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• SPECIAL EMPHASIS: WELDING EDUCATION

F e a t u r e A r t i c l e s

• Program Answers Industry's Call for Entry-Level Welders M. R. Johnsen Manufacturers and educators collaborate in a unique program designed to attract individuals to the welding profession and satisfy the need for entry-level welders/29

A Wise Method for Assessing Arc Welding Performance and Quality D. D. Harwig A systematically developed database of welding parameters for specific applications shows promise for eliminating time-consuming and costly trial-and-error methods that many engineers traditionally use/35

• Training Welders in Mexico A. H. Price Understanding and accepting cultural differences goes a long way in ensuring training success/41

• Who Will Become a Welder? W. Western A veteran instructor identifies personality traits of those inclined to be welders and uses them to define an approach to instruction that offers the greatest chance of success/45

• Training for the Future D. Landon What starts as an industry in-house training program expands into a work-study course for students from a local high schooV48

Welding Research Supplement A New Ferritic-Martensitic Stainless Steel Constitution Diagram M. C. Balmforth andJ . C. Lippold The comparison of new equivalency formulae to existing formulae show improved accuracy in predicting microstructure of ferritic and martensitic stainless steel welds/339-s

A Martensite Boundary on the WRC-1992 Diagram - - Part 2: The Effect of Manganese D.J. Kotecki A modification to the WRC- 1992 Diagram that takes into account martensite formation will allow the use of one diagram for FN prediction and dissimilar metal joining/cladding situations/346-s

The Stress-Relief Cracking Susceptibility of a New Ferritic Steel - - Part 1: Single-Pass Heat-Affected Zone Simulations J. G. Nawrocki, et al. Under different heat inputs and postweld heat treatments, a new alloy is tested against a standard alloy used in high-temperature applications/355-s

Control for Weld Penetration in VPPAW of Aluminum Alloys Using the Front Weld Pool Image signal B. Zheng, et ai. A model is developed of the relationship between the bottom diameter of a keyhole and the size of the keyhole weld pool as recorded with an image sensing system/363-s

Welding Journal (ISSN 0043-2296) is the official monthly publication of the American Welding Soci- ety. Editorial and advertising offices are located at 550 N.W. LeJeune Rd., Miami, FL 33126; telephone (305) 443-9353. Printed by R. R. Oonnelley & Sons Co., Senatobia, Miss. Subscriptions: $90.00 per year in the United States and possessions, foreign countries $130.00. Single copies: members $6.00, nonmembers $8.00. Periodicals postage paid at Miami, Fla., and additional mailing offices. POST- MASTER: Send address corrections to Welding Journal, 550 N.W. LeJeune Rd., Miami, FL 33126. Starred (*) items excluded from copyright. Readers of the Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or resale. Per- mission is granted to quote from articles, provided customary acknowledgment of authors and sources is made.

AWS Web site: http'd/www.aws.org

M o n t h l y C o l u m n s

P r e s s - T i m e News . . . . . . . . . . . . . . 7

W a s h i n g t o n W a t c h w o r d . . . . . . . . . 9

Edi tor ia l . . . . . . . . . . . . . . . . . . . . 10

C o m m e n t a r y . . . . . . . . . . . . . . . . . 12

CyberNotes . . . . . . . . . . . . . . . . . . 14

C o n f e r e n c e s . . . . . . . . . . . . . . . . . 16

News of the I n d u s t r y . . . . . . . . . . . 18

New P r o d u c t s . . . . . . . . . . . . . . . . 22

We ld ing W o r k b o o k . . . . . . . . . . . 51

Navy J o i n i n g Cen t e r . . . . . . . . . . . 55

C o m i n g Events . . . . . . . . . . . . . . . 5 6

Braz ing Q&A . . . . . . . . . . . . . . . . . 6 0

New Li te ra tu re . . . . . . . . . . . . . . . 62

S ta in less Steel Q&A . . . . . . . . . . . . 6 4

P e r s o n n e l . . . . . . . . . . . . . . . . . . . 6 6

Society News . . . . . . . . . . . . . . . . . 6 7

Guide to AWS Serv ices . . . . . . . . . 92

Welding Journal I n d e x . . . . . . . . . 9 4

Class i f ieds . . . . . . . . . . . . . . . . . . 108

We ld ing C o n s u l t a n t s D i r ec to ry . . 1 1 0

Adver t i se r I n d e x . . . . . . . . . . . . . 113

P e e r Review . . . . . . . . . . . . . . . . 1 1 4

WELDING JOURNAL I $

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May 6-10, 2001 Filling the entire

International Exposition (I-X) Center Cleveland, Ohio

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New Recycling Process Uses Lasers to Separate Aluminum A newly developed recycling process employs lasers to iden-

tify and recover metals from scrap lasers, according to the Auto Aluminum Alliance, in conjunction with the U.S. Department of Energy. The lasers can distinguish between cast and wrought alloys, as well as separate wrought alloys from each other at commercially viable rates.

During the process, which uses a technique called laser- induced breakdown spectroscopy, a laser is used to clean the surface of the particle by laser ablation, and then a laser pulse hits the same spot as it moves down a conveyor belt. The second laser pulse vaporizes a small amount of material from the metal's surface, which creates a small, highly luminescent plume of plasma. To quantitatively determine the metal's chemical makeup, the plume is analyzed using optical emission spectroscopy. Once verification is made, the scrap is sorted by alloy on a piece-by-piece basis. Up to now, such alloys were sorted manually, a costly, slow process. It is estimated the first commercial sorting center will be able to analyze and sort 100 million lbs of aluminum per year.

Aluminum is now the third most-used material in cars and trucks, and nearly 90% of automotive aluminum is recovered and recycled. While this aluminum represents less than 10% of the average motor vehicle by weight, it accounts for about half of the vehicle's value as scrap.

"The techniques we're exploring will allow us to recapture more of the value and performance capability of the many high- quality aluminum alloys that are used in our vehicles," said Jim Quinn, staff engineer, General Motors Corp., and chairman of the U.S. Automotive Partnership, Automotive Metals, United States Council for Automotive Research (USCAR).

Huron Valley Steel Corp., a metals processing firm in Belleville, Mich., is evaluating the new method. The Auto Alu- minum Alliance is working with the company as part of a one- year agreement launched August 24. The Auto Aluminum Al- liance is an interindustry collaborative research effort between USCAR and The Aluminum Association, Inc.

Praxair Forms Metals Technologies Business

Praxair, Inc., Danbury, Conn., recently formed Praxair Met- als Technologies, a separate business dedicated to the commer- cialization of technologies and services for the global metals industry, including the company's patented Co Jet TM system.

The new business will develop and market technology for li- censing, process control software and technical services in energy conservation, product quality and productivity to steel, aluminum and other metals customers around the world.

Michael J. Douglas, vice president, Praxair Metals Technolo- gies, will head the new business. He will report to Dennis H. Reil- ley, president and chief executive officer.

Valley National Gases Acquires Titan Welding Supply

Valley National Gases, Inc., Wheeling, W.Va., recently purchased Titan Welding Supply, Ltd., Willoughby, Ohio. Titan provides welding supplies, propane and industrial, medical and specialty gases. Combined annual sales are approximately $1.5 million.

Valley National Gases is a packager and distributor of industrial, medical and specialty gases, welding equipment and supplies, propane, and fire protection equipment. It operates 59 locations in ten states. It has seven production and distribution centers in the mid-Atlantic and midwestern regions of the United States. The company has completed six acquisitions during the last 12 months, adding approximately $14 million in annual sales.

Rofin-Sinar Appoints Board Director and New Presidents for Subsidiaries

In connection with its recent acquisition of Baasel Lasertech Group, Rofln-Sinar Technologies, Inc. (Hamburg, Germany, and Plymouth, Mich.), appointed Carl E Baasel to its board of directors. He will keep his position as managing director of Carl Baasel Lasertechnik GmbH, Stamberg, Germany, and will serve as a board member of several subsidiaries of the newly formed ROFIN Group.

The Acton, Mass., operation, formerly known as A-B Lasers, Inc., has been renamed Rofin-Baasel, Inc., and is headed by Dr. Walter Volkmar. It will concentrate on manufacture and sale of turnkey standard and customized laser marking systems.

Lou Molnar has been named president of Rofin-Sinar, Inc., Plymouth, Mich.

Manitowoc Acquires Marinette Marine

The Manitowoc Co., Inc., a diversified manufacturing company with operations in food service equipment, lattice-boom cranes and marine services, recently purchased the stock of Marinette Marine Corp. for approximately $48 million as part of an all-cash transaction.

Marinette operates one of the largest shipyards on the U.S. Great Lakes. It is located in Marinette, Wis., just across Green Bay from Manitowoc's shipbuilding facility. It is currently under contract to build six oceangoing buoy tenders for the U.S. Coast Guard, as well as two 269-ft APL barracks barges for the U.S. Navy. It currently employs more than 800 people. A pri- vately held corporation, Marinette has revenues of approximately $100 million.

WELDING JOURNAL [ 7

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BY HUGH K. WEBSTER AWS Washington Government Affairs Office Was , word

Regulatory Reform Law Adopted For the first time since 1996, a new law has been enacted

aimed at reforming the federal regulatory system. The Truth in Regulating Act is designed to give Congress a means of verifying certain claims made by federal agencies in connection with proposed and final rules. Specifically, the Act gives Congress the authority to direct the General Accounting Office to review and analyze cost-benefit analyses of federal regulations. In connection with such a review, the GAO would also examine other data or assumptions underlying these regulations.

The impetus for the Truth in Regulating Act is an increasing distrust by Congress of claims by federal agencies regarding the regulations they impose, particularly with respect to the expected burden these rules may impose. There has also been frustration at the reluctance of federal agencies to disclose all underlying assumptions of regulations, including research studies.

Some have questioned the effectiveness of this new law. In 1996, a similar law was enacted giving Congress the authority to review and disapprove federal agency rules. Since then, Congress has not reviewed a single regulation.

National Standards Policy Hearing Held

The House Technology Subcommittee recently held a hearing titled, "The Role of Standards in Today's Society and in the Future." Witnesses from government, industry and the nonprofit sector discussed the importance of standards to the competitiveness of American industry in international markets. They emphasized the need for these three elements to cooperate in the international standards arena. This hearing also addressed the National Standards Strategy recently developed and approved by the American National Standards Institute. This strategy establishes a framework with which to use the standards process to improve U.S. competitiveness overseas.

intentionally conceal product defects that result in death or grievous bodily injury. This legislation is a direct result of the Firestone tire matter.

