the many faces of welder certification

M A R C H 2 0 0 1

The Many Faces of Welder Certification

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Lasers and GMAW-P in Shipbuilding

Welding ications

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NASA White Sands Testing Laboratory Announces results for Oxygen-safe Thread Sealants

FORMULA-8 and LOX-8 oxygen-safe thread sealants have recently been tested at NASA's White Sands Testing Laboratory. Each product was subjected to a two-part test; 1) Auto-ignition for temperature and 2) Mechanical Impact for pressure. The results were incredible!

The auto-ignition tests prove these thread sealants can withstand temperatures over 8000F/4500C. The impact tests confirmed a pressure limit over 3000psi on each product without a hint of reactivity.

This is confirmed over-whelming proof that either LOX-8 or FORMULA-8 can be confidently used in high pressure oxygen systems without concern.

Both products are oxygen-safe and chemically inert. LOX-8 was specifically d e s i g n e d for s e v e r e h i g h p r e s s u r e a p p l i c a t i o n s where aggressive chemicals such as chlorine or powerful oxidizers are present. LOX-8 is recommended for use under aqueous conditions. For applications that involve large diameter pipes and/or uneven, broken threads, use SUPER LOX-8. It has all the same qualities as regular LOX-8, with the addition of larger particles to help fill the voids and gaps that can occur with irregular threads.

FORMULA-8 is AGA certified (now known as "SA") - perfect in natural gas applications. It is spec i f ica l ly formula ted for n o n - a q u e o u s applications such as welding, gas bottle valves, oxygen distribution and hydraulics.

Choose the EXACT thread sealant for your special welding needs. Use LOX-8 in wet applications (even underwater, it's super- hydrophobic). Use it with harsh chemicals like chlorine and strong alkali or powerful oxidizers. Use FORMULA-8 in dry applications. It is chemically inert and requires no curing time.

That 's especial ly i important in those hard-to-reach places. FORMULA-8 is a thixotropic paste that forms a seal over the entire thread length; J size and length of ~ ~ ; ~ ~i;~,,~ thread are not a ~ ~ limiting factor.

These thread sealants are manufactured by Fluoramics Inc. of Mahwah, N.J. Fluoramics is known in the industry for their impeccable credentials and high technology products. Our "Tufoil" product line consists of lubricants and greases for applications ranging from high temperature greases for high-speed rotating machinery to lubricants made specifically for applications where corrosion and rust are a problem. In 1996, "Tufoil" was chosen by the Guinness Book of World Records as "The World's Most Eff ic ient Lubr icant" and published in their Science/Technology section. The record still stands today.

Engineers are now available to answer your questions and help you determine which product would be best for your specific application. Call Fluoramics at 1-800-922-0075 or 201-825-8110 for more information and ask for a free sample.

You can also visit us on the web at www.f luoramics . com


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Miller. The Power of BlueZ

ISSUE HOW a major truck . . . . . . . . . . . . . . . . . . manufacturer's welding

operators could eliminate excessive burnbacks while M~G welding on aluminum.

SOLUTION The XR-Edge by Mil ler- a true push-pull wire feed system that provides accurate and positive wire feed speed.

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Circle No. 31 on Reader Info-Card SYLVANIA

Feature Ar t ic les AWS Website: h t tp : / /www.aws.org

Monthly Columns

Orbital Welding Helps NASA's X-34 Rocket Soar D. Brown andJ. Neuman Welding butt joints in heavy-walled tubing in confined spaces proved a perfect fit for the orbital welding process/33

Aluminum Ferries Rely on Inverter Technology D. Keddei Hard work mid patience were what a contractor needed to develop procedures for welding aluminum that surpassed ABS requirements/38

Welder Certification: Many Thrusts, Few Agree B. Irving The many certification plans in industry require welders to constantly test and retest, but there are a few programs that are trying to change the pictureJ41

Lasers: The N e w Wave in Sh ip C o n s t r u c t i o n P. Denney Advances in laser technology and robustness of equipment are fueling interest from the shipbuilding industry/47

Orbital Welding Delivers Treatment Plant on Time The construction of a $100-million water treatment plant uses orbital welding to gain time in the schedule/51

Welding Research S u p p l e m e n t

Experimental Evaluation of Fe-AI Claddings in High-Temperature Sulfidizing Environments S. W. Banovic, et al. The corrosion behavior and weldability of Fe-Al cladding were characterized in aggressive reducing environments/63-s

Effect of Thermal Cycling on Friction Stir Welds of 2195 Aluminum Alloy G. Oertelt, et al. Thermal cycles in the dynamically recrystallized zone were shown to affect grain growth/71-s

The Effects of Root Opening on Mechanical Properties, Deformation and Residual Stress of Weldments G. B. Jang, et al. A new model is developed to predict residual stress and deformation in welded steel structures/80-s

Press -Time News . . . . . . . . . . . . . . 9

Wash ing ton W a t c h w o r d . . . . . . . . 11

Editorial . . . . . . . . . . . . . . . . . . . . 12

C o m m e n t a r y . . . . . . . . . . . . . . . . . 14

CyberNotes . . . . . . . . . . . . . . . . . . 17

Confe rences . . . . . . . . . . . . . . . . . 18

News of the Indus t ry . . . . . . . . . . . 20

Letters to the Edi tor . . . . . . . . . . . 24

New Produc t s . . . . . . . . . . . . . . . . 26

Brazing Q&A . . . . . . . . . . . . . . . . . 32

Welding W o r k b o o k . . . . . . . . . . . 53

Coming Events . . . . . . . . . . . . . . . 56

Navy Jo in ing Center . . . . . . . . . . . 62

S o d e ty News . . . . . . . . . . . . . . . . . 63

Guide to AWS Services . . . . . . . . . 80

Stainless Q&A . . . . . . . . . . . . . . . . 82

New Literature . . . . . . . . . . . . . . . 88

RWMA . . . . . . . . . . . . . . . . . . . . . 90

P e r s o n n e l . . . . . . . . . . . . . . . . . . . 91

Classifieds . . . . . . . . . . . . . . . . . . 92

Advert iser I ndex . . . . . . . . . . . . . . 94

Welding Journal (ISSN 0043-2296) is published monthly by the American Welding Society for $90.00 per year in the United States and possessions, $130 per year in foreign countries: $6.00 per single issue for AWS members and $8.00 per single issue for nonmembers. American Welding Society is located at 550 N.W. LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals postage paid in Miami, FL, and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 N.W. LeJeune Rd., Miami, FL 33126-5671.

Printed by R. R. Donnelley & Sons Co., Senatobia, Miss. Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sales or re- sale. Permission is granted to quote from articles, provided customary acknowledgement of authors and sources is made. Starred (*) items excluded from copyright.

BPA International Membership Applied for (February 2001)

WELDING JOURNAL I 7

MAX INTERNATIONAL . Two Great Organizations

Bring you One Great Opportunity

~ars, the Precision Metalforming Association Metalform Expo and the American Welding Society's Welding Show have pulled in the leaders, buyers and specifiers that define the heart of the manufacturing industry. By co-locating their shows, they have created an expanded marketplace that draws the key industry principals. Each, in its

own right, is THE driving force in promoting and establishing its industry segments. Together, they represent the core of the manufacturing industry. Individually, each show is recognized by Tradeshow Week magazine, the leading authority in the tradeshow industry, as being among the top 200 tradeshows in America. By joining forces, they are an even stronger and more compelling tradeshow market- force.

• Stamping

• Forming

•Welding

• Cutting

• Joining

• Fabrication

• Cutting

• Pipe

• Services and Supplies

MAX INTERNATIONAL is a comprehensive manufacturing technology event. Whatever products or services you are looking for--MAX is the expo for you. Our exhibitors are looking to answer your tough questions. They want to see you as much as you want to see them. They want to learn about your manufacturing needs. AND, they want you to show you how to be even more productive with the products and services you currently use. They want you to help you achieve your objectives.

.:,~ ~ i B B B B B m m 4 m B B B m m m

I N T E R N A T I O N A L M a y 6-10, 2 0 0 1

I -X C e n t e r Cleveland, O H

A W S and Moody International to Collaborate on Overseas Certification

Moody International , Houston, Tex., will soon offer the American Welding Society's Certified Welding Inspector (CWI) training and examination programs outside the United States under the terms of an agreement signed in January at AWS headquarters in Miami.

"The partnership will promote AWS's certification and membership programs to a segment of the fabrication market that is otherwise unattainable," according to AWS Executive Director Frank G. DeLaurier. He emphasized the program will not com- pete with the Society's current global partners. Instead, he said, Moody will "focus on in-house programs for specific companies."

Moody International, which will celebrate its 90th anniversary this year, provides quality assurance, quality control, inspection and other engineering and technical services to a wide range of industries. The company has 70 offices in 54 countries. The company already has thousands of clients in China, and will initially concentrate its efforts to provide CWI training and examinations in Asia, said president Todd S. Fleckenstein. Moody will translate the AWS training and testing materials and present them to potential CWls in their own language. Plans call for the program to be operational within six months.

"The United States remains the largest buyer of fabricated products, but much of the manufacturing takes place outside the U.S.," Fleckenstein said. "U.S. manufacturers like to have production referenced to U.S. Codes and standardized programs." The agreement will provide the necessary certified personnel where they have not before been available.

"International marketing of our programs will greatly expand AWS's presence worldwide," AWS Vice President Richard Arn said, as well as "open and expand the welding certification mar-

Moody International President Todd S. Fleckenstein (seated, left) and A WS Executive Director Frank DeLaurier sign the agreement for Moody to offer A WS Certified Welding Inspector training and examinations outside the United States. A W S Vice President Richard Arn (standing, left) and Deputy Executive Director Jeffrey Hufsey look on.

ketplace and benefit end users whose overseas projects call for CWls."

Further information about the program will be available on the Internet at www.aws.org and www.moodyint.com. Moody In- ternational personnel will also be available at its booth at the MAX International show in Cleveland, Ohio, May 6-10, at the I-X Center.

Northrop Grumman and Litton Industries Amend Merger

The boards of directors of Northrop Grumman Corp. and Litton Industries, Inc., recently approved an amendment to their merger agreement. As amended, the transaction will be struc- tured as an exchange offer for all Litton common stock by which Litton stockholders have the right to receive $80 per share in cash, or the equivalent of $80.25 in common stock or $80 in liq- uidation value of a new preferred stock. The equity will be issued on a basis intended to be tax free.

In December, the two companies signed an agreement under which Northrop Grumman would acquire all of the outstanding Litton shares for $80 per common share and $35 per Series B preferred share. The transaction was valued at approximately $5.1 billion, which included the assumption of Litton's $1.3 billion in net debt.

Following the close of the transaction and during the initial transition period, Litton will be operated as a wholly owned sub-

sidiary of Northrop Grumman. Litton's current president and chief operat ing officer, Ronald D. Sugar, will become a Northrop Grumman corporate vice president and president and chief executive officer of the new Litton subsidiary. He will also be nominated to the Northroup Grumman board of directors. Michael R. Brown, Litton's chairman and chief executive officer, plans to retire.

Northrop Grumman, based in Los Angeles, provides systems integration, defense electronics and information technology for U.S. and international military, government and commercial customers. It has approximately 39,0000 employees and reported sales of $7.6 billion in 2000.

Litton is the largest builder of nonnuclear ships for the U.S. Navy, and designs, builds and overhauls surface ships for government and commercial customers worldwide.

WELDING JOURNAL I 9

This ~ M m

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IMA61NE A PIPE WELDING SYSTEM 50 51MPLE TO OPERATE THAT YOU SIMPLY MOUNT THE HEAD ON THE PIPE AND BEGIN MAKING PERFECT WELDS. A third generation system, the Pipetiner II, was developed in conjunction with the Electric Power Research Institute (EPRt). Electric utility members supporting EPRI's research specifically targeted pipe welding as a significant cost factor in power plant maintenance. Mechanized pipe welding was given top priority. The result: the Pipeliner I!. Extensive trials by EPRI have proven that the Pipeliner II consistently produces GMAW/FCAW welds meeting ASME Section IX Code Standards. EPRI has approved the Pipeliner II for use by its 800 Utility members for all high-pressure piping. But the Pipetiner II's application doesn't stop here. Any industry welding pipes 6" and larger, regardless of quality standards, can now obtain productivity of 3.5 kg. (8 Ibs.) per hour deposition rate in all gravity positions.

HIGH DEPOSITION RATE WITHOUT 5ACRIFICIN~ QUALITY The Pipeliner II System is capable of producing high-quality welds in all gravity positions - meeting both ASME IX and API 1104 code requirements. Deposition rates of 3.6 kg. (8 Ibs.) per hour are easily achieved welding uphill with flux core filler wire. The system can also be used with solid wires.

PIPELINER I! - GTAW QUALITY WITH GMAW SPEED. SIMPLY THE FASTEST WAY TO ORBITALLY WELD PIPE.

L

BY HUGH K. WEBSTER AWS Washington Government Affairs Office

OSHA Issues New Steel Safety Standard

The U.S. Occupational Safety and Health Administration (OSHA) has issued a new final rule on safety standards for steel erection. OSHA anticipates the rule will prevent 30 fatalities and 1100 injuries annually suffered by workers during steel erection activities. The standard is designed to enhance protections already provided to iron workers by addressing hazards identified as the major causes of injuries and fatalities in the industry. These are injuries associated with working under loads; hoisting, landing and placing decking; column stability; double connections; landing and placing steel joints; and falls to lower levels. The standard, issued January 18, will become effective July 18.

The steel erection rule is the first OSHA safety standard developed under the negotiated Rulemaking Act of 1990. Mem- bers of the Steel Erection Negotiated Rulemaking Advisory Committee, representing employers and employees affected by the standard, developed the rule.

New Administration to Review Clinton Regulations

The incoming Bush administration has announced it will review regulations enacted during the Clinton administration, particularly the so-called "midnight regulations" enacted within the last few weeks of the Clinton presidency. Presumably, this will include OSHXs massive ergonomics rule and the Depart- ment of Labor's federal contractor "blacklisting" rules. Both have been particularly controversial.

Although a review is planned, it should be noted formerly adopted federal regulations cannot be reversed by a new administration with the simple stroke of a pen. Rather, changes would need to be adopted pursuant to the full rulemaking process, including notice and public comment. Changes would also face the inevitable legal challenges that are concomitant with all major regulations.

Industry Leads the Pack in R&D Funding Surge

Total research and development expenditures in the United States are expected to increase to almost $300 billion in 2001, according to an annual forecast prepared by the Battelle Memo- rial Institute and R&D magazine. According to this report, the expected increase is largely driven by industrial support, which continues to dominate both the amount and growth of R&D spending. Federal government spending on R&D is also expected to increase, although at the lesser rate of 1.3%, as op- posed to 6.5% in industry. Academic institutions and other non- profits are also expected to dedicate approximately $15 billion to research in the coming year, representing a 6.2% increase. Information on how to obtain a copy of the study can be found on the Battelle Web site, www.battelle.org.

Family Medical Leave Survey Results Issued

The U.S. Department of Labor has issued its most recent summary of employee and employer surveys on family and medical leave policies. The federal Family and Medical Leave Act allows workers to take up to twelve weeks of unpaid leave to care for a seriously ill child, spouse or parent; a new born, newly adopted or newly placed child; or for a worker's own se- rious health problems. The Act covers employers with 50 or more employees. However, many states have similar acts as well, often with no minimum number of workers that could exempt employers.

According to the survey, most employers reported the obligation to provide such leave was not particularly disruptive to business productivity, profitability or growth. This had been of primary concern when the federal act was adopted in 1993. Not surprisingly, the survey also found the vast majority of employees support some kind of unpaid leave for family and medical exigencies.

Venue Set for Ergonomic Rules Challenge The U.S. Court of Appeals for the District of Columbia Cir-

cuit has been selected to hear all lawsuits challenging OSHA~s final ergonomics standard. Individual suits filed throughout the country by industry and labor have been consolidated into one case, which will be heard by the District of Columbia Court.

Although its selection was random, the D.C. Circuit is an appropriate choice. Because of its location, this court has the most experience in dealing with administrative rules. The court typically shows great deference to federal agencies, but in recent years has invalidated rules that were not adopted in an appropriate manner.

EPA to Revise Confident ial In format ion Rules

The Environmental Protection Agency (EPA) is currently considering whether to revise its rules regarding the submission of confidential information. Very often, in complying with EPA requests for information, companies must submit data that is proprietary and commercially sensitive. Under the present rule, companies submitting such data can identify it as confidential, forcing the EPA to protect it from disclosure. The agency is considering whether it will require companies to substantiate claims of confidentiality in advance. In other words, status as confidential may not be automatic. This proposal was generated under the prior administration; it remains to be seen whether the Bush administration will continue this course.

Contact the A WS Washington Government Affairs Office at 1747 Pennsylvania Ave. NW, Washington, DC 20006; telephone (202) 466-2976, FAX (202) 835-0243.

WELDING JOURNAL J II

Y o u r G r e a t e s t M e m b e r B e n e f i t - - - O n e A n o t h e r

Early in my career, I at tended my first AWS meeting. I had been a member for a while, but that was only so I could receive the Welding Journal and Welding Handbook. I came just to hear the speaker, but I also met a lot of people who were enthusiastic about welding. Shortly after that first meeting, I changed jobs. Soon, however, I became active in the AWS Section in my new "home town." There I quickly discovered the greatest benefit of being a member of the Amer ican Welding Society was the o ther members I met at my Section meetings. I found that while the speaker for the evening may or may not have been one who interested me, I always learned a lot from the other members. A few years later, I moved once more. Again, I a t tended an AWS Section meeting in my newest (and still current) "home town" and was happy to find the same kind of enthusiastic, helpful people at my new Section as I had at the previous one. More than twenty-five years later, I am still active in this Section.

I tell you this because I think many of our members are missing out on the greatest benefit of AWS. I know it is difficult to find the t ime to at tend meetings. Along with my working wire, I 've raised three children during my career. There was always someplace we needed to be, something we needed to do. But I always found the t ime at an AWS Section meet ing was well spent. Where else are you going to have ready access to hundreds of years of welding experience and people who are willing to share that accumulated knowledge? Whether it 's information on a material, a process, or where to get something done locally, someone in your Section has the information. In addition to saving me a lot of work, the members in my Section have become some of my best friends. Certainly these meetings have been t ime well spent.

Finally, keep in mind that the Amer ican Welding Society is a membership- based organization. This means the members direct the Society, and the local Section is the basic organizational unit of AWS. Our corporate direction starts there. Through Section visits, district meetings and phone calls, your Section officers keep in contact with your District Director, the person who is your voice on the AWS Board of Directors. In addition, your local Section helps decide which students get AWS scholarships, which instructors receive awards, etc. There are lots of reasons to go to a Section meeting, starting with a great speaker and a nice meal at a good price. All in all, though, I think the best reason to at tend will be meeting your d inner companions . I 'm posit ive you'll get to know some terrific people. I strongly encourage you to take advantage of this great opportunity and discover your greatest membership benefit. Go to a meeting.

Thomas M. Mustaleski A WS Vice President

AMERICAN WELDING SOCIETY

Officers

President - - L. W. Myers Consultant

Vice President - - R. L. Am Teletherm Technologies, Inc.

Vice President - - E. D. Levert Lockheed Martin Missiles and Fire Control

Vice President - - T M. Mustaleski BWXT-Y12 LLC

Treasurer - - N. A. Hamers DaimlerChrysler

Executive Director - - E G. DeLaurier, CAE

D i r e c t o r s

O. A1-Erhayem (At Large), JOM Institute

J. M. Appledorn (Dist. 18), The Lincoln Electric Co.

B. J. Bastian (At Large), Benmar Associates

H. J. Bax (Dist. 14), Cee Kay Supply

M. D. Bell (Dist. 22), Preventive Metallurgy

H. E. Bennett (Dist. 8), Bennett Sales Co.

B. A. Bernstein (Dist. 5), TechniWeld Lab

S. W. BoUinger (Past President), consultant.

C. B. Bottenfield (Dist. 3), Dressel Welding Supply

J. C. Bruskotter (Dist. 9), Project Specialists, Inc.

C. E Burg (Dist. 16), Ames Laboratory

S. C. Chapple (Dist. 11), Midway Products Group

G. R. Crawmer (Dist. 6), GE Power Generation Engineering

A. E Fleury (Dist. 2), A. E Fleury & Associates

J. R. Franklin (At Large), Sellstrom Mfg. Co.

J. D. Heikkinen (Dist. 15), Spartan Sauna Heaters, Inc.

J. L. Hunter (Dist. 13), Mitsubishi Motor Mfg. of America, Inc.

M. D. Kersey (Dist. 12), The Lincoln Electric Co.

N. R. Kirsch (Dist. 20), Northeastern Junior College

D. J. Kotecki (At Large), The Lincoln Electric Co.

R. C. Lanier (Dist. 4), Pitt community College

G. E. Lawson (At Large), ESAB Welding & Cutting Products

V. Y. Matthews (Dist. 10), The Lincoln Electric Co.

G. H. Putnam (Dist. 1), Thermal Dynamics

O. E Reich (Dist. 17), Texas State Technical College at Waco

E R. Schneider (Dist. 21), Bob Schneider Consulting Services

T. A. Siewert (At Large), NIST

R. J. Tabernik (Dist. 7), The Lincoln Electric Co.

R. J. Teuscher (Past President), High Plains Fabrication

E E Zammit (Dist. 19), Brooklyn Iron Works, Inc.

12 I MARCH 2001

P

POWERFUL MACHINE. POWERFUL OFFER. The Ranger TM 250 gasoline engine- driven welder has always delivered 250 amps of pure DC output and 8,000 watts of continuous AC power.

Now, check out that power for yourself through a special offer: Buy a new Ranger 250 from your Lincoln distributor between now and March 31 and if you're not satisfied with its performance, return it within 30 days for a refund.*

But you'll find plenty of reasons to hang on to the Ranger:

• Exclusive Lincoln Chopper Technology TM for easy starts, a smooth arc, and low spatter.

• Four welding modes: stick, pipe, wire, and TouchStart" TIG.

• 12-gallon fuel capacity and an optional all-terrain undercarriage that let you weld anywhere from dawn to dusk.

C i r c l e No . 25 on Reader I n f o - C a r d

• An enclosed case for easy access, quieter running, and better protection.

• A 3-year warranty and the unmatched support of Lincoln Electric.

See your Lincoln distributor today for a no-risk look at the Ranger 250.

LINCOLN EE ELECTRIC The Welding Experts

The Lincoln Electric Company Cleveland, Ohio U.S.A. 216-481-8100 www.lincolnelectric.com

AR01 3 *See your local Lincoln Electric distributor for details. Customer must register to participate.

Com Deal Yourself

a Winn ing Hand When you're playing for high stakes in a tough global game, AWS can be

your ace in the hole. In response to input from a number of end-user companies, the AWS

Board of Directors approved the formation of a new Standing Committee known as the Welding Industry Network (WIN) with the mission of "providing a forum for industry leaders to identify best practices and to address materials joining, managerial, scientific, technical and operational issues that impact competitiveness."

To paraphrase President Abraham Lincoln, this is a committee of the members, by the members and for the members. In addition to the many benefits of a Sustaining Membership, WIN members can take advantage of a number of exclusive benefits:

• Senior industry leaders have the opportunity to exchange viewpoints and interpret and evaluate new ideas in a relaxed informal setting at the annual WINner 's Circle meeting.

• An annual conference addressing subjects ranging from welding applications and product reliability to cost containment, managing, environment, safety and health, or any other subject the participants choose.

• Only WIN partner employees may become Corresponding Members of any AWS technical committee or subcommittee. You choose one or more areas that affect your organization. By becoming involved in the process, you gain a powerful voice as the content of the standard evolves - - a standard that directly impacts your organization.

• Become Web VIPs through WlN's password-protected, members-only site that will offer an on-line directory of members, thumbnail sketches of products and services, Web links and instant communication between members on subjects of your choice

• Gain an international presence through WIN as you participate in the activities of both ISO (International Organization for Standardization) and IIW (International Institute of Welding). Gain access to leading-edge technologies while international standards are being processed and negotiated.

• As a WIN partner, take your savings to the bank with member discounts on in-house education and certification programs, conferences and the Professional Program at the AWS Annual Convention, the largest gathering of welding researchers in North America.

If your organization is responsible for welding and allied processes in fabrication, construction, maintenance or repair of a product, and you would like more information on becoming a charter partner in the Welding Industry Network, you need only click on WIN on the AWS Web site at www.aws.org, or contact me directly at [email protected].

Other smart business players are improving their odds for success by dealing themselves a WINning hand. So should you.

Charles R. Fassinger A IT'S Associate Executive Director

14 I MARCH 2001

WELDING JOURNAL Editorial Staff Publisher

Jeff Weber Editor

Andrew Cuilison Features Editor

Mary Ruth Johnsen Managing Editor

Christine Tarafa

Associate Editor Susan Campbell

Assistant Editor Doreen Yamamoto

Production Coordinator Zaida Chavez

Peer Review Coordinator Doreen Kubish

Contributing Editor Bob Irving

Publications, Expositions, Marketing Committee G. D. Unrach i G . M . Nally Commi t t ee Cha i rman Consultant ESAB Welding & Cutting

R. G. Pall G. O. Wilcox J.P. Nissen Co. Vice Cha i rman Thermadyne Industries S. Roberts

Whitney Punch Press J. Weber Secretary J. E Saenger , Jr. American Welding Society Edison Welding Institute

P. Albert R . D . Smith Krautkramer Branson The Lincoln Electric Co.

R. L. Arn P.D. Winslow, Ex Off. Teletherm Technologies, Inc. Hypertherm

T. A. Barry E . D . Levert, Ex Off. Miller Electric Mfg. Co. Lockheed Martin

Missiles and Fire Control C. E. Boyer ABB Robotics L . G . Kvidahl, Ex Off.

lngalls Shipbuilding T. C. Conard ABICOR Binzel N. Homers , Ex Off.

DaimlerChrysler D. L. Doench Hobart Brothers Co. S .W. Bollinger, Ex Off.

Consultant J. R. Franklin Sellstrom Mfg. Co. J . C . Lippold, Ex Off.

The Ohio State University N. R. Hel ton Pandjiris, Inc. W. Gaskin, Ex Off.

Precision Metalforming Association V. Y. Mat thews The Lincoln Electric Co. L .W. Myers, Ex Off.

Consultant T. C. Myers DovaTech Ltd. E G. DeLaur ie r , CAE, Ex Off.

American Welding Society

Advertising Director of Sales

Rob Saltzstein Advertising Sales Representatives

Blake and Michelle Holton 1-800-644-5563

Advertising Production Manager Colleen Beem

Subscriptions Orlando Collado

American Welding Society 550 N.W. LeJeune Rd., Miami, FL 33126 (800) 443-9353

Copyright © 2001 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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www.nationalstandard.com

M A N U F A C T U R I N G A P P L I C A T I O N S E X P O

THE AT THE CORE OF FACTORING IND

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May 6-10, 2001 International Exposition (I-X) Center, Cleveland, Ohio

Featuring

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Visit us at www.maxinternationalexpo.com

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I N T E R N A T I O N A L

EXPOSITION REGISTRATION A. General Information (Please Print Clearly) First Name Title (Required)

May 6-10, 2001 I-X Center Cleveland, OH

FREE EXPO ADMISSION REGISTER BY APRIL 20, 2001• After April 20, bring

this registration form to the Expo to receive $5 off the regular $30 admission.

(EXHIBITS O N L Y ) I MAKE COP,ES TO REGISTER YOUR TEAM! I

(No one under 12 admitted. Students 12-17 years of age must be accompanied by an adult at all times.)

Last Name

Company.

Address

City Province/Country

Phone.

B. Primary Show Interest 0 AWS Welding Show 0 PMA METALFORM ExpoSium

C, Are You A Member of: AWS PMA Not a member/Unsure

~1 Other (specify)

D, Primary Function (check one) 01 0 President, owner, partner, officer, corporate executive 02 ~ Manufacturing production 03 ~ Engineer--manufacturing 04 0 Product design, research & development 05 0 Qualify control, quality assurance 06 0 Factory automation 07 0 Purchasing 08 0 Marketing/sales 09 0 Manager, director, superintendent (or assistant) 10 [~ Engineer--welding 11 ~ Engineer~esign 12 I~ Engineer---other 13 0 Architect designer 14 ~ Metallurgist 15 ~ Inspector, tester 16 ~ Supervisor, foreman 17 0 Technician 18 0 Welder, welding or cutting operator 19 0 Consultant 20 0 Educator 21 0 Librarian 22 0 Student 23 0 Customer service 24 Q Other (specify)

E. Purchasing Authority (check one) 26 O Recommend 27 O Specify 28 O Approve

Educational Sessions Presentations from leading experts on the latest technical and management developments are available. (Separate fee applies.)

[] Yes! I'm interested. Send more information on the Educational sessions.

E-Mail

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F. Company's Primary Business (check one) Manufacturing 29 0 Furniture & fixtures

J, Company's Activity Includes: (check ~1 that app.)

57 0 Stamping 30 0 Primary metal products 58 [~ Sheet metal fabricating 31 ~ Fabricated metal products 59 ~ Spinning 32 ~ Machinery except elect. (inc. gas welding) 60 ~ Finishing 33 [J Electrical & electronic equip., supplies, electrodes 61 ~3 Tool & die 34 0 Petroleum & coal industries 62 [J Welding 35 ~ Transportation equip.--air, aerospace 63 0 Slide forming 36 0 Transportation equip.--automotive 64 ~ Rollforming 37 ~ Transportation equip.--boats, ships 65 ~1 Coil processing 38 [:3 Transportation equip--railroad 66 ~ Perforating 39 ~1 Instrument & related equipment 67 ~ Assembly 40 [~ Contract construction 68 ~1 Machining 41 ~ Chemicals & allied products 69~1 Deep drawing 42 ~1 Utilities 70 [J Tube/Pipe 43 [~ Welding distributors & retail trade 71 [J Advanced materials, intermetallics 44 Q Misc. repair services (inc. welding shops) 72 ~ Aluminum 45 [J Educational Services (univ., libraries, schools) 73 [J Arc welding 46 0 Engineering & architectural services (inc. assns.) 74 {3 Automation 47 0 Misc. business services (inc. commercial labs) 75 ~ Bending and shearing

76 ~ Brazing and soldering 48 [~ Government (federal, state, local) 77 ~ Ceramics 49 ~ Other (specify) 78 ~ Computerization Non-Manufacturing 79 [::1 Cutting 50 [~ Metal Service Centers & Offices 80 ~ Ferrous metals 51 0 Other (specify) 81 [3 High energy beam processes

82[~ NDE G • Type of Company (check one) 83 E] Nonferrous metals except aluminum 52 ~1 Contract manufacturer/job shop 84 ~ Pressure vessels and tanks 53 ~ End product manufacturer/0EM 85 ~1 Punching 54 ~ Non-manufacturing 55 ~ Distributor 56 0 Other (specify)

H, Total Employees at this location: (check one) A ~ 1-19 B ~1 20 - 49 C 0 50-99 D 131 100-249 E ~ 250 - 499 F ~ 500 - 999 G ~ 1000 +

J, Primary Product Manufactured at this Location

Fax or mail to: Fax: 301-694-5124

Mail: MAX International c/o ExpoExchange, LLC

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86 ~ Resistance welding 87 ~ Robotics 88 ~ Safety and health 89 ~ Sheet metal 90 0 Structures 91 0 Thermal spray 92 ~ Laser Welding 93 ~ Software/systems 94 0 Other (specify) 95 ~ None of the above

K. rl YES, I would like to receive (continue receiving) MetalForming magazine FREE! CI No (MY, MN, MU)

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If you have a disability that may impact your participation in this show, please check here and append a statement regarding your disability-related needs. You will be contacted prior to the event. Advance notification is required to ensure availability of appropriate accommodations.

A collection of[industry newsfromthe Internet [

BY MARY RUTH JOHNSEN, Features Editor

Site Offers Autodarkening Welding Filter Information

Jackson Products, Inc. The Web site for this Chesterfield, Mo., based manufacturer highlights its line of products, which includes autodarkening welding helmets, powered air-purifying respirators, electrode holders and ground clamps, and pipe marking tools. The site features an autodarkening filter selection guide and parts breakdown guide.

Visitors can download product literature using Adobe Acrobat Reader® or can request a printed copy. Users can also locate the nearest distributor by typing in their zip code. Additional information includes proposed changes to industry standards and how users will be affected by them, job listings for the company and links to related industry sites such as the American Welding Society.

The FAQ section answers such questions as "what is NIOSH and how does it differ from OHSA?" The answer: "The National Institute for Occupational Safety and Health (NIOSH) was established by the Occupational Safety and Health Act of 1970. As part of the Centers for Disease Control and Prevention, NIOSH is the only federal institute responsible for conducting research and making recommendations for the prevention of work-related illnesses and injuries. OSHA is in the Department of Labor and is responsible for creating and enforcing workplace safety and health

regulations. NIOSH is responsible for identifying the causes of work- related disease and injuries and the potential hazards of new work practices and determining new and effective ways to protect workers from these hazards."

The site also includes a password- protected site area for distributors only. Among other things, distributors can view pricing, download product photos and order literature.

http://www.jacksonproducts.com

Pipeline Research Advancements Detailed

Pipeline Research Council International, Inc., (PRCI). Based in Arlington, Va., PRCI offers a wide array of publications dealing with system reliability and integrity, as well as other pipeline-related topics. All materials are indexed on the Web site. The publications can be searched by key words, title, technical area, project number and catalog number. There is also a listing of eBook documents. Some documents are available for downloading at no charge, and the organization's technical publications catalog can be downloaded in an Adobe® Acrobat or Microsoft® Word version. Visitors can also sign up for an e-mail copy of the PRCI newsletter and update service.

Previously an unincorporated affiliate of the American Gas Association, PRCI is now a not-for-profit corporation

comprised of natural gas transmission companies from the United States, Canada, Europe, Asia and Australia. The PRCI includes six technical area committees: line pipe, compressor, welding, nondestructive testing, corrosion and onshore/offshore design applications. The mission of the welding committee is "to advance and transfer technology for the joining of materials used in gather and transmission pipeline systems by addressing

present and projected concerns of the industry." Areas it covers include welding on pressurized lines, joining of high- strength materials, new and improved joining processes and welding for severe service. The site lists the committee's recent accomplishments and a program and project list.

Also featured on the site are commentaries from industry and PRCI personnel and industry news and events. Included as well are areas for members only and contractors only.

http://www.prci.com

Gas Detection Instruments Featured

Thermo Gas Tech. Located in Newark, Calif., the company develops, markets and services portable and fixed system gas detection instruments, transmitters and sensors that monitor and/or check for the presence of combustible gases, toxic gases and oxygen content. The company's Web site offers plenty of product information, and visitors can find the products they need by model number, application or industry.

The site also features information on training sessions; product manuals, both for purchase or downloaded in Adobe Acrobat format; and lists of service centers, regional sales offices and trade shows the company will be attending.

The '~amswer Man" section answers questions such as why alkaline batteries for some gas detectors weren't longlasting. The answer, in part: "First, check the type of batteries you are using. I would strongly recommend you stick with high-quality alkaline batteries. Some batteries marked 'industrial strength' will not provide the current capacity your instrument needs for proper operation. Second, in colder months, if your instruments are left outside in trucks or in unheated warehouses, the cold temperature can reduce the operating life of the batteries. A size D alkaline battery supplying 750 mA current at 68°F will operate for approximately 12 h. If the temperature decreases to 14°E it will only power the load for about 3 h."

http : / /www.gastech.com

WELDING JOURNAL I 17

AWS D I. I CODE WEEK The #1 selling welding code now comes alive in a five-day seminar that begins with a roadmap of D1.1:2000, Structural Welding

Code - - Steel This is your opportunity to learn from an expert AWS instructor and ask your toughest questions about DI.1. Code week continues with corresponding subjects geared toward engineers, supervisors, planners, welding inspectors and welding technicians. Since your

work is based on a reputation for reliability and safety, you want the latest industry consensus on prequalification. If you want to improve your competitive position by referencing the latest workmanship standards, inspection procedures and acceptance criteria, you won't want to miss this seminar! Each day will be in-depth and intense.

(Day 1, Monday) D I. I Road Map St. Louis, M o . - April 9 Chicago, I l l . - July 16 Las Vegas, Nev. - - September 17 Atlanta, Ga.-- November 5

(Day 2, Tuesday) Design of Welded Connections

St. Louis, Mo. - - April 10 Chicago, Ill. - - July 17 Las Vegas, Nev. - - September 18 Atlanta, Ga. - - November 6

(Day 3, Wednesday) Qualifications St. Louis, M o . - April 11 Chicago, I l l . - July 18 Las Vegas, Nev. - - September 19 Atlanta, Ga. - - November 7

(Day 4, Thursday) Fabrication St. Louis, Mo. - - April 12 Chicago, Ill. - - July 19 Las Vegas, Nev. - - September 20 Atlanta, Ga. - - November 8

(Day 5, Friday) Inspection St. Louis, Mo. - - April 13 Chicago, Ill. - - July 20 Las Vegas, Nev. - - September 21 Atlanta, Ga. - - November 9

Prices Member Nonmember

(One-day seminar) $345 $420 (Entire week) $795 $870

U P C O M I N G C O N F E R E N C E S W E L D C R A C K I N G :

C A U S E S A N D CURES C O N F E R E N C E June 7-8 1 Houston, Tex.

Hydrogen-induced cracking isn't the only culprit engineers and QC professionals need to be on the alert against. AWS experts will identify other, often unknown or overlooked cracking scenarios, along with the best use of counteroffensives, including preheat and peening. Other areas covered include the best use of ultrasonics and Charpy tests, plus the lowdown on new test options. This intense day-and-a-half program covers cracking in steels, aluminum, stainless steels and titanium.

T H E C U T T I N G OF PLATES C O N F E R E N C E July 17-18 1 Chicago, I I I .

For decades, the only plate cutting method was oxyfuel cutting. It is still used, but recently, methods like plasma cutting, high- definition plasma cutting, water jet cutting and both CO 2 and YAG laser cutting are more frequently used. Many companies are in turmoil deciding which method is best. This conference will provide engineers with greater understanding of the issue, knowledge about the cost of equipment, payback, cutting performance and valuable information that can be implemented profitably into their company's production lines. This conference will cover mostly steel, with some mention of stainless and aluminum. Topics include laser cutting, plasma

cutting, high-definition plasma cutting, water jet cutting and innovations in oxygen cutting.

E L E V E N T H I N T E R N A T I O N A L C O N F E R E N C E O N C O M P U T E R T E C H N O L O G Y IN W E L D I N G

September 19-20 - - Columbus, Ohio.

The eleventh in a series of computer conferences will provide the welding industry with the latest information regarding the use of computers for welding. The conference brings together experts on sensors, equipment control, process modeling and data acquisition. Engineers, managers and system integrators will benefit from discussions of hardware and software installations and user experiences with these systems. Integration of welding systems with network and Web applications will be emphasized. Topics to be discussed include modeling of welds and welding processes; off-line planning/weld simulation/visualization; computerized data acquisition and sensing systems; real-time welding information and control systems; weld process automation; network and Web-based implementations; case histories/experiences with commercial software (by users); welding documentation (e.g., WPS, PQR); databases, database applications and knowledge bases; standards.

For further mforrnatton contact." Conferences, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126. Telephone:

I (800) 443-9353 ext. 223 or (305) 443-9353 ext. 223, FAX: (305) 443-1552. Visit the Conference Department homepage http://www.aws.org for upcoming conferences and registration information.

18 I M A R C H 2001

'1, ~ ~i!

ARCWlSE'"' EWl Products & Services

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Recomrnenclecl Optimum arametem

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Arc Welding

Solid State Welding

Laser Processing

Micro joining

Plastics

NDE

Brazing, Soldering

Materials

Engineering

Testing Services

Member Services

Contract Services

Assessments

Conferences

Training

News (Industry Creaky W o r l d W a r II Relic Returns H o m e to

The success of the LST 325's long voyage home to the United States is a tribute to the welders and other workers who built the vessel in 1942, according to Capt. Robert Jornlin of Earlville, II1., who led the crew of mostly World War II and Korean War veterans on their voyage from Greece.

"We left from Crete," Jornlin said. "That 's more than 6500 miles. So it was quite a feat for these old engines. The manufacturers deserve a lot of credit for making a product that has lasted 58 years. This is a testament to how well these ships were made and a

Begin N e w Life as a Museum

The World War H U.S. Navy ship LST 325 and its veteran crew returned to the United States from Greece on January lOth where it was welcomed by a jubilant crowd at the Alabama State Docks in Mobile. (Photo courtesy of the Mobile Register 2001©. All rights reserved. Reprinted with permission. Photo by Bill Starling, printed originally in the January 11, 2001, Mobile Register.)

testament to the people who made them. A lot of them were women because all of the young men were in the Army, Navy and Air Force fighting the war. So a lot of the welders were women and they deserve a lot of credit."

LST (Landing Ship Tank) 325 delivered troops to Normandy during the D-Day invasion. It was decommissioned in 1946, then lent to the Greek government in 1964. The Greek Navy took it out of service this past summer and the U.S. Congress passed a bill authorizing Greece to turn it over for use as a memorial. The LST Association, an organization of veterans who served on the 325 and similar ships, hopes to turn the ship into a floating museum that would sail to different parts of the country.

The crew members, whose average age was 72, paid their own way to Greece and another $2000 to help fund the voyage. They left Greece November 17 and crossed the Mediterranean in 11 days. At that time, one member suffered heart problems and returned home, dying shortly after arriving in the United States. The remaining 29 crew members were at sea continuously after leaving Gibraltar on December 12 until their arrival in Mobile,

Ala., January 10. It was a voyage the U.S. Coast Guard advised them not to take, citing the ship's lack of safety equipment, steering problems and its concern about the crew's ability to respond to emergencies during a stormy, winter Atlantic crossing.

The 327-ft-long, 50-ft- wide ship was in poor shape. An observer who watched it sail into Mobile Bay called it a "rust bucket," and the Associated Press quoted crew member Lauren Whiting as saying, "The ship was a derelict. Nothing worked." However, Whiting, who was responsible for keeping the engines running, stressed the ship was structurally sound.

"We maybe did a miracle by bringing it home," Jornlin said. "but I never had a doubt if we could get it running that we could get it home. I had faith in the engines and after we were aboard a while, I had faith in my crew."

Prior to the trip and during the voyage, the crew cleaned the ship and made repairs. However, much more work needs to be done before it can be opened to the public either as a mobile museum or a static one, Jornlin said. A hole in the hull needs patching. Both engines need an overhaul and the electrical, drainage and bilge systems need repairs, as do other parts of the piping system. New gangways and permanent display areas must be built and a variety of safety-related items put in place before the general public can be allowed aboard.

Jornlin said a shipyard has expressed interest in having the ship moved to its facility where it would make the repairs as part of its training program. Unless it is moved to a repair facility, the LST 325 will remain in a small harbor just outside Mobile until late August when it will be the highlight of the LST Association's convention there. - - Mary Ruth Johnsen, Features Editor

Spectra-Physics Opens Industrial Laser Applications Lab

Spectra-Physics recently opened an industrial laser applications laboratory at its facility in Mountain View, Calif. The lab will enable manufacturers in industrial markets, such as micro- electronics, to investigate the use of solid-state lasers. In particular, the company aims to facilitate and advance the use of high-

20 ] MARCH 2001

power, ultraviolet lasers for high-volume micromachining tasks. Dr. Mingwei Li is head of the laboratory. Li holds a Ph.D. in

materials science from Ohio State University and has extensive experience in implementing industrial, laser-based manufacturing processes.

Spectra-Physics manufactures semiconductor-based lasers and laser optics for a variety of markets.

South Carolina Nuclear Power Plant to Restart Soon upon Completion of Weld Repairs

South Carolina Electric & Gas Co. (SCE&G), Columbia, S.C., recently announced repairs to a weld in a pipe in the reac- tor coolant system at the V.C. Summer Nuclear Station are nearly complete and the plant should return to service this month

The company shut down the 1000-MW plant for a routine refueling and maintenance outage October 7, 2000. During inspection, employees discovered indications of a small leak. The leak was found to be coming from a 3/16-in.-diameter hole in a weld in a 30-in.-diameter primary coolant system pipe. A 12-in.- long section of the pipe, which includes the entire weld, has been cut out and a new section is being installed.

"We have successfully completed about 90% of the welding process and expect all repair and testing to be completed in the next several weeks," Steve Byrne, vice president of nuclear operations for SCE&G, said January 30. "This repair work is unique so we're taking our time to do it right. Once repair work is completed, we expect to go through the normal startup process."

SCE&G, the principal subsidiary of SCANA Corp., an energy-based holding company based in Columbia, S.C., provides electricity to more than 533,000 customers in central and southern South Carolina.

ESAB Leases New Equipment to California School

The Welding and Inspection Department at San Bernadino Valley College, San Bernadino, Calif., recently received more

than $100,000 in new equipment through ESAB Welding & Cutting Products' Equipment Exchange Program.

The college signed an exclusive seven-year lease agreement with the company. Under the terms of the lease, the college will buy the equipment outright at a discounted price in seven years.

The college received a line of industrial gas regulation and flow control devices, as well as cutting and welding equipment.

Approximately 2000 of the 15,000 students who attend San Bernadino Valley College are enrolled in the technical division. The welding department offers classes leading to certificates and associate's degrees. The school has also hosted the regional and state SkillsUSA/VICA contests for the past several years. Department head Bill Kastner approached ESAB about equipment after hearing about the program.

"We were looking for a college or technical trade school that turns out a significant number of graduates, runs a quality program and is recognized as such by employers," said John Weber, the ESAB territory sales manager who oversaw the equipment exchange. "We want to get our product in the hands of the young and entry-level people who are going to be making purchasing decisions in their workplace."

Industry Notes

The U.S. Navy recently awarded Newport News Shipbuilding, Newport News, Va., a contract to design and con- struct the tenth Nimitz-class aircraft carrier, CVN 77. The as-yet unnamed ship will serve as the first transition ship to a new class of large-deck, nuclear-powered carriers. The contract is valued at approximately $3.8 billion and the carrier is scheduled for delivery in 2008. Unlike its contracts for other Nimitz-class car-

We have been told that we are the best-kept secret in the welding industry. In an effort to correct this situation we advise that:

WE MAKE Stainless Cast Iron Cobalt AISI Nickel

410N iMo FC 3 3 % Ni 1 4130 ENiCrFe-2 502 FC 5 5 % Ni 6 4140 ENiCrFe-3 505 FC 9 9 % Ni 12 4340 EniCrCoMo-1 E2553 FC 21 ERNiCrMo-3 E2209 FC 2101 ERNiCr-3 E630 FC 904L FC

THE ABOVE ARE JUST A FEW OF THE CORED WIRES THAT WE MAKE. FOR MORE I N F O R M A T I O N CALL:

Circle No. 8 on Reader Info-Card WELDING JOURNAL I 7. I

Inltmi#¢i#B..

The WELD HUGGER inert Gas Delivery System

• Advanced cover gas-nozzle system acts like a miniature "Air Hockey" table to surround the weld in argon / inert gas.

• Designed for a variety of welding cover gas applications.

Simulated nozzle flow Universal kit includes: Nozzles & Feed Supply

] All Stainless Steel 316L 1.00" X 1.25" Bottom Feed 1.25" X 1.25" Top Feed 1.00" X 2.50" Bottom Feed 1.00" X 2.50" Top Feed 1.00" X 4.00" Side Bottom Feed 2.75" X 2.75" Bottom Feed F /'~/1 0.250" Tube Manifold ~ j ,1 Spare Screws & Seals, ~'~4 ~ / ~ e t ~ / ~ // , ' ~ /

Weld Huggers are bendable ~ . ~ . ' ~ ~

Order your WELD HUGGER from ~ ~#.~e.~..

HUGGER ~idlr, l, IB LLC 7201 West Oakland St., Chandler. AZ 85226-2434

Toll Free: (877) WELDHGR (877) 935-3447 Fax: (480) 940-9366 Visit our website at: ww~we/dhuggercom


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riers, Newport News will be responsible for delivering the ship's warfare system, a task previously performed by the Navy.

• The Metropolitan Transportation Authority/New York City Transit (MTA/NYCT) recently awarded Bombardier Transportation an order for the production and supply of 350 R142 rapid transit cars. The order is valued at $418.9 million. The R142 stainless steel car bodies will be manufactured at Bombardier's La Pocatire, Quebec, Canada, plant with additional manufacturing and assembly taking place at its Plattsburgh and Auburn, N.Y., plants. The cars are customized to MTA/NYCT specifications. Five-car sets are arranged into base operating units consisting of one motorized car at each end and three half-motorized cars. Ten prototype cars completed extensive testing in New York in September 2000 and R142 trains have been in revenue service since October.

• Robotic Workspace Technologies, Inc., recently opened a new facility in Fort Myers, Fla., to house its corporate offices, software development teams, new product development teams and technical support personnel. The 13,000-sq-ft facility includes training facilities and a large environmental chamber to test the performance of the company's Universal Robot Controller TM, as well as robots under extreme environmental conditions.

• Lincoln Electric Holdings, Inc., Cleveland, Ohio, recently announced both of its U.S.-based arc welding machine and consumables divisions have achieved ISO 9001 certification. The International Organization for Standardization's ISO 9001 quality standard requires a company have excellent quality control procedures for all stages of design, production, installation and servicing of products. Of Lincoln's 25 global manufacturing facilities, 10 have ISO 9001 certification, including facilities in Italy, Turkey, Mexico and China; 15 have achieved ISO 9002 certification.

• Selectrode Industries, Huntington Station, N.Y., recently purchased a ten-acre site in Beaver County, Pa., and plans to immediately begin construction of a 62,000-sq-ft building that will house all of the company's manufacturing operations. A major feature of the new plant will be a highly sensitive climate control/humidity system that will allow products on the three extrusion flux coating lines to have precise levels of moisture content. The plant is expected to be operational by July.

• Scania Buses & Coaches, Stockholm, Sweden, recently received orders for 160 city and intercity buses from several of the largest bus operators in the Nordic region. The buses will be built at Scania's production plants in Sweden and Poland and are scheduled for delivery later this year. Connex of France placed the largest individual order of 71 buses, including 44 for Oslo, Norway. One hundred of the buses will be from Scania's Omni line, which features an aluminum body and a 9-liter, Euro 3 diesel engine; the remainder will be built on the company's L94 intercity bus chassis with body work by Vest, a Norwegian company.

