Sunteți pe pagina 1din 32

CWA engage

Canadians supporting Canadian Welding

Vol. 1

Issue. 3

CWA engage
e gag A en CW
EL STE IMA GE OF THE MO NTH

the

aRt

oF

y uRg all met

november 2011
n articlEs
e. 3 Issu 13 Pg.
nifica tion )

x e, a e tim sam never the ld . At shou e of this them gas ey ting ielding . The sh nnec c roke t, co lly this ery st aphi join Idea logr on ev the etal r. em ong the ai perfect shar . al al ith rt met ting w elder is ed to elts w ac e. tend call it a is in lly m from re eon or mistak even refu rg onth r ca d metal ter, su welding e M e might de of th d, w wel da wel pain age de er, a molten er, no bble an eel Im lly min e geth wev gas bu . St es to ects th al. Ho over technica ot ped piec et ing etal g gas pr weld m a trap t so paus th om in e orth e weren of bo in tw shield in th w ns w To jo ialized apped idence tter g. If bit pa pleasin spec me entr ows ev exhi sh s lly etal beco crater tica d of m aesthe wel ages nd es im could fi e etim Som that on s sight (100

1 Vol.

mag

rg cs.o

Types of
ge lima

hazards
a-a w w.c

CWB Gr

Brian

CWA e ngage
Chmay
ining Re presen tative

types of hazards 4 the world is not at 8

oup Tra

tee ww.s

.ca

ww

Failu

re a

sis an naly

on uati eval eld dW

Vol. 1

Issue

age eng CWA


THE LAS TW ORD

Vol.

Is

3 sue.

N DIA NA CA

remarque :
les documents seront imprims dans la langue dans laquelle ils ont t reus.
Cette publication officielle de lACS, un organisme sans but lucratif, contient des avis et des articles faisant autorit lgard des activits de lAssociation. Dautre part, ni lAssociation ni lditeur dEngagement dACS ne sont responsables du contenu ou des opinions des collaborateurs qui sy trouvent. De plus, nous navons aucun droit de regard sur linformation affiche sur les sites lis celui par des hyperliens. LACS ne sera en aucun cas tenue responsable de lutilisation dun site hyperli. Des parties de cette publication sont protges par des droits dauteur ( 2011) dtenus par lACS ou par un ou plusieurs auteurs respectifs. Tous droits rservs. Aucune reproduction totale ou partielle nest autorise sans le consentement crit de lACS.

note:
Printed material will be in the language in which it was received.
As an official publication of CWA, a non-profit organization, this publication carries authoritative notices and articles regarding the activities of the Association. In all other respects, neither the Association nor the publisher of CWA engage is responsible for the contents thereof or the opinions of the contributors. We have no control over information at sites hyperlinked to or from this publication. In no event shall CWA be responsible for your use of a hyperlinked site. Portions of this publication are copyright 2011 by CWA or the respective author(s). All rights reserved. Nothing may be reproduced in whole or in part without written permission from CWA.

pour voir cet article en franais, cliquez sur la Fleur de lys

Cliquez sur cet icne pour apprendre plus de le sujet

Within articles in this publication click on this icon to learn more about the subject.

Vol. 1

Issue. 3

ng weldi ch as are en bs su to ed jo use wom e able ca rform wer en pe ng. Be they wom d traini stature . on l an dian ly Cana ired skill physica precisi t supp in ith in Our shor requ bs w aller e in omen that rally sm eous jo s wer of the w scarce. er m gene ry dext y ite ion ere coal ns w ar II man d fash do ve War ess an and nylo ting a ch usion dr orld ters g W ed the ons, silk to pain ve the ill le doing ive R n Durin pact . Butt verted Whi in and to gi im erica the that orkforce even re their legs ockings. femin w Am ar II, osie el st w r fello orld W so the women back of g nylon to fe n R W d ou al ted e e As di during women place Som wn th e wearin still wan nt. r ow rs e do wer our - ou ey siste nadian take th . Our job fro line rved ce en th the Ca they kfor es, up to our ho se that ork of m that on ped the wor m hom d d en w do so. w step rate the wom e to d fro ies an en in onst nu dian of m en worke factor dem Cana ho conti our wom munition tary. lute l, and w ili sa in am the m the We try wel se to first joined coun ey en ro was ritten wom oved th in ters w dian ble d pr e Rivein a song Jacob ed Cana ion an an capa ce e th hn ss Rosi in 1942 s and Jo record occa more th was on men. at e used dd Evan ce been cluding wer jobs th work of Re has sin tists in me a e g by . It doin ered th well! co s ar id it Loeb merou d had be cons ey did ed th by nu ser an lder And Ky d so dian : hit. Kay song ed, an r Cana ters. onal the drill ou ve nati urday from They came ie the Ri e a s sat ing Rosie be sert ckwell tur and n of Ros describ ited an in y long, shine, line. Norman Ro st cover fea shing. to io or da mbly Publi ed e Un on g Po vers All er rain e asse evenin eter - Curtis of th ok rm us th th A te ral icon who to g the Riv whe part of history, s cultu women ers durin as a She making ctory, ed n ica rivet ly us s Amer rs and mmon power. She ng for vi ter. ted de r is co ic ki flec wel wor the Rive at re ork of Rivete s econom e lw es, th Rosie Stat dustria Rosie th d women . in ar II inism an the ld W Wor l of fem bo sym

a lo

ck ok ba

www.

cwa-a

welde r has ma many ny oppo diff in a sm erent fields rtunities to wo . Wheth all fab er it is rk in always complex or ricating sho overex working p, a perhaps the posure of hazard possibilit the oil large indust X-rays to y of and gam the sun. Ion includ . Some of the being exp fields, there rial flaws. izing rad ma ray e: ose is Thi hazard s, s a we d to some typ to pene s type of rad are used to iation, such lder ma as tra inspect iation y encou e El EC tr can cau te metals, not on welds nter ly has but hu se dam iC sh oC the abi for Many ma leadin k we lity g to can age to the DN n tissue as power. lding and cutti well. cers. A in the Contact ng pro cells of This circuit cesses Bu rn our bo or an ele with electr use ele s dy ically live burns ctrically Burns ctrical to res be cau the body or powered too parts of a we sparks ult from con sed ldin l, can fatal ele and tac equipme by contac ctric sho cause sev g colourati spatter. Ma t with hot t with ere par nt, ina Welde damaged ck. This that som on after the ny metals do ts or weldin dequ can rs y or fau contac should ensur ate training has a cha eone could are welded. not exhibit anyg lty or t e that handle If wet glo with live me they do operator err HOT. nce to cool that we there is a cha tal par or. ves and no down, ldmen nce clothing. ts or weld t come in then it Weldin t should before it g sparks with dam ra di at from the be ma and spa p or rked tter can The we io n causin work area travel and ign g lding arc quite form of ite moved a fire. If this produ flamma flammable a distance or pro Acute visible light, ces non-ion tected mater stand izin ult eff ial, , then ble material by as a anothe canno includ ects of exp raviolet ligh g radiation fire wa t be e osu r worke in t tch. of exp arc flash and re to non-i and infrared the Fu mE r should osure s can lea skin burns. onizing radiati light. Du ring the Lon d to ski on weldin n cancer g term effect the mo g pro s, much s lten pu When ddle vap cess, some like of the known y condense ourizes into the metal fro the atm , they as fum m for e. The health m fine metal osphere. effects caused lic particles by exp osure

new high definition plasma cutting solution provides speed and precision 15 how conductivity can aect your welding operation 17 3 CnC machine mishap prevention tips for the new user 21 Cyber insurance 26
.3 Pg.4

cs.org

Pg.31

N ME WO

n Business neWs 24 n Course reFerenCe 29 n EvEnts 14 n steel image oF the month 13 n tEch advisor 30 n teChniCal reFerenCe 31 n the last Word 32

ww

ac waw.c

s.org

CWA engage
Change
Its been said that sometimes you have to change direction to move forward. Unfortunately when it comes to changes in technology and standards, the direction forward is not always a straight line. Companies looking at adopting new welding technology, or doing business outside their traditional market, may feel that they are charting new territory on their own, sometimes without a compass. For individuals looking to acquire new skills and expand their careers, the road forward may be no clearer. In most cases, the issue is not a lack of options, rather a lack of help guring out which option is right. What is needed is a map, clear directions, and help navigating through the options to arrive at the desired outcome. For some this outcome might be education to land a better job, for others it could be improved productivity or maybe a stronger competitive position. Regardless, its about making a change to move things forward. As your Association, we are always looking for ways of helping you make and navigate change. Through the Advanced Welding Technology Centre (AWTC), we provide the ability to see rst hand the latest and greatest welding technology. Think of the AWTC as a way to do a test drive, without having the salesman in the car. CWA programs such as TechTalk and our Annual Conference provide opportunities to speak to and learn from experts from around the world. These programs allow you to understand how changes can be made, and see the results. Even this magazine plays a part by helping to expose you to new ideas, equipment and people on a monthly basis. Beyond the CWA, our parent organization the CWB Group is known world wide as a leader in helping companies navigate and comply to the standards that dene the work we do. As a CWA Premium Member, you have access to their services and programs at a discounted rate. Can we do more? The answer is yes, and more positive changes are coming soon. We have several new programs in the works for 2012 so stay tuned to these pages to nd out what we are up to. The CWA is your Association, we are here to help you, and as a not-forprot organization, we only have your best interests in mind. Clearly change can be a good thing - if theres something you need or would like to see us do, please let us or your chapter heads know.