Skilled Worker Visa Legislation Approved Congress and the President have once again approved

legislation that will increase the number of visas available for "highly skilled" foreign workers. Pushed by the technology industry, but applicable to all industry sectors, this new law increases the number of H-1B visas to 195,000 for each of the next three fiscal years. If this legislation had not been passed, the number for this fiscal year 2001 would have been 107,500, dropping precipitously to 65,000 for subsequent years.

Efforts at bringing

some federal reform to

the area of products

liability once again

have failed at the

federal level.

Product Liability Reform Effort Fails Again Efforts at bringing some federal reform to the area of

products liability once again have failed at the federal level. Supporters had changed their strategy in recent months, advocating legislation targeted at specific issues rather than pushing for a comprehensive reform package. While there was initial optimism that this approach might be successful, it has not been. In fact, Congress ended its year by approving legislation, signed by the President, that would impose criminal penalties on transportation industry executives who

High Court Hears Argument in Regulations Case

The U.S. Supreme Court recently heard oral arguments in a potentially ground- breaking case regarding the regulatory authority of federal agencies. Last year, a federal appeals court in the District of Columbia declared part of the Clean Air Act unconstitutional because it gave the Environmental Protection Agency unfettered discretion to adopt any regulations it wished without any discernible standard. The EPA has appealed that ruling to the Supreme Court. Also at issue is a decision by the same appellate court to the effect the EPA need not undertake a formal cost/benefit analysis when promulgating anti-smog regulations. Like the other issue, this one has potential implications for all federal agencies.

Web Site Offers Federal Register Assistance

A new nonprofit Web site has been established designed to assist those who regularly peruse the Federal Register to monitor federal regulatory activity. RegRadar.org, owned and operated by the Mercatus Center at George Mason University, an educational and research organization that studies and comments on regulations, aims to be a one-stop site for monitoring planned, proposed, pending and final federal regulations.

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

WELDING JOURNAL ] 9

A Society of the Members...

As I approach my year as president of the American Welding Society, I am humbled by the breadth and depth of talent this society represents. Our membership spans the entire scope of our industry. It includes the skilled craftsmen that apply the welds, the engineers who design those welds, the managers who supervise the people and processes used to produce the products. It includes the people who produce the welding equipment, filler metals and supplies that ultimately go into the products that are made and the sales personnel who sell them. The American Welding Society also includes the research and development engineers and scientists who give us new and improved joining processes and welding educators at all levels who pass welding knowledge on to the next generation. The members of the American Welding Society span industry from the shop floor welder to the presidents and CEOs of major corporations.

The strength of our society comes from that diverse and talented membership, and together we've formed one of the most internationally respected and admired professional societies in existence today. Our society treats the contributions of all its members with equal respect. And any member, whether a shop floor welder or the president of a company, can rise up through the ranks of our local Section, District and national leadership positions to become the president of our society. The strength and diversity of our membership helps to produce the volunteer leaders who have propelled our society into being one of the leading voices of the international welding community. The volunteer leaders of the American Welding Society, however, have not worked alone.

During my years serving our society on a national level, I have come to respect and admire the dedicated service of our professional staff. While we, the members and volunteer leadership of AWS, set the direction of the society, it is our dedicated staff who carry out the daily tasks that make the publications and programs of our society work. Whether they serve as secretaries of our technical committees, as the publishers of the codes and standards those committees produce, as the publishers of the award-winning Welding Journal or keep track of our CWI program and the many other international certification programs AWS administers, I have found our staff to be both dedicated to and enthusiastically engaged in the programs of the society. Since the volunteer leadership changes each year, it is the work of the staff and its leadership to keep our programs moving forward through those changes.

In their wisdom, the founders of our society established a system in which our society is strengthened by a diverse and changing leadership, one where all of the people engaged in our industry have the opportunity to give something back by serving as volunteer leaders for our local, district and national activities. They also gave us a staff organization that keeps the wheels of that society turning as that volunteer leadership changes. The leadership of our society is made up of the members, who by the work of the dedicated staff, together create services for the members.

Don ' t sit on the sidelines, get involved in your society. We need people like you to fill the many Section, District and national leadership positions that make our Society as diverse and strong as it is. The founders of our society gave you that opportunity. Take advantage of it. We need the breadth and depth of your experience to carry us into the future.

Richard L. Arn A WS Vice President

10 I DECEMBER 2000

A M E R I C A N W E L D I N G S O C I E T Y

Officers

President - - L. W. Myers

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

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

Vice President - - T. M. Mustaleski Lockheed Martin Energy Systems

Treasurer - - N. A. Hamers DaimlerChrysler

Executive Director - - E G. DeLaurier, CAE

Directors

O. AI-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. Bollinger (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 Fleurs & 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. Kirseh (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. Zabernik (Dist. 7), The Lincoln Electric Co. R. J. Teuscher (Past President), Springs Fabrication. Inc.

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

Lincoln Electric. NASCAR Officially Licensed welding

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Com t-t Going to the Max

It 's official. Our new show has a new name and identity. Welcome to MAX International presented by the American Welding Society and the Precision Metalforming Association. Where we were once in the category of one of the top 200 trade shows in America, according to Tradeshow Week Magazine, this new association places us as one of the top 50 trade shows.

Essentially overnight, our entire presence has doubled. For example, at our upcoming show at the I-X Center in Cleveland, May 6-10, MAX International will fill the entire exhibit hall. More than 800,000 gross sq ft will be filled with welding, stamping, forming, shaping and cutting equipment of all types and sizes along with the accessories to make operations more efficient and productive. More than 1200 exhibitors are expected.

We will present a totally integrated manufacturing environment from which an attendee can gather all the information needed to improve and enhance operations limitlessly.

We anticipate a crowd of 30,000 to 40,000 attendees. In surveys taken at past AWS Welding Shows, some 80% of attendees wanted to see more metalworking equipment. Now they'll get their chance. PMA is the most respected association of metalworking equipment manufacturers in the world. With friends like that, and the depth of representation we have in the welding industry, MAX International will become the driving force at the core of industry.

Because there are so many more things to see and do, the show is going to last longer. Instead of being three days, it will start on Sunday and last through Thursday, or five days. And the timing couldn't be better. Attendees will like how much they can save on airfare by flying in on a Saturday, hitting the key exhibits on Sunday and Monday and catching the red-eye home Monday night. That only means one day of work to catch up on and airfare savings, too.

Also, be aware that even though we are working together with the Precision Metalforming Association, our show will stay unique. We are collaborating not combining. So, you will find all the traditional welding and cutting equipment, services, accessories and supplies on our side of the hall - - where you expect it to be. However, your admission to the welding show, also gives you direct access to PMXs exhibits.

MAX International is where the next generation of technology, innovation and knowledge will be introduced, not only on the show floor but in meeting rooms and conferences. Your universe of information just expanded, too. Certainly you'll be able to attend seminars, sessions and conferences on the topics with which you're familiar, but now you'll have access to leading edge technology throughout the entire range of manufacturing. You'll gain the best of every discipline.

If you haven't already, now is the best time to make plans to attend in May. Don't miss this opportunity to be a part of the inaugural MAX International.

Tom L. Davis Managing Director, Convention and Expositions

12 I DECEMBER 2000

WELDING JOURNAL Editorial Staff Publisher

Jeff Weber Editor

Andrew Cullison 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. Ut t rachi G . M . Nally Commi t t ee Cha i rman Consultant ESAB Welding & Cutting

R. G. Pall G. O. Wilcox J. E 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. Alber t 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.

Ingalls Shipbuilding T. C. Conard ABICOR Binzel N. Hamers , 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. F . 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 Nancy Batista

American Welding Society 550 N.W. L eJeune Rd., Miami, FL 33126 (800) 443-9353 Copyright © 2000 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.

A warehouse o f changes at Nauonal- - Standard.

A recent merger has made National-Standard a stronger, more. efficient company.

N-S CopperFree and SATIN GLIDE solid wires are still in

continuous production. Our ready-to-ship inventory

has never been bigger. Our trademark strengths

remain unchanged. We still make the best

MIG wire in the world. We still are supported by an

outstanding distribution system. And our innovative bulk packaging sets the standard for the industry.

See the new National-Standard in action. Call us today.

0 National-Standard Welding Products Division

Niles, Michigan Ph: 800-777-1618 Fax: 616-683-9276

www.nationalstandard.com

Welding wire to robotic standards


OS-O000

A collection o)~industry news from the lnternet !

BY MARY RUTH JOHNSEN, Features Editor

S t r u c t u r a l S t e e l F a b r i c a t i o n I n f o r m a t i o n

Max Weiss Co. The Web site for this Milwaukee, Wis. company highlights the company's experience in rolling and forming structural steel sections for architectural and industrial applications. The site details its operations, which include welding and fabricating, hot forming and forging, and blacksmithing and machining services, including turning, milling, drilling and punching.

The site has an extensive photo gallery that includes pictures of the company's facilities and operations, as well as client project photos. The site also lists affiliations the company has with organizations such as the American Welding Society and includes links to those organizations' Web sites. Visitors can also request information via an electronic form.

http://www.maxweiss.com

Tailor-Made Cables H i g h l i g h t e d

Eiocab. Based in Kitchener, Canada, with production facilities in Canada and Germany, this company manufactures ta i lor-made cables for applications ranging from automation and robotics to t ransportat ion and medical equipment. The heart of the company's Web site is an easy-to-use questionnaire that asks customers to define their specifications or problems. It includes a checklist that asks questions regarding tension resistance, high-flex performance, chemical and thermal jacket durability and required cable diameter. At the click of a mouse, the information is sent to one of the company's product engineers.

The site also includes a listing of articles dealing with cable applications and solutions, with links to the publications. Other information provided includes the standards to which the company's products are manufactured, the trade shows it will be attending, a map and information regarding sales representatives.

http://www.elocab.com

Site Details Hazardous Material Storage

Safety Storage, Inc. Scroll-down menus at the bottom of each page make it easy to navigate around the site for this Hollister, Calif., based manufacturer of prefabricated, re- locatable steel buildings for the storage, handling and use of chemicals and hazardous materials.

The site includes a detai led information request form. Visitors can submit a

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summary of their applications, the time when the product would be needed, a list of the materials that need to be stored and outline requirements for materials handling, tempera ture control and code/regulatory requirements, as well as other information.