• Taylor-Winfield, a metalworking machinery manufacturer based in Brookfield, Ohio, recently opened a Detroit-area sales office in Livonia, Mich. The office and laboratory are located in the premises of its sister company, Accum-Matic Systems, Inc., which will also house Taylor-Winfield's Denton & Anderson division, a distributor of equipment to support resistance welding, induction heating and related technologies.

22 I MARCH 2001 Circle No. 30 on Reader Info-Card

A B Y R. L. P E A S L E E

Q: We are experiencing problems with stop-off materials and hope you can help us solve them. First, the green stop off we are using on the internal threads of a 347 stainless steel part is very hard to remove and in ter feres wi th the assembly . Second, the same stop off l imits the flow of brazing filler metal where it is used on the outside of parts. After brazing, parts are sent to the plater, who is unhappy because the plating does not take on the stop-off area and the stop off cannot be readily removed. Is there a stop off that is easily removed for the plating process, or one that can be easily removed from the internal threads?

A: While the green-colored stop off is probably the best for controlling the flow of brazing filler metal, it is difficult to remove. It is generally best removed mechanically - - by vapor blasting, grit blasting, bead blasting, wire brushing or polishing. It can also be removed with an acid t r ea tmen t of approximately 10% nitric acid, 2% hydrofluoric acid and ba lance water hea ted to 150°F (65°C). Because the hydrofluoric acid is very potent and extremely harmful to skin, most people prefer other removal methods.

Yellow stop off is very similar to the green, but is much easier to remove. White stop off, in general, can be wiped off of surfaces, but it would be too diff icul t to wipe the threads on an internal part. White stop off is available in three forms: powder that can be mixed with various cement materials; a lacquer-based binder , which can be painted or sprayed on; and a viscous water-based binder that can be used in a hypodermic syringe to fill small holes and for other similar applications.

The Best Stop Off for the Application

In my opinion, the most sui table material for your application is a red stop off. Several compan ie s have indicated this material holds on well and can be left on the part for two or

more runs when successive brazing operations are necessary. The benefit of this type of stop off for your application is that it is an acid-soluble material. Because you are working with 347 stainless steel, you are probably going to passivate the parts before shipping. This stop off can be r emoved in a few seconds in nitric-acid-type passivating solutions. This treatment allows 100% of the stop off to be removed and requires no additional treatment. The same stop off can be used for plated parts since standard plating operations requi re the parts to be placed in a caustic bath to remove oils, then dipped into an acid bath to remove any oxides and clean the surface. In the acid bath, the stop off will be removed immediately, thereby allowing proper plating of the base metal. The platers may have questions when parts come in with a little bit of red stop off remaining on them, but you can assure them it will be readily removed in a diluted acid dip.

While on the subject of stop offs, there are two additional types on the market that were developed primarily for use with very reactive materials such as titanium and zirconium. One stop off is orange in color and the other is blue. These stop-off materials are very inert and can be used on t i t a n i u m and z i r con ium wi thout af fec t ing base metals. The orange stop off appears to have h i g h - t e m p e r a t u r e lub r i ca t ing properties. It has been used on fixtures where there is a d i f fe rence in coefficience of expansion between the part and the fixture, and also where

parts are quite large and need to slide rather than stick, to the fixture. Another application is the coating of dies for superplastic forming of titanium.

Other Types of Stop Offs

While these stop offs have been developed for brazing applications, they have found use in some unusua l applications far from brazing, such as coating the inside or outside of exhaust pipes to reduce the temperature of the part or reduce rad ia t ion emana t ing from it. This application works quite well since most of these materials are ceramic in nature.

In your case, red stop off is the best choice for both coating the in ternal threads to prevent the brazing filler metal from flowing up the threads and to use on the outside of parts that are to be plated. While it is preferable to not have to apply stop off to parts, it is often the only way to control the flow of brazing filler metal into unwanted areas. This is why stop offs were developed.*

R. L. PEASLEE is Vice President, Wall Colmonoy Corp., Madison Heights, Mich. This article is based on a column prepared for the A WS Detroit Brazing and Soldering Division's newsletter. Reader questions may be sent to Mr. Peaslee c/o WeMing Journal, 550 N. W. LeJeune Rd., MiamL FL 33126.

Welding Positioners nc rea se P roduc t iv i ty by over 125 %

All-Fab Corporation welding positioners from 200 to 1250 pound capacity. Compare our price, quality and features.

~ , ~ P ¢ " /MI-Fab Corp-~" Call or Fax for free i¢- ~ : = v brochures and price sheet.

We also sell used welding pos i t ioners of all sizes.

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WELDING JOURNAL J 2.3

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Compare quality, toughness, balance, Ionglife and selection.., you won't find a better weld cleaning tool anywhere.

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Lette ( Editor

A L o s e r N o M o r e

I am writing in regard to the article in the D e c e m b e r 2000 issue of the Welding Journal t i t l ed " W h o Wil l B e c o m e a W e l d e r ? " by W a y n e Western. I have a couple of questions. F i r s t , have you been fo l lowing me around all of my life? Second, where is my royalty check for printing my life story?

As I read the art icle, I could not believe there were actually others out there just like me. It has always been my belief that my high school teachers were a lot smarter than I was and when they told me that I was a reject, they must have been right. Af te r all, they were e d u c a t e d and they were the teachers.

Imagine my surprise and delight to find out after all these years that they are really no smarter than I am. They jus t l e a rn d i f f e r en t ly . T h e r e a re probably thousands of young men and women out there right now being told that they are learning disabled who will go through life thinking they are below grade. That is a pitiful shame.

I walked away from my high school p r i n c i p a l ' s of f ice f ee l ing to t a l l y worthless the day he told me I had no future. I went to work in a fab shop from noon until eight, cutting up scrap, sweeping floors and doing whatever the welders said. That was in 1972. Today, I own the company.

I am going to look up my old high school principal and I 'm going to sock him right in the eye.

Thank you for helping me finally r ea l i ze where I am in l ife. P l ease continue to let the young people know they are not rejects or losers.

Jud M. Hirschfeld Hirschfeld Welding

Pagedale, Me.

Circle No. 6 on Reader Info-Card 241 MARCH 2001

UNIVERSAL BALANCE POSlTIONERS FOR EASY ACCESS, SAFE MANIPULATION It's like having an extra set of hands. Universal Balance Positioners with their unique balance

GEAR-DRIVEN POSIT IONERS ELIMINATE THE WORK Tough. Reliable. Safe. That describes Koike Aronson's line of gear-driven positioners. They provide tilt and rotation for parts weighing from 66 to 2 million lbs. The gear-safe design delivers the ultimate in safety. These bench or floor models deliver a lifetime of performance with minima maintenance. C I R C L E NO. 9 5

system makes manual parts positioning effort- less. They eliminate the need for unsafe benches, and saw horses and unwieldy crane. Available in capacities from 100 lbs to 4,000 lbs.

C I R C L E NO. 9 6

ROTATE PIPES AND VESSELS FOR M A I N T E N A N C E OR FABRICATION Precision turning rolls provide invaluable assistance when manufacturing or maintaining cylin-

drical vessels and pipes. Choose rubber, steel or composite wheels depending on your needs. Heavy-duty design handles the tough loads - from 3,000 lbs to 1200 tons

C I R C L E NO. 9 7

HEAD AND TAILSTOCK POSlT IONERS ADAPT FOR LONG S T R U C T U R E S For full rotation through the horizontal axis, an Aronson headstock/tailstock positioner adapts the load for your working conditions. You can achieve that important downhand or horizontal

welding position to reduce your handling and production costs. Capacities from 600 to 240,000 lbs.

C I R C L E NO. 9 8

Koike Aronson puts you in ostTJO"

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to weld better and more productively

Decades of experience has made Koike Aronson the recognized leader worldwide for positioning excellence. Our positioners, turning rolls and manipulators put a weldment in the right position for efficient downhand welding. That saves you time and money, while driving up welding quality.

All Aronson PosiUoners are solidly built and engi. neered to provide years of reliable performance.

Designed for safety and productivity. Built for a lifetime of service.

Check it out at www.ko ike .com

K01KE ARONS0N 635 West Main Street, Arcade, NY 14009 1-800-252-5232 Fax 1-716-457-3517

Elk Grove Village, IL - Tel: 1-708-228-7040 Fax: 1-708-228-9304 San Leandro, CA-Tel: 1-510-352-8840 Fax: 1-510-483-6390

Santiago, Chile- Tel: 562-211-1081 Fax: 562-246-7387

Products For more information, circle number on Reader Information Card.

Waterproof Cables Aid Underwater and Outdoor Applications

The manufacturer has used special jacketing designs, swelling fillers or tapes and unique coating materials in its waterproof cables. Tailor-made cables can be manufactured for almost any application, even extreme down-hole and deep sea operations. Options include filling the interstices in the cable interior with waterblocking fillers and tapes, in lieu of thixotropic gel, or designing the outer jacketing in layers, creating an efficient diffusion barrier. The cables can also be made watertight by in- corporating swelling fillers and special sealing tapes consisting of nonwovens loaded with polyacrylate powder that will swell instantly if exposed to water. Each stranded

Robotic Lathe Welding Made Easy

The Ti tan robot ic lathe welding machine for G M A welding handles parts that are turned on center. The five-axes, cartesian-based welding arm is integrated with the surface motion of the part fixtured in the welding lathe. The combined motions of the arm and lathe provide full articulated control of

conductor is specially sealed to ensure that a ruptured or cut cable cannot cause damage to adjacent electrical systems. Cables can be designed and built at the company's Canadian and German production facilities in order volumes starting at 100 m (300 ft).

elocab 100 258 McBrine Dr. Kitchener, Ontario N2R IHS, Canada

the gun for welds associa ted with fabricated cylinder products, including circumferential, base-plate, rod-end and port/saddle welds.

Pa rame t r i c p rog ram gene ra to r s simplify programming of complex welds by au tomat ica l ly c rea t ing the weld program based upon part diameters and desired torch angles at each quadrant. G e n e r a t e d p rograms util ize lathe motion to maintain the weld pool at top dead center of the cylinder throughout the weld. This welding mach ine provides a 120- x 24- x 24-in. working envelope with gun and lead angles of -+90 and -+50 deg, respectively. A PC- hosted , Windows®-based con t ro l system with simplified teach-pendant programming provides storage of up to 55,000 programs.

EC&S Robotics 101 5639 Millers Industrial Blvd., Birmingham, ALL 35210

Toolsetter Allows 'On-the-Fly' Operation and Detection

The NC1 laser-based toolset t ing system offers high-speed, noncontact operation and broken tool detection on machining centers. The setting of both length and diameter are carried out at normal spindle cutting speeds, allowing fast identification and compensation of errors caused by radial run-out of the tool and tool holder. The system can measure tools anywhere along the laser beam (up to 2 m in length), minimizing cycle times, especially for broken tool detection. Tools as small as 0.2 mm

26 [ MARCH 2001

(0.008 in.) can be measured with system resolution of one micron (0.00004 in.). Noncontact measurement ensures no damage to brittle coatings found on high-performance CBN tooling. The laser toolsetter detects broken tools in unmanned machining operations where tool damage can cause costly scrap or rework. The transmitter and receiver are available either premounted as a single unit or as individual modules ope ra t ing with up to 2 m (6.6 ft) separa t ion . The system can be purchased with new machines or retrofitted to machining centers already installed.

Renishaw Inc. 5277 Trillium Bird, Hoffman Estates, IL 60192

102

Weld ing System's Planetary W i r e Drive Reduces D o w n t i m e

The Mongoose push/pull gas metal arc welding system has a planetary wire drive system that increases productivity by reducing downtime caused by wire bi rdnest ing. The e lec t r i c -powered

planetary feeder motor automatically synchronizes with the gun's planetary feeder drive for superior control and consistency of the wire feed. The drive also assists the o p e r a t o r by compensating for meltback. The wire feed rolls rotate 360 deg around the wire, e l iminat ing wire damage and deformation. The rolls are universally adaptable to different wire types and

sizes. Cor rec t roll p ressure is au tomat ica l ly control led. The guns perform well with aluminum and small- diameter wires and are available up to 400 A. The adjus table a rmored gooseneck rotates 360 deg, and features a s t andard gun - to - f eede r quick disconnect and remote wire feed speed adjustment. The guns are available in 15-, 25- and 50-ft lengths.

ESAB Welding & Cutting Products 103 411 S. Ebenezer Rd., Florence, SC 29501-0545

Ultrasonic We ld ing Machines Assemble Plastic Parts

The 1000-W Z a p p e r PW-10, designed for joining smaller plastic parts , and the 2000-W PW-20, for joining larger and diff icul t - to-weld plastic parts, are ultrasonic welding machines for the assembly of plastic componen t s . The mach ines are intended for use in the automotive, appliance, toy, business and consumer electronics, textile, personal products

Transportation

Aerospace

Manufacturing

Petrochemical

Power Generation

Do Y o u V v ' e l d . . . .

GTAW (TIG)

PAW (Plasma)

GMAW (MtG)

SAW (Subarc)

LW (Laser)

Do You H e e d . . . .

Cannister filters Electric motor casings . Exhaust mufflers Ducting and flues Fuel tanks Huclear storage containers

Higher productivity Greater consistency More precision Less pa r t s m i s m a t c h Lower manufacturing costs Sa t i s f i ed c u s t o m e r s

Jet l ine has a so lu t ion for al i your s e a m w e l d i n g a p p i | c a t i o n s .

l 5 G O O D Y E A R 5 T R E E T , I R V I N E , C A 9 2 6 I B T E L : ( g 4 g ) g 5 1 - 1 5 1 5 * F A X : ( g 4 9 ) 9 5 1 - g 2 3 7

emaih [email protected] • www.jetline.com An ITW Company



and injection molding industries. Both machines are compact, benchtop units with a buil t- in power supply and can weld, stake, insert, spot weld and degate plastics. They can also be used to seal synthetic fabrics, film and other thin thermoplastic materials. Both machines feature constant ampli tude and force t r igger mechanisms, come equ ipped with a mechanical stop to prevent horn travel beyond the desired setting and have a pretrigger mechanism.

Ultrasonics for Less 974 United Circle, Sparks, NV 89431

104

Stainless-Steel Oxyfuel T ip Lasts Longer

The company is offer ing the new Long-Las t ing® oxyfuel t ip des igned specifically for its Multi-Use® system.

The addition of a stainless-steel insert into the tip orifice lengthens tip life. The insert helps make cleaning slag and ca rbon re s idue eas i e r and p reven t s orifice distortion. Tips come in a wide range of sizes and can be used with most gases.

The American Torch Tip Co. 6212 29th St. E., Bradenton, FL 34203

105

Recovery System Removes Oil f rom W a t e r

The Model 6V oil recovery system removes petroleum-based oils, animal and vegetable fats, grease and oily waste f loa t ing on water . Oi l s t icks to the outside of a polyurethane closed-loop

co l l ec to r tube that snakes over and around debris. The tube is lifted out of the water and drawn through scrapers that remove the oil. The clean tube is then r e t u r n e d to the wa te r and the process repeated. Tubes can withstand temperatures up to 200°F and will not

SMART Portable X-Ray Systems Highest Quality

Withstands Extreme Conditions

- Short exposure times

- Low weight

- 100% duty cycle

- High reliabil ity

With systems ranging from 160kV to

300kV, we meet your needs. Contact us.

YXLON International Inc. Successor to Andrex, LumenX and Philips Industrial X-Ray 3400 Gilchrist Road • Akron, Ohio 44260-1221 • USA • Phone 330.798.4800 • Fax 330.784.9854 • www.yxlon.com

I l l I !

,y YXLON International

281 HARCH 2001


f rac tu re in f reez ing cond i t ions . Des igned with nonc logg ing c o m p o n e n t s , this un i t can run unattended 24 hours a day, year-round. The system is adaptable for outside or in-plant oil recovery and can remove as much as 100 gal of waste oil per hour. All waste oil can be decan t ed into drums. Oil recovery systems can be customized and sized to specification.

Oil Skimmers, Inc. 106 P.O. Box 33092, Cleveland, OH 44133

Chi l ler 's Digital T e m p e r a t u r e C o n t r o l l e r is Standard

The JT Series of chillers come with digi tal t e m p e r a t u r e con t ro l l e r s as s tandard equipment . Opera tors can control temperature set point; an easy- to-read display provides real-time status of fluid temperature. All models are stand-alone units designed to supply a c losed- loop circui t of cons t an t - t e m p e r a t u r e water. Each model includes a pump and reservoir. The JT Series of chillers have brushed stainless steel cabinets, casters for easy mobility, nonfe r rous fluid circuits to prevent corrosion and a full, one-year parts and

labor warranty . Cool ing capaci t ies range from 1500-14,000 BTU/h.

Koolant Koolers 107 2625 Emerald Dr., Kalamazoo, MI 49001

Hose Reel Faci l i tates Extract ion of Exhaust Fumes

The company has made a series of vehicle exhaust hose reels in diameters ranging from 4-6 in. The hose reels facilitate extraction of fumes and gases produced by automobiles, trucks and other industrial machinery. Hose reels can also be used to extract fumes in remote areas such as in the hulls of ships or in tanks. Hose reels are made of

flexible material and have a temperature ra t ing up to 2000°F. They are fully adjustable in tension to give the desired retraction, can be fitted with a variety of ta i lp ipe nozzles and have out le ts designed to connect to 6-in.-diameter ducting. Uni t s come in a variety of standard product ion models, with or without fans and filters, and can be customized to suit specific applications.

OsKar Antipollution of America Inc. 108 8031 Jarry Street E., Montreal, QC, HIJ IH6, Canada