The CWA would like to give-back, and thank its members

We look forward to hearing from you soon!

www.cwa-acs.org

Sharing your copy with others Contributing ideas, stories, pictures and comments (i.e. the last word section) Sending us your comments, concerns and questions An association is only as good as the members in it, and engage is only as good as the members who contribute to it. Help us grow both by contributing. Drop us a line at: marketing@cwbgroup.org

Vol. 1

Issue. 3

Like what you see in engage so far? Then help us by:

Pg.3

Contribute

CWA engage

Types of hazards

Brian Chmay

CWB Group Training Representative

Many welding and cutting processes use electrical power. Contact with electrically live parts of a welding circuit or an electrically powered tool, can cause severe burns to the body or fatal electric shock. This can be caused by contact with damaged or faulty equipment, inadequate training or operator error. Welders should ensure that they do not come in contact with live metal parts or weld with damp or wet gloves and clothing. The welding arc produces non-ionizing radiation in the form of visible light, ultraviolet light and infrared light. Acute effects of exposure to non-ionizing radiation include arc flash and skin burns. Without proper protection, long term effects of exposure can lead to

ElEctric shock

During the welding process, some of the metal from the molten puddle vaporizes into the atmosphere. When they condense, they form fine metallic particles known as fume. The health effects caused by exposure

Fumes

www.cwa-acs.org

radiation

Burns result from contact with hot parts or welding sparks and spatter. Many metals do not exhibit any colouration after they are welded. If there is a chance that someone could handle that weldment before it has a chance to cool down, then it should be marked HOT. Welding sparks and spatter can travel quite a distance from the work area and ignite flammable material, causing a fire. If this flammable material cannot be moved or protected, then another worker should stand by as a fire watch.

Burns

Vol. 1

Issue. 3

Pg.4

welder has many opportunities to work in many different fields. Whether it is working in a small fabricating shop, a large industrial complex or perhaps the oil fields, there is always the possibility of being exposed to some type of hazard. Some of the hazards a welder may encounter include:

skin cancers, much like overexposure to the sun. Ionizing radiation, such as x-rays and gamma rays, are used to inspect welds for flaws. This type of radiation not only has the ability to penetrate metals, but human tissue as well. This can cause damage to DNA, leading to potential health risks.

CWA engage
to these fumes depend on the fume constituents, concentration, duration of exposure and the individuals own sensitivity. An assessment of the airborne particulates should be made, so that an effective means of respiratory protection can be selected and implemented. Many types of gases are used as part of the welding and cutting process. Inert gases such as argon and helium are used for shielding the welding arc, whereas fuel gases, such as acetylene and propane, are used for oxy-fuel welding and cutting. These gases are stored in high pressure cylinders or cryogenic containers. The hazards associated with these gases include asphyxiation, fire and explosions. Gaseous by-products are also produced as the result of the welding or cutting process. The nature and amount of gas generated depends on the arc power, the welding process and the material being welded. As with welding fumes, an assessment of the types of gases produced should be made so that proper ventilation methods and/or respirators are used. The work environment in most fabricating shops and worksites can be quite loud, with noise levels often exceeding 85dB. The permissible time periods and noise levels appearing in occupational health and safety regulation tables have been established for workers not wearing hearing protection. Welders working in areas at these noise levels, without hearing protection, are still likely to suffer temporary and permanent hearing loss. A note in CSA W117.2, Clause 11.5, mentions that continued exposure to sounds that are too loud, leads to a loss of sensitivity, which impairs our ability to detect faint sounds. It also states that this hearing loss may also interfere with the welders ability to communicate with others and enjoy leisure activities. Unfortunately, this is all too true for many welders. Some welding processes are known to produce strong electromagnet fields and high frequency voltages. Not only can these interfere with important radio communication wave frequencies, there are also documented incidents where they have affected people with surgical steel implants (and there are concerns about pacemakers). Always ensure that your welding equipment is properly grounded and follow the manufacturers recommendations stated in their service manuals. This category accounts for between 30 to 40% of all compensation claims. Much of it is a result of poor housekeeping. Take the time to ensure that the workplace is as tidy as it can be. Cleaning up after the job is completed demonstrates professionalism.

eleCtromagnetiC ForCes

GasEs

slips, trips and Falls

noisE

Many welders have been injured by machinery that they did not expect or anticipate to move. It is very important that all workers be trained to identify different types of prime movers (electrical, hydraulic, pneumatic etc.) and to lock out and de-energize them properly.

unexpeCted movement From maChinery and vEhiclEs

Always test and verify the lockout to make sure it is effective.


The use of signs, barriers, safety persons and communication with vehicle drivers provides a means of protection from vehicular movement. The purpose of establishing an effective health and safety program is to provide a safer workplace. Being able to recognize these hazards is an important first step in reducing or eliminating accidents in the workplace.

Remember, you dont get used to noise, you become deaf to it!

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.5

CWA engage
Vision T5c controls from 1 to 12 stations without additional panels and controls numerous axes for variable beveling and rotating tools. Automatic machine referencing makes machine startup quick and easy. Program parking allows cutting of rush jobs without losing your place in a nest. Remote diagnostics using a live connection between ESAB service and your control speeds up trouble-shooting or training. Designed for retrofitting, with matching mounting holes and all electronics built into the operator console, the Vision T5c is quickly mounted in place of older Vision controls, including the Vision 1000, Vision 2000, and Vision PC. Depending on the original machines electrical systems, the Vision T5c is capable of fully integrating all process controls for every cutting or marking tool, making operation quicker and easier for every machine. The Built-In Process Database can simplify cutting tool setup by automatically setting parameters such as cutting speed, kerf offset, and timers based on material thickness, material type and cut quality desired. The operator sees a picture and part number for the torch parts that are needed for both plasma and oxy-fuel torches. All cutting and marking tools can be controlled directly on the touchscreen. With more than 100 years of experience, ESAB Welding & Cutting Products is one of the worlds largest and most skilled manufacturers of welding and cutting equipment and welding filler metals. Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for their customers.

esaB introduces vision t5c Control for retrofits


Florence, SC ESAB Cutting Systems introduces the Vision T5c Control for retrofit onto cutting gantries. This updated version of ESABs Vision T5 CNC is re-packaged for quick and easy installation in place of existing Vision controls on ESAB cutting gantries. Designed for ease of use and improved productivity, the Vision T5c features an ergonomic, wide-screen layout and an advanced touch-screen interface that offers twice the display area of other CNC controls, as well as unique process control features designed to simplify operation and boost productivity. The large, bright 18.5 wide-format touch-screen features an ergonomic layout with controls positioned for easy access to reduce vertical arm motion and improve operator comfort. Simple up/down toggle switches provide intuitive operation of station lifters. These are easily serviced or added in the field. Dual USB ports are positioned to prevent interference with the operator. The five-wire resistive touch display panel offers unmatched durability, reliability and performance. The touchable, graphical user interface provides more information and feedback to the operator than typical controls. Important information is always visible, and operating steps are clear and intuitive, guiding the operator every step of the way for enhanced productivity. The new Operating Wizard guides users with clear, step-by-step instructions, providing simple prompts with limited choices that lead from file selection to starting the cut. This allows even new operators to become productive more quickly. This unique system starts at power-up, simplifying control start-up and machine referencing, and includes steps for torch setup and positioning the machine. The built-in shape library also uses a wizard to simplify part programming of complex shapes and maximize cut quality on small holes and inner contours.

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.6

CWA engage

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.7

CWA engage
The World is Not Flat: Tips to Improve your Out-of-Position Welding
Part 1, TIG Welding
Fabricators often need to weld out-of-position when working with large/heavy weldments and with pipe, which requires adjusting the electrode angle, puddle manipulation, body position and equipment settings. The first in this two-part series takes beginning TIG knowledge to an intermediate/advanced level by comparing right and wrong methods of making these adjustments. Everybody learns to weld in the flat position, but advancement in the skilled welding trades requires learning to weld in the horizontal (2F, 2G*), vertical (3F, 3G), overhead (4F, 4G) and 45 deg fixed (6G) positions. Further, codes and weld procedure specifications in the power generation, petrochemical and process piping industries call for both the TIG and stick process. Of course, structural steel welding also heavily involves all-position stick welding. In short, the more processes on which an apprentice or journeyman can become qualified, the greater their income potential. Part One of this discussion emphasizes the mechanics for welding out-of-position for TIG welding and, next month, Part Two will focus on stick welding.