The site also includes detailed product information, which is provided by product category and for some specific industries.

http://www.safetystorage.com

Site Profiles Microjoining Applications and Solutions

Micro Join, Inc. A drop-down menu bar plus a search feature makes it easy to navigate around this Web site. The site details the company's products and services regarding resistance welding and integrated hot bar bonding systems for solder reflow, anisotropic conductive film and heat seal bonding processes.

Visitors are self-guided through photos and informational tables along three paths - - applications, processes and products - - to select the technology and system they need.

The site includes a company profile, information on how to contact a sales representative, a list of company clients and the industries they belong to and press releases. Copies of the company's newsletter, The Joule, can be down- loaded in PDF format.

A detailed Frequently Asked Ques- tions section explains what resistance welding is, the differences between resistance welding and resistance brazing, offers help on how to select a power source,

and more. For instance, in answer to the question on which electrode to use, the site offers the following:

"The first thing to remember is to use resistive electrodes for conductive materials and conductive electrodes for resistive metals. If neither the electrode nor the weldment is highly resistive, current from the welding machine passes easily through the weldment and not enough heat is generated to make a weld.

"On the other hand, if both the electrode and weldment have too much resistance, their interface will become too hot. This causes the weldment to spatter, discolor or destroy.

"If the electrode is conductive, however, and the material to be welded is resistive, current will easily pass through the electrode and the electrode will remain cool. The weldment will resist the current and generate enough heat to make a good weld."

http : / /vwv.microjoin.com

14 I DECEMBER 2000

I n t r o d u c i n g O u r N e w W e l d i n g P r o d u c t s

/"

152T 155T Two Stage Regulator Two Stage Regulator

591 153T Piston Type Regulator Two Stage Regulator

152L 152S Line Regulator Station Regulator

153M 196 Manifold Regulator Duat-Flowmeter

Regulator

SO 9001 CERTIFIED " UL LISTED PRODUCTS

Balloon Regulator / \ T"

230HGMYA Mylar Balloon

Gas Saver Regulator

GENERICO produc ts are p roduced, assembled, and tes ted by an exper ienced and ded ica ted work force that is commi t t ed to the highest s tandards of p roduc t integr i ty and exce l lence cons is tent wi th our ISO 9001 cert i f icat ion and UL l isted products .

)UR MAIN EMPHASIS IS ON VALUE THE HIGHEST QUALITY AT THE LOW PRICES! Quality and price must speak for themselves, so we encourage your inquiry. See for yourself why - the wor ld over - more and more professionals are using GENERICO products.

rilE BEST WARRANTY IN THE BUSlNES~ Flashback Arrestor

162L

3ROAD P R o D U c T SELECTIOI~

Air Torch

Tweco Electrode Holder

MC200

Ground Clamp

20-1710~5 Welding Goggle Filter Plate

TWO YEAR "OVER THE COUNTER REPLACEMENT" WARRANTY All GENERICO manufactured weld ing apparatus and equipment is warranted to be free from defect ive material and workmanship for a per iod of two years f rom the date of purchase.

Regulators Welding Apparatus Welding Accessories • Single Stage • Torch Handles • Electrode Holders • Two-Stage • Cutting Attachments • Ground Clamps • Station • Cutting Torches • Cable Connectors, • Line • Machine Torches Lugs & Splicers • Manifold • Air Torches • Chipping Hammers • Flowmeter & Flow Gauge • Welding & Heating Nozzles • Magnetic Holders • Piston • Cutting Tips * Tip Cleaners & Drills • Balloon • Flashback Arrestors • Spark Lighter

• Check Valves • Welding Goggles

G E N S T A R T E C H N O L O G I E S CO. , INC. 4525 Edison Ave • Chino, CA 91710 Tel: (909) 606-2726 • Fax: (909) 606-6485 Websi te: w w w genstar tech corn

PRODUCTS ALSO AVAILABLE FROM THE FOLLOWING WHOLESALERS:

• United American Sales, Inc (U.A S.) Wilmington, OH 800-421-7081 • Westgate Sales Corp., Oakland, NJ 201-337-0024 • Doyle's Supply, Inc, Decatur, AL 800-633-3959

- ~ _ Circle No. 17 on Reader Info-Card

"Pros Who K n o w . . . Go G E N E R I C O ""

Aws 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 Houston, Tex. - - January 29, 2001 San Francisco, Calif. - - March 5, 2001 St. Louis, Mo. - - April 9, 2001 Chicago, Ill. - - July 16, 2001 Las Vegas, Nev. - - September 17, 2001 Atlanta, Ga. - - November 5, 2001

(Day 2, Tuesday) Design of Welded Connections

Houston, Tex.-- January 30, 2001 San Francisco, Calif. - - March 6, 2001 St. Louis, Mo. - - April 10, 2001 Chicago, Ill. - - July 17, 2001 Las Vegas, Nev. - - September 18, 2001 Atlanta, Ga. - - November 6, 2001

(Day 3, Wednesday) Qualifications Houston, Tex. - - January 31, 2001 San Francisco, Calif. - - March 7, 2001 St. Louis, Mo. - - April 11, 2001 Chicago, Ill. - - July 18, 2001 Las Vegas, Nev. - - September 19, 2001 Atlanta, Ga. - - November 7, 2001

(Day 4,Thursday) Fabrication Houston, Te~ - - February 1, 2001 San Francisco, Calif. - - March 8, 2001 St. Louis, M o . - April 12, 2001 Chicago, I l l . - July 19, 2001 Las Vegas, Nev. - - September 20, 2001 Atlanta, Ga. - - November 8, 2001

(Day 5, Friday) Inspection Houston, Tex.-- February 2, 2001 San Francisco, Calif. - - March 9, 2001 St. Louis, Mo. - - April 13, 2001 Chicago, I11. - - July 20, 2001 Las Vegas, Nev. - - September 21, 2001 Atlanta, Ga. - - November 9, 2001

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

A W S 5th R O B O T I C A R C W E L D I N G C O N F E R E N C E A N D E X H I B I T I O N February 5-6, 2001 - - Orlando, Fla.

This conference is aimed at welding engineers and technicians, manufacturing specialists, managers and all others concerned with the latest developments in the fast-changing field of arc welding robotics and associated topics. Particular emphasis is given to case studies of actual applications in motorcycle, ship and heavy equipment manufacturing, and on criteria used in robot selection. Other areas covered include the impact of the Internet, fixturing, off-line programming, remote monitoring, computer interfaces with welding cells and metal arc welding. A special activity is a luncheon featuring a keynote speech on the present status of robotic welding.

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, 2001 - - Houston, Tx. Hydrogen-induced cracking isn't the only culprit that 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, 2001 m Chicago, I I .

For decades, the only plate cutting method was oxyfuel cutting. It is still used, but we are seeing much more plasma cutting, high- definition plasma cutting, water jet cutting and both CO 2 and YAG laser cutting. Many companies are in a turmoil deciding which way to go. This conference will provide engineers with an understanding of this whole matter. They will gain knowledge about the cost of equipment, the payback, cutting performance, and they will return home with valuable information that can be implemented profitably into their company's production lines. This conference will cover mostly steel, but there will be some mention of stainless and aluminum. Topics covered: laser cutting, plasma cutting, high-definition plasma cutting, water jet cutting, innovations in oxygen cutting.

I F or further information contact: Conferences, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126, Telephone: (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.

16 I D E C E M B E R 2 0 0 0

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Industry General Tool Awarded Contract to Build Friction Stir Welding Machines

Lockheed Martin Space Systems, Michoud Operations, New Orleans, La., recently awarded a multimillion dollar contract to General Tool Co. (GTC), Cincinnati, Ohio, to design and build three friction stir welding machines. The machines, the largest ever built, will be used to weld the large 2195 aluminum-lithium alloy panels that form the external fuel tank for the space shuttle.

The first machine is scheduled for delivery in July 2001, with the other two machines scheduled for delivery in September 2001. GTC will also install the machines and assist Lockheed Martin during the training phase of the project.

Acute Technological Services Moves into New Facility

Acute Technological Services, Inc., Houston, Tex., recently moved into a 27,000-sq-ft facility on the west side of the city. The company, which primarily focuses on the offshore industry, provides welding engineering consulting, testing and specialty fabrication services. It also serves as the U.S. stocking agent for

Acute Technological Systems recently moved into this new facility in Houston, Tex.

Oerlikon welding consumables. Housed in the new facility are several orbital gas metal arc

welding stations, as well as stations for gas metal arc, shielded metal arc and submerged arc welding.

• auxiliary board fi~r 4-quadrant converters, parallel SCRs and sequence reversing controllers

• regulator board (or battery charging and electr~,-cbemical p~wer supplies

Enerpro Inc., 5780 Thomwood D~ , Go~eta, CA 98117 In CA 805/683-2114 Fax 805/964-0798 www.enerpro.thomasrwister.com enerpro@aoLcorn

tg

• fused power transformer

variable frequency and 12-pulse firing boards also available!

Air Liquide America Announces Plan to Improve Profitability

Air Liquide America Corp., Houston, Tex., recently announced a plan to improve profitability in the United States. The plan concentrates on the company's small- and medium-size industries (merchant) business segment, which represented 43% of its total U.S. sales of $1.4 billion in 1999. The plan is expected to improve operating margins by five points while reducing capital employed by about $100 million within two years. Key components of the plan follow:

• Air Liquide America will divest its retail outlets. • The company will continue to manufacture and distribute

industrial welding gases, but it will service its small and retail cylinder gas customers through a new distributor network called ALNET. It will continue to service large cylinder customers, con- centrating on selling welding and cutting gases to this market, but hard goods will be provided through ALNET.

• The company will no longer directly resell welding hard goods once the divestitures are complete. The products will be available to all Air Liquide America customers through ALNET.

The company expects the transition to be completed in the second quarter 2001. No interruption of service is expected.

Project to Develop Lower Cost Linear Friction Welding Machine

An international project is working to reduce the cost of linear friction welding equipment. The project has a budget of 1.25 million Euro and is partly funded through the European Community's CRAFT initiative.

Black Equipment is coordinating the project, which is being managed by TWI, both from the United Kingdom. Klaus Raiser and Harms & Wende from Germany, Dartec and ABB Alstom

Circle No. 12 on Reader Info-Card 18 I DECEMBER 2000

Power from the U.K., Deltamatic of Italy and Technische Universit~it Graz from Austria are the other members of the con- sortium.