CREATING A PERFECT WELD ENVIRONMENT

Pipe-Align Clamps

T

Pipe-Align Chains

Purging Units from 1/2 "- 40 "+

Oxygen Sensors

~~~ .i ̧.

Aluminum Tape

PURGING EQUIPMENT & ACCESSORIES ~ ~ FOR THE WELDING OF PIPES & VESSELS ~ ~ J ~

Tel:(800) 665-6655 Fax: (604) 946-5340 T.,~ ~,, , e , , S / e ~' .~, ~d e . ~ ' w w ~ . i n t e r c o n o n l i n e . c o m T . n gs ten Cr inders

Gircle No. 21 on Reader Info-Card SEE US AT BOOTH 4626

WELDING JOURNAL 29

Versatile Air-Cleaning Systems Used for Laser Cutting

The company's air-cleaning systems are designed to work with any laser- cutting fabrication or manufacturing operat ion. To help el iminate laser- cutting pollutants at the source or in ambien t p lant air, the system uses source-capture exhauster arms, portable sou rce -cap tu re air c leaners , dust collectors, ambient air cleaning units, downdra f t tables and l a rge -duc ted

collection systems. Cartridge-model air cleaners and dust collectors incorporate

V O U

J u n e 7 - 8 , 2 0 0 1 H o u s t o n

To rev iew the p rogram on-line, go to ht tp : / /www.aws. org/OONFERENOES/

confFP.html ( 8 0 0 ) 4 4 3 - 9 3 5 3 , e x t . 2 2 3

e - m a i l c o n f @ a w s . o r g .

Visit our website http://www.aws.org

a cartridge-cleaning system. Custom engineering is available for specific laser cutting applications.

Micro Air 109 P.O. Box 1138, Wichita, KS 67201

Power Supply Designed for Microwelding

The new series of TruPulse" power supplies has been des igned for precision-intensive applications. The microwelding power supplies provide the super ior cont ro l necessary for joining tungstcn rod to molvbdenum-

based sealing foil commonly used in special ty light bulb and lamp manufac tu r ing . The units provide c losed- loop mon i to r ing with rapid response times. The power supply delivers two quick pulses of heat energy and uses linear mode power transistors that react and adapt within 10 microseconds. With low signal-to:noise ratios, the microwelding power supplies are able to deliver greater accuracy and process control. Power supplies feature front panel control settings and are available in 1000, 2000 and 4000 A.

Micro Join 110 13535 Danielson St., Poway, CA 92064

More Economical Tungsten Electrode Grinder Offered

The company offers a lower-cost tungsten electrode grinding machine that accepts all c o m m o n sizes of tungsten electrodes as standard. It also accepts short pieces of tungsten with the aid of a low-cost collet accessory. A diamond wheel is fitted to the unit and protected by a front cover that prevents the grinding of anything other than a tungsten electrode, thus eliminating the risk of contaminating the tungsten with o the r mater ia ls . The tungs ten electrodes are ground axially to as small as 12 mm in length. A high-speed motor provides the cor rec t speed and is suitable for connection to a ll0-V, 60- Hz, s ingle-phase connec t ion . An optional vacuum dust extraction facility is also available.

COB Industries Inc. P.O. Box 361175, Melbourne, FL, 32936-1175

30 I MARCH 2001

Serving you Through the AWS Foundation!

ii

The AWS Foundation is proud to present two new National Scholarships for students preparing for a career in the welding industry.

These scholarships have been created by sponsors with the belief that our future industry depends on a strong educational base.

Matsuo Bridge International Scholarship

MAC M a t s u o America Company

Purpose: To provide a two-week training opportunity for a student pursuing a welding or civil engineering degree, at the Matsuo Bridge Company's facilities in Japan.

Jerry Robinson- Inweld Corporation Scholarship

Purpose: To provide a scholarship to a student with significant financial need who is pursuing a degree in a welding program at an accredited university. Renewed annually with satisfactory grades.

Information and applicat ions are avai lable by contacting

< ~ Foundation, Inc____~. A Foundation of the American Welding Society

550 NW LeJeune Road Miami, F1 33126 1-888-WELDING, ext. 212 FAX: (305) 443-7559 E-mail: [email protected] www.aws.org/foundation/index.html

For more than 40 years, the American Welding Society has proudly recognized National Welding Week, an indusW- wide celebration of the accomplishments of the welding community. Over the years, AWS members have been the catalyst for generating the support for this recognition program. You have gone to your shops, your schools and your businesses, and helped spread the word on the importance of backing the industry that literally holds the

world together.

This year, National Welding Week will take place May 5 - 12, 2001. Once again, your help is needed to bring awareness about the importance of welding.

Here's what you can do. Tear along the perforation on the opposing page and proudly display this year's National Welding Week 2001 Poster in your homes, schools, shops or offices. Help pass on the message that welding is an invaluable joining method that impacts many manufacturing applications (automotive, aerospace, hygienic food processing, structural, and man), more). We also encourage you to go to your local governments and request that they recognize and celebrate National Welding Week by issuing an official proclamation. And, stayed logged on to w~v.aws.org for the latest stories about what your fellow members are doing to support this most important program. Finally, you can call AWS for tips, ideas or to simply express your accomplishments; 800-4443-9353, extension 308 -AWS Communications Department.

Thank you for being involved. AWS Members. Together, you are helping to bring awareness about the importance of welding to the world.

Visit our website http:/A~'w~v.aws.org

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May 5-12, 2001 i

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Computer-controlled orbital tube welding was used on every weld to ensure repeatability and quality traceability during production.

A new, economical reusable launch vehicle relies on repeatable orbital tube welding

E ver since the creation of NAS.Ns famed X-1 research rocket plane, which first broke

the sound barrier with Chuck Yeager at the controls, orbital tube welding has been the welding method of choice for aerospace. Now Orbital Sciences Corp., Dulles, Va., and NASA have teamed up to create the X-34 reusable launch vehicle (RLV), the newest generation of rocket planes. The X-34 is being designed to take the place of some of the more fami l ia r - - but also more expensive - - spacecraft and boosters in use today.

The X-34 is air- launched from an L-1011 Tri-Star jet to reduce launch cos t s - - Fig. 1. The low-cost X-34 test vehicle is designed specifically to demon-

BY D O N B R O W N A N D JAY N E U M A N

strate new operational approaches that will dramatically reduce the cost, time and number of personnel required to process and launch reusable launch ve- hicles in the future. More than ever, the need for highly reliable, low-maintenance, leak-free tubing systems has driven the requirement for au tomated tube-welding equipment.

Orbital Sciences chose the Liburdi Dimetrics Centaur III 150 PTW computer-control led orbital tube welding machine for the job. Critical to the X- 34's construction requirements was the ability to butt-joint weld heavy-wall tubing in tight spaces. The X-34 quality team also required real-time data acquisition of welding schedule parameters

for every weld to monitor repeatability and provide quality traceability. A computer-control led orbital tube welding system could fulfill both requirements.

The X-34 spacecraft contains more than 2000 ft of tubing, ranging in diameters from 0.250 to 4.500 in. with wall thicknesses from 0.028 to 0.120 in. More than 500 tube welds are needed to inte- grate the X-34's systems and all welds must be square butt joints. As a result of these requirements, it was necessary to develop welding protocols, parameters, schedules and qualifying procedures to meet the requirements of the X-34 program. A variety of issues had to be addressed and solutions worked out to move the project forward.

DON BROWN, (704) 892-8872, is with Liburdi Dimetrics, Davidson, N.C., and JAY NEUMAN (neuman.j@orbitaLcom) is with Orbital Sciences Corp., Dulles, Va.


Challenges to Overcome Material chemistry. The X-34 uses

only seamless 316L tubing. Fittings had to be made from either billet or forging, and both tubing and fittings had to comply with ASTM specifications. One problem encountered was a welding phenomenon referred to as "pool shift," where different surface-active elements in the parts being welded cause the weld pool to shift to one side of the joint being welded. Surface-active elements, like sulfur, have a pronounced influence on the surface tension of a molten weld pool. A lower sulfur content on one side of a joint can have a stronger tension than the higher sulfur side, causing the pool to be drawn to one side of the joint being welded.

If this happens, full penetration of the weld can still occur, but penetration of the weld bead can miss the joint. In such cases, the appearance of the weld bead on the outside of the tube would have only a slight indication of the weld bead shift. The weld bead on the inside would reveal a more obvious shift that can be detected visually with a borescope or sight pipe. The weld would fully pen- etrate the work, but it would be shifted to one side of the joint, leaving the inner diameter unconsumed.

The sulfur contents involved in such scenarios are minute. Welding materials with a sulfur content of roughly 0.1 to 0.3% usually present no problem, but when trace amounts of sulfur are very low (i.e., 0.007 to 0.028%), the influence as a surface-active element can be significant. Sulfur can vary over a wide range

of concentrations in the 300 series of stainless steel - - used extensively on the X-34 - - and would have a profound influence on weldability if there was even a small difference (as low as 0.011%) in sulfur content.

Material weldability. Different heats of stainless steel tubing can make it difficult to weld by automatic fusion welding techniques. ASTM specifications for each type of stainless steel such as 304, 316, 304L and 316L may vary in concentrations of alloying elements such as chromium, nickel, molybdenum, copper, sulfur, etc., resulting in no two heats of 304 or 316 being exactly alike. Variations in alloying elements could dramatically affect the weld bead appearance and depth of weld penetration of two samples of 316L stainless steel tubing, both with a 1-in. outer diameter (OD) and wall thickness of 0.083 in., but neither having the same heats as a result of varied alloy concentrations - - Fig. 2.

An unusually wide weld bead relative to the depth of penetration characterizes heats that are low in sulfur content. The large weld pool can be difficult to control and sensitive to gravity. As a result, the weld could become concave on the outside of the tube and lack repeatability.

Several irregularities have been observed in the weld bead when sulfur concentrations are above 0.024%. If orbital tube welding is to be employed, it is recommended that sulfur content not vary by more than 0.010% between tubes being welded together.

Orbital Sciences had to exercise tight control over the purchase of stainless tubing intended for orbital welding to

minimize this problem. The X-34 program has had to weld heats of tubing and fittings that had as much as a 0.021% difference in sulfur content, which can result in a significant pool shift. Despite the differences, weld consistency and high quality have been achieved by means of developing techniques, procedures and welding parameter controls aided by a computer-controlled orbital welding machine.

Joint type. The type of joint an application requires can be important when choosing weld equipment and approach. The X-34 required square butt-joint welds for the following reasons:

• No slag or flux is permitted to cont- aminate the tubing as a result of the welding process. The X-34 uses liquid oxygen (LOX) systems in which the LOX is a vigorous fuel oxidizer. In such systems, very small amounts of contamination can result in catastrophic failure of the vehicle.

• Product scrap is reduced due to the typically lower porosity in these types of welds and lower stress-intensity factor. Welds that require welding wire have a much greater chance of porosity due to all the possible sources of contamination. Since all X-34 welds are square butt-joint welds, no welding wire has been used.

• Single-pass welds avoid many weld defects associated with multiple-pass welds and fewer weld passes result in less shrinkage. This also makes the weld bead crowning less sensitive to weld joint orientation during welding. Almost half the welds made on the X-34 were made inside the vehicle and, as such, could not

34. I MARCH 2001

Fig. 2 - Transverse cross-section microspecimens were taken through the circumferential weld at two locations. The cross sections were mounted in plastic and carefully ground, polished and etched to develop the general microstructure o f the weld bead. A - - The weld bead profile; B - - weld penetration.

be conveniently oriented. Shielding/Purge gas. Shielding gas

can be a critical ingredient in the success of a weld. Shielding gas minimizes porosity in a weld and can, in some cases such as mixed gases, almost eliminate porosity. Also, shielding gas is used to purge possible contaminants from a weld area, and manipulation of purge pressure can be used to support a weld while it is molten. For the sake of economy and simplicity, most welds are developed using only argon for shielding and purging. However, some of the more difficult applications necessitate the use of mixed welding gases to achieve the weld qual-

ity and results demanded by the X-34's high-pressure applications.

Mixed gases were used for both shielding and purging. Although mixed welding gases have their problems, the benefits allowed the X-34 program to weld difficult - - but necessary - - applications that would have otherwise forced program costs up and vehicle delivery schedules to slip. Specific benefits of the mixed welding gases include setup of a reducing atmosphere that effectively eliminates moisture from the welds, resulting in little or no porosity; consumption (burning) of the hydrogen component of the gas mixture during welding, which effectively

adds heat energy to the weld; heavier wall tubing that can be welded with less amperage; and a more focused weld, with better direct penetration.

Shielding gas was critical in solving problems when welding difficult applications of very heavy wall tubing/fittings with dissimilar chemistries (i.e., different sulfur contents) and in addressing severe pool shift, but its use created other problems related to mixed purge gases in K-bottles and the obtaining of a consistent mixture ratio during purging. For instance, if the bott les yielded a slightly higher hydrogen rat io during welding, the weld would be hotter than expected and the subsequent weld probably would not meet inspection criteria. Therefore, consistent mixture-ratio delivery became a critical factor that had to be controlled.

The gas supplier suggested that, when using a gas mixture of argon and hydrogen, a K-bottle with a siphon tube that stirs the gas mixture as it siphons through the tube should be used. This would help prevent gas mixture stratifi- cation. Another vendor recommended using a lamp on one end of the K-bottle to mildly heat it, creating a convective heat flow inside the bottle to stir the gas mixture.

Orbital Science specified gases to have less than 10 ppm of oxygen and 3 ppm of moisture to minimize porosity in the final weld. The X-34 program required the following welding purge gases: 100% argon, 95/5 (95% argon/5% hydrogen), and 92/8 (92% argon/8% hydrogen). The reason 95/5 was chosen was because it is a standard mix and a rea- sonable starting point. Another particularly difficult application required further weld development, which determined the need for a 92/8 mixture. Once the desired results were obtained, the application was discontinued, but it is believed further potent ial exists in higher hydrogen mixtures. Practical limits of this approach are in the 12 to 15% hydrogen range.

E l e c t r o d e s . Electrode geometry has always been an important orbital welding parameter because it has such a pronounced effect on weld shape and penetration. The use of properly prepared tungsten helps ensure repeatable welds. The typical geometry is a 22-deg taper with a 0.010 to 0.020 flat tip. A tip without a fiat point may create an unstable arc and produce welds that wander from side to side. A fiat point allows the arc to come off an edge, thus producing a stable arc. The flat point also has the other advantage of extended tungsten life and, most important, a tungsten-to-work distance not compromised by having a sharp- pointed tungsten tip break or wear back.

WELDING JOURNAL [ 35

The X-34 weld schedules were relatively insensitive to changes in electrode geometry between a wide breadth of weld schedules. The majority of the electrodes have a 20-deg taper with a 0.010- to 0.015-in. flat tip. Electrode material did matter in some cases, depending on joint size (i.e., tube OD, wall thickness, weld head, purge gas, etc.). The program migrated from thoriated to both ceriated and lanthiated tungsten electrodes, which is consistent with what is used in Europe and Japan. Health hazards associated with grinding thoriated tungsten are behind the move to ceriated and lanthiated tungsten. More than half the applications favored ceriated tungsten, and lanthiated worked well when using mixed purge gases.

Tube preparation. As in all welding, fitup is critical to successfully producing repeatable welds. It is especially critical with orbital welding because specific parameters such as travel speed, welding amperes and arc volts are preset. Any high-low condition or tube ovality problems will have an adverse effect on weld quality. The tubing used for square butt joints must be cut square and the end face machined perpendicular to the tube centerline using a facing tool. A tight

butt joint is a critical factor in fitup. Beveling, or chamfering, the tube

ends was not desirable. Material removed by chamfering could result in additional weld joint concavity and cause the wall of the weld joint to thin. All X- 34 tubing butt joints used only the base material being welded.

Why Welding Was Chosen for the X-34

NASA did not require the X-34 RLV subsystems to be welded. The reliability and low maintenance objectives of the RLV program drove the need for welded systems. There was also a low fluid leak- age rate objective the company wanted to achieve, which had been the cause of cancellations in other propulsion system development projects. Once the deci- sion was made to use welding as much as practical, the need for high-quality welds using equipment that could meet X-34 weld application and tight installation clearance requirements was a determining factor in developing a plan and selecting welding equipment for the X-34 system. Once everything was in place, the focus shifted to carrying out the design and weld quality/qualification nec-

essary to build a reliable and safe system. The X-34 uses 5000 lb/in3 pneumatic

systems. If tubing failed, a considerable safety hazard would be presented to personnel in close proximity. Also, these high-pressure lines run near an assembly of large pressure tanks, also operating at 5000 lb/in.2. If a weld failed on a tube adjacent to this bank of tanks, it would represent a major explosion hazard when the system is under operating pressure. The weld development work was done with this in mind.

The engineers and technicians also relied on real-time data acquisition to ensure weld quality and repeatability. Before inspecting and proof pressure testing the welds, the team needed to have high confidence in the quality of the work done. The real-time data acquisition capability of the orbital machine provided the confidence and necessary traceabili ty required by the project.

Before long, the X-34 will progress from the developmental stage to the front pages of daily newspapers and lead stories on television news. It is expected to be an important element in NASA~s more economical space launch program.4

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36 I MARCH 2001


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Fig. 1 - - Fast ferries fabricated by Dakota Creek can carry 300 passengers and attain speeds o f 42 knots.

A fabricator of fast ferries patiently developedpulsed gas metal arc weldingprograms that exceeded ABS tensile and yield strength requirements f or joining 5083 aluminum

BY D O N K E D D E L

I f Rick Kirschman had believed the experts, he 'd be selling insurance or teaching welding at a community college.

"I still keep a sticky note from a welding consultant in my handbook next to the ABS specifications for an aluminum vessel," said Kirschman, project manager for Dakota Creek Industries, Inc., a shipyard in Anacortes, Wash. "The consultant's note said, 'These values cannot be attained. There are very few people in the world who can attain these values.'"

Fortunately for Dakota Creek, who

had just won the contract to build two aluminum fast ferries, Kirschman didn't believe the consultant or in accepting failure. Instead, he believed in pulsed gas metal arc welding (GMAW-P), inverter power sources and programmable wire feeders.

After hundreds of test coupons, technical support and six weeks of intense work, Kirschman developed procedures for pulsed G M A welding 5083 aluminum from 2.5 mm (0.10 in.) to more than 75 mm (3 in.) thick.

The welds produced have yield

strengths of 27,250 lb/in. 2, tensile strengths of 45,270 lb/in. 2 and passed all bend tests. This exceeds American Bu- reau of Shipping (ABS) and Coast Guard standards by more than 21% on the yield and 12% on the tensile.

Not Too Hot, Not Too Cold

The 143-ft fast ferries (Fig. 1) can carry 300 passengers at speeds of 42 knots because hull, superstructure and

DON KEDDEL is fabrication and aluminum segment manager, Miller Electric Mfg. Co., Appleton, Wis., (800) 426-4553.

38 1 MARCH 2001

most other components are made from lightweight aluminum - - Fig. 2. The aluminum in the hull ranges from 4.75 to 6 mm (0.19 to 0.024 in.) near the bow and midsection, and 8 and 10 mm (0.31 and 0.40 in.) near the engines, as thicker sections better withstand vibration. Most aluminum on the superstructure is 2.5 or 3 mm (0.10 or 0.12 in.) thick.

In other industries, most fabricators would use the GMAW process in the short circuit mode to weld thin aluminum and the spray transfer process to weld thicker sections. Dakota Creek, however, could not use either of these processes. ABS does not permit short circuit transfer because of historical concerns caused by incomplete fusion. Spray transfer can guarantee complete fusion and is accepted by ABS, but it wouldn't work for the critical butt joint welds.

"Spray transfer hits the metal so hard, and aluminum absorbs heat so quickly, that this process destroys the temper of the metal," said Kirschman. As a result, welds fail yield and tensile strength tests. With short circuit and spray transfer disqualified, only the GMAW-P process could provide a solution. ABS accepts the GMAW-P process because it's technically a modified spray transfer process.

The welding system the company chose consisted of 450-A, 100% duty cycle Phoenix and Maxtron inverters from Miller Electric Mfg., Appleton, Wis. The thicker sections of aluminum required peak amperages of more than 400 A. Included in the system was Miller's 60M wire feeder.

The welding equipment allows the pulse wave form components (peak amperage, background amperage, pulse width and pulses per second) to be ad- justed with the push of a few buttons.

"Fine tuning pulsing values can be a deceptive process, as a beautiful looking weld does not necessarily indicate weld quality," noted Kirschman.

"A flat and shiny bead with good wet out probably won't pass ABS tests because it went in too hot," explained Kirschman. "Such a weld passes the bend test, but it probably won't have high enough tensile and yield values. Too much heat also degrades metal composition, so the weld won't pass an X-ray or ultrasonic test, either." Conversely, if the weld goes in too cool, the metal loses ductility and subsequently fails the bend test. Too little heat also produces incomplete fusion. 'Aluminum dissipates heat so quickly that the base metal can rob heat from the weld pool, especially in the first few inches of the weld," said Kirschman.

Kirschman explained the latter con-

Fig. 2 - - The bow, hull attd superstrucmre of an alttnzinum feny in various stages o/ fabrication.

cept from an experience he had when he visited another shipyard. The welding operator there didn't believe him. The operator indicated some fillet welds and boasted of their excellent fusion. Kirschman proved his point by slamming a hammer against the weldment. The fillet welds popped off; they had failed to fuse to both surfaces.

Documentation and Patience Required

Kirschman stresses that creating a successful GMAW-P program requires a methodical approach. He changed one variable at a time, documented every change and waited patiently for results after an ABS-cert if ied lab calculated tensile, yield and bend values.

"Only after you get the lab results can you see how changing one variable af- fects the quality of the metal," he said. "That 's really important when dealing with ABS specifications."

He ultimately created 14 pulsing programs for welding aluminum with g,,,-in. (1.2-mm) diameter wire. He could have covered his aluminum needs with four programs, but created the addit ional programs to lock welding operators within narrow wire feed speed and trim adjustment ranges. This better ensured tensile, yield and bend values remained within ABS specifications for the different thicknesses.

N e w Rules

Although the welding consul tan t the company h i red u n d e r e s t i m a t e d

Ki rschman ' s pa t ience and skill with GMAW-P programs, he did provide other good aluminum welding advice.

"Coming from a steel background, I didn't believe most of the things he told me at first," said Kirschman. "But after a month of testing, I understood." He says he learned that good mechanical strength in a butt-joint weld demands using an included angle of more than 60 deg.

After completing the first side, aluminum also demands backgouging (from the base metal through to the weld bead) and creating another 60-deg included angle. Dakota Creek operators used a grinder with a heavy 4~-in. (114.3- mm) blade designed to cut at 60 deg.

"With anything less than a 60-deg angle, aluminum pulls apart prema- turely in a bend test, even if the weld passes X-ray," stated Kirschman. "A lot of people argue with that, but they haven't done the testing we have." The company's welding procedures ensure that if the fast ferry's hull ever takes a hit, such as from a buoy or large log, the welds will remain as mechanically sound as possible. "Backgouging is critical with aluminum because, unlike malleable steel, aluminum does not retain its mechanical properties once overstressed." said Kirschman.

"Making a good butt weld is by far harder than making a good fillet weld," noted Kirschman. "Of the 30 operators we trained to weld aluminum, eight are butt welders. It 's not that the others aren't good, but those eight guys have the patience to follow procedures to company standards every time. And since ABS X-rays butt welds (fillet welds can't be X-rayed), their welds get inspected closely."

WELDING JOURNAL] 2,9

Fig. 3 - - Operator Joe Gilden welds stainless steel pipe with the pulsed gas metal arc' process.

Even making an ABS-quality fillet weld requires that every welding operator adhere to established gun techniques. Consistency is not easy either, due to the great number of welds made on a fast ferry. A single 40 x 30 ft over-

head ceiling panel has more than 14,000 fillet welds.

When welding aluminum, operators cannot strike the arc at the spot where they want the weld to begin. Instead, they must draw the gun slightly back,

perhaps 'A to 1 in. (12.7 to 25.4 mm), as they pull the trigger and establish the arc. They then move forward and weld over the point of arc initiation, always using a forehand or push technique to ensure good gas coverage. Because a short circuit can occur during arc start, this method washes out any cold spot and ensures complete fusion.

M u l t i p l e F u n c t i o n s

For welding in a shipyard, a multiple- process, inverter power source provides the most value and best return on investment. "We need to be able to stick weld, MIG and pulsed MIG weld aluminum and stainless, TIG weld ferrous metals and arc gouge with the same power supply," said Kirschman. "Even though we justified purchasing five new inverters for the aluminum fast ferries, we wanted their versatility for use on future steel and stainless projects."

Since the initial two fast ferries, the company has completed a contract for two fast ferries for the state of Washing- ton, a multimillion dollar luxury yacht hull and the stainless steel pipe systems (Fig. 3) on five tugboats, all manufactured with the GMAW-P process.~

4o I MARCH 2001


Welder Cert i f i ca t ion: Many Thrusts, Few Agree

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A pipe/itter prepares a pipe Jbr welding.

U.S. welders must submit to

constant testing and retesting to

satisfy the plethora of certification

requirements in the industry. Are

they victims of too many

standards?

BY BOB IRVING

T imes have changed. The old days when a group of welders spent their entire careers with one employer are gone. Projects are now short term. Welders are being forced to move from one company to another many

times during their careers. But movement can be complicated. The various standards created by organizations like ASME, AWS and API - - each organization with its own separate body of codes and standards - - has created a situation where companies must adhere to one, or more, set of standards, depending upon the industry.

Caught in the middle are welders, whose performance is held accountable to a particular standard required for a particular job. So, if a welder certified by, say, AWS standards for one job, decides to move to another company or another industry, he or she will often be faced with the prospect of being retested according to ASME, or some other standard, in order to be properly certified to weld on the new job.

The reality of undergoing constant tests and retests has led many welders to the conclusion that their destinies are controlled by others, that they have no voice, no freedom of choice when it comes to employment. And this disen- chantment comes at a time when there is a growing shortage of welders in many parts of the country.

BOB IRVING (BobbyRea [email protected]) is Consulting Editor of the Welding Journal

WELDING JOURNAL 141

Fig. 1 - - A welder prepares to use the shie lded me ta l arc weMing process.

Fig. 2 - - A n observer looks on as a weMer prelmres to p e r f o r m a gas tungsten arc weld.

One Company, Multiple Standards Trinity Industries, Inc., Dallas. Tex., is a case in point. Trinity

builds bridges, barges, freight cars and tank railcars. The company also fabricates a majority of the propane tanks built in this country. As a result of this varied product mix, the engineers are working with ASME, AWS, ABS, AAR, API and other standards.

H. Blake Craft, vice president and general manager of Trin- Manufacturing Systems, Inc., Dallas Tex., a consulting subsidiary of Trinity, noted welders qualified under AWS standards may have to be requalified if they are assigned to a division within the company that adheres to ASME. Although the products being produced may have similar materials, processes, electrodes, joint geometry or other attributes, the limitations of variables as specified by each code or standard may be inconsistent with one another. As a result, the industry often has to subject its employees to redundant testing.

With Trinity's diverse product mix, Craft noted, it is not un- common to have welders certified to several different codes and standards. As a builder of barges, pressure vessels, freight cars and other products, the company must answer to many industrial codes, including ASME, the American Bureau of Shipping, the Association of American Railroads, and AWS. In-house training and testing programs designed to enhance employee competencies and skills must shoulder the task of helping welders adjust from one code to another.

Depending on the business activity at the time, Trinity em- ploys between 2000 and 4000 welders. The cost to the company of administering these tests can be extremely high, especially if such factors as material, lost productivity, administrative personnel to conduct and witness the test, and the cost of evaluat- ing the welder's test sample are included.

Some Industries Test In-House Welders who work for the Norfolk Southern Corp.,

Roanoke, Va., are qualified to AWS D15.1, according to Ken R. Rollins, system welding coordinator for the major railroad. Welders are tested for competency in shielded metal arc welding, flux cored arc welding and gas metal arc welding processes. They are expected to pass tests that show they can weld materials of unlimited thickness in all weld positions. For example, plate tests are conducted in the 3G and 4G positions and pipe welds are made with the SMAW process.

Weld testing is administered by one of the company's certified welding instructors. Most instructors hold certifications as AWS Certified Welding Inspectors and Educators and also have

experience doing welding. Visual and bend tests are used to qualify each welder's tests. Once a welder fulfills qualification requirements, he or she will be able to work within the company's various mechanical departments. The qualification is good for 180 days and welders are expected to update that qualification prior to its expiration.

New employees joining Norfolk Southern's welding work force must go through a four-week-long training course in McDonough, Ga. Each candidate welder is trained in shielded metal arc and flux cored arc welding of steel plate and in shielded metal arc welding of steel pipe - - Fig 1.

Others Tap National Test Facilities Welders that belong to the International Association of

Bridge, Structural, Ornamental and Reinforcing Iron Workers, AFL-CIO (the Ironworkers) union in Washington, D.C., are qualified at 35 AWS Accredited Test Facilities throughout the country, said Ray Robertson, general vice president and executive director of apprenticeship and training. The program is known as the Ironworkers Welder Certification Program of North America. Most of the jobs they obtain are in areas covered by AWS DI.1. So far, about 5000 welders have been qualified.

Currently, about 15,000 individuals are enrolled in the Iron- workers apprentice program. Of this total, Robertson estimates about 11,000 of them will eventually be qualified at one of the AWS test facilities. Acceptance of the program's graduates is growing; building inspectors in Clark County, Nev., employ welders who have finished the Ironworkers program.

About three years ago, the International Training Institute (ITI) for the sheet metal and air conditioning industry and AWS joined forces to sponsor the ITI/AWS Certified Welder Pro- gram. This particular program is for members of the Sheet Metal Workers International Association and Air Conditioning National Contractors Association. ITI uses more than 70 AWS- certified test facilities throughout the country where welder qualification tests are performed. Welder certification training prior to testing is available at any of 162 training centers run by the local Joint Apprenticeship and Training Committees. There are now more than 1000 qualified welders in the ITI/AWS database, according to S. L. Raymond, welding assessor for ITI.

Sheet metal welders move into a wide variety of industries, typically construction, pharmaceutical, chip-making and power plants. Most of the welders end up working under AWS DI.1, D9.1 or ASME Section IX codes. Processes covered include (but are not limited to) shielded metal arc, gas metal arc and gas tungsten arc welding, soldering and orbital welding - - Fig. 2.

42 I MARCH 2001

Fig. 3 - - The bend test, shown here using equipment produced by Triangle Engineering, Inc., West Hanover, Mass., is used widely in welder qualification work. Triangle Engineering is also an A WS Accredited Test Facility.

Depending on the situation, welds are either bend tested, X- rayed or visually inspected - - Fig. 3. AWS B2.1 standard welding procedures and qualified welding procedure specifications are used in testing.

Fig. 4 - An instructor at the Umted Association 1)ipeJittet:s • program observes an apprentice performing a shielded metal arc welding procedure.

Stanching the Need to Retest Efforts are being made to make it easier for welders to move

from job to job. For example, more than 7000 welders have been qualified by Common Arc, a nonprofit corporation established by the National Association of Construction Boilermaker Em- ployers with help from the International Brotherhood of Boil- ermakers, headquartered in Geneva, Ill. Initiated in 1988, the Common Arc welder certification program provides precertifi- cation that will be recognized by multiple contractors for specific processes, thus eliminating the need for retesting at each new job.

Common Arc is used mainly to qualify welders to ASME Sec- tion XI. In this setup, representatives from as many as 20 contractors will travel to a test facility to witness the testing of welders. Each weld test in this arrangement is given a bend test. The advantage of this approach, according to supporters of Common Arc, is that a welder can become qualified with multiple Common Arc contractors simply by taking just one test. The contractor has an immediate source of skilled welders who meet ASME requirements, thus eliminating the cost of job-site testing and the time constraints presented when a contractor

needs qualified welders during emergency situations like power outages.

In the UA Pipefitters' Welder Certification Program (WCP), more than 300 training schools, owned and operated by the UA, prepare and test welders who are candidates for WCP qualification. Large facilities are located in Ypsilanti, Mich., Colton, Calif., and Charleston, S.C., for training instructors. Additional facilities are under construction at Peekskill, N.Y., and Jackson, Miss.

Much of the work in this program is directed at welders seeking qualification on jobs covered by the ASME Code for Pressure Piping, B31. The United Association's goal is to train welders with qualifications that will be interchangeable between different manufacturers and contractors. According to Stephen E Kelly, special representative of the UA, the WCP focuses on improving inadequate welding practices like the lack of covering the full range of pipe diameters, pipewall thicknesses, and the deposit thicknesses for the welding process that are essential to ASME standards. He adds that the UA program is also intended to reduce the costs of testing and requalifying welders for different jobs. This is accomplished by making use of independent third-party witnesses, qualified inspectors, independent auditors and qualified independent testing laboratories for test evaluation who evaluate by means of recognized industry standards. Tests are X-rayed and inspected by representatives from the Hartford Steam Boiler Insurance Co. Proctors for testing are often AWS Certified Welding Inspectors.

Those who successfully complete the program enter the job market as pretested, certified and immediately available jour- neymen welders for the piping industry in the United States and Canada, at no cost to the employer. The United Association un- derwrites the cost of testing and qualifying its welders by independent testers, auditors and other third parties involved in this sphere of activity - - Figs. 4 and 5.

States that accept welders who have completed the United Association's program are Arkansas, California, Georgia, Illi- nois, Kentucky, Maryland, Michigan, Ohio, Oregon, Pennsylva- nia and Wisconsin. Seventy-three companies have also accepted the program for various locations, among them Bechtel, Black & Veatch Construction Co., Detroit Edison Co., Dow Chemical Co., Fluor Constructors International, Inc., Georgia Power Co., Morrison Knudsen Corp., New York Power Authority, Shell Chemical Co., Southern California Edison Co. and Stone & Webster Construction Co., Inc.

Bechtel Construction Co. in San Francisco, Calif., hires many welders who have been qualified in both the Common Arc and UA Pipefitters programs. According to projects labor relations


Fig,. 5 - - Welders" qualified by the UA Pipefitters become expert in various processes, including gas tungsten arc welding.

manager, Jeff Teather, the company is pleased with the large numbers of qualified welders coming out of the program who can begin work on short notice. Prospective welders for the company must finish a weld on the job that is X-rayed. "If the individual's first weld fails to meet the criteria established by X-ray," said Teather, "the individual is dismissed."

The American Welding Society administers an independent Certified Welder program that allows the welder to carry certification from job to job. The program requires testing at an AWS Ac- credited Test Facility to demonstrate welding proficiency to codes used in structural steel, pipeline, sheet metal or chemical industries. If the welder successfully passes the test and pays a registration fee, a qualification card is issued, which the welder can keep, to let employers know he or she is certified by AWS. If desired, the certified welder's name will also be listed in the AWS National Registry of Welders. This registry serves two purposes. It is a source for contractors who may be searching for certified welders. Also, employers can use it to verify AWS certification.

AWS Accredited Test Facilities for Certifying Welders

The following is a listing of AWS Accredited Test Facilities located throughout the United States.

Alabama • Welding Engineer Supply Co., Prichard

Indiana • Calumet Testing Services, Griffith

California • Grossmont Union High School, E1 Cajon • Southern California Edison Industrial &

Application Center, Long Beach • Bess Testlab Inc., Santa Clara

Florida • Santa Fe Community College, Gainesville • Pinellas Technical Education Center, Clearwater • N.D.T and Inspections, Inc., Ft. Lauderdale • Engineering & Inspection Unlimited Inc.,

Ft. Lauderdale

Georgia • Gwinnett Technical Institute, Lawrenceville • Quality School of Pipe Welding, Atlanta • Georg ia Power Co., Skills D e v e l o p m e n t Center ,

Milledgeville

Idaho • Idaho National Labora tory , Welder Test Facility,

Idaho Falls

Illinois • Rock Valley College, Rockford • Illinois Power Operat ions Training Center, Decatur • Caterpillar Inc., East Peoria

Kansas • KAW Area Technical School, Topeka

Kentucky • Elizabethtown Technical College, Elizabethtown • Technical Mayo, PaintsviUe

Louisiana • Inspection Specialists, Inc., Marrero • Welding Testing Laboratory, Baton Rouge • Scientific Testing Labs, Inc., Baton Rouge

Maine • The Welding Center, Bangor

Maryland • Delta Welding & Engineering Corp., Baltimore • Maryland Q.C. Laboratories, Inc., Aberdeen

Massachusetts • Triangle Engineering, Inc., West Hanover

Michigan • National Testing & Research Lab, Detroit • Washtenaw Community College, Ann Arbor

Minnesota • J.B. Testing, Inc., Minneapolis

44 I MARCH 2001

Nuclear Industry Seeks to Limit Retesting Even in the nuclear industry, initiatives are underway to re-

duce the amount of retesting currently required in many industries. ASME nuclear code case N-600 was first presented to the ASME Boiler and Pressure Vessel Main Committee in Decem- ber 1997 and is currently proceeding through the ASME approval process. If approved, N-600 would enable a welder to go from one nuclear facility to another by taking one test that would qualify him or her at a second plant. This code case would be an exception to Section IX.

There is a need for the ease of movement provided by N-600, according to Bruce Newton, writer of the code case and a for- mer welding engineer in the nuclear power industry now with Welding Services Inc., Norcross, Ga. Nuclear plant welders employ skills that exceed minimum Section IX qualification requirements. A nuclear welder, Newton observes, must under- stand and endorse nuclear QA program requirements, and the welder must be able to represent the owner in discussions with auditors, inspectors and jurisdictional/regulatory authorities.

"N-600 would improve quality and safety by improving access to welders with proven nuclear knowledge and experience," he said. "Concurrently, N-600 would reduce owner costs by eliminating redundant performance qualification tests for welders with proven skills. N-600 acknowledges that extensive nuclear QA program controls can prove advantageous because of the increased credibility these controls guarantee. It is these very con-

trois that ensure qualification sharing will not compromise the owner's welding program. The case provides restrictions applicable to both the owner who administers and documents the performance qualification test, and to the owner receiving the completed performance qualification record." The approach is similar to that currently used in ANSI B31.1 and ANSI B31.3, Newton observed.

The James A. FitzPatrick Nuclear Power Station, Oswego, N.Y., recently tried a solution offered by the United Association of Plumbers and Pipefitters, Washington, D.C., that would allow welders to transfer welder qualification test data between plants. It hired about 50 welders qualified by the Fitzpatrick power station and another nuclear plant in the area to do repair work during a scheduled outage. Many of the welders had already been qualified under the WCP. "The use of these welders enabled us to avoid 80% of the cost of qualification. It saved the company $40,000 by using the UA-sponsored and utility cooperative tests. Prior to this outage, we tried this and saved $10,000," said Neal Chapman, site welding engineer for the plant.

Public Sector Moves toward Acceptance between Industries

In New York, the testing of field welders for highway bridges is conducted either at one of the New York DOT facilities or at

Montana • MSE Weld & Fabricat ion Center, Butte • Mon tana State University - Nor thern , Havre

Nebraska • Southeast Communi ty College, Milford • Central Communi ty College, Grand Island • Southeast Communi ty College, Lincoln

Nevada • Allied Inspect ion & Testing, Las Vegas

New Mexico • JCI Welder Testing and Training Facility,

Los Alamos

New York • Lucius Pitkin Co., New York • Niagara Mohawk Power Corp., Oswego

North Carolina • Central P iedmont Communi ty College, Charlot te

Ohio • Hobar t Insti tute of Welding Technology, Troy • Vantage Vocational School, Van Wert

Oregon • Mt. H o o d Communi ty College, Gresham

Pennsylvania • Welder Training & Testing Institute, Al lentown • Grea te r A l toona Career & Technology

Center, A l toona • Eas tern Wes tmore land Career and

Technology Center, La t robe

• Pennsylvania College of Technology School of Industr ial /Engineering Technology, Will iamsport

• G r e a t e r J o h n s t o w n C a r e e r & Technology, Johns town

• Norfolk Southern, Hol idaysburg

South Carolina • F lorence-Dar l ington Technical College, Florence

Tennessee • Mater ia l s E n g i n e e r i n g & Test Co rp /Weld Test

Facility, Oak Ridge

Texas • Base Line Data, Inc., Port land • Texas Engineer ing Ext. Service, San Anton io • Alcoa Rockdalc Test Facility, Rockdale • W H Laborator ies , Hous ton

Washington • Bates Technical College, Tacoma

Wisconsin • Nor theas t Wisconsin Tech. School, Green Bay

Wyoming • Eas tern Wyoming College, Torrington • Western Wyoming College, Rock Springs

Note: There are also Accredi ted Test Facilities overseas. Test sites can be found in Chile, Peru, Trinidad/To bago and Venezuela. Contac t Amer ican Welding Society, Certification Dept. , 550 N W LeJeune Rd.. Miami, F L 33126, for more information.


one of a number of recognized welding schools. The tests are witnessed by a state representative. Shop welders are usually tested on site where their work is also witnessed by an individual employed by an inspection agency representing the state. Each welder is tested separately for each process and in the appropriate welding position. According to A. C. Kelly, a supervisor in the Structures Division of the New York State Depart- ment of Transportation, welders tested on shielded metal arc welding have to perform satisfactory uphill welds in the 3G and 4G positions on 1-in.-thick steel plate, an extremely difficult test of a welder's skill.

But those who successfully pass the tests obtain certifications valid for three years. Some fabricators of buildings in New York state have hired welders who have passed the New York DOT examinations, indicating some evidence of acceptance by industry.

Bruce L. Abernathy, metals specialist for the Maryland State Highway Administration, said the Maryland State Highway Ad- ministration in Greenbelt, Md., is undertaking similar efforts. The Mid-Atlantic Structural Committee for Economic Fabrica- tion, which includes state highway representatives from Mary- land, Virginia, Delaware, Pennsylvania, and West Virginia, plus the District of Columbia, was formed to establish rules whereby a welder can own his or her certificate or record of test results. The test procedure observed for this test is the AWS D1.5 Bridge Welding Code and welders must prove they are qualified in shielded metal arc welding as well as gas metal arc welding. Ac- tual welding is witnessed by quality control inspectors from the state agencies.

Testing is Part of the Job Some organizations accept the reality that welder qualifica-

tion standards are varied and welders will have to hold a variety

of certifications to remain employable. The Anniston Army Depot (ANAD) in Anniston, Ala., for example, has amassed a team of 130 certified welders who hold 311 active certificates. The welders are also capable of welding in accordance with 18 separate standards, including military, aerospace, ground support, industry, British and German.

All ANAD welders are required to be experienced journey- men or graduates of a trade school, pass a written test, demonstrate their knowledge and use of official AWS welding symbols and definitions, be able to read welding drawings and follow weld procedure specifications. The welders must be able to demonstrate their skills by welding a series of test plates, which are visually inspected and then radiographed. The certified welders at the depot are also trained as inspectors.

Lyle E. Binns, an instructor at the Lincoln Electric Welding School, Cleveland, Ohio, also advises welding students to accept the fact they will be tested often. "We tell our students that certification is like a diploma, that it's a means of getting a job in- terview, and you have to prove to a prospective employer that you know how to weld. The employer will test you again. We tell them to expect to be tested throughout their careers. When they change from one process to another, they will probably be tested. When they adjust from one position to another, they will probably be tested. We tell our students to become familiar with as many processes and with as many positions as practicable."

The editors wish to thank Spencer Luke, Senior Welding Engineer for Dresser-Rand, Inc., Olean, N. Y., for his assistance in the preparation of this article. •

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461 MARCH 2001 Circle No. 38 on Reader Info-Card

Laser cutting, cladding

and welding are having

an impact on how ships

are built and maintained

BY PAUL D E N N E Y

D uring the past ten years, laser materials processing has been accepted into a number of industries. The automotive, medical devices, electronics and con-

sumer products industries have developed laser materials processes and designs to improve product performance and/or productivity. With advances in hardware and processing, lasers are now making inroads into industries with new material and fabrication demands. These industries include heavy machinery, construction equipment, aerospace, oil/chemical, power generation and shipbuilding.

Laser materials processing utilizes the energy of photon- matter interaction to heat a targeted material. This is similar to the electron-matter interaction of electron beam processing, but for lasers the processing normally is accomplished in air rather than a vacuum. The density and interaction time of the laser beam with the material determines what process is accomplished. At lower power densities and longer interaction times, the laser can be used to heat treat or thermally form materials. As the power density is increased, materials can be melted to form resolidified or clad surfaces. At higher power densities (104-107 W/cm 2) and shorter interaction times, the

PAUL DENNEY ([email protected]) is with the Edison Weld- ing Institute, Columbus, Ohio.

USS Mt. Whitney antenna platform constructed from 316L-based LASCOR panels. (Photo courtesy of ARL Penn State.)

laser can produce a keyhole in the molten material and achieve deep penetration welds with very high depth-to-width ratios. Further modification of the interaction can result in cutting and drilling with very little heat input into the part.

Process and application determine the advantages of using lasers. At lower power densities, the laser has an advantage over induction and furnace heating because of its accuracy in treating specific areas, which can minimize thermal impact to surrounding materials. At higher power densities, heat input can be accurately controlled, permitting high-quality clads and direct material buildups. In welding, the laser permits deep welds to be made with very low heat input at very high speeds. The result is weld joints with low impact to the surrounding materials and low distortion. While other processes can cut faster (oxyfuel or plasma) or without heat (water jet), the laser is flexible and precise for a wide range of thicknesses and types of metals and non- metals.

The possible use of lasers in ship fabrication has been of interest for a number of years (Refs. 1-4). The U.S. Navy conducted studies in the late 1970s and early 1980s on how lasers could be used for cutting and fabricating Navy combatants and submarines and what impact that would have on the materials used in naval structures. Most of these applications were based


ser Beam

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r

Fa~lates

Webs

Fig. 1 - - Diagram of "sandwich panel" being fabricated by Meyer Werft Shipyard for shipboard application.

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s~,~..__ Face/heets

I J¢ J l

Material

t & I I I

Fig. 2 - - Basic diagram of LASCOR panel. A number of factors, including core spacing, face plate and core material thickness, and the separation of the face sheets, determines the performance of the panel.

on use of high-power (> 10 kW) CO2 lasers and complex delivery systems. While technically feasible, it was determined equipment and operational costs, reliability and return on investment for such applications did not justify their use.

Since these early studies, there have been improvements in lasers and laser systems that have had a positive impact on laser applications in thick-section materials. First, changes in laser designs have increased beam quality and improved laser welding and cutting capabilities. Second, lasers have become more "industrialized" through improvements in design and standardization of components. Third, the cost, or "dollars per kilowatt," has decreased in real dollar terms. Other industries, such as automotive and sheet metal fabrication, where laser processing has been easier to justify, have driven these changes.

A wide range of laser processes has been investigated for heavy manufacturing, especially shipyard applications. Niche applications have been developed for laser heat treating and cladding (Ref. 5), including selective heat treating of components and refurbishment of high value items by laser cladding. The use of lasers for fabrication and dismantling of ships (Ref. 6) has been investigated using both CO2 and fiber-delivered Nd:YAG lasers. While cutting speeds have not been competitive with plasma or oxyfuel cutting processes, cut quality, accuracy, low heat input and portability are factors that have driven the investigation of laser cutting for shipyards. Laser welding (Refs. 7, 8) has also been investigated. The driving force for using lasers has been low heat input for decreased distortion, high production rates and/or the ability to use lasers to fabricate alternative designs not practical with other processes. In addition to having a direct influence on fabrication costs, factors such as distortion and alternative structures may result in savings in "downstream" fabrication, maintenance or operation costs.

One factor that has limited the insertion of laser processing into ship applications has been the lack of standards and specifications. ASME and AWS have specifications for pressure structures and recommended practices, respectively, but there are few widely accepted standards for laser-fabricated structures. The International Organization for Standardization (ISO) has, or is, developing specifications (Ref. 9) for laser cut quality determination and laser cutting systems. European ship- builders and regulatory organizations are developing welding certifications for laser-welded structures (Ref. 10). In the United States, the AWS C7C Committee is developing general laser processing specifications. The U.S. Navy, in previous ef-