Ken alrick

Product Manager, Thermadyne Industries

mechanical contractor in the country according to Contractor magazines 2011 Book of Giants. In addition to supplying prefabricated piping for internal mechanical projects, its Pipe Fabrication Division supplies more than $25 million of piping annually to outside mechanical contractors, owners and municipalities for industrial, power, utility and water/wastewater projects. It holds ASME PP and U stamps, a National Board R stamp and welds to ASME Codes B31.1, B31.3, B31.9 and API-1104 codes. Before discussing welding in various positions, it is useful to review what the operator needs to accomplish, says Hidde. He notes three key tasks:

Achieve required penetration at the root of the weld. For an open root joint on pipe, this requires complete penetration through to the backside of the joint. On plate, the procedure generally involves gouging out the backside of the weld and completing the joint from the backside. Have good tie-in at the toes of fillet weld without any undercut. On a groove weld, this especially means good sidewall fusion. Produce a weld bead face that conforms to codes and specifications, being neither too concave nor convex. A rule of thumb states that the bead crown should be no more than one electrode diameter high and no more than three diameters wide (or dime wide, nickel high when using a 1/8 in diameter electrode).

Welding oBJeCtives

www.cwa-acs.org

Fixed pipe welding is considered the ultimate all-position application: the position changes constantly as the operator works around the circumference of the pipe, covering the flat, overhead, horizontal and vertical positions. As a result, the TIG mechanics described in this article are largely applicable to both pipe and plate. Sharing his experience on the mechanics of welding is Todd Hidde, the shop superintendent for the Pipe Fabrication Division of J. F. Ahern Co. (Fond du Lac, WI) and a journeyman with UA Local 400. Hidde has been welding for 29 years and supervises a crew of up to 40 welders. Ahern is ranked the 25th largest

When welding in the flat position, gravity pulls the molten pool into the root opening, making penetration easier. In all other positions, the molten weld puddle wants to roll out of the joint. For this reason, Hidde says that, Out-of-position groove welds tend to be more difficult than fillet welds. Operators need to concern themselves with directing the molten metal

Vol. 1

Issue. 3

Pg.8

CWA engage
at the bottom of the root and tying in to the sidewalls vs. just having good tie-in at the toes of a fillet weld.

reFerenCe point: Flat position

Setting aside the technical terms, pipe fabricators commonly use a clock face reference for welding positions. When the pipe can be fixed in a positioner and rolled, operators in the flat position typically hold the torch at 1:30 to 2 oclock. In this position, the combination of gravity and weld puddle surface tension helps pull the molten metal off the end of the filler rod and into the root.

6 oCloCK, or overhead position

variaBlEs to control

When welding out of position, operators must rely on their skill to deposit filler material and use the force of the arc to direct the weld puddle into the joint. Chris Brownlee regularly works with Hidde. He is a CWI and weld process specialist for Weld Specialty Supply Corp. based out of Fond du Lac. Brownlee notes that operators can control weld puddle and weld bead profile by manipulating the following variables: Amperage. Reduce amperage by 15 percent for out-of-position welding. Arc length. Generally, arc length should equal electrode diameter. Because voltage is directly proportional to arc length, operators often hold a shorter arc to reduce heat when welding out-of-position. Electrode work angle. The angle of the electrode relative to the joint. TIG welders also must concern themselves with filler rod angle (more on this later). Direction of travel. Usually described in terms of push/forehand or drag/pull/backhand. TIG welding always uses a push technique. Electrode travel angle. The angle at which the electrode travels (e.g., how far back the torch is tipped; more later). Electrode (torch) manipulation. More later. Travel speed.

When welding overhead, operators need to manipulate the puddle faster or it will fall into the cup, says Hidde. Manipulation refers to the zigzag motion of the torch. The welders wrist/forearm motion most closely resembles that of an infinity symbol. Rhythm is the key to cup walking (or a good freehand). Hidde says that, Good rhythm has a 1-2, 1-2 metronome-like tempo. Journeymen can help inexperienced welders by counting out the tempo and even grabbing their hand and showing them the motion. When cup walking, the cup rests directly on the top of the joint. For this reason, start with perhaps a #6 or #7 cup and increase cup size after the root or hot pass. Set the electrode in the root opening or bottom of the joint, start the arc in the centre of the joint, establish the puddle and place a small amount of pressure on the cup. Slide the left side of the cup forward about 1/16 in using the right side of the cup as the pivot point. As the cup pivots, direct the tungsten at the left edge of the joint (toward the leading edge of the cup) and pause momentarily. Next, slide the right side of the cup up 1/16 in, move the electrode across the root, direct it at the right side, pause and repeat the steps described. The timing, pauses and movement involved with cup walking are as intricate as a waltz. Things happen quickly in any position and need to happen even faster when welding overhead. Fast manipulation keeps the puddle and its freeze rate under control, says Hidde. Slow manipulation either causes the filler metal to pile up or puts too much heat into the joint and blows open the window or keyhole.

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.9

CWA engage
WindoWs, travel speed and tie-in
When welding an open root joint, operators look for several things. First, they look for a window or keyhole to open up in front of the arc and close behind it as fusion occurs. The objective is to maintain a consistent window size by achieving the optimum balance between travel speed and filler rod feeding rate. Browlee notes that, Another indicator of a quality weld is that as the molten puddle ties into the sidewalls, it starts circulating. Impurities and non-worrisome elements such as silicon rise to the top of the puddle and become clearly visible. If this scum line of impurities circulates, it indicates good tie-in. A still puddle usually means little or no sidewall fusion, which is a common bigger mistake. weld metal can be stacked without falling out of the joint. For a horizontal weld, remember to direct the arc slightly more toward the top of the joint. Once the torch position reaches 2 oclock, gravity takes over and helps pull the puddle into the joint and makes it easier to direct at the sidewall. Return manipulation speed to normal. In conclusion, beginning welders need to learn different manipulation speeds for different positions and the freeze rate of the metal. They need to learn how gravity affects the weld puddle in terms of how it falls into the root opening, how it affects penetration and how their manipulation enables good sidewall fusion. The only way to understand welding mechanics and how they affect the weld puddle is to get under the hood and practice a lot, says Hidde. *G = groove weld, F = fillet weld

5 oCloCK: the haZard Zone

The 5 oclock position is the most hazardous. Hidde says beginners fail here for two reasons. First, as a transition zone, its the least practiced, being neither overhead, nor vertical nor flat. Second, it is where their 6 oclock position becomes stretched and uncomfortable. Browlee adds, An uncomfortable operator should stop before the cup slips or the tungsten becomes contaminated because the operator dipped it into the weld pool or pushed the filler rod into it. If the tungsten becomes contaminated, stop, grind out any flaws and redress the tungsten. Electricity likes to come off a point, and a contaminated tungsten cannot precisely direct arc force. Other uncomfortable errors include holding the filler rod too perpendicular to the pipe (which could lead to excessive reinforcement) or holding the filler metal too far in front of the arc and removing it from shielding gas coverage. Its always better to make a short weld and stay in control through frequent repositioning than it is to make a longer weld that might have a flaw. 3 oCloCK sloW doWn As operators approach the 3 oclock position, they can slightly reduce manipulation speed compared to overhead welding. In this position, the puddle freezes and provides a shelf on which additional molten

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.10

CWA engage
Key specifications: Axial Travel Wire Diameter Range Step Range/Pitch Rotational Direction Auto-Skip Standard Torch Range 152.4 or 304.8 mm 0.58 1.14 mm Step Range: 1.0 5.6 mm Reversible Pie/Carriage Return/Skip 22.4 330.2 mm

Climax autoBoreWelder 3000Z provides preCise, high-quality Welds


The Climax AutoBoreWelder 3000Z is an automated welder designed to decrease weld time and improve productivity for welders and machinists who perform in-situ machining and welding in the shipbuilding and ship repair, power generation, construction, mining, and service sectors. The AutoBoreWelder enables a uniform weld build-up for bores, flanges and O.D. shafts, keyways, and valve repair work. It also can be used for repairs on any equipment with a pivot point, including most construction equipment such as tractors and earthmovers, large steel fabrications, or shipbuilding equipment such as stern tubes. The system interfaces with Climax portable boring machines and allows one set-up for both welding and boring. The patented technology of the AutoBoreWelder enables welders and machinists to produce precise, uniform, high-quality welds in a variety of settings, in significantly less time compared to hand welding. The AutoBoreWelder 3000Z has a patented step process that enables precise control of weld placement throughout the application. It also features an auto-skip function, which allows users to designate weld only or skip weld areas.