In linear friction welding, two surfaces are rubbed together in an oscillating fashion. A variety of complex shapes can be joined and the process has been applied to a wide range of alloys, including titanium, stainless steel, aluminum and intermetallics. However, high capital costs have hindered its use in industry. TWI LinFric 'M has trademarked a prototype machine, which incorporates ways for more efficient use of power sources and stored energy concepts, which should lead to reductions in equipment price.

Street Rod Project Concludes First Phase

The first phase of the Miller Electric Mfg. Co. traveling street rod seminar series concluded with installation of a stainless exhaust system at the Good Guys 7th Southeastern PPG Nationals in Charlotte, N.C., in October. Since May, the company has held a series of hands-on seminars and demonstrations at regional and national street rod shows.

In 2001, the seminars will continue at street rod shows and will focus on additions to the 1931 Ford Coupe's interior. Miller Electric district managers Wayne Reece and Jim Ne will demonstrate how to install power windows, air conditioning, a motorized trunk and flush-mounting doors.

Wayne Reece demonstrates installing steel inserts into the street rod at the Street Rod Nationals in Louisville, Ky.

As work on the car progresses, seminar attendees learn about the different types of welding and plasma cutting equipment required during every step of construction. They can also ask questions about their own projects and try out equipment.

For more information regarding the street rod project, contact Wayne Reece at (502) 239-4488.

INEEL Researchers Create Strong Magnets with Miniscule Structure

Researchers at the Department of Energy's Idaho National Engineering and Environmental Laboratory (INEEL) recently discovered a way to make magnets used in computer hard drives and motors more powerful and durable while cutting their manufacturing costs.

Scientist Dan Branagan discovered slight changes to the standard format for these magnets produces stronger magnets that can withstand high manufacturing temperatures. High heat usually transforms these rare earth magnets into worthless hunks of metal. Branagan worked in collaboration with researchers from Ames Laboratory in Iowa and Brookhaven National Laboratory in New York.

Magnets are a composite of thousands of miniature magnetic fields. Tiny crystals, or grains of metal, form a magnet.

IS THE LACK OF A CWl KEEPING YOU FROM

REACHING THE NEXT LEVEL? NO PROBLEM.

The Hobar t Inst i tute offers two-week courses to he lp you prepare for the Cert if ied Weld ing Inspec tor and Educa to r exams. W h i l e a very high percentage of our students pass, those who don't can r e tum within six months free of charge:

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

NOVEMBER 6 • DECEMBER 4 ° JANUARY 15

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Call 1-800-332-9448 or visit www.weldingAgg

HOBART INSTITUT] OF WELDING TECHNOLOGY 1.~

*Some restrictions apply Please contact the Hobart Institute for details. © 2009 Hobart Institute of Welding Technology State of Ohio Registration No. 70-12-0064HT


WELDING JOURNAL I 19

ARONSON POSITIONERS

POSITIONING Made Easy

Now you can get Aronson positioning quality at a popu- lar price. Koike Aronson engineered in the accuracy, safety and reliability you've come to expect, but at a lower cost. MD (metric designed) two-ax positioners provide y with full continuous 3 bi-directional rotatiol and 135 o tilt from horizontal. And, they're rated for full-load, non-stop us

• 4 models to choos . . . . . . . • 1000 to 5000 kg capacit ies • solid state variable speed rotation; dynamic braking • anti-friction bearings for greater life and efficiency

Your Koike Aronson distributor has all the details.

- -~ KOIKE ARONSON 635 West Main Street Arcade, NY 14009


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2o I DECEMBER 2000 Circle No. 35 on Reader Info-Card

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These tiny grains of metallic glass form powerful magnets more temperature resistant than most rare earth magnets.

Alignment of the grains affects the strength of the magnet. At INEEL, they form magnets composed of grains so tiny each one is too small to host more than one direction of magnetic field. The researchers found adding extra elements to the mix of rare earth elements improves temperature resistance and magnetic field strength. The extra elements improve the magnet by forming nonmetallic compounds. The researchers also added another important step, creating a metallic glass.

I n d u s t r y N o t e s

• Ford Motor Co., recently named BOC Gases, Murray Hill, N.J., as one of its Top 33 Industrial Materials Suppliers. The company received the highest performance rating of any industrial gases supplier in Ford's supplier evaluation program and has won Ford's Q1 certification for quality, service and customer satisfaction.

• Cincinnati Thermal Spray, Inc., Cincinnati, Ohio, recently developed and filed for a patent on a process that enables fused coatings to be applied reliably and economically to noncylindri- cally shaped parts. Usual practice for irregularly shaped parts is to fuse them in a protective atmosphere furnace. The company's invention eliminates the need to perform the fuse operation in a heat treat furnace with a protective atmosphere.

• Sellstrom Mfg. Co., Palatine, I11., recently acquired an equity interest in XELUX TM and will be marketing the European company's autodarkening filter in the United States. XELUX produces waterproof, solar-powered, lightweight, autodarkening welding helmets, as well as several models of manually variable filters.

Correction

Please note that in the article titled Welding a Pathway to the Stars in the October 2000 Welding Journal, Figs. 2 and 4 were switched. Also, CWI Services, an inspection and testing consulting business owned by CWI Lawrence E. Smetana, is located in Bloomingdale, II1., not Bloomington, as mentioned in the article. The Welding Journal regrets the errors.

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0 TIG PRODUCT Industry Standard Air-Cooled & Water-Cooled Torches

0 TUNGSTEN GRINDER Patented Wet Grinder

0 TUNGSTEN ELECTRODES Meets AWS Specifications A BI C OR

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

Robotic Welding Cell Boosts Productivity

The System 10 is a compact, preengineered robotic welding cell with a two-fixed- table welding workstation designed for small- to medium-sized parts that can be welded without reorientation. Features of the welding cell include a Fanuc Robotics ArcMate 50iL 3-kg, 6-axes robot and Fanuc FJ3 controller; the Lincoln CV-400 power source: Synergic 7 four-roll wire feeder: and LN-10 weld controller. The unit

has a complete metal surround flash and safety barrier and bifold safety doors with inter locks. An opt iona l welding fume control hood and f i l t ra t ion system are available. The flexible automation capabilities of the System 10 make upgrading from various forms of arc welding processing easy. The small 66 x 90-ft footprint makes the unit forklift compatible and minimizes the amount of floor space needed. The workstation is assembled complete and shipped ready to install.

The Lincoln Electric Co. 22801 Saint Clair Ave., Cleveland, OH 44117-1199

100

Modular Tool Changer Makes Maintenance Easy

The SW-150A modular tool changer has four easy-to-change modules: an air- actuated locking mechanism with ball- locking technology and position sensing proximity sensors; rhodium-plated, con- ical mating contacts that resist damage

from weld spat ter and other airborne contaminants; a fluid/air module with self-sealing air and fluid ports and low pressure, high water flow rates for better transgun cooling; and a signal module with 19 rhodium-tipped contacts for longer life and stronger electrical connections. High-power contacts are easy to replace with a hex wrench. The fluid module 's 1.7 Cv allows a 20% increase in water flow volume that helps reduce or prevent clogging. High acid pH problems associated with the available water supply are neutral ized by a s tandard ZICOR TM coating that protects the alu-

minum manifold from acid attack.

ATI Industrial Automation 101 Peachtree Center, 503D Hwy. 70 East, Garner, NC 27529

Turntables Ease Assembly Jobs

Powered and nonpowered turntables can make repetit ive jobs easier and reduce the risk of potential injury or acci- dent. The company's line of powered turntables comes in a variety of sizes and styles: s tandard circular platforms, adjustable speed control, low and high profile platforms, and weight capacities from 2,000-10,000 lb. Its nonpowered, freestanding turntables can be manually pushed to put parts within easy reach of

22. I DECEMBER 2000

an employee, thus reducing fatigue and potential accidents due to lifting, bending or twisting. Nonpowered turntables have a weight capacity of 2,000-10,000 lb; standard square platform dimensions range from 2 x 2-ft to 8 x 8-ft; circular platforms are optional.

Advance Lifts, Inc. 701 Kirk Rd., St. Charles, IL 60174

102

Air-powered Arc Welding Reel Handles High Amps

The Series A W C R reel is a heavy- duty arc welding reel designed to handle cable current of up to 400 A. The reel has a rotary electrical device that can be instantly used with any unwound cable length. The A W C R chain and sprocket drive is powered by a compressed air

motor and includes a standard auxiliary rewind. The reel is designed for use with single conductor electrode cable or grounding lead. Provision is made for connection to the welding machine.

Hannay Reels 553 State Route 143, Westerlo, NY 12193-0159

103

Brazing Technique Repairs Aircraft Engines

The PreSintered Preform (PSP 'M) is a combination of superalloy and braze powders that can refurbish the cold section compressors and superalloy hot

section components of aircraft engines. PSP restores distorted and worn airfoil contours to its original shape; it can be used to repair airfoil throat reduction and dimensional res tora t ion of high- pressure turbine nozzle guide vanes. The p r o d u c t e l i m i n a t e s shr ink d e p r e s s i o n s , m i n i m i z e s p o s t - b r a z e gr inding, and removes the need for rebraze cycles.

Morgan Advanced Ceramics 582 Monastery Dr., Latrobe, PA 15650

104

Bevel Head Produces Better Edge Quality

A new programmable plasma contour bevel cutting head enables better plasma beveling on gantry shape-cutt ing ma-

chines. The new torch station, working with the CNC controller, automatically

compensates for the natural bevel inher- ent in plasma cutting. The plasma bevel head rotates the torch so that the same side of the torch is used to cut on all sides of the plate. A new tactile sensor system maintains torch height from the workpiece and is not influenced by electrode wear. An improved collision protection system provides better protection for the torch in all lateral directions as well as on the vertical axis. The magnetic torch mount detaches the torch holder before the torch can be damaged; the mount can also be removed manually from its bracket, making torch inspection and nozzle or electrode change easier. The plasma bevel system operates on ESAB's Avenger series gantry.

ESAB Welding & Cutting Products 105 411 S. Ebenezer Rd., Florence, SC 29501-0545

Laser Head Opens for Easy Maintenance

The S-Series family of CW diode- pumped solid-state laser systems has expanded on the Stiletto laser system. The

new unit has multiple triggering options and field-replaceable components. The unit delivers up to 50-W CW, or can be AO Q-switched from 1-50 kHz, deliver- ing up to 35 W. Several models are available, including a TEM °° unit.

