liquation during
suggesting a liquation crack tendency in FB2 steel. Subsequently, hot ductility tests welding thermal cycles, suggesting a li-
further confirmed the existence of a liquation crack. The evolutionary behavior of the quation crack tendency in the heat-
Laves phase during welding thermal simulation was analyzed, and the Chi phase was affected zone (HAZ) of FB2 steel. Then
found as a eutectic constituent during cooling. In specimens experiencing a peak temper the evolutionary mechanism of the
ature of 1350C, some grain boundaries were surrounded by eutectic microstructures, Laves phase during heating and cool-
forming ghost boundaries, in which way the grain boundary strength was severely
ing was analyzed. This work is impor-
weakened.
tant in guiding the practical produc-
tion of welded turbine rotors made of
KEYWORDS FB2 steel.
Laves Phase FB2 Steel Constitutional Liquation Liquation Crack

Chi Phase Materials and Experiment
Procedure
Introduction FB2 steam turbine rotors, so it is nec-
essary to carry out experiments on The specimens for scanning elec-
Elevating steam parameters is the FB2 steel welding, gaining experiences tron microscopy (SEM) observation of
main key to enhancing the efficiency to guide the practical production. the Laves phase were sampled from
of fossil power plants to reduce fuel On the other side, the Laves phase virgin FB2 steel (tempered at 700C
consumption and noxious emission usually occurs in martensitic stainless for 4 h), of which the chemical compo-
(Refs. 1, 2). Therefore, a lot of new steels after long-term, high-tempera- sition is listed in Table 1.
creep-resistant martensitic steels have ture exposure (Refs. 79), but there is The specimens were electrolytic
been developed in the frame of the Eu- still a limited number of reports about etched at 5V in oxalic acid for 10 s fol-
ropean Cooperation in Science and the Laves phase in 912% Cr marten- lowing mechanical polishing. Welding
Technology (COST) program. Among sitic steels in the as-received (or vir- thermal cycle simulation was carried
them, FB2 steel is the most promising gin) condition (Refs. 10, 11). Among out on dilatometer DIL 805A, and
candidate to be widely used in turbine the numerous martensitic stainless peak temperatures (Tp) were 1150,
rotors operated at a temperature range steels, CB2 is a cast steel with a similar 1200, 1250, and 1350C with a hold-
from 600 to 650C (Ref. 3). FB2 steel chemical composition to FB2 steel, ing time of 0.5 s. Both the heating and
is a forged, boron-added, and 9% Cr- mainly used for steam turbine compo- cooling rates were 100C/s. After ther-
containing martensitic stainless steel nents. The occurrence of a micron mal simulation, all the specimens were
(Ref. 4). Welding is now widely applied sized (Fe, Cr)2Mo-type Laves phase in electrolytic etched followed by SEM
in manufacturing large components virgin CB2 steel was reported by Kasl observation. In specimens experienc-
operated at high temperatures to over- (Ref. 11) and Jandov (Ref. 12). How- ing peak temperatures of 1350C,
come the limit of forging capacity ever, the evolutionary behavior of the some eutectic structures with net-like
(Refs. 5, 6). Up to now, there is still a Laves phase during welding and the morphology were found, and focused
limited number of reports on welded influence of the Laves phase evolu- ion beam (FIB) was employed to sam-
K. LI, Z. CAI (likejian07@163.com), Y. LI, and J. PAN are with the Department of Mechanical Engineering, Tsinghua University, Beijing, China.
CAI is also with the Collaborative Innovation Center of Advanced Nuclear Energy Technology and the State Key Laboratory of Tribology,
Tsinghua University, Beijing, China.

WELDING RESEARCH
ple a specimen for transmission elec- A B

tron microscopy (TEM) observation of
the eutectic structures. Selected area
electron diffraction (SAED) was car-
ried out to identify the types of eutec-
tic constituents.
Hot ductility tests were conducted
on a Gleeble-3500 thermal simulator,
and protected by an argon atmosphere
from oxidation of the fracture appear-
ance. The rod specimens for hot duc-
tility tests were 121.5 mm in length
and 10 mm in diameter. The peak tem- Fig. 1 A The Laves phase in virgin FB2 steel observed by SEM. B Chemical
peratures were 1350C (labeled 1) and composition of the Laves phase obtained by EDX.
1250C (labeled 2), and the displace-
A B
ment load was 0.5 mm with a velocity
of 0.1 mm/s at peak temperatures.
The fracture appearance of ruptured
specimens was observed by SEM.
Results
Observation of the Laves Phase
in Virgin FB2 Steel
In virgin FB2 steel, some micron- C D
sized particles were found, as shown in
Fig. 1. All the particles were distributed
randomly and inhomogeneously, and
most parts of the matrix were free of
the particles. Based on our experience,
the particles could only be found when
the entire specimen was traversed by
SEM with about 1000 magnification.
Most of the particles were located
within austenitic grains and were much
larger than conventional precipitates,
E F
such as M23C6 or the MX phase.
The results of energy-dispersive
x-ray (EDX) show the particles were
enriched in boron, oxygen, molybde-
num, vanadium, and chromium com-
pared with the nominal chemical com-
position of the FB2 steel listed in Table
1. The main alloy elements in the par-
ticles were molybdenum, chromium,
and ferrite, suggesting they may be
some kind of intermetallic compound.
In addition, the mole ratio of (Fe + Cr)
Fig. 2 Microstructures observed by SEM in FB2 steel after thermal simulations: A
and Mo in the particles is nearly 2. All
Tp = 1150C; B Tp = 1200C; C and D Tp = 1250C; E and F Tp = 1350C.
of the characteristics mentioned were
Table 1 Chemical Composition of FB2 Steel (wt%)
C Si Mn Ni Cr Mo V Nb N Co B Fe
0.13 0.05 0.40 0.15 9.3 1.5 0.2 0.05 0.02 1.0 0.01 Balance

WELDING RESEARCH
periencing peak temperatures below

1200C (including 1200C) stayed un-
changed, as shown in Fig. 2A and B,
while in specimens experiencing higher
peak temperatures (1250 and
1350C), some microstructures with
morphologically distinct forms instead
of the Laves phase particles were found,
as shown in Fig. 2CF. Based on the
morphology, it can be speculated they
were eutectic structures. It is notewor-
thy that in Fig. 2CF, the eutectic mi-
crostructure observed by SEM is just
one eutectic constituent and the other
eutectic constituent located in the in-
tervals of the eutectic microstructures
might be electrolytic etched.
In specimens experiencing a peak
temperature of 1250C, the net-like
eutectic microstructures (indicated by
solid arrows) are surrounded by some
separated particles (indicated by
dashed arrows), and they all locate
within austenitic grains, while in spec-
Fig. 3 The chemical composition of eutectic microstructures obtained by EDX.
imens experiencing a peak tempera-
ture of 1350C, the morphology of eu-
tectic microstructures is more typical,
A B and the size was much larger than that
in Fig. 2C and D. The net-like eutectic
microstructures (indicated by solid ar-
rows) locate at triple grain junctions
with tails along grain boundaries
(indicated by dashed arrows).
The chemical composition of the
eutectic microstructures listed in
Fig. 3 shows the content of Mo was
lower than that in the Laves phase,
and the contents of other elements
C D were similar to those of the Laves
phase. Based on the differences in
morphology and chemical composi-
tion, it can be speculated that the eu-
tectic microstructure was a new phase
rather than the Laves phase.
The Results of Hot

