After FABTECH, but before Thanksgiving, please come out tolearn and earn (PDHs) from one of Detroit’s very own RWpractitioners: Don Maatz. Hard on the heels of last April’s successfulEducation Night [RW Maintenance War Stories with Bruce Kelly] wewill now build upon the related principles of RSW and PW quality.This promises to be a unique and energetic session designed tomake you think about the quality standards associated with twovery common forms of resistance welding.

A concise session illustrating the fundamentals of RW standards/codes and terminology, including quality attributes (both DT andNDE), and discontinuities and defects will be discussed. After this presentation, it isvery possible that you will never look or think about a resistance weld the same wayagain. Please bring and ask your questions to challenge the night’s forum.

1 NOVEMBER TECHNICALMEETING

2 COMMITTEE CHAIRS2 CHAIR’S MESSAGE2 MEETING PRESENTER’S

BIO3 COMING EVENTS:

•CHRISTMAS PARTY•LADIES NIGHT

3 EDITOR’S NOTE4 NOVEMBER HOTLINE4 WELDING CHALLENGE

CONTEST5 PATRONS8 ASK THE WELDING

ENGINEER11 MEET OUR MEMBERS12 SMWC XVIII CALL FOR

PAPERS

November 2017

Inside This Issue

Follow Us: awsdetroit.org

AWS Technical Nights are open toeveryone! We encourage thatmembers bring students and non-members to learn more about ourorganization and industry.

November Education NightThursday, November 16, 2017

Affiliated With

For AdvertisingOpportunities

Contact Don Crist810-217-9897

dcrist@romanmfg.com

Ukrainian Cultural Center26601 Ryan Rd., Warren, MI 48091

Map/DirectionsTechnical Liaison: Nate Miller

Resistance Spot and ProjectionWelding Standards & Quality

Email & phone RSVP by Nov.6th Amanda Davis via email atamanda.davis@fcagroup.comorby phone @ (248) 512-1803. A $10scholarship donation welcomed atthe door.

AGENDA5:30 – 6:00pm Welcome Reception &

Networking6:00 – 6:15pm Opening Remarks6:15 – 6:45pm Dinner6:45 – 8:15pm Educational Presentation

Donald F. Maatz, Jr.

Presenter

See “Presenter bio” on page 2Ukrainian Cultural Center

Presenter BioDonald F. Maatz, Jr. has over 35 years’ of experience in the welding industry. He is

presently associated with R&E Engineering Services (RES), a subsidiary of R&E AutomatedSystems, LLC, and serves in the capacity of Laboratory Manager. Prior to joining RES he workedwith RoMan Engineering Services, Tailor Welded Blank, and the Ford Motor Company. He isalso a veteran of the U.S. Navy’s Silent Service.

An AWS member for 24 years, Mr. Maatz is past-chairman of the AWS-Detroit Section andthe recipient of the Elihu Thomson Resistance Welding Award. He serves on the D8 and D8DAutomotive Welding Committees, the D8.1 and D8.9 Automotive Welding Sub-Committees,

and is an advisor to the C1 Resistance WeldingCommittee. Additionally he is an AWS endorsedCertified Welding Inspector (CWI), an instructor forthe RWMA Welding School, and Vice-Chairman ofthe Certified Resistance Welding Technician workinggroup. He also serves on several committees of theAuto/Steel Partnership.

Mr. Maatz is a co-author for the 2011 edition ofASM Metals Handbook on Welding and Brazing (Vol.6A, Resistance Welding Power Supplies and Controls).In addition, he has authored or co-authored featurecolumns and peer-reviewed papers for the AmericanWelding Society and the Society of AutomotiveEngineers. He has given presentations at the Advancesin Resistance Welding International Seminar,International Autobody Congress, and the AWS-Detroit Section Sheet metal Welding Conference. Mr.Maatz is a graduate of Ohio State with a BS inWelding Engineering.