Cutting Edge Optronics, Inc. 106 20 Point West Boulevard, St. Charles, MO 63301

Water Saver Monitors up to Eight Weld Guns

The IntelliFlow TM III Water Saver features remote control bypass, line restart, and shutdown. The IntelliFlow monitors supply and return lines to detect leaks as small as -+3% of the monitored flow rate


,jet.n, l lng i e e i g ,

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while compensating for normal pressure fluctuations and the robot's dynamic motion. The entire water circuit, not just the weld gun tips, is monitored via a built-in microprocessing sensor method. Hose configuration, mineral ized waters and pressure drops will not cause a line shut- off because Intelliflow measures the dif-

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ference between supply and return flow rates only. The water saver automatically shuts off the water flow within 0.4-0.7 s for gun tip removal. When finished, the system can be reset. Automatic setup and monitoring is one-touch, with continuous visual feedback on an easy-to-read LCD screen. The system also has an optional DeviceNet T M interface.

DE-STA-CO Industries 107 31791 Sherman Drive, Madison Heights, MI 49071

High-Temp, Inert Atmosphere Furnace Handles Heat

Treating Jobs

No. 854 is a special high-temperature, 2200°F electrically heated, inert atmosphere floor furnace; the maximum operating tempera ture is provided by 53 kW from heavy-gauge, high-temperature Kanthal A F alloy wire and rod overbend design heaters. The furnace features 9- in. insulated walls and 2-in. thick block

insulation. A firebrick plate hearth is supported on firebrick piers. An electrically opera ted vertical lift door is provided, with remote foot pedal control. Special inert a tmosphere construction on the unit includes a continuously welded outer shell, h igh-temperature door gasket, sealed heater terminal boxes and inert atmosphere inlet, outlet and flowmeter. Safety and control equipment include a digital indicating temperature controller, manual reset excess tempera ture control ler with separate contactor, and a four-channel strip chart

recorder.

The Grieve Corporation 108 1540 E. Dundee Rd., Suite 250, Palatine, IL 60074-8311

24 I DECEMBER 2000

Power Source and Robotic Interface Combined in

One Package

The Auto InvisionT"II is a robotic GMAW/pulsed G M A W power source that incorporates the Invision TM 456P

wire welding power source with the

b . .

g

Robotic Interface TM II into one package. The unit provides up to 600 A of welding output (450 A at 100% duty cycle) and has a 230/460-V or a 575-V, 60 Hz input. The Auto InvisionTMII provides standard programs designed for commonly used materials and shielding gas types. The "one box" solution eliminates external cabling and connectors between the power source and the robotic controls. A standard quick-change connec- tor make adaptation to robots easier, and an optional hi-flex cable is available for applications with complex robotic mo- tions that can put stress on standard cables.

Miller Electric Mfg., Co. 1635 W. Spencer St., Appleton, W1 54912-1079

109

Robot Control ler Handles Multiple Tasks

The XRC control ler can control up to three robots (or 27 axes), allowing for independent job control for up to six con-

current tasks (three robot motion jobs, one external axis motion job, and two I/O instruction jobs). The XRC combines simple programming with dedicated arc welding functions and advanced features, including multi-axis control capabilities. Customized application programming packages are available for arc welding, as well as dispensing, material cutting, jigless (dual robot) , material handling, painting, spot welding, or general-purpose applications. The XRC offers standard networks for Device Net, Profibus-DP, and Interbus-S for connection with infrastructure. A built-in PCMCI card reduces installation and system upgrade time. With Ethernet TCP/IP capability, the XRC offers high- speed networking capability with a PC.

Motoman, Inc. 110 805 Liberty La., W. Carrollton, OH 45449

Til t Table Assists Testing

A dual-direction tilt table has been designed to facilitate off-center testing

of a personnel carrier vehicle and to assist in the testing of prototype stability and structural analysis. The tilt table can be tilted up to 45 deg in one direction and up to 40 deg in a secondary direction. The table allows a running personnel carrier to be tilted in order to monitor and starvation test a vehicle's fuel and lubrication system.

Pentalift Equipment Corp. P.O. Box 1510, Buffalo, NY 14240

111

Walk- in Ovens Heat Heavy Applications

A comprehensive line of 24 heavy- duty walk-in ovens suitable for heavy

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load applications like heating heavy castings pr ior to welding is available. The ovens offer maximum temperatures to 450°F (232°C), 650°F (343°C) and 750 ° F (398 ° C), and work area capacities of 96-360 ft 3. Both gas and electric heated versions are available, and standard features include digital temperature control, adjustable air ducts and alu- minized steel, interior, t r iple-hinged nonsag doors.

Precision Quincy Corp. 1625 W. Lake Shore Drive, Woodstock, IL 60098

112

Lightweight Magnets Lift Big Loads

The NEO-500 weighs just 42 lb but can lift a 1100-1b steel plate or a 550-1b

round bar. Utilizing neodymium magnet material , the NEO-250, NEO-500 and NEO-1000 are designed for use in steel, supply, machine and die shops where heavy steel objects must be moved rapidly and safely.

O.S. Walker 113 Rookdale St., Worcester, MA 01606

Lens Mounts Prevent Damage

Lens Savers ® lens mounts have been developed for Trumpf L3030 and IA030 lasers with 5.0- or 7.5-in. focal lengths. The Lens Savers ® are placed in front of the focusing lens in CO 2 lasers to help prevent damage to focusing lenses caused by the sparks, smoke and spatter unleashed during laser beam cutting or welding. The patented mounts and adapters enable use of the Lens Savers ® with high pressure.

International Crystal Laboratories 114 11 Erie St., Garfield, NJ 07026

System Monitors Nut Weld Quality

The company offers a weld quality monitoring system consisting of an industrial-duty linear displacement transducer (LVDT)and the Model WM9100 weld meter. This system can detect miss- ing or upside-down nuts or studs, measure weld "set-down," determine correct part dimension before welding, and monitor tool wear. The LVDT displace-

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ment sensor features ranges to fit all weld machines and requires two shoulder bolts for mounting. The meter provides four programmable limits with relay contacts (AC or DC) that interface directly to your weld controller, PLC or quality system. Relays can also control light posts to provide instant visual display of weld quality status. A serial interface (RS232 or 485) allows data to be down- loaded directly into a spreadsheet on a remote computer, providing permanent traceability for each weld.

Sensotec, Inc. 2080 Ariingate La., Columbus, OH 43228

115

Single-Pass Deslagger Cuts Clean

The single-pass carbide deslagging machine deslags one or two sides of oxyfuel-cut parts quickly and without using abrasives, leaving a clean surface. The machine eliminates hand chiseling and grinding of slag from plasma or oxyfuel- cut parts. By using a roll with floating carbide inserts, s tandard widths of 39, 55, and 78 in. are available. This machine is capable of handling many cutting tables and is equipped with motorized in- feed and out-feed tables. Parts can be fed directly from the cutting table with thicknesses ranging form 0.200 to 3 in., while the speed ranges from 12 to 240 in./min. There is a built-in auto-warpage compensation feature. The EM machine can deslag for such applications as agricultural, vessel, service centers, and anywhere oxygen cut deslagging is required.

Cimid Corporation 50 S. Center St., Orange, NJ 07050

116

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A collaboration between manufacturers and educators in southwestern Pennsylvania provides free entry-level welder training

BY MARY RUTH JOHNSEN

A n ordinary Saturday morning. You drive over to Eat 'n Park and slide into a booth. The waitress flips over a white crockery mug, pours you a cup of coffee, then

hurries off to turn in your order. You take a sip, look down at the place mat to see who the Charleroi Cougars will be playing Friday night and see something that just might change your life - - an ad on the upper left-hand corner offering free welder and machinist training. "Get the free training that gets you the job," it says. You decide to call the 800 number.

Sound farfetched? Well, the free training is currently available to workers in southwestern Pennsylvania through a Pitts- burgh-based nonprofit organization called New Century Ca- reers (NCC), the result of a col laborat ion between area manufacturers, vocational schools, community colleges, the business school at Duquesne University, the University of Pitts- burgh's Manufacturing Assistance Center, and with funding in part from local foundations. The place mat ads are just one of the marketing tools being used to recruit students.

The training, textbooks and other materials are provided to the students at no cost on condition they make every effort to take a job with one of the member companies. "This program is all about getting a job," explained Paul Anselmo, NCC president. "If you're not interested in getting a job, don't come into this program."

Manufac ture rs Make T h e i r N e e d s Known

The genesis for New Century Careers was a series of meet- ings in the mid-1990s between executives from manufacturing companies in Pittsburgh and the Mon (Monongahela) Valley and Barry Maciak and Silvio Baretta, partners in World Class Industrial Networks, a consulting firm whose clients include Duquesne University and New Century Careers. Maciak serves as executive director of the Institute for Economic Transforma- tion, part of Duquesne's business school. Through the Institute, the two men brought companies together to talk about their common issues, foremost of which was the work force.

Originally, most of the talk centered on the need to improve the skills of workers the companies already employed. '~ round three years ago," Maciak said, "we started to see that conversation change. A lot of the conversation focused on 'I can't find good, quality, entry-level employees,' particularly in some of the most critical occupation areas like welding and machining."

"It used to be people could go into manufacturing with no skill and get a good job," Baretta said. "That's not true today."

Getting new people in the door soon took priority over the need to train and advance incumbent workers.

Although many of southwestern Pennsylvania's largest employers have left the area or reduced the size of their work force,

MARY RUTH JOHNSEN ([email protected]) is Features Editor of the Welding Journal


manufacturing still accounts for 15.9% of private-sector jobs in the 13-county area, according to figures from NCC. That translates into 162,633 jobs, making manufacturing the second-largest private sector employer in the area. And 44% of Pittsburgh's industrial manufacturing base is still related to metalworking, Maciak said.

From these dialogues, a group of 17 manufacturers was established to address the emerging work force cri- sis. "One of the first things we asked them when we got to training was 'Who do you turn to to provide training in welding and machining?'" Maciak said. "Who's your best source for training locally?" The companies di- rected Maciak to the Steel Center Vocational-Technical School in Jefferson Hills, Pa., and Anselmo, then the school's adult education coordinator.

The manufacturers identified entry-level machinists as their greatest need. Anselmo and others developed a curriculum for training machinists and in 1998 a pilot program called Manufacturing 2000 was set up with the goal of training 20 machinists and placing them in jobs.

"We almost immediately geared that up," Anselmo recalled. "We realized that putting 20 machinists or 20 welders or anything else out in the street in one year isn't going to make any kind of an impact, so we immediately set out to increase that."