The AutoBoreWelder 3000Z is available for sale or rent from Climax Portable Machine Tool, whose machines are used by master machinists worldwide.

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.11

CWA engage

Safety First

CWA enga ge

Its surprising the number of photos and material we come across on a daily basis here at engage HQ that would send a safety inspector into a fit.

CONTEST

Canadians

supporting

Canadian Wel

ding

In the first issue of engage, we made several mistakes with respect to welding safety. Clearly this was not intentional, but once pointed out, it did cause the production team to look harder at the material we use in each publications.

to help draw attention to the importance of safety, we had put together a small contest find all the safety issues in the first issue of engage and send the list to marketing@cwbgroup.org. All those who submitted a list were entered into a draw that took place last week. thank you for your submissions, the winner who has already been notified has won an ipod shue!

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.12

STEEL IMAGE OF THE MONTH

CWA engage

the art oF metallurgy

(100x magnification)

Sometimes images of metals exhibit patterns worth pausing over. Steel Image of the Month is intended to share metallographic sights that one could find aesthetically pleasing. If we werent so technically minded, we might even call it art.

Failure analysis and Weld evaluations

www.steelimage.ca

www.cwa-acs.org

Vol. 1

To join two metal pieces together, a welder carefully melts metal along the joint, connecting them. At the same time, a specialized shielding gas protects the molten weld metal from reacting with the air. Ideally this shielding gas should never become entrapped in the weld metal. However, no painter, surgeon or welder is perfect on every stroke. The eye of this weld crater shows evidence of both a trapped gas bubble and a welding mistake.

Issue. 3

Pg.13

UPCOMING EVENTS

CWA engage
ADVANCED AUTOMATED WELDING SOLUTIONS Lincoln Electric, Calgary November 29 & 30th, 2012
An automation seminar on welding and cutting spotlight on productivity. A one-day seminar featuring presentations and hands-on demonstrations of welding and cutting technologies that can increase productivity, reduce costs and improve quality.
For more information or to register for a session email: david_jordan@lincolnelectric.com

Cippe 2012

New China International Exhibition Center, Beijing, China March 19-21, 2012 The 12th China International Petroleum & Petrochemical Technology and Equipment Exhibition. The largest Petroleum Exhibition in the World. Over 40,000 visitors attended Cippe 2011 which hosted over 1,500 exhibitors from 45 countries. To learn more visit: http://www.cippe.com.cn/cippeen/html/ content_84.html

iWJC-Korea 2012 (international Welding/Joining Conference)


Ramada Plaza Jeju Hotel, Jeju, Korea May 8-11, 2012

Green & Advanced Technology in Welding & Joining IWJC-Korea is indeed a fundamental ground for exchanging cutting-edge research outputs within the industry of welding and joining, and its related areas. A great opportunity for both researchers and practitioners to come together to share outstanding findings and results. To learn more visit: http://iwjc2012.org/download/ IWJC2012_1st_CFP.pdf

OCEANTEX WORLD EXPO 2012


Bombay Exhibitions Centre, Mumbai, India - February 8-11, 2012
India is clearly a goldmine of opportunities for the Oil & Gas Industry. Oceantex brings together national and international experts to exchange knowledge, identify areas of cooperation and find ways to use the worlds petroleum resources in the most optimal and efficient manner. For more information including a list of topics visit: http://www.chemtech-online. com/events/oceantex/index.html

northern Welding trade shoW

To learn more visit: www.northernweldingtradeshow.com New China International Exhibition Centre, Beijing - June 4-7, 2012 As one of the top 2 expositions in the world focusing on welding and cutting products and services, Beijing Essen Welding & Cutting Fair offers the most ideal platform for information exchange, contact establishment and market development. To learn more visit: http://www.chinaexhibition.com/trade_ events/1025-BEW_2012_-_The_17th_Beijing_Essen_Welding_and_Cutting_Fair_2012.html

BeW2012 exhiBition (BeiJing essen Welding)

www.cwa-acs.org

Vol. 1

This action-packed event includes trade show booths, a welding skills competition, welding seminars, live welding product demonstrations, dinner and entertainment.

Issue. 3

The first of its kind in north-eastern Ontario. A state-of-the-art welding technology center in the North dedicated to the advancement of welding technology.

Pg.14

Kirkland Lake Campus, Kirkland Lake, ON - May 30-31st, 2012

CWA engage
New High Definition Plasma Cutting Solution Provides Speed and Precision
Jim Colt
Strategic Account Manager - Hypertherm Inc.

GT

Offering a choice of plasma or CO2 laser expands customer options

Metal Products is a custom metal fabrication job shop located in Edmonton, Alberta, Canada, which manufactures power distribution panels, grain hopper bottoms and aeration tubes, stair cases, hand rails and steel structures, computer module consoles, and complete communication and electrical cabinets. The company has a wide range of capabilities, including CNC forming, plasma and laser cutting, robotic welding, rolling, shearing, punching and drilling, as well as drafting and engineering design. Their extensive fabrication capabilities range from the design, build and delivery of a single custom part, to large scale mass production requiring multi-process manufacturing. GT Metal Products found that, to be competitive in the market, the pressure was on to supply a far higher level of precision cutting than had previously been required. The company was looking for ways to ensure the proper angularity of cuts and accuracy of parts to customer drawings. They had to maintain required tolerances and make sure parts were straight and smooth, with few customer rejects.

In addition, GT Metals had found that the laser tables, which measured 5-feet by 10-feet, were resulting in plate size limitations, because there was an increasing demand for cutting 6-feet by 24-feet plate. Since increased cutting time was crucial to its continued growth and success, GT Metals went looking for a cutting solution that would offer the fast cutting speeds and low maintenance costs typically associated with plasma, combined with a cut quality comparable to laser. Their goal was to find a tool that could handle the backlog that had been building up on the lasers, ensure parts flow to their seven full-time welders, and provide more quoting and business growth opportunities.

www.cwa-acs.org

In response to customer demand for more precise cutting than could be obtained with their older plasma system, GT Metal Products replaced it with two CO2 lasers a few years ago. Unfortunately, while the new CO2 lasers were indeed able to deliver on their high precision claims, their slower cut speeds seriously disrupted production flow and limited business growth. Operating and maintenance costs for the lasers were also higher. Also, the thickness range was affected. The CO2 lasers reached their limit of effectiveness at thicknesses up to inch, so the company was faced with the need to turn away customer requests for cutting of over inch mild steel.

GT Metal Products owner worked with Pinnacle Industrial Automation Inc., the OEM that had sold the company the CO2 lasers, to find a plasma cutting solution that would offer the necessary productivity improvements along with a cut quality comparable to laser. The integrated plasma cutting solution Pinnacle recommended features an ultra-precise table motion that provides a near laser quality cut. This system, made by Hanover, NH-based Hypertherm, Inc. expands GT Metal Products already extensive offerings beyond the limitations of the lasers, and enables greater flexibility

Vol. 1

high deFinition plasma Cutting solution oFFers speed and preCision

Issue. 3

Pg.15

CWA engage
in quoting, materials use, and production, with lower operating and maintenance costs. The full suite of Hypertherm components includes a HyPerformance Plasma HPR130XD, which delivers near laser cut quality with minimized operating and maintenance costs; an EDGEPro CNC; and ArcGlide THC, to deliver Rapid Part technology with significant productivity improvements without operator intervention to increase plasma cut speed 3 times over CO2 laser; and ProNest2010 nesting and process optimization software, which enables the programmer to more easily monitor material usage and minimize scrap. The system features Hypertherms True Hole technology, which minimizes drilling and secondary operations by automatically delivering bolt-quality holes. HyPerformance Plasma cuts at lower cost, at higher speeds, with greater quality, comments GT Metal Products owner, Dennis Berreth. We have gone from cutting at 26 inches per minute (ipm) with the lasers to 80 ipm with the plasma, and drilling has been minimized due to the True Hole technology, The addition of the True Hole-enabled cutting machine immediately allowed GT Metal Products to reduce their operating expenses by eliminating the second shift, and returning to the one-shift model, which decreased heating and cooling, supervision, and overtime costs. The ProNest2010 software helps their programmer monitor material usage and minimize scrap, giving GT Metal Products greater flexibility with quoting projects because they can offer both laser and plasma pricing. With quotes 30 percent less than laser quotes for the same job, plasma is often better than the job requires, so we are able to give our customers the choice, as well as the option to save money. Reduced maintenance costs have proven to be a benefit as well. The plasma system is much easier to maintain and requires less than half the time, said Berreth. The material range of the HPR130XD has also expanded the services GT Metal Products offers, by allowing them to cut A516 (PVQ 516-70) steel plate, abrasion resistant (AR) steel, and quenched and tempered (QT) steel plate. Any material with scale or rust now automatically goes to the plasma. We dont cut a lot of it, but to keep our customers happy, we can cut it when we need to, and that is important, Berreth states.