R&E Engineering ServicesA subsidiary of R&E Automated Systems, LLC(586) 228-1900 x4420 – Office(586) 566-0471 – Fax (734) 793-2304 - Direct70701 Powell Road, Bruce Township, MI 48065dmaatz@reautomated.com

November 2017This Issue of the Bulletin

can be viewed on the web at

awsdetroit.orgA chill is in the air as we move into November,

but things are just heating up at AWS. The largest annualAWS event is this month as thousands of welding industryprofessionals descend on Chicago for the AWS Fabtechevent November 6th thru 9th. The show in Chicago is much

more than a trade show, it is a week packed with education seminars, meetingsand luncheons where companies and individuals are recognized for theircontributions to our organization. If you have never attended the show Iencourage you to visit. You don’t even need to drive or stay overnight as thedaily round trip Amtrak schedule can bring you to and from Chicago viatrain - I hope to see you there. The Detroit Section has been working hard tobring Technical and Education seminars to our over 1000’s members locallyin the Detroit Metro area. We are always looking for seminars and professionalswho would like to engage with us to bring more value to our organization andat the same time educate local people and companies. If you have an interestin contributing please contact me directly. I will put you in touch with thecorrect Executive Committee member. As we get closer to closing out 2017, theholidays are fast approaching. I hope everyone is able to get a break fromtheir busy schedules and spend time with family and friends duringThanksgiving. Have a safe and Happy Thanksgiving.

Wes

Wes DonethChairman’s Message

�Chairman

WESLEY DONETH

First Vice ChairMARK GUGEL

Second Vice ChairJOHN SUTTER

SecretaryDAVID BENETEAU

TreasurerANDRE YOUNG

Bulletin EditorROBIN MICHON

WebmasterRODNEY BEREZNICKI

Hotline Coordinator: BRIAN PETERSON

Meeting Reservations: AMANDA DAVIS

AdvertisingDONNIE CRIST

Assistants to Chairman:JOHN PIPPIN, JR.ERIC LICHTFUSZNATHAN MILLER

Upcoming Events Editor’s NotesAnother month has flown by, and I feel as though I’ve

let some of you down. So, this month, I’m reaching outto all of you, young and old, students, teachers, engineers,welders, instructors, etc.

What do YOU want to see and read in YOUR e-bulletin?What types of articles make you want to scroll throughthe pages when you get the email blast saying that thebulletin is in?

That being said, I’m expecting to hear something fromyou, our readers, letting us know what you value in thise-bulletin, and even what you’d like to see disappearfrom our bulletin.

With FabTech this month, as well as the beginning ofthe Holiday season, I know that time is of value. So pleasedrop me an email and/or stop me when you come to oneof the technical meetings.

Until next month, Keep on Welding…

Robin M. Michon – ebulletin editor rmmichon@gmail.com

ICR Celebrates 25 Years of BringingExcellence to AutomationOn Friday, September 29, 2017, ICR (formerly knownas Industrial Control Repair) held an open house for itscustomer base to commemorate a diverse, minority-owned business that’s supported manufacturers largeand small since 1992. Helping ICR celebrate the occasionwas Mobsteel, a design/build company that manu -factures automotive aftermarket products and buildscustom cars in Detroit.

Adam Genei, Owner of Mobsteel, and his crew can beseen locally at their shop, events around Metro Detroitor on their TV show Detroit Steel,which airs on History.ICR developed a relationship with the company that leadto a few highlights of our robotics facility on the debutepisode of their series.

A few of ICR’s repair and OEM partners stopped by ourevent to showcase their service offerings. We were veryfortunate to have Atlas Copco, Dengensha America,GTI Spindle and Threadcraft on hand to celebrate amomentous occasion.

We’ve posted a video recap of the event and an image gallery here.

November Hotline

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Left to right: Glenn Dantes, ICR VP - Automation Division; Adam Genei,Owner of Mobsteel / Detroit Steel Wheel Co.

OctoberTechnicalMeeting Recap

The AWS-Detroit sectionhosted its October Technicalmeeting at Easom Automa-tion in Madison Heights,Michigan. Mr. FrankWennberg, the Sales Man-ager of Lincoln ElectricAutomation Solutions atEasom Automation Division, gave a presentationon modular arc weldingcell advancements oncoated material regardingvarious auto equipment.His presentation detailedhow Lincoln ElectricAutomation Solutionsinnovatively designed thearc welding cell in amodular fashion for less maintenance effort, short downtime, and flexible upgrade/interexchange of some portionof the cell for multiple welding applications. There wereabout 30 attendees in the meeting. A shop tour of Easomautomation was given after Mr. Wennberg ‘s presentation.