forts, has accepted laser processing only for specific applications. For a number of active programs, efforts are under way to develop acceptance criteria for laser cut and welded structures for ABS and the U.S. Navy applications.

Shipyard Laser Use around the W o r l d

A number of shipyards have or are in the process of implementing laser processing. As an example, Odense Lindo Steel, Meyer Werft and Fincantieri are all involved in implementing laser beam welding in the fabrication of ship structures. Other European yards such as Blohm & Voss and Vosper-Thornycroft (Ref. 11) are involved in laser cutting. In Japan, a major pro- ducer of high-power laser cutting systems, a large number of shipyards have implemented laser cutting.

The work being accomplished at two European shipyards, Fincantieri and Meyer Werft, is of special interest. Fincantieri has approached laser welding as a replacement process to submerged arc welding in panel line fabrication. This effort uses a 17-kW CO2 laser to join plates in its panel line. To date, it has certification for production of 5.5- and 7-mm plates with a goal of 12 mm. Low distortion from the laser improves downstream fitup and results in substantial labor savings in ship construction.

Meyer Werft is utilizing the deep penetration characteristics of the laser to alter the design of the bulkhead and deck panels for improved productivity. Using face plates on either side of a series of vertical webs, laser stake welds are made through each faceplate and into the vertical webs - - Fig. 1. The resulting "closed-cell" design is stiffer than a conventional plate/stiffener design and occupies less space. Also, "flatness" of the finished panels makes outfitting (installation of flooring, insulation, wiring and other piping) easier and faster. The reduced space also can mean a decrease in the overall height of the ship or the addition of an extra deck.

In the United States, there have been few cases where lasers have actually been used in shipyard applications, although laser materials processing for shipboard applications has been under investigation for more than 20 years. This has been partially due to the low production rate of commercial ships in the United States and in part because of the qualification requirements for the U.S. Navy. Applications currently used in U.S. shipyards of laser-processed materials include cladding, welding and cutting.

As an outcome of research accomplished by the U.S. Navy Manufacturing Technology (MANTECH) program, there have

481 MARCH 2001

Fig. 4 - - Cross section of l 2-mm-thick steel plate laser welded with hybrid system ( GMA Wand 4-k W Nd: YA G laser). Weld was made at I m/min in square butt joint with 0.9-mm root opening.

Fig. 3 - - Cross section of l 9-mm-thick steel plate laser welded with a 2-kWdiode-pumped Nd:YAG laser developed by TRW.

been a number of applications for laser cladding and welding. Laser cladding for repair and refurbishment has been accomplished with steel, nickel, aluminum and cobalt-based alloys. Procedures have been, or are, being qualified for the repair of such items as diesel cooling pump shafts, steam valve seats, aircraft carrier catapult components and aluminum torpedo shell sections (Refs. 12, 13). In many cases, the laser process has been selected because of low dilution and heat input, which result in a "near-pure" deposition of material with minimal thermal or dimensional impact on the part. The repairs are justified because of the high cost of replacing the parts and/or the long lead times required to qualify new suppliers and receive replacement parts. In some cases, laser cladding actually improves part performance, decreasing maintenance costs.

Structural laser beam welds - - selected because of the laser's low heat input - - have been used to fabricate frames used in U.S. Navy shipboard filter systems. Laser welding has also been used to fabricate lightweight, corrugated panels known as LASCOR (Ref. 14) - - Fig. 2. In creating these panels, a laser was used to join face plates to corrugated sheets. The resulting structure weighs about 50% less than conventional plate-stiffener designs. These panels have very good fire, blast

Cutting is presently the

most active U.S. shipyard

application for lasers.

and penetration properties and can be fabricated from any laser-weldable materials, including steel, stainless steel, nickel, aluminum and titanium alloys. Stainless steel LASCOR panels (316L stainless steel) have been used in the construction of two antenna platforms installed on the USS Mt. Whitney (see lead photo). The panels were constructed at the Applied Research Laboratory at Pennsylvania State University (ARL Penn State) as 1.5- x 4-m sections using a 14-kW CO2 laser and a robotic welding system. These LASCOR panels saved more than 9000 kilograms and had better stiffness than panels made with conventional construction methods. Two U.S. Navy shipyards (formerly Mare Island and Philadelphia Naval Shipyards) have fabricated panels using fiber-optically delivered Nd:YAG lasers and simple manipulation. LASCOR panels have been considered for a number of U.S. Navy programs and commercial applications, but no commitments for actual construction have been made at this time.

Cutting is presently the most active U.S. shipyard application for lasers. Bender Shipbuilding and Repair of Mobile, Ala., has purchased a 6-kW CO2 laser cutting system with a 4- x 44-m cutting table for the processing of steel, stainless steel and aluminum alloys. The system is part of a "first operations" that re- ceives, cleans, primes and cuts plates prior to fabrication in the

shipyard. The laser system can cut steel up to 32 mm thick and aluminum up to 12 mm thick. The advantage of the laser has been the ability to "common line cut," which is not possible with plasma. The laser system can also be used to pierce and cut openings in the plate that would otherwise be drilled and manually cut as secondary processes. Bender has already used the laser system to cut steel for its ships and is looking ahead

to other applications. Bender is working with Caterpillar, Edi- son Welding Institute/Navy Joining Center (EWI/NJC) and IPSCO Steel to develop advanced fabrication methods and "laser-friendly" steel alloys.

N e w Efforts

In addition to recent activities using laser processing in shipyards, additional research is being accomplished for other applications. Some of this research is centered on new lasers and laser systems; some is in the area of advanced processes.


Diode Lasers

These solid-state lasers in the 0.8- to 0.95-mm wavelength range are of extreme interest for laser materials processing. While CO2 and Nd:YAG lasers operate at 2 to 14% efficiencies, diode lasers can operate at 50%. While individual diode bars can only produce an average of 100 W each, they can be "ganged" into systems that will produce 4 kW of total power. While the power, size and efficiency of these systems are benefits, they cannot be focused to small spots and, therefore, high power densities (> 1@ W/cm2) are not possible. This limits their possible use in shipyards to heat treating, cladding, surface cleaning and thin-plate welding. Research efforts are ongoing to focus the output of these lasers to smaller spot size or to use in conjunction with other processes.

Diode-Pumped Lasers

To address the efficiency and beam quality issues of Nd:YAG lasers, which are pumped by flash or arc lamps, the use of diode lasers is being heavily investigated. The result is a laser with lower power consumption and better beam quality. TRW is leading the DARPA-sponsored Precision Laser Machining (PLM) program that has developed a diode-pumped pulsed slab laser that has demonstrated penetration through 35 mm of steel at 2 kW of average power in a single pass but at very slow processing speeds (< 25 mm/min) - - Fig. 3. A number of other laser companies and government programs are developing diode- pumped, solid-state lasers at power levels > 1 kW. These lasers will be smaller and use smaller-diameter fibers for delivery that should allow for better cutting and deeper welding in shipyard applications.

High-Power COz Lasers

While CO2 lasers in the 45-kW power level have been available for years, size and operating costs have limited their use, especially in shipyard applications. These high-power have lasers have not had the good beam quality needed for thick-section cutting. New developments in laser designs have resulted in high-power systems with very good beam quality well suited for the thick-section cutting needed in shipyards. Further improvements in power, optics and controls are aimed at increased cutting thickness and higher processing rates. The use of CO2 lasers in shipyard welding applications will also increase as laser operating costs decrease and acceptance of the process increases.

Hybrid Welding

This technology is being developed to address many of the disadvantages of laser welding in thicker materials. In many automotive applications, laser welding is normally accomplished without filler metal (autogenous) in joints with little or no root opening. In thicker section welding, such as would occur in shipyards, the chemistry of the materials and fitup may dictate the use of filler materials. There is also the issue of laser power vs. penetration. Both cold and hot welding wire additions have been investigated as methods for addressing chemistry and fitup issues (Ref. 3). To address penetration, laser combined with gas tungsten arc, gas metal arc and plasma arc processes are being investigated with Nd:YAG, CO2 or diode lasers for possible application with thicker materials typical of shipyard fabrications. EWI/NJC have been able to weld 9-mm-thick plate at 1 m/min with a 4-kW Nd:YAG/GMAW system - - Fig. 4. This process is

being developed in support of Navy MANTECH efforts and also has potential for pipeline applications as well.

Laser Use Growing Worldwide Use of lasers in shipyards is on the rise throughout the world.

Laser cutting is quickly replacing more traditional oxyfuel and plasma cutting techniques due to the cost savings and the laser's precision and flexibility. The advantage of laser welding for the fabrication of ship structures also appears promising. To take full advantage of these properties, new designs, lasers and processing techniques are being developed. At the same time other "secondary" processes, such as heat treating, forming and cladding, are being developed for fabrication and repair. New specifications are being written that will cover the implementation of lasers into ship fabrication. All of these indicate lasers will be the "new tool" in the fabrication of ships and naval structures in years to come. •

References

1. Metzbower, E. A., and Moon, D. W. 1978. Properties and structures of laser welds of high-strength alloys. Proceedings of the 5th Bolton Landing Conference, 1978 Weldments, eds. R. J. Christoffel, E. E Nippes and H. D. Solman.

2. Metzbower, E. A. 1981. Laser welding. Naval Engineers Journal 93(4): 49-58.

3. Denney, E E., and Nurminen, J. I. 1986. Program to develop enhanced laser welding for automation and shipbuilding - - RFP N0014- 84-R-TL29. Westinghouse R&D Center Report.

4. Locke, E. 1973. Laser welding techniques for fabrication of naval vessels. Avco Everett Research Lab., Boston, N.T.I.S. Report No. AD- 786-211.

5. Bartley, J., Denney, P. E., and Grubowski, A. 1992. Using fiber optics for laser cadding. Journal of Ship Production 8(3): 157-162.

6. Nick, E., and Denney, P. E. 1993. Cutting of structural materials utilizing high-powered CO2 laser. Journal of Ship Production 4(3): 236-244.

7. Hakansson, K. High-power laser beam welding of T-sections with different edge preparations. Kockums AB, Malmo, Sweden, unpub- lished.

8. Kaufman, E. J. 1996. Fatigue performance of advanced weld processes for double-hull ship construction. ATLSS Engineering Re- search Center, Lehigh University, Bethlehem, Pa., ATLSS Report No. 96-12.

9. Specification and approval of welding procedures for metallic materials - - Part 11: Welding procedure specification for laser beam welding. 1996. Ref. No. ISO 9956-11:1996(E), first edition 1996-10-01.

10. Guidelines for the approval of CO2-1aser welding. 1996. Laser Welding in Ship Construction, 7th Edition. Classification Societies.

11. Barry, C. 2000. Laser applications in European shipbuilding. Pre- sentation at Lasers in DoD Applications. ARL Penn State.

12. Personal conversation with Nick Eutizzi; Code 138, Puget Sound Naval Shipyard, Bremerton, Wash.

13. Personal conversation with Mike D. Lehman; Code 20T, Naval Undersea Warfare Center, Keyport, Wash.

14. Marsico, T. A., Denney, E E., and Furio, A. 1993. Laser welding of lightweight structural steel panels. Proceedings oflCALEO '93 Con- ference. Laser Institute of America, pp. 444-452.

50 I MARCH 2001

O r b i t a l W e l d i n g D e l i v e r s T r e a t m e n t

P l a n t o n T i m e Switching to

automated orbital

welding helped a

major water treatment

project stay on

schedule in spite of a

30% increase in scope

S witching from shielded metal arc i welding (SMAW) to orbital welding was a key factor in meeting

original project delivery deadlines after a 30% increase in the scope of a water treatment facility.

The $100 million Scottsdale, Ariz., Water Campus project is considered the largest ever in the United States, and it represents a departure from traditional t reatment methods in the western United States. This project will pump a large portion of the treated water into the ground to recharge an aquifer rather than use it for irrigation.

New Approach to Welding While orbital welding is frequently

used in the semiconductor and pharmaceutical industries, this represented one of its first uses in construction of a water treatment plant. This automated method in-

Based on a story by Arc Machines, Inc., Pacoima, Calif., (818) 896-9556, www.arcmachines.com.

Fig. 1 - - The contractor conducted a series o f tests before orbital welding was approved for the project.

creased productivity from 3 to 4 welds per day to 13 to 16 on the 6- to 8-in. pipe used for air distribution to the microfiltration system.

Meeting Water Needs Designed by Black & Veatch, the

Water Campus is the largest U.S. facility for treatment of raw sewage to potabl- quality water. In the summer months, this plant is projected to treat 12 million gallons per day of wastewater conven- tionally for golf course irrigation. In the winter, when irrigation requirements are lower, 10 million gallons per day of the water treated by the plant will receive advanced treatment, microfiltration and reverse osmosis to exceed potable standards. This purified water will be rein- jected into local groundwater aquifers. Once completed, the Water Campus is designed to help ensure the city of Scottsdale's supply of drinking water for the next 100 years and to comply with Arizona's 1980 Groundwater Manage- ment Act, which prohibits communities

from extracting more groundwater than is naturally or artificially recharged.

Process Flow at Treatment Plant

At the purifying facility, wastewater undergoes primary, secondary and tertiary t reatments and advanced water treatments. The primary and secondary treatments are sedimentation basins that remove larger particles from the waste stream. The tertiary stage is a sand filter that removes finer particles. Chlorina- tion is also performed at several stages of the treatment process. The final stage is reverse osmosis through a semiperme- able membrane that raises the water to drinking quality standards. A portion of the water will then be used to recharge the aquifer in the Carefree/Cave Creek Basin. Without this recharge, concerns have been raised that with the present rate of usage this aquifer could run dry by the year 2007.

The piping contractor on the project


Fig. 2 - - Orbital welding model that uses an adjustable clamp on the pipe.

was University Mechanical, a mechanical contractor that specializes in the installation of sophisticated process piping. High-purity piping is used in the facility for gases in the laboratory and the air distribution system that performs backwashing operations on the microfiltration system.

Laboratory Gas System The laboratory gas distribution sys-

tem involves a network of piping with many complicated twists and turns, providing a high potential for leaks. Since most of the lines are concealed in ceil- ings, it would be very difficult to identify and repair leaks in the fittings. It was suggested to the owner that orbital welding be used to create a completely seamless system. He purchased a Model 9-750 orbital welding head from Arc Ma- chines, Inc., Pacoima, Calif., and used it mostly in controlled off-site conditions. When welding was completed, testing showed there were no leaks in the laboratory gas network.

The air distribution system represented one of the most challenging parts of the entire project. It consists of 6- to 8-in. headers used to reverse the flow through the system in order to remove particles from the microfiltration filters. Using tradi t ional shielded metal arc welding would have been a very labor-intensive task and one that would have been challenging from a quality stand- point. While the company had a team of experienced welders, their productivity was limited by the tools they used. As this phase of the project neared, it was real-

ized the scope increases would make it impossible to meet the project deadline using the methods that had originally been envisioned. The owner began in- vestigating alternative technologies in an effort to keep the project on track.

Increasing Productivity "We have used orbital welding for a

number of years on projects for semiconductor and pharmaceutical manufacturers in order to make identical high- quality welds in small bore piping such as that used in the lab gas system," said Tom Gusich, project manager for University Mechanical. "But we had never tried it on anything with this large a bore in the past." A series of tests (Fig. 1) revealed each head and machine outperformed the company's best welders by a factor of 3 or 4. "The tradespeople learned the new technology very quickly and did a great job. Each welder was able to produce an average of 15 welds per day on the large bore welds in the air distribution system. Three weeks were saved on the overall schedule, and the quality of the welds on the larger bore pipes was as good as previously seen in smaller bores. As with the lab gas system, there wasn't a single leak in the air distribution system," said Gusich.

Orbital Welding Basics Orbital welding is an automated ver-

sion of the gas tungsten arc welding (GTAW) process. In manual GTAW, the welder moves the welding torch and controls the welding current. In orbital

GTAW, the tungsten is installed in a weld head that clamps on the tube or pipe - - Fig. 2. The tube remains in place while the weld head rotor revolves around the weld joint circumference to complete the weld. Welding is done in an inert atmosphere to protect the metal from oxidation as it is heated to melting temperature.

The welding power supply controls weld parameters such as welding current, primary and background amperes, travel speed, wire feed speed, weld bead overlap, delay of rotation at the start of the weld and current downslope at the end of the weld. The enclosed weld heads used for small-diameter tubing welds provide a chamber filled with inert gas that encloses the entire joint during the weld. A timed prepurge and post- purge are usually used to time the flow of inert gas into the weld head before arc initiation and to continue the purge for a timed period after the arc has been ex- tinguished. This allows the weld tool to cool sufficiently to prevent oxidation before the weld head is opened to remove the welded tube.

Welding Process Steps Model 15 uses a track and Model 79

uses an adjustable type of clamp on the pipe during welding. The welder starts the operation by aligning the tungsten to the bevel in the joint, then adjusts the wire feed and centers the oscillation with the actual weld. Tabs on the welding machine hold the cable out of the way as the welding head wraps around the bore to complete the pass in about four minutes on a 7-in.-diameter pipe. The welder then removes the head. The only cleanup that is required is brushing the weld to remove any excess discoloration. The orbital welding systems used in this project provided a display for the operator to view the welding operation along with a screen that shows welding current and other programmed functions.

Will Use It Again Orbital welding was so successful on

this project that the contractor plans to use the technology in water supply and wastewater treatment projects on a regular basis. With the addit ion of new processes and new chemical additives, piping installation in wastewater plants is continually getting more challenging. "We intend to respond by increasing the use of orbital welding to provide the same productivity gains that we have already achieved in the semiconductor and p h a r m a c e u t i c a l i n d u s t r i e s , " sa id Gus ich .O

52 I MARCH 2001

Datasheet 250a wel f Workbook

Practical information for welders and others involved in welding and its allied processes.

Local Heating of Pipes and Tubes During the course of pipe fabricating there may be a need to

apply preheat, maintain interpass temperature or perform a postweld heat treatment. One of the main reasons for performing preheat or maintaining interpass temperature is to slow down the rate at which the weld metal and heat-affected zone cool. These heat treating steps counteract quench hardening that might result from rapid cooling, and increase the rate at which hydrogen and other gases diffuse from the weld zone.

Postweld heat treatment is often performed to restore ductility to metals susceptible to a hardening martensite formation.

Postweld heat treatment also reduces residual stress induced by welding and, in some instances, may increase corrosion resistance.

Shop manufacturing may utilize a heat treating furnace to perform this operation, but if the part is too large to place in a furnace or heat treatment is required in the field, some method of localized heating is administered. Some common methods used are induction heating, electric resistance heating, flame heating and exothermic heating.

~ CONNECTION BLOCK LEAD

/ PIPE WALL / CHROMEL-ALUMEL J

INSULATION WIRE

Cross section of pipe weM ready for postweld heat treatment.

Excerpted from ANSI/AWS D 10.10 Recommended Practices for Local Heating of Welds in Piping and Tubing.


Datasheet 250b

Local Heating of Pipe and Tubes In any heating operation, some device is needed to indicate

temperature. Thermocouples, infrared instruments, temperature- indica t ing crayons or paints , b imeta l l ic switches or expansion bulbs a re all used a lone, or in combina t ion , to perform this funct ion.

Parts heated to elevated temperatures can lose strength; therefore, they should be supported in some manner. The heat treating procedure may be difficult to perform because of excessive heat loss, and the presence of liquids or gases in pipes can be the cause. Their removal and the prevention of flow through the pipe should be done before heating. Piping should also be vented to prevent pressure buildup, but the venting must be performed in a manner that does not create air flow through the pipe, since this can also cause cooling.

In heat treating, the thermal cycles that must be controlled are heating rate above a specified temperature, holding temperature, time at which it is held at that temperature and cooling rate to a specified temperature. These cycles may be established by codes and specifications, and they are dependant on material thickness and composition.

Whenever heat is applied to one side of a pipe, there will always be thermal gradients between the inner wall and the outer wall, which produce their own set of stresses. The thicker the wall,

the greater the gradient. It has been shown that the through- thickness gradient is proportional to the width of the heated band on the surface. It has been determined that, generally, the width of the circumferential band to be heated should be at least five times the thickness of the thickest pipe. For welds that attach nozzles or lugs, the heated width should be increased by the width of the attachment. Of course, applicable codes and documents should be consulted before establishing the heated width.

In any heat treating method, heat loss to the cooler adjacent environment must be addressed. Heat conduction through the structure, convection from air moving within the pipe and normal radiation all carry heat away from the local area to be treated. Insulation material can be used to prevent heat loss to the surrounding air. Mineral wool and ceramic fiber mats are commonly used as insulating materials. Glass wool insulation might be used for an outer layer or away from the heat source, but it should never come into contact with that source or any material hotter than 1200°F (650°). Greater heating efficiencies are achieved when the insulation is extended beyond the local heated area. Not all heating methods allow this, but, generally, it is good to have the insulation three times as long as the heated band.

k ~ f ~ 0 0 0 (

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I N D U C T I O N C O I L S

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54 I MARCH 2001

WELDING E N C Y C L O P E D I A

Welding Metallurgy

I ~ Qwqle IL I . l~u~

Ordering your FREE book is 0 Fill out card below. Be sure to include

your A WS Member number. (Please note: i f you sent in your book request last month, do not send in a duplicate card).

@ Cut out card on dotted lines.

WELDING HANDBOOK m m

easy: @ Insert the card in an envelope and mail to:

AWS Membership Department 550 N.W. LeJeune Rd. Miami, FL 33126

O Please allow 6-8 weeks for book delivery. (Note: I f selecting the Welding Handbook, it will not be delivered until Apri12001).

Design and Planning Manual for Cost-Effective Welding- This manual is a practical guide for engineers, planners, and hands-on professionals to improve scheduling and lessen rework. Includes sections on cost analysis, concepts of welding design and more.

Jefferson's Welding Encyclopedia - No matter your involvement in the industry, Jefferson's puts the world of welding right at your fingertips. A useful tool for any level in the industry- from student to the experienced veteran. Includes a historical look at the welding industry, a handy Buyer's Guide, and an exhaustive listing of key industry suppliers.

• Yes! I'm an AWS Individual Member*. Please send my free book!

(Please check ONE only from the following five book options. One card per AWS Individual Member). • Design and Planning Manual for Cost-Effective Welding • Jefferson' s Welding Encyclopedia • Soldering Hmldbook • Welding Metallurgy • Welding Handbook, 9th Ed., Vol. 1 (Not availal)le until March 2001. l )d ivc U will be in Ai,ril 20h i . )

*(Jilt,]' applies ill :x~s Individual Menlbcrs I)L]I~. TO tLpgradt' your membership, c~di (800l q.+3+9353, ext..180.

AWS Member # Name Address

City State Country Zip. Phone ( ) E-mail Fax ( ) IMPORTANT: Please allow 6-8 weeks for book delivery (ff Welding Handbook selected, delivery will be in April 'O1). Books will be delivered to the same address as your lgeldingJoumal.

Soldering Handbook - written for individuals from a variety of backgrounds, this handy reference is geared toward allowing soldering technology to be more fully utilized in advanced structural joining applications. Topics include fundamentals, materials, fluxes, assembly processes, inspection techniques, safety and health.

Welding Metallurgy - The premier publication on the welding metallurgy of steels. Builders, manufacturers, welding shops, colleges and universities will benefit from this valuable reference book, which places a lifetime of welding research and experience at their fingertips.

Welding Handbook, 9th Ed., Vol. 1 - written in descriptive, reader-friendly language, the Handbook offers ample detail to satisfy the welding professional, while simultaneously serving as a thorough introduction to students and others who are new to the field.

*Free book is a benefit of AWS Individual Members only. All other members, including A WS Student Members, may upgrade their memberships (and select a free book) by calling the aws Membership Department at (800) 443-9353, ext. 480. Individual Member dues are $75.

American Welding Society 550 N.W. LeJeune Rd. Miami, FL 33126

Visit our website http://www.aws.org

Com ) ( EVents

C o n f e r e n c e s and Exhib i t ions International Laser Safety Conference. March 5-8, Catamaran Resort Hotel, San Diego, Calif. Sponsored by the Laser Insti- tute of America. Contact: LIA, 13501 Ingenuity Dr., Ste. 128, Orlando, FL 32826.

NACE International - - Corrosion 2001, Conference and Exhi- bition. March 11-16, George R. Brown Convention Center, Houston, Tex. Sponsored by NACE International, the Corro- sion Society. Contact: NACE Membership Services, (281) 228- 6223, FAX: (281) 228-6329, www.nace.org.

WESTEC 2001: Advanced Productivity Exposition. March 26-29, Los Angeles Convention Center, Los Angeles, Calif. Sponsored by the Society of Manufacturing Engineers. Contact: SME Customer Service, One SME Dr., Dearborn, MI 48121, (800) 733-4763, (313) 271-1500, FAX: (313) 271-2861.

MAX International. May 6-10, I-X Center, Cleveland, Ohio. Cohosted by the American Welding Society and The Precision Metalforming Association, this collocated event is comprised of the AWS International Welding and Fabricating Exposition and Annual Conference and METALFORM ExpoSium. Contact:

AWS Convention and Exhibitions Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 256 or (305) 443-9353 ext. 256, FAX: (305) 442-7451.

Nashville Advanced Productivity Exposition (APEX). April 10-11, Opryland Hotel and Convention Center, Nashville, Tenn. Sponsored by the Society of Manufacturing Engineers (SME). Contact: SME Customer Service Dept., (800) 733-4763, FAX: (313) 271-2861. www.sme.org/nashville.

41, Tenth International JOM-Jubilee-Conference on the Joining of Materials, JOM-10. May 11-14, Helsing0r, Denmark. Cosponsored by the Institute for the Joining of Materials and AWS. Contact: Institute for the Joining of Materials, Klintoh0j V~enge 21, DK-3460 Birker0d, Denmark, 45 45 82 80 85, FAX: 45 45 94 08 55 or e-mail: [email protected].

Twin Cities 2001 Advanced Productivity Exposition. May 15-17, Minneapolis Convention Center, Minneapolis, Minn. Spon- sored by the Society of Manufacturing Engineers (SME), Amer- ica Machine Tool Distributors' Association (AMTDA) and The

Note: A diamond ( 0) denotes an A WS-sponsored event.

Sheet Metal Welding Code Thanks to the AWS D9 Committee on Welding, Brazing and Soldering of Sheet Metal, this popular code is ready to improve workmanship to a 21st century level. Covers the arc and braze welding requirements for nonstructural sheet metal fabrications. Includes process procedure

qualification; welder/operator performance qualification; workmanship; and inspection. Annexes include recommended filler materials; gauge numbers and U.S. Customary and SI Unit equivalents; WPS and PQR forms; arc and brazing welding joint designs; recommended arc and recommended braze welding practices. 10 tables, 8 figures, 11 annexes, 56 pages, published in 2000. ANSI Approved.

D9.1M/I)9.1:2000 .............. $72.00 AWS Members .................... $54.00

Order Now! AWS has secured Global Engineering Documents for sales and order

fulfillment to ensure Member and customer satisfaction. Call (800) 854-7179.

AWS D9 Committee on Welding, Brazing and Soldering of Sheet Metal

J. E. Roth, Chair, J.L. Cooley, JC & Associates, Inc. James E. Roth, Inc. J.E. Curry*, Rowe Corporation

R. E. Stanley, 1st Vice Chair, J.R. Miller, Murray Construction Services International Training Institute

W. S. Harker, 2nd Vice Chair, O. E Prah, U. S. Department of Energy Prah Engineering Company

J. L Gayler, Secretary J.J. Sekely, Eichleay Corp. American Welding Society E.R. Shafer Jr., Consultant

*Advisor

if you'd like to serve on a committee, go to www.aws.org/technical/comm form.html to electronically complete an application or call (800) 443-9353 ext. 340

American Welding Society 550 N.W. LeJeune Rd. * Miami, FL 33126 Visit our website http://www.aws.org

5 6 I MARCH 2001

Association for Manufacturing Technology (AMT). Contact: SME Customer Service, (800) 733-4763 or (313) 271-1500 ext. 1600. www.sme.org.

International Robots and Vision Show. June 5-7, Rosemont Convention Center, Chicago. Sponsored by the Robotic In- dustries Association (RIA) and Automated Imaging Associ- ation (AIA). Contact: RIA/AIA, 900 Victors Way, P.O. Box 3724, Ann Arbor, MI 48106, (734) 994-6088, www.robotics. org or www. automated-imaging, org.

• Weld Cracking: Causes and Cures Conference. June 7-8, Houston Tex. Sponsored by the American Welding Society. Contact: AWS Conference Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552.

• The Cutting of Plates Conference. July 17-18, Chicago, Ill. Sponsored by the American Welding Society. Contact: AWS Conference Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552.

15th International Joining, Cutting and Surfacing Fair "Schweissen & Schneiden." Sept. 12-18, Essen, Germany. Con- tact: Claus-Peter Regiani or Christina Kursawe, 49(0)201-7224- 227 or -529, FAX: 49(0)201-7244-435, e-mail regiani@messe- essen.de or [email protected], www.messe-essen.de.

First Middle East Nondestructive Testing Conference and Ex- hibition. September 24-26, Gulf International Convention Centre, Bahrain. Cosponsored by the Saudi Arabian Section of the American Society for Nondestructive Testing and the Bahrain Society of Engineers. Contact: The Conference Secre-

~ ~'i reliable power control system. Enerpro has your answer!

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You can mark on almost any material, even on wet or 0ily surfaces. The marks are permanent; they won't chip, peel, fade or rub off. They will withstand heat and weathering under adverse conditions.

The Feltip Paint Markers are available in Standard and Fine-Line versions, and in nine high-gloss, lead-free colors: white, yellow, red, black, blue, green, orange, silver and gold.


MIX YOUR OWN SHIELD GASES

Upgrade your MIG or TIG well operation by replacing premi> cylinders with a Thermco gas mixer with these benefits: * Adjust CO,Jargon or oxygen/argon to o p t i m u m

ratio with one dial ........ .................. ~ ~=.


W E L D I N G J O U R N A L I 57

IS THE LACK OF A CWI KEEPING YOU FROM

REACHING THE NEXT LEVEL? NO PROBLEM.

The Hobart Institute offers two-week courses to help you prepare for the Certified Welding Inspector and Educator exams. While a very high percentage of our students pass, those who don't can return within six months free of charge*.

REGISTER NOW FOR ONE OF THESE UPCOMING TWO-WEEK SESSIONS:

MARCH 12 • APRIL 16 • JUNE 4 • JULY 23

SEPTEMBER 10 • OCTOBER 22 • NOVEMBER 26

Call 1-800-332-9448 or visit www.weldin .g.0.~g

HOBART INSTITUT]

*Some resmction~ apply. Please conhact the Hobart Institute for details. © 2001 Hobart Institute of Welding Technology Stale o[ Ohio Registration No 70-12-00641tT


58 J MARCH 2001

tariat, Bahrain Society of Engineers, EO. Box 835, Maama, Bahrain, 973-727 100, FAX: 973-729 819, e-mail: Mohandis@batelco. com. bh.

International Conference on Advances in Materials and Pro- cessing Technologies. September 18-21, Legan6s, Madrid, Spain. Contact: AMPT '01 Congress Secretariat, Fundaci6n Universidad Carlos III, Congrega, Avda. de la Universidad, 30, 28911 Legan6s, Madrid, Spain, 34 91 624 91 42, FAX: 34 91 624 91 47, e-mail: [email protected].

Las Vegas Machine Tool Exposition. September 24-26, 2001, Las Vegas Convention Center, Las Vegas, Nev. Contact: William Yeates, Show Manager, (702) 566-7300, FAX: (702) 566-7300.

Fourth Annual North American Orbital Welding Symposium. October 22-23, Rosemont, Ill. Cosponsored by Polysoude, its North American subsidiary, Astro Arc Polysoude, and the Fab- ricators and Manufacturers Association (FMA). Contact: Astro Arc Polysoude, W133 N5138 Campbell Dr., Menomonee Falls, WI 53051. www.polysoude.com and www.fmametalfab.org.

Fourth Pacific Rim International Conference on Advanced Ma- terials and Processing. December 11-15, Hilton Hawaiian Vil- lage, Honolulu, Hawaii. Organized by the Chinese Society for Metals, the Korean Institute of Metals and Materials, the Min- erals, Metals and Materials Society and the Japan Institute of Metals. Contact: The Japan Institute of Metals, ATTN: PRICM 4 Secretariat, Aoba, Aramaki, Aoba-Ku, Sendal, 980-0845.

Cut & Clamp Pipe? We Make It Easy!

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Clamp It! Mathey Dearman chain clamps align and reform pipe and fittings for welding. Available in three models to fit any clamping need. Saves time. Saves money. Clamp pipe 3/4" and

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Educational Opportunities

Rocky Mountain Comprehensive Review of Industrial Hygiene. March 5-9, Salt Lake City, Utah. Sponsored by the Rocky Mountain Center for Occupational and Environmental Health, University of Utah. Contact: Registration Coordinator, Rocky Mountain Center for Occupational and Environmental Health, University of Utah, 75 South 2000 E., Salt Lake City, UT 84112, (801) 581-5710, FAX: (901) 585-5275.

Automotive Laser Application Workshop (ALAW) 2001. March 13-14, Dearborn Inn, Dearborn, Mich. Organized by the Uni- versity of Michigan, College of Engineering, Center for Profes- sional Studies. Contact: Beth Hillis, (734) 647-7194, FAX: (734) 647-7182, e-mail: [email protected], http://cpd.engin. umich.edu.

Blueprint Reading and Graphic Symbols Course. March 28-30, New York, N.Y. Conducted by the American Society of Me- chanical Engineers. Contact: Shari Romar, Senior Education Specialist, ASME International, Three Park Ave., New York, NY 10016, (212) 591-7902, FAX: (212) 591-7143, e-mail: [email protected].

Geometric Dimensioning and Tolerancing (GD&T) Level 1 Course. April 9-11, Opryland Hotel and Convention Center, Nashville, Tenn. Conducted by the Society of Manufacturing Engineers (SME). Contact: SME Customer Service Dept., (800) 733-4763, FAX: (313) 271-2861. www.sme.org/nashville.

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Hardness Tester

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46th Annual Appalachian Underground Corrosion Short Course (AUCSC 2001). May 15-17, West Virginia University, Morganstown, W.Va. Contact: Angela Durham, (304) 293-3745, FAX: (304) 293-6751, c-mail: [email protected]. www.aucsc.com.

2001 Motorsports Welding School. Classes are scheduled at the Lincoln Electric headquarters in Cleveland, Ohio, and the Alexander Technical Center in Griffin, Ga. For more information and a complete schedule, contact: Lincoln Electric Motor- sports Welding School, 22801 St. Clair Ave., Cleveland, OH 44117, (216) 383-2461, FAX: (216) 383-8088. www.lincolnelectric.com.

4, DI.I: 2000 Structural Welding Code - - Steel. A five-day seminar. Sponsored by AWS. For more information and complete schedule, contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552.

Boiler and Pressure Vessel Inspectors Training Courses and Seminars. 2001 schedule, National Board of Boiler and Pres- sure Vessel Inspectors Training and Conference Center, Columbus, Ohio. Conducted by The National Board of Boiler and Pressure Vessel Inspectors. For courses and times, contact: Richard McGuire, Manager of Training, (614) 888-8320, e-mail: rmcquire@nationalboard, org; www.nationalboard.org.

Plasma 2000 Training Courses. Conducted by Centricut. For class times and locations, contact: Centricut, LLC, Two Tech- nology Dr., West Lebanon, NH 03784, (800) 752-7623 or (603) 298-7849, FAX: (800) 317-0438 or (603) 298-5938.

Downdraft Tabl O Dust

Collect dus t and weld ing smoke wi th Airf low Systems, Inc. new D o w n d r a f t Bench. Self-con- ta ined unit has self-cleaning cartr idge filtration and built-in m o t o r / b l o w e r .

See our Website for complete specifications and technical brochures:

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T E M S I N C . 11370 Pagemill Road Dallas TX 75243-8306 USA

214-503-8008 - FAX 214-503-9596 1-800-818-6185 E-mail: airf [email protected]


60 I MARCH 2001

Educational Opportunities

AWS Schedule - - CWI/CWE Prep Courses and Exams

Exam application must be submit ted six weeks before exam date. For exam informat ion and application, contact the AWS Certification Dept. , (800) 443-9353 ext. 273. For exam prep course information, contact the AWS Educat ion Dept. , (800) 443-9353 ext. 229. Dates are subject to change.

Cities Exam Prep CWI/CWE Cities Exam Prep CWI/CWE Courses Exams Courses Exams

Anchorage, Alaska EXAM ONLY March 24 Miami, Fla. EXAM ONLY March 15 Bangor, Maine April 2--6 April 7 Miami, Fla. EXAM ONLY May 17 Baton Rouge, La. June 4-8 June 9 Miami, Fla. June 18-22 June 23 Beaumont, Tex. June 11-15 June 16 Minneapolis, Minn. March 5-9 March 10

(API 1104 Clinic & SCWI also offered) Nashville, Tenn. May 21-25 May 26 (API 1104 Clinic also offered)

New Orleans, La. April 30-May 4 May 5 (API 1104 Clinic also offered)

Newark, N.J. March 12-16 March 17 Perrysburg, Ohio EXAM ONLY March 24 Phoenix, Ariz. March 24

Birmingham, Ala. EXAM ONLY May 26 Chicago, Ill. April 30-May 4 May 5 Cincinnati, Ohio May 14-18 May 19 Cleveland, Ohio May 11 VIW ONLY May 12 Columbus, Ohio EXAM ONLY March 3 Columbus, Ohio April 23-27 April 28 March 19-23 Corpus Christi, Tex . EXAM ONLY May 5 Pittsburgh, Pa. May 14-18 May 19 Davenport, Iowa EXAM ONLY April 21 (API 1104 Clinic also offered) Detroit, Mich. EXAM ONLY April 21 Roanoke, Va. June 11-15 June 16 Detroit, Mich. June 18-22 June 23 San Fernando, Calif . EXAM ONLY June 23 Fargo, N.D. June 18-22 June 23 San Francisco, Calif. May 14-18 May 19 Idaho Falls, Idaho June 11-15 June 16 (API 1104 Clinic also offered) Jacksonville, Fla. EXAM ONLY April 28 Seattle, Wash. EXAM ONLY April 28 Knoxville, Tenn. March 12-16 March 17 Spokane, Wash. May 14-18 May 19

(API 1104 Clinic also offered) Springfield, Mo. March 19-23 March 24 Las Vegas, Nev. April 23-27 April 28 St. Louis, Mo. May 21-25 May 26

(API 1104 Clinic also offered) Tulsa, Okla. EXAM ONLY March 10 Long Beach, Calif. May 21-25 May 26 York, Pa. EXAM ONLY April 28 Louisville, Ky. June 18-22 June 23

(API 1104 Clinic also offered)

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A MANTECH Center of Excel lence

I C e n t e r Operated by

NJC Developing Weld and Fatigue Data for New Marine Corps Howitzer

T he Navy Joining Center and Edi- son Welding Institute (EWI) are currently working with the U.S.

Marine Corps Ordinance Maintenance Group, Picatinny Arsenal, N.J., and BAE Systems, United Kingdom, on joining activities for the development of the next-generation field portable howitzers. The U.S. Marine Corps has placed an initial order for eight prototypes that are currently undergoing testing and evaluation at a number of sites including the Yuma Proving Ground.

The howitzers are to be capable of firing 155-mm ordnance and are required to be portable for air transport by a wide variety of NATO helicopters. This combination of firepower and portability has placed many constraints on the product design. One significant requirement is for a maximum "all up mass," which by implication requires a light, but strong, structure capable of transferring large firing loads to the projectile while trans- mitting the opposing forces to the ground in a controlled manner. In order to meet these demanding requirements the structure has been designed primarily from Grade 5 titanium alloy (Ti6AIaV), a material with a very good strength-to-weight ratio. While this ma-

terial is not new, it is believed to be the first time it has been used extensively in a complex, land-based military structure.

The use of titanium alloy presents many challenges for both the designers and production manufacturing teams, thus requiring the development of new design rules, tools and welding techniques. EWI and BAE Systems are currently refining and developing fatigue design data to produce increasingly accurate rules for titanium weldments. His- torically, only limited titanium fatigue life engineering data has been available. The more general approaches used for steel and aluminum structures, based on extensive test data, are not available. Steel fatigue data have been applied to titanium structures by applying a correction factor based on Young's moduli for steel and titanium alloys. This may in- troduce error in the design of fatigue- critical components manufactured from titanium alloys, resulting in the unreal- ized full potential fatigue life of the components.

The work currently under way has required the development of both manual and mechanized welding procedures to create a variety of test weldments. Fa- tigue data have been generated from the

COR MET S P E C I A L T Y C O R E D W I R E

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Troops field testing portable howitzer.

welds based on various joint geometries, weld quality, welding process and postweld heat treatments. The experience gained by testing titanium structures provides an accurate methodology for the design of allowable stress in comparison to previous practice.

With increased knowledge and more accurate design rules in place, design engineers will have the necessary tools to support their conceptual designs. It will now be possible to refine the design of the howitzer even further to meet its life cycle constraints and production needs for innovation and continuous improve- ment in the design process, which will lead to leaner manufacturing processes.

For further details, please contact John Lawmon, Senior Engineer, Arc Welding & Automation Group at EWI, phone: (614) 688-5054, e-mail: John_Lawmon@ ewi.org.

The Navy Joining Center 1250 Arthur E. Adams Dr.

~ ] ~ J ~ Columbus, OH 43221 Phone: (614) 688-5010

Operated by FAX: (614) 688-5001 E ~ i e-mail: [email protected]

www: http://www.ewi.org Contact: Harvey Castner


62 I MARCH 2001

/ N E W

By Susan Campbell

¢ Project Snowflake Sparks the Interest of Bay-Arenac Welding Students

F or t h e p a s t t h r e e years , w e l d i n g i n s t r u c t o r Michae l J . J o n e s ' s s t u d e n t s at t he Bay-Arenac ISD C a r e e r Cen- ter, Bay City, Mich. , h a v e p u t a lo t o f h e a t i n to mak-

ing c o o l s n o w f l a k e s for t h e c i ty ' s a n n u a l ho l i day display, t h e R ive r o f L igh t s Tour , w h i c h r u n s a l o n g t h e S a g i n a w River.

T h e s t u d e n t s w e r e r e a d y a n d w a i t i n g t h i s p a s t y e a r w h e n t o u r o r g a n i z e r T e r r y W a t s o n c a l l e d J o n e s to see if t h e y w o u l d o n c e a g a i n p r o v i d e s n o w f l a k e s a n d o t h e r i t e m s for t h e p r o j e c t . T h e s t u d e n t s w e r e m o r e t h a n ready; t h e y e v e n h a d a n a m e p r e p a r e d , P r o j e c t S n o w f l a k e 2000.

J o n e s c h o s e J o n Gal lagher , a s e n i o r at B a n g o r Town- s h i p J o h n G l e n n H i g h S c h o o l , a n d K e n n y K a u n i t z , a se- n i o r at Bay City W e s t e r n High Schoo l for t h e task of cre- a t ing a p r o j e c t m a n u a l as a w o r k - s t u d y p r o j e c t . " T h e f i rs t t w o yea r s w e k i n d of w e n t wi l ly -n i l ly , " Jones s a i d . " T h i s y e a r w e a p p r o a c h e d J o n a n d K e n n y b e c a u s e t h i s is t h e f ie ld t h e y are g o i n g into."

G a l l a g h e r a n d K a u n i t z , b o t h s e c o n d - y e a r s t u d e n t s w h o w o r k e d o n t h e f a b r i c a t i o n o f s n o w f l a k e s las t year, d e s i g n e d t h e p l an , w h i c h i n c l u d e d s h o p l ayou t a n d sta- t ion iden t i f i ca t ion , a s n o w f l a k e b l u e p r i n t , a ma te r i a l s list, sa fe ty p r o c e d u r e s , a l ist o f n e c e s s a r y too l s a n d t i m e esti- m a t e s . T h e i r p l a n ca l l ed for a n i n e w o r k s t a t i o n a s s e m b l y l ine . " W h a t w e h a d in m i n d was a k i n d of a s s e m b l y l ine

Bay-Arenac ISD Career Center Students in f ron t o f a 30-Jt. snowman and l O-ft candy cane they fashioned fo r the Bay City River o f Lights Tour along the Saginaw River.

w h e r e w e c o u l d b a n g t h e s e t h i n g s out," said Ga l l aghe r . And t h e y d i d . T h e s t u d e n t s fab- r i c a t e d m o r e t h a n 30 s n o w f l a k e s for Snow- f lake 2000, as we l l as t w o lO-f t -h igh c a n d y canes . Past c l a s ses c o n t r i b u t e d , in addi- t i on to snow-f lakes , a 30-ft , 3-D F r o s t y t h e S n o w m a n , a n d a n 18 x 14-ft e i g h t - p o i n t e d s tar w i t h 174 w e l d e d c o n n e c t i o n s , 400 ft of r e b a r s t ee l w e i g h i n g less t h a n 200 lb a n d m o r e t h a n 350 l ights. W h e n d i s p l a y e d , t h e s t a r s i t s o n t o p o f a 50-ft t e l e p h o n e pole ,

Welding students fi 'om B,(y-A renac ISD Career Center fabr icated this eight-pointed star f o r Bay City's River o f Lights Tour, the city's annual holiday display.

p l a c e d t h e r e by t he Bay City Light & P o w e r D e p a r t m e n t . The n i n e s t a t ions , w i t h a c o u p l e of s t u d e n t s at e a c h

s t a t i on , m a d e p r o d u c i n g t h e s n o w f l a k e m u c h m o r e effi- c i e n t t h a n in pa s t yea r s .A t t h e s t a t ions , s t u d e n t s cu t t h e r e b a r ; d e b u r r e d t h e s h a r p m e t a l e d g e s ; s h a p e d , t a c k e d a n d w e l d e d t h e f l ake s ; a p p l i e d w h i t e p a i n t ; a n d w i r e d t h e m for l i gh t ing .A t t h e last s t a t ion , t h e s n o w f l a k e s w e n t t h r o u g h a q u a l i t y c o n t r o l c h e c k , w h i c h , G a l l a g h e r said, " real ly pays of f as n o t o n e has eve r c o m e b a c k b roken . "

T h e s t u d e n t s a d d a 4- in. t ag in t h e c e n t e r o f e a c h p i e c e t h e y m a k e for t h e River of Lights Tour. O n t h e tag is a s m i l e y face , w h i c h is t h e c l a s se s ' u n i q u e s i g n a t u r e , t h e y e a r and , if o n l y a c o u p l e o f s t u d e n t s w o r k e d o n a c e r t a i n s n o w f l a k e , t h e i r ini t ials . "Tha t way, w h e n w e are o l d e r a n d s h o w i n g o u r k ids e v e r y t h i n g , w e c a n say, 'See t h a t smi l ey face? I m a d e tha t , ' " Kaun i t z said.

"Th i s is a g r e a t p r o j e c t fo r t h e s t u d e n t , " J o n e s said. "It g ives s t u d e n t s a rea l l o o k i n t o t h e w e l d i n g m a n u f a c - t u r i n g w o r l d w i t h o u t l e a v i n g s c h o o l . T h e p r o j e c t p r o - m o t e s b e t t e r c o m m u n i c a t i o n a n d t e a m b u i l d i n g ski l ls , a l o n g w i t h g i v i n g t h e s t u d e n t s an o p p o r t u n i t y to b e ac- t ive in t h e i r local communi ty . " 0


• A W S Officers At tend FMS Reception

A W S Pres iden t Bi l l Myers, center, Vice Pres iden t Ernes t Lever t a n d A WS Gov- e r n m e n t A f fa i r s Lia ison H u g h K. Webs ter a t t e n d i n g the Federa t ion o f Mater i - a ls Soc ie ty r ecep t ion f o r N a t i o n a l M a t e r i a l s A d v a n c e m e n t A w a r d r e c i p i e n t Dr. M i l d r e d S. Dresse lhaus . The recep t ion w a s h e l d on D e c e m b e r 6, 2000 , a t the N a t i o n a l Press Club in Washington , D.C. •

• S u b m i t Y o u r T e c h n i c a l

C o m m i t t e e R e p o r t s

C o m m i t t e e C h a i r m e n - - We want to recognize the efforts of your committee and inform our readers of its accomplishments . Send a brief profile of its activities and recent accomplishments, along with a member roster and contact numbers, and we will publish it in the Welding J o u r n a l ' s Society News section.

Send your submissions to

Susan Campbell,Associate Editor American Welding Society

550 N.W. LeJeune Rd. Miami, FL 33126

Telephone, (305) 443-9353 ext. 244, FAX: (305) 443-7404

e-mail: campbel l@ aws. org •

4 AWS F o u n d a t i o n A n n o u n c e s S i l e n t A u c t i o n

T he AWS Founda t ion p roud ly a n n o u n c e s the p re sen t donor s to its first MAX In te rna t iona l Silent Auct ion, May 6 -10 at the Cleveland, Ohio, I-X Cen te r .The auc t ion benef i t s the AWS Founda t ion ' s schola rsh ip programs. Companies wish ing to donate i tems for auc t ion ($250 min imum value), p lease call Vicki Pinsky at

(800) 443-9353 ext. 212, or e-mail [email protected]. To bid in advance on i tems, c o n t a c t the AWS Founda t ion at (800) 443-9353 ext. 689, w i t h the i t em n a m e

and your bid, c o m p l e t e name, address and t e l e p h o n e number . To bid on an i tem whi le a t t end ing MAX Interna- tional, please go to the AWS Foundat ion booth. •

Thermographic Measurements, Inc. Hornell, Inc. Thermax MeltStix H C) R N E L L Speedglas 9000V welding lens and helmet

~ g Minimum bid" $250 Minimum bid: $160

Flange Wizard Tools Fitters' and welders' case Minimum bid: $300

Jackson National Products, Inc. Jackson 3N1Executive autodarkening helmet Minimum bid: $150

Triple-A-Manufacturing, Inc. T l U P l ~ ~ Portable welding & equipment storage racks m n ~ ~t. Minimum bid: $134

The Lincoln Electric Company Autographed Joe Gibbs racing helmet Minimum bid: $275

G-Tec Natural Gas Systems GT-Pak natural gas burning table system Minimum bid: $1000

UNITFIOL Unitrol Electronics, Inc. Unitrol "Accustart" Minimum bid: $100

J.A. Cunningham Equipment, Inc. L-Tec HW-17 torch outfit Minimum bid: $150

Applied Robotics Arc welding collision sensor Minimum bid: $447

Pac-Mig, Inc. Robotic arc welding end of arm tooling package Minimum bid: $875

lnweld-, Inweld Corp. Gas welding and cutting outfit minimum bid: $105

64 I MARCH 2001

. . . . . . . . . . . . . 0 . . . . . . . . . . . 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V . . . . . . . . . . . . . . . 0 " "

the AWS Foundation and discounted student memberships. 9. To strengthen your leadership skills by serving as a Section Officer or

Committee Member. 8. For discounts on travel accommodations, insurance, and more! 7. To gain access to technical knowledge with 300+ publications available. 6. To experience the wave of the future through the world's largest fabricating

show by attending MAX International. 5. Because AWS seminars and conferences allow you to establish

important contacts and increase knowledge.

. . . . . . . . . . . . . . . . . . . r , ,

seminars and certification programs. 3. Because the Welding Journal provides invaluable information through

informative articles on trends, products and new industry technology. 2. To build your network of peers and professionals by attending local Section

Meetings and utilizing bulletin boards on the AWS Website, <www.aws.org>.

And the #1 reason to become an AWS Member...

..,Because the prestige of being an AWS Member is knowing that you belong to the premier Society for materials joining professionals.

PRIZE CATEGORIES President's Honor Roll: Recruit 1-5 new Individual Members and receive 25 AWS Dollars.

President's Club: Recruit 6-10 Ilew Individual Members and receive 50 AWS Dollars.

President's Roundtable: Recruit 11-19 new Individual Members and receive 100 AWS Dollars.

President's Guild: Recruit 20 or more new Individual Members and receive the "Shelton Ritter Member Proposer Award" Certificate, one-year free membership, 200 AWS Dollars and membership in the Winner's Circle.

Winner's Circle: All members who recruit 20 or more new Individual Members will be honored with a spotlight at the annual Awards Ceremony and recognition in the AWS Membership Booth at MAX International.

SPECIAL PRIZES Participants will also be eligible to win prizes in specialized categories. Prizes will be awarded at the close of the campaign.

Sponsor of the Year: The individual who sponsors the greatest number of new Individual Members during the campaign will receive a plaque, a trip to the 2002 MAX International in Chicago, a free AWS Membership renewal and recognition at the Awards Luncheon at MAX International.

Student Sponsor Prize: Student Members who sponsor two or more new Student Members will receive 20 AWS Dollars.

The AWS Member who sponsors the most Student Members will receive a free, one-year AWS Membership and 100 AWS Dollars.

LUCK OF THE DRAW For every new member you sponsor, your name is entered into a quarterly drawing. The more new members you sponsor, the greater your chances of winning. Prizes will be awarded in August and November 2000, as well as in February and June 2001. Prizes Include: • Swiss Army Knife • 1-page, black/white ad in the Welding Journal • Complimentary AWS Membership renewal • 100 AWS Dollars, good toward the future purchase

of any AWS-produced offering such as a publication, conference, seminar, or certification exam.

• AWS Key Chain

SUPER SECTION CHALLENGE The Section in each District that achieves the highest net percentage increase in new individual Members before the June 2001 deadline will win a prize of 500 AWS Dollars.

International Sponsor Prize: Each member residing outside of the United States, American W e l d i n g S o c i e t y Canada and Mexico who sponsors the most new Individual Memberswinsl00AWSOo,arsand acomplimentm AWS Membership renewal. Visit our website http://www.aws.org

Sheet Metal Fabricators Benefit f rom A W S D9. I