Ductility Tests
In the hot ductility tests, specimen
1 (Tp = 1350C) ruptured without
Fig. 4 The fracture appearance of a ruptured specimen in hot ductility tests: A necking, and the peak force was
Macroscopic fracture appearance; B and C microscopic fracture appearance; D 16,000 N. Specimen 2 (Tp = 1250C)
chemical composition of eutectic microstructures in B and C obtained by EDX. did not rupture with a slight necking
of about 0.4 mm. The result shows
that the zero ductility temperature
consistent with the Laves phase in Evolution Behavior of the (ZDT) of FB2 steel is between 1250
CB2 steel reported by Kasl (Ref. 11). Laves Phase during the and 1350C.
Therefore, it can be speculated that The fracture appearance of speci-
the particles observed in virgin FB2
Welding Thermal Cycle men 1 presents a typical liquefied
steel were the Laves phase. The results of thermal simulation morphology, as shown in Fig. 4A. In
show the Laves phase in specimens ex- Fig. 4B, some microstructures exist on

WELDING RESEARCH
the fracture surface, indicated by black

arrows. The microstructures distribute
along grain boundaries or at triple
grain junctions, because the trace of
grain boundaries can be seen on the
microstructures, indicated by white ar-
rows in Fig. 4B.
The microstructures present a typi-
cal eutectic morphology, as shown in
Fig. 4C, with a similar chemical compo-
sition to that shown in Fig. 3. It can be
concluded the microstructures found
on the fracture appearance were the
same with those in thermal simulated
specimens shown in Fig. 2E and F.
Discussion
The Origin of the Laves Fig. 5 Equilibrium phase diagram of the eutectic constituent obtained by JMatPro.
Phase in FB2 Steel
In 9% Cr martensitic stainless Constitutional Liquation rich Nb(C, N) carbonitrides (Refs.
steels, the Laves phase usually occurs Resulting from the Eutectic 1416), Ti-rich TiC carbides, and the
after long-term, high-temperature ex- Laves phase (Refs. 17, 18).
Reaction between the Laves In the present study, results of the
posure, and it was found the Laves
phase nucleates at martensitic lath Phase and Austenite thermal simulation with different
boundaries or around M23C6 carbides, peak temperatures suggest that con-
coarsening at the expense of alloy The occurrence of eutectic mi- stitutional liquation of the Laves
atoms in the matrix or M23C6 (Refs. 7, crostructures strongly suggests a li- phase in virgin FB2 steel accounts for
8). Some researchers found the forma- quation phenomenon in specimens ex- the liquation phenomenon. The heat-
tion of the Laves phase at 650C need- periencing peak temperatures above ing rate of the welding thermal simula-
ed at least hundreds of hours (Ref. 7). 1250C (including 1250C), implying a tion was nonequilibrium, which
As to virgin FB2 steel, it was impossi- liquation crack tendency in the HAZ of caused rapid decomposition of the
ble for the Laves phase to form during FB2 steel during welding. The results Laves phase. This decomposition high-
tempering due to the too short time. of hot ductility tests further con- ly enriched the region adjacent to the
There is only one possibility left firmed the existence of liquation crack dissolving Laves particles in solutes
that the Laves phase formed in prior in FB2 steel at 1350C. such as Cr and Mo. The equilibrium
processing, such as casting and forg- A prerequisite for liquation crack in phase for this high-solute composition
ing. As mentioned in the introduction, the HAZ was the formation of discrete was a liquid that surrounded the dis-
a similar Laves phase was also found liquid regions within the solid metal solving Laves particles. The liquid re-
in virgin CB2 steel, a cast steel with experiencing enough high tempera- gion remained until the Laves particles
similar chemical composition to FB2. tures during welding. If this liquid ex- dissolved completely.
In virgin CB2 steel, sparse, relatively hibits a tendency to wet, and thereby It was noted that the Ac3 of FB2
large particles of the Laves phase (Fe, form a continuous or semicontinuous steel at a heating rate of 100C/s
Cr2)Mo are present in interdendritic thin film of liquid along grain bound- measured previously was about 960C,
areas (Ref. 12), indicating that the aries, and if sufficient strains are pres- so the matrix had all transformed into
Laves phase forms during the casting ent in this weld region, then inter- austenite at peak temperatures of
process. Considering that the FB2 granular separation will occur. The ori- thermal simulation. Therefore, the
specimens observed also went through gin of such liquation in the HAZ was constitutional liquation in the heating
the casting process, the Laves phase most often attributed to the constitu- process of thermal simulation resulted
was most likely formed in this process. tional liquation phenomenon, which from the eutectic reaction between the
The results of our experiment was originally proposed by Savage and Laves phase and austenite.
showed the Laves phase remained sta- coworkers (Ref. 13). This phenomenon In specimens experiencing a peak
ble at temperatures below 1200C, so involves a eutectic reaction between a temperature of 1250C, every eutectic
the forging process following casting secondary constituent phase and structure was separated, and the size
could not eliminate it. In forging, all the matrix, and mostly occurs in was similar to that of the Laves phase
the dendrites recrystallized, and large austenitic stainless steels such as in virgin FB2 steel, as shown in Fig.
Laves particles remained within the Alloy 718, A-286, GH150, and so on. 2AD. This phenomenon can be ex-
austenitic grains. In addition, it was During the past decades, HAZ liqua- plained by the poor flowing ability of
noted that the formation of the Laves tion in austenitic stainless steels con- liquid at 1250C. In the present work,
phase should be attributed to dendrit- taining Nb and Ti has been attributed the Laves phase remained stable at
ic segregation in the casting process. to the constitutional liquation of Nb- 1200C, and when the peak tempera-