Anselmo eventually left the public school system to become president of New Century Careers, which was in- corporated in April of this year. After machinists, the manufacturers identified welders as their next greatest need, so a pilot welder training program was established through area community colleges in 1999. Welder training became part of NCC with the spring/summer session. Each term, Anselmo said, the program has expanded. The current fall/winter session offers 10 classes in eight locations in four counties. The number of participating manufacturers has also grown from the initial 17 to more than 80.

Finding the Students One element that distinguishes NCC from other pro-

grams is its use of a professional direct response marketing firm, Elliott Marketing Group. John and Jane Elliott have worked with NCC since the initial machinist pilot project, and are responsible for all recruitment and fulfillment activities.

All of NCC's recruiting efforts include a toll-free telephone number. Within 24 hours after receiving a call, an information packet is sent via first-class mail to the caller. "The package includes a complete description of the program," John Elliott explained. "The call to action is to reserve a place in a seminar or to actually sign up to test for the program." If they desire, prospective students can also sign up for the information seminars when they make their initial call. For the fall sessions, NCC personnel held 32 seminars explaining the program.

Follow-up is vital. "If we send an information package and they don't sign up for a seminar, we follow up," John Elliott said. "If they don't show up at the seminar, they receive a call. If they come to the seminar but don't sign up, they receive a call." He likens the recruiting effort to a funnel. For instance, for this fall's classes between 2500 and 3000 responses were needed to fill the 200 available spots, John Elliott said. About 10% of the people who respond apply. Of those, about half take the screening test and enter the program. It costs approximately $750 to actually acquire a student, he explained. "For every dollar we spend generating a lead, we spend one to two dollars to follow up on that lead."

Over the past eighteen months to two years, about 6000 responses have been received through a variety of means. The El-

A student enrolled in the New Century Careers program at Westmoreland County Community College practices his welding skills.

liotts utilize direct mail; the list is now self-generating from people who have responded in the past but for whatever reason did not enter the program. They advertise in a wide variety of media, from newspapers to billboards to bus shelters to inserts that can be placed in church bulletins, as well as the restaurant place mats. The program has also benefited from news stories from local newspapers and television stations.

The Penny Saver, a free, weekly shopping guide, produces the single best results, according to Jane Elliott, followed by the Green Sheet, another free publication distributed through local grocery stores. Other community newspapers, shoppers and fly- ers are also effective, she said. The restaurant place mats, church bulletins and some of the other methods produce a small, but steady, trickle of leads.

New Century Careers had been relatively unsuccessful in at- tracting African-Americans to the program until recently. While respondents are never asked questions regarding race or ethnic background, the Elliotts do make use of demographic information. Leads from predominantly African-American neighbor- hoods are passed on to Ken Nesbit, an NCC employee responsible for outreach in the African-American community. Nesbit speaks to community organizations and works one-on-one with prospective students. "One of Ken's key roles is to explain this isn't another program to train African-Americans for jobs that don't exist," John Elliott said.

30 J DECEMBER 2000

Through Nesbit's efforts and working with established media such as the New Pittsburgh Courier, probably the oldest African- American newspaper in the United States, more African-Amer- icans are entering the program.

The Welder Training Program Still in its infancy, New Century Career's welder training pro-

gram is constantly being tweaked to make improvements, Anselmo said. Welder training consists of 400 hours over a 15 or 16 week period; machinist training is 525 hours. Class hours differ at each site, but most are in late afternoon and evening. At least once each term, the students are taken on field trips to visit manufacturers and see what their working life might be like. Stu- dents taking classes at the community college sites earn college credits.

Prior to entering the program, students take a screening test that evaluates their verbal, mathematical, mechanical reasoning and problem solving skills. They must also present two letters of recommendation. New Century Careers is not involved with re- medial education, although Anselmo works with other agencies that can provide that type of help. Students typically are 24 to 30 years old. While some are displaced or otherwise unem- ployed workers, many are currently employed. For instance, seven members of the pilot machinist training class either made or delivered pizzas.

The welding course covers welding safety, fundamentals such as the types of joints, blueprint reading, oxyfuel cutting and the shielded metal arc, gas metal arc and gas tungsten arc welding processes. Students learn to weld in the fiat, horizontal, vertical and overhead positions.

Henry Cabrera, one of the instructors at Westmoreland County Community College (WCCC), said they aim for the students to spend about 90% of their time in the welding lab and 10% covering theory. Students demonstrate their competency in one area before advancing to the next level.

At the end of the program, students take certification tests according to the requirements ofAWS DI.1, Structural Welding Code - - Steel. While passing the tests is not a requirement for graduation, certification is a strong selling point to prospective employers, Anselmo said. "We recognize that most manufacturers now are looking for some real industry standards, not just the educational curriculum," he said.

Starting the Program at Westmoreland County Community College

The inaugural class at WCCC started with the spring/summer session and consisted of five students - - Fig. 1. (Typically, NCC classes include 15-20 students.) All five students first con- tacted NCC after seeing an ad in a community newspaper or shopper, although student John Cortese first learned of the program through his mother-in-law who works at the Community College of Allegheny County, another NCC site.

The students entered the program for a variety of reasons. Although he'd never welded before, Cortese had observed the welders at factories he'd worked in and became interested. "I have the feeling I can find a long career in welding," he said. "I 'm not interested in job-to-job. I 'm looking for a career." Steve Jordan had taken welding classes in high school and had intended to enter the regular welding program at WCCC after graduation. However, he changed his mind and took a job. Jor- dan viewed the NCC program as a way to get back into welding. Nick Danser said he joined the program because of its offer of free training and promises regarding job placement. Eric Cal- gagirone's goal also was for a good job with benefits. Earning

Fig. 1 - - A l l five members of the inaugural NCC welding class at Westmoreland Community College have now graduated. Shown standing from left to right are Nick Danser, Eric Calgagirone, John C. Cortese, Jr., and Rick Kurdilla. Kneeling are Steve Jordan and instructor Henry V. Cabrera (in red).

college credit was a plus for him. Rick Kurdilla, a displaced steelworker who had worked as a welder many years ago, said he viewed the program as an opportunity to catch up on any changes in technology that had occurred since his welding days. He also welcomed the opportunity to earn college credits.

While the students praised the welding lab at the school, which is housed in a new facility, and instructor Cabrera, most expressed some concerns regarding being the guinea pigs for the program at Westmoreland. Some textbooks and materials had been late in arriving and they felt they'd had too many instructors. "We've had four different teachers," Jordan said. "I think it should be narrowed down at least to two." Anselmo countered that since it is an accelerated course, more than one instructor is usually needed to teach it; however, he acknowledged some changes may need to be made.

"I was in a guinea pig class myself, and it had some straight- ening out to do," Cabrera said. "These guys, in fact, will be better prepared to be in the field because of the adversity they've overcome. Right now they have a legitimate beef and complaint because of some of the things that haven't worked out, but out in the field they're going to run into problems like that, too, and they're going to be better prepared to handle it and be able to adapt, improvise and overcome." At the time this article was being written, all five class members had graduated and were interviewing for jobs.


Job Placement

Another of the distinguishing features of the New Century Careers program is the level of accountability for each party. New Century Careers agrees to recruit, train and help place the students. The member companies agree to serve as advisors to the program, open their facilities for field trips and to pay $1250 to NCC for each student they hire that passes a three-month probationary period. "I don't think we'd be doing this if the manufacturers wouldn't be contributing to it," Maciak said. "And not just in paying for the graduate, but in their time and energy and helping us to design and direct the program." The $1250 mostly covers recruiting and placement costs. Actual training cost runs between $5000 and $7500 per student, Ma- ciak said.

In turn, the students sign an agreement at the beginning of their training in which they promise to attend at least 90% of all classes, to show up at the job fair held at the end of each course and to give NCC the opportunity to place them with one of the member companies, and that if they don't do so they will reim- burse NCC the same amount the member company would have paid, $1250.

Toward the end of each class, NCC personnel work with the students to hone their job search and interviewing skills and to help them prepare r6sum6s.

Since so many companies were in need of entry-level employees, it was decided early on the fairest method to introduce companies and graduates was through a job fair, Anselmo said. The companies get no information about the students until the

job fair and students are not allowed to leave the program or be placed in a job prior to the job fair. The companies can attend any or all of the job fairs, although many attend only the ones at the training sites closest to their plants.

What's Next for New Century Careers Through surveys of the manufacturers in the region, Maciak

said, they know 1500 to 2000 new welders a year are needed just to sustain the business economy as it is, let alone allow companies to take on additional work. "We have the capacity to graduate and place 200 to 300 students annually right now," he said. "We have to build that capacity to handle a couple of thousand annually, and in business you have to do that very carefully."

For NCC to produce large numbers of graduates, Maciak said, "The model we're using now can't remain the same, even though it's successful. We have to change the way we do things if we really want to hit the scale that's going to help support the economy in the region."

In the meantime, plans call to gradually add more classes and training sites for the welding and machinist programs. New Cen- tury Careers is also considering adding classes to train front-line supervisors and electronics assembly workers. It has also obtained a more than $1 million grant from the U.S. Department of Labor to provide advanced training to manufacturing workers. The money will be used to launch the Advanced Manufac- turing Education program. •

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32 I DECEMBER 2000

A Wise Method for Assessing Arc

Welding Performance and Quality

Straightforward strategy

antiquates trial-and-

error methods

BY DENNIS D. H A R W I G

T raditionally, welding engineers, technicians and operators are not taught a systematic

strategy to develop procedures that produce consistent weld quality under the full range of production variations. When facing a new welding application, a common approach is to arbitrarily select a process (usually one already in use on other applications) and values for certain welding parameters such as voltage, current and travel speed. Incremental adjustments are then made until a satisfactory weld is achieved. While the re- suiting procedure may be workable, it may not be robust enough to accommodate small changes in welding conditions or variations in production factors, such as part mismatch, root opening variations, part cleanliness and torch offset, which may cause the quality of welds to deteriorate quickly. When this occurs, there is often no clear direction toward the solution of the problem.

The trial-and-error approach for developing arc welding procedures can be replaced with a systematic experimental strategy known as '~RCWlSE." Developed by Edison Welding Institute (EWI) and in use since 1996 (Refs. 1, 2) to assess arc welding

The development of a comprehensive database of optimum welding parameters for specific applications has the potential for saving industry millions of dollars.

processes for specific applications, this straightforward method provides a data set that relates functional welding parameters to productivity and weld quality. This data set provides a foundation for selecting welding parameters and permits benchmark- ing of welding processes. In addition, because tests are performed under carefully controlled conditions, the data can be stored for future use on similar applications and compared to alternative processes. A database, which already contains details of nearly 100 applications, is currently being built by EWI.