T h e u se o f AWS D9.1 Sheet Metal Welding Code signif- i c a n t l y i m p r o v e s t h e p r e -

d i c t ab i l i t y a n d qua l i ty of w e l d s in s h e e t m e t a l g a u g e t h i c k n e s s ma- t e r i a l , i n c r e a s e s p r o d u c t i v i t y , l e s s e n s o r e l i m i n a t e s r e w o r k a n d i m p r o v e s w e l d e r w o r k m a n s h i p .

T h e c o d e r e q u i r e s w r i t t e n , q u a l i f i e d w e l d i n g p r o c e d u r e s t h a t d i r e c t t h e w e l d e r ve ry spec i f - i ca l ly r e g a r d i n g m a t e r i a l s , e l ec - t r o d e s , w e l d i n g p r o c e s s e s , ma- c h i n e s e t t i n g s , s h i e l d i n g gas a n d p e r m i s s i b l e w e l d p o s i t i o n s to use . T h e w e l d e r wi l l n o t h a v e to d e t e r m i n e t h e s e w e l d i n g var i - a b l e s t h r o u g h t r i a l a n d e r r o r , w h i c h c a n b e c o s t l y a n d u n p r e - d i c t a b l e . T h e p r e d i c t a b i l i t y af- f o r d e d by u s i n g th i s c o d e e x t e n d s to t h e e s t i m a t i o n a n d p r i c i n g o f s h e e t m e t a l w c l d m e n t s . W e l d e r s u s i n g q u a l i f i e d p r o c e d u r e s wi l l c o n s i s t e n t l y a c h i e v e d e p e n d a b l e d e p o s i t r a t e s o f qua l i t y , a c c e p t - a b l e , i n s p e c t e d w e l d s , w h i c h c a n b e c o n v e r t e d i n t o a c c u r a t e p r i c i n g to b e u s e d in e s t i m a t i n g t h e c o s t o f w e l d e d p r o d u c t s .

T h e D9.1 Sheet Metal Welding Code is i n t e n d e d to b e u s e d o n n u m e r o u s s h e e t m e t a l g a u g e s , t h i c k - n e s s e s a n d w e l d e d p r o d u c t s . It is d e s i g n e d spec i f i ca l ly to b e u s e d o n d u c t w o r k ( h e a t i n g , v e n t i l a t i o n a n d a i r c o n d i t i o n i n g [HVAC]), d u s t c o l l e c t o r s a n d c o l l e c t i o n s y s t e m s , i n d u s t r i a l v e n t i l a t i o n s y s t e m s , HVAC u n i t s , e l e c t r i c a l pane l s , c o m p u t e r c a b i n e t s , s h e l v i n g a n d con- so les , c o u n t e r t o p s , s t a i n l e s s s t e e l k i t c h e n e q u i p m e n t a n d h o o d s , a r c h i t e c t u r a l m e t a l b u i l d i n g t r im, c a n o p i e s , e n t r y ways , c o l u m n c o v e r s , f asc ia , c o p i n g a n d g r a v e l s t o p . T h e c o d e is n o t i n t e n d e d to be u s e d in t h e fabr i - c a t i o n o f p r e s s u r e v e s s e l s o r s t r u c t u r a l a p p l i c a t i o n s . T h e w e l d i n g o f s t r u c t u r a l m e m b e r s w h o s e so l e pu r - p o s e is s t i f f en ing , s u p p o r t i n g o r r e i n f o r c i n g t h e s h e e t m e t a l is p e r m i t t e d , r e g a r d l e s s of t h e t h i c k n e s s of t h a t m e m b e r . T h e c o d e c o v e r s s h e e t m e t a l w e l d i n g u p to #3 gauge , o r 6 .35 m m ( 0 . 2 5 0 i n . ) . T h e c o d e c a n b e u s e d o n a b r o a d r a n g e of gauge t h i c k n e s s s h e e t m e t a l p r o b - l ems .

To b e n e f i t f r o m D9.1 Sheet Metal Welding Code, t h e f a b r i c a t o r n e e d n o t b e d o i n g o n l y w o r k s p e c i f y - i ng t h e c o d e . Any w e l d i n g d o n e w i t h i n t h e s c o p e o f t h e c o d e c a n , a n d s h o u l d , b e p e r f o r m e d u s i n g w e l d - ing p r o c e d u r e s qua l i f i ed in a c c o r d a n c e w i t h t h e c o d e . T h e b e n e f i t s to t h e f a b r i c a t o r , t h e e s t i m a t o r , t h e we lde r , t h e s u p e r v i s o r and t h e i n s p e c t o r of h a v i n g pre- d i c t a b l e , r e p e a t a b l e q u a l i t y w e l d s as a r e s u l t of u s i n g t h e s e p r o c e d u r e s c a n n o t b e o v e r e m p h a s i z e d . T h e ben - e f i t s a n d a d v a n t a g e s p r e v i o u s l y d e s c r i b e d a re l i m i t e d

o n l y by h o w w e l l t h e c o d e a n d w e l d i n g p r o c e - d u r e s are fo l l owed .

T h e c o d e s h o u l d b e a pa r t of any s h e e t m e t a l w e l d e r t r a in ing p rog ram. It is an e x c e l l e n t v i sua l aid to t h e w e l d i n g o r w e l d i n g t h e o r y i n s t r u c - tor. S t u d e n t s c an use t h e c o d e to h i g h l i g h t t he im- p o r t a n c e of c h a n g e s in e s s e n t i a l w e l d i n g vari- ab les , b a s e me ta l , p rocess , polari ty, gas, etc. S t u d e n t s a n d i n s t r u c t o r s c a n also l e a r n h o w to judge a f i n i shed w e l d . T h e i n s t r u c t o r a n d t h e stu- d e n t s h o u l d use qual i f ied w e l d i n g p r o c e d u r e s as p a r t o f t h e t r a i n i n g pro- g ram. S t u d e n t s c a n l e a r n t h e p r a c t i c a l , h a n d s - o n use of w h a t wi l l b e ex- p e c t e d in i n d u s t r y . T h e

c o d e ' s a n n e x e s i nc lude t e rms , def in i t ions , types of joints , f o rms , r e c o m m e n d e d p r a c t i c e s and s u g g e s t e d r e a d i n g for t he i n s t r u c t o r ' s use.

T h e G e n e r a l K n o w l e d g e Tes t in A n n e x J c a n b e p u t to e x c e l l e n t use n o t on ly by t he i n s t r u c t o r bu t also by t h e f a b r i c a t o r ' s w e l d i n g s u p e r v i s o r to d e t e r m i n e a s t u d e n t ' s p r o g r e s s or t he level of k n o w l e d g e of t h e i r w e l d e r s .

T h e D9.1 Sheet Metal Welding Code is v e r y u s e r f r i e n d l y . It is n o t a c o m p l e x , c o m p l i c a t e d c o d e . T h e q u a l i f i c a t i o n t e s t s for p r o c e d u r e s a n d w e l d e r s are no t n u m e r o u s w h e n c o m p a r e d to o t h e r c o d e s . R e q u i r e d t e s t s a re d e s c r i b e d in t h e t e x t a n d s h o w n in f i gu re s . T h e v a r i a b l e s r e q u i r i n g r e q u a l i f i c a t i o n are f e w e r t h a n o t h e r c o d e s . I n s p e c t i o n a n d a c c e p t a n c e c r i t e r i a a re s i m p l e a n d c o n c i s e , w i t h all i n s p e c t i o n b e i n g v i s u a l a n d n o t r e q u i r i n g e x p e n s i v e e q u i p m e n t o r d e s t r u c - t i on of t he w e l d m e n t .

The n o n m a n d a t o r y a n n e x e s c o n t a i n an a b u n d a n c e o f u s e f u l i n f o r m a t i o n for t h e u s e r a b o u t e l e c t r o d e s , gauge n u m b e r s and t h e i r t h i c k n e s s e s for d i f f e r e n t metals, s a m p l e f o r m s , j o i n t d e s i g n a n d de t a i l s , t e r m s a n d d e f i n i t i o n s , a n d r e c o m m e n d e d p r a c t i c e s , all r e l a t e d s t r i c t ly to s h e e t m e t a l w e l d i n g .

Th i s c o d e is n o t i n t e n d e d to be u s e d for s t r u c t u r a l a p p l i c a t i o n s s u c h as f l o o r d e c k s , r o o f d e c k s , s i d i n g f l o o r jo is ts , wal l s tuds , e tc . , o r any p r e s s u r e ves se l ap- p l i c a t i o n s s u c h as b o i l e r s , c o m p r e s s e d a i r t a n k s , e t c . It is u s e d for w e l d i n g n o n s t r u c t u r a l s h e e t m e t a l p r o d - uc t s s imi la r to t h o s e n a m e d above . • - - J a m e s E. Roth, c h a i r m a n o f the board, J a m e s E. Roth, Inc., (724) 776-1910.


S A F E T Y A N D T 0 P I

H E A L T H C S

• Graphic Symbols for Precautionary Labels Fact Shee t No. 14

I n t r o d u c t i o n

Exis t ing s t anda rds , such as A m e r i c a n Na t iona l Stan- da rds I n s t i t u t e (ANSI) Z49 . I ,ANSI Z535 .4 and Na t iona l E l e c t r i c a l M a n u f a c t u r e r ' s Assoc . (NEMA) EW6, t h o r - o u g h l y p r e s e n t g u i d e l i n e s for t h e m i n i m u m r e q u i r e d i n f o r m a t i o n , m e t h o d of p r e s e n t a t i o n , s igna l w o r d s , c o l o r use and labe l fo rmat .

Def in i t ions

G r a p h i c s y m b o l s a re p i c t u r e s , s o m e t i m e s c a l l e d p i c t o g r a p h s , p i c t o g r a m s or p i c t o r i a l , u s e d in p l a c e of, or s u p p l e m e n t a l to, w r i t t e n w o r d s . T h e s e s y m b o l s pro- v ide n o n v e r b a l c o m m t m i c a t i o n a b o u t a p o s s i b l e hazard. They r e p r e s e n t or s y m b o l i z e t h e hazard .

Rat iona le for Graph ic Symbols

P i c t u r e s s o m e t i m e s c o n v e y i n f o r m a t i o n b e t t e r t h a n w o r d s . T h e r e f o r e , t he logical e v o l u t i o n of p r ecau - t i o n a r y l a b e l i n g acids g r a p h i c s y m b o l s to s h o w t h e m a j o r w e l d i n g or c u t t i n g haza rds . T h e use of s y m b o l s o n p r e c a u t i o n a r y l a b e l s is o p t i o n a l a n d is r e c o m - m e n d e d for the f o l l o w i n g reasons :

• S y m b o l s may i l l u s t r a t e a n d h e l p to e x p l a i n haz- a rds qu i ck ly - - fast c o n c e p t t r a n s f e r - - and use v isual ( n o t ve rba l ) r e c o g n i t i o n .

• Symbols a d d r e s s n o n r e a d e r s as wel l as r eade r s . • S y m b o l s may b e m u l t i l i n g u a l a n d usua l ly t rans -

late d i r ec t ly in to all l anguages .

Rat iona le for S t a n d a r d i z e d Symbols

The w e l d i n g and c u t t i n g i n d u s t r y n e e d s s t a n d a r d - ized s y m b o l s and u n i f o r m m e t h o d s of use to avoid u se r c o n f u s i o n a n d to s u p p l e m e n t a n d r e i n f o r c e t h e wr i t - t en message .

NEMA EW6 s t a n d a r d p r o v i d e s a list of s y m b o l s and m i n i m u m s y m b o l s ize for l abe l s a l o n g w i t h c o m p l e t e i n f o r m a t i o n r e g a r d i n g t h e i r use and a p p l i c a t i o n .

How to Use the Symbols

• Use t he s y m b o l s to s h o w t he a s soc i a t ed hazard . • Take s t a n d a r d s y m b o l s f rom NEMA EW6. • Fol low a b u i l d i n g b lock a p p r o a c h .

• Se l ec t a b a s e s y m b o l - - o f t e n u s e d a l o n e , s u c h as a fire symbol .

• C h o o s e a d d i t i o n a l s y m b o l e l e m e n t ( s ) to ful ly s h o w the hazard .

• C o m b i n e t h e c h o s e n s y m b o l e l e m e n t ( s ) , s u c h as t h e s h i e l d e d m e t a l a rc e l e c t r o d e s y m b o l , w i t h t h e ba se symbo l , s u c h as f u m e s and gases.

• Careful ly r e v i e w all s y m b o l s on th i s Heal th a n d Safe ty f a c t Sheet and in NEMA EW6.

• Fol low the d e s i g n m e t h o d s and s t a n d a r d way of i n c o r p o r a t i n g s y m b o l s o n t o t he safe ty labe l a c c o r d i n g to EW6.

I n f o r m a t i o n Sources

N a t i o n a l E l e c t r i c a l M a n u f a c t u r e r ' s Assoc . Guide- l ines. f i , r P r e c a u t i o n a r y Labeling.fi~r Arc: Welding and C u t t i n g P r o d u c t s , Arc W e l d i n g S e c t i o n , NEMA EW6. W a s h i n g t o n , D.C.: N a t i o n a l E l e c t r i c a l M a n u f a c t u r e r ' s Assoc ia t ion .

A m e r i c a n N a t i o n a l S t a n d a r d s I n s t i t u t e (ANSI) . SafeOe in Weld ing a n d C u t t i n g . A m e r i c a n W e l d i n g So- ciety, 550 N.W. LeJeune Rd., Miami, FL 33126.

A m e r i c a n Na t iona l S t a n d a r d s I n s t i t u t e (ANSI). Cri- t e r ia .[br S a f e t y 5)~mbol, ANSI Z 5 3 5 . 3 . A m e r i c a n Na- t i ona l S t a n d a r d s I n s t i t u t e , 11 West 4 2 n d St., N e w York, NY 10036.

A m e r i c a n N a t i o n a l S t a n d a r d s I n s t i t u t e (ANSI). P r o d u c t Se(fety S igns a n d Labe ls ,ANSI Z535.4 . Amer i - can Na t iona l S t anda rds Ins t i t u t e , 11 West 4 2 n d St., N e w York, NY 10036.

A m e r i c a n We ld ing Society. l , abe l ing a n d Safe Prac- t i ces C o m m i t t e e Stt4.

FMC Corp . P r o d u c t SafeO~ Sign a n d Label ,System. Santa Clar:t, Calif.

W e s t i n g h o u s e E l e c t r i c C o r p . MB 3662 . P r o d u c t Safetl , Label H a n d b o o k . P i t t s b u r g h , Pa.

I n t e r n a t i o n a l O r g a n i z a t i o n for S t a n d a r d i z a t i o n . Graphic ,S),mbols f o r Use on E q u i p m e n t , ISO 7000. In- t e r n a t i o n a l O r g a n i z a t i o n for S t a n d a r d i z a t i o n , 1, r ue de w t r embe , 1211 G e n e w t 20, Swi tze r l and .

Examples from NEMA EW6

On t h e f o l l o w i n g p a g e a re s y m h o l s w i t h h a z a r d s t h a t are r e c o m m e n d e d and e n d o r s e d by t he A m e r i c a n W e l d i n g Soc i e ty L a b e l i n g a n d Safe P r a c t i c e s C o m m i t - t e e a n y t i m e o p t i o n a l s y m b o l s a re u s e d o n a p r e c a u - t i o n a r y label . •

The Salcty and Health Fact Sheets, 2nd ed., cover all as- pects of safi, ty and health applicable to welding and cutting. The t:act Sheets include 20pages on sttDjects such as f umes and gases, radiation, noise and electrical hazards. Compiled in 1998. Price Jbr AWS members is $27; nonmembers, $36. Copies of Salcty and Health Fact Sheets can be ordered 1 O, call- Dig Global EngineerDtg Documenls at (800) 854-7179.

68 I MARCH 2001

Examples from NEMA EW6 These symbols with hazards are recommended and endorsed by the American Welding Society

Labeling and Safe Practices Committee anytime optional symbols are used on a precautionary label.

H A Z A R D S O U R C E O F H A Z A R D S Y M B O L S O U R C E

Electric Shock

Electric Shock

Electric Shock

Fumes and Gases

Fumes and Gases

Arc Rays

Fire

Fumes and Gases

Fumes and Gases

Moving Parts Causing Bodily Injury

Welding Electrode

Wiring

Welding Electrode and Wiring

Any Source

Welding Fumes and Gases

Welding Arc

Engine Fuel

Engine Exhaust

Engine Exhaust and Welding Arc

Moving Parts Such as Fans and Rotors

2' ISO, FMC, NEMA

ISO, FMC

ISO, FMC, NEMA

ISO, NEMA

ISO, FMC, NEMA

ISO, FMC, NEMA

FMC, NEMA

ISO, FMC, NEMA

ISO, FMC, NEMA

FMC, NEMA


# Sustaining Member Companies

R a n k i n I n d u s t r i e s , I n c . R a n k i n I n d u s t r i e s , Inc . ,

. D i e g o , Calif . , h a s b e e n a w i t h h e a d q u a r t e r s in San

228"3 M a i n S t r e e t

S a n l ) i c g o , CA 9 2 ! "34 p r i m e f o r m u l a t o r a n d p r o d u c e r ( 6 19) 5 7 5 - 6 0 0 1 ) o r of b u i l d u p a n d h a r d f a c i n g p rod - ( 9 0 0 ) 8 5 + 2 1 ~ 9 u c t s s i n c e 1938 . T h e c o m p a n y FAX: ( 6 1 9 ) 5 7 5 - 6 0 0 3 s p e c i a l i z e s in m a n u a l e l ec - e - m a i l : h a r d f : l c e @ r a n k i n i n d . c o m t r o d e s , gas r o d s a n d s e m i a u t o -

m a t i c w i r e s , as w e l l as e q u i p - m e n t a n d s y s t e m s for a u t o m a t -

ing a p p l i c a t i o n s in a n u m b e r of i ndus t r i e s . T h e R a n k i n m a n u a l b u i l d u p a n d h a r d f a c i n g e l e c t r o d e s are i d e n t i f i e d

w i t h t he p o p u l a r Raui te TM t r ade n a m e ; s e m i a u t o m a t i c w i r e s are i d e n t i f i e d w i t h t h e t r ade n a m e R a n o m a t i c f M . T h e c o m p a n y also p r o d u c e s a c o m p l e t e l ine o f c a s t - t u n g s t e n c a r b i d e p r o d u c t s , k n o w n as R a u t u n g T M . T h e t r a d e n a m e R a n t u b e TM i d e n t i f i e s a l ine of t u b u l a r h a r d f a c i n g e l e c t r o d e s t h a t are h e a v y in a l loy c o n t e n t a n d p r o v i d e v e r y h i g h d e p o s i t i o n ra t e s . Recen t ly , R a n k i n d e v e l o p e d a n d m a r k e t e d t h e f i rs t t ubu la r , h igh -a l loy w i r e in 0 .035 in. d i ame te r . R e c e n t r e s e a r c h a n d d e v e l o p m e n t p r o j e c t s h a v e b e e n d e v o t e d to t he f o r m u l a t i o n a n d p e r f e c t i o n of t h e 0 .035 , 0 .045 and 1/16 in. wi res , all of w h i c h h a v e b e e n w i d e l y a c c e p t e d .

The c o m p a n y hits a u t o m a t e d severa l h a r d f a c i n g a p p l i c a t i o n s w i t h cus- t o m w e l d i n g sy s t ems d e v e l o p e d a f t e r l ong in-field e x p e r i m e n t a t i o n . Dredge p u m p shel ls , for e x a m p l e , st i l l c o n t i n u e to b e r e c o n d i t i o n e d w i t h t h e pop- u la r S h e l l m a t i c a u t o m a t i c w e l d i n g s y s t e m d e v e l o p e d in t h e 1960s. D r e d g e o p e r a t o r s a n d i n t e r n a t i o n a l m a i n t e n a n c e s t a t i o n s s t i l l re ly o n t h e Shel l - m a t i c a n d R a n o m a t i c w i r e s for qu ick , t r o u b l e - f r e e r e c o n d i t i o n i n g . R a n k i n a lso i n t r o d u c e d t h e R a n o m a t i c 18-24 s y s t e m for a u t o m a t i c a l l y h a r d f a c i n g c o n e c r u s h e r s .

R a n k i n p r o d u c t s arc m e r c h a n d i s e d o n an i n t e r n a t i o n a l bas i s t h r o u g h i n d e p e n d e n t w e l d i n g s u p p l y d i s t r i b u t o r s w h o are t r a i n e d to p r o v i d e pro- f e s s iona l w e a r - p r o b l e m re so lu t i ons . •

AWS WELCOMES

N E W S U P P O R T I N G C O M P A N I E S

New Supporting Companies

3M 3M Cen te r St. Paul, MN 55144

Scanner Inspec t ion Company Cassrrera J8A # 3 1 - 4 9 Casilla Real I, Giron Bucaramanga, Santander 057 Colombia

SVEMCA Zona Industrial Matanzas Calle Los Bucares con La Arboledad Diagonal Transpor tes Ivan Guayana, Bolivar 8050 Venezuela

¢ A W S MEMBERSHIP

Member A s o f G r a d e s F e b r u a r y 1, 2 0 0 1

Sustaining Companies ................. 342 Suppor t ing Companies ............... 159 Educational Inst i tut ions .............. 165

Tota l C o r p o r a t e M e m b e r s ....... 666

Individual Members ............... 43,633

Student Members ..................... 4,892

T o t a l M e m b e r s .. 4 8 , 5 2 5

F o u n d e d in 1919 , Pac i f i c Sci- e n t i f i c Sa fe ty & A v i a t i o n G r o u p is a l e a d e r in d e s i g n ,

d e v e l o p m e n t a n d p r o d u c t i o n o f a v i a t i o n s a f e t y e q u i p m e n t fo r c o m m e r c i a l , m i l i t a r y a n d g e n e r a l a v i a t i o n i n d u s t r i e s . T h e c o m p a n y is c o m p r i s e d of s ix d i v i s i o n s w i t h l o c a t i o n s t h r o u g h o u t N o r t h a n d S o u t h Amer i ca , E u r o p e and Asia.

S i n c e 1957 , t h e c o m p a n y ' s H T L / K i n - T e c h D i v i s i o n h a s b e e n a l e a d e r in t h e d e s i g n , q u a l i f i c a - t i o n a n d m a n u f a c t u r e o f a v i a t i o n s a f e t y c o m p o n e n t s . O v e r t h e y e a r s , t h e d i v i s i o n d e v e l o p e d a n e x t e n s i v e p r o d u c t l i ne i n c l u d i n g f ire e x t i n g u i s h e r s , p e r s o n a l sa fe ty r e s t r a i n t s , m e c h a n i c a l a n d e l ec t ro - m e c h a n i c a l s u b s y s t e m s , h igh -p re s - s u r e v e s s e l s , v a l v e s a n d p r e s s u r e gauges .

T h e H T L / K i n - T e c h D i v i s i o n ' s m a j o r c u s t o m e r s i n c l u d e c o m m e r - c ia l , m i l i t a ry , r e g i o n a l , b u s i n e s s a n d g e n e r a l a v i a t i o n a i r c r a f t man- u f a c t u r e r s . T h e c o m p a n y ' s p n e u - m a t i c d e v i c e s a n d d i r e c t r e a d i n g p r e s s u r e g a u g e s a re c u r r e n t l y in u s e o n t h e H e l f i r e II, A d v a n c e d M e d i u m R a n g e Ai r - to -Ai r Mis s i l e (AMRAAM), S i d e w i n d e r , P a t r i o t a n d S t i n g e r m i s s i l e s . O t h e r p r o d - u c t s in u s e i n c l u d e e s c a p e s l i d e i n f l a t i o n s y s t e m s a n d e m e r g e n c y d o o r a c t u a t i o n s y s t e m s o n t h e DC- 1 0 , 7 4 7 a n d 777 a i rcraf t .

Pacif ic Sc ien t i f i c Av ia t ion Ser- v i c e s C o m p a n y p r o v i d e s cus- t o m e r - f o c u s e d r e p a i r , o v e r h a u l , a n d s p a r e s s u p p o r t s e r v i c e s fo r o p e r a t o r s o f Pac i f i c S c i e n t i f i c ' s H T L / K i n - T e c h D i v i s i o n p r o d u c t s a n d o t h e r a i r c r a f t s a f e t y - r e l a t e d e q u i p m e n t . E q u i p m e n t s e r v i c e d i n c l u d e s f i re e x t i n g u i s h e r s , oxy- g e n e q u i p m e n t , p r e s s u r e v e s s e l s , gauges a n d a i rc ra f t sea t r e s t r a in t s . T u r n a r o u n d t i m e s a re g u a r a n t e e d in as l i t t l e as o n e day w h e n re- q u e s t e d . •

70 I MARCH 2001

• Volunteers Sought for the D9 C o m m i t t e e on Welding, Braz ing and Solder ing of Sheet Metal

T h e A m e r i c a n W e l d i n g Soci- e ty (AWS) D9 C o m m i t t e e o n Weld ing , Braz ing a n d Solder-

ing of Shee t Metal is l ook i ng to add m e m b e r s to t h e C o m m i t t e e .

T h e C o m m i t t e e r e c e n t l y p u b - l i s h e d AWS D 9 . 1 : 2 0 0 0 , Sheet Metal Welding Code.The C o m m i t - t e e is se t to b e g i n t h e n e x t r ev i - s i o n o f t h e c o d e . I n d i v i d u a l s k n o w l e d g e a b l e in t h e w e l d i n g a n d b r a z e w e l d i n g o f s h e e t m e t a l in n o n s t r u c t u r a l a p p l i c a t i o n s a re e n c o u r a g e d to apply. C o n t r a c t o r s , w e l d i n g i n s t r u c t o r s a n d w e l d e r s i n v o l v e d in h e a t i n g , v e n t i l a t i n g a n d a i r c o n d i t i o n i n g , f o o d p r o - c e s s i n g e q u i p m e n t , c a b i n e t r y , e l e c t r i c a l p a n e l s o r o t h e r n o n - s t r u c t u r a l a p p l i c a t i o n s are pa r t i c - u la r ly s o u g h t .

If y o u a re i n t e r e s t e d in par - t i c i p a t i n g in t h i s w o r k , p l e a s e s u b m i t y o u r a p p l i c a t i o n o n t h e AWS Web s i te at www.aws.ocq or c o n t a c t t h e D9 C o m m i t t e e Secre - t a ry , J o h n Gay lc r , a t ( 8 0 0 ) 443 - 9 3 5 3 ex t . 472 o r v ia e - m a i l a t g a y l e r @ a w s . o r g . •

• S t u d e n t C h a p t e r s , S e n d U s

Y o u r N e w s

S t u d e n t C h a p t e r s a re e n c o u r - a g e d t o s e n d r e p o r t s o f t h e i r m e e t i n g s , a c t i v i t i e s a n d e v e n t s , a l o n g w i t h p h o t o g r a p h s , t b r p u b - l i c a t i o n in t h e Welding Journal 's S t u d e n t Ac t iv i t i e s d e p a r t m e n t .

S e n d y o u r m e e t i n g / e v e n t re- p o r t s to

S u s a n C a m p b e l l , Assoc . Ed. W e l d i n g J o u r n a l 5 5 0 N.W. L e J e u n e Rd. Miami , FL 3 3 1 2 6 .

R e p o r t s c a n a l so b e f a x e d to ( 3 0 5 ) 4 4 3 - 4 7 0 4 o r e - m a i l e d to campbell@aws, org. •

• A W S to Host U.S. OpenWeldTrials at M A X International

w h e n MAX In t e rna t i ona l , t he largest a n n u a l fa b- r i c a t i n g s h o w in t he wor ld , o p e n s o n May 6, 2001, at C leve land ' s I-X Center , one of its key

a t t r ac t i ons wil l be t he U.S. O p e n Weld Trials. T b e s t u d e n t w e l d e r c o m p e t i t i o n is c o s p o n s o r e d

by t h e A m e r i c a n W e l d i n g S o c i e t y (AWS) a n d Ski l IsUSA/VICA. It is d e s i g n e d to e f f e c t i v e l y d e m o n - s t r a t e t he qua l i ty of we ld ing , a m a j o r p r o d u c t i o n skill, a n d to i l l u s t r a t e to m a n u f a c t u r i n g o f f i c i a l s v i s i t i n g t he show- t he s u p e r i o r t r a i n i n g t he fu tu re g e n e r a t i o n of w e l d e r s are rece iv- ing t h r o u g h o u t t he wor ld .

A m a x i m u m of six f inal is ts f rom SkilIsUSA reg iona l c o n t e s t s will qual i fy for t h e Trials . Based o n t h e f ina l t a b u l a t i o n of s c o r e s , t h e e n t r a n t s wi l l b e c h o s e n f rom the fo l lowing area w inne r s :

• B r y a n Lee, Ferr is State Universi ty, Big Rapids, Mich.; J e f f C a r n e y , in- s t ructor .

• D a n i e l W i t t e k i n d , L i n n - B e n t o n C o m m u n i t y Col lege , Albany, Oreg . ; D a v i d K e t l e r , ins t ruc tor .

• M a t h e w P i s c h k e , N o r t h w e s t Tech Col lege , G r e e n Bay, Wis. ; S c o t t Tenant, ins t ruc tor .

• A m a n d a S c h e f f l e r , \ V a s h t e n a w ( ~ o m m u n i t y Col lege , A n n A r b o r ; Mich.; Bi l l Fig, ins t ruc tor .

• A n d r e w N o l a n , NE I o w a C o m m u n i t y Col lege , Peos ta , Iowa; M i k e D a u g h e r t y , ins t ruc tor .

• T o l n F o s t e r , Pike Cent ra l High School , Pe t e r sburg , Ind. ; K e v i n Carter, ins t ruc tor .

• C h r i s t o p h e r L o w e , A i k e n C o u n t y C a r e e r & T e c h n o l o g y Center , Lan- gley, S . C . ; J o h n Bal l , ins t ruc tor .

• D i e n T r a n , P-TEC Clearwater, Clearwater, Fla. ; J e r r y G a y l e n , instructor. • K y l e T h o m a s , N o r t h D a k o t a Sta te Co l l ege o f S c i e n c e , W a h p e t o n ,

N . D . ; J o e l J o h n s o n , ins t ruc tor . • J a m e s M a r t i n , S o u t h e r n A r k a n s a s C o m m u n i t y Col lege , E1 D o r a d o ,

Ark.; B e n n y W i l s o n , ins t ruc tor . • J o n a t h a n J a c k s o n , Lee C o u n t y High Schoo l , L e e s b u r g , G a . ; J i m

M c B r i d e , ins t ruc to r . • J a e l D e L e o n a r d i s , Santa Fe Techn ica l High School , Santa Fe, N.M.; AI

T r u j i l l o , ins t ruc tor . This is the first year t he b i enn ia l e v e n t has b e e n o p e n e d to i n t e r n a t i o n a l

s t u d e n t s . R e p r e s e n t a t i v e s f r o m Aust ra l ia , N e w Z e a l a n d a n d I r e l a n d are ex- p e c t e d to p a r t i c i p a t e in the c o m p e t i t i o n .

T h e s c o p e of t he Trials i nvo lves t h e t e s t of skil ls in spec i f i c p r o c e s s e s i n c l u d i n g SMAW/GMAW al l -pos i t ion tes t p la tes , s ta in less steel , s tee l and alu- m i n u m s h e e t m e t a l w e l d m e n t s a n d SMAW/GMAW p r e s s u r e v e s s e l ( t e s t e d us ing w a t e r p r e s s u r e at 1000 l b / i n . 2 ) . J u d g i n g is b a s e d on a n u m b e r of com- p e t e n c i e s r ang ing f rom b l u e p r i n t reading; safety; p e n e t r a t i o n / f u s i o n ; the set- t ing of a m p e r a g e , wi re feed speed , vo l tage and gas f l ow rate; to s e l e c t i o n of f i l ler m e t a l s a n d wi re ; m a n i p u l a t i v e skill , s p e e d a n d a c c u r a c y ; d e s t r u c t i v e and n o n d e s t r u c t i v e e x a m i n a t i o n ; gene ra l a p p e a r a n c e of t he p r o j e c t and dis- t o r t i on con t ro l .

N ew to th i s yea r ' s c o m p e t i t i o n wil l be c l o s e d c i r cu i t "Ac t ionCam" coverage of the act ivi t ies , a l lowing v is i tors to get a c l o s e u p v i ew of the w e l d i n g exerc i ses . In add i t ion , a s c o r e b o a r d will p r o v i d e a r u n n i n g t a b u l a t i o n on t he s ta tus of e ach c o n t e s t a n t .

T he h i g h e s t A m e r i c a n f i n i she r in t he U.S. O p e n w e l d t r ials wil l r e ce ive

CHAMPIONSHIPS

a $40 ,000 , four -year s c h o l a r s h i p f rom t h e Mil ler E lec t r i c Mfg. C o . , A p p l e t o n , W i s . T h e w i n n e r and t h e w i n n e r ' s i n s t r u c t o r a lso r e c e i v e an AWS ex- p e n s e - p a i d t r ip to Seoul, Korea, to c o m p e t e in the w e l d i n g e v e n t s at t h e Wor ld Skills c o m p e t i t i o n s in Sep tember . Gold, s i lver and b r o n z e meda l s have b e e n e a r n e d by t he A m e r i c a n s at t be Wor ld Skills C o m p e t i t i o n d u r i n g the pas t t en years. •


E I N E W S

Long Island Section gttest speaker Tom Jeramaz during his presentation to the Section.

D I S T R I C T I Director: G e o f f r e y H. P u t n a m

Phone: ( 8 0 2 ) 4 3 9 - 5 9 1 6

D I S T R I C T 2 D i r e c t o r : A l f r e d F. F l e u r y

P h o n e : ( 7 3 2 ) 8 6 8 - 0 7 6 8

• PHILADELPHIA OCTOBER 13, 2000 Speaker: H a n n y R i k o n e n and J o h n Nash. Affi l iation: Kvaerner Philadelphia Shipyard. Topic: Rikonen and Nash led the Sect ion on a tour of the Kvaerner Philadelphia Shipyard.

• LONG ISLAND DECEMBER 14, 2000 Speaker: T o m J e r a m a z , market specialist. Affiliation: MSA Corp. Topic:What is a confined space and what makes it dangerous?

York-Centred Penn.2Flvania Section Publicity Director George Botten- f ie ld talking to a s tudent and his parents at the York County School o f Technology's Career Days event.

Philadelphia Section member and u,elding instructor David L. Vinson, right, with students during the Section's tour of the Kvaerner Philadel- phia Shipyard in October

• NEW JERSEY DECEMBER 19, 2000 Activi ty: The Sect ion held Manu- facturers ' Night. More than a dozen manufacturers exhibi ted the latest in machinery, e q u i p m e n t and safety products. Note: The Sect ion dona ted $2000 to the Middle Earth Founda t ion , a n o n p r o f i t g roup for teens , to

he lp r ebu i ld its f l o o d - d a m a g e d communi ty center.

D I S T R I C T 3 Director: Claudia Bottenfield

Phone: ( 7 1 7 ) 3 9 7 - 1 3 1 2

• YORK-CENTRAL PENNSYLVANIA DECEMBER 7, 2000 Activity: The Section held a small

72 I MARCH 2001

9

AttendiHg the TriaHgle Secthm ~ November meeting cite, staHdDtg, J}'om left, First Vice Chairman Bill CarOJ, Chairman Russell Wahrman, Secre- tary/Treasurer Spencer Aycock, Mike Rozzo, guest speaker Ed Dougherty (back, center), Bob Dickerson and Elton Short, seated, f r o m left, are Mark Jeffries and Leon Short.

A Rochester Secliolt member tries his haltd at using the gas tungsten arc welding "cup walking"technique at the Section's October Hands- On Night.

Vince M/irray, left, and Rcllph Ko- hart, Jr., right, h a v i n g f u n at the New Jersey Sect ion 's Manufac - turer's Night showcase.

trade show and ()pen house for Ca- reer Days at the York County School of Technology. Members discussed welding career opportunit ies with students and their parents.

D I S T R I C T 4 D i r e c t o r : R o y C. L a n i e r P h o n e : ( 2 5 2 ) 3 2 1 - 4 6 1 1

• TRIANGLE NOVEMBER 30, 2000 Speaker: Ed D o u g h e r t y , d is t r ic t manager. Affi l iat ion: Miller Electric Mfg. Co. Topic: Advanced t e chno log i e s in plasma arc cut t ing, gas tungs ten arc welding and other processes.

D I S T R I C T 5 D i r e c t o r : B o r i s A. B e r n s t e i n

P h o n e : ( 7 8 7 ) 8 8 3 - 8 3 8 3

D I S T R I C T 6 D i r e c t o r : G e r a l d R. C r a w m e r

P h o n e : ( 5 1 8 ) 3 8 5 - 0 5 7 0

• ROCHESTER OCTOBER 18, 2000 Act iv i t y : Hands-On Night of fered members the chance to to try various processes and techniques for welding and nondestruct ive examination.

NOVEMBER 6, 2000 Speakers: D a v i d L o c k e , NE regional manager, s tand-alone and mult iaxis lasers; J o h n F r a n c h i , p res ident ; and M i c h a e l F r a n - c o e u r , sales engineer. Aff i l ia t ions:TRUMPF (Locke) and Joining Technologies (Franchi and Francoeur). Topic: Laser and e l ec t ron beam welding.

NOVEMBER 11, 2000 Speakers: R o b e r t F e r r e l l , sen ior staff eng ineer ; P a u l C o n k l i n , su- p e r v i s i n g bo i l e r i n s p e c t o r ; and P e t e r V e s c i o , s en io r bo i l e r inspector.

Aff i l ia t ions:The National Board of Boiler and Pressure Vessel Inspec- tors (Ferrel l ) and State of New York, Dept. of Labor, Div. of Health and Safety (Conclin and Vescio). Topic: Boiler and pressure vessel repair and regulations.

• TWIN TIERS JANUARY 9 Speaker: Rich Sca rna t i . Af f i l ia t ion : Harr is /Lincoln Elec- tric, Cleveland, Ohio. Topic: Oxyfuel safety and operations. A c t i v i t y : T h e guest speaker at the m ee t i ng was s p o n s o r e d by Qual- ity Welding Supply, Elmira, N.Y. In addi t ion, the com pany dona ted a c o m p l e t e to rch out f i t that was awarded as a door pr ize . Dis t r ic t 6 D i r e c t o r G e r a l d C r a w m e r at- t ended the meet ing.

D I S T R I C T 7 Director : R o b e r t J. Tabe rn ik

Phone : (614) 4 8 8 - 7 9 1 3

• PITTSBURGH NOVEMBER 14, 2000 Speaker: Paul B. D i c k e r s o n , consultant. Affi l iat ion: Retired from Alcoa and a m e m b e r and prev ious chair of the A5C Subcom m i t t e e on Alu- minum Alloy Filler Metals.

WELDING JOURNAL 1 73

Pittsburgh Section member Dick LaFave, left, thanking guest speaker Paul Dickerson.

Mobile Section guest speaker Ger- ald Taylor, right, receiving a speaker's p laque f rom Lavon Mills.

Topic: D i s c o n t i n u i t i e s in a l u m i n u m w e l d i n g - - c a u s e s a n d cures .

DECEMBER 8, 2000 Activ i ty:The S e c t i o n h e l d i ts 1 4 t h A n n u a l S t u d e n t Weld-Off.

D I S T R I C T 8 Direc tor : Harre l l E. B e n n e t t

P h o n e : ( 4 2 3 ) 4 7 8 - 3 6 2 4

D I S T R I C T 9 D i r e c t o r : J o h n B r u s k o t t e r

P h o n e : ( 5 0 4 ) 3 6 7 - 0 6 0 3

• MOBILE OCTOBER 19, 2000 Speaker: G e r a l d T a y l o r , p r e s i - den t .

Posingjor a photograph at the Neu, Orleans Section's anmla l holidc O' party are, f rom left, Anna and Robert Gautreaux, Janet and Robert Duhon, District 9 Director John Broskotter and his wife, Donna, and Phyllis and Mason Punch.

A f f i l i a t i o n : T e c h - Weld. Topic: CWI tes t ing . Activity: It was de- c ided m e m b e r s wil l bu i ld p i c n i c b e n c h e s for area s choo l s as a c o m m u n i t y s e rv i ce p ro j ec t . D i scuss ions w e r e he ld o n the Sec- t ion ' s p lan to deve lop a t o i l e r outf i t ted w i t h w e l d i n g and c u t t i n g e q u i p m e n t for visits to s choo l s to p r o m o t e w e l d i n g as a c a r e e r choice.

A d a m Roberts addresses Lakeshore Section members wh i l e l ead ing t h e m on a t o u r o f the Title Town Brewery.

• NEW ORLEANS DECEMBER 19, 2000 Speaker: J o h n B r u s k o t t e r . Aff i l ia t ion: P r o j e c t S p e c i a l i s t s , Inc. , G r e t na , La. Activi ty: T h e S e c t i o n h e l d i t s an- nua l ho l i day party. Di s t r i c t 9 Direc- t o r J o h n B r u s k o t t e r a d d r e s s e d t h e g u e s t s a n d u p d a t e d t h e m o n t h e D i s t r i c t ' s ac t iv i t ies .

D I S T R I C T I 0 Direc tor : V i c t o r Y. M a t t h e w s

P h o n e : ( 2 1 6 ) 3 8 3 - 2 6 3 8

D I S T R I C T I I D i r e c t o r : S c o t t C. C h a p p l e

P h o n e : ( 9 1 3 ) 2 4 1 - 7 2 4 2

D I S T R I C T 12 Direc tor : M i c h a e l D. K e r s e y

P h o n e : ( 2 6 2 ) 6 5 0 - 9 3 6 4

• F O X VALLEY JANUARY 9 Speaker: M i k e B r a c e . Aff i l ia t ion: Mil l e r E l e c t r i c Mfg. Co., A p p l e t o n , Wis. Topic:The e v o l u t i o n o f eng ine -d r i - v e n w e l d i n g m a c h i n e s - - g e n e r a - t o r s to i n v e r t e r s . Activity: M i k e B r a c e was t h e win- n e r of t h e e v e n i n g ' s 50-50 d r a w i n g a n d g e n e r o u s l y c o n t r i b u t e d h i s w i n n i n g s to t h e Fox Val ley s c h o l - a r s h i p fund .

• LAKESHORE JANUARY 11 Speaker: A d a m R o b e r t s , b r e w mas ter .

741 MARCH 2001

Arrowhead Section guest speaker J im Messmer, right, with members Tom Baldwin, center, and Doug Mroz during the Section's December plant tour

Af f i l ia t ion: Title Town Brewery, Green Bay, Wis. Topic: How the b rew process works, what it takes to start a brewery and where this indus t ry is going. Activi ty: The Sect ion toured the Title Town Brewery and sampled five of its brews with dinner.

AWS National Vice President Ernest Levert, left, joins North Texas Section Sec- retary Kirk Jordan at Molina High School's Career Day/College Night to discuss opportunities in the welding industry with students and their parents.

D I S T R I C T 1 3 D i r e c t o r : J . L. H u n t e r

( 3 0 9 ) 8 8 8 - 8 9 5 6

D I S T R I C T 14 Director: Hil Bax

Phone : (314) 6 4 4 - 3 5 0 0 , ext. 105

D I S T R I C T 1 5 D i r e c t o r : J . D. H e i k k i n e n

P h o n e : ( 2 1 8 ) 7 4 1 - 9 6 9 3

• ARROWHEAD DECEMBER 21, 2000 Speaker: J i m Messmer , manager. Aff i l ia t ion: Taconite Engineer ing and Mfg. Co. (TEMCO), Hibbing, Minn. Activi ty: The Sect ion received a tour of the TEMCO facilit ies and discussed the need for product iv- ity and business diversification.

D I S T R I C T 16 Director: C. F. Burg

Phone: ( 5 1 5 ) 2 9 4 - 5 4 2 8

Puget Sotlnd Section member Jint Agnew at the Section's December meeting.

D I S T R I C T 1 7 D i r e c t o r : O r e n P. Reich P h o n e : ( 2 5 4 ) 8 6 7 - 2 2 0 3

• NORTH TEXAS NOVEMBE~ 14, 2000 Activi ty: AWS Vice Pres ident Ernest L e v e r t and North Texas Section Secretary K i r k J o r d a n spoke wi th teachers , paren ts and s tudents at Molina High School 's Career Day/College Night in Dal- las ,Tex.They p resen ted the many oppor tun i t i e s a career in welding holds and discussed the various AWS scholarship programs.

• SABINE JANUARY 16 Speaker: David Morgan , manager. A f f i l i a t i o n : Q/A Weld ing Labs, Orange, Tex. Topic: Training an adequate work force.

Guest speaker David Morgan during his presentation to the Sabine Section in January.

Act iv i ty: Lee L i n a m was presented with his Silver Anniversary Certificate.

D I S T R I C T 1 8 D i r e c t o r : J . M. A p p l e d o r n P h o n e : ( 2 8 1 ) 8 4 7 - 9 4 4 4

D I S T R I C T 19 D i r e c t o r : P h i l Z a m m i t

Phone: (509) 4 6 8 - 2 3 1 0 ext. 1 2 0

• PUGET SOUND DECEMBER 7, 2000 Speaker: D a v i d Braze l l , dis tr ict sales manager. Affiliation: Hypertherm. Topic: Plasma arc cu t t ing techniques, theory and development.

WELDING JOURNAL ITs

Puget Sound Section Past Chairman Gordy Robertson, left, accepting the District 19 Meritorious Award f rom District 19 Director Phil Zammit.

Ac t iv i t y : C h r i s Mi l l e r , a weld ing s tudent at Renton Technical Col- lege, was awarded a scholarship by Sect ion Chairman K e n J o h n s o n . J i m P. A g n e w was named Educa- tor of the Year for his ded ica t ion to his s tudents at In ter lake High School in Bellevue,Wash.

JANUARY 4 Speaker: C h r i s S u n d b e r g , principal structural engineer. Affi l iat ion: CH2M Hill. Topic:An overview of the Las Vegas water supply project. Act i v i t y : Past Chai rman G o r d y R o b e r t s o n was p r e s e n t e d wi th the District 19 Meri tor ious Award by District 19 Director P h i l Zam- mit .

• ALASKA JANUARY 19 Speaker: Mar ty A n d e r s o n . Affi l iat ion: MIAC. Topic: NACE and AWS. Material select ion, design and mit igat ion systems.

DISTRICT 20 D i r e c t o r : N e i l R. K i r s c h

P h o n e : ( 9 7 0 ) 8 4 2 - 5 6 9 5

• COLORADO DECEMBER 14, 2000 Speaker: D i c k Shee tz , opera t ions manager, and M i k e M o l l i c a n , plant superintendent . Af f i l ia t ion: Nor thwes t Pipe Com- pany, Denver, Colo. Topic: Manufacturing spiral-welded pipe with a concrete lining.

Matt Pttrvis, staHding left o f cente,; enterlaDtiHg 5"acramenlo Seclion members u'ith his saxophone at their annual holiday party

District 22 Director Mark Bell, left, presenting awards with the help o f San Francisco Section Past Chairman Mike Urioste, standing, center, a t the Section's January meeting.

Ac t i v i t y : The Sec t ion r e c e i v e d a tour of Northwest ' s p ipe manufac- tu r ing faci l i ty in Denver . Steve D u r a n demonst ra ted full penetra- t ion first-pass we ld ing wi th Lin- coln Electr ic 's pulsed arc welding machines.

JANUARY 11 Speaker: R i c h a r d C a m p b e l l , director of engineering. Af f i l i a t ion : Purity Systems, Inc., San Jose, Calif. Topic: Borescope i n spec t ion of welds. Act iv i ty : C h u c k C a r n s , also wi th Puri ty Systems, assisted wi th the presentation.

DISTRICT 21 D i r e c t o r : F. R. S c h n e i d e r P h o n e : ( 6 1 9 ) 6 9 3 - 1 6 5 7

DISTRICT 22 D i r e c t o r : M a r k B e l l

P h o n e : ( 2 0 9 ) 3 6 7 - 1 3 9 8

• SACRAMENTO DECEMBER 21, 2000 Act i v i t y : The Sect ion ce l eb ra t ed the season at its annual hol iday party. Ma t t P u r v i s e n t e r t a i n e d with his saxophone and accompa- nying boom box.

• SAN FRANCISCO JANUARY 10 S p e a k e r : J o h n D w y e r . Af f i l i a t i on : Air Products and Chemicals Co. Topic: Furnace atmosphere. A c t i v i t y :Th i s was a joint mee t ing with ASM and ASNT. District 22 Di- r ec to r M a r k B e l l a t t ended the meeting. •

76 I MARCH 2001

S E C T I O N E V E N T S C A L E N D A R @ • HILWAUKEE MARCH 15 Topic: Lates t a d v a n c e m e n t s in s tud w e l d i n g . S c h o l a r s h i p Night .

API',I L 19 Act iv i t y : ABB F l e x i b l e A u t o m a t i o n p lan t tour.

MAY 17 ActiviOe: Past Spouse ' s Night .

C h a i r m e n ' s and

• LAKESHORE MARCh 14 Activi ty: Studen t Day Event.

APRIl. 12 Activi ty: MG Indus t r i e s p h m t tour.

MAY 18 ActiviO~: Dist r ic t C n n f e r e n c e .

• YORK-CENTRAL PENNSYLVANIA MARClt Act i v i t y : Ladies ' N igh t a n d an e v e n i n g on the d i n n e r train. Date:To be a n n o u n c e d .

APRIl. 5 Activi ty: Jo in t m e e t i n g w i t h ASNT. S p e a k e r : W i l l i a m DeFel ice . Topic: Cryogen ics .

MAY 3 Speaker: C h a r l e s C o l b u r n , s cu lp - tor. Topic: Welded Art. Activi ty: Studen t s ' Night .

• ALASKA kbr f u r ther infi~rmation on meetings, e-mail awsalaska@altavista, com.

MARCrl 16 Topic: To be a n n o u n c e d . Location: Fairbanks.

APRIl. 20 Topic:To be a n n o u n c e d . Location: Anchorage .

MAY 19 Actit 'iOc AWS Alaska Sec t ion Picnic . Location: Palmer, Alaska.

• C O L O R A D O For m e e t i n g updates , call the

Colorado Sec t ion ' s u p d a t e l ine a t (303) .313-9645. Visit the Section k Web site, at www.aws039. t r ipod.com.

MARCH 8 Speaker: T e r r y M c C l e l l a n d . Topic: How to wr i t e a WPA.

APRIl. 12 3jgeaker: Chuck Howard. Topic: How to wr i t e a PQR.

MAY 10 Speaker: Jack Harkness . Topic: How to w r i t e a WQTR. Act iv i t y : S t u d e n t R e c o g n i t i o n and Award Night .

Juxl! 14 Activi ty: Execu t ive Board Meet ing .

AU(;UST 9 Activi ty: Execu t ive Board Meet ing .

• A n n o u n c e Y o u r S e c t i o n ' s A c t i v i t i e s

S t i m u l a t e a t t e n d a n c e at y o u r S e c t i o n ' s m e e t i n g s and t r a i n i n g p r o g r a m s w i t h f ree l i s t ings in t he Sec t ion M e e t i n g Ca l en d a r c o l u m n of Socie ty News.

Use fu l i n f o r m a t i o n i n c l u d e s y o u r S e c t i o n n a m e ; a c t i v i t y da t e , t ime and loca t ion ; s p e a k e r ' s name , t i t le , a f f i l i a t i on and s u b j e c t ; and n o t i c e s o f go l f o u t i n g s , selninars, c o n t e s t s and o t h e r spec ia l Sec t ion activities.

If s o m e of y o u r m e e t i n g p l a n s are s k e t ch y , s e n d t h e m u n e and p h o n e n u m b e r of a p e r s o n to contact for more information.

S e n d y o u r n e w c a l e n d a r to Susan C a m p b e l l , A s s o c i a t e Editor , W e l d i n g J o u r n a l D e p t . , A W S , 550 N.W. LeJeune Rd., Miami, FL 33126; FAX (305) 443-7404.

S T U D E N T A C T I V I T I E S

• Soon-to-Be-Chartered Student Chapter Holds Technical Meeting

On O c t o b e r 23, 2 0 0 0 , J o h n C a r r i o n of Airgas West v is i ted the VoTech Welding s h o p at S o u t h e r n Nevada Vocat ional Technica l C e n t e r w i t h a cylin- de r o f p r o p y l e n e and all the e q u i p m e n t to d e m o n s t r a t e t he o x y p r o p y l e n e c u t t i n g p r o c e s s . Af ter a b r i e f talk on the s u b j ec t , Ca r r ion se t up the t o r c h and p r o c e e d e d to d e m o n s t r a t e t h e p r o p y l c n c ' s c u t t i n g c a p a b i l i t i e s . Car- r ion t h e n t u r n e d the t o r c h ove r to i n s t r u c t o r Richard Boyer and the stu- d e n t s for hands -on d e m o n s t r a t i o n s . Car r ion left the e q u i p m e n t at the s ch oo l for t h r e e days to e n s u r e all 26 m e m b e r s of t he s o o n - t o - b e - c h a r t e r e d stu- d e n t c h a p t e r had t ime to use the e q u i p n l e n t . •


S T A N D A R D N O T I C E S

AWS was a p p r o v e d as a n accredited standards-preparing o r g a n i z a t i o n b y t h e A m e r i c a n N a t i o n a l S t a n d a r d s I n s t i t u t e (ANSI) in 1979. AWS ru les , as approved by ANSI, r e q u i r e al l standards be open to p u b l i c r e v i e w fo r com- m e n t d u r i n g the a p p r o v a l p rocess . This c o l u m n also advises of ANSI a p p r o v a l of documents. Copies m a y be o b t a i n e d by contacting the AWS Techn ica l Dept. , 550 N.W. LeJeune Rd., Miami, FL 33126, o r by ca l l ing (800) 443-9353, ext . 451.

New Standard Approved by ANSI:

D 17 .1 :2001 , S p e c i f i c a t i o n f o r F u s i o n W e l d i n g f o r A e r o s p a c e A p p l i c a t i o n s . Approva l d a t e : J a n u a r y 19, 2001.

Reaffirmed Standard Approved by ANSI

A5.7-84, S p e c i f i c a t i o n f o r C o p p e r a n d C o p p e r A l loy B a r e We ld ing Rods a n d Electrodes . Approva l date: D e c e m b e r 19, 2000. •

• CAN WE TALK?

The Welding J o u r n a l staff e n c o u r a g e s an e x c h a n g e of ideas w i t h you, ou r readers. If you 'd like to ask a quest ion, share an idea or voice an opinion, you can call, write, e-mail or fax. Staff e-mail addresses are listed below, along wi th a guide to he lp you interact wi th the r ight person.

P u b l i s h e r J e f f W e b e r [email protected] General Management , Reprint Permission, Copyright Issues

Editor A n d r e w C u l l i s o n [email protected] Article Submissions

F e a t u r e s Editor M a r y R u t h J o h n s e n

[email protected] Feature Articles

Associate Editor S u s a n C a m p b e l l campbel [email protected] Society News

Assistant Editor Doreen Yamamoto [email protected] New Products

M a n a g i n g E d i t o r C h r i s t i n e T a r a f a [email protected] Design and Product ion

Product ion Assistant Zaida Chavez [email protected] Design and Produc t ion

Advert is ing Sales Director Rob Saltzstein

[email protected] Advertising Sales

Advert i s ing Product ion Manager Col leen B e e m

[email protected] Advert ising Produc t ion

Advert is ing Coordinator Lea G a r r i g a n

[email protected] Produc t ion and Promot ion

Peer Rev iew Coordinator D o r e e n K u b i s h

[email protected] Peer Review of Research Papers

D e p a r t m e n t Secretary P a o l a C h a c 6 n

[email protected] General Informat ion

W e l d i n g J o u r n a l Dept. 550 N.W. L e J e u n e Rd. M i a m i , FL 3 3 1 2 6 ( 8 0 0 ) 4 4 3 - 9 3 5 3 ex t . 348 FAX ( 3 0 5 ) 4 4 3 - 7 4 0 4

T E C H N I C A L C O M M I T T E E

M E E T I N G S

A l l A W S t e c h n i c a l c o m m i t t e e meet ings are open to the public. Per- sons w i sh ing to a t t e n d a mee t ing shou ld contac t the s taJf secretary o f the commit tee as listed below at AWS, 550 3dgg LeJeune Rd., Miami, FL 33126; telephone (.305) 443-9353.

March 1-2, C3 C o m m i t t e e o n Braz- ing a n d S o l d e r i n g . D a y t o n a , Fla. S t a n d a r d s p r e p a r a t i o n m e e t i n g . Staff con tac t : C. B. Pollock.

M a r c h 11,A5X E x e c u t i v e S u b c o m - m i t t e e (A5), O r l a n d o , Fla. G e n e r a l and s t anda rds p r e p a r a t i o n mee t ing . Staff con t ac t : Rakesh Gupta .

M a r c h 1 2 - 1 3 , A5 C o m m i t t e e o n Fi l ler Meta l s a n d Al l ied Mate r i a l s , Or lando , Fla. Gene ra l and s t anda rds p r e p a r a t i o n mee t ing . Staff c o n t a c t : Rakesh Gupta .

M a r c h 13, G1A S u b c o m m i t t e e o n Hot Gas W e l d i n g a n d E x t r u s i o n We ld ing . H o u s t o n , T e x . S t a n d a r d s p r e p a r a t i o n mee t ing . Staff c o n t a c t : J. L. Gayler.

M a r c h 14 ,A5M S u b c o m m i t t e e o n C a r b o n a n d Low Alloy Steel Elec- t r o d e s for Flux C o r e d Arc Welding , Or lando , Fla. S tandards p r e p a r a t i o n m e e t i n g . S taf f c o n t a c t : R a k e s h Gupta .

March 2 0 - 2 1 , B 4 C o m m i t t e e on Me- c h a n i c a l T e s t i n g of Welds. S tandards p r e p a r a t i o n mee t ing . Staff con t ac t : C. B. Pollock.

M a r c h 2 0 - 2 3 , D1 C o m m i t t e e o n S t ruc tu ra l Weld ing .Tampa, Fla. Stan- d a r d s p r e p a r a t i o n m e e t i n g . S taf f con t ac t : H. H. Campbe l l . •

• AWS F o u n d a t i o n o n t h e Web

For f u r t h e r i n f o r m a t i o n o n t h e AWS F o n n d a t i o n s c h o l a r s h i p a n d s t u d e n t l o a n p r o g r a m s , v is i t t h e AWS F o u n d a t i o n o n t h e W e b at

~, I I l u u u . a u s . o r g / f o u n d a t i o n / .

78 I MARCH 2001

• 2 0 0 0 - 2 0 0 1 Member-Get-A-Member Campaign L i s t e d b e l o w a r e t h e p e o p l e p a r t i c i p a t i n g i n t h e 2 0 0 0 - 2 0 0 1 M e m b e r - G e t - A - M e m b e r C a m p a i g n . F o r c a m p a i g n r u l e s

a n d a p r i z e list, p l e a s e s e e p a g e 6 5 o f t h i s Welding Journal. I f y o u h a v e a n y q u e s t i o n s r e g a r d i n g y o u r m e m b e r p r o p o s e r p o i n t s , p l e a s e c a l l t h e M e m b e r s h i p D e p a r t m e n t a t

( 8 0 0 ) 4 4 3 - 9 3 5 3 ext . 4 8 0 .

W i n n e r ' s C irc l e ( A W S M e m b e r s s p o n s o r i n g 2 0 or m o r e

n e w I n d i v i d u a l M e m b e r s , p e r year ,

s i nce J u n e 1, 1 9 9 9 )

J. Compton, S a n F e r n a n d o Valley*

E. H. Ezell, M o b i l e *

B.A. Mikeska, H o u s t o n *

J. Merzthal, P e r u * W. L. Shreve, F o x Val ley*

R. Wray, N e b r a s k a *

G. Woomer, J o h n s t o w n / A l t o o n a *

* D e n o t e s t h e n u m b e r o f t i m e s a n I n d i v i d u a l M e m b e r h a s a c h i e v e d

W i n n e r ' s C i r c l e s t a t u s . S t a t u s w i l l

b e a w a r d e d a t t h e c l o s e o f e a c h

m e m b e r s h i p c a m p a i g n y e a r .

P r e s i d e n t ' s Gui ld ( A W S M e m b e r s s p o n s o r i n g 2 0 or m o r e

n e w I n d i v i d u a l M e m b e r s b e t w e e n J u n e

1, 2000 , a n d M a y 31, 2 0 0 1 . )

J. Compton, S a n F e r n a n d o Val ley - - 49 G.Taylor, P a s c a g o u l a - - 27 J. Mcrzthal, P e r u - - 21 G. W o o m c r , J o h n s t o w n / A l t o o n a - - 20

P r e s i d e n t ' s R o u n d t a b l e ( A W S M e m b e r s s p o n s o r i n g 1 1 - 1 9 n e w I n d i v i d u a l M e m b e r s b e t w e e n J u n e 1,

2000 , a n d M a y 31, 2 0 0 1 . )

P. Baldwin, P e o r i a - - 15 A.A.AI-Atxltf l l fabbar, S a u d i A r a b i a - - 13

A. O. Smith III, T u l s a - - 13

R. L. Peaslee, D e t r o i t B & S - - l 3 E. H. Eze l l , M o b i l e - - 12 L.J. Smith, H o u s t o n i 12

P r e s i d e n t ' s Club ( A W S m e m b e r s s p o n s o r i n g 6 - t O n e w

I n d i v i d u a l M e m b e r s b e t w e e n J u n e 1,

2000 , a n d M a y 31, 2 0 0 1 . )

W. R. Beck, R o c h e s t e r - - 9

C. Alonzo, Jr., S a n A n t o n i o - - 7

R. Buse, M o b i l e - - 6 C.-L.Tsai, T a i w a n - - 6

P r e s i d e n t ' s H o n o r Ro l l (AWS m e m b e r s s p o n s o r i n g 1 - 5 n e w In-

d i v i d u a l M e m b e r s b e t w e e n J u n e 1,

2 0 0 0 , a n d M a y 3 I, 2 0 0 I. O n l y t h o s e s p o n s o r i n g 2 or m o r e A W S I n d i v i d u a l

M e m b e r s are l is ted.)

J.T. Blank, N o r t h e r n M i c h i g a n - - 5

C. M. Murray, C l e v e l a n d - - 5 G. P. Neal, F o r t S m i t h - - 5

D.J. Nelson, P u g e t S o u n d - - 5 W. L. Shreve, F o x V a l l e y - - 5

H. E. Cable, Sr., P i t t s b u r g h - - 4

J. c . Cooley, B i r m i n g h a m - - 4 W GalveryJr ,/xmg Bch . /Orange Cnt~ - - 4

D. L. Hatfield, T u l s a - - 4

J. D. Sanders, H o u s t o n - - 4 L. Schweinegruber , P i t t s b u r g h - - 4

J. H. Smith,Jr., M o b i l e - - 4 M. R.Tyron, U t a h - - 4

J. N. Carney, W e s t e r n M i c h i g a n - - 3

R. Grays, K e r n - - 3 C. R. Hein, C e n t r a l A r k a n s a s - - 3

S. D. Keskar, I n d i a - - 3

J. Koster, W e s t e r n M i c h i g a n - - 3

B. L Marini, D e t r o i t - - 3

J.A. Rosado, P u g e t S o u n d - - 3 R. D. Rux, W y o m i n g - - 3

M.A. Sandvig, N o r t h w e s t - - 3

B. Saraswat, I n d i a - - 3

M.Tait, L . A . / I n l a n d E m p i r e - - 3 P. G.Walker, O z a r k - - 3

R.Wright, S o u t h e r n C o l o r a d o - - 3

J. E. Campbell , M i l w a u k e e - - 2

L. DeFreitas, S a n t a C l a r a V a l l e y - - 2

D. S. Dodds, P i t t s b u r g h - - 2 T.A. F l y n n , A t l a n t a - - 2 M. Gartm~m, Northeast M iss i s s i p p i - - 2 R. Ghamsari, C a n a d a - - 2

G. L. Hargis, C h a t t a n o o g a - - 2 S. P. Hoff, S a n g a m o n V a l l e y - - 2

J .W Jaeger, S o u t h e r n C o l o r a d o - - 2

R. S.Judy, P o r t l a n d - - 2

J. Knapp, T u l s a - - 2 M.A. Latif, H o u s t o n - - 2

J. R. Leavitt, S o u t h w e s t I d a h o - - 2

J.A. Livesay, N a s h v i l l e - - 2 D. G. Luna, L . A . / I n l a n d E m p i r e - - 2

S. M. McCasland, S y r a c u s e - - 2

H.V. McRae, N e w Y o r k - - 2

M. P. Mott, F l o r i d a W e s t Coast - - 2

A. O. Ochoa, S a n F r a n c i s c o - - 2 C. N. Por to , C l e v e l a n d - - 2

M. 1. Pressel, D a y t o n - - 2

S. M. Qureshi, I n t e r n a t i o n a l - - 2 A. Reyna, N o r t h T e x a s - - 2

K. L. Rigsby, N e w Y o r k - - 2

H.A. Rodriguez, P u e r t o R i c o - - 2 W. Shields, N o r t h e a s t M i s s i s s i p p i - - 2

E Soto, N e w J e r s e y - - 2

J. Stewart, S a n g a m o n V a l l e y - - 2 G. S.Teague, E a s t e r n C a r o l i n a s - - 2

J.Thompson, G r e a t e r H u n t s v i l l e - - 2

R. L.Vann, S o u t h C a r o l i n a - - 2 M. G.Weeks, S a b i n e - - 2

R. B.Wiser, R i c h m o n d - - 2

D.A.Wright, K a n s a s C i t y - - 2 R. Zabel, S o u t h e a s t N e b r a s k a - - 2

S t u d e n t S p o n s o r s ( A W S m e m b e r s s p o n s o r i n g 3 or m o r e

n e w AIVS S t u d e n t M e m b e r s b e t w e e n

J u n e 1, 2 0 0 0 a n d M a y 31, 2 0 0 I . )

M. R. Pointer, S i e r r a N e v a d a - - 49 T. M. B u c h a n a n , M i d - O h i o V a l l e y - - 29 PJ. B e t t s , M o b i l e - - 24 T. C. M u r r o w , A r i z o n a - - 22

J.Jones, N o r t h T e x a s - - 21 D. Serrano, P u e r t o R i c o - - 21

J.J. Daugherty, L o u i s v i l l e - - 20 G . W o o n m r J o h n s t o w n / A l t o o n a - - 20 N. D. Zeiter, N o r t h w e s t O h i o - - 19 M. R. Anderson, I n d i a n a - - 18 R.J. DePue, O l e a n - B r a d f i ~ r d - - 18 K. R. Moore, C o r p u s C h r i s t i - - 18 H.Jackson, L . A . / I n l a n d E m p i r e - - 17 D. C. Marquis, O z a r k - - 17 T Strickland, A r i z o n a - - 16

K.A. Ellis, M a r y l a n d - - 15 T. Geisler, P i t t s b u r g h - - 15 K.A. Dietrich, W h e e l i n g - - 14 D. L. Hatficld, T u l s a - - 14 D.J. Roskiewich, P h i l a d e l p h i a - - 14 S. E Siviski, M a i n e - - 14 R. Zabel, S o u t h e a s t N e b r a s k a - - 14 J. H. Smith,Jr., M o b i l e - - 13 H. R. M a d r o n , M a r v l a n d - - 12 B. McKenna, N o r t h w e s t O h i o - - 11

P. G. Childers, O k l a h o m a C i t y - - 10 A. E. Classens, C h a r l o t t e - - 10 L.J. Heath, M a r y l a n d - - 10 W. H. Kielhorn, E a s t T e x a s - - 9 A. K. Mattox, L e x i n g t o n - - 9 C.Alonzo,Jr. , S a n A n t o n i o - - 8

S. D. Gore, C h a r l o t t e - - 8

H.W. Pelster, S E N e b r a s k a - - 7

M. E.Tait, L . A . / I n l a n d E m p i r e - - 7

J.T. Blank, N o r t h e r n M i c h i g a n - - 6 W. CralveryJr.,Ltn,g Beach~Orange CnOz - - 6

R. Schneider, W y o m i n g - - 6

T. Shirk, T i d e w a t e r - - 6

J.J. Swoyer, L e h i g h V a l l e y - - 6 E G.Walker, O z a r k - - 6

E Baldwin, P e o r i a - - 5

J. N. Carney, W e s t e r n M i c h i g a n i 5

E. L. Harris, P a s c a g o u l a - - 5 C. E Kipp, L e h i g h V a l l e y - - 5

D.J. Nelson, P u g e t S o u n d - - 5 J. Pummer, L o n g B c h . / O r a n g e C n ~ - - 5

R. D. Rux, W y o m i n g - - 5

J. L. Sullivan, H o l s t o n V a l l e y - - 5

R. D.Tupta , J r . ,Mi lwaukee - - 5

S. R. Zwilling, L o u i s v i l l e - - 5

M.J. Bannester, M o b i l e - - 4

J. R. Carter, St., C a r o l i n a - - 4

R. S.Judy, P o r t l a n d - - 4

C.J. Ray, I n d i a n a - - 4 K. L. Rigsby, N e w Y o r k - - 4 K. E. Samuelson, A l b u q u e r q u e - - 4

J. D. Sanders, H o u s t o n - - 4 R. L.Vann, S o u t h C a r o l i n a - - 4

T. R.Alberts, S W V i r g i n i a - - 3 G. Callender, S a n F e r n a n d o Val ley - - 3

R. Grays, K e r n - - 3 N. R. Hel ton, St. L o u i s - - 3

G. L. Kimbrell , St. L o u i s - - 3

S. K. C. Liu, C o l o r a d o - - 3 T. E McClelland, C o l o r a d o - - 3

P O'Leary, E a s t e r n I d a h o / M o n t a n a - - 3

E.J.Warren, C o l o r a d o - - 3 C. B.Wesley, N o r t h w e s t e r n Pa. - - 3 •


G U I D E T O A W S S E R V I C E S 5 5 0 N . W . L c J e u n c R d . , M i a m i , F L 3 3 1 2 6

P h o n e ( 8 0 0 ) 4 4 3 - 9 3 5 3 ; T e l e x 5 1 - 9 2 4 5 ; ( 8 8 8 ) W E L I ) I N G

F A X ( 3 0 5 ) 4 4 3 - 7 5 5 9 ; l n t e r n e t : w w w . a w s . o r g P h o n e e x t e n s i o n s a p p e a r i n p a r e n t h e s e s .

AWS PRESIDENT

L.Will iam Myers 482 Wolf Run Road

Cuba , NY 14727

ADMINISTRATION

Corpont te Director of Administrative Services Jim Lankf(/rd (214)

Corpora te Director of Marketing "l~*chnical Services I)ivision

l)ebndl C W c i r (279)

P r o m o t e s S o c i e t y p r o g r a m s a n d a c t i v i t i e s t o AWS n l c m l ~ c r s , t h e w e l d i n g c o n l n l u - n i t y a n d t h e g e n e n t l p u b l i c .

Executive l ) i rector Frank G. I)eLanrier, CAli (210)

I)eputy Executive l ) i rcctors Richard D. French ( 2 1 8 ) Jel]i'ey R. Hufsev (264)

.lohn J. Mclaughl]n ( 2 3 5 )

Assistant Executive l ) i rector 1)ebhie A. Cadavid ( 2 2 2 )

l ) i rector of Quality Managenlent Systems Linda K.Williams (298)

Corpora te I)irector of Finance/Comll t rol ler Frank R.Tarafa (252)

INFORMATION SERVICES

Corpora te Director Joe Cilli ( 2 5 8 )

HUMAN RESOURCES

l ) i rector l.uisa f te rnandez ( 2 6 6 )

INTERNATIONAL INS'II"I-tJTE OF W E L D I N G

ln lormat ion ( 2 9 4 )

P r o v i d e s l i a i son a c t i v i t i e s i n v o l v i n g o t h e r p r o f e s s i o n a l s o c i e t i e s a n d s t a n d a r d s o r g a - n i z a t i o n s , n a t i o n a l l y a n d i n t e r n a t i o n a l l y .

GOVERNMENT LIAISON SERVICES

I tugh K.Webster XX/~'hster, ( 'hamber la in & Bean

Washington, I).C. (202) 46&2976

FAX (202) 835-O243

Ident i f ies sou rce s of f und ing fl)r w e l d i n g ed- u c a t i o n and r e s e a r c h & d e v e l n p m c n t . Moni- to r s legis la t ive a n d r e g u l a t o r y i ssues impor - tan t to the industry.

W E L D I N G EQUIPMENT MANUFACTURERS COMMITTEE

Associate Executive 1)irector Richard L Alley (217)

INDUSTRY ACTION COMMITTEE

Associate Executive l ) i rcctor Charles R. Fassinger ( 2 9 7 )

COMMUNICATIONS

Corpora te l)irector, Comnmnica t ions Natmette M. Zapata (308)