WELDING RESEARCH
A B stituent is a new phase and another

type of eutectic reaction might occur
during cooling.
To clarify the type of the eutectic
constituent, thermodynamic software
JMatPro was employed to get all the
possible phases in equilibrium condi-
tion based on the chemical composi-
tion listed in Fig. 3. Although welding
is a nonequilibrium process, and the
results obtained by JMatPro were
speculative, they can provide some in-
formation for reference.
Fig. 6 The results of TEM analysis of the eutectic microstructures: A Bright field The equilibrium phase diagram of
image; B SAED results of the different areas in A. the eutectic constituent is shown in
Fig. 5. It was evident there are two ma-
ture arrived at 1250C, every separat- strength was not impaired. As a result, jor phases at room temperature; one is
ed particle of the Laves phase dis- the specimen exhibited some plasticity ferrite and the other is the Chi phase.
solved and formed some separated liq- at 1250C. In specimens experiencing The existence of ferrite in the eutectic
uid cells owing to the eutectic reaction peak temperatures of 1350C, some constituent can be excluded because
between the Laves phase and austen- grain boundaries were wet by the liq- ferrite is not corrosion resistant. So
ite (or the matrix). At this tempera- uid and lost strength. When the load the Chi phase is most likely the eutec-
ture, the mobility of the liquid was was applied, the areas losing grain tic constituent.
very limited, so every liquid cell stayed boundary strength acted as crack initi- The Chi phase is an intermetallic
where the Laves particle originally was ation, thereby intergranular fracture compound containing primarily Fe, Cr,
instead of flowing and merging to- occurred without any plasticity. and Mo. It is a body-centered-cubic
gether. In cooling, every separated liq- Owing to distribution characteris- phase (-Mn structure) with a lattice
uid cell transformed into a solid phase, tics of the Laves phase, it was men- parameter of a0 = 0.892 nm (Ref. 19).
as shown in Fig. 2C and D. While in tioned in the observation of Laves The Chi phase is often found in
specimens experiencing a peak tem- phase in virgin FB2 steel section, austenitic and ferritic stainless steels
perature of 1350C, the mobility of most of the grain boundary area re- containing Mo (Refs. 20, 21). Kautz
liquid was greatly promoted by the mained free of liquid to maintain and Gerlach have reported finding the
higher temperature, which means that some strength, so the specimen at Chi phase as a eutectic constituent in
the liquid could flow in long distances 1350C exhibited some load-bearing Type 316 stainless steel, which was
and combine together. capacity. heated to 1380C and then water
In addition, the growth of quenched (Ref. 22). Cieslak and Ritter
austenitic grains promoted the im- The Evolutionary Behavior of also found the Chi phase as a eutectic
pingement of grain boundaries with Liquid during Cooling constituent along solidification grain
the liquid regions, so most liquid dis- boundaries in CF-8M welds, and they
tributed along grain boundaries or at It has been mentioned in the section pointed out that the kinetics of the
triple grain junctions, as shown in Fig. titled evolution behavior of the Laves Chi phase formation are greatly en-
2E and F. phase during the welding thermal cy- hanced by the presence of Mo, but the
Based on the liquation mechanism cle, the eutectic microstructure ob- mechanism of eutectic reaction was
discussed, the results of hot ductility served by SEM in Fig. 2CF is just one not clarified in his work (Ref. 23). In
tests can be explained. In these, the of the eutectic constituents, and the Cieslak and Ritters research, the eu-
displacement load was applied to the other eutectic constituent in the inter- tectic Chi phase occurred along the hot
specimens at peak temperatures of vals might be etched. Both the mor- crack in welds (Ref. 23).
1250 and 1350C. phology and chemical composition of The chemical compositions of the
At 1250C, the limited mobility of the eutectic constituent were different Chi phase obtained by Cieslak (Ref.
liquid retarded wetting grain bound- from those of the Laves phase in virgin 23) and Weiss (Ref. 24) are the same
aries, so the grain boundaries FB2 steel, suggesting the eutectic con- as that obtained in the present work
to a large extent. All three chemical
compositions are summarized in Table
Table 2 Chemical Composition of the Chi Phase Obtained by Two Other Authors and 2. Based on morphology and chemical
in the Present Work (wt%) composition already discussed, it is
preliminarily speculated that the eu-
Material Fe Cr Mo Ni tectic constituent observed by SEM is
the Chi phase. The speculation is fur-
Cieslak (Ref. 23) CF8M austenitic stainless steel 45 26 20 4 ther supported by the results of TEM
Weiss (Ref. 24) 316 austenitic stainless steel 52 21 22 5
Eutectic constituent FB2 martensitic stainless steel 5154 2325 1824 0
analysis.
in the present work The TEM specimen shown in

WELDING RESEARCH
The divorced and symbiotic eutectic

is illustrated in Fig. 7D.
In the case of the specimen cooled
from 1350C, solute atoms diffused
adequately in the liquid because of
the higher temperature. At grain
boundaries, the liquid film was thin
and (Fe) precipitated from the liquid
film and merged with the matrix,
forming tail-like divorced eutectic,
which is labeled by dashed arrows in
A B C D Fig. 2E and F. The amount of liquid at
triple grain junctions was larger, so
(Fe) and the Chi phase could precipi-
Fig. 7 Schematic of the Laves phase evolution during welding, Tp = 1250C: A Before
heating; B the interface between the Laves phase and (Fe) melted first during heat tate alternatively, forming symbiotic
ing; C the central part of the Laves phase melted subsequently; D during cooling, eutectic, which is labeled by solid ar-
the Chi phase and austenite precipitated from the liquid. rows in Fig. 2E and F. The grain
boundaries surrounded by the eutec-
tic structures became ghost bound-
aries, of which the strength was im-
Fig. 6A was sampled by FIB, and in the Based on this analysis, the mor- paired and crack initiation would pre-
bright field image, the eutectic con- phology difference of eutectic mi- fer to take place at this site.
stituent observed by SEM can also be crostructures in Fig. 2CF can be ex-
seen clearly, indicated by white arrows. plained. As to the specimen experienc-
Because the specimen was not etched, ing a peak temperature of 1250C, it Conclusions
the other eutectic constituent in inter- was mentioned in the constitutional li-
vals can also be seen, indicated by quation resulting from the eutectic re- In the present work, constitutional
black arrows. The four SAED patterns action between the Laves phase and liquation resulting from the eutectic
in Fig. 6B labeled 14 correspond to austenite section, the interface be- reaction between the Laves phase and
the areas in Fig. 6A labeled by 14, tween the Laves particles and matrix (Fe) was found, suggesting a liqua-
respectively. dissolved first, as shown in Fig. 7B. tion crack tendency in FB2 steel dur-
The results of SAED indicate that The chemical composition of the ing welding. Then the origin and evo-
the eutectic constituent observed by liquid deviated from the eutectic com- lutionary behaviors of the Laves
SEM had a body-centered-cubic (BCC) position, biased toward austenite, be- phase in the welding thermal cycle
structure, consistent with the Chi cause the solute (Cr and Mo atoms) were analyzed. There are four conclu-
phase, and the lattice parameter of the was diluted by the matrix. Subse- sions obtained as follows:
eutectic constituent was 0.906 nm quently, the rest of the Laves particles 1) The large particles of the Laves
(see the appendix for the calculating dissolved, as shown in Fig. 7C. phase in virgin FB2 steel formed in
process), close to that of the Chi Because there was no direct contact the casting process, which was attrib-
phase. The other eutectic constituent between the central part of the Laves uted to dendritic segregation.
also had a BCC structure, and the lat- phase and matrix, and because the 2) The fast heating rate of welding
tice parameter was 0.271 nm. mobility of Cr and Mo atoms was lim- led to constitutional liquation in ar-
Its acknowledged that martensite ited, the solute in the central part eas where the temperature was above
has a body-centered-tetragonal (BCT) could not be diluted adequately like 1250C (including 1250C), and the
structure, of which the lattice parame- that at the interface. Thereby, the eutectic reaction between the Laves
ter a is equal to b, but is not equal to chemical composition of liquid in the phase and (Fe) should account for
c because of the distortion during central part was biased toward the the constitutional liquation.
martensitic transformation. However, Laves phase enriched in Mo and Cr. 3) The areas where constitutional li-
the lattice parameter a is almost During cooling, austenite precipitated quation occurred would act as crack ini-
equal to c, so the diffraction patterns from liquid at the interface as the pre- tiation when some load was present at
of martensite are almost the same as dominant phase and merged with the 1350C, leading to intergranular frac-
those of BCC, such as ferrite. matrix, leaving a very small amount of ture. At 1250C, the limited mobility re-
In addition, the lattice parameter of Chi phase alone, which formed di- tarded liquid wetting grain boundaries,
martensite was almost equal to that of vorced eutectic. so hot plasticity was present.
ferrite at 0.2866 nm. Based on the The divorced eutectic is indicated 4) The Chi phase was found as a
structure and lattice parameter, the by dashed arrows in Fig. 2C and D. eutectic constituent during cooling.
other eutectic constituent can be pre- While in the central part, the amount The mobility of atoms and liquid in-
liminarily judged as martensite. Con- of liquid was larger than that at the influenced the final morphology of eu-
sidering that martensite was trans- terface, so the Chi phase and (Fe) tectic microstructures, and divorced
formed from austenite, the eutectic re- could precipitate alternatively, form- eutectic as well as symbiotic eutectic
action in cooling was most likely to be ing net-like symbiotic eutectic, labeled were observed in specimens experi-
L Chi + (Fe). by solid arrows in Fig. 2C and D. encing different peak temperatures.