ATI IndustrialAutomation

Aro WeldingTechnologies

Dengensha America

Luvata

RoManManufacturing

Matheson

Centerline Windsor

Leoni

Obara

Staubli

Genesis Systems

Grossel Tool

United Technologies

Airgas

Fusion Welding

Fronius

ICR

Ashley Jones

Matuschek

Ohio State UniversityWelding Alumni

2017/18 Patrons

Co-op Welding Students,Summer Interns andPart-time Welders

Contact Pat Bell:patricia.bell@detroitk12.orgor (313) 282-8171 in Detroit

“We are resistance spot weldingon galvanized coated parts andexperiencing what we consider

to be short electrode life. We start eachproduction run with welds that barelymeet their size requirements but finishwith expulsion so severe we end updestroying the electrode face. We arehesitant to change the weld scheduledue to the small initial weld size andhave instead focused on the currentstepper, to little effect. The water flow,electrode cap size, weld force, secondarycurrent and weld time are all in linewith RWMA and AWS C1.1 guidelines.Any ideas would be appreciated.”

“This question intrigues me. If it isassumed that all other aspects ofyour Resistance Spot Welding (RSW)

application are within acceptable industrynorms, and that you are welding partswith a coating that is not too detrimental(they all are to a certain extent) to theelectrode caps, you may actually have acurrent stepper boost issue. However, asI hope to illustrate, this boost issue maybe of a very different kind than one wouldtypically encounter. But, before we moveforward, the following caveat must beunderstood: This discussion is reallyrelevant only for automotive grade coatedsteel products, with the assumption thatyou are referring to hot-dipped galvanizedparts for your application. I say this asother automotive grade coatings (electro-galvanized, galvanneal, etc.) do exhibitthis behavior but typically to a muchlesser degree. The welding of any othermaterial substrate (stainless, etc.), or gradeof galvanized coating (i.e. commercial,military, etc.) on steel, falls outside of therealm of this article’s applicability. Also,please note that for this discussion allaspects of the RSW process are correct forthe application being discussed. Theimportant elements of materialweldability, part presentation, weld guncapability, configuration and condition,electrode alignment, cooling, stack-upratio, plus the actual weld schedule itself,are suitable for the application. If thiswere not the case, we would not be ableto correctly evaluate the application forelectrode wear and weld performanceover the course of a production run.Now, back to the matter at hand, yourquestion. To help answer it one must first

understand what would occur if we wereusing the RSW process and did not havea current stepper boost feature on ourweld control. As each weld is made, theact of applying the scheduled weld timeand secondary current, combined withthe application of the needed weld force,physically degrades the condition of theelectrode contact face. Some in theindustry refer to this as mushrooming.This degradation may be subtle andbarely noticeable even after many welds,or it may be dramatic, occurring veryquickly in the production run. As anexample, when the RSW process is usedon bare steel and the parts are free of dirtand lightly coated with a known benignoil, it may be possible to make manythousands of welds before the electrodecaps are no longer able to produce a weldof acceptable quality. On the other hand,I have seen coatings that acted so aggres -sively as a wear agent that the electrodecaps were essentially ruined and requiredmaintenance after less than a few dozenwelds. The most common electrode main -tenance activity involves renewing thecontact face geometry either by dressingthe electrode cap, or replacing it.The current stepper is a feature of theweld control and was created as a meansto help increase the number of weldsbetween electrode maintenance cycles.It accomplishes this by the adjusting thesecondary current in a programmedmanner so that the current density(amps/unit area) remains relativelyconsistent as the electrode cap contactface area increases with every weld. Theearly weld controls only permitted for theaddition of current at discrete intervalsand a plot of their profile over time lookedlike a set of steps, hence the name. Amore modern weld control permits for acustomized profile plot (e.g. boost of 1amp/weld). However, despite the factthat the profile is a sloped line and nolonger looks like set of stairs, the namehas stuck. As an aside, there has beenmovement at the OEM level away fromutilizing the boost feature of currentsteppers and strictly using them as acounter to trigger a maintenance activity.This no-boost (or minimal boost), dressearly, dress often philosophy has meritbut really needs to be the subject of aseparate discussion.For context, we last took a look at thecurrent stepper in an earlier column (Oct-

15 ATWE). That column dealt with thecreation of a generic stepper profile. Butas eluded to above, I sense that there is aboost issue at work here that is a bitunique and may not have beencompletely addressed with the previouscolumn. Now that we have some essentialbackground information, we will continuethe discussion of stepper boost in thisapplication in a future column.”