CONVENTION & EXPOSITIONS Exhihiting Infi)rmatinn ( 2 2 1 , 2 5 6 )

Managing Directnr qbm L. Davis (231)

National Sales Manager G e n t Pesant (458)

O r g a n i z e s t i le w e e k l o n g a n n u a l AWS hl- t e r n a t i o n a l W ' e l d i n g a n d F a b r i c a t i n g Ex- p o s i t i o n a n d C o n v e n t i o n . I l e g n l a t e s s p a c e a s s i g n n l e n t s , r e g i s t r a t i o n m a t e r i - a ls a n d o t h e r F~xpo a c t i v i t i e s .

PUBLICATION SERVICES Division Information (348)

Managing l ) i rector JeffW~:ber (246)

WELDING JOURNAL

Publisher Jeff Weber (246)

Editor Andrew Cullison (249)

National Sales l ) i rector Roh Saltzstein (243)

WELDING HANDBOOK

Welding Handbook Editor Annet te O'Brien (303)

P u b l i s h e s A W S ' s n l o n t h l y m a g a z i n e , t h e Welding Jot trnal , w h i c h p r o v i d e s inlk*r- n l a t i o n o n t h e s t a t e o f tilt" w e l d i n g in- d u s t r y , i ts t e c h n o l o g y a n d S o c i e t y ac t iv i - t i e s . P u b l i s h e s t h e Welding t t a n d b o o k a n d b o o k s o n g e n e r a l w e l d i n g s u b j e c t s .

MEMBER SERVICES

l )epar tment lni%rmation (261)

Managing l) i rector Cassie R. Burrell (253)

I) ircctor Rhcnda A. Mayo ( 2 6 0 )

Serves as a liaison b e t w e e n Sect ion lllenlhcrs and AWS headquar ters . Informs member s ahont AWS benefits and o ther activities of interest.

CERTIFICATION PROGRAMS/ BUSINESS DEVELOPMENT

Director of Int'l I?,usiness l )eve lopmcnt Walter Herrera ( 4 7 5 )

For c u s t o m i z e d ce r t i f i ca t ion and educa t iona l p rngmms to industr T and government .

EDUCATION

I) irectnr James R Cunn ingham (219)

Inff ) rmat ion o n e d u c a t i o n p r o d u c t s , p ro j ec t s a n d p r o g r a m s . CWI, SCWI a n d o t h e r semi- na r s d e s i g n e d 121r ass i s tance in Cer t i f ica t ion . R e s p o n s i b l e for t he S.E.N.S.E. b e g i n n i n g w e l d e r p r o g r a m a n d d i s s e m i n a t i o n o f educa t ion inf i ) rmat ion on the Web.

CONFERENCES

Director Gisdle I. Rodriguez ( 2 7 8 )

R e s p o n s i h l e for n a t i o n a l a n d loca l c o n f e r - e n c e s / e x h i h i t i o n s a n d s e m i n a r s on i n d u s t r y t o p i c s r a n g i n g f r o m the b a s i c s to t he leading edge of techm)logy.

CERTIFICATION OPERATIONS I n f o r m a t i o n a n d a p p l i c a t i o n m a t e r i a l s o n c e r t i f y i n g w e l d e r s , w e l d i n g i n s p e c t o r s a n d educa to r s . ( 2 7 3 )

Managing Director Wendy S. Reeve ( 2 1 5 )

Awards & Fe l l ows

Managing I) ircctnr Wendy S. Reeve ( 2 1 5 )

(k×)rdinatt,'s awm~s and AWS FeUow nunlincL%.

TELEWELD

FAX: (3o5) 443-5951

For i n f o r m a t i o n a h n u t AWS t e c h n i c a l publ i - c a t i o n s , c o n t a c t tile T e c h n i c a l Se rv i ce s per - sonne l listed below.

TECHNICAL SERVICES

l)et~artment h l lbrmat inn (340)

Managing l ) i rector Leonard P C(mnor (299)

(.)ualification, hlspect ion, Food Processing Equipment

Andrew R. I)avis ( 4 6 6 ) International Standards Prngram Manager, Welding in Marine

(~onstruction

Stephen P Hedrick (305) Safety and Health Manager, SyruP)Is and l)efinitiorts

Engineers

Hardy H. C a m p h d l Ill ( 3 0 0 ) Structural

Rakesh Gupta ( 3 0 1 ) Filler Metals

Christopher B. l~fllock (304) BrazJng,~)ldefing, "R~ting, Railrt rids, ( k )lllputeri/ation,

lnstnlmentatk)n

Tim Potter (309) Robotics,Joining of Metals and All( )ys, Piping and Tubing,

Friction W~:ldirlg

John L. Gayler (472) Metric Practices, Sheet Metal, Plastics and Conlpositcs, Personnel

Qualification

Ed E Mitchell (254) Thermal Spray, High-Energy Beafll Welding arid Cutting, Resistance Weld-

ing,Automotive,Aerospace

80 I MARCH 2001

PUBLICATION SALES

Call Global Engineering Documents

(800) 854-7179

Publ icat ion orders .

Senior Publications Coordinator

Rosalinda O'Neill (451)

AWS publishes more than 160 volumes of material, including standards that are used throughout the industr~

With regard to technical inquiries, oral opinions on AWS standards may be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them.These individuals do not speak on behaff of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations ofAWS. In addition, oral opinions are informal and should not be used as a substitute lot an official interpretation.

It is the in ten t o f the A m e r i c a n Weld- ing .S'ocietl, to bu i ld the Society to the highest qua l i t y s tandards possible. W~" welcome any suggestions y o n *nay have.

Please contact a n y o['the s ta f f listed on the p r e v i o u s p a g e or A WS Pres ident L. Wil l iam ,~Fers, 482 Wolf R u n Road, Cuba, N Y 14727.

AWS FOUNDATION, INC.

550 N.W. LeJeunc Rd. Miami, FL 33126 (305) 445-6628

(800) 443-9353, ext. 293 Or c-mail: b o b w @ a w s . o r g

Cha i rman , Board o f Trus tees Ronald C. Pierce

Execut ive l ) i rec tor Fnmk G. DcLattrier, CAE

Direc tor of D e v e l o p m e n t Rober t B.Witherell

T h e A W S F o u n d a t i o n is a no t - f o r - p r o f i t c o r p o r a t i o n e s t a b - l i s h e d t o p r o v i d e s u p p o r t t b r e d u c a t i o n a l a n d s c i e n t i f i c e n d e a v o r s o f t h e A m e r i c a n W e l d i n g Society . I n f o r m a t i o n o n g i f t - g i v i n g p r o g r a m s is ava i lab le u p o n r e q u e s t .

• N o m i n e e s for Na t iona l Off ice Only Susta ining Members , Members , Honor a r y Members , Life M e m b e r s or Re-

tired Members w h o have been m e m b e r s for a per iod of at least three years shall be eligible for election as a Director or National Officer.

It is the duty of the National Nominating Committee to nominate candidates for national office.The committee shall hold an open meeting, preferably at the Annual Meet- ing, at wh ich m e m b e r s may appear to present and discuss the eligibility of all candidates.

To be considered a candidate for positions of President,Vice President,Treasurer or Director-at-Large, the following qualifications and conditions apply:

President:To be eligible to hold the office of President, an individual mus t have served as a Vice President |o r at least one year.

Vice President :To be eligible to hold the office of Vice President , an individual mus t have served at least one year as a Director, o the r than Executive Director and Secretary.

Treasurer :To be eligible to hold the office of Treasurer, an individual mus t be a m e m b e r of the Society, o the r than a Student Member, mus t bc f requent ly available to the Nat ional Office and shou ld be of execu t ive s ta tus in b u s i n e s s o r i ndus t ry wi th exper ience in financial affairs.

Director-at-Large: ' lo be eligible for e lect ion as a Director-at-Large, an individual shall p rev ious ly have he ld office as Cha i r ma n of a Section; as C h a i r m a n o r Vice Chai rman of a standing, technical or special commi t t ee of the Society; or as District Director.

I n t e r e s t ed par t ies are to s end a le t ter s ta t ing w h i c h pa r t i cu la r office t hey are seeking, including a s ta tement of qualifications, their wil l ingness and ability to serve if" nomina ted and elected and 20 copies of their biographical sketch.

This material should be sent to Rober t J.Teuscher, Chairman, National Nominat- ing Commit tee ,Amer ican Welding Society, 550 N.X~ LeJeune Rd., Miami, FL 33126.

The nex t m e e t i n g of the Nat ional N o m i n a t i n g C o m m i t t e e is c t t r rcnt ly sched- tiled Ior May 6, 2001, in ( ' leveland, Oh io . The t e rms of office for candida tes nominated at this meet ing will c o m m e n c e June 1,2002. •

• H o n o r a r y - M e r i t o r i o u s A w a r d s The Honorary-MeritoriousAwards Committee has the dnty to make reo)mmendations

regarding nominees presented for Honorary Membership, National Meritorious Certificate, William lrrgang Memorial and the George E.Willis Awards.These awards are presented in conjunction with the AWS Exposition and Convention held each spring.The descriptions of these awards follow, and the submission deadline for consideration is July 1 prior to the year of presentation. All candidate material should be sent to the attention of John J. Mcl.aughlin, Secretary, Honorary-Meritorious Awards Committee, 550 N.W LeJeune Road, Miami, FL 33126.

National Meritorious Certiticate Award: This award is given in recogni t ion of the candidate 's cotmsel, loyalty and devotion to the affairs of the Society, assistance in promot ing cordial relations with industry and o ther organizations, and for the con- t r ibut ion of t ime and effort on behalf of the Society.

Wi l l i am I r r g a n g Memoria l Award: This award is administered by the American Weld- ing Society and sponsored by The Lincoln Electric Company to honor the late William Irrgang. It is awarded each year to the individual w h o has done the most to enhance the American Welding Society's goal of ad- vancing the science and technology of welding over the past five-year period.

G e o r g e E. Wi l l i s Award: This award is administered by the American Welding So- ciety and sponsored by The Lincoln Elec- tric Company to honor George E.Willis. It is awarded each year to an individual for p r o m o t i n g the advancemen t of weld ing internat ional ly by fos ter ing coopera t ive participation in areas such as technology transfer, standards rationalization and pro- motion of industrial goodwill.

I n t e r n a t i o n a l M e r i t o r i o u s Cer t i f i - c a t e A w a r d : This a w a r d is g iven in r e c o g n i t i o n of the c a n d i d a t e ' s signifi- can t c o n t r i b u t i o n s to the w o r l d w i d e we ld ing indus t ry .This award shou ld re- f lect "Service to the In te rna t iona l Weld- ing Commtmi ty" in the b roades t t e rms . Thc a w a r d c e is no t r e q u i r e d to be a m e m b e r of the A m e r i c a n Weld ing So- ciety. Multiple awards can be given per year as the s i t u a t i o n d i c t a t e s . The a w a r d c o n s i s t s of a c e r t i f i c a t e to be p r e s e n t e d at the a w a r d ' s h m c h e o n or at a n o t h e r t ime as a p p r o p r i a t e in con- j u n c t i o n w i t h the AWS P r e s i d e n t ' s t ravel i t inerary , and, if a p p r o p r i a t e , a one-year m e m b e r s h i p to AWS.

H o n o r a r y M e m b e r s h i p A w a r d : An H o n o r a r y Member shall be a p e r s o n of a c k n o w l e d g e d e m i n e n c e in the welding p r o f e s s i o n , o r w h o is a c c r e d i t e d w i t h e x c e p t i o n a l a c c o m p l i s h m e n t s in the d e v e l o p m e n t of the w e l d i n g art , u p o n w h o m the Amer ican Welding So- ciety sees fit to c on f e r an h o n o r a r y dis- t i n c t i o n . An H o n o r a r y M e m b e r shal l have full r ights of m e m b e r s h i p . •


Q&A B Y D A M I A N J. KOTECKI

Q. I have always understood 309L is the best filler metal for crack-free joining of

304 stainless to mild steel, and I have used it successfully many times for this application. Recently, I changed jobs from a commercial fabricator to a shipyard. To my surprise, my very first joint of 304L stainless to mild steel, with 309L-covered electrodes, cracked along the centerline. I ground out the cracked weld and repeated the joint with the

Circle No. 10 on Reader In fo -Card

same results. Another welder, with long experience in the yard, suggested I turn back the heat on my machine and try again. I did, and this time the weld didn't crack but welding was much slower and the weld looked cold. I never had to change to this cold procedure before with 309L electrodes. What is different now?

A : I expect the shipyard's 309L elec- t rodes are produced to the MIL-E- 22200/2 specification. These electrodes are not the same as commercial 309L electrodes. While both commercial and MIL 309L electrodes are designed to meet AWS A5.4 composition limits, the design aims within these composit ion limits are different. The AWS A5.4 specification limits for the 309L weld metal are given in Table 1.

In producing heats of steel to be used as core wires for covered 309L stainless steel electrodes, the steel mill rod supplier is driven by considerations affect- ing the ease of reducing the as-cast steel to rod diameter. In particular, the steel mill is well aware zero-ferrite and high- ferri te composit ions are more difficult to convert to rod than low-ferrite compositions. This consideration generally drives the steel mill rod supplier to melt to an aim composition that is in the upper half of the 309L nickel range (13 to 14%), and in the lower half of the 309L chromium range (22 to 23.5%).

Nickel, the principal e lement working to reduce ferrite, is not a readily oxidized element, so nickel of the core wire is transferred almost 100% to the weld metal. On the other hand, some chromium, the principal element working to increase ferrite in the weld deposit, tends to be oxidized and transferred to the slag covering, depending, to a certain extent, upon the silica content of the coating design. So the electrode manufacturer 's latitude to design ferrite content of the weld deposit is mainly limited to adjustment of metallic chromium content of the e lectrode coating. By only putting in enough metallic chromium to make up for oxidation losses, the elec-

- - continued on page 90

D A M I A N J. K O T E C K I is Technical Director for Stainless and High-Alloy Product Development for The Lincoln Electric Co., Cleveland, Ohio. He is a member of the A WS A5D Subcommittee on Stainless Steel Filler Metals; A WS D1 Structural Welding Commit tee , S u b c o m m i t t e e on Stainless Steel Welding; and a member and past chair o f the Welding Research Counci l S u b c o m m i t t e e on Welding Stainless Steels and Nickel Base Alloys. Questions may be sent to Mr. Kotecki c/o Welding Journal, 550 N W LeJeune Rd., Miami, FL 33126.

82 I MARCH 2001

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See Us at AWS Welding Show Booth No. 5024


AWS S h o w P r o d u c t s / N e w Products Stop By Our Website www.abpaper.com

AB Paper Company was established in 1983 for the purpose of prefabricating water-soluble materials for the pipe welding industry. Our Shur-Purge TM and Shur-Gap® products are used worldwide to expedite welding set-up and completion. They save valuable time and give positive, proven results time and time again.

AB Paper Company P.O. Box 622

Multi-Function Welding Power Supply Arc Machines, Inc., will perform live welding demonstrations with their orbital, GTAW narrow-gap welding system with vision. Live demonstrations will also be performed with the Windows-based Model 415 Multi-Function Welding Power Supply that is finding new applications in factory automation. AMI will also be demonstrat- ing the Model 227 portable pipe welder power supply and the Model 79 Series of clamp-on weld orbital weld heads with arc length control and oscillation for pipe sizes from 1/2" to 6" IPS pipe. Arc Machines Inc. 10500 Orbital Way

Centralia, WA 98531 (800) 408-0739 FAX: (360) 740-0738

Abicor Binzel Alpha Series

Gas cooled GMAW torches from The World Leader! Features include remov- able swannecks with neckliners for fast replacement and gun liner cost savings. Positionable 60, 45, or 22 degree necks for improved job access. Universal rear connector allowing direct mount to most feeders. Plus, world class customer service and technical support.

ABICOR Binzel Corporation 650 Research Drive, Ste. 110 Frederick, MD 21703-8619 (800) 542-4867 FAX: (301) 846-4497

Dust Control Booth TM

Removes Grinding Dust and Welding Smoke

Airflow Systems, Inc.®, introduces a new product line of enclosed side draft booths that collect dust, smoke and fumes from industrial operations using high-tech cartridge filtration and unique Vibra-Pulse® automatic filter cleaning.

Airflow Systems, Inc. 11370 Pagemill Road


Pacoima, CA 91331 (818) 896-9556 FAX: (818) 890-3724


Atlas Model 500 Welding Positioner Can Increase Production and Cut Costs

• Designed to Handle 500 Ibs. • 1/4-HP DC Motor • 400-Amp Grounding Circuit • On/Off Foot Switch • Front Panel Speed and

Rotation Controls • Full Speed Jog for Stitch

Welding • Dynamic Braking

Atlas Welding Accessories RO. Box 969 Troy, MI 48099 248-588-4666 FAX: 248-588-3720

New MIG Welding Super Q Gun from Bernard Delivers Superior Performance and Reliabi l i ty

The new Super Q1 welding gun from Bernard brings superior performance and exceptional reliability/ to lower amperage MIG applications m a welder-friendly, ergonomically sound design. Rated at 180 amps with 100% CO 2 shielding gas at 100% duty cycle, the Super Q1 is the first of a series of Super Q MIG guns that

Bernard will release to complement its industry-leading, higher amperage Q-Gun line. Call for more information.

Dallas, TX 75243-8306 (214) 503-8008 FAX: (214) 503-9596 E-mail: [email protected] Website: www.airflowsystems.com

Welding Positioners

AII-Fab Corporation manufactures welding positioners from 200-lb. to 1250-1b. capacity. Standard features include infi- nitely variable speed table rotation, on/off foot control, 135-degree table tilt and 120-volt input power. For a complete catalog and price sheet contact AII-Fab.

AII-Fab Corp. 1235 Lincoln Road Allegan, MI 49010 (616) 673-6572 FAX: (616) 673-1644 E-maih [email protected]


SPECIALTY CORED WIRES COATED ELECtrODES

$OUD WIRE MIG AND TIG


Bernard A Div. of DovaTech, Ltd. 449 W. Corning Road Beecher, IL 60401 (708) 946-2281 FAX: (708) 946-6726

New Out-Of-Position Nickel-Base Cored Wires

Cormet, Inc., is pleased to announce that our new Out-Of-Position Nickel- Base Cored Wires will be shown at our booth at the AWS Welding Show in May. In addition to the new wires, some new hard-facing electrodes will be shown. Please be sure to see what's really new in nickel cored wires.

Cor-Met Inc. 12500 E. Grand River Brighton, MI 48116 (800) 848-2719 FAX: (810) 227-9266 Website: www.cor-met.com E-Mail: [email protected] 83

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S h o w P r o d u c t s / N e w Products IntelliFlow II Water Saver

The IntelliFIow II water saver from EOA Systems, an operating unit of DE-STA-CO Industries, can increase welding efficiency while decreasing costs and maintenance downtime. The IntelliFIow II can monitor and detect leaks as small as +3% of the monitored flow rate as well as distinguish leaks from water fluctuations due to normal dynamic motion.

DE-STA-CO Industries 2121 Cole Street Birmingham, MI 48009 (248) 594-5600 Website: www.destaco.com


Tri-Mix TM Tungsten Diamond Ground Products, Inc., offers Tri-Mix TM tungsten. This premium quality tungsten material is non-radioactive and offers superior performance in TIG and plasma welding applications. It is blended with three rare earth elements that scientifically balance the migration and evaporation rates to extend service life with increased number of arc starts and fewer misfires. Its lower work function requires less energy to start and also runs cooler. Free samples available on request. Diamond Ground Products, Inc. 2550 Azurite Circle Newbury Park, CA 91320 (805) 498-3837 FAX: (805) 498-9347 [email protected]

New CNC Controls on Plate Rolls & Angle Rolls Eagle Bending offers Siemens OP-7, 0P-17, & 0P-27 CNC controls on 4 Roll Plate Rolls and all Double Pinch Angle Rolls, easily automating production cycles. Advantages: rapid/easy programming, 12- axis capability for loader/ejec-

tor integration and graphic interface display during operation. Eagle & Siemens products are supported globally via a network of factory trained technicians and engineers.

Eagle Bending Machines Inc. P.O. Box 99 Stapleton, AL 36578

See Us at AWS Welding Show (334) 937-0947 Booth No. 3863 FAX: (334) 937-4742

Solutions to Mabarlall Joining Challll11pll

See Us at AWS Welding 8 4 Show Booth No. 5040

Materials Joining Solutions This full color brochure tells how, as an EWl member, you have access to the largest materials joining information and technology transfer network in North America. EWl services include consultation, design review, material and process implementation, automation, trouble shooting, testing, and education and training. EWl membership can help your business improve productivity, quality, and customer satisfaction while reducing

SCR Power Control Product Guide

SCR Firing boards, regulators and assemblies guide illustrates the many possibilities available for the control of power where voltage and current regulation is a must.

Enerpro 5780 Thornwood Drive Goleta, CA 93117 (800) 576-2114 FAX: (800) 486-0798 E-mail: info@enerpro-incocom Website: www.enerpro-inc.com

Multimaster 260 Offers Superior Weld Performance In a Multiprocess Machine Multimaster 260 offers superior welding performance for MIG, DC TIG and stick electrode welding, combined with exceptional simplicity of set-up and operation. Proprietary Super Switch TM technology features a high-speed solid-state power control that produces arc performance comparable to that obtained by more complex and expensive power sources, with high efficiency and low current draw for economical operation.

ESAB Welding & Cutting Products 411 S. Ebenezer Road Florence, SC 29501-0545 (800) ESAB-123 Website: www.esab.com

T ~

popular bend testers and the new Model IT2 Tensile Tester will be demonstrated at the AWS Welding Show. costs and improving profits.

Edison Welding Institute (EWI) 1250 Arthur E. Adams Dr. Columbus, Ohio 43221 (614) 688-5000 FAX: (614) 688-5001 Website: www.ewi.org


Fischer Engineering Co. 8220 Expansion Way Dayton, OH 45424 (937) 754-1750 FAX: (937) 754-1754 Website: www.fischerengr.com

Tensile Testers Fischer Bend and Tensile Testers can be used to test all welded materials and product forms covered by ASME, AWS, API and Military codes and standards. The Model BTIB, other

See Us at AWS Welding Show Booth No.

3400 & 3600

dards, and convert the L-value to HRC, HRB, HB, HV, HS, and tensile strength from our booth at the May 2001 AWS Welding Show.

Equotip Associates P.O. Box 548 Harvey, LA 70059 (800) 394-5815

See Us at AWS Welding FAX: (504) 393-9737 Show Booth No. 5424 Website: wwwequotipassoc.com

NEW Versions of the EQUOTIP and EQUOSTAT at the AWS Welding Show

The EQUOTIP Associates will be displaying NEW versions of the EQUOTIP and EQUO- STAT metal hardness testing instruments that meet the ISO 9001 and ASTM A956 stan-

RB HOT t AWS S h o w P r o d u c t s / N e w Products Thread Sealants for Specific Welding Needs FORMULA-8 and LOX-8 oxygen-safe Thread Sealants have passed the NASA White Sands Testing with spectacu- lar results[ Use LOX-8 in wet applications(even

New Paint Marker Designed to Disappear In Pre-Galvanizing Pickling Bath The Galvanizer's Feltip Paint Marker contains a paint specially formulated by J.P. Nissen Co. for fabricators who have their material galvanized. The valve-action marker writes easily on rough or smooth steel, even if the surfaces are wet or oily. The marks won't chip, peel, fade or rub off. They will withstand heat and weathering. underwater, in super-

hydrophobic situations); with harsh chemicals, chlorine and strong alkali, etc. Use FORMULA-8 in dry applications; it is AGA certified (now "SA") and requires no cure time (important in hard-to-reach places).

Fluoramics Inc. 18 Industrial Ave. Mahwah, NJ 07430 (201) 825-2110 FAX: (201) 825-7035

The New H&M Master Chain Clamp

The new Master Chain Clamp is a versatile clamping system designed to increase productivity. One person can easily and safely perform perfect fit-ups of flanges, tees and elbows in just minutes. The new clamp works 4"- to16"-diameter pipe. Chain links and jackbars may be added to accommodate larger pipe sizes.

H&M Pipe Beveling Machine Co. 311 East Third Street Tulsa, OK 74120-2417 (918) 582-9984 FAX: (918) 582-9989



However, they will be completely removed by the pickling bath prior to galvanizing. The marks will not interfere with the plating process or mar the finished plated surface. J.P. Nissen Co. P.O. Box 339 Glenside, PA 19038 (215) 886-2025 FAX: (215) 886-0707

Jetline ALC-401-6 Arc Length Control

Jetline Engineering, an ITW company, announces the first microprocessor based arc length control for GTAW AC or DC, and Plasma welding. The ALC- 401-6 is simple to operate and install. The ball screw slide actuator gives accurate control and a weight capacity of 40 pounds to handle torch, wire feed head, magnetic arc probe, and vision cameras. Jetline Engineering Inc. 15 Goodyear Street Irvine, CA 92618 (949) 951-1515 FAX: (949) 951-9237 Website: www.jetline.com

Weld_IT@ Networks

Find the solution to all your welding challenges, with the most comprehensive welding resource software featuring: a 800-page welding encyclopedia, 11 welding-related calculators, WPS & WPQR tem- plates for the structural and pressure vessel codes, a customizable testing module, and more. Perfect for welding instructors and professionals, Weld_IT has all the answers! ORDER TODA~ 800 332-9448, ext. 5433.

Hobart Institute of Welding Tech. 400 Trade Square East

See Us at AWS Welding Troy, OH 45373 Show Booth No. (800) 332-9448, ext. 5433

3429 & 2967 Website: www.welding.org See Us at AWS Welding Show Booth No. 4021

LA-CO/MARKAL Metal Markers

Silver-Streak® and Red-Rite TM metal markers for use in place of soapstone make flame-resistant, rub-proof marks on oily, wet, or rusty steel and other metals. Marks are clearly visible through welders' filter plates. They will not scratch or abrade marked surfaces. Available in round and flat styles, with pocket clip and holder.

LA-CO Industries, Inc./Markal Co. 1201 Pratt Boulevard Elk Grove Village, IL 60007 (847) 956-3867 Website: www.laco.com


TIG Grinder at Lower Price

Intercon will be displaying its popular tungsten electrode grinder with its new lower price. Get accurate, centric and longitudinal tungsten grinds with the best grinder on the market for a lot less. For the AWS show, we will also include 3 free collets. Visit out booth for details and a demonstration.

Intercon Enterprises, Inc. 1125 Fir Ave. Blaine, WA 98230 (800) 665-6655 (604) 946-6066 FAX: (604) 946-5340 Website: www.intercononline.com E-Maih [email protected]

See Us at AWS Welding Show Booth No.

3434 & 3634

New Lincoln "Ready-To-Weld" Packages Provide All Needed Equipment In One Unit

The Lincoln Electric Company is offering some of its most popular welding power sources, wire feeder and gun in "Ready-To-Weld" packages. With these packages, consumers or distributors order one product number and receive all the necessary hardware to get up and running. These packages are available with: Inverteco ® V350-PRO, CV- 300, and Square Wave TIG 275.

Lincoln Electric Co. 22801 St. Clair Ave. Cleveland, OH 44117 (888) 355-3213 Website: www.lincolnelectric.com 85

86

Rfn HOTt,,

i TM :


IS S h o w P r o d u c t s / N e w Products New Model of Orbital Weld Head Welds Pipe "In Place" Magnatech introduces the E-Head for automation of thin wall pipe and tube welding in the fabrication shop or in the field. The compact weld Head utilizes the GTAW process and is designed for making circumferential butt welds where the pipe cannot be rotated. The E-Head can be used on pipe 25mm to 356mm (1" to 14"). Only 2.5" (64mm) of radial clearance between pipes is required, allowing use for applications difficult to weld manually because of access. Magnatech Limited Partnership Bradley Park, P.O. Box 260 East Granby, CT 06026 (860) 653-2573 FAX: (860) 653-0486


MagnaCut The MagnaCut uses powerful and permanent magnets to hold the machine in perfect alignment as it moves around pipe from 6 5/8" and larger O.D. or 24" and larger I.D. The MagnaCut can be used to cut plate or split beams. It travels at speeds of up to 32" per minute. A switch on the motor control box controls the forward and reverse action of the MagnaCut. A motor-driven torch arm enables a horizontal adjustment of the cutting torch. The MagnaCut requires only seconds of setup for a fast and accurate cut. A free instructional video is available. Mathey Dearman 4344 South Maybelle Tulsa, OK 74107 (800) 725-7311


Miller Electric Enters The TIG Torch Market

Designed for optimum performance and hand comfort, Miller Electric has introduced its Diamond Back TM TIG torch series. The head of the Diamond Back torch features scal- loped indentations on the right, left and top sides for finger-grip placement. For precision operators who hold the torch like a pencil, this shape increases control over torch move- ments while reducing hand fatigue.

Miller Electric Mfg. Co. 1635 West Spencer St. Appleton, Wl 54914 (800) 426-4553 FAX: (877) 327-8123


N-S SATIN GLIDE@

The industry's best-performing stainless steel welding wire now performs even better. A new, state- of-the-art cleaning process makes N-S Satin Glide's unique surface treatment more consistent. You get superior feedability and arc stability in robotic and semi-automatic welding with this newgeneration of stainless welding wire.

National-Standard 1618 Terminal Road Niles, Michigan 49120 (800) 777-1618 www.nationalstandard.com



Nederman Introduces Wallcart The Nederman Wallcart is a very simple and economical way to extract harmful smoke and fumes in your welding shop. The Wallcart, has flexible connections for extraction hoods and ventilation ducts. Filter change is made easy - - no tools required. Choose between a Basic or Gas/Micro Filter and size a Nederman fan to suit your application. The Wallcart comes ready to install and weighs approximately 671bs. For more information about the products Nederman will have on display, call Technical Services at 1-800-575-0609.

Nederman, Inc. 39115 Warren Road Westland, MI 48185 Website: nedermanusa.com

New Catalog Covers Hand Tools For Pipe Welding Tasks A new custom catalog from PFERD Inc. and their subsidiary, the PFERD Milwaukee Brush Co., presents a full- line of quality abrasive and wire brush hand tools specifically for pipeline weld preparation, cleaning and finishing tasks. Over 130 products are covered in this 12-page buyer's guide. Complete size and specification information are shown in easy-to-read tables along with pictures of the products and the recommended types of power tools that are applicable.

PFERD Inc. 30 Jytek Drive Leominster, MA 01453 (800) 342-9015

Metal-Cored Electrode for Harsh Conditions

Select-Arc offers a carbon steel, composite metal-cored electrode that features higher manganese and silicon contents to provide more deoxidation and a flatter bead geometry. The extra deoxi- dizers make Select 70C-6 the ideal choice to handle heavier sheet metal fabrication applications.

Select-Arc Inc. P.O. Box 259 Fort Loramie, OH 45845-0259 (800} 341-5215 FAX: (937) 295-5217 Website: www.select-arc.com

Vibratory Stress Relief

"FORMULA 62" portable stress relief unit puts an end to the high cost of thermal stress relief. Work is performed in- house, no transportation or clean-up required. Procedures are quick and easy to follow. Use on weldments or machined parts from one pound to tons in the shop or field.

Stress Relief Engineering Company

1725 Monrovia Ave., A-1 Costa Mesa, CA 92627 (949) 642-7820 FAX: (949) 642-0430

RED HOT AWS Show


Products /New Products Manual Welding Accessories Save 30% tO 50% on electrode holders, cable connec- tors, copper and steel ground clamps, chipping i hammers, tank wrenches, i hammer and solder on lugs ! & splicers. No one has lower prices. Visit our booth at the AWS Welding Show.

T.J. Clark 3962 Portland St. Coplay, PA 18037 (610) 261-1900 FAX: (610) 261-0744

SNAKE HUGGER Snake Hugger Inert Cover Gas System acts like a miniature air hockey table for flowing argon/inert gas mixtures uniformly behind your weld pool. The gas nozzle is designed to minimize part oxidation and discoloration and to reduce cover gas consumption. Complete kits runs $349.95. To order, call toll-free (877) 935-3447 or visit our website.

Weld Hugger LLC. 7201 West Oakland St. Chandler, AZ 85226-2434 (877) 935-3447 FAX: (480) 940-9366 Website: www.weldhugger.com.

Tempil ° Introduces Its Newest Welding Accessory Product Line Tempil °, will display its temperature indicating products and acces-

ories. The Company will demonstrate Tempirs complete line of welding related products. Featured will be the standard of industry, Tempilstik °, the world's most trusted temperature indicator for over 60 years. Tempilstik ° temperature indicators last 50% longer than other brands. Tempilstik ° temperature indicators accurately indicate preheat interpass and postweld heat treatment temperatures and are systematically spaced from IO0°F up to 2,500°F. They meet AWS, ASME and ANSI codes and are lot numbered for NIST traceability.

Tempil 2901 Hamilton Blvd.

See Us at AWS Welding S. Plainfield, NJ 07080 Show Booth No. 3729 (800) 757-8301

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The Ideal Portable Gas Analyzer

The Model 6900 gas analyzer can measure nine different binary gas mixtures, including C02/AR, 02/Ar, He/Ar, and C02/N 2. The user does not need calibration gases to make an analysis. This portable unit is ideal for checking gas mixtures in the field or in the cylinder filling environment. This analyzer will be demonstrated at the show.

Thermco Instrument Corporation 1201 West US Hwy. 20 LaPorte, IN 46350 (219) 362-6258 FAX: (219) 324-3568

Did You Know You Can Now Bevel Pipe With Your Model 700 Power Drive? Tri Tool's rugged new 4X4 TM Pipe Beveler is perfect for the welder who needs a dependable and economical weld preparation solution for 2" to 8" pipe. The new ID mount beveler features a patent pend- ing bit with four cutting edges for 4X the bit life and 4X the economy. Best of all, the 4X4 TM Beveler works with your existing power drive to generate rapid and reliable 37.5 ° bevels, ensuring faster fit-ups and superior welds while saving you time and money! Visit our website at: www.tritool.com/4X4/or call for a free brochure. Tri Tool Inc. 3806 Security Park Dr. Rancho Cordova, CA 95742 (916) 351-0144

I I B ~ The Most Accurate Low Welding System Current

• on the Market The precision weld fabrication of deli- cate heat-sensitive assemblies is now a practical reality. Finally there is an

.... , alternative to complicated and costly beam welding systems. Very low- heat, high-speed welds can now be

made in materials as thin as .001" and as thick as .125" with the Weldlogic PA-10/100-STD. Thousands of these productive systems are in daily use throughout the world. Contract welding services also available.

Weldlogic Inc. 2550 Azurite Circle Newbury Park, CA 91320

See Us at AWS Welding (805) 498-4004 FAX: (805) 498-1761 Show Booth No. 0000 E-Maih [email protected]

SMART ~ ~dO,4,160Eh.5.1SOW, 200, 2(~. 2gOL"IH. 200PC 225, 225X, 300 HP Technical Data

Portable Weld Inspection This brochure describes YXLON International's SMART Portable Constant Potential X-ray Units. These low weight, compact units are ideal for field inspection. High frequency switching technology provides extremely stable X-ray output for short exposure times. The control unit recognizes individual tube- heads and automatically selects the required running-in programs. Call us for more information.

YXLON International Inc. 3400 Gilchrist Road Akron, OH 44260-1221 (330) 798-4800 FAX: (330) 784-9854 E-Mail: [email protected]

B ";?Y~ 0 ;g G ~AC" POSI-TURNER® Load Rotation System A true problem solver for any application that requires both lifting and rotating of the load. This innovative below- the-hook rotation system with heavy- duty slings and optional powered load leveler allows one operator to easily rotate and position the product. Industries currently utilizing the POSI- TURNER® are aircraft, metal fabrications, equipment maintenance, contain- er handling, marine, dies and molds, and many more. The Caldwell Group, Inc. 5055 25th Avenue Rockford, IL 61109 Toll Free (877} 852-7833 FAX: (815} 229-5686

See Us at AWS Welding See Us at AWS Welding Show Booth No. 5229 Show Booth No. 4129 87

Literature For more information, circle number on Reader Information Card.

C o r r o s i o n C o u r s e O f f e r e d on C D - R O M

Basic Corrosion Course is a self-study CD-ROM version of the course developed in cooperation with Katholieke University in Leuven, Belgium. The course contains all the technical information presented in the classroom course, allowing those who are unable to attend

2 (

Quality. Precision. Tradition. What's Old Is New Again. H&M's history of setting industry standards for pipe- end preparation grows on with Christopher Bones, the fourth-generation heir to H&M! Christopher is already drawing on a wealth of expertise from H&M's

~_~lllm~ family of employees, whose combined experience exceeds 225 years! Look forward to H&M's 66-year tradition of innovation, precision and quality to continue well into the next centu~...because with Christopher,

~,~ ~,~ history is already repeating itself

Pipe Beveling Machine Company, Inc. ~' / ~ 011 East Third Street / Tiisa, Oklahoma 74120-2417

~, i R I f . ~ . , ~ l i ~ ~ (018) 582-0084 / Fax (918) 582-0989 '. ~ , ~ ~ Web: Mtp:llwww.Mp~e.cem I E-mail: [email protected]|

~ - , ~ ~ 24-heur Fax-gn-gmaand (918) 582-0210 (Call from any fax machine er ~nee for fax-back laferimdlne.)


BT1C

DO YOUR OWN TESTING

Bend Testers - Test Materials -Tensile Testers

• Train welders • Qualify welders • Qualify procedures

• • Meet ASME, AWS, API, |1 psite for sizes MIL codes s available. TT2 TIT]

i i l EngiNeering Company I'q L

www.fischerengr.com • (937)754-1750 ~ , i ~ - i - ~

88 I MARCH 2001


in person the opportunity to receive comprehensive NACE training on corrosion basics. The self-study course was designed for professionals who need to un- derstand the language of corrosion control and be able to recognize corrosion and its related problems. Within an eight- chapter framework, the fully searchable CD-ROM presents information on elec- trochemistry, environments, engineering materials, forms of corrosion, recognition and mechanical methods of corrosion control and corrosion monitoring techniques. The interactive program also features video footage of corrosion and cathodic protection experiments. License fees for the course are $850 for members; $950 for nonmembers. The license fee includes payment for a proctored final exam taken in person from an approved NACE proctor. Proctors are available throughout North and South America, Europe, the Middle East, Africa and Asia. Those who complete the CD-ROM material and pass the proctored final exam may opt to apply for NACE Corro- sion Technician certification if they meet work experience requirements.

NACE International The Corrosion Society P.O. Box 218340, Houston, TX 77218

V i d e o Presents S c u l p t i n g w i t h W e l d i n g

Sculpting with Welding is volume one in a series of videos presenting sculptor and welder Hunter Herman teaching his workshop on welded sculptures. The video focuses on shielded metal arc welding and demonstrates step by step how to weld proficiently and professionally. Oxyfuel cutting and heating and plasma arc cutting are covered. Other cutting procedures and finishing techniques are discussed using pneumatic and electric hand tools. Emphasis is placed on proper industrial grade standards and procedures including a section on safety parameters. Fabrication and assembly of a sculpture, using the procedures of this program, are shown. Future videos in the series will include gas metal arc and gas tungsten arc welding. The video in VHS format lists for $54.95. PAL format is available for $79.95.

Vantage Productions 11 Vosburgh Rd., Averill Park, NY 12018-5705

G u i d e A i d s in C h o o s i n g C o n s u m a b l e s

The Weld Metal Selector Guide allows users to specify an ASTM, AI or ABS

WELD METAL 5ELEL'TOR GUIDE

steel type and learn the company ' s appropriate self-shielded and gas-shielded flux-cored electrodes to use for manual shielded metal arc welding, gas metal arc or submerged arc welding. The first two pages of the guide consist of a legend of the codes that appear throughout the re- ma inde r of the l i tera ture . These codes make it easy for the user to quickly find the electrode that works best with the selected appl icat ion. The ent i re guide is p resen ted in a chart format , making it easy to conc lude which types of metals and processes work best together.

The Lincoln Electric Co. 112 22801 St. Clair Ave., Cleveland, OH 44117-1199

M i n i a t u r e P n e u m a t i c s F e a t u r e d in P r o d u c t C a t a l o g

A 230-page catalog of min ia ture pneumat i c products and accessories is now available from the company. A large select ion of fittings, tubing, mufflers, manifolds, valves, filters and accessories - - in a complete range of sizes - - are described. A full line of plastic tubing is also included and the catalog has a chemical compatibili ty chart and engineering data section.

Industrial Specialities Mfg. 2741 W. Oxford, Unit #6, Englewood, Co 80110

113

weld of.045

* Photos provided by Advanced Welding Service

MICRO ~ I N G SYSTEM j WELDLOGIC "MICRO-TIG" / PLASMA SYSTEM ~ IS THE MOST ADVANCED AND ACCURATE FORM OF

PRECISION WELDING AVAILABLE • MINIMAL STRESS & DISTORTION • MINIMAL HEAT

A R C STABILITY DOWN TO. 1 AMP • NO A R C WANDER NO HIGH FREQUENCY BURNING t PRECISE STARTS IN DEEP POCKETS

#1 CHOICE OF WELDING PROFESSIONALS

WELDLOGIC INC.I "-'G~ "- 2550 Azurite Circle, Newbury Park, California 91320 Phone (805) 498-4004 • FAX (805) 498-1761

Welding Solutions For ~.,'~.- Website: www.weldlogic.com • E-mail: [email protected] Advanced Manufacturing ~'~


THERE WHEN YOU NEED ITi

GONE WHEN YOU DON'T!

with Shur-Purge'" and SHUR GAF"

Products from

AB PAPER COMPANY

Shur-Purge Prefabricated Water Soluble

Purge Dams

• Used in Pipe Welding where an inert gas purge is required.

• Water Soluble for easy removal with water and/or steam.

• Assures a positive purge with oxidation risk reduced.

• Prevents costly repairs from inefficient purges.

• Sizes from 3/4" to 30" pipe or tubing.

SHUR-GAF SPACERS Give the Required I " ~ Gap ~ for Socket Weld fit-ups. ~

• Gives the required 1116" gap. • Dissolves away when water and

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• Saves time and thousands of dollars in cracked weld repairs.

• Sizes from 1/2" to 3" inches and tubing sizes as required.

For a sample and more information give us a call or write:

AB PAPER COMPANY P. O, BOX 622

CENTRALIA , WA 98531 1-800-408-0739

FAX 360-740-0738 www.abpaper.com


WELDING JOURNAL J 89

The Resistance Welder Manufactur- ers' Association (RWMA) videotape, Ba- sics to Resistance Welding, is the ideal orientation tool for new entry-level employees joining your business. In one hour, new employees will learn the basic terminology of the four resistance welding processes, the variables that must be controlled in order to have a reliable, repeatable process and the different components of a resistance welding machine.

Basics to Resistance Welding begins with an introduction to the advantages of the processes. The video takes the viewer step by step through the basics of spot welding. General topics covered include how resistance welding machines work, with an emphasis on the the three major variables in the resistance welding process (pressure, current and time), variations in the welding process and Q/A. In later segments of the video, the viewer is introduced to other types of resistance welding processes: project ion welding; seam welding; and flash, upset and butt-joint welding.

Basics to Resistance Welding uses ani- mated sequences that simulate a real resistance welding machine reproducing spot welds during manufacturing. In some instances, the viewer is shown a "see-through" view of the action occurring within the machine during a resistance weld.

This professionally produced video is a valuable training tool for your video training library. Basics to Resistance Welding is available for $395 ($320 for RWMA members) by contacting RWMA at (215) 564-3484.

For more information about the resistance welding process or joining the Re- sistance Welder Manufacturers' Associa- tion, call (215) 564-3484 or visit the Web site at www.rwma.org.,

This column enables welding-related organizations to inform Welding Journal readers of their activities and services. This information was provided by the Resistance Welder Manufacturers' Association.

Tab le I - - A W S A5.4 E309L-XX Composition Limits

% C % Mn % P % 5 % Si %Cr % Ni

0.04 0.5 to 0.04 0.03 0.90 22.0 to 12.0 to max 2.5 max max max 25.0 14.0

% Mo % Cu

0.75 0.75 m a x m a x

t rode manufacturer can make the weld metal reproduce the low ferrite of the rod as it came from the steel mill. Or, by putting extra chromium in the electrode coating, the electrode manufacturer can raise the chromium content into the upper half of the 309L range (23.5 to 25.0%). In this latter situation, the weld deposit will have appreciably more ferrite than was designed into the core wire by the steel mill.

In general, the root pass of a joint between mild steel and 304L stainless steel, made with a 309L electrode will have a lower ferrite content than the undiluted 309L composition due to pickup of carbon from the mild steel side of the joint. Carbon is very powerful in promoting austenite or in reducing ferrite. So, if the ferrite content of the undiluted 309L filler metal is higher, the electrode can tolerate more dilution from the mild steel side while still producing a root- pass weld deposit with enough ferrite to prevent hot cracking (typically 3 FN is sufficient). Since most joints of 304L to mild steel are used in the as-welded condition, commercial design of 309L electrodes is aimed toward the upper half of the chromium range so the undiluted weld metal will have something more than 10 FN to maximize tolerance for dilution without hot cracking in such joints.

However, avoidance of root-pass hot cracking in dissimilar metal joints, along with meeting AWS A5.4 309L composition limits, are not the only concerns in designing 309L-covered electrodes. 309L electrodes are not only used for joining mild steel to stainless steel but can also be used for joining low-alloy steels to stainless steels. Many low-alloy steels re-

quire postweld heat treatment (PWHT) to temper martensite in their weld heat- affected zones. When the 309L electrodes are used to make a multipass, dissimilar metal joint, there will generally be a gradient in ferrite content of the weld metal, from the lowest level in the diluted root pass to nearly that of the undiluted 309L filler metal in upper weld passes away from the mild steel or low-alloy steel side of the joint. Then, when PWHT is performed on such a joint, typically at temperatures from 1150 to 1300°F (620 to 705°C), the ferrite initially present tends to transform to sigma phase, a brittle iron- chromium intermetallic compound. If there is a lot of ferrite in the upper weld passes initially, there is likely to be a lot of sigma phase after PWHT. If a side bend test is made of an initially high-ferrite joint after PWHT, it is likely to fail in a brittle manner.

Enter MIL-E-22200/2. The U.S. Navy wants 309L electrodes to be suitable for use, in both the as-welded and PWHT conditions, for joining either mild steel or low-alloy steel to austenitic stainless steels such as 304L. So MIL-E-22200/2 imposes limits for ferrite in undiluted weld metal of 4 to 10 FN, which is in addition to the requirements of the AWS A5.4 specification. Then, the resulting weldment will pass a side bend test in either the as-welded condition or after PWHT, provided the root pass does not develop hot cracks. But tolerance for dilution in the root pass of dissimilar metal joints is reduced with such electrodes. Your experience with root pass hot cracking, and the "fix" given by your coworker are consistent with my experiences with such electrodes.

Of course, from a purely technical

Vibratory Stress Re l i e f R e d u c e s Res idua l Stresses

D u e to Weld ing " F o r m u l a 6 2 " m e t h o d u t i l izes h igh amp l i - t u d e v i b r a t i o n s to r e d u c e p e a k r e s idua l s t resses c lo se to y i e l d s t ress levels n e a r t he w e l d cen te r line. Vibrat ions r emove h igh tensi le

res idual stresses due to we ld ing in fer rous a n d nonfe r rous metals.

S e n d f o r f ree b r o c h u r e . M

STntSS RILmF EnG,neeR,nG company

1725 M o n r o v i a A v e . , A-1 • Cos t a Mesa, CA 9 2 6 2 7 (949) 642-7820 • FAX (949) 642-0430

Circle No. 34 on Reader Into-Card 90 I MARCH 2001

viewpoint you could use a high-ferrite commercial 309L electrode for the root pass, then switch to the lower ferrite military electrode for the remainder of the joint. But the Navy, and the shipyards, generally won't allow the high-ferrite commercial 309L electrodes on the job site. They are rightly concerned with the possibility of a mix-up resulting in the higher ferrite commercial electrodes being used for multiple passes in a joint to be given PWHT. So, it seems you are likely to be stuck learning and using the lower current, lower dilution technique for the root pass with 309L electrodes for dissimilar metal joints in the shipyard.,

Matheson Names VP/GM

Matheson Tri-Gas, Parsippany, N.J., has named Rick Kowey to senior vice president and general manager of the Specialty Gas Division. Kowey has held various positions in the specialty gas business for 17 years. He joined the company in 1997 as eastern region sales man-

Kowey

ager and, prior to this appointment, was vice president of sales for the Specialty Gas Division.

Unitek Miyachi Appoints Chief Marketing Officer

Victor H. Prushan has been named chief marketing officer at Unitek Miy- achi International (UMI), Monrovia, Calif. Prushan joined UMI in Septem- ber 2000. For 19 years previous, he led his own strategic marketing consulting company, VHP Associates. He is the author of the book No-Nonsense Market- ing: 101 Practical Ways to Win and Keep Customers, published by John Wiley & Sons in May 1997. Prushan is a graduate of the U.S. Naval Academy and holds an M.B.A. from Northeastern University in Boston, Mass. His background includes positions in both sales and marketing at Honeywell, Texas Instruments, Litton and Iotron, among others. He also served as an adjunct professor teaching marketing and international business at a Los Angeles-area university.

Tregaskiss Appoints Technical Director

Tregaskiss Ltd., Ontario, Canada, has appointed Julio Villafuerte [AWS] senior technical director. His position includes responsibility for all engineering and research and development activities with the company. Villafuerte has more than 15 years of experience within the welding industry. A Ph.D. graduate from the University of Waterloo, Ontario, Canada, he spent several years as director of technology for the Welding Insti- tute of Canada prior to becoming director of research and development for Tre- gaskiss in 1996. Villafuerte is the author of numerous technical articles and books and holds patents in welding technology. He is an active member of NEMA's Arc Welding Standards Committee and a past member of the AWS Welding Re- search Committee. Villafuerte currently serves as a reviewer for the ASM Jour- nal of Materials Engineering and Perfor- mance magazine.

Obituaries

Myron Davis Stepath

Myron Davis Stepath [AWS], founder of The Arcair Company and an AWS Fellow, passed away on January 2 in Lancaster, Ohio.

Stepath worked as a surveyor for New York State in 1928, and as an engineering aide for the Massachusetts Public Works in Boston from 1930 to 1935. He graduated from Purdue University in 1939 with a degree in structural engineering. While at Purdue, he was awarded membership in the Civil Engi- neering Honorary Society, became a member of Sigma Alpha Epsilon and a member of the Purdue fencing team.

After graduation, Stepath worked as assistant engineer for New York Ship. In 1944, the company sent him to Hanford Washington as head welding engineer on the Atomic Energy Project. He was welding engineer for the Puget Sound Naval Shipyard from 1945 to 1949. In 1949, Stepath founded The Arcair Company in Lancaster, Ohio, based on his invention of the air carbon arc process and torch, which contributed significantly to metal working worldwide in foundries, fabrication plants, automobile construction and repair, railroad equipment, and underwater salvage and fabrication operations. In addition to Arcair's headquarters in Lancaster, Stepath established Arcair

Canada, Arcair Mexico and Arcair Bel- gium. Stepath was president and chairman of Arcair until 1970, when he merged the company with Air Products and Chemicals. He remained CEO until 1974, when he retired from the company.

In 1983, Stepath founded Ashwood Thoroughbreds, Inc., breeding and training thoroughbred horses on his farm in Lancaster. His Ashwood horses have won more than sixty races, including ones at Belmont Park, Churchill Downs, Hialeah, Monmouth Park and many other tracks.

SICpath

From 1955 to 1981, Stepath received nine U.S. patents and many equivalent worldwide patents for heavy metal removal systems and underwater welding. In honor of his contributions to the weld-

ing industry, Stepath was awarded Hon- orary Membership in the American Welding Society, received the Samuel Wylie Miller Memorial Medal Award, the Gold Certificate for fifty years of service and was inducted as an AWS Fel- low. He also received the U.S. Govern- ment's Excellence in Exporting Award. In 1970, as a charter member of the Na- tional Management Association, Stepath accompanied a mission to the Soviet Union.

Stepath initiated and developed the Junior Achievement program in Fair- field County and endowed the Myron Stepath Scholarship Fund. Among the many other charitable causes he supported are the Cato Institute, the Her- itage Foundation, the Ludwig von Mises Institute for Austrian Economics, North- wood Institute, Hillsdale College and Auburn University.

Shortly before his death, Stepath endowed the Myron Stepath Fellowship through the AWS Foundation. The fellowship carries a $25,000 annual award for graduate studies in the field of welding.

Stepath was preceded in death by his first wife, Cherrill Gibson Stepath. He is survived by his wife of thirty years, Ginny Stepath; son, Carl Myron; daughter, Sally Ann Stepath; stepdaughter Susan Azzano; and five grandchildren, Pietre, Joshua and Dylan Clayton, and Sorisa and Sarah Stepath.

WELDING JOURNAL 191

f

CWI- Immediate, Full-Time Opening. Du- ties include interpreting shop fabrication drawings, performing quality inspections and maintaining work performance reports at upstate NY shop fabrication sites. Inspection of structural steel and CWl experience a MUST. NYSSCM work and other NDE certifications a plus[ Forward resume to

Engineering Personnel

Able Testing & Inspection Inc. PO Box 158

Howes Cave, NY 12092 Fax: 518-357-4683

/VELDING ENGINEER'.

WELDING ENGINEERS CAREER OPPORTUNITIES

PRI is a Recruitment Coordinator for 350 Search Firms nationwide. High demand for junior through advanced levels in variety of industries. Top companies, $40-80K. Fee paid. Contact Wayne.

Professional Recruiters, Inc. P.O. Box 24227

Omaha, NE 68124 800-999-8237 or Fax: 402-397-7357

wayne@prionl ine.com www.jobteam.com

Industrial Steel Construction, a steel bridge fabricator in the Chicago area, has an immediate opening in engineering for experienced personnel. The ideal candidate has a strong background in drafting, detailing and structual steel fabrication. Computer skills a plus. Must be self-moti- vated and capable of working professionally with customers. Competitive salary and full benefits package. Contact or send resumes to

Industrial Steel Construction, Inc. 86 N. Bridge Street Gary, Indiana 46404

Phone: 708-482-7500; Fax: 708-482-8549 or e-mail

[email protected]

I HAVE 30 YEARN EXI'I.:lilI,~N('I, AS A NATIONWIDE WELDING ENGINEERING SPECIALIST I

Numerotts client companies have engaged me [ to recruit welding pros at various levels of experience. I

If your expel~ise is Welding Engineering: [

Call 732-390 4600 • Fax 732-390-9769 [ e-mail [email protected] or Mail Resume to [

Bill Elias, Dept WE PO Box 396, E.Brunswick, NJ 08816 I

ELIAS ASSOCIATES I "Annual/v A National Award Winning Search Firm" I

ATTENTION!

Welding Equipment Sales Personnel We pay you for finding us good used welding

systems, seamers, positioners, manipulators, turning rolls, etc. We will buy

your customers' trade-ins.

WELD PLUS, INC. 1-800-288-9414

Montana Tech is seeking a tenure track faculty member in the area of Metals Fabrication. Duties include teaching approximately 25 contact hours of welding and machine shop courses per semester, including day, evening and occasional weekend classes. Applicants must be able to do the following at minimum: oxyacetylene cutting, welding and brazing; SMAW; GMAW; GTAW; blueprint reading; pipe fitting; pipe welding; and basic machining. Will maintain safe, clean and functional welding and machine shop laboratories. Will maintain equipment and supplies as necessary. Additional responsibilities include actively promoting the Metals Fabrication program and working with local and regional industries.

Bachelor's degree in Welding Engineering, Manufacturing Technology, Metals Technology or equivalent required; Master's degree preferred. Applicant must have 5+ years' experience in a metal fabrication shop. Must be able to operate equipment such as a break, shear, roll, punch, ironworker, vertical and horizontal milling machines, lathe and various welding and machine shop equipment. American Welding Society certification, American Welding Society Educator certification or related welding certifications are required. Certified Welding Inspector certification and classroom teaching experience are preferred. Salary will be commensurate with education and experience; starting salary will be $25,800 - $32,710.