WELDING RESEARCH
ence and Engineering A 527: 75057509. 21. Song, Y., McPherson, N. A., and
Acknowledgments
8. Xu, Y., Wang, M., Wang, Y., Gu, T., Baker, T. N. 1996. The effect of welding
Chen, L., Zhou, X., et al. 2015. Study on process on the Chi phase precipitation in
The authors would like to thank the nucleation and growth of Laves phase as-welded 317L weld metals. ISIJ Interna-
Senior Engineers R. Wang and W. Yang in a 10% Cr martensite ferritic steel after tional 36: 13921396.
for their guidance in SEM and EDX long-term aging. Journal of Alloy Com- 22. Kautz, H. R., and Gerlach, H. 1968.
analysis. Dr. Guo at the University of pounds 621: 9398. Mechanical and corrosion-resistance
Science and Technology Beijing is also 9. Shi, R., and Liu, Z. 2012. Growth be- Properties of unstabilized fully austenitic
haviour of Laves phase of -ferrite in P92 steels used in reactors and steam-boiler
thanked for her help in thermal simu-
steels. Iron and Steel 47: 5559. plants. Arch Eisenhuttenw. 39: 151158.
lation work. 10. Dimmler, G., Weinert, P., 23. Cieslak, M. J., Ritter, A. M., and
Kozeschnik, E., and Cerjak, H. 2003. Savage, W. F. 1984. Chi-phase formation
Quantification of the Laves phase in ad- during solidification and cooling of CF-8
vanced 912% Cr steels using a standard M weld metal. Welding Journal 63(4): 133.
References SEM. Mater Charact. 51: 341352. 24. Weiss, B., and Stickler, R. 1972.
11. Kasl, J., and Mikmekov, Jandov Phase instabilities during high tempera-
D. 2014. SEM, TEM and SLEEM (scanning ture exposure of 316 austenitic stainless
1. Blaes, N., Donth, B., and Bokelmann,
low energy electron microscopy) of CB2 steel. Metallurgical Transactions 3:
D. 2007. High chromium steel forgings for
steel after creep testing. IOP Conference 851866.
steam turbines at elevated temperatures.
Series: Materials Science and Engineering.
Energy Materials 2: 207213.
12. Jandov, D., Kasl, J., and Chvos-
2. Lu, F., Liu, P., Ji, H., Ding, Y., Xu, X.,
tov, E. 2014. Microstructure of CB2 steel Appendix
and Gao, Y. 2014. Dramatically enhanced
before and after long-term creep tests.
impact toughness in welded 10% Cr rotor
Materials Science Forum: 782.
steel by high temperature post-weld heat
13. Pepe, J. J., and Savage, W. F. 1967.
treatment. Mater Charact. 92: 149158. From Fig. 6B (number 1), we can
Effects of constitutional liquation in 18Ni
3. Di Gianfrancesco, A., Cipolla, L., get the interplanar distance in the
maraging steel weldments. Welding Jour-
Paura, M., Vipraio, S. T., Venditti, D., Neri, three directions. Now, as an example,
nal 46(9): 411-s to 422-s.
S., et al. The role of boron in long term take the interplanar distance of (1,
14. Lee, C. H., and Lundin, C. D. 1998.
stability of a CrMoCOB (FB2) steel for ro-
tor application. Advances in materials
Relationship between hot ductility behav- 2, 1) d(1, 2,1).
ior and microstructural changes in TP347 It is easy to get the length from the
technology for fossil power plants. Pro-
stainless steel. Welding Journal 77(1): 29-s central spot to this spot (1, 2, 1)
ceedings from the Sixth International Con-
to 37-s. R(1, 2, 1) = 2.7034 1/nm on the recipro-
ference, August 31September 3, 2010,
15. Thompson, R. G., and Genculu, S. cal space.
Santa Fe, N.Mex. ASM International, p.
1983. Microstructural evolution in the
342.
HAZ of Inconel 718 and correlation with
Then the interplanar distance
4. Nakano, M., Kawano, K., and Mika- d(1, 2, 1) = 1/R(1, 2, 1) = 0.3699 nm.
the hot ductility test. Welding Journal
mi, M. Manufacturing of trial rotor forging The relationship between the lat-
62(12): 337-s to 345-s.
of 9% Cr steel containing Co and B (X13Cr- tice parameter a0 and interplanar dis-
16. Andersson, J., Sjberg, G. P.,
MoCoVNbNB9-2-1) for ultrasupercritical tance d satisfies the equation below
Viskari, L., and Chaturvedi, M. C. 2012.
steam turbines. Advances in materials
Effect of solution heat treatments on su-
technology for fossil power plants. Proceed-
ings from the Seventh International Confer-
peralloys. Part 1 Alloy 718. Mater. Sci. d = a0 / h2 + k 2 + l 2
Tech-Lond. 28: 609619.
ence, October 2225, 2013, Waikoloa,
17. Brooks, J. A. 1974. Effect of alloy where (h, k, l) is the corresponding in-
Hawaii. ASM International, p. 321.
modifications on HAZ cracking of A-286 dices of the crystal face.
5. Shige, T., Magoshi, R., Itou, S.,
stainless steel. Welding Journal 53(11):
Ichimura, T., and Kondou, Y. 2001. Devel-
517-s to 523-s.
In this way, it is easy to get the lat-
opment of large-capacity, highly efficient tice parameter a0.
18. Baeslack, W. A., Lata, W. P., and
welded rotor for steam turbines. Mit-
West, S. L. 1988. A study of heat-affected
subishi Heavy Industries Technical Review
38: 611.
zone and weld metal liquation cracking in a0 = d h2 + k 2 + l 2
Alloy 903. Welding Journal 67(4): 77-s to
6. Kern, T. U., Almstedt, H., Thiemann,
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87-s. = 0.3699 ( = 1)2 + 22 +( = 1)2
19. Kasper, J. S. 1954. The ordering of
Role of Rotor Welding Design in Meeting Fu- = 0.906 nm
atoms in the Chi-phase of the iron-
ture Market Requirements. ASME, pp.
chromium-molybdenum system. Acta In the same way, we can get the lat-
V5BV25B.
Metallurgica. 2: 456461. tice parameter in Fig. 6B (numbers 2
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20. Okafor, I., and Carlson, O. N. 1978.
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through 4).
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steel X12CrMoWVNbN10-1-1 during
Transactions A 9: 16511657.
short-term creep exposure. Materials Sci-

Xu Supplement 201501.qxp_Layout 1 6/9/16 4:54 PM Page 264
WELDING RESEARCH
UltrasonicInduced Rising and Wetting of

a SnZn Filler in an Aluminum Joint
The feasibility of ultrasonicinduced solder capillary rise above the bath level
was demonstrated and the underlying mechanism was proposed
BY Z. XU, L. MA, J. YANG, J. ZHANG, AND J. YAN
duced when power ultrasonic is intro-