GT Metal Products now uses both technologies to give customers the full range of thickness with the level of detail needed for the particular project or application. They offer laser cutting for fine features and extra detail on thinner materials used for precision parts with tight tolerances, very thin (less than 10 gauge) stainless steel, or for parts with lots of holes that are very close together. For the larger, thicker, or longer pieces, like those for drilling rigs, construction or agricultural installations, the plasma cutting tool is ideal. Since the high definition plasma offers excellent cut accuracy at about 30 percent less cost, some customers who originally requested laser cutting may opt for plasma when they see the results. Having both technologies in house also avoids problems frequently associated with subcontracting out jobs. GT Metal Products can control quality and doesnt have to deal with labor costs and safety risks of loading, unloading, and inspecting material. Transportation of parts slows down turnaround time, and fuel and shipping costs can mount up. Having both cutting tools in house removes all the variables and allows GT Metal Products to turn around work more quickly and avoid being at the mercy of a subcontractors schedule. Our integrated plasma cutting solution delivers increased productivity with 3 times improvement in cut speed over CO2 lasers, said Berreth. We can now offer more cutting time and provide what our customers need at the quality and price they need it.

tWo teChnologies are Better than one

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.16

CWA engage
How Conductivity Can Affect Your Welding Operation
ost people understand that the electrical circuit is at the heart of the welding operation. What you might not be aware of, however, is how easy it is for disruptions in this circuit to interfere with productivity, weld quality and equipment service life. All of these factors are ultimately affected by conductivity: the ability of the electrical current to flow along the welding circuit. Conductivity can also be referred to through its inverse: resistance, or the interference of electricity to flow freely along the circuit. If the electrical current moves with very little resistance, the material is very conductive. Gold, for example, is one of the most conductive materials on earth (which is why it was used in early telephones and other electrical equipment), but its cost prevents its use in welding equipment. Copper, aluminum and other metals are used in welding equipment because they strike a good balance between cost and conductivity. The copper used in welding equipment does a good job allowing the electrical current to flow. There is still a very small amount of resistance inherent in the properties of the material, but it is not enough to interfere with the welding operation. Excessive resistance along the circuit, however, can cause weld defects, reduce productivity and lead to premature equipment failure. To understand exactly how conductivity impacts almost every aspect of your welding operation, it helps to think about the welding circuit like a garden hose. The water flowing through the hose is analogous to the electrical current in the circuit. If you squeeze the hose in one spot, it reduces the amount of water that is able to flow from the hose. Likewise, an area of electrical resistance, such as a worn out or dirty power pin connection, restricts electrical flow along the entire length of the circuit.

andy monk

Product Manager, Bernard

www.cwa-acs.org

When resistance prevents the electrons from continuing along the circuit, they convert their energy to heat, which is absorbed by the surrounding components. Heat causes plastic and metal components to expand and to contract when cooled, creating mechanical stress that can lead to premature equipment failure. Interestingly, heat itself is a source of resistance, which is why high heat welding processes, such as with metal-cored wire, demand that the contact tip be recessed as far from the welding arc as practicable. As the contact tip absorbs the heat from the arc, it loses its ability to transfer the current to the wire, resulting in increasingly poor welding performance.

Vol. 1

Issue. 3

Pg.17

Understanding the role conductivity plays in the welding operation and how to troubleshoot problems can reduce downtime, rework and unnecessary equipment costs.

CWA engage
durability and repairability. Set screw fittings are easily repaired, but often come loose and require frequent tightening. Crimped fittings provide good contact between the cable and gun, but are also susceptible to overheating and gradual degradation. Loose cable, gun and power source connections should be tightened to manufacturer specifications or replaced if damaged. Because the welding wire wears the bore over time, the contact tip should be one of the first areas checked during troubleshooting. A contact tip that doesnt maintain constant connection to the welding wire should be replaced, regardless of whether it is the primary source of the conductivity problem. Paint and other surface contaminants can reduce the conductivity of the work lead connection. To ensure maximum electrical flow, attach the work lead clamp to clean, unpainted metal and as close to the weld joint as possible. If using rotating work leads, such as turntables and positioners, conductive grease can help increase the conductive surface area between the moving and non-moving parts. The other most frequent source of interruptions in conductivity is frayed copper stranding within the gun or, less frequently, in the work lead cables. These strands can fray and break due to repeated bending and twisting, particularly on guns that dont contain strain relief components at the connection points with the gun and power source. Also, thermal stresses can cause the copper stranding to become brittle, increasing the likelihood of fatigue failure. For this reason, the gun cable should only be bent or twisted if absolutely necessary. The resistive heat caused by frayed cable stranding, in addition to causing poor weld performance, can also accelerate the degradation of the remaining intact strands and cause the eventual failure of the cable. Unfortunately, it is difficult and often impractical to inspect the cable for damage as a preventative measure. Check the mechanical connections and fittings first if poor conductivity is the suspected source of a welding problem, and then proceed to check the condition of the cable.

As seen in this schematic, there are many areas for interruptions in conductivity to occur. Routinely checking the mechanical connections between the components can avoid problems before they arise. Excessive resistance anywhere along the circuit can result in a wide range of problems, including a sputtering or erratic arc, inconsistent weld appearance and frequent contact tip burn-back. These problems occur because resistance in the circuit reduces the amount of current that can flow to the welding arc. When the power source senses the reduced current at the arc, it sends a surge of voltage in order to overcome the restricted current flow. This increased voltage causes the popping and sputtering that leads to poor and inconsistent weld quality.

There are three main types of power cable terminations: compression, set screw and crimped. Compression fittings typically provide the best combination of

www.cwa-acs.org

Being able to correctly identify and troubleshoot excessive electrical resistance is critical to reducing the equipment and rework costs. The mechanical connections between the welding components account for most interruptions in conductivity. These include: the connection between the power source and the guns power cable plug; the fittings and connections between the guns power cable, neck, diffuser, contact tip and welding wire; and the connections between the work lead, welding table and power source. Routinely check these connections before problems arise in order to avoid compounded problems down the road.

accuratE trouBlEshootinG

Vol. 1

Issue. 3

Pg.18

CWA engage
It may be possible to cut and re-terminate the cable if the damage occurs near the connections to the power source or gun. Severe cable damage or damage near the middle of the cable may require replacement of the cable or the entire gun. Welding technology has advanced substantially since the days of DC buzz boxes, but one thing that has remained constant throughout the decades is the need to establish and maintain a robust electrical circuit. Resistance from loose fittings and connections will occur as a natural part of the wear and tear that welding equipment undergoes during normal use. However, knowing the common signs of poor conductivity and following a regular inspection routine will help ensure that built-up resistance doesnt cause undue equipment and rework costs.

The power pin connection can become loose and cause increased resistance. The strain relief feature on this gun reduces the chances of the cable stranding breaking at the connection to the power pin.

THE BACKING THAT WEARS TO KEEP YOU WORKING

HAS ARRIVED

WEARABLE BACKING FLAP DISCS ARE NOW AVAILABLE

DEMAND

dewalt.com/abrasives

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.19

CWA engage
cracks commonly seen in other fiberglass caps for long-lasting, professional-looking wear.

new Fibre-metal(r) roughneck(r) p2a Fiberglass hard hat delivers uncompromised protection and Comfort in extreme environments

The Roughneck P2A delivers best-in-class heat resistance, meeting ANSI-Z89.1-2009 impact resistance tests at temperatures up to 370 degrees Fahrenheit. Its technically advanced SuperEight(r) suspension, with eight load-bearing points, spreads weight over a wide area for the ultimate in balance, stability and impact protection. The caps reduced weight and adjustable, custom-fit features deliver added comfort for all-day wear. Its exclusive smooth crown design eliminates the risk of trapping a falling object, which can adversely affect a caps impact reduction capability. Fibre-Metal continues to set the standard for quality and performance with the introduction of the Roughneck P2A, said Katie Twist-Rowlinson, Fibre-Metal head protection product manager for Honeywell Safety Products. Featuring new material formulations that provide higher heat resistance without compromising durability or weight, this new protective cap underscores Fibre-Metals ongoing commitment to innovation and worker safety. The Roughneck P2A is available with a choice of three high-performance headgear options: the Fibre-Metal nonslip/non-strip ratchet, SwingStrap(tm) or TabLok(tm). It also comes ready to use with the industrys most versatile Quick-Lok(r) or Speedy(r) Loop helmet attachment system for faceshields and welding helmets. Each of the caps nine shades of solid-color resin provides a permanent, no-chip, no-peel finish. The Roughneck P2A Hard Hat is available now through major safety equipment distributors in the U.S. and Canada or by contacting the Fibre-Metal customer care department directly at 800-430-4110. For more information about Fibre-Metal safety equipment, please visit www.fibre-metal.com.