Applications should be received by March 30, 2001. Starting date will be August 2001. Interested individuals must submit a cover letter, resume and the name, address and phone number of at least three references who we may contact and any other supporting documentation to Steve Luft, College of Technology, 25 Basin Creek Rd., Butte, MT 59701, e-mail [email protected]. EEO/AA.

CWI Wanted CommSteel Inc.

Large Structural Steel Shop Located In Cleveland, Ohio

401 K, Hospitalization, Competitive Wages

Call Us At 1-800-881-7987

Positions available $45-80K. Fees paid. Au- tomotive, automation, manufacturing GMAW, GTAW, RW, LBW, robotics.

David Smith, CPC - Capital Source National Personnel Recruitment

PO Box 20987 Roanoke, VA 24018 Fax (540) 989-6557

Phone (540) 989-6551 Email [email protected]

Immediate opening for FULL TIME, EXPERIENCED ARC WELDER.

Well-established shop in a desirable southern California location offers

competitive pay and generous benefits. Must pass a company welding test. Please call Ward Shimada at (310) 333-1700 or fax resume to

(310) 651-5492.

WELDING JOBS.corn

Leading job site for all Welding Jobs. Top 10 listing on major search engines.

250 total visitors/day and growing. Site has Mailing Lists,

AD Stats, Job Links. Com nanies/Racruiters Place ADS

http ://www.WeldingJobs.com

~ HORIZON PERSONNEL

Weld Eng., superalloys/R&D/process $75K Weld Eng., SS/titanium/thin gage $55K Mfg. Eng., GMAW/roboti( s/steel $60K Weld Eng., hispeed/robotic/laser $75K Quality Mgr., weld/stamp/automotive $75K Dir Quality, 6sigma/weld/stamping $80K

Companies pay all costs. Send resume in confidence to

Joe Micksch, ASM Life Member 683 Fox Meadow Road Princeton, KY 42445

Emaih [email protected] www.jobsonthehorizon.com

Phone 270-365-9165 or Fax 270-365-2248

921 MARCH 2ool

E Q U I P M E N T R E N T A L

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Mitrowski Welding Equipment 1315 College Ave. South Houston TX 77587 Phone 800-218-9620 Fax 713-944-1060 [email protected]

W e Buy & Sell Surplus

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Re-Ground Tops | | FOB: Shipping Point • Call for Details I I Weldsale Company (215) 739-7474 i L _ _ __w~w.w__elL"le/_co~ _ _ _ _ _,

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RED-D-ARC Quality-Checked" Used Equipment

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Web site: www.weldplus.com e-maih [email protected]

W E L D PLUS, INC. Cincinnati, Ohio

Jack Schroeder 1-800-288-9414 Fax: I-513-467-3585

PIPE W E L D I N G V I D E O S

Acquire difficult pipe welding skills and techniques through easy-to-follow instruction. Six different videos are available at $39.95 each: SMAW 2G, 5G and 6G. Techniques are demonstrated, including walking the cup, tungsten extension, welding 1/4" gap, etc. Call today for more info. Visa and M.C. accepted.

Quality School of Pipe Welding 600 Great SW Pkwy Atlanta, GA 30336

phone 404-629-9909 fax 404-629-1229 pipewelding.com

Accredited AWS test facility.

• ~u!punj VA Joj paAoJdde 'alqel[eAe suo[leg[Idde ueo I },uapnls

i ~ - FI:II1 Joj 1[ ocI " / ~' iMON 1[ o13

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ila~pv d uo.~vutaoJu I ~ut.ut.vaL ad~ ano~ oa~aoaa ol sn llVO puv auoqd aql ol lo~ s! op ol paau no£,vq/~6 "u[eJ]~ o] no/, aoj a3eld aq:l s! IMV pue/,J].uno3 aq~ ssoJ3e papaau aJe sJaplaAa aqn] pue ad!d aJnssaJd-Ll~!H

iJaaJe3 ~u!l!3xa ue ol Ae~ JnoA uo aq pue alnl!lSUl gu!plaM euozpv ~e iioJu:l

ipuno.~ V aJ.~ 7 .~no A m n £

931 MARCH 2001

T R A I N I N G 2 0 0 1

C W I P R E P A R A T O R Y

Course Guarantee - Pass or Repeat FREE!

M a r J 9 -23 J u n 11 - ] 5 Test fo l lows o n S a t u r d a y @ s a m e

fac i l i ty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loca t ion : La faye t t e , Z.A Dates: Apr 13 ,14 ,20 ,21 ,22 ,28

A P P L I C A T I O N S O F VISUAL WELDING INSPECTION

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AB P a p e r ........................................................................... 89 A B I C O R Binzel .................................................................... 2 A i r f low Sys tems ................................................................. 60 All Fab Co rp ..................................................................... 23 A m e r i c a n Weld ing Soc ie ty ............... 8 ,16 ,31 ,32 ,37 ,55 ,56 ,59 Arc M a c h i n e s .................................................................... 61 At las Weld ing .................................................................... 24 Ca ldwe l l G r o u p .................................................................. 61 C o r - M e t ........................................................................ 21 ,62 D e - S t a - C o ......................................................................... 82 D i a m o n d G o u n d Produc ts ................................................. 24 Eag le Bend ing ................................................................... 60 Ed ison Weld ing Inst i tute .................................................... 19 Ene rp ro ............................................................................. 57 Equot ip .............................................................................. 59 ESAB Weld ing & Cut t ing Produc ts ................................ O B C F ischer Eng ineer ing .......................................................... 88 F luo ramics ........................................................................... 3 H & M Pipe .......................................................................... 88 Hoba r t Inst i tute .................................................................. 58 In tercon ............................................................................. 29 Je t l ine Eng ineer ing ............................................................ 27 J.P. N issen ........................................................................ 57 Ko ike A r o n s o n ................................................................... 25 L a - C o Marka l ..................................................................... 40 L incoln Electr ic ................................................................. 13 M a g n a t e c h ........................................................................ 10 M a t h e y D e a r m a n ............................................................... 58 Mi l ler Electr ic Mfg. Co ..................................................... 4&5

Nat iona l S tanda rd ............................................................. 15 N e d e r m a n ......................................................................... 22 O s r a m Sy lvan ia ................................................................... 6 Pferd .................................................................................... 1 Se lec t Arc ........................................................................ IBC S t ress Rel ie f E n g i n e e r i n g " . ............................................... 90 T.J. C la rk ........................................................................... 36 Tempi l , Inc ......................................................................... 60 T h e r m c o ............................................................................ 57 Tr i -Too l .............................................................................. 46 We ldc ra f t ......................................................................... I FC Weld H u g g e r ..................................................................... 22 We ld log ic ........................................................................... 89 Yx lon In ternat iona l ............................................................ 28

IFC = Inside Front Cover IBC = Inside Back Cover OBC = Outside Back Cover

9 4 I M A R C H 2001

W E L D I N G R E S E A R C H

SUPPLEMENT TO THE WELDING JOURNAL, MARCH 2001 Sponsored by the American Welding Society and the Welding Research Council

Experimental Evaluation of Fe-AI Claddings in High-Temperature Sulfidizing Environments

Assessment of Fe-AI claddings in aggressive reducing environments showed compositions with properties of weldability and

high-temperature corrosion resistance

BY S. W. BANOVIC, J. N. DUPONT AND A. R. MARDER

ABSTRACT. The corrosion behavior of iron-aluminum alloys and their potential as protective corrosion claddings in sulfidizing environments were investigated. As-solidified castings of Fe-AI alloys with 0-20 wt-% AI were isothermally held at temperatures between 500 and 700°C for up to 100 h in a reducing atmosphere using thermogravimetric techniques. Specially tailored gases maintained partial pressures of oxygen and sulfur at each temperature [p(O 2) = 10 -25 atm, p(S 2) = 10 -4 atm]. Postexposure characterization of the corrosion scales consisted of surface and cross-sectional microscopy in combination with energy-dispersive spectroscopy and electron probe microanalysis. From these results, it was found the corrosion behavior was directly related to the alloys' aluminum content. For high aluminum compositions (10 wt- % AI and above), protection was afforded due to the development of a thin, continuous alumina scale that inhibited rapid attack of the alloy. Increasing the aluminum content of the alloy was found to promote the formation and maintenance of this scale, leading to excellent corrosion behavior. For low aluminum contents (<10 wt-% AI), the ability to form and/or maintain the alumina scale was not observed. Instead, thick sulfide

S. w. BANOVIC J. N. DUPONT and A. R. MARDER are with Department of Materials Science and Engineering, Lehigh University, Bethlehem, Pa.

phases developed either in the form of localized nodules (7.5 wt-% AI) or as a continuous surface scale (5 wt-% AI and below). Formation of these fast growing, nonadherent sulfide phases resulted in accelerated degradation of the alloy and unacceptable waste. With both good weldability and corrosion characteristics, alloys approaching 10 wt-% AI have excellent promise for providing protection as claddings in aggressive reducing environments.

Introduction

The choice of Fe-AI alloys in cladding applications requiring good corrosion resistance (e.g., waterwall structures of coal-fired boilers with low NOx burners) is attractive due to their low cost, the lack of macro- or microsegregation upon solidification during welding (Ref. 1 ) and better corrosion resistance compared to

KEY WORDS

Corrosion Resistance Cladding Iron-Aluminum Alloys Boilers Sulfidizing Environment

conventional Ni-based and stainless steel-type compositions presently in use (Refs. 1-11 ). In addition, it would eliminate the brittle martensitic region that develops in the partially mixed zones of the above-mentioned austenitic alloys (Ref. 12). To date, their use is limited due to weldability issues stemming from cold cracking (Refs. 1, 13-16) and their lack of corrosion characterization in aggressive reducing environments at boiler service temperatures (typically below 700°C). In light of these facts, research was initiated to examine the sulfidation behavior of weldable Fe°AI compositions in highly aggressive reducing atmospheres. From a previous study (Ref. 1), alloys with 10 wt-% AI were identified as being readily weldable under normal field applications (Fig. 1) and had excellent corrosion behavior in moderately reducing atmospheres (Refs. 1, 13). While increasing the aluminum content has been shown to improve the corrosion resistance (Refs. 1-11), these compositions were not weldable. Some investigations (Refs. 15, 17) have cited the use of preheat and postweld heat treatments (PWHT) to relieve part of the hydrogen cracking problems, thus allowing for crack-free claddings with higher aluminum contents; however, the employment of such extensive treatments is not practical when coating large-scale structures such as utility boilers. Therefore, the objective of this work was to further characterize the corrosion behavior of weldable Fe-AI composi-

WELDING RESEARCH SUPPLEMENT I 63-s

IDCracked I 14 A40 o w E E 3 0

~ 2o

~ lO o E $ = 0

1100

, • No crack

16.1 [ ] 6

23.2 []M 16.2 [ ]M 14.1 [ ] 4

13.4 [~3 13.2 [ ]3 10.2 •

14.5 []1 9.9 • 7.5 •

9.5 • 6.6 •

1200 1300 1400 1500 1600

Energy input (J/mm)

==1' I lO m

lie .E

4O0

b)

[] ® [] [ ] [ ]

[ ] 27 wt% AI in fi l ler metal

i D Cracked I I No crack

13 wt% AI in fi l ler metal

600 800 1000 Energy input (J/ram)

1200

Fig. 1 - - Sample matrix of multiple-pass welds. A - - Gas tungsten arc welding (GTAW); B - - gas metal arc welding (GMAW). Each box represents a sample deposited at that processing condition and was subsequently labeled as cracked or not cracked. For GTAW, numbers to the right o f the cracked data points signify the number o f cracks that occurred, with M being more than 15. The numbers to the left denote the wt-% of alurninum in the deposit (Ref. 1).

5

0

-5

~ -10

-15

-20

-34

AI2S3

-32 -30

FeS2 ,., " " " ~'~=" AI203

X Fel-xS

Fo

-28 -26 -24 -22 -20

log p(O=)

Fig. 2 - - Superimposed thermostability diagrams for Fe and AI at 600°C The solid lines represent equilibrium boundaries between the iron-based phases and the dashed line between the aluminum-based phases. The partial pressure of oxygen and sulfur place the testing environment in a region of aluminum oxide and iron sulfide (Fel.~5), as indicated by X. (Diagrams calculated using Ref. 21.)

tions in more aggressive reducing environments at service temperatures. The results of this work permitted these alloys to be evaluated for possible use in cladding applications that require a combination of good weldability and corrosion protection in aggressive sulfidizing atmospheres.

Experimental Procedure

The materials used in this study were a series of monolithic, iron-based alloys with varying amounts of aluminum (5, 7.5, 10, 12.5, 15 and 20 wt-% AI). These compositions were chosen based upon

the previous weldability study - - Fig. 1. All Fe-AI alloys were produced at Oak Ridge National Lab- oratory (Oak Ridge, Tenn.) by arc melting high-purity Fe (99.99%) and AI (99.99%) under argon and drop casting into a water-cooled copper mold. For comparison, a low-carbon steel alloy with 0.05 wt-% C was chosen. As-solidified castings were used to study the high-temperature sulfidation behavior instead of actual cladding material in order to eliminate the timely procedure of extracting a corrosion coupon from a deposited cladding. In addition, the aluminum-depleted region near the cladding- substrate interface, pro-

duced due to poor mixing during the welding process (Ref. 1 ), will be avoided. Prior research (Ref. 7) demonstrated that the corrosion products more readily formed on the specimen face located closer to the substrate due to the inho- mogeneous composition (lower aluminum content) in this area. This was found to result in higher corrosion rates of the specimen. Furthermore, it was also shown the sulfidation behavior of Fe-AI claddings in reducing environments could be explained on the basis of what was known from cast alloys of equivalent compositions (Ref. 7). The reason for this stems from the fact the microstructure

and distribution of alloying elements in the monolithic alloys and the claddings are essentially identical (Ref. 1)and, therefore, should have similar behavior/reactions in the corrosive atmosphere. Thus, based upon these experimental observations, the use of as-cast alloys to study the corrosion behavior of claddings of identical compositions is clearly justified.

For the corrosion testing, substrates with dimensions of 1 cm x 1 cm x 2 mm were sectioned from the bulk using a high-speed diamond saw. Subsequent grinding of the surface to 600 grit was also conducted. Specimens were prepared immediately before insertion into the balance with prior steps of ultrasonic cleaning in soapy water and methanol. A Netzsch STA 409 high-temperature thermogravimetric balance was used to measure weight gain as a function of time, with the gas compositions and temperatures chosen so as to produce a highly reducing environment indicative of low NOx gas conditions (Refs. 18-20). Sam- ples were heated at a rate of 50°C/min and isothermally held at temperatures of 500, 600 and 700°C for various times (1, 5, 15, 25, 50 and/or 100 h). Mixtures of H2-H2S-O2-Ar gases were determined so as to maintain equivalent partial pressures for oxygen, p(O2), and sulfur, p(S2), at different temperatures. Table 1 shows the gas compositions, as reported by Scott Specialty Gases, and the corresponding p(O 2) and p(S 2) values for each temperature. The p(O 2) was determined using a solid-state oxygen detector and the p(S 2) was calculated using the Sol- GasMix program (Ref. 21 ). According to superimposed thermostability diagrams for iron and aluminum at test tempera-

64-s I MARCH 2001

tures, the location of the testing environment was found to lie in a region of aluminum oxide and iron sulfide (Fel_xS). These stability diagrams will indicate which phases (e.g., Fe, AI, alumina, iron sulfide) are thermodynamically stable on all of the alloy's surface for the given testing parameters; they do not indicate which scales will actually be observed to form. An example of one developed at 600°C is shown in Fig. 2, with the location of the testing parameters denoted by X. The present gas mixtures chosen were more aggressive than those used during the early study (Ref. 1) in which only moderately reducing atmospheres were investigated. For comparison, the composition, p(O2), and p(S 2) of this previously used gas is also shown in Table 1.

Postexposure characterization of the corroded surfaces was conducted using a JEOL 6300F scanning electron microscope with an Oxford (Link) energy- dispersive spectroscopy (EDS) system capable of detecting light elements. Pol- ished cross-sections were obtained by mounting in cold setting epoxy with subsequent grinding procedures to 1200 grit with silicon-carbide papers. A final polishing step was conducted using 1-pm diamond paste on a low-nap cloth. Further polishing with any type of colloidal alumina or silica was avoided to minimize the possibility of contamination or pull- out of the scale. Cross-sectional scale thicknesses were measured on electron micrographs using a digitizing pad inter- faced with a Nikon Optiphot microscope. A minimum of 20 lengths were taken per layer per sample on various planes. Quantitative chemical information was obtained on polished cross-sections using a JEOL 733 electron probe mi- croanalyzer (EPMA) equipped with wavelength-dispersive spectrometers (WDS). The accelerating voltage and probe current were 20 kV and 50 nA, respectively. K~ X-ray lines were analyzed and counts converted to wt-% using a ~0(p. z) correction scheme (Ref. 22).

A fracturing technique using liquid nitrogen was also employed to view the scales in cross-section. By notching the back side (approximately 4/s of the thickness of the substrate) with a low-speed diamond saw and submersing the specimen for a minimum of 3 min in liquid nitrogen, the samples easily broke. Cross-sectional micrographs of these samples were also taken using the JEOL 6300E

Results

Corrosion Kinetics

Figure 3 displays the kinetic results obtained at each temperature for the longest

Table 1 - - Corrosion Gas Compositions and Corresponding Partial Pressures of Oxygen (Measured) and Sulfur (Calculated) at Temperature

Gas Composition Temp (by volume) (°C)

1.1 %H2S-0.0%H2-98.9%Ar (500 ppm 0 2 ) 500 0.9%H:S-0.0%H2-99.1%Ar (50 ppm 02) 600 1.0%H:S-0.1 %H2-98.9%Ar (5 ppm 02) 700 0.1%H_~S-3.0%H2-96.9%Ar (5 ppm 02) 600 (previous study) (a)

p(O2) p(S2) (atm) (atm)

9.2 x 10 =26 7.5 x 10 -4 7.4 x 10 -25 4.0 x 10 4 3.4 x 10 _25 5.4 x 10 -4 4.5 x 10 -28 3.8 x 10 9

(a) From Ref. 1.

exposure time for each alloy. In all cases, shorter time exposures (1, 5, 15 and 25 h) followed their respective weight gain data curves for the longer times with good repro- ducibility. From this data, a general trend was observed that an increase in aluminum content produced a decrease in the weight gain, and once above 7.5 wt-% AI, the increase was relatively small. It was also noted that an increase in temperature from 500 to 600°C led to a decrease in weight gain for alloys with less than 10 wt-% AI, while the increase from 600 to 700°C produced a significant increase in the weight gain.

Corrosion Morphologies

As a general trend, increasing the aluminum content led to decreased amounts of corrosion product on the surface. For the low-carbon steel sample, a thick, bilayered scale was found - - Fig. 4. The outer scale appeared to be dense and columnar with the inner scale being fine- grained and porous. EPMA data (Table 2) indicated both layers were iron sulfide (Fel_xS), with separation between these two morphologies. This separation indicated poor adhesion between these two morphologies and, on occasion, resulted in scale spallation prior to mounting. The 5 wt-% AI alloy also grew a continuous surface scale

2o[ i A 500°C

z / 0,12.5, o~ 4 / / _ , j ~ 15, 20 AI

0

0 20 40 60 80 I00

Time (hrs)

2O 600°C

E 16 o

E,~12 = 0 AI

10, 12.5,

e .

g 4 0

0 20 40 60 80 I00

Time (hrs)

50 . . . . o q I - 0 AI 700 CI 'ol / /

"~ / / J .~p 7.5 AI / / L 10,12. , 15, 20 ,1

0 t

0 20 40 60 80 100

Time (hrs)

Fig. 3 - - We igh t ga in vs. t ime for various exposure temperatures

at p ( O 2) = 10 -25 a tm a n d p(S 2) = 10 -4 atm. A - - 500°C; B - -

600°C; C - 700°C

W E L D I N G RESEARCH SUPPLEMENT [ 65-s

[ LI I E l h !

d |

m l I

U l D I

IJ i n

m i I

m . m i

m . I

U l n l U l w= | h i I

U l E l

w I D I

i l l

m i

arl U l

U l p ! im I

m |

P I b= |

LII E l h | = t !

U l D I

u I ml |

m i

m . i

wI n l u I m. i b |

u I E l

i I

U I D I

I . I I

m ! m |

m- |

u I

I l l

Table 2 - - Representative EPMA Data, Reported in Weight Percentages, for Thick Sulfide Phases Taken from the Low-Carbon Steel and Fe-5 wto% AI Alloy

Sample Scale Feature Fe AI S Phase(s)

Low-carbon steel Outer scale 61.7 + 0.5 0.0 37.7 + 0.3 Fel.xS Low-carbon steel Outer scale 61.7 + 0.8 0.0 37.5 + 0.5 Fe l_x s Fe-5 wt-% AI Outer scale 61.7 + 0.5 0.9 + 0.2 37.6 + 0.4 Fel_xS Fe-5 wt-% AI Scan of inner 45.1+ 0.3 8.3 + 0.5 43.3 + 0.7 T + Fel.xS

layer Fe-5 wt-% AI Dark, inner 24.0 + 0.8 20.7 _+ 0.3 52.8 + 1.0 "c

layer plate Fe-5 wt-% AI Substrate near 95.4 + 0.3 4.9 + 0.1 0.0 0~-(Fe)

scale Fe-5 wt-% AI Alloy at far 95.7 + 0.3 4.9 + 0.5 0.0 (x-(Fe)

distances

that was bilayered - - Fig. 5. Quantitative chemical analysis (Table 2) showed the outer scale consisted of irregularly shaped iron sulfide (Fel_xS) plates, and the inner scale was found to be a two- phase mixture of "~-phase platelets (FeAI2S4), a spinel-type compound (dark in Fig. 5B) and Fel_xS particles (light particles in Fig. 5B). Sampling of the inner layer as a whole was obtained by scanning areas of approximately 25 pm 2. The results placed it in the two-phase region of "~ and Fe l_x S on the ternary phase diagram - - Fig. 6. Porosity in the inner scale was also found (black in Fig. 5B). In the alloy located next to the inner scale, depletion of either metallic element (Fe, AI) or the ingress of sulfur into the alloy was not observed, within the detection limits of the electron microprobe equipment (-1 [am). In addition, it was observed that the sulfide scales of the above-mentioned samples exhibited poor adherence to the alloy and easily flaked off during handling.

With compositions of 10 wt-% AI and above, the samples did not develop the thick, surface corrosion products that

were found on the previous specimens. In- stead, electron micrographs of the surfaces revealed continuous coverage by a granular scale (Fig. 7A) that had the appearance of either a tan, blue or purple color to the naked eye. Qualitative analysis by EDS indicated high counts orAl and O with minor amounts of Fe and S - - Fig. 7B. Fractured cross-sectional micrographs in these areas were also obtained (Fig. 7C) with arrows denoting the scale. It appeared to be uniform across the sample with the cross-sectional thickness having a relationship with both time and temperature - - Fig. 8. However, changes in aluminum content for a given testing condition did not lead to significant differences in scale morphology or thickness.

Samples with 7.5 wt-% AI were found to develop localized sulfide growths that were randomly dispersed across the surfaces - - Fig. 9. These nodules had a similar appearance regardless of the exposure time and temperature. Exposures above 15 h led to the coalescence of some of the nodules, and, as they were well dispersed across the sample face, it did not appear that the substrate grain

boundaries played a major role in their location. A granular surface scale, similar to the one found on the higher aluminum alloys, was present in the nodule- free areas - - Fig. 9C. Cross-sectional analysis (Fig. 9D) showed the nodules consisted of similar phases as seen in the thick scale growths. The overall appearance had a lenticular shape with further analysis revealing an outer scale of thick Fel_xS plates with various growth direc- tions. The inner scale was also composed of T-phase platelets and Fel_xS particles that developed normal to the surface. In the substrate directly below the nodules, EPMA analysis did not indicate the presence of sulfur or the depletion of either metallic element. The same can be said for the alloy located below the thin granular scale.

Discussion

The corrosion behavior of weldable Fe-AI alloys, for use as protective corrosion claddings in oxidizing-sulf idizing environments, was studied through thermogravimetric methods with the resulting corrosion scales characterized by microscopy techniques and chemical analysis. The alloy compositions were chosen based on previous weldabi l i ty studies (Ref. 1 ) that indicated Fe-AI alloys with 10 wt-% AI or less were readily weldable under typical field applications - - Fig. 1. Therefore, compositions on both sides of this weldabil ity l imit were evaluated with respect to their corrosion characteristics. From these experiments, it was found the corrosion behavior of these alloys was directly related to the aluminum content of the sample. This variable dictated the type (oxide/sulfide), morphology and amount of corrosion product that formed during high-temper-

a shield

Fel.xS , | !,~ , , columnar

substrate

Fel _x $ fine _ i " ~ ' ~ ~

Igramed . . ~ . . . . . ~ " -"

substrate

2 0 p m m

Fig. 4 - - Light optical micrograph of a polished cross-section showing the scale that developed on the low-carbon steel sample after 50 h at 600°C. A - - Full scale; B - - higher magnification of the inner scale with separation between the two morphologies.

66-s I MARCH 2001

Fig. 5 - - Secondary electron image of a polished cross-section showing the bilayered scale that formed on the 5 wt-% AI sample after 50 h at 600°C. A - - Full scale; B - - higher magnification of the inner scale showing T-phase platelets and Fe t.xS particles.

ature exposure in the reducing atmosphere. These growths were typically in the form of a surface scale or scales that developed with time. As a general trend, increasing the amount of aluminum in the alloy led to decreased corrosion rates and the amount of corrosion product. These results are discussed below as they relate to the prospect of using Fe-AI compositions as corrosion protective claddings.

Additions of aluminum at 10 wt-% and above were found to decrease the corrosion rates by promoting the formation of a slow-growing surface scale on the alloy during exposure. The low weight gain data obtained during corrosion testing was indicative of this fact - - Fig. 3. The surface scales were composed of tightly packed, equiaxed grains of an aluminum- and oxygen-rich scale - - Fig. 7. While definitive identification of the scale could not be made, enough evidence suggests it is an aluminum oxide, probably y-alumina, in terms of the EDS analysis, color (Ref. 23) and temperature regime in which it has

S ~S) acan of inner scale .// I\ \ T-phase

/ / ~ . . _ _ - - l ~ ~ A 1 2 $3 Fel-xS~////l ~

Fe2A15 FeA13

Outer Fel.xS scale

Fe

Fig. 6 - - Fe-AI-S ternary phase diagram at 900°C with overlaid EPMA data for the corrosion products and underlying substrate (Ref. 36). Axes are in weight percentages.

formed (Ref. 24), and its protective nature (low weight gain and thickness). In addition, numerous researchers working on similar alloys have also found protection due to y-alumina scales

in these types of mixed oxidizing-sulfidizing environments (Refs. 3-5). Other surface characterization techniques, such as grazing incidence X-ray diffraction (GIXRD) and backscatter electron kikuchi patterns (BEKP), were used in an attempt to identify the scales. Unfortu- nately, results from these analyses could not confirm the crystal structure. In any event, this scale formed due to preferential oxidation of the aluminum on the alloy surface, and the results indicated that formation of this scale was pro- moted through increasing the aluminum content of the alloy.

When the aluminum content was decreased to 7.5 wt-% or lower, thick sulfide phases were found to develop either in the form of nodules or a continuous surface scale due to the lack of aluminum at the surface. The growth of these corrosion products was found to be diffusion controlled, predominantly through the outward movement of Fe cations, to form an external layer of iron sulfide (Fel_xS), and the inward diffusion of sulfur, as indicated by the inner scale development

of "~-phase platelets and Fe1_xS particles. For the 7.5 wt-% AI sample, initial formation of the alumina scale was observed, as indicated by the granular scale in the nodule-free areas - - Fig. 9C. At extended times, mechanical failure of this scale, and the inability to heal itself due to the low AI content of the alloy, led to the short-circuit diffusion of sulfur through the passive layer (Ref. 25). This resulted in the subsequent growth of the sulfide phase at the alumina scale/alloy interface. The higher nominal aluminum compositions did not experience this failure as sufficient amounts of aluminum were located at the surface to repair the breakdown in the scale. As the nominal aluminum content of the alloy was further decreased to 5 wt-% and lower, the formation of a protective alumina scale was not observed. Instead, thick scale growths accompanied by relatively high weight gains were found from the onset of exposure, which led to excessive degradation of the alloy. This type of scale formation would lead to rapid deterioration of the cladding as the morphologies were porous and observed to readily spall. Eventually, this would result in the corrosive gas having direct access to the underlying tube material after the cladding material was completely consumed by the corrosion process.

From these results, it appears the Fe- AI compositions that perform well in the reducing environments are alloys that formed the surface scale of alumina. The protectiveness of this thermally grown oxide manifested itself in two ways: 1)

W E L D I N G RESEARCH SUPPLEMENT J 67-S

b X-RAY: 0 - 20 koV L i v e : 100 i B e s e t : 100 i Rea l : 1 2 8 i 22% Dead

R m m a i n i n g :

A 1

O

F S e F

e

, L . _ _ L . . . . . . . . I _ i , < . 0 5.163 key FS~ 4K OS~ -80 ch 268- 181 ors b~(l: FE-10AL 80RFACE

08

i | , J

10 .3>

Fig. 7 - - Characteristic secondary electron image of the granular surface scale formed on alloys of 10 wt-% AI or higher after 100 h at 600°C A - - Surface morphology; B - - the associated EDS spectrum; C - - fractured cross-section with arrows indicating thickness of alumina scale. Sample shown is Fe-10 wt-% AI.

low weight gains and corresponding thinness of scale and 2) lack of sulfur ingress into the alloy. While it is intuitive that formation of a protective scale will result in lower weight gains from reduced attack of the alloy, it is also important to

250

i 200 tl

' ~ = 150

P, ?: 1oo

o Z ~ *" 50 E

< 0

mlOAl / 112.5AII • J

700°C ...... ~ ........

, ........ ;;0:; , . . . . . . . . . . . 7;;;;7;;# ........................... i"- 500°C ::._-_-.'_ ...........

20 40 60 80 10

Exposure time (hrs)

Fig. 8 - - Cross-sectional alumina scale thickness as a function of time and temperature (ranges indicated by dashed lines) for various aluminum contents.

note the thickness of the scale providing protection at temperature. The alumina scales observed to grow on the weldable compositions (10 wt-% AI) barely attained 100 nm of growth at 600°C over the 100-h exposure period, yet were able to maintain less than 0.5 mg/cm 2 in weight gain. Other alumina scales, with different crystal structures, also provide protection at higher temperatures, but have a ten- dency to become much thicker over time even though their weight gains are also relatively low. As an example, another phase of alumina, c(, provides protection for iron aluminide compositions above 1000°C. At exposure temperature, these scales can grow to a thickness of 8 IJm within 100 h (Ref. 26). Preferential aluminum removal through thick scale growth de- pletes the alloy of this element at a relatively fast rate, and, after long times, the nominal aluminum composition of the alloy can drop to significantly low levels.

Rapid consumption of aluminum due to alumina scale growth is critical when considering the Fe-AI alloys for use as protective claddings, as the weldable compositions considered here have relatively low aluminum reserves to begin with. In terms of the corrosion re-

sistance, the effectiveness of a cladding can be defined by the oxidation lifetime, or the amount of time over which a surface scale (such as alumina) will be maintained to provide protection for the underlying material. This concept was studied and modeled by Quadakkers, et al. (Refs. 27, 28), and recently reviewed by Tortorelli and Natesan (Ref. 29). The time frame for protection has been found to be a function of the total amount of aluminum available for reaction (at the surface and in reserve within the bulk) and the rate at which it is consumed. The effective lifetime of a cladding ends when the aluminum content falls below a composition such that continuous formation of the alumina scale is not possible and the development of less protective products, such as sulfide phases, can occur, leading to high wastage rates.

Through the use of Fe-AI alloys as protective claddings, the reservoir of aluminum in the deposit will automatically be limited due to the thickness of the deposited cladding, typically 1-2 mm. Therefore, it is natural to conclude that increasing the nominal aluminum content of the deposit will further increase the potential effective lifetime of the protective coating. However, it has been shown a limit (approximately 10 wt-% AI) is imposed on the system in order to produce sound claddings deposited under conditions typically utilized in practice - - Fig. 1. Aluminum contents above this value have been found to be susceptible to cold cracking subsequent to welding (Reg. 1, 13-16) , with the severity of the problem increasing with aluminum content (Reg. 1, 30-32). Cracking of the cladding would enable the corroding specie to have direct access to the less corrosion- resistant substrate, typically a low-alloy steel, allowing for high corrosion rates. Consequently, without the option of in-

68-s I MARCH 2001

C

I

~ +

Fig. 9 - - Secondary electron images o f the surface scale developed on alloys with 7.5 wt-% AI after 50 h o f exposure at 600°C. A and B - - Nodu le sulfide phases on the surface; C - - granular scale in the nodule-free region; D - - pol ished cross section o f the nodules.

creasing the nominal aluminum content of the deposit, the other alternative to increasing the effective lifetime of weldable compositions is by reducing the rate at which aluminum is consumed. In this study, it was shown through the thickness (thinness) of the scale that the rate of aluminum consumption at these test temperatures was very low - - Fig. 8. In addition, this thinness may be beneficial in that large growth stresses, which could enhance spallation of the scale during thermal cycling, may not have developed. This spallation is detrimental in that it would lead to faster consumption rates of aluminum as the scale must now reform. While thermal cycling of the specimens was not conducted nor stress measurements of the scale made during this phase of the work, at no time was the alumina scale ever observed to crack, spall or flake off, even after fracturing in liquid nitrogen (for samples with 10 wt-% AI or higher). This suggests an adherent scale. There- fore, the thinness of the scale over extended periods of time, combined with the lack of spallation, results in a very low rate of aluminum consumption and suggests these alloys will provide protection for extended periods of time at applica-

tion temperatures (around 500°C). While the alumina scale was able to

maintain low weight gains for long times, it was also protective in the fact that internal sulfidation of the alloy did not occur. Microprobe traces near the alloy- scale interface did not detect an increase in sulfur when compared to far distances into the substrate, which suggests the scale was somewhat dense and impervi- ous to inward diffusion of the anion. This may be related to the fact that 7-alumina primarily grows via an outward cation diffusion mechanism (Refs. 24, 33) and not an inward anion diffusion as pre- dominately found for c~-alumina scale formation (Ref. 34). Sulfur penetration can be disastrous to the protective scale due to the formation of sulfide phases be- neath its surface, which can lead to mechanical degradation of the passive layer, as found for the 7.5 wt-% AI alloy. How- ever, the corrosion behavior observed here suggests this should not be a problem for these higher-aluminum-content alloys.

As a final note, it was observed that increasing the exposure temperature did not produce a trend in the weight gain data. Whereas corrosion rates were ac-

celerated by increasing the temperature from 600 to 700°C, exposures at 500°C produced higher weight gains than at 600°C. This was unexpected as diffu- sional processes are thermally activated, and thus, should decrease in magnitude as the temperature is decreased (Ref. 35). Therefore, another mechanism may be controlling the growth of these sulfide scales in this temperature regime (500°C) and work is currently under way to investigate this apparent anomaly.

Summary

The objective of the present study was to investigate the corrosion behavior of weldable compositions of iron-aluminum alloys in sulfidizing environments indicative of low NOx gas compositions. From this work, it was observed the corrosion behavior was directly related to the aluminum content of the alloy. For high aluminum compositions (10 wt-% AI and above), protection was afforded due to the development of a thin, continuous alumina scale that inhibited rapid degradation of the alloy. Increasing the aluminum content facilitated the formation and maintenance of this scale. Alloy con-


tents at or be low 7.5 wt-% AI led to high waste rates due to the formation of thick sul f ide phases that were fr iable. Wi th these results, weldable composit ions of Fe-AI alloys show the potential promise for applications requiring a combinat ion of weldabi l i ty and corrosion resistance in aggressive sulf idizing conditions. There- fore, these alloys are viable candidates for further evaluat ion for use as corrosion- resistant coatings.

Acknowledgments

This research was sponsored by the Fossil Energy Advanced Research and Technology Development (AR&TD) Ma- terials Program, U.S. Department of En- ergy, under contract DE-AC05- 96OR22464 wi th Lockheed Mar t in Energy Research Corp. The authors wish to thank V. K. Sikka and P. F. Tortorell i from ORNL for the cast-Fe-AI alloys used in corrosion testing and technical discussions, respectively.

References

1. Banovic, S. W., DuPont, J. N., P. F. Tor- torelli, and Marder, A. R. 1999. The role of aluminum on the weldability and sulfidation behavior f iron-aluminum cladding. Welding Journal 78(1 ): 23-s to 30-s.

2. McKamey, C. G., DeVan, J. H., Tor- torelli, P. E, and Sikka, V. K. 1991. J. Mater. Res. 6 (8): 779-805.

3. DeVan, J. H., and Tortorelli, P. F. 1993. Mater. High Temp. 11 (1-4): 30-35.

4. Tortorelli, P. F. and DeVan, J. H. 1992. Mater. Sci. and Eng., A135 (1-2): 573-577.

5. DeVan, J. H. 1988. Oxidation of High Temperature Materials, eds. T. Grobstein and J. Doyhak. TMS, Cleveland, Ohio, pp. 107-115.

6. Natesan, K. 1997. Proceedings of the Eleventh Annual Conference on Fossil Energy Materials, pp. 289-299. Oak Ridge National

Laboratory, Oak Ridge, Tenn. 7. Tortorelli, P. F., Goodwin, G. M., How-

ell, M., and DeVan, J. H. 1995. Heat-Resistant Materials II, pp. 585-590. ASM International, Materials Park, Ohio.

8. Tortorelli, P. F., DeVan, J. H., Goodwin, G. M., and Howell, M. 1994. Elevated Tem- perature Coatings: Science and Technology I, pp. 203-212. TMS, Warrendale, Pa.

9. DeVan, J. H., and Tortorelli, P. F., 1992. High temp. corr. of iron aluminides. Corrosion 92, Paper 127.

10. Kai, W., and Huang, R. T. 1997. Oxid. Met., 48(1/2): 59-86.

11. Kai, W., Chu, J. P., Huang, R. T., and Lee, P. Y. 1997. Mater. Sci. Engr. A239-240, pp. 859-87O.

12. Gittos, M. F., and Gooch, T. G. 1992. The interface below stainless steel and nickel- alloy claddings. Welding Journal 71 (12): 461 - s to 472-s.

13. Banovic, S. W., DuPont, J. N., and Marder, A. R. 1998. Scripta Metall 38(12): 1763-1767.

14. David, S. A., Horton, J. A., McKamey, C. G., Zacharia, T., and Reed, R. W. 1989. Welding of iron aluminides. Welding Journal 68(9): 372-s to 381 -s.

15. Maziasz, P. J., Goodwin, G. M., Liu, C. T., and David, S. A. 1992. Scripta Metall. 27(12): 1835-1840.

16. Fasching, A. A., Ash, D. I., Edwards, G. R., and David, S. A. Scripta Metall. 32(3): 389-394.

17. David, S. A., and Zacharia, T. 1991. Heat-resistant materials. Proceedings of the 1st International Conference, pp. 169-173, Fontana, Wis.

18. Chou, S. F., Daniel, P. L., Blazewicz, A. J., and Dudek, R. F. 1984. Hydrogen sulfide corrosion in low NOx combustion systems. Babcock & Wilcox report No. RDTPA 84-1, Metallurgical Society of AIME. Detroit, Mich.

19. Urich, J. A., and Kramer, E. 1996. In- ternational Joint Power Generation Confer- ence, Vol. 1, pp. 25-29. ASME, EC-Vol. 4/FACT-Vol. 21.

20. Gabrielson, J. E., and Kramer, E. D. 1996. International Joint Power Generation Conference, Vol. 1, pp.19-23. ASME, EC-Vol. 4/FACT-Vol. 21.

21. HSC Chemistry for Windows, Version 3.0.1997. Outokumpu Research Oy, Finland, www.outokumpu, fi/hsc.

22. Goldstein, J. I., et al. 1992. Scanning Electron Microscopy and X-ray Microanalysis, 2nd edition. Plenum Press, New York, N.Y.

23. Hagel, W. C. 1965. Corros., 21, pp. 316-326.

24. Prescott, R., and Graham, M. J., Oxid. Met. 38(3-4): 233-254.

25. Banovic, S. W., DuPont, J. N., and Marder, A. R. 1999. submitted to Oxid. Met.

26. Pint, B. A. 1997. Mater. Sci. Forum, pp. 251-254, 397-404.

27. Quaddakers, W. J., and Bongartz, K. 1994. Werjst. Korros., 45, pp. 232-238.

28. Quaddakers, W. J., and Bennett, M. J. 1994. Mater. Sci. Technol., 10: 126-131.

29. Tortorelli, P. F., and Natesan, K. 1998. Mater. Sci. Engr., A285, pp. 115-125.

30. Woodyard, J. R., and Sikka, V. K. 1993. Scripta Metall., 29, pp. 1489-1493.

31. Sikka, V. K., Viswanathan, S., and Vyas, S. 1993. High temperature ordered intermetallic alloys V. Materials Research Soci- ety Symposium Proceedings, Vol. 28, pp. 971-976, eds. I. Baker, R. Darolia, J. D. Whit- tenberger, and M. H. Yoo. Materials Research Society, Pittsburgh, Pa.

32. Vyas, S., Viswanathan, S., and Sikka, V. K. 1992. Scripta Metall., 27, p. 185.

33. Prescott, R., and Graham, M. J., Oxid. Met. 38(1-2): 73-87.

34. Pint, B. A. 1997. FundamentalAspects of High Temperature Corrosion, eds. D. A. Shores, R. A. Rapp, and P. Y. Hou, pp. 74-85. Electrochemical Society, Pennington, N.J.

35. Kofstad, P. 1992. High Temperature Corrosion. Elsevier Applied Science, New York, N. Y.

36. Raghavan, V. 1988. Phase Diagrams of TernaryAIIoys, Pt 2, pp. 5-9. The Indian Insti- tute of Metals, Calcutta, India.

70-s I M A R C H 2001

Effect of Thermal Cycling on Friction of 21 95 Aluminum Alloy

Stir Welds

Postweld thermal cycling of friction stir aluminum alloy welds leads to complex microstructural evolution

BY G. OERTELT, S. S. BABU, S. A. DAVID AND E. A. KENIK

ABSTRACT. The microstructure in friction stir welded (FSW) aluminum Alloy 2195 was investigated in the as-welded and postweld thermal cycled conditions. The as-welded microstructure in the dynamically recrystallized zone (DXZ) contains both dislocated and recovered grains. This DXZ region was subjected to thermal cycling. Thermal cycling led to a decrease in dislocation density and precipitation of the second phase within and along the grain boundaries. These results show the DXZ region is supersaturated with alloying element. The grain growth kinetics in the DXZ region were complicated because of the interaction of precipitation and the recovery of deformed grains.

Introduction

Friction stir welding (FSW) involves plunging a rotating shouldered pin tool into the faying surface of two plates and traversing the tool along its length (Ref. 1 ). Welding, which is in solid state, is achieved by plastic flow of frictionally heated material. Extensive research has been accomplished on developing the friction stir welding process for aluminum alloys used in aerospace applications (Refs. 2-6). The process has been applied to both precipitation-strengthened (Refs. 1-9) and nonprecipitation-strengthened aluminum alloys (Ref. 10). Even Alloy 7075 (AI-Zn-Mg type), which is considered difficult to weld with conventional welding processes, was successfully welded with FSW and exhibited good properties (Ref. 7). In addition, friction stir welds of 5454 (AI-Mg) alloys have shown potentially good corrosion properties (Ref. 10). Results of these investigations

G. OERTELT is with the University of Leoben, Leoben, Austria. S. S. I3ABU, S. A. DAVID and E. A. KENIK are with the Metals and Ceramics Division, Oak Ridge National Laboratory, Oak Ridge, Tenn.

show the FSW process yields better properties than conventional welding processes for aluminum alloys.

The details of the microstructural evolution during the severe thermomechanical conditions imposed by this welding process are far from being completely understood. For example, the grains in the dynamically recrystallized zone are not completely recrystallized and there exists a high density of dislocations within these grains (Ref. 6). The precipitation of various phases may also com- plicate the microstructural evolution; these precipitation reactions are determined by the initial state of the base metal (Ref. 8) and alloy composition. In addition, the precipitation characteristics may influence the final grain size of these welds. Besides the microstructural evolution during welding, the stability of the microstructure during subsequent heat treatment is also not understood. In particular, the response of DXZ microstructure to another weld thermal cycle is not known. This subsequent weld thermal cycle may be due to repair welding or subsequent weld overlaps. In addition, the stability of this microstructure during high-temperature exposure is not known. In particular, the initial state of the DXZ may affect the grain growth characteris-

KEY WORDS

Friction Stir Welding Aluminum Alloy 2195 Postweld Thermal Cycling Dynamically

Recrystallized Zone Thermomechanically

Affected Zone Heat-Affected Zone

tics. Therefore, in this work, microstructural evolution in the DXZ, stability of the microstructure to multiple thermal cycles and grain growth characteristics of DXZ regions were investigated in friction stir welds of 2195 aluminum alloy.

Experimental

Aluminum Alloy 2195 (AI-4.0 wt-% Cu-1.0% Li-0.5% Mg-0.4% Ag-0.1% Zr) was used in this investigation, and the plate was in the T8 (solution treated, cold worked and artificially aged) condition (Refs. 6, 11) before the FSW operation. The friction stir welding was done at the Lockheed Martin Manned Space System Complex, New Orleans, La. The 5.8- mm-thick (0.23-in.) plates were friction stir welded with the following process parameters: 10.9-mm (0.43-in.) pin-tool diameter; 7.9-mm (0.31-in.) pin-tool height; 0.18-mm (0.007-in.) penetration ligament; 27.9-mm (1.1-in.) shoulder diameter; 200-250 rpm pin-tool rotation speed; 1.59 mm/s (3.75 in./min) welding speed. Samples were cut from the welds along the transverse direction. The DXZ regions in these samples were subjected to postweld thermal cycling using a Gleeble~ thermomechanical simulator. The particulars of this thermal cycle are given in the Result section of this paper. Long-term grain growth behavior was investigated by subjecting the DXZ regions to thermal aging at 200, 300 and 400°C in a furnace for different times.

The samples were characterized with standard optical microscopy. The grain size measurements were performed on scanned images of optical micrographs using the public domain NIH image program (developed at the U.S. National Institute of Health and available on the Internet at http: / / rsb. info.nih.gov/ nih-image/). Backscattered electron imaging was performed with a Philips XL30/FEG scanning electron microscope


t ¢

Fig. 1 - - Friction stir welded 2195 aluminum alloy weld. A - - Micrograph illustrates different zones (dynamically reerystallized zone, thermomechanically affected zone and heat-affected zone); B - -

1- high-magnification micrograph of DXZ shows equiaxed grains; C - - leading edge of DXZ and TMAZ (right side of the micrograph in A) shows a sharp change in equiaxed to elongated orientation.

Table I - - Raw Data from the Image Analysis of Precipitates from SEM Micrographs from the As-Welded and after TC1 Treatment. (Numbers for Precipitates and area percent are given.)

As-Welded TC 1 Frame Number Percent Number Percent

1 48 1.082 131 5.114 2 137 2.261 108 5.849 3 73 2.948 99 7.196 4 65 1.191 155 6.24 5 87 1.838 119 5.118 6 38 0.778 122 3.601 7 97 2.465 173 5.05 8 93 1.593 126 6.38 9 111 2.744 84 3.281 10 76 1.696 93 5.664 Average 1.8606 +.731 5.349 + 1.209

(SEM) to analyze coarse second-phase precipitates. The precipitate volume fractions in these images were also measured with the NIH image analyzer program. Transmission electron microscopy (TEM) was performed with a Philips CM12 microscope to evaluate the recovered structures and precipitates in the weld. Hard- ness variations across the weld were measured using a LECO M-400 H2 mi- crohardness tester.

Results and Discussions

As-Welded Microstructure

The macrostructure of the 2195 aluminum alloy weld is shown in Fig. 1A. The macrograph indicates three distinct

regions of the weld: dynamically recrystallized zone (DXZ), thermomechanically affected zone (TMAZ) and heat- affected zone (HAZ). The macrograph shows the lack of symmetry along the centerline of the weld. This is attributed to the nature of the plasticized metal movement around the rotating tool during welding. The micrograph in Fig. 1B shows primarily equiaxed grain structure in the DXZ region. The sharp boundary between the DXZ and the leading edge of the TMAZ is shown in Fig. 1C. These results are consistent with other published work on FSW (Refs. 3, 6). In order to compare the microstructure in the DXZ region with that of the base metal (BM), SEM and TEM characterizations of the base metal were also performed - -

Fig. 2. The backscattered SEM image with EDS analysis indicated a small number of Cu-rich and Cu-Fe-rich precipitates (<0.5 pm) in the base metal region. The reasons for the presence of Fe in these precipitates are not known. TEM characterization with electron diffraction showed the presence of very fine T1 (AI2CuLi type, -50 nm long and -1 nm thick) precipitates.

The DXZ contained a fine grain structure, including Cu-rich and Cu-Fe-rich precipitates along the grain boundaries-- Fig. 3B. In general, the Cu-Fe-rich precipitates were coarser than the Cu-rich precipitates. The SEM analysis at high magnification showed small precipitates within the grain-- Fig. 3C. It is speculated these are the same precipitates observed in the base metal region, which might have undergone some coarsening during friction stir welding. The EDS spectrum from the matrix showed the presence of copper in the matrix (Fig. 3D) and indicates some copper supersaturation in the matrix. Therefore, on thermal cycling, the precipitation reaction is expected. The presence of Cu and Fe in the grain boundary precipitates is supported by EDS analysis-- Fig. 3E. The micrograph in Fig. 3C shows the precipitate fraction is higher than that of the base metal region. This indicates thermal cycles experienced by the metal during the friction stir welding process are sufficient to initiate precipitation reactions within the grains and along the grain boundaries.

Transmission electron micrographs of the DXZ are shown in Fig. 4. Interestingly, dislocation networks were observed within the grain - - Fig. 4A. The electron diffraction indicated the absence of T1 precipitates. These results are in agreement with the published literature (Ref. 6). Off-zone imaging (Fig. 4B) and EDS analysis of some of the grains indicated the presence of small Cu-rich precipitates within grains and along the grain boundaries. Note these precipitates are smaller than those observed in the SEM. Based on previous literature (Ref. 6), these precipitates are expected to be equilibrium (AITCu4Li- type) T R precipitates. The present characterization did not detect any [~' (AI3Zr) precipitates in the DXZ. The TEM charac-

terization of the DXZ region also indicated there are grains in the process of recovery (Fig. 4C) adjacent to grains that exhibit large dislocation density. The micrograph shows a grain with dislocations aligning to form a subgrain boundary, and this grain did not exhibit extensive dislocation networks as shown in Fig. 4A. Such microstructural features were not previously reported, and it is interesting to note that grains with different degrees of recovery exist next to each other. This phenomena

72-s I MARCH 2001

cannot be attributed to differences in thermal cycles because of the large thermal conductivity of aluminum alloys. Li, et al., attributed the observed high-dislocation density in the grains to possible deformation by the friction stir welding tool shoulder and metal interactions (Ref. 6). If that were the case, the dislocation density would be uniform throughout all the grains in certain regions and it would be absent away from the shoulder tool. The observed dislocation density differences in the current welds are for neighboring grains. Therefore, the observed phenomena may be attributed to deformation gradients across the grains during the welding operation. This speculation is supported by the results of a detailed com- putational model with meso-scale plastic deformation, recovery and recrystallization models (Ref. 12) subjected to nonuniform deformation.

The above-mentioned microstructural observations showed the DXZ region essentially consists of grains at different stages of the recovery process. Moreover, almost all the grains had Cu-rich precipitates along the grain boundary and within the grain.

Effect of Thermal Cycling on Microstructure Development

The stability of the DXZ region in friction stir welds to subsequent thermal cycling was evaluated. Samples were cut in the transverse direction, as shown in Fig. 5A, and subjected to two sets of thermal cycles (Fig. 5B) in a Gleeble ~ thermomechanical simulator. Experiments were designed so that the DXZ region was heated to peak temperature by adjusting the copper jaws that restrain the sample in the Gleeble instrument. As a result, the uniform temperature zone was centered on the DXZ region; its thermal cycles are shown in Fig. 5B. In the first stage (TC1), the DXZ was heated to 430°C and cooled continuously. That thermal cycle represents a typical one experienced by the DXZ region during FSW (Refs. 3, 13). The reason for this thermal cycle was to evaluate the effect of subsequent FSW passes on the previously formed DXZ. In the second stage, to consider the effects of multiple passes, the TC1 samples were subjected to an additional thermal cycle (TC2) similar to that of TC1.

Hardness variations across the DXZ are compared in Fig. 5C. The plots also show the hardness in the TMAZ, HAZ and BM regions. Hardness across the DXZ regions decreases from 122 to 106 VHN after TC1. But the additional TC2 did not result in a significant further drop in hardness. It is interesting to note hardness after TC1 is similar to that of the

HAZ. Hardness in the TMAZ, HAZ and BM reduced slightly, since they were not subjected to high temperature. The results show the thermal cycles do reduce the hardness and the reduction is essentially complete after TC1. Therefore, the microstructure after TC1 was characterized with SEM and TEM. The backscattered electron image of the DXZ region subjected to TC1 cycle is shown in Fig. 6A. The grain size of the samples remained the same in these alloys. The microstructure exhibited extensive grain boundary precipitation and small precipitates were also observed within the grains - - Fig. 6B. An image analysis of all the precipitates (Table 1) showed the volume percentage of precipitates in the TC1 condition (5.35%) is higher than that of the as- welded (1.86%) condition. The nature of dislocation content and precipitation were also evaluated with TEM. The TEM micrograph and electron diffraction showed the absence ofT1 precipitates - - Fig. 6C. However, extensive dislocation networks were absent in this condition, except for small loops. Detailed analysis showed Cu-rich precipitate within and along the grains. Some of these small precipitates were rich in Cu and A g - Fig. 6D. In some areas, coarse composite precipitates with a Ag-rich center and Cu-rich exterior were observed. None of the EDS analyses on the precipitates showed the presence of Mg.