ABSTRACT duced into the molten solder. This
process disrupts and disperses the ox-
The filling and wetting of a SnZn solder in a vertical aluminum joint clearance under
ide layer of a metal surface and allows
ultrasonic agitation was investigated and the mechanism underlying ultrasonicinduced
capillary rise was explored. The liquid solder was pumped into the capillary and rose the molten solder to wet the clean
above the solder bath level to a constant height after 16 s of ultrasonication, even metal surface. The wetting mechanism
though the base material was not wetted. The surface oxides of the base material were in ultrasonic soldering has been firmly
gradually removed from the bottom of the clearance after prolonging the ultrasonic ex established and gained widespread ac-
posure time. This phenomenon resulted in the formation of a metallurgical bond ceptance (Ref. 12). However, capillary
between the solder and the base material. Solder rise increased roughly linearly with the filling, another important aspect of ul-
increase in applied ultrasonic amplitude but decreased with the increase in joint trasonic soldering, has not been well
clearance and heating temperature. A physical model comprising water and a glass capil documented, and studies on this issue
lary tube was used to examine the acoustic pressure inside and outside of the capillary. still provide inconsistent results (Refs.
Results showed the ultrasonicinduced capillary rise may be attributed to the
1317).
considerable drop in the acoustic pressure at the entrance of the capillary and the
decline in the acoustic pressure gradient along the capillary. Fuchs (Ref. 14) graphically illustrat-
ed the interaction of solder and capil-
lary with flux or ultrasonic energy. He
KEYWORDS stated that flux chemically removes
oxides and functions as a wetting
Ultrasonic Soldering Capillary Rise Wetting Oxide Film Acoustic Attenuation agent to reduce surface tension and
promote the flow of solder alloy. As a
result, the solder climbs in the capil-
Introduction alloys (Ref. 7), sapphires (Ref. 8), Ti/ lary sometimes to a height that ex-
stainless steels (Ref. 9), and Cu/ceram- ceeds that of the surrounding solder
Ultrasonic soldering/brazing is a ics (Ref. 10), which are extremely diffi- through wicking. Ultrasonic energy
fluxless method of joining difficult-to- cult to wet and join. could effectively remove surface oxides
join materials, such as aluminum, Ultrasonic soldering/brazing stud- but cannot duplicate the wetting agent
magnesium, and titanium (Refs. 13). ies have primarily focused on engi- effect of flux to allow the solder to fill
This technique has attracted consider- neering applications (Refs. 1, 2). These and wet to a height above the level of
able attention since its development in investigations have been generally the surrounding solder.
the 1940s and was used in the large- aimed at the engineering or commer- Vianco (Ref. 15) obtained similar re-
scale production of joining aluminum cialization of a particular procedure or sults in his study on the wetting and
heat exchangers during the 1970s product. Despite being considerably capillary action between two parallel
(Ref. 1). Interest in ultrasonic solder- limited, fundamental investigations of sheets of copper that were vertically
ing/brazing has resurged in the last solder wetting and joint formation are dipped in an ultrasonic-activated Sn-Pb
few years because of the increasing significant to guarantee or improve solder bath. A small volume of molten
need for powerful and reliable meth- joint reliability. Noltingk and Neppiras solder penetrated into the base of the
ods to join new or dissimilar materials, (Ref. 11) first discovered that cavita- joint clearance because of the hydrostat-
such as metal matrix composites (Refs. tion is a fundamental mechanism in ic pressure during immersion. Cavita-
4, 5), ceramics (Ref. 6), amorphous ultrasonic soldering. Cavitation is in- tion in the penetrated solder removed
Z. XU (xuzw@hit.edu.cn), L. MA, J. ZHANG, and J. YAN are with the State Key Laboratory of Advanced Welding and Joining, Harbin Institute of
Technology, Harbin, China. J. YANG is with the Institute of Process Equipment and Control Engineering, Zhejiang University of Technology,
Hangzhou, China.

WELDING RESEARCH
Fig. 1 Schematic of the ultrasonicassisted capillary filling.
Fig. 2 Acoustic pressure test in the ultrasonicactivated water

rise.
Fig. 3 Capillary rise of the filler metal without exposure to

ultrasonic vibration.
the surface oxide films of the clearance. between the solder

This process allows the solder to wet and the inside tube
and protrude progressively toward the diameter above the Fig. 4 Variation in the vertical filling height with ultrasonic
bath surface. However, rising of the sol- immersion depth. exposure time.
der to the bath level causes the hydro- We recently ex-
static pressure to disappear and leads to amined solder capil- surface tension act during ultrasonica-
the lack of a prefilled solder to support lary in the the level joint clearance un- tion. This phenomenon is different
oxide removal (cavitation). Therefore, der ultrasonic activation (Refs. 16 from that in flux soldering, in which
further wetting and capillary rise could 18). The use of a solder droplet instead solder filling depends on wetting (Ref.
not occur. Vianco (Ref. 15) also suggest- of a solder pool eliminated the effect 19). However, the possible mecha-
ed that the substrate should be im- of hydrostatic pressure created after nisms underlying ultrasonic-induced
mersed into the solder bath for ultra- sample immersion on the capillary fill- capillary rise remain ambiguous.
sonic soldering to produce a joint. ing. The solder droplet located at one Accordingly, the present study inves-
By contrast, Antonevich (Ref. 13) end of the clearance readily filled an tigated the capillary rise of liquid solder
reported that ultrasonic-agitated zinc oxide-covered joint clearance under ul- in a vertical joint under ultrasonic acti-
solder fills the vertical aluminum cap- trasonic activation. Thus, either in vation and identified the influencing
illary to a maximum height of 2 mm vertical or horizontal joints (Refs. 13, factors of this process to acquire in-
above the normal liquid level at a spe- 1618), the solder filled the capillary depth information about the ultrasonic-
cific immersion depth. However, no al- before wetting or alloying the capillary induced capillary filling of liquid solder.
loying or metallurgical bonding occurs wall, suggesting that forces other than Considering the difficulty of observing
Table 1 Chemical Compositions (wt%) of 2024 Al
Alloy Element
Mg Cu Si Fe Mn Ag Cr Ni Al Zn
2024 Al 1.21.8 3.84.9 <0.5 <0.5 0.30.9 <0.1 Bal.