If you have more questions about this topic,Contact Don Maatz at:R&E Engineering ServicesA subsidiary of R&E Automated Systems, LLC70701 Powell Road, Bruce Township, MI 48065(586) 228-1900 – Office(734) 793-2304 – Directdmaatz@reautomated.com

References:1) Resistance Welding Manual, revised 4thEdition2) AWS C1.1M/C1.1:2012, RecommendedPractices for Resistance Welding

s

Ask the Welding EngineerBy Donald F. Maatz, Jr.

A:

Q:

Hi Brian and Welcome to theColumn! I’d also like to welcome youto the AWS Detroit Executivecommittee! This is the first time, I’vebeen able to interview one of ourmembers who is actually the newcolumnist for this section of the e-bulletin.

Brian, why don’t you tell us a littlebit about yourself?Hi, my name is Brian Hanhold and I’ma Joining Engineer, Body ConstructionEngineer at Ford Motor Company.

Brian, tell us a little bit about yourposition, what do like or even dislikeabout your position.I enjoy my fellow colleagues andcollaboration we have not only withinFord, but with the supply base as well. Ienjoy the feeling of watching F-Seriesdriving down the road and knowing Iwas critical in making that productavailable. (I also like pointing out tidbitsof information about it to anyone thatwill listen!) The one thing I dislike is thesheer number of hours that launchingvehicles can consume. But that feelingof seeing all those long hours becomesomething tangible and people love,makes it worth it.

Why did you join AWS? In 2008, I joined the student chapter atThe Ohio State University. I havecontinued paying dues because the Societyand local chapters have been worthinvesting in for continued pursuit ofwelding excellence by supporting trainingon technical knowledge, providingscholar ship assistance for future genera -tions of welders/engineers, and a greatnetwork to be involved with for my career.

What’s your favorite AWS event? National level I enjoy FABTECH andlocally, I enjoy the Technical Series andLadies’ Night.

What kindof things doyou enjoyoutside ofwork?I play beerleaguehockey,

softball, and volleyball, ride bikes, visitnew breweries, and travel to whereverpeaks my interest (usually involveshiking/kayaking, or one of the previouslymentioned interests)

I always like to ask our guests if theyhave a funny moment or story thatthey don’t mind sharing. Forgetting to turn the water back on aRSW test bench when I interned at GM.The sound of the electrode caps blowingwas quite the shocker. I am glad no onegot hurt considering how far the electrodetraveled from where I was working.Needless to say, I didn’t forget to turn thewater back on after that.

What is your most memorablemoment?Back in school, I captained a studentproject, making a human-powered“Moonbuggy” we tested the night beforewe had the competition in Huntsville, ALand somehow broke a control arm goingover a curb. Needless to say, we pulledan all-nighter to fabricate another andwere still able to finish with the 2nd besttime in the competition.

What do you see as the biggestchallenge for welders in the future? The age gap between veterans in theindustry and newcomers. The knowledgeand experience are not easily replaceable.Another tough challenge is increasinglymore difficult materials to weld in allindustries. This requires a constant needfor education and training that makesour occupation very exciting, yetchallenging.

Have you ever used your weldingskills outside the workplace? I have made a couple minor home projectsincluding an INCONEL spatula, somesheet metal “art,” and some repairs toold bicycle frames.

What would you tell someone whomay be “on the fence” about gettinginto welding as a career? There are great opportunities in variousindustries that aren’t going away anytimesoon. Even if you are local and it onlyseems like automotive options are avail -able, there are still numerous companieswithin the Detroit section that do fabrica -tion for automotive or are in aerospace,

military, oil&gas, andnumerousotherindustries.

If youweren’tinvolved in the welding industry,what would be your dream job? Growing up, depending on the week, Iwanted to be a professional baseballplayer, FBI agent, or an astronaut. Now,I’d probably like to start my own brewery,even though I think that market is over-saturated.