It is important to emphasize the ARCWISE experimental method is best suited to evaluate and compare processes for a

DENNIS D. HARWIG is Manager, Arc Welding & Automation, Edison Welding Institute, Columbus, Ohio. (614) 688-5000.


,.,7

Fig. 1 - - Bead shape photomacrographs for a GMA Wprocess (average deposit area = O. 0362 in.2).

~ ~,'~r)~ ~

z ~

10 ~m

Tmvll Speed

- - !

cr

~ c

Fig. 2 - - Bead shape photomacrographs for a FCA W process (average deposit area = 0.0342 in.2).

plication, taking into consideration weld quality requirements. It also shows productivity capability compared to the level that will balance work flow in production.

A major reason for the effectiveness of the method is that all test welds involve a constant ratio of deposition rate to weld travel speed. In this manner, the deposit area is kept constant while variations in tip-to-work distance, arc length, shielding gas and other factors are evaluated.

In typical welding-related reference publications, it is common to find the following types of operational characteristics for consumable electrode processes: voltage vs. current, wire feed speed vs. current and deposition rate vs. current.

Graphs showing these data often include the effects of electrode diameter, shielding gas, electrode extension and polarity. However, they ig- nore the effects of weld size and joint design, contact tip-to-work distance and arc length. Therefore, these graphs are not "application representative," making it difficult for an engineer to select actual weld parameters. In contrast, the ARCWISE data set yields a set of graphs that can be used to define an operational window and select the best welding parameters.

The definition of an application is a set of fixed design factors such as base materials, joint type, position, weld size, bead shape and mechanical properties requirements. The operational windows developed with this method are for a specific process-consumable combination that was evaluated on an application.

specific application. In contrast, statistical methods yield algo- rithms relating many factors and may be preferred when the relationships between process and production factors need to be fully optimized. The statistical approach requires a high level of expertise and is sometimes applied without a thorough understanding of the welding process, producing results that do not reliably represent welding process behavior. The author be- lieves this systematic method identifies key relationships between process parameters and provides a solid foundation for optimizing the relationship between process, design and production factors. In other words, a systematic experimental method is an ideal first step in optimizing the welding process for an application.

This method is part of a broader program at EW! to develop procedures and data that optimize parameter selection for arc welding applications.

Importance and Value of the Technique From a relatively small group of 15-24 test welds, this

method yields an integrated set of parameter relationships, corresponding weld bead shapes and graphical representations that describe operational and productivity capabilities of the welding process and filler metals being tested. Done properly, it ex- amines the full operating range of the process for a specific ap-

1. Note that filler metal deposit efficiency for FCA W is based on wire outside diameter.

Applying the Method The best way to illustrate ARCWISE is through example.

Below are details from one application used in an ongoing program to develop an extensive database for user reference.

The Application

The gas metal arc welding (GMAW) and flux cored arc welding (FCAW) processes were compared for welding T-joints on mild steel in the flat position. The base material was ~-in. SA36 hot-rolled bar sandblasted to remove scale. A ¼-in. fillet weld was specified.

The GMAW process was used with 0.045-in.-diameter ER70S-6 electrode and 80% argon-20% CO 2 shielding gas at a contact tip-to-work distance (CTWD) of ¾ in. The FCAW process was used with 0.078-in. E70T-1 electrodes and CO 2 at a CTWD of 1 in. All welds were made using a constant voltage (CV) power supply rated at 600 A.

Components of the Method The five elements of the method are as follows:

1) Weld size and acceptance criteria 2) Constant deposit area test matrix 3) Constant arc length testing 4) Bead shape measurements 5) Welding productivity windows-- voltage-current, voltage-

wire feed speed and current-wire feed speed graphs.

36 [ DECEMBER 2000

Step I m Acceptance C r i t e r i a

Acceptance criteria for the application is the first thing that must be established. For this application, it was as follows:

• No porosity greater than ~2 in. • No cracks. • No convexity greater than ~2 in. • Depth-to-width ratio less than 2.

Step 2 m Cons tan t Depos i t A r e a Test M a t r i x

The deposit area of a fillet is the triangular area based on leg size plus reinforcement. For welds this size (¼ in.), a reinforcement factor of 20% was selected to assure leg size with some convexity. Con- stant deposit area tests are based on the volume balance between the wire feed speed (WFS), wire area (Aw), and filler metal deposit efficiencyO) (fd); and to the deposit area (DA), reinforcement factor (r) and travel speed (TS) where the WFS/TS ratio must be maintained constant as follows:

DAx TS x r = WFS x A w x fd

WFS/TS = (DA x r) / (Aw × fd) For our examples:

WFSfFS0.045 = (0.03125 in. 2 x 1.2)/

(0.00159 in. 2 x 0.95) = 24.82

WFS/TS0.078 = (0.03125 in. 2 x 1.2) / (0.00477 in. 2 x 0.80) = 9.81

0 .25

0.2

0.15

0.!

0 . 0 5

0.25

0.2

i O.l~i

0. I

O .06 With the WFS/TS ratios established, a range of travel speeds is selected. Processes such as GMAW and FCAW in the automatic mode are typically tested from travel speeds starting at 10 in./min, e This speed represents a travel speed that can also be applied semiautomatically. Travel speeds are increased in 5- or 10-in./min increments to build the constant deposit area test matrix. The goal is to bracket the entire productive range of the process in 15-24 tests. The weld size determines the travel speed test increments, Le., smaller welds would be evaluated with larger travel speed increments. The maximum speed may vary from 30 in./min for large fillet welds to more than 100 in./min for sheet welding applications.

Step 3 ~ Cons tan t Arc Length Testing

Arc length test conditions are then determined for the application. Constant deposit area tests are performed at two or three arc lengths to define the useful range for the process. Arc lengths selected vary from the buried condition (apparent arc length of zero) to arc lengths up to ¼ in.

Buried, ~-in. and Z-in. arc lengths were used to bracket the range of arc lengths that could be used with these processes. Test travel speeds started at 10 in./min and were increased in 5- in./min increments up to the maximum attainable speed for each

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process. At each travel speed, three tests were performed to evaluate each arc length. Arc length was set visually for the buried arc condition. A tungsten pointer was positioned in front of the electrode extension to set the ~- and V44-in. arc lengths. Note the set arc length was the observed distance between the electrode tip and the surface of the workpiece. (The true arc length depends on the weld pool size and shape, and arc pressure.) At high travel speeds and currents, the arc cavity was submerged into the workpiece. Short circuiting often occurred using the buried arc length at the lower wire feed speeds.

Contact tip-to-work distance, travel angle and work angle are held constant for each set of tests. During each test, the voltage was adjusted to produce the desired arc length. Weld pool stability was observed and gross spatter or unstable weld pool behavior was noted. After welding, the weld surface was inspected

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visually for porosity and undercut. Data acquisition is used to record voltage, current, wire-feed

speed and travel speed. The voltage meter leads are mounted on the torch barrel (or wire-feed drive) and on the fixture to measure the true arc voltage as closely as possible, i.e., avoiding voltage drops in leads and connections. This method is used to calibrate other welding setups so procedures can be transferred.

Step 4 - - Bead Shape Analysis

A weld cross section is removed from each test in an area that represents steady-state conditions. These sections are mounted, polished and etched to reveal the weld macrostructure. Bead-

shape image analysis was performed to measure leg length, penetration, undercut, deposit area and nugget area, etc. The measurements are then compared to the acceptance criteria for the application.

Figures 1 and 2 show the range of weld cross- sections from this test series. Several observations can be made from this analysis.

In general, penetration, nugget area and base metal dilution increased as the productivity increased for these ¼-in. fillet welds. The weld cross sections from each test set were arranged to illustrate how weld bead shape changes as a function of productivity and arc length. These changes were dramatic over a travel speed range of 10-30 in./min for GMAW and 10-35 in./min for FCAW. Penetration into the fillet root varied from negligible at 10 in./min to more than 0.20 in. for GMAW

Base metal dilution increased as nugget area increased with increasing productivity since these were constant deposit area tests. As shown in Fig. 6, nugget areas varied from 0.045 to 0.110. The base metal dilution ranged from 17-56% for GMAW and from 19-69% for FCAW. Using this information, the base metal dilution can be engineered for a given welding application.

Finally, consistent with the principle melting efficiency increases with increasing travel speed, weld nugget area increased with productivity, but only to a point. With both processes, the nugget area began to decrease beyond a certain welding speed: 30 in./min for GMAW and 35 in./min for FCAW - - Fig. 3. The trend for penetration was approximately the same, indicating the same effect - - Fig. 4. This behavior typically coincides with the onset of process instability, spatter or unstable weld pool oscillations, and is an indicator of the maximum productivity of the application being studied.

Step 5 - - Displaying the Results: The Weld Productivity W i n d o w

Finally, a series of graphs were made to evaluate the relationships between voltage vs. current, current vs. wire feed speed (the process characteristics), voltage vs. wire feed speed, and heat input vs. deposition rate (i.e., the welding productivity windows). Each graph was plotted as

a function of arc length, creating a window of parameters that represent the test matrix. Regions of acceptable bead shape are shaded on the welding productivity windows to display the useful range of each process. The shaded region connected all the test points in each graph that had acceptable bead shape. For weld tests that had unacceptable bead shape, the boundary of the shaded region was estimated depending on the reject criteria. A linear approximation was made between points that had acceptable and unacceptable convexity.

This example showed the limit of productivity for many process applications is the capability of the power supply. This was the case for the FCAW process as shown in Fig. 5 where the maximum achieved productivity was 35 in./min and 27 lb/h, but bead-shape observations suggested higher welding speeds might

38 I DECEMBER 2000

be possible with careful control of arc length. In contrast, the maximum productivity for the GMAW process (Fig. 6) was 25 in./min and 17 lb/h. In both cases, higher travel speeds are probably possible by further optimizing travel angle and work position for downhill welding. In general, the preferred arc length for this application was ~-in. At lower productivity levels of travel speeds from 10-20 in./min, the '/,-in. arc length also gave desirable bead shapes.

Bead-shape analysis can also be performed and related to welding parameters for leg length, convexity, sidewall penetration, toe radius, etc., depending on the application. The purpose of this example was to show by using the systematic ARC- WISE method, significant knowledge can be developed for the welding process and application.