WELDING RESEARCH
Fig. 6 Microstructure of the wetting interface after 4 s of

ultrasonic exposure.
C with a 500-grade was transmitted to the solder bath by

emery paper prior to coupling the sonotrode to the solder
ultrasonic cleaning. container at 0.2 MPa. The sonotrode
A capillary parallel was operated at 20 kHz, with ampli-
to the long surface tudes of 1022 m on the top surface.
of the coupon was The dwell time of the ultrasonic vibra-
D prepared in each tion ranged from 4 to 24 s, and the
coupon through heating temperature ranged from 250
electric-sparking to 350C. The soldering temperature of
wire-cutting. The Sn-9Zn is generally about 250C when
capillaries possessed using flux. The viscosity of the liquid
sizes ranging from solder would increase without flux since
Fig. 5 Overall appearance of the filler metal in the clearance
under different ultrasonic exposure times: A 4 s; B 8 s; C 300 to 800 m and a the solder is easily oxidized and covered
16 s; D 24 s. constant length of by an oxide film in air. Heating temper-
30 mm. A Sn-9Zn al- atures higher than 250C were used in
loy was used as the this work. Moreover, examination of
capillary effects in a liquid metal sys- filler metal. This alloy is a highly po- the effect of a wide range of heating
tem, we conducted a simulation experi- tential lead-free solder that presents a temperature on soldering is beneficial
ment involving water capillary rise in a melting point (198C) close to that of for fundamental research. Each capillary
glass tube under ultrasonication. The a Sn-37Pb solder (183C) but exhibits was cut after the filling test, and the fill-
driving force for nonwetting filling and superior shear strength and fatigue re- ing height was measured. The mi-
the relationship between wetting (i.e., sistance. The base material and filler crostructure of the filler/base metal in-
surface oxide removal) and ultrasonic metal were ultrasonically cleaned in terface was observed under an optical
capillarity were determined. acetone for 30 min before the capillary microscope and a scanning electron mi-
rise test. croscope equipped with an energy-dis-
Experimental Procedures The experimental conditions are persive x-ray spectrometer. Specimens
summarized in Table 2. for microstructural analysis were pre-
An Al-Cu-Mg alloy (2024 Al-T3) was Figure 1 shows the schematic of ul- pared using conventional metallograph-
used as the base material in this study. trasonic-assisted capillary filling. The ic techniques.
The chemical composition of the base specimen was vertically fixed and A glass tube with a length of 325
material is given in Table 1. Rectangle dipped into a solder bath (depth, 2 mm and dual inner diameters/capillar-
coupons with a dimension of 40 10 mm). The solder was held in a titanium ies was used for simulation. The top
mm and a thickness of 6 mm were ma- alloy container and heated by a resist- capillary was 1.5 mm in diameter and 8
chined, and their surfaces were ground ance heating system. Ultrasonic energy mm in length, followed by a capillary
with a diameter of 5 mm to the end.
The glass tube was immersed gradually
Table 2 Experimental Test Matrix and vertically into the deionized water
activated in a normal ultrasonic clean-
Description Value ing tank, and the water rise in the capil-
lary was observed. The maximum pow-
Coupon size 40 mm 10 mm 6 mm er of the ultrasonic cleaning machine
Capillary size (300800 m) 30 mm was 99 W. The deionized water bath
Sn9Zn melting point 198C
was 50 mm deep. In particular, an
Solder bath depth 2 mm
Sonotrode pressure 0.2 MPa acoustic pressure gauge with a cus-
Ultrasonic frequency 20 kHz tomized probe was used to test the
Ultrasonic amplitude 1022 m acoustic intensity inside and outside of
Ultrasonic vibration time 424 s the capillary. The acoustic-intensity
Heating temperature 250350C measuring device was based on the di-
rect piezoelectric effect of the piezo-

WELDING RESEARCH
creased with ultrasonic exposure time

A and reached a relatively constant level
when the ultrasonic exposure time ex-
ceeded 16 s.
Figure 5 reveals the overall appear-
ance of the filler metal in the clearance
under different ultrasonic exposure
times. Except at the capillary bottom,
the filler metal was not compact and
remained unbonded to the base metals
when the ultrasonic exposure time was
4 s Fig. 5A. The filler metal ap-
peared to be injected from the capil-
B
lary bottom in this case. The filler
metal in the clearance was compact
and did not contain any void or porosi-
ty when the ultrasonic exposure time
exceeded 4 s.
Whether or not the solder wet the
base metal is difficult to detect in Fig. 5.
Detailed examinations of the wetting
interface between the solder and the
base metal are illustrated in Figs. 68.
After 4 s of ultrasonic exposure, poor
C wetting was observed along the sol-
der/base metal interfaces; this phenom-
enon involved a number of small cavi-
ties and oxide inclusions Fig. 6. The
wetting of the solder to the base metal
at the bottom of the capillary was
markedly improved when the ultrasonic
exposure time was prolonged to 8 s.
The solder/base metal interfaces
were free of oxide inclusions and con-
tained nearly negligible cavities Fig.
Fig. 7 Microstructure of the wetting interface after 8 s of ultrasonic exposure: A clear
7A. In fact, only one suspected cavity
ance bottom; B backscattered image of the clearance bottom; C solder head. of less than 50 m was observed at the
wetting interfaces (inset of Fig. 1). The
backscattered image of the clearance
electric ceramic. Piezoelectric ceramics cracks appeared between the solder bottom shows that aluminum den-
were installed in a stainless steel probe and the base material, demonstrating drites nucleated at the wetting inter-
with a diameter of 4 mm, which was a nonwetting status between them. faces and grew into the solder Fig.
smaller than the inner diameter of the When the capillary was immersed in 7B. This finding indicates that wetting
glass tube applied. the molten solder, the solder rise was occurred between the solder and the
The acoustic pressure test in the ul- depressed because the surface oxides base metal. However, the diffusion of
trasonic-activated water rise process is of the base material hindered the wet- solder into the aluminum substrate
illustrated in Fig. 2. ting and the capillary force did not was limited. This result can be inferred
work. However, solder rise still oc- to the Sn-Al and Zn-Al phase diagrams
Results curred under this condition. In fact, (Refs. 10, 18) showing that the solder
the rise resulted from a competition constituents (i.e., elemental Sn and
between dewetting effect and hydro- Zn) do not react with the aluminum
Characteristics of the static pressure. substrate to form intermetallic com-
UltrasonicInduced Figure 4 shows the effective capil- pounds and that the solubility of Sn in
Solder Rise lary rise of the filler metal as a func- pure Al is very low from ambient tem-
tion of dwell time for the 6-mm-thick perature to 300C. In stark contrast to
Figure 3 illustrates the capillary rise specimen exposed to 20 m of ultra- the bottom of the capillary, poor wet-
of the filler metal without exposure to sonic vibration. The clearance value ting was still observed at the
ultrasonic vibration. Limited solder was 300 m, and the heating tempera- solder/base metal interfaces of the sol-
rise was observed in the capillary; ture was 300C. In all cases, the filler der head Fig. 7C. Numerous oxide
specifically, it was markedly lower metal reached a level that exceeded inclusions and pores were present at
than the solder bath level. Evident that of the bath. The filling height in- these zones, preventing metal-metal

WELDING RESEARCH
A A
Fig. 8 Microstructure of the wetting interface after 16 s of ultrasonic

exposure: A clearance bottom; B solder head.
Fig. 9 Microstructure of the wetting interface after