Would you encourage more schools(high schools and junior high) toencourage more young people to lookinto technical schools and jobs andnot just degreed positions? Explainyour answer. Yes, I think we are at a loss for skilledpositions, not only welding, butelectricians, millwrights, pipefitters,mechanics, you name it. These are stillhighly regarded and well-paying jobs,but there isn’t a focus on it anymore. Iwish I had taken more trade/technicalcourses to be more self-reliant (i.e.wood/metal working, plumbing, homeconstruction projects, etc.). So, I eitherlearn from online videos or payingsomeone to do something I should beable to do myself.

Thank you, Brian, for being ourNovember featured member. And,thank you as well for taking over thiscolumn.

If you’re interested in being featuredin our monthly e-bulletin as a AWSDetroit Section member, pleasecontact Brian Hanhold atbhanhold@ford.com for moreinformation and/or to set up aninterview opportunity!

MEET OURMembers Brian Hanhold

Please complete the Author Application Form (below or available ataws.detroit.org) and submit it along with a 100–300 word paper abstractto smwcpaper@awsdetroit.org by April 27, 2018. If you have any questionsrelated to submission, please contact: Jerry Gould, Technical Chair, EdisonWelding Institute, jgould@ewi.org

Call for PapersThe Sheet Metal Welding Conference

(SMWC) is the premier technicalconference dedicated to bringing expertstogether to discuss state of the art weldingand joining technologies for theautomotive, transportation, and light

manufacturing industries. SMWC alsoprovides important opportunities forengineers and researchers frommanufacturers, suppliers, universities andresearch institutes to network and meetexperts in the field of welding.

SMWC XVIII will emphasize recentdevelopments in welding and joiningsolutions that enable lightweight vehicledesign and construction. You are invitedto submit technical papers for presentationat this conference.

PLEASE PRINT: Author / Presenter __________________________________________________________________________________

(If there are additional authors, please submit the above information for each co-author on a separate sheet.)

Company/Organization:_______________________________________________ Title or Position:________________________________

Email:_______________________________________________ Phone:___________________________ Fax:__________________________

Mailing Address:_______________________________________________________________________________________________________

City/State/Zip:___________________________________________________________________

PROPOSED TITLE: (10 words or less)___________________________________________________________________________________

_______________________________________________________________________________________________________________________

• By submitting a paper for presentation at the Sheet Metal Welding Conference, the author(s) grant a non-exclusive license to the American WeldingSociety-Detroit Section to publish and distribute the paper as part of the Conference Proceedings.

• Please type your technical abstract in a double-spaced format and limit it to no more than 300 words. The abstract file should be sent together withthe author application form to smwcpaper@awsdetroit.org.

In Partnership with ESD The Engineering Society; Conference Chair: Warren Peterson, United Technical Solutions; Co-Technical Chairs: JerryGould, EWI; Menachem Kimchi, OSU Material Sciences and Engineering; Publicity: Donald Crist, Roman Manufacturing

Sheet Metal Welding Conference XVIIIWelding Solutions for Lightweight

Vehicle ProductionOctober 17 & 18, 2018

Laurel Manor, Livonia, MI

• Fusion Welding and Brazing (Resistance,Arc, Laser and others)

• Solid-State Joining • Mechanical Fastening • Adhesive Bonding • Hybrid Joining Methods

• Weld Inspection and Repair• Welding and Joining Process Simulation • Vehicle Performance Simulation andAssessment

• Joining of Advanced Steels• Joining of Lightweight Materials

• Joining of Dissimilar Materials• Materials and Weldability• Non-sheet-metal Automotive Joining• Joining Tooling & Equipment• Welding Process Monitoring & Control

Topics of interest include, but are not limited to:

Author Application FormComplete and email the electronic version of this form together with a technical abstract to smwcpaper@awsdetroit.org.

Note: the conference will be preceded by a one-day workshop on 10/16/18 Important Deadlines

Abstract Submission . . . . . . . .By April 27, 2018Notification of Acceptance . . .By May 31, 2018Full Paper Submission . . . . . . .By August 31, 2018

A single complimentary admission to the conference is available for each presented paper.