SMITHFIELD, R.I. - October 31, 2011 - Honeywell Safety Products (HSP), a global leader in personal protective equipment (PPE), today introduced the Fibre-Metal Roughneck P2A Hard Hat for extreme work environments. Through advanced design and materials, the Roughneck P2A delivers uncompromised protection in a lightweight design that ensures all-day comfort. Distinctive in its smooth, round design and matte finish, the P2A is the latest member of the Roughneck line of protective caps, which are recognized as the industry standard for high-quality, heavy-duty head protection. Ideally suited for workers on construction sites and heavy industry jobsites such as steel plants, foundries, forges, fabrication shops and chemical plants, the Roughneck P2A is stronger and more durable than common high-density polyethylene (HDPE) cap shells. Constructed of a proprietary injection-molded fiberglass compound, the P2A cap offers exceptional impact and crack resistance. Furthermore, it handles hard knocks in the toughest places without developing nicks and

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.20

CWA engage
3 CNC Machine Mishap Prevention Tips for the New User
Jack douglass
Research & Development Engineer, Torchmate

ost people do not usually buy personal CNC (computer numerical controlled) cutting centers every day. In fact, this technology used to be reserved for only the deep-pocketed machine shop elite. So when I took the time to consider what most home shop machinists might go through when they set up their first system, I knew I would have to take into account the fact that there is a large variation in individuals experiences with CNC cutting machines. Most metalworking, woodworking, and DIY enthusiasts have a detailed knowledge of the hand-held processes and skills that are required to complete their projects, but they are often lacking experience in the world of fully automated computerized tools, which could cause them serious problems down the road when it should be making their job easier. CNC can help increase the efficiency and accuracy of your shop, but only if you take the proper precautions and preventative measures. Following here is my list of considerations for first-time CNC users when they take the step of setting up a new system. Once you have these details down, you will be producing intricate, professional-quality parts and pieces in a fraction of the time, with far fewer mishaps.

dust danger. Metal dust on electronic circuits is usually a very bad thing. Metal dust sitting on a circuit board can cause shorts across the traces (tiny metal paths on the board) and cause components to fail. So if you are operating in a dirty or metallic dust-ridden environment, it is always good practice to remove the cover from the electronics boxes as well as the computer every few months, to blow away with clean dry air any metal dust that has accumulated on the electronic boards. Cable clutter. With computer control comes cords. You would not string electrical cords across your house: Do not do it with CNC wires in your shop either. Keep motor and height control cables free and clear of foot traffic to prevent any accidental tripping or cable damage. This will prevent damage to a drive card as well as to someones ego if they trip and fall over them in the shop. When disconnecting motor cables, make sure that the box powering the motors is turned off. In most cases pulling a cable out from a drive card that is turned on will do nothing, however there is a chance that a short circuit caused by unplugging while powered, will result in a failure of the components of the card. When this happens, cards may cost hundreds of dollars to replace. positioning. Make sure that the torch lead is located on one side of the cable carrier, and the motor and height control cables are located on the other side of the cable carrier. This tip is mostly for older plasma units but it is good practice for all machines. When the plasma cutter fires, there is a surge of power through the torch lead. Separating the wires helps prevent any induction of electrical current from the lead to the control wires. While separating them is key, the better practice is to prevent them from crossing. If they have to cross, make sure that they cross 90 degrees to each other. Also avoid coiling cables to avoid inductance.

www.cwa-acs.org

1) maintenanCe & organiZation. Many common problems are easy to prevent with proper preparation and maintenance of your CNC work area and equipment. Anybody who works in a shop for a living or for fun knows that a clean work area is crucial to organization and efficiency when completing a project. But most people forget that CNC cutting machines are still computers operated by electrical circuits.

Vol. 1

Issue. 3

Pg.21

CWA engage
tips. The drier the air in your area, the longer consumable tips will last. Of course, a torch tip can only last so long but if you do notice them wearing out a lot faster than you expect, or are told to expect, air quality may be the culprit. (I would say this is the case in perhaps 25 percent of poor cuts.) Empty your air dryers and the air tank itself (the main function of the purge setting is to set air pressure while flowing the type of slag that can accumulate on a torch tip will not blow away with the purge setting; I wouldnt mention this as a good practice). This is easy to forget about, but it is crucial to getting the most out of your consumables. If you continue to experience significant tip wear, make sure your plasma cutter is selected on the right amperage setting that matches the tip you are using in the torch; proper cutting height can also extend consumable life. 2) height Control preparation. In order to use your CNC cutting machine to the best of its ability and get the right cut every time, height control has to be a top priority. If it is not taken into consideration, it will make for a far less constructive CNC job. physical testing. Before cutting with a height control, it is critical that the settings are checked without firing the torch. Most height controls have the option to drop to the operating height without firing the torch; this can be controlled either through the software or height control. For most cutting the torch height will be 1/8 to 3/16 away from the material. Plasma manufacturers will publish charts with recommended cut settings, and in general these will give a good cut. Setting the height too high or too low can result in poor cut quality, incomplete cuts, or torch damage. automatic safety. Never start using a height control in automatic mode. Leave the unit in manual mode and cut a straight line, and watch the current voltage being displayed. That is the average voltage at which to set your height control to safely transition into automatic mode. When a safe voltage is set, the voltage can be fine tuned for the best overall cut. As the voltage, gets lower, the torch will cut lower to the plate. The higher the voltage, the higher it will cut from the plate when in auto mode. 3) Computer glitches. Considering that CNC cutting machines are susceptible to glitches like any other computer, it is always best to prepare for them to prevent your project from being ruined or incomplete. process is everything. When operating a CNC cutting machine, finding a sequence or methodology that works for you is critical. Throughout the process of creating a part certain things need to happen in order to prevent problems. Ironing out the steps that work for you is critical. Familiarize yourself with the whole process of designing, tool-pathing, and cutting a part. The same process to cut a simple square can be applied to an entire laid-out sheet of intricate parts.
Jack Douglass is an R&D engineer with Torchmate, a Lincoln Electric Company and supplier of fabricating machinery for a range of applications and functions. From shipbuilding machinery to the recently released 2X2, Torchmate has a product for every segment of the metal cutting, prototyping, and fabricating market.

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.22

CWA engage

Free Online Webinars on Welding Fume Extraction and Safety in the Workplace by Electrocorp
Learn more about source capture, fume extraction or general IAQ management by taking one of our complementary webinars. What pollutants may be present and what are the associated health risks? What can you do to protect yourself? Studies indicate that welders may have up to a 30 to 40 percent increased risk of lung cancer than workers in other occupations. They can be exposed to ozone, nitrogen oxides, hexavalent chromium and many other toxins that have been linked to cancer as well as permanent eye damage, skin rashes, and ulcers. MIG, TIG and aluminum welding produce the most ozone and pollution. Without proper air filtration and ventilation, these pollutants pose a serious occupational health and safety threat to welders. Electrocorps free online webinars are tailored to the specific needs of your industry (such as welding and soldering), and they provide solutions-based guidance on IAQ awareness and air treatment systems. The 30-minute webinars present details on the air quality in the workplace to avoid health hazards and associated complications. For more information, e-mail leif@electrocorp.net, visitwww.electrocorp.net or call 1.866.667.0297, ext 263.

Welding WeBinar

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.23

BUSINESS NEWS

CWA engage

skilled trades groups make pitch to students

CBC news - earlier this month skilled trades organizations and companies campaigned in ottawa to get more young people to consider programs on construction, welding and plumbing. We are facing a shortage in Canada of about 80,000 technology workers today. To read the full article click on this link: http://www.cbc.ca/news/canada/ottawa/ story/2011/11/01/ottawa-skilled-trades-shortage.html

rough weld caused avondale train derailment


CBC news - november 7th, 2011 The derailment of a train carrying dangerous goods is being blamed on a poorly welded plate that hampered a tank cars ability to turn. To read the full article click on this link: http://www.cbc.ca/news/canada/nova-scotia/story/2011/11/07/ns-avondale-train-derailment-weld. html?cmp=rss