contact between the solder and the this region. Nevertheless, 24 s of ultrasonic exposure: A, C solder head;
base metal. the several microcracks and B the middle.
The solder rise reached a maximum limited aluminum den-
height when the ultrasonic exposure drites that grew from the ly, with the ultrasonic amplitude ap-
time was prolonged to 16 s. Compara- solder/base metal interfaces indicated plied. The solder rise was 4 mm when
tive results between Figs. 7 and 8 that no alloying or metallurgical bond- the input ultrasonic was approximate-
show that solder wetting to the base ing occurred between the solder and the ly 11 m, which is only 2 mm over the
metal was markedly improved not only base metal. solder pool level. The level reached 8
at the clearance bottom but also at the The above observations illustrate mm when the ultrasonic input was in-
solder head under prolonged ultrason- several distinctive aspects of solder rise creased to 20 m.
ic exposure time. The amount of cavity under ultrasonic agitation compared Figure 11 shows the variation in
and oxide inclusion was markedly re- with those found in previous ultrasonic solder filling height with the joint
duced at the wetting interfaces of the soldering applications (Refs. 1315) or clearance value. Solder rise was fa-
solder head with prolonged ultrasonic in the conventional soldering process vored when the joint clearance was
exposure time. (Ref. 19). First, liquid solder filling can less than 500 m and became negligi-
Further extension of the ultrasonic exceed the normal solder level and reach ble when the joint clearance exceeded
exposure time did not enhance solder a stable height after 16 s of ultrasonica- 700 m. Therefore, the solder filling
rise but improved the wetting between tion. Second, filling is not dependent on height decreased with increasing joint
the solder and the base metal Fig. 9. the removal of the surface oxides of the clearance. This decrease was more sig-
On the one hand, most oxide inclusions base metal; that is, the liquid solder ris- nificant for capillaries with diameters
were removed from the wetting inter- es between the two layers of the surface lower than 500 m.
faces, and the solder presented a close oxide regardless of the absence of simul- Figure 12 illustrates the variation
contact with the base metal at the sol- taneous wetting. In addition, the sur- in solder filling height with heating
der head Fig. 9A. On the other hand, face oxides of the base metal are gradu- temperature. In the range of 250
the interaction between the solder and ally removed from the clearance bottom 350C, the solder increased to a lower
the base metal became more intense ei- to the solder head with prolonged ultra- level at an elevated temperature.
ther at the bottom or in the middle of sonic agitation time, and metallurgical
the clearance, as evidenced by the in- bonding is formed between the solder
creased number of aluminum dendrites and the base metal.
Discussion
being transferred into the solder Fig.
9B. However, a focus on the filling front Influence Factor of Driving Force of Sonocapillarity
revealed that an approximately 500-m- UltrasonicInduced Solder Rise
long solder exhibited poor wetting to In addition to the ultrasonic solder-
the base metal Fig. 9C. No obvious Figure 10 shows the effective capil- ing system, a similar abnormal ultra-
oxidation occurred at the wetting inter- lary rise of the solder as a function of sonic-induced capillary filling has also
faces, and most of the solder shared an ultrasonic intensity. The filling height been observed in several other fields,
intimate contact with the base metal in of the solder increased, roughly linear- and several hypotheses in terms of

WELDING RESEARCH
Fig. 10 Variation in solder filling height with ultrasonic Fig. 11 Variation in solder filling height with joint clearance
amplitude. value.
Fig. 12 Variation in solder filling height with heating tempera Fig. 13 Acoustic pressure in the water outside and inside the
ture. capillary.
sonocapillarity have been formulated cavitation area. This finding is in con- channel followed by surface acoustic
(Refs. 13, 2023). trast to the observation that the capil- wave-assisted coalescence could lead
Lobova (Ref. 20) found the use of lary liquid nonsignificantly increases to a net fluid movement.
high-intensity ultrasound, which ex- when the ultrasonic pressure is below From the hydrodynamic point of
ceeds the cavitation threshold, facili- the cavitation threshold. view, a pressure difference/gradient is
tates the infiltration of the vertically Hu (Ref. 22) experimentally con- a fundamental factor causing fluid
placed quartz capillary with a poorly firmed the transportation of water flow. In the present study, the liquid
wetting Ga-In melt (its contact angle through a bundle of metal wires and solder flowed from the bath into the
on quartz in air at 6070C is 85 its dependence on ultrasonic vibration clearance and increased above the bath
5C) to a height of 0.838 mm. This parameters. However, he inferred that level. A pressure deviation may have
infiltration is due to a sharp increase acoustic cavitation is unnecessary for existed between the solder bath and
in liquid pressure at the capillary base. ultrasonic capillary action and argued the solder in the clearance because the
Antonevich (Ref. 13) and Malykh that ultrasound may weaken the cohe- solder rise in the capillary under ultra-
(Ref. 21) attributed the sonocapillary sive force among liquid molecules. sonication is nearly independent of its
effect to ultrasonic cavitation at the Thus, the adsorption force between wettability to the aluminum substrate
end of the capillary. The researchers the capillary tube and the liquid may Figs. 59. However, measuring the
observed that the height of the liquid become larger than the cohesive force, pressure of the liquid solder outside
rise is a power more than that result- thereby enhancing capillary action. and inside the clearance is impractical.
ing from the surface tension when a Cecchini (Ref. 23) demonstrated Thus, we used a sonocapillary system
capillary end is located in a developed that atomization within the fluidic requiring deionized water and a glass

WELDING RESEARCH
Fig. 15 Variation in acoustic attenuation coefficient with

the capillary diameter d for the solder Sn9Zn.
Only a small part the dynamic viscosity and density of

of the ultrasonic the liquid, respectively (Refs. 24, 25).
waves were trans- Equation 2 shows that the coeffi-
mitted into and cient of acoustic attenuation is propor-
propagated in the tional to the square root of liquid vis-
Fig. 14 Model for the propagation of ultrasonic waves in the capillary by the cosity and acoustic frequency, and in-
capillary.
prefilled liquid versely proportional to the diameter of
(this liquid fills the capillary. These characteristics in-
capillary tube Fig. 2. The capillary into the capillary under the hydrostat- dicate that a higher frequency and
top was located 13 mm away from the ic pressure). The propagation of ultra- smaller capillary size correspond to an
bath bottom. The water in the capil- sonic waves in the capillary induced acoustic energy with a higher dissipa-
lary rose at an observable stable rate liquid flow. The viscous resistance of tion ratio. Thus, immersing a capillary
and reached a maximum height of 60 the liquid itself and the friction forces with a diameter of hundreds of mi-
mm above the normal bath level under of the liquid on the capillary wall pro- crometers in an ultrasonically agitated
ultrasonication. By contrast, the water moted the gradual dissipation of ultra- liquid decreases the acoustic energy
increased extremely slowly, and only 2 sonic energy through conversion into from the outside to the inside of the
mm of a water head was observed in heat energy, which led to ultrasonic at- capillary and leads to the formation of
the absence of ultrasonication. tenuation. The propagation of acoustic a decreasing gradient of acoustic ener-
Acoustic pressure in water outside waves in a capillary can be expressed gy along the capillary. In consequence,
and inside the capillary was then as follows: capillary rise of the liquid occurs to
measured by using an acoustic pres- compensate for this acoustic energy
sure meter, and the results are illus- difference (as acoustic pressure differ-
trated in Fig. 13. The data exhibited x ence) regardless of the wetting status
variance to a certain extent. However, P = P0e e j(tkx ) ( 1) of the liquid to the capillary material.
the acoustic pressure from the outside In other words, the liquid is ultrasoni-
to the inside of the capillary consider- cally pumped into the capillary with-
ably declined. At the same time, the where P is the acoustic pressure at a out the driving force of surface
acoustic pressure in the capillary de- traveling distance x in the capillary, P0 tension.
creased with increased capillary is the initial acoustic pressure at the When a capillary end is located in a
height. These results indicate that the entrance of the capillary, is the an- developed cavitation zone, the capil-
distinct capillary rise of liquid under gular velocity, k is the wave number in lary rise would be considerably higher
ultrasonic agitation may be attributed the capillary, and is the attenuation than that in the noncavitation zone
to the decline in acoustic pressure gra- coefficient. can be expressed as because of the great acoustic pressure
dient from the entrance of the capil- difference between the outside and the
lary to the capillary surface. inside of the capillary. Previous studies
1
For a glass tube located in an ultra- = (2) (Refs. 13, 20, 21) have shown that a
sonically agitated liquid bath (Fig. 14), dC 2 sharp increase in liquid pressure at the
most of the ultrasonic waves were re- base of a capillary, which manifests in
flected by the end of the tube when where d is the capillary diameter, C is the presence of cavitation bubbles, is
travelling to liquid/tube interfaces. the acoustic velocity, and and are unilaterally responsible for nonwet-