An attempt was made to predict the precipitating phase for the 2195 alloy using a thermodynamic software called ThermoCalc~ (Ref. 14) with an aluminum alloy database (Ref. 15). These calculations considered the AI, Cu, Mg and Zr elements and the phase equilibrium between AI2CuMg, AI~Zr, AI2Cu, A!~Mg2,

Fig. 2 - - Characterization of base metal microstructure: A - - 5EM backscattered electron image showing the presence of Cu-rich and Cu- and Fe-rich particles; B - - transmission electron micrograph with electron diffraction indicating the presence of T1 precipitates.

liquid and FCC solid solution. Since there are no thermodynamic data on the metastable T1 and other precipitates, they were not included in the analysis. The equilibrium calculations for the alloy composition AI-4.0 wt-% Cu-0.5% Mg- 0.1% Zr were performed as a function of temperature and the results are presented in Fig. 7. The results show the predomi- nant second-phase precipitates will be AI2Cu, AI2CuMg and AI3Zr at low temperatures. But, at around 400°C, only AI2Cu will be the stable precipitate and the volume percentage will be 3.3% (4.7% wt-%). The calculations qualitatively agree with the measured precipitate volume percentage and type observed in thermal cycled samples.

These observations suggest the soften- ing observed in the TC1 condition may be due to many competing mechanisms.

W E L D I N G RESEARCH SUPPLEMENT I 73-s

D e2~

j .

ileo

~ ? e t-

i-

+ 2 1 -

~1~ Cu l l l . l O ++,+I :l.+O I . o 0 4 . I I I S*o0 I . O H . O O l . O a I, .0o 'IO,,

keV

E

12B

I~o.oe 1 . ~ o ' ,.J

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keV

Fig. 3 - - Detailed analysis of the weld DXZ: A - - Optical micrograph shows equiaxed grain structure; 8 - - backscattered electron SEM image shows the presence of large grain boundary precipitates; C - small rod-/disklike in- tragranular precipitates; D - - the ED5 spectrum obtained from the matrix shows the presence of copper; E - - similar analysis from the grain boundary precipitates shows the presence of copper and iron.

Essentially, the strength of the aluminum alloy can be factorized into different parameters as given in the following:

Strength = O'in t + CTsoli d solution

+t~ ppt + adislocation + (Tgrain size (1)

In the above expression, (~int corresponds to the intrinsic strength of an aluminum alloy, a+otid +o~u,~on is the strength contribution due to solid solution, appt is the strengthening due to age-hardening precipitates, admocat~on is the strengthening due to dislocation content and (~grain size is the contribution from the grain size variation. All of these components may operate in the age-hardening alloy subjected to thermomechanical deformation. Each component in turn depends on other variables such as alloying element concen- tration, precipitate volume fraction, dislocation density and grain size. With known

74-s1 MARCH 2001

relations (Ref. 16), Equation 1 can be converted to the following form:

n

Strength = O'in t + ~_kie i i=1

+kppt(fppt )m + kdislocation'\/P

kgrain -f (2)

where k~ corresponds to the coefficient of solid-solution hardening, e i is the con- centration of each alloying element, n is the number of alloying elements, kppt is the coefficient of hardening due to precipitation, fppt is the volume fraction of precipitates, m is the power constant for precipitate hardening, p is the dislocation density, kd~stocat~on is the coefficient for dislocation hardening that is related to shear modulus, kgrain is the coefficient for grain size effect and d is the grain diam-

eter. It is also important to note that in polycrystalline materials, the hardening resulting from dislocations and finer grain size is related. Although it is difficult to evaluate all of the constants in Equation 2 for the alloy considered in this work, the effect of each parameter on overall strength can be evaluated qualitatively. In the as-welded condition, the microstructure contains fine grains (-10 lum) with large dislocation density, as well as recovered structure and small precipitates (10-50 nm) within the grain, and coarse precipitates along the grain boundaries. This condition will yield large strengthening characteristics and, as expected, the hardness in the DXZ region is high and is equivalent to that of base metal in the aged condition. It is important to note base metal strengthening is achieved because of fine metastable, semicoherent T1 and other precipitates,

and the DXZ region does not contain these precipitates. On thermal cycling, the dislocation density decreases and volume fraction of other precipitates increases in the DXZ, leading to reduced strength levels. The precipitation reaction is expected to reduce the solid-solution hardening. There was no change in grain size during thermal cycling and, therefore, grain size contribution will remain the same. This suggests the precipitation during thermal cycling is insufficient to offset the drop in strength due to the reduction in dislocation and solid-solution hardening.

Grain Growth Characteristics in the Weld Metal Region

In addition to precipitation reactions and the recovery process, it is important to consider grain growth characteristics of the DXZ region. The DXZ regions were subjected to grain growth experiments at 200, 300 and 400°C for various periods of time. The SEM backscattered electron images of microstructures from samples after 8 h at different temperatures are shown in Fig. 8. The micrographs show that, in addition to grain size changes, the precipitation characteristics also changed. With an increase in temperature, the grain boundary precipitation became more copious and the average size of the precipitates increased. This suggests these precipitates will influence grain growth characteristics. Grain size of these samples was measured using optical microscopy and manual tracing of grain boundaries. Typical grain structure traces from the as-welded condition and after 8 h at 400°C are compared in Fig. 9. These tracings were analyzed with the

Fig. 4 - - A - - Detailed transmission electron microscopy of DXZ in the weld showing a grain with high dislocation density. The electron diffraction patterns indicate the absence of T1 precipitates. In addition, DXZ regions also showed the following: B - - small Cu-rich precipitates (imaged off-zone) within the matrix; C - - initial stages of a subgrain boundary formation.

NIH image analyzer and grain size distributions were obtained. Interestingly, these data showed on aging at 200°C, the average grain size reduces. This is evi- dent in the comparison of grain size distributions shown in Fig. 10. The distribution after 256 h of exposure at 200°C was skewed toward a smaller grain size compared to that of the as-welded condition. This could be related to the recrystallization of deformed grains present in the as- welded condition. The average grain size distribution from all temperatures is shown in Fig. 11. The results show the grain size increased without any initial decrease only at 400°C. The average grain size decreased initially at 300°C; above 2 h of exposure, the grain size increased. It is important to note the grain size changes shown in Fig. 11 are statis- tically significant, because they are

based on a large number of grain sam- plings.

The grain growth equations with the influence of precipitates have been dealt with before (Ref. 17) and are expressed by the following equation:

d = rppt I 3 - 71 3fppt ~ 2 ) (3)

w h e r e rpp t is the radius of the precipitate, fppt is the volume fraction of precipitate and Z is the ratio of maximum grain size to the average grain size. This grain size limiting relation will change with a change in fppt o r rpp t. In the present case of grain growth experiments at 200 and 300°C, in the initial stages the fppt is expected to increase and thereafter will remain constant. However, the change in rpp, in the present case is expected to be


I Water-Cooled Copper Jaws

T h e r m o c o u p l e s

::Uniform Temperature Zone

Water-Cooled Copper Jaws

B 500 - ......... ITCl-Cycle I . . . . . . . . . . . . . . ITC2-Cycle I ........

400 -

g 3 o o -

200-

1 0 0 -

/ 0

0 I I

100 I I I

200 300 400 500 Time (s)

C 1 5 0 -

140 -

~" 130-

120-

- r 1 1 0 -

100-

90-

HAZ i TMAZ DXZ TMAZ HAZ

[as-w elded I

! l j i

I I I I I I I

-15 -10 -5 0 5 10 15 Distance (m rn)

Fig. 5 - - A - - Geometry o f the sample for thermal cycling; 8 - - thermal cycles used in this investigation; C - - comparison of hardness variations after thermal cycling conditions with the one measured from the as-welded condition. The regions corresponding to hardness distributions are also marked on the plot.

complex. This is because of the nucle- ation of small precipitates within the grain and along the grain boundary, as well as growth of existing coarse precipitates along the grain boundary. There-

fore, there is a need to model these interactions between precipitation kinetics (change offpp t and r~t with time) and grain growth behavior. Although Equation 3 suggests a possible decrease in limiting

grain size due to interaction with a precipitation reaction, the reduction in grain size from the as-welded condition cannot be easily explained. The initial decrease in grain size may be attributed to the recrystallization of those grains that exhibited large dislocation density in the as-welded condition - - Fig. 4A. In the case of grain growth at 400°C, the precipitation reaction and dissolving reaction may occur rapidly and the sample will reach the equilibrium fraction of precipitates. After this, the precipitates will undergo simple Ostwald ripening-type growth and will lead to an increase in grain size. Equation 3 will then hold well. These results and TEM observations (Fig. 4) suggest DXZ regions are not in a completely recrystallized state in the as- welded condition.

Summary and Conclusions

Microstructures of friction-stir-welded 2195 aluminum alloy were characterized in the as-welded, postweld thermal cycled and isothermally aged conditions. The as-welded microstructure consists of microstructure gradients, including a dynamically recrystallized zone, thermomechanically affected zone and a soft heat-affected zone. Transmission electron microscopy of the DXZ illustrated the absence of T1 precipitates and also the coexistence of recovered and heavily dislocated grains next to each other. EDS analysis identified the presence of small precipitates within the grain and along the grain boundaries that are either rich in copper alone or in both copper and iron.

After postweld thermal cycling, hardness in the DXZ decreased. Transmission electron microscopy of these samples revealed average dislocation density in these regions was qualitatively less than that in the as-welded condition. EDS analysis indicated the presence of small (<20 nm) precipitates containing silver, as well as composite copper-rich precipitates containing a silver-rich phase, along the grain boundaries. Transmission and scanning electron microscopy revealed the precipitate fractions increased with thermal cycling. These results show the matrix in the as-welded condition is supersaturated and that precipitates form within the grains and at grain boundaries during thermal cycling.

Grain growth kinetics of DXZ at 200°C indicated a small decrease in grain size as a function of time. However, as the temperature increased to 400°C, the grain size increased monotonously with time. This is related to competition between recrystallization of new grains, precipitation reactions and grain growth mechanisms.

76-s I MARCH 2001

J

,? /;.~/ i

!i! i

;ich

~a-rich

Fig. 6 - - Detailed analysis of thermal cycled samples: A - - 5canning electron backscattered image showing grain boundary precipitates ; B - - small precipitates within the grain; C - - transmission electron micrograph showing the dislocation loops, as well as the small precipitates within the grain; D - - precipitates observed along the grain boundaries•

Acknowledgments

This research was sponsored by the Division of Materials Science and Engi- neering, U.S. Department of Energy, and Assistant Secretary for Energy Efficiency and Renewable Energy, Office of Indus- trial Technologies, Advanced Industrial Materials Program under contract DE- ACO5-00OR22725 with UT-Battelle and through the SHARE Program under contract DE-AC05-76OR00033 with Oak Ridge Associated Universities. The authors thank William J. Abergast and Paula J. Hartley of Lockheed Martin Manned Space System Complex, New Orleans, La., for providing the welds used in this investigation.

c o

LL E

~j FCC /i

f l AI2Cu / Z i -L iqu id 0.1 / / !. //

4: .... . . . . . . . . . . . . . . . . . . ,., / • AI2CuM g "'-, ,

o q / AI3Zr ' \ ":: t

1 I / 2"

o.oot~ ......... ;- I ! , , 200 300 400 500 600 700

Temperature (°C)

I

800

Fig. 7 - - Predicted weight fractions of various phases calculated with ThermoCalc software as a function of temperature.


Fig. 8 - - Scanning electron micrographs o f DXZ after grain growth experiments: A - - After 8 h at 200°C; B - - after 8 h at 300°C; C - - after 8 h at 400 °C

Fig. 9 - - Typical grain growth profiles obtained from the optical micrograph samples: A - - As-welded condition; B - - 8 h at 400 °C

References

1. Dawes, C. J. 1996, Friction stir welding of aluminum. I IW-DOC X11-1437-96, pp. 49-57.

2. Knipstorm, K. E. 1995. New welding method for aluminum. Svetsaren 50: 5-6.

3. Arbegast, W. J., and Hartley, P. 1999. Friction stir weld technology development at Lockheed Martin Michoud Space System - - an overview. Proc. Intl. Conf. on Trends in Welding Research, eds. J. M. Vitek, S. A.

David, J. A. Johnson, H. B. Smartt and T. Deb- Roy. ASM International, Materials Park, Ohio, pp. 541-546.

4. Waldron, D. J., Roberts, R. W., Dawes, C. J., and Tubby, P. J. 1999. Friction stir welding characterization for aerospace structures. Ibid, pp. 547-552.

5. Jones, Ill, C. S. 1999. Friction stir welding of large-scale cryogenic fuel tanks for aerospace applications. Ibid, pp. 553-557.

6. Li, Z. X., Arbegast, W. J., Hartley, P., and Meletis, E. I. 1999. Microstructure characteri-

zation and stress corrosion evaluation of friction stir welded AI-2195 and AI-2219 alloys. Ibid, pp. 568-573.

7. Mahoney, M. W., Rhodes, C. G., Flintoff, J. G., Spurling, R. A., and Bingel. 1998. Prop- erties of friction stir welded 7075 T651 aluminum. Metall. Mater. Trans. A., 29A: 1955-1964.

8. Sato Y. S., Kokawa, H., Enomoto, M., and Jogan, S. 1999. Microstructure evolution in 6063 aluminum during friction stir welding. Metall. Mater. Trans A., 30A: 2429-2437.

78-S I M A R C H 2001

0.08 1

006 J C

~ 004-

0.02-

0.00 -

~ / ~ i n @ 200 °Cl

j:. . . . . .

i ~ i I 10 20 30 40

Grain Diameter (lain)

12- I

-t ~5 c

8 o 200 cl ....... ~ ......... / + 300 cl

7 J ' ' ' . . . . . I . . . . . . . . I . . . . . . . . I . . . . . . . . I

0.1 1 10 100 1000 Time (h)

Fig. 10 - - Comparison of grain size distribution obtained from the as- welded condition and that of 256 h at 200°C.

Fig. 11 - - Grain growth kinetics as a function of temperature for the DXZ region of the weld. The error bars correspond to standard error of 0.1 pm.

9. Murr, L. E., Liu, G., and McClure, J. C. 1998. A TEM study of precipitate and related microstructures in friction-stir welded 6061 aluminum. J. of Mater. Sci. 33: 1243-1251.

10. Frankel, G. S., and Xia, Z. 1999. Lo- calized corrosion and stress corrosion cracking resistance of friction stir welded aluminum alloy 5454. Corrosion 55:139-150.

11. Diwan, R. M. 1994. Quantitative microstructural analysis and weldability study of aluminum lithium alloys. Proc. Conf. on Met- allographic Characterization of Materials Be- havior. Microstructural Science 21 : 343-356.

12. Radhakrishnan, B., Sarma, G., and Zacharia, T. 1998. Monte Carlo simulation of deformation substructure evolution during recrystallization. Scripta Metal. 39:1639-1645.

13. McClure, J. C., Tang, W., Murr, L. E., Guo, X., Feng, Z., and Gould, J. E. 1999. A thermal model of friction stir welding. Proc. Intl. Conf. On Trends in Welding Research, eds. J. M. Vitek, S. A. David, J. A. Johnson, H. B. Smartt and T. DebRoy. ASM International, Materials Park, Ohio, pp. 590-595.

14. Sundman, B., Jansson, B., and Anders- son, J. O. 1985. The Thermo-Calc databank

system. Calphad 9:153-190. 15. Saunders, N. Al-data information.

ThermoTech Ltd., Guildford, Surrey, U.K. 16. Dieter, G. E. 1981 Mechanical Metal-

lurgy. New York, N.Y.: McGraw Hill. 17. Martin, J. W., and Doherty, R. D. 1976.

Stability of Microstructures in Metall ic Sys- tems. Cambridge Solid State Science Series, University Press, Cambridge, U.K.

IrHIDI


The Effects of Root Opening on Mechanical Properties, Deformation and Residual Stress

of Weldments Mechanical properties for multipass welds are investigated and weld deformation

and residual stress are simulated using finite element analysis

BY G. B. JANG, H. K. KIM A N D S. S. KANG

ABSTRACT. In steel bridge manufacturing, dimensional differences caused by weld deformation often occur because multipass welding is used to join thick plates. It frequently develops that root openings are out of tolerance at butt joints. For example, to be within tolerance, root openings must be controlled to below 6 mm for butt-joint welds in plates under 20 mm thick, but a root opening of 30 mm can develop in the field. In that case, a part 24 mm out of tolerance is generally built up. However, there has been no accumulated data and standards developed regarding these built-up welded parts. In the present case, a study was performed to accumulate data on the behavior of built-up parts and to verify the effects of root opening on the mechanical properties of the welded parts. For that purpose, tensile, bend, impact and hardness tests were carried out on weld specimens having 0-, 6- and 30-mm root openings. Additionally, the finite element common code (MARC) was used to study the effects of 0-, 6- and 30-mm root openings on residual stress and weld deformation in multipass welding. The results of the experiments and of the analysis were compared. In the analysis, a 100% ramp heat input model was used to avoid the numerical convergence problem caused by an instantaneous increase in temperature near the fusion zone. The effect of a moving arc in a two-dimensional plane was also included. Additionally, to ensure the accuracy of the analysis and to save time, small time increments were applied in a period with instantaneous temperature fluctuations, while large time increments were used in another period. The experimental and analytical results show good correlation. Weld-included residual stresses and deformation distribution of

G. B. JANG, H. K. KIM and S. S. KANG are with the Micro-Plasticity Laboratory in the Dept. of Mechanical Engineering, Pusan Na- tional University, Pusan, Korea.

80-s I MARCH 2001

the specimen with the 30-mm root opening appeared to be asymmetric and the magnitude was larger than those of root opening specimens in tolerance.

Introduction

When steel structures are welded, a localized fusion zone is generated in the weld joint because of the high heat input from the arc, and then nonuniform temperature distribution through heat conduction is induced. Therefore, nonuniform heat deformation and thermal stress are included in the as-welded parts. As a result, plastic deformation is retained within the weldment and nonlinear plastic deformations and residual stresses exist after cooling of the welded joint (Refs. 1, 2). Many problems occur in the field because of dimensional differences that occur as a result of these weld deformations during manufacturing of large steel structures (Ref. 3). For thick-section welded steel bridges, many welders frequently neglect the occurrence of dimensional differences caused by the weld deformation that results from multipass welding. When an out-of-tolerance root opening arises from the dimensional difference through weld deformation, parts out of tolerance are built up in the field. While this phenomenon is com-

KEY WORDS

Multipass Welding Root Opening Residual Stress Deformation Sequential Thermal-

Mechanical Analysis

mon, building up the weld is usually performed without systematic inspection.

Steel plate 15 mm thick is limited in practice to a root opening of less than 6 mm. However, dimensional differences caused by the weld deformation from heating and cooling of a localized fusion zone result in a root opening of greater than 6 mm to a maximum of 30 mm. In that case, after grinding, welding is performed to build up the weld by 24 mm in order to make a 6-ram root opening. There are difficulties, however, acquiring satisfactory data about problems that arise from this built-up weld and, furthermore, no standards exist regarding the built-up weld.

Although the built-up weld compen- sates for the dimensional difference in the root opening caused by weld deformation, it may impede work progress and create safety problems by lowering structural strength.

Many engineers have had difficulty in systematically quantifying weld residual stresses and deformations in large welded structures that use thick, welded steel plates (Ref. 4). Recently, finite element analysis has been used to quantify data about weld residual stresses and deformations (Refs. 5-7). However, it has emphasized single-pass welding rather than multipass welding. The effects of root opening size on weld residual stress and deformation have been analyzed using MARC, a software for finite element analysis (Ref. 8). The comparison between finite element analysis and experimental measurements through a systematic approach can be utilized as fun- damental data for quantifying weld residual stresses and deformations for the design of welded steel structures (Refs. 9-12). In comparison with the existing heat-input model, this paper suggests a new model as an efficient analysis method for improving the accuracy of the solution and reducing analysis times.

Exper imenta l Procedure and W e l d i n g Cond i t ions

The steel, SWS 490A, used in this study is a hot-rolled steel util ized in the manufacture of bridges, vessels, automobiles, fuel storage tanks and other structures. It has excellent weldabi l i ty. The chemical composition and mechanical properties of the base metal are shown in Tables 1 and 2. Welding was performed with the f lux cored arc welding (FCAW) process. The welding wire used was SF- 71. The shielding gas was an Ar-CO2 mixture with a f low rate of 20-30 Umin. The test specimens had a 60-deg-angle V- groove. Their dimensions were 300 x 500 x 15 mm (2W x L x h). A cross section of the test specimen is shown in Fig. 1. The welding condit ions for each specimen are shown in Tables 3-5. The surrounding atmospheric temperature was approximately 20°C, and postweld heat treatment was not applied.

In the experiments, butt-joint, multipass weldments with 0-, 6- and 30-mm root openings were manufactured with FCAW. Tensile, bend, impact and hardness tests were performed to evaluate mechanical performance. Moreover, microstructures were observed with an op- t ical microscope. Charpy impact and Rockwell hardness tests were measured at distances 2.5, 7.5 and 12.5 mm from the upper surface of the specimens. To provide data for verification of the thermal analysis, thermocouples were placed on the specimens at node 84 (at a distance of 5 mm from the weld interface). After welding, a three-element, strain-gauge rosette was applied at a distance from the weld interface (Fig. 4), and the residual stresses were determined by using the hole-dri l l ing method according to ASTM Standard E837. Lastly, weld deformation of the thickness direction was measured with a dial gauge. Dimension and shape of the experimental test specimen are shown in Fig. 2.

Finite E lement Analysis

Finite Element Modeling and Mesh Generation

The coupling between the thermal and mechanical analyses takes place through

A

I I Omm

B

I I Smm.l L _ _

C s~

I I

Fig. 1 - - Schematic cross sections o f the test specimens. A - - O-mm root opening; B - - 6 -mm root opening; C - - 30 -mm root opening bui l t up with 24 m m o f weld material to create a specimen with a 6-ram root opening (the numbers in each area o f the weld zones represent the welding sequence o f the multipass weld).

Table 1 - - Chemical Composition of Base Metal

Material Chemical Composition (wt-%)

SWS C Si Mn 490A 0.15 0.43 1.45

P S 0.03 0.03

Table 2 - - Mechanical Properties of Base Metal

Material Mechanical Properties

SWS Yield Strength (N/mm 2) Tensile Strength (N/mm 2) 490A 310 490 - 610

Elongation (%) 17

Table 3 - - Welding Conditions for 0-mm Root Opening

Pass No. Electrode Diameter of Ampere Volt Interpass Polarity Electrode Temperature

1 DCEP 1.4 220 26 Ambient 2 DCEP 1.4 230 27 94 3 DCEP 1.4 210 27 66

Backgouging 4 DCEP 1.4 190 26 45

Ti m e Weld Length Speed Heat Input

(mm) min s (cm/min) (kJ/mm)

580 4 7 14.1 2.4 610 3 30 17.4 2.1 610 4 6 14.9 2.3

560 3 15 17.2 1.7

W E L D I N G RESEARCH SUPPLEMENT I 8 I-s

A

2111

u m t : n u ~

B

i ~ r I

u r u t : n u n

C

I i j l I

297

un i t : m m

Fig. 2 - - Dimensions and shape o f the test specimens. A - - Tensile specimen; B - - impact specimen; C - - bend specimen. (Test specimens were acquired in a perpendicular direction to the weld interface.)

the temperature- dependent material properties in the mechanical stress problem, which serves as input for heat transfer analysis. Addit ion- ally, a change in the temperature distribution contributes to deformation of the body through thermal strains and influ- ences the material properties. Through this process, sequential thermal-mechanical analysis, from which the temperature distribution, stress and displace- ments induced by the thermal strain were obtained, was performed (Refs. 13, 14). Of course, all mechanical and thermal material properties may be temperature dependent and the governing matrix equations may be expressed as the fol-

lowing (Ref. 8):

M + D(T) + K(T)u = f (1)

C(T) + K(T)T -- Q + Q1 (2)

where M is the mass matrix, C(T) is the specific heat matrices, K(T) is the thermal conductivity matrices, D(T) is the temperature-dependant displacement matrices, T is the nodal temperature vector, u is the displacement vector, f is the plastic work and Q1 is the amount of heat generated because of the plastic work.

The characteristics of the weld analysis require a large amount of t ime and storage memory to model the weld fusion and heat-affected zones. In the case of a single-pass weld, 3-D analysis that con- siders moving heat sources can be used, while for a multipass weld it is important to know many engineers tried to simplify the problem because of the difficulty of 3-D analysis. In this study, the assumption the cross section of each specimen has the same temperature distribution was used to predict the weld residual stresses and deformations during multipass welding of thick plates. A vertical cross section of the weld interface was used for 2-D analysis. In other words, the assumption of plain strain is utilized to consider the stress of the thickness direction to avoid


Time Pass No. Electrode Diameter of Ampere Volt Interpass Weld Length Speed Heat Input

Polarity Electrode Temperature (mm) min s (cm/min) (kJ/mm)

1 DCEP 1.4 210 26 Ambient 620 5 51 10.6 3.1 2 DCEP 1.4 230 27 114 640 3 35 17.9 2.1 3 DCEP 1.4 230 29 111 660 4 41 14.1 2.8 4 DCEP 1.4 210 30 42 570 5 43 10.0 3.8


Pass No. Electrode Diameter of Polarity Electrode

1 DCEP 1.4 2 DCEP 1.4 3 DCEP 1.4 4 DCEP 1.4 5 DCEP 1.4 6 DCEP 1.4 7 DCEP 1.4 8 DCEP 1.4

Welding after grinding 9 DCEP 1.4 10 DCEP 1.4 11 DCEP 1.4 12 DCEP 1.4 13 DCEP 1.4 14 DCEP 1.4 15 DCEP 1.4 16 DCEP 1.4 17 DCEP 1.4

Time Ampere Volt Interpass Weld Length Speed Heat Input

Temperature (mm) min s (cm/min) (~/mm)

180 26 Ambient 620 4 6 15.1 1.9 180 27 123 620 3 54 15.9 1.8 200 27 72 620 3 7 19.9 1.6 200 27 89 620 3 48 16.3 2.0 200 27 120 620 3 6 20.0 1.6 200 27 128 620 3 54 15.9 2.0 200 26 133 620 2 50 21.9 1.4 200 26 87 620 3 17 18.9 1.7

180 26 62 620 7 12 8.6 3.3 210 28 162 620 1 45 35.4 1.0 220 28 135 620 2 0 31.0 1.2 220 28 75 620 3 29 17.8 2.1 210 28 63 620 4 30 13.8 2.6 210 28 110 620 3 20 19/8.6 1.9 210 28 120 620 3 38 17.1 2.1 210 28 60 620 3 59 15.6 2.3 210 28 103 620 4 9 14.9 2.4

82-sl M A R C H 2001

Fig. 3 - - Schematic of the weld specimen and analysis zone showing the dimensions.

errors by generating excessive stress in the thickness direction if the multipass weld is analyzed as plain stress to predict residual stresses. The analysis model of the size of the weld specimen and vertical cross section passing unit length of the weld interface is presented in Fig. 3.

Localized heat input creates a fine mesh around the weld zone, which has an abrupt temperature gradient, and the size of the elements at a distance far from the weld fusion and heat-affected zones is increased to reduce analysis time. The node numbers for the analysis results and finite element model are presented in Fig. 4. The mesh for analysis is comprised of a four-node quadrilateral element and deactivated element in the weld joint.

Deactivate options deactivate elements except for the first of the multiple layers. When an element of the weld zone is deactivated, it does not con- tribute to stiffness and internal force. When an element is reactivated after welding of the first layer, it will have the stress level from when it was deactivated. The iterated process is performed continually until formation of the weld bead is complete. When the 24-mm built-up area is welded, a connected region as a nonbuilt-up mesh is deactivated to increase the accuracy of the deformation analysis. For this study, after the 24-mm buildup was finished, analysis methods were used that reactivated a connected nonbuilt-up mesh of 6 mm.

Boundary Conditions

The initial temperature of all nodes was 20°C, which was equivalent to atmospheric temperature. The nonlinearity

A 93 119

N o de 147 \

4 6 , 8 4 , 8 7 , 9 0

[ ~ Node 147 93 119

46, 84, 87, 90

Z C

Node 147 Node 293 275 270 9 3 ; 1 9

/ \ / _ _ _ _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L I ! LI[ .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i i I I

~24, 515, 47"/ 46, 84, 87, 90

L Fig. 4 - - Mesh generation and node numbers. A - - Model of a O-ram root opening specimen that uses 272 elements and 304 nodes; 8 - - model of a 6- mm root opening specimen that uses 326 elements and 364 nodes; C - - model showing a 24-ram bui ldup and 6-ram root opening. It uses 489 elements and 534 nodes. The node index made at the beginning of a model is a measurement position for thermal cycle, residual stress and displacement. (Distance from weld interface of nodes 46, 84, 87, 119 and 147 is 2, 5, 8, 24 and 140 ram, respectively. Distance from the weld interface of nodes 477, 524, 275 and 293 is 2, 8, 20 and 118 mm, respectively. The distance from the surface is 4 ram.)

in the analysis includes temperature- dependent properties, latent heat (phase change) effects, heat convection in the flow direction and nonlinear boundary conditions. In turn, temperature distributions can be used to generate thermal loads in a stress analysis. The thermal expansion coefficient, elastic modulus and yield strength as mechanical properties of material and heat convection coefficient, heat conduction coefficient and specific heat were input as a function of temperature in order to consider variations in material properties. Weld heat is lost to the surrounding atmosphere through convection and radiation, and radiation losses are greatest close to the weld pool. At some distance from the weld pool, convection is the primary mechanism for heat loss to the atmosphere. The effects on latent heat through phase change from solid to solid and

solid to liquid were considered during welding. The material is isotropic and its yield behavior is applied by Von Mises' yield criteria.

The nodes in the center of the bottom surface were perfect as the boundary conditions required for mechanical analysis of the 0- and 6-mm root opening weldments. Since the specimen was welded under a condition where it lifted up at the steel or ceramic plates, the nodes of the region contacted at the plates were limited to the thickness direction (+y-direction). The center nodes of the upper surface were constrained because the 0-mm root opening sample was finished after the third pass and then backgouged. Finally, the 24-mm specimen was restricted at the center region of the built-up and 6-mm weld area. The weld zone lifted up atthe steel or ceramic plates was restricted in a similar way.


Heat Flux (J/cmZ /see)

Heat Flux (J/crn 2 /see)

tl t2 t3

IO0%Ramp

Time(see)

q

tl : initial ramp time t2 : maximum ramp time t3 : decayed ramp time t l+t2 : actual heat scanning time during welding ramp time percentage = 100tl/(t~+t3)

) Time(see)

600

575

. • 550

z '~ 525

_~ 500

I'-- 475'

450

J e • o

i i • i I • i

Omrn gap 6mm gap 30mm gap

Fig. 5 - - Shape of ramp heat input function. The area under the ramp function curve was kept constant to maintain the same net heat input energy and to study the effect on thermal and stress responses.

Fig. 6 - - Plot o f the tensile strength of each weld specimen.

Heat Input Model

It is important that heat input from the arc is exactly duplicated in modeling because the heat input model has an important effect on the accuracy of analysis from the temperature distribution, cooling rate, size of fusion zone and heat- affected zone to the strength of the weldment. The heat input model for analysis of weld residual stresses and deformations was distinguished as a ramp heat input model and a lumped pass model. A ramp heat input model was developed to avoid numerical convergence problems because of an instantaneous increase in temperature near the fusion zone, and enabled the model to include the effect of a moving arc in a 2-D plane. It takes into account the variation of plane energy flow in a 2-D model as the arc approaches, travels across and departs from each plane under investigation.

The lumped pass model for thick multipass welds developed to reduce analysis times and costs is useful in predicting residual stress, but it is troublesome in predicting weld deformation. In a single- V groove, the center of the total shrinkage force does not coincide with the neutral axis because the bead deposits are not symmetric about the neutral axis. This results in larger bend stress and produces different final stress or strain rates. The lumped pass amplifies these effects, so the ramp heat input model is recommended for welds that have unsymmetri- cal bead depositions such as a single- V-groove weld. The level is particularly severe in cases that have many weld passes such as the 30-mm root opening weld in this study.

As previously described, the following heat input model is used to reduce

calculation costs and times through 00" the ramp heat input model in this study. 25- Small time increments are applied to ,-E. 20. a period of instanta- >,

neous temperature ~ 15 fluctuation that gen- ® = erates stiff tempera- ~ lo ture gradients due to ~- the localized high - 5 heat input and rapid cooling near the fu-

0 sion zone; large time increments are applied for other periods. Next, 100% ramp ratio is provided to improve the convergence of the analyses. These methods make a difference between the total time of actual welding and the analytical one, including cooling time. Figure 5 shows the heat input model of the 100% ramp ratio.

In other words, the interpass temperature (the temperature to which the weld region cools between passes) exists in the actual weld. The total weld time is the sum of the welding time of each layer and the cooling time required for each interpass temperature. However, if ramp ratio is increased to improve analyses, the total time of analysis is greater than the actual welding time. Therefore, this time difference must be considered in the analysis. The heat input rates of the 2-D analysis are given by the surface flux and expressed as the following:

Q = ~EI/bL (3)

where q represents 0.8 as the arc effi-

i •

s

i i ~ ! , !

Omm gap 6mm gap 30mm gap

Fig. 7 - - Plot o f the impact energy of each weld specimen.

ciency, E and I are arc volts and amperes, and b and L represent the width of the weld bead and the length of the weld direction of the heat input region, that is, unit length at the 2-D analysis, respectively.

Results and Discussion

Experimental Results and Considerations

Tensile test results for each specimen are presented in Fig. 6. The figure shows approximately 534-540 MPa for the 0- mm root opening, 528-537 MPa for the 6-mm root opening and 536-547 MPa for the weld with the 24-mm buildup and 6- mm root opening. In total, the differences are not large. The tensile strengths for each specimen were shown to be satisfied because fractures were generated in the base metal, not the weld metal. The 30-mm root opening weldment had sufficient static strength, but dynamic

84-s J MARCH 2001

strength such as impact and fatigue strength may be insufficient. For that reason, large scattered tensile tests were suggested because of the size of the weld pool and fusion zone. The bend test for each specimen was performed four times, and the criteria of no cracks was satisfied for each specimen. Bend test results are presented in Table 6.

Figure 7 shows the impact energy of each weld specimen. There is no difference between the impact energy of the welds with 0- and 6-ram root openings. In the case of the 30-mm root opening, it is assumed the large scatter between the measured data is because of the effects of an enlarged heat-affected zone caused by high heat input. Consequently, it is expected the 30-mm root opening weldment will have a problem with dynamic strength such as fatigue strength because of the nonuniformity of its tensile strength and impact values.

The results of the hardness measurement are presented in Fig. 8A-C. Hard- ness was measured at 2.5, 7.5 and 12.5 mm from the upper surface of the specimens. The hardness of the 0- and 6-mm root opening weldments showed little difference. In the case of the weldment with a 30-mm root opening, which was out of tolerance, the total hardness is slightly lower than that of the other welds.

Microstructures were acquired for each weld specimen. For the 0-mm root opening weld, the microstructure of the weld zone is nonuniform because of the effects of the multiple passes. An inherent segregation structure of the weld and a finely diffused region caused by multipass welding were observed. The microstructure of the heat-affected zone showed high heat input and the elimina- tion of the initial hot-rolled structure. The lower and upper portions of the weld zone showed severe coarseness and segregation of the microstructure. Because the heat of welding in the lower portion of the weld zone transferred to the supporting plate with ease, weld heat caused only a small effect. The solidification structure is also retained because of the small effect of weld heat in the upper weld zone, which is filled with filler metal.

The microstructure of the weld with the 6-mm root opening was slightly different from that with the 0-mm root opening. Since the width of the weld cross- section, which was filled with all-weld metal in the upper portion, was increased by 21 mm, the solidification structure of the welded layer disappeared because of the relatively greater heat input. How- ever, that of the welded upper layer was widely distributed. This result is equivalent to the fact that the hardness of the

Table 6 - - Result of Bend Test

Welding specimen

0-mm root opening 6-mm root opening 30-mm root opening

Test times

3 3 3

Crack occurrence

No No No

Criterion

satisfaction satisfaction satisfaction

upper solidified structure appears high, that is, despite the coarseness of the structure, the hardness is relatively widely distributed because of the exis- tence of a martensitic structure due to rapid cooling.

For the 30-mm root opening specimen, solidified structures and refined regions by heat appear as a nonuniform structure. Since the solidified structures are not dis- solved by the weld heat, but are instead retained, they may have a problem if used in steel fabrications. This phenomenon may lead to the 30-mm root opening specimen being less reliable because of deterioration of the weld-included parts.

Analysis Results

Analysis of Thermal Cycle

The results of the analysis of the temperature cycle for different positions (note the node index in Fig. 3) of the width direction (x-direction) from the weld interface and a 4- mm distance from the surface is represented in Fig. 9. The 0- and 6-mm root opening welds are presented in Fig. 9A, B. The thermal cycle of the buildup area and the actual weld in the 30-mm root opening specimen are presented in Fig.

A

95

o so

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Fig. 8 - - Comparison o f the results and measured posit ion o f the hardness tests. A - - O-ram root opening weld specimen; B - - 6 -mm root opening specimen; C - - weld specimen with a 24-ram bui ldup and 6- m m root opening.


A B l )

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Fig. 9 - - Comparison of the thermal cycles at various locations of each weld specimen. A - - O-mm root opening; B - - 6-ram root opening; C - - left side after 24-ram buildup and 6-ram root opening weld; D - - right side after 24-ram buildup and 6-ram root opening weld. (Horizontal axis: time Is x 10000], vertical axis: temperature [°C x 10001.)

9C, D. The higher the peak temperature and 48°C for the 6-mm root opening. For quently, the maximum value of retained i U l @11 i . I mll i I

im i

i = i

I~1 W I

!1 ~ e

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of the thermal cycle, the more it mea- sures the position approach in the weld interface. Figure 10 shows a comparison between measured and analyzed results of the thermal cycle of the initial pass at the position (node number 84 of each test specimen) at which thermocouple was installed for the 0- and 6-mm welds and the 6-mm root opening weld after 24-mm of buildup. The analyzed data shows the measured temperature cycle is biased to the right side, and the peak temperature of the built-up weld is higher because of a more elongated weld time through the 100% ramp, as shown in Fig. 5. How- ever, it shows some of the thermal cycles are very similar to others.

The equilibrium temperature (without differences in temperature in the various positions during the cooling process) is about 47°C for the 0-mm root opening

these two cases, the equilibrium temperature differed little because the number of passes and total heat input was nearly equal.

The equilibrium temperature after the 24-mm buildup was approximately 62°C - - Fig. 9C, D. In this case, there were situations in which heat was not transferred to the right plates. The equilibrium temperature reached approximately 40°C after the 24-mm buildup and 6-mm root opening weld. The heat was transferred only to the left plate, but not the right one, when the buildup weld was performed. It shows equilibrium temperature is lower for the within-tolerance specimen because of the asymmetric heat transfer to the right plate when the 6-mm root opening weld is performed. The lower equilibrium temperature means cooling velocity is rapid. Conse-

stress is high when cooling velocity is slow. This can be verified by evaluation of residual stresses.

R e s i d u a l Stress E v a l u a t i o n

A weldment is locally heated, therefore, temperature distribution is not uniform, and structural and metallurgical changes take place in the joint during multipass welding. The weld metal and heat-affected zone immediately adjacent to the weld are at temperatures substan- tially above that of the unaffected base metal. As the weld zone solidifies and shrinks, it begins to exert stress on the surrounding weld metal and heat- affected zone. Because of that process, the retained Von Mises' equivalent stress after cooling of the three types of welds is retained in the weld metal and listed in

86-S I MARCH 2001

A =o 5001-

40O I-

E , .--e-- FEM[0mm gap] ---=-- FEM[6mm gap] - - A- - experiment[0mm gap] - - , - - experiment[6mm gap]

Time[sec]

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500

400

E

100

, 0

--&-- Experiment ,~1) ~ - -e . - F.E.A

p,

I I I , l I 20 40 60 80 100

Time [sec]

Fig. lO - - Comparison between measured and analyzed results of the thermal cycle. A - - 0- and 6-mm root opening weld specimen; B - - 30-ram root opening weld specimen.

A ,oo - - C ~ 6 m m gap ( F.E.A ) ]

• / - -o- - - 0ram gap ( F.E.A ) / 300 J . . . . . . . . . ] • 6mm gap ( Experiment ) t

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B

2504 ° b o , 1 , _ u ~ " L ~

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-1so -loo -so o so 1oo t s o

Displacement from Center Line[mm]

Fig. 11 - - Comparison of the residual stress distribution by analysis and experiment. A - - 0- and 6-mm root opening weld specimen; B - - 30-mm root opening weld specimen.

Fig. 11. This shows the measured values of the experiment and analysis coincide well. The maximum Von Mises' equivalent stress for the 0- and 6-mm root opening welds is approximately 307 MPa, and it is concentrated symmetrically at the weld metal and heat-affected zone of the workpieces. The initial weld passes preheat the base metal of multipass welds. The effects are greatest on the second pass. As the preheating conditions after the second pass are stabilized, the resul- tant change in thermal cycle and cooling rate is less significant. However, final welding of the bottom surface after backgouging followed by the third pass leads to considerable reduction of the residual stress and deformation contrary to the others as shown in Fig. 11A. As a result, when plates with a long, thick butt joint are welded, welding of the bottom surface after backgouging can be used to reduce the residual stresses and deformation of the welded plate.

For the 6-mm root opening weld without backgouging, the maximum residual stress is distributed in a wide range be-

cause of the large weld pool. In the 24- mm buildup with a 6-mm root opening weld, the residual stress after cooling is retained as an asymmetric type and biased to the buildup weld as shown in Fig. 11 B), because heat is not uniformly transferred to the plates. Since the final equilibrium temperature is lower than in the specimens within tolerance, the maximum Von Mises' equivalent stress is higher than that of the 0- and 6-mm root opening welds.

Weld Deformation Evaluation

The deformation of thickness direction (y-direction) after cooling followed by the final pass is shown in Fig. 12. These results show the measured values in the experiments and analysis coincide well. For the 0-mm root opening specimen, a small drop in angular deformation was generated when the final pass was performed on the bottom surface after backgouging, but this value was infini- tesimal. For the 6-mm root opening specimen, general types of angular deforma-

tion typical in a butt weld showed displacement was limited to weld deformations of less than 1 mm by keeping the interpass temperature under 200°C. Weld deformation for the 24-mm buildup, 6- mm root opening specimen was opposite to the others. The buildup weld generated a positive angular deformation, and the 6-mm weld after buildup generated a negative angular deformation, that is, a drop due to sudden expansion because of high heat input.

To verify a history of weld deformation, the displacement of thickness (y-direction) and width (x-direction) at the edge of the upper surface (node number 147) is shown in Fig. 13. The horizontal axis is time (s) and the vertical axis is displacement of the thickness direction (cm). Displacement in the thickness direction after the final pass subsequent to backgouging approached zero in the case of the 0-mm root opening because of itera- tion of expansion and contraction - - Fig. 13A. The instantaneous lifting that occurred with the heat input of the final pass followed by backgouging was at the bot-

W E L D I N G RESEARCH SUPPLEMENT J 87-S

A t . . . . . . . . . . . . . . .

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~ 0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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D i s t a n c e from Center L i n e [ m m ]

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-]

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T l ~ e ( x l O 0 0 0 ) ~ t S p I ~ B S ~ W H ~ 14~ ~ £ = p ~ ¢ t m e n t X ~ d e 147

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0 I

i • i • i

-150 -100 -50

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Displacement from Cent8r Line[ram]

Fig. 12 - - Comparison of the displacement of the thickness direction (y-direction) by analysis and experiment. A - - 0- and 6-ram root opening weld specimen; B - - 30-ram root opening weld specimen.

tom surface, and then there was a drop because cooling occurred. As a result, angular deformation approaches zero.

For the 6-mm root opening (Fig. 13B), there was a large displacement in the thickness direction after the final pass as a result of the high heat input from the final pass. Asymmetric deformation behavior (node number 293 and 147) is shown in Fig. 13C. Displacement of the thickness direction at node 239, which was generated by the buildup weld, was maintained without change until the final situation. Weld deformation, which had stayed at zero at node 239 during buildup welding, occurred suddenly after the 6-mm weld. In particular, considerable deformation was observed in the initial pass of the 6-mm weld. Finally, angular deformation dropped because of asymmetric heat transfer.

Conclusions

The following results were obtained through comparison of the finite element analysis and experimental data.

According to the tensile tests, tensile strength is approximately 534-540 MPa for the 0-mm root opening, 528-537 MPa for the 6-mm root opening and 536-547

B 0~, m y ( x . l )

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MPa for the 30-mm root opening. There is little difference in the results, but in the case of the 30-mm root opening weld, the scatter in the tensile strength data is higher than for the other welds because of the extensive weld fusion zone and weld pool. Since no crack propagation was observed for each specimen, the results of the bend tests were satisfactory. According to the impact tests, there was little difference in the 0- and 6-mm root opening welds, but the scatter of impact values for the 30-mm root opening weld was higher and nonuniform. In terms of microstructure, refined regions resulting from weld heat and solidification that were not dis- solved by the heat but were retained, appeared as a nonuniform structure. With regard to mechanical properties, it appears there are problems in attaining

0.~

--cT-r

- 2 . 1

j ° u l

~N t T ' B - , ,

~4 d l m p l i ~ l l l n t W NDaQ IA ~ 7

m

8,016

1

Fig. 13 - - Comparison of the relation between displacement and time for each weld specimen. A - - O-ram root opening weld specimen; B - - 6-mm root opening weld specimen; C - - 24-mm buildup and 6- mm root opening weld specimen. (Horizontal axis: time [s x 10000]; vertical axis: displacement [cm].)

toughness. The static strength such as tensile and bend strength in the 24-mm buildup weld should have no problems in manufacturing structures, such as the steel bridges. However, there may be problems in reliability of the weldment as a result of reductions in toughness because of nonuniformity in the deterio- rated regions of the weldment.

The residual stress is distributed symmetrically, and maximum value is the

88-S I MARCH 2001

same for the 0- and 6-mm root opening welds. In the case of the 30-mm root opening weld, the equilibrium temperature is lower than the within-tolerance specimens and the distribution of the residual stress extends over a wide range asym- metrically because of the buildup weld. It might have a problem in dynamic strength because most of the residual stress is biased toward the built-up weld part.

Displacement in the thickness direction after the final pass followed by backgouging has little effect in the case of the 0-mm root opening. In the case of the 6-mm root opening weld without backgouging, a little angular distortion occurs, but the level of deformation is small. Therefore, there is no problem for the specimens within tolerance. However, in the case of the 30-mm root opening weld, the angular deformation in the asymmetric region where the side of the built-up weld is lifted up and the other side is dropped is greater than the other specimens.

In this study, the predicted weld residual stress and deformation as calculated from finite element analysis are found to be in close agreement with the experimental data.

References

1. Masubuchi, K. 1980. Analysis of Welded Structure. Pergamon Press.

2. Masubuchi, K. 1991. Recent research activities at MIT on residual stresses and distortion in welded structures. Welding Journal 70(12): 41-47.

3. Shibata, N. 1991. Prevention and esti- mation of welding deformation --thick plates steel structure (steel bridge). JWS 60(6): 20-25.

4. Natume, M. 1983. Weld distortion control on steel bridges and steel structures. JWS 52(8): 30-40.

5. Mahin, K. W., Winter, W., and Hoden, T. M. 1991. Prediction and measurement of residual elastic strain distribution in gas tungsten arc welds. Welding Journal 70(9): 245-s to 260-s.

6. Shim, Y., Feng, Z., Lee, S., Kim, D., Jaeger, J., Papritan, J. C., and Tsai, C. L. 1992. Determination of residual stresses in thick-section weldments. Welding Journal 71(9): 305-312.

7. Free, J. A., and Poter Goff, R. F. D. 1989. Predicting residual stress in multi-pass weldments with the finite element method. Com- puter and Structures 32(2): 365-372.

8. MARC User's Manual. 1996. Analysis Research Corp.

9. Shim, Y., Feng, Z., Lee, S., Kim, D., Jaeger, J., and Tsai, C. L. 1991. Modeling of welding residual stresses. Proceedings of the Winter An- nual Meeting of the ASME, pp. 29-41.

10. Leung, C. K., and Pick, R. J. 1990. Fi- nite element analysis of multipass welds. WRC Bulletin 356, pp. 11-33.

11. Ueda, Y., Takahashi, E., Fukuda, K., and Nakacho, K. 1974. Transient and residual stresses in multi-pass welds. Transactions of JWRI 3(1 ): 59-67.

12. The Ohio State University. 1992. Ex- perimental verification of finite element modeling procedures for thick plates. Technical report submitted to U.S. Army Corps of Engineers Department of Welding Engineering.

13. Hibbit, H. D., and Marcal, P. V. 1973. A numerical thermo-mechanical model for the welding. Computer and Structures 3(11): 1145-1147.

14. Friedman, E. 1975. Thermo-mechanical analysis of the welding process using finite element method. Journal Press. Vessel Tech. ASME, Series J, pp. 206-243.

15. Hong, J. K., Dong, P., and Tsai, C. L. 1994. Finite element simulation of residual stresses in multipass welds. International Con- ference Proceedings on Modeling and Control of Joining Processes, ed. T. Zacharia. American Welding Society, Miami, Fla., pp. 470-476.

16. Dong, Y., Hong, J. K., Tsai, C. L., and Dong, P. 1997. Finite element modeling of residual stresses in austenitic stainless steel pipe girth welds. Welding Journal 76(10): 442- s to 449-s.

Preparation of Manuscripts for Submission to the Welding Journal Research Supplement

All authors should address themselves to the following questions when writing papers for submission to the Welding Research Supplement:

• Why was the work done? • What was done? • What was found? • What is the significance of your results? • What are your most important conclusions? With those questions in mind, most authors can logically

organize their mater ial along the fol lowing lines, using suitable headings and subheadings to divide the paper.

1) Abstract. A concise summary of the major elements of the presentation, not exceeding 200 words, to help the reader decide if the information is for him or her.

2) Introduction. A short s tatement giving relevant background, purpose and scope to help orient the reader. Do not duplicate the abstract.

3) Experimental Procedure, Materials, Equipment. 4) Results, Discussion. The facts or data obtained and

their evaluation. 5) Conclusion. An evaluation and interpretation of your

results. Most often, this is what the readers remember. 6) Acknowledgment, References and Appendix. Keep in mind that proper use of terms, abbreviations

and symbols are important considerations in processing a

manuscript for publication. For welding terminology, the Welding Journal adheres to ANSI/AWS A3.0-94, Standard Welding Terms and Definitions.

Papers submitted for considerat ion in the Welding Research Supplement are required to undergo Peer Review before acceptance for publication. Submit an original and one copy (double-spaced, with 1-in. margins on 8~ x 11-in. or A4 paper) of the manuscript. Submit only the abstract on a computer disk. The preferred format is from any Macintosh® word processor on a 3.5-in. double- or high-density disk. Other acceptable formats include ASCII text, Windows TM or DOS. A manuscript submission form should accompany the manuscript.

Tables and f igures should be separate from the manuscr ipt copy and only high-qual i ty f igures will be published. Figures should be original l ine art or g lossy photos. Special instructions are required if f igures are submit ted by electronic means. To receive complete instructions and the manuscript submission form, please contact the Peer Review Coordinator, Doreen Kubish, at (305) 443-9353, ext. 275; FAX 305-443-7404; or write to the American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126.


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