Over the next decade, at least one million jobs are expected to open up in the province, and 75 per cent of them will require some post-secondary education or skills training. This growing demand comes at a time when the provinces existing skilled workforce is shrinking as more tradespeople transition to retirement. Recent forecasts predict a skilled labour shortage of at least 160,000 by 2015. To read the full article click on this link: http://www.vancouversun.com/opinion/Investment+skilled+trades+training+will+future/5680046/story.html

air liquide launches new online welding courses

discover the new online welding courses created by air liquide Welding specialists. the first course is Free! For more information click on this link: http://93.186.241.62/airliquide/alwvideomail/landing_en.html

www.cwa-acs.org

Vol. 1

Issue. 3

investment in skilled trades training will aid future


vancouver sun - november 9, 2011

Pg.24

CWA engage
paint booth. With a Duroair system, you can save on material handling costs and improve safety within your facility. The retractable technology allows you the full use of your valuable shop floor space when the paint booth is not in use. The cost to outsource your coating needs is increasing. When considering the cost and logistics of transportation as well as the painting service cost, the decision becomes clear that painting in-house with a Duroair retractable paint booth is the more affordable option. Completing your painting needs in-house further allows you to maintain greater control of the total production time. With a Duroair retractable paint booth, you can control when your product is ready for shipping instead of having to rely on the painting service provider. By bringing your painting process in-house, you can save on outsourcing costs, increase productivity and have greater control on delivery times of your product to your customers. Imagine a space saving paint booth in your facility where you could not have imagined before.

duroair retractable paint Booths: No project too big, no space too small
Affordable compliant paint booths Space saving design with retractable enclosure Efficient dry times with the Duroair patented airflow have you considered bringing your coating process in house?

to learn more visit: www.duroair.com or contact ryan at: ryan@duroair.com / 416.988.7576

www.cwa-acs.org

Duroair manufactures retractable paint booths which retract to 20% of their size. Whether you require a large or small painting enclosure, the Duroair system will match the airflow required to ensure a quality finish in a compliant work environment. Duroair retractable paint booths are an excellent solution to challenging space constraints and work where other paint booths simply cannot. With Duroair, facilities can now place their paint booth anywhere on the shop floor without requiring additional space around the booth. Simply retract the enclosure, load the spray area with the use of an overhead crane or fork truck, pull the enclosure around your work piece and you have a fully compliant

Vol. 1

Issue. 3

Pg.25

Many manufacturers and fabricators must apply a protective coating to their finished product or incur large outsourcing costs to do so. Without a compliant coatings facility, many of these businesses are in violation of workplace health and safety regulations and, as such, expose their valued employees to health risks as well as exposing their businesses to the risk of being temporarily shut down through regulatory enforcement. Duroair is an efficient and affordable solution for those businesses who previously only had the option of purchasing expensive, fixed-installation paint booths or incurring expensive outsourcing costs.

CWA engage

Cyber Insurance
Organizations are increasingly dependent on computer systems, networks and the internet to drive business strategy and productivity. Many organizations are not fully aware that this increased use of information technology has brought with it new threats to the balance sheet, many of which are unlikely to be covered by traditional insurance. The exposures are both internal (computer networks) and external (the Internet) and the losses can be First Party (the organizations own losses) or Third Party (its liability to others). Some of these risks are insurable by Cyber Insurance. Cyber insurance products are relatively new and can vary in their coverage terms. The exclusions should be carefully reviewed.

Judi smith, Crm, Ba

Senior Commercial Insurance Broker, HUB International Ontario Ltd. ?

dave Whyte, FCip (author)


introduCtion: types oF CyBer risK?

Vice President of HUB International Ontario Ltd.

Disgruntled employees, malicious insiders and criminals from outside the organization may sabotage the system. These individuals internally or externally may be motivated with the objective of financial theft; identity theft; fraud; extortion; revenge; pride; or fun and may with malicious intent identify weak points in the system or weaken the system for profit, amusement or revenge. Criminals often use the internet as a means to achieve fraud, data extortion, ransom or blackmail. Their tools include Viruses, Encryption Cracking; Eavesdropping; Spyware; Malware; Zombies; Stealth Bombs; Trojan horses; Worms; Crawlers, Data Mining, Phishing, Hackers and Denial of Service Attacks. A web-site exposes an organization to the same legal liability as a publisher; they can be sued for libel, slander, defamation, and copyright and intellectual property infringement. The use of email also presents potential personal injury loss scenarios. Organizations have a responsibility to protect, store and manage data - their own and that of a customer. They can be held legally liable for a data breach. Notification expenses can be significant in the event of an electronic security breach. Organizations may also be at risk from third party contractors or others who have access to the computer system. These individuals may damage the system or create a security breach or in some other way create legal liability for the organization by way of their activities. Human Error and Natural Disasters such as flood, earthquake or fire can result in the accidental damage or destruction of the IT system and /or its data.

In simple terms, cyber risk is the exposure to financial loss to an organization arising out of computer networks and the internet. First party losses can arise from- loss destruction or damage of data; network damage; system failure; theft; increased cost of working; loss of business revenue; and damage to reputation. third party losses can arise from defamation; infringement of copyright and intellectual property; breach of confidentiality; disclosure of private facts; misappropriation of name or likeness; invasion of privacy; misleading advertising; and transmission of computer virus. Organizations that hire third parties to manage their systems or data and those that employ independent contractors may have an exposure to both first and third party losses arising out of the activities and services provided by these third parties.

What is CyBer risK?

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.26

CWA engage
The electronic age has created threats to an organizations intangible assets that are relatively new creating new issues for traditional insurance. Coverage gaps in many traditional policies can range from but are not necessarily limited to data theft, destruction by hackers, liability for privacy breach from the unauthorized disclosure of data through human error, system malfunction or hackers. Most traditional property and machinery breakdown policies exclude cyber risks. The coverage trigger under a standard property or machinery breakdown policy is direct physical loss or damage to tangible property. Data is not considered tangible property and in many cases the door to possible coverage is further closed by specific data exclusions. Malicious code, viruses, and network corruption are key perils to data. Business Interruption losses without corresponding physical damage to tangible property is excluded. Note: An electronic data processing policy will typically include provision to cover data and media but may contain specific exclusions for cyber risks such as computer viruses. Typically, commercial general liability (CGL) policies contain an electronic data exclusion for damages arising out of the loss of, loss of use of, damage to, corruption of, inability to access or inability to manipulate electronic data. Generally, electronic data means facts or programs stored as or on, created or used on, or transmitted to or from computer software, including systems and applications, software,hard or floppy disks, CD ROMS, tapes, devices, cells, data processing devices or any other media which is issued with electronically controlled equipment. Most CGL policies define invasion of privacy as the oral and written publication of confidential information. The unauthorized disclosure of data in a hacking incident or a lost laptop does not involve any kind of intentional publication. Therefore there is unlikely to be coverage for such an incident.

traditional insuranCe:

CGL policies tend to cover emotional distress only if it is associated with physical injury. Physical injury does not result from a privacy breach. Typically, a privacy breach lawsuit will allege damages for mental anguish, stress, embarrassment etc. creating a potential coverage gap. Crime insurance policies may or may not include some coverage for electronic activities such as computer fraud and funds transfer coverage but few, if any, will extend to cover all cyber related risks. The theft of intellectual property or confidential material by hackers or disgruntled employees may not be covered under traditional property or crime policies because these policies apply to theft of tangible property. In rare circumstances it may be possible to extend a crime policy to cover the theft of the insureds information but few if any insurers will agree to cover the liability exposure to the insured should the confidential information of a third party be stolen while in the insureds possession. Until recently most web-sites were relatively innocuous resembling electronic promotional brochures. The material on these web-sites was typically covered against claims for copyright or trademark infringement and libel under the advertising injury coverage in a CGL policy. However, many websites have evolved. Some include advice, research and articles published by the organization; some are interactive with links to other sites; some allow for the payment of goods and services

www.cwa-acs.org

Vol. 1

Issue. 3

Pg.27

CWA engage
whereby confidential information may be collected. In addition, some websites and blogs are used to facilitate interaction with third parties. As a general statement many websites now include activity and material that transcends the definition of advertisement. In many cases there is a publishers liability exposure. Traditional Errors and Omissions policies may or may not contain data exclusions.

Examine the coverage carefully particular attention should be paid to the exclusions.

CyBer insuranCe - points to Consider:

Does the policy cover your IT systems data and media for damage caused by hackers, viruses, denial of service attacks etc.? Is the IT system insured on a functional replacement cost basis? What is the extent of the Business Interruption coverage?