WELDING RESEARCH
ting capillary rise. However, the variation in joint clearance. Decreasing trasonication was investigated, and
acoustic propagation characteristics the joint clearance not only decreases the following conclusions could be
(i.e., acoustic attenuation) in the capil- the volume of the ultrasonic energy drawn.
lary should also be considered because transmitting into the capillary but also 1. Filling of liquid solder in a verti-
both of these aspects contribute to the accelerates the dissipation of the ultra- cal joint above the normal solder level
capillary rise of the liquid. To calculate sonic waves inside. As depicted in was realized under ultrasonic agitation
the height and speed of the capillary Equation 2, the acoustic attenuation regardless of the presence of oxide lay-
rise of the liquid, we should resolve a coefficient is mainly dependent on ers on the surface of the base material.
hydrodynamic equation of the liquid the diameter of the capillary for a giv- Surface oxides were gradually removed
movement with the integral acoustic en ultrasonic system. Figure 15 shows from the clearance bottom to the sol-
pressure from the cutoff point to the the variation in acoustic attenuation der head by prolonging ultrasonic agi-
capillary surface. coefficient with capillary diameter d tation time, which resulted in metal-
On the basis of the above analysis, for the Sn-9Zn solder. increases sig- lurgical bonding between the solder
ultrasonically induced capillarity is not nificantly when d is reduced from 500 and the base material.
wetting based but rather significantly m to 0. By contrast, presents an ex- 2. The mechanism for the ultrasoni-
dependent on the acoustic pressures at tremely small value and changes mini- cally induced capillary rise of liquid
the cutoff of the capillary P0 and in the mally with the variation in d when d was proposed. The propagation char-
capillary P. P0 is generally a function of exceeds 500 m. Therefore, the acteristics of acoustics in the capillary
the input acoustic power, the acoustic acoustic pressure difference in the liq- significantly decreased the acoustic
velocity in the liquid, and the location uid outside and inside the capillary, as pressure at the entrance of the capil-
of the capillary end. P is illustrated in well as the acoustic gradient along the lary and the acoustic pressure gradient
Equations 1 and 2. Considering these capillary, is substantially augmented along the capillary. This phenomenon
conditions, we can easily understand when the capillary is sufficiently small. was basically responsible for the non-
the natures of the abnormal capillary In other words, the driving force of traditional capillary rise of the liquid
phenomena occurring in ultrasonically solder rise is increased in the capillary under ultrasonic agitation.
agitated water or liquid metal systems with a diameter under a critical value. 3. Solder rise increased roughly lin-
mentioned in Refs. 13, 2023. Combining Figs. 11 and 15, we con- early with the applied ultrasonic am-
clude that the critical capillary diame- plitude and decreased with increased
Effect of Soldering Variables ter in the current study is 500 m. In joint clearance and heating tempera-
on the Solder Rise addition, smaller clearance contains ture. The acoustic pressure at the en-
less liquid to be driven, resulting in a trance of the capillary and the acoustic
A high ultrasonic amplitude decrease in driving resistance, which pressure gradient along the capillary
markedly improves the solder rise. also contributes to the enhancement depended on ultrasonic intensity and
The mentioned ultrasonic amplitudes of solder rise when the capillary di- joint clearance. The process by which
were those on the top surface of mension is reduced. heating temperature influences the
the sonotrode. The vibration of the The effect of heating temperature propagation characteristics of ultra-
sonotrode was transmitted through on solder rise is apparently complex. sonic waves in the solder warrants fur-
the titanium plate to the bottom of The physical properties of the solder, ther investigation.
the vessel and finally injected into the the base material, and the vessel vary
solder bath. That is, the vibrating bot- with the temperature. These varia-
tions consequently influence the prop- Acknowledgments
tom surface of the vessel served as the
agitator for the solder bath. agation characteristics of the ultrason-
Our previous study (Ref. 26) re- ic waves in the system. For example, This project is supported by the Na-
vealed that the surface vibration of a temperature elevation normally re- tional Natural Science Foundation of
solid plate agitated by a sonotrode fol- duces the solder viscosity and density, China (Grant No. 50905044), Postdoc-
lows a linear relationship with the in- which strengthens the cavitation ef- toral Science-Research Developmental
put amplitude. Thus, the input energy fect in the solder bath by lowering the Foundation of Heilongjiang Province
to the solder bath increases with in- cavitation threshold. However, this (Grant No. LBH-Q12075), and Funda-
creasing sonotrode vibration, resulting condition also declines the elastic mental Research Funds for the Central
in a significant elevation of the modulus of the vessel and thus re- Universities (Grant No. HIT. NSRIF.
acoustic pressure level of the solder. duces the ultrasonic energy transmit- 201129).
Given that the ultrasound incident ted to the solder bath. To date, clarify-
into the capillary would be dissipated, ing which factor behaves dominantly
References
the difference in acoustic pressure be- during ultrasonication remains chal-
tween the outside and the inside of lenging, and further investigation is
the capillary is enlarged when the necessary.
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Solder rise is highly sensitive to the in a vertical joint clearance under ultrasonic soldering. Welding Journal 79(9):

WELDING RESEARCH
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Cover JULY 2016.

qxp_4/06 Cover 6/8/16 1:17 PM Page C1

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July 2016 Volume 95 Number 7 CONTENTS

38 Sunny Economics: Using Solar Power to Save Money

46 International Thermal Spray Association Holds Its

56 Thermal Spray The Misunderstood Process

WELDING RESEARCH SUPPLEMENT

248s Characterization of Constitutive Behavior of

JULY 2016 / WELDING JOURNAL 3

M. Skiles (Dist. 9), Consultant D. Marquard, IBEDA Superflash

Executive Director Ray W. Shook Design and Production

4 WELDING JOURNAL / JULY 2016

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6 WELDING JOURNAL / JULY 2016

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PRESS TIME NEWS

FlexNGate to Build Nearly $100Million Facility Large Commercial Vacuum Furnace

8 WELDING JOURNAL / JULY 2016

Youll nd it with us.

For more info

Women Building Futures Celebrates First

Architects from Landmarken AG and KPF (right) officially handed

10 WELDING JOURNAL / JULY 2016

2% Thoriated Tungsten has been the welding industry standard

The Tungsten Electrode Experts at Diamond Ground Products

Call DGP today to get your 2% Thoriated Tungsten. You might

Stick with Tungsten

NEWS OF THE INDUSTRY

Pipeline Inspection Certification Program

This graphic displays the structure of inspector certification

American Welding Society (AWS) Certified Welding In-

12 WELDING JOURNAL / JULY 2016

A more efficient unit construction will increase shipbuilding

to leveling structures, handling/setting bulkhead structures,

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NEWS OF THE INDUSTRY

GAWDAs Spring Conference Draws

At GAWDAs spring conference, Disruption: Recognize It, Under

Distributor and supplier member attendance at the

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Essex Weld Solutions to Establish Cherokee

16 WELDING JOURNAL / JULY 2016

1400 Blauserr Dr. Tipp City, OH 45371

Table 1 Dilution Calculations in Joining Carbon Steel to 304 with ER309/309L

Typical Chemical Composition, wt%

Carbon Steel 0.15 0.90 0.10 0 0 0 0 0 0.005

18 WELDING JOURNAL / JULY 2016

Fig. 1 WRC1992 diagram including typical compositions of car

JULY 2016 / WELDING JOURNAL 19

in. maximum, and that it often closes

1. Kotecki, D. J. 2000. A martensite

DAMIAN J. KOTECKI is president, Damian

20 WELDING JOURNAL / JULY 2016

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tion in the welding machine secondary

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24 WELDING JOURNAL / JULY 2016