First party losses:

Is a legal liability arising from a privacy breach from unauthorized disclosure of private information in the organizations care, custody and control covered? Are complaints for failure to comply with privacy laws covered? Some policies exclude coverage if there was a failure to abide by such laws? Are the costs to notify third parties of a possible privacy breach covered? Does the policy cover potential legal liabilities arising from the activities of third party contractors or vendors who handle or have access to the insureds confidential information? Is the Insured covered for claim(s) by third parties that result from the work, actions or services provided by independent contractor working on behalf of the insured?

third party losses:

For more info contact Judi Smith at: judi.smith@hubinternational.com This article is not a substitute for legal advice. It provides general and generic information only. Any definitions provided have been simplified for explanatory purposes. Coverage can vary from one insurance policy to another. Please refer to the actual policy wordings for the exact extent of coverage. Discuss any areas of concern with your legal counsel and/ or insurance broker.

www.cwa-acs.org

Do they have appropriate Professional Liability / Errors & Omissions coverage?

indEpEndEnt contractors and sErvicE providers:

Vol. 1

Issue. 3

Pg.28

COURSE REFERENCE upcoming CWB institute Courses


CWB
Welding supervisor seminar - steel
(Visit www.cwbinstitute.org for online course options) This five day course is designed for Welding Supervisors who want to increase their knowledge of managing a Certified welding shop. This course is also of interest to engineers, shop foreman, quality assurance personnel. Edmonton Dec 5-9, 2011 Sudbury Nov 28-Dec 2, 2011 Saskatoon Nov 28-Dec 2, 2011 Kelowna Jan 23-27, 2011

CWA engage
Code endorsement
These one or two-day courses (7.5 or 15 hours) are designed to help you gain endorsement and inspection qualifications. The choice of endorsements you would like to receive is up to you.

quasar
quasar internal auditor training
QUASARs ISO 9001:2008 Internal Auditor Training course provides you with the tools to help your company operate more cost effectively and efficiently.

Welding health and safety

(Visit www.cwbinstitute.org for online course options) Want to expand your knowledge of welding health and safety and learn how to identify welding hazards in your welding shop? Get information on how to reduce the risk of accidents and injuries to your employees.

intEG
materials & processes
This detailed 5-day (40 hours) training course will provide NDT technicians and Quality Control personnel with an extensive understanding of the production, composition and properties of metals.

Welding supervisor seminar - aluminum

This three day course is designed for Welding Supervisors who want to increase their knowledge of managing a Certified aluminum welding shop. This course is also of interest to engineers, shop foreman, quality assurance personnel.

liquid penetrant level 2

Welding inspection Course level 1

Welding inspection Course level 1 - exam preparation


The Level 1 inspection course is 10 days of instruction, reviewing the necessary welding and welding inspection theory to challenge the Level 1 Welding Inspector certification examinations. Milton Jan 30-Feb 10, 2012

Film interpretation

level 2 upgrade Course

www.cwa-acs.org

This seven-day course (52.5 hours) is designed for Level 1 Welding Inspectors who want to further increase their knowledge of inspection and testing techniques. Edmonton Feb 1-9, 2012 Milton Feb 6-10 (5 day course), 2012 Dartmouth Feb 22-Mar 2, 2012

Vol. 1

This three day course (24 hours), will provide participants with a basic understanding of radiographic film imaging, and processing etc. Calgary Dec 5-7, 2011

Issue. 3

(Coming soon to www.cwbinstitute.org) The Level 1 inspection course is 9 days of instruction, reviewing the necessary welding and welding inspection theory to challenge the Level 1 Welding Inspector certification examinations. Day 10 of the course gives you the opportunity to challenge the CSA W178.2 Visual Welding Inspector Level 1 certification examinations. Edmonton January 16-27, 2012, Mar 5-16, 2012 Dartmouth January 23-February 3, 2012 Saskatoon Jan 30-Feb 10, 2012

This five-day course (40 hours) will provide the NDT knowledge and the confidence for participants to assume the responsibilities of a Level 2 Liquid Penetrant Technician.

magnetic particle level 2

This five-day course (40 hours) will provide the NDT knowledge for participants to assume the responsibilities of a Level 2 Magnetic Particle Technician. This seventeen day course (136 hours) will provide the NDT information for participants to assume the duties of a Level 2 Radiographic Technician. Calgary Nov 14-Dec 2, 2011

Pg.29

radiography level 1 & 2

TECH ADVISOR

CWA engage
characteristics in terms of the materials employed, the quality of the clad layer and various practical issues including throughput speed, process compatibility, and cost. Laser-based processes are amongst these techniques, however, their implementation has been limited due to both cost and various implementation factors. Over the past several years, a new type of cladding tool based on high-power diode lasers has become available. In many instances, this technology offers superior overall clad quality, reduced heat input, minimal part distortion and better clad deposition control than traditional technology, while also delivering lower operating cost and easier implementation than other laser-based methods.

Cladding with high power diode lasers


By: Keith parker
Senior Business Development Manager- Direct Diode & Fiber Laser Systems Cladding is a well established process used in a variety of industries for improving the surface and near surface properties (e.g. wear, corrosion or heat resistance) of a part, or to re-surface a component that has become worn through use. Cladding typically involves the creation of a new surface layer having different composition than the base material, as opposed to hardening, which simply entails changing the properties of the substrate itself in a thin surface layer. There are currently quite a number of different techniques for performing cladding, each with its own specific

To read the complete article click on this icon.

cutting manual welding

robotic welding
Pg.30

Products

Services Nederman o ers portable, stationary and modular ltration solutions for your fume and dust extraction needs proudly assembled and serviced in Canada

1-866-332-2611 www.nederman.ca

www.cwa-acs.org

Your Extraction and Filtration Experts

Solutions

Vol. 1

Issue. 3

TECHNICAL REFERENCE

CWA engage

Flux and metal-Cored eleCtrode ClassiFiCation system


E XX X T - XMJ - HZ E XX X C - XMJ - HZ
Electrode Minimum tensile strength in MPa/10 43 = 430 MPa 49 = 490 MPa Position 1. all positions 2. flat groove welds and flat and horizontal fillets

Optional designator indicating controlled hydrogen Z indicates the number of ml of hydrogen, per 100 g of deposited weld metal Z can have the values: 2,4,8 or 16

The letter J designates that the electrode meets the requirements for improved toughness of 27J at - 40C. Absence of the letter J indicates normal impact requirements The letter M designates that the electrodes is classified using 75 - 80% argon, balance CO2 shielding gas. When the letter M designator does not appear, it signifies that either the shielding gas used for classification is 100% CO2 or that the electrode is self-shielded. Usability and performance characteristics T = flux-cored C = metal-cored

Why iiW
(International Institute of Welding) Founded in 1948 with just 13 Member Companies, the IIW has grown to become a truly international organization.

For more information call: 1.800.844.6790.

www.cwa-acs.org

Through the IIWs qualification and certification programs, to date the IIW has issued over 70,000 diplomas and have certified more than 500 companies and has become the premier welding standard for many countries. As an IIW diploma holder or IIW certified company (following ISO 3834), you get international recognition and easily transferable qualifications.

Vol. 1

Issue. 3

Fig 3.6

Backed by numerous international Technical Commissions, Select Committees, Study Groups and Working Units, IIWs programs leverage a worldwide network focused on providing knowledge exchange for joining technologies. Canadians can participate in the IIW technical network through the Canadian Council of the IIW (CCIIW), which represents Canada as the IIW Member Organization. To find out how you can participate visit www.cciiw.ca

Pg.31

EXPAND YOUR SKILLS, EXPAND YOUR REACH

With an active presence in over 50 countries and spanning all continents, the IIW is the logical choice for companies or individuals looking for an accreditation that opens doors around the globe.

THE LAST WORD

CWA engage

a look back
CANADIAN WOMEN
Rosie the Riveter would soon become Rosie the Welder
As did our fellow American sisters during World War II, our Canadian women also stepped up to take the place of men in the workforce. Canadian women rose to the occasion and proved they were more than capable in doing jobs that were once considered the work of men. And they did it well! They drilled, and soldered and became our Canadian version of Rosie the Riveters, a term used to describe a cultural icon of the United States, that reflected American women who took on the industrial work of welders and riveters during World War II . Welding really took off during the war; it was the quickest and most economical way to join metal. During 1943 at the peak of war-time production, more than $360 million was spent in the United States alone on welding equipment and materials. Ship construction time was reduced by 243 days due to welding during the First World War to 28 days into the Second World War. Even Rosie lost her job as a riveter. It was inevitable, Rosie the riveter would soon become Rosie the welder! Our Canadian women held these welding positions that required skill and training. Women are generally smaller in physical stature they were able to do very dexterous jobs with precision. During the war, many items were in short supply that impacted the dress and fashion of the women in the workforce. Buttons, silk and nylons were scarce. Some women even reverted to painting a charcoal line down the back of their legs to give the illusion that they were wearing nylon stockings. While doing the work of men they still wanted to feel feminine and demonstrated that on the job front. We salute our Canadian women who served our country well, and who continue to do so.

an insert from the song: All day long, whether rain or shine, Shes part of the assembly line. Norman Rockwells saturday Shes making history, evening Post cover featuring Rosie working for victory, the Riveter - Curtis Publishing. Rosie the Riveter.

www.cwa-acs.org

Rosie the Riveters was first used in 1942 in a song written by Redd Evans and John Jacob Loeb. It has since been recorded by numerous artists including Kay Kyser and has become a national hit.

Vol. 1

Issue. 3

Pg.32