Conclusion The ARCWISE method provides a

structured approach to characterizing welding process applications• The method develops relationships between welding parameters, productivity and weld quality. Welding procedures can be quickly developed for both semiautomatic and mechanized welding applications by selecting the weld bead shape or desired productivity and graphing the preferred arc length, voltage, wire feed speed and travel speed. The knowledge created by this method also supports the use of knowledge-based design of experiments to optimize the relationship between production factors, such as root opening and offset, and the process application. In the future, it is hoped a comprehensive database will be created, thereby minimizing redundant procedure development. The use of optimized welding procedures and the knowledge developed by this method could minimize redundant procedure development, which will save industry millions of dollars.

Acknowledgments

Charlie Ribardo (former applications engineer), Matt Robinson and Mai Itti- wattana (graduate fellows) are acknowledged for their help in preparing test data. Fritz Saenger, director of marketing, is acknowledged for his help in preparing this article. 4,

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References

1. Harwig, D. D., et aL 1997. The ARCWISE technique for increasing productivity in arc welding. ICAWT 97, Columbus, Ohio.

2. Harwig, D. D. 1996. Weld parameter development for robot weld-

ing. SME Technical Paper RP96-291 Chicago, Ill.

SME Manufacturing 96,

W E L D I N G J O U R N A L I 39

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1RAINING WELDEBS IN MEXICO For U.S. educators working in Mexico, an understanding of the

differences between the two cultures can greatly improve the chance for success BY ANGLE HILL PRICE

M any companies are turning to Mexico as a site for their manufacturing facilities because of

the low labor costs and increasing productivity. In an article in the June 1999 Welding Journal titled Welding Forges into the Future, industry leaders indicated part of the future of welding is centered in Mexico, as well as other Latin American countries. To move successfully in that direction, managers, educators and engineers must understand and

ANGLE HILL PRICE (PRICE@ENT. TAMU.EDU) is an Assistant Professor of Engineering Technology at Texas A&M University, College Station, Tex. She gained insight for this article while training workers at Grant Prideco S.A. de C.V. in Veracruz, Mexico.

expect cultural differences. Anticipating and adjusting to these differences will result in the success of these endeavors, just as much as denial and ignorance will guarantee certain failure. This is certainly true regarding welding.

Before trainers and educators from the United States are sent to work with Mexican welders, they should undergo training themselves. This training should prepare the educator for the cultural differences that will be encountered and must be accommodated in order to succeed. To understand and appreciate other cultures, we first must identify the American culture so we can make com- parisons. An excellent reference is The Challenge of Living and Working in Mex- ico by Dr. Marc I. Erlich. Educators must keep an open mind and remember

neither culture is to be ranked better or worse, just different.

Evaluate C u l t u r a l D i f ferences

The first step to ensure success in training welders in Mexico is to understand and appreciate their culture. To do this well, we must step back and look at our own culture, then identify the differences. Avoid the temptation to label these differences as right or wrong. While there is always a hazard in gener- alization, the statements below are intended to serve as guidance and as an initiation point. We must learn to em- pathize with our Mexican coworkers and to appreciate their background and the


Table I m Identifying Differences in Cultures Facilitates Training

American System Mexican System

Commitments are to be honored. Schedules and deadlines are taken seriously.

Information should be available to all. If it's broken, replace it. Change is improvement. Choose the best qualified person for the job.

Macromanagement. Look toward future. "Live to work: '

Commitments are good intentions. Schedules and deadlines should not be taken too seriously. Information is power and may be withheld. If it's broken, repair it. Stability is important. The person is more important than the performance. Micromanagement. Look at present. "Work to live."

cultural differences that influence their behavior. In his book, Dr. Erlich describes cultural tendencies of interest to management. These are broad statements that apply to general groups. With exceptions, they essentially were true of welders and welder/operators . These differences are summarized in Table 1.

American attitudes include the belief success relies on hard work. Americans believe individual effort will be re- warded; the amount of reward is expected to be in proportion to the amount of work done. Time is taken seriously, it governs our lives. We rush to meet deadlines, race to and from work. Work is our priority and life is what happens on the side. We work later, longer and harder in a never-ceasing effort to get ahead. We make promises fully intending to keep them and we expect others to do the same, for a broken promise is a serious matter. Money, at least in comparison to other countries, is readily available in corporate America, so, in our disposable society, we spend money replacing items rather than repairing them. Change is an ever-present part of our lives; the "status quo" can always be improved, hence our policies of continuous improvement. We believe in seeking the best person for the job and giving that person all the information we can. We tend to use macromanagement and look toward the future, sometimes completely disregard- ing the present.

The Mexican culture is oriented to the family and life outside of work. Work supports the life, never dictating to it. Family is very important to Mexi- cans and will not be sacrificed in favor of work. Mexicans appreciate the present and worry about the future mahana or tomorrow. They tend to believe success in work relies on politics, luck and training. It is more who you know than what you know, much more so than in the Uni ted States. Commitments and promises are made with good intentions, and usually in good faith, but little or no penalty is expected if there is no follow-through. Time does not gov- ern work life; if something is not finished today, it can be completed tomorrow. A person is selected for a position based more on who they are rather than their skills. Information implies power and control; managers share little information in the fear they will undermine their own authority. Stability in all facets of life is very important.

Historically, Mexican companies and people have had little money, so when something is broken, it is repaired again and again, though the total cost of repair may far outweigh the one-time replacement cost. Incremental costs rather than total are more obvious. Another contr ibutor to the repair vs. replacement issue is the availability of commercial goods. Access to imported products in part icular has been extremely limited

Keys to Successful Training in Mexico

Provide basic information. Accommodate varying educational levels.

Remember the lack of documentation in Spanish. Repeat training at intervals.

Offer help constantly and respectfully. Avoid being critical.

Work at speaking Spanish. Respect cultural differences.

because of a constrained distribution infrastructure.

Mexican management tends toward micromanagement techniques. A president or high-level manager may spend a great deal of time on what might be considered lower-level management decisions in the United States. The percep- tion of power - - who has it and how much - - is very important in Mexican companies and in the culture.

Preparation An American educator of welders

who goes to Mexico and utilizes Ameri- can training methods and techniques full of American cultural biases will fail. Those methods will result in quality and productivity decreasing and an increase in worker turnover. A refusal to consider cultural differences leads to resentment on both sides. Preparation will soften adjustment difficulties and facilitate a smooth transition.

Before traveling to Mexico, spend some time reading about the country's history and culture. Familiarize yourself with the political structure and the work structure, including the unions. Prepare for the differences in work philosophy that may impact your training efforts. The Internet facilitates the gathering of information regarding these topics.

Learn as much of the language as possible in advance. You will find the Mexican people greatly appreciate any attempt you make to speak Spanish. As they are extremely polite, they will not ridicule your accent or attempts to speak the language.

E d u c a t i o n a l T e c h n i q u e s

As you initially work with people who are employed as welders in Mexico, you will find, in many cases, they have had little formal training for their occupations. Often welders have been educated through informal apprenticeships or cursory training programs, with little exposure to the technical background of welding. Expect a wide difference in the education and skill levels of people clas- sified as welders and be prepared to accommodate them. One hindrance is a lack of documentation in Spanish. The American welder has access to a great deal of written information the Mexican welder does not. The American Welding Society has made great strides in addressing this issue with the publication in Spanish of Volume 2 of the Welding Handbook, Eighth Edition, as well as Arc Welding Safety. Beware when writing welding procedures for translation. A

4 2 [ D E C E M B E R 2 0 0 0

fluently bilingual person should review company documentation translations. A number of computer translation programs are available, but many fail when used on technical papers.

When working with Mexican welders, offer help constantly, yet respectfully. Do not wait until a problem is noticed by quality assurance; instead, be observant and anticipate errors. Avoid being critical. No one enjoys being told what they are doing is wrong; this is particularly true of the Mexican worker. Criticism is apt to be met with silence and passive resistance. Positive reinforcement is the best way to obtain the welder's best. You will also face passive resistance if the welders are asked to try something new or to make changes without explanation. Make them a part of the change process; educate them as to the reasons for doing something differently. There is little faith that change will result in any reward for the employee because of their views regarding success and how it is achieved. Make them know their efforts are appreciated and find some way to reward them, such as with certificates or peer recognition, if monetary rewards are not options.

You may be told something can be done and then find it does not happen. This is not intentional dishonesty but

rather overwhelming optimism, a commitment to trying. When the welders and supervisors at a manufacturing facility initially were asked to make changes, they almost invariably agreed, whether or not such a thing was possible - - perhaps equipment, parts or personnel were unavailable. Americans are ac- customed to discussing difficulties and obstacles up front in order to formulate a solution rather than address each issue as it arises. In Mexico, don't expect to effect alterations immediately, but have patience and understand it takes time. Mexican workers are expected to do their jobs and no one else's - - initiative is not always encouraged with a micromanagement philosophy. This could be construed as an encroachment on another person's power and is frowned upon. For example, to improve weld quality, welders at one facility not only had to be trained to inspect their parts but also made to understand that it was acceptable to do so.

In a poor economy, there is little surprise that parts or machines are repaired many times without consideration of replacement. If something is no longer in stock, a substitution is found. For example, at the same facility, when the tool room ran out of the correct diameter contact tubes, welders made do by ma-

chining the smaller diameter tubes on hand. Rather than this being regarded as a creative quick fix, it was viewed more as a permanent solution. No one took the responsibility to follow up by ordering the correct replacement parts and the tool room operator was not informed these parts were critical and should be kept in stock. With education and training in work and quality issues, the welders learned to take more responsibility for all the aspects of their work.

One last thing to consider is reitera- tive training. Repeat training at frequent intervals, repeat elements and essential facts, and review the basics. Again, never assume that because a person is employed as a welder, he or she has had any real prior training. Don' t assume the employees will ask for help or clarifica- tion when needed. Offer assistance; don't be critical, but instead provide a supportive environment. Respect the differences in work philosophies and cultures and find a means to work within these constraints. Using these techniques, American educators seeking to establish themselves in Mexico can be truly successful and productive. •

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A veteran instructor identifies the character traits and learning styles that lead a student to a career in welding

BY W A Y N E W E S T E R N

O ver the years, as I've dealt on a personal basis with literally thousands of welders, I've no-

ticed some common behaviors among them. I've spent 20 years training welders at a technical school in Utah, and I've also owned several small welding shops and worked for a number of welding companies during that same time period. I currently teach full time but also work as a welding consultant for one of the larger welding companies in Utah.

While I have tracked some of my former students for nearly ten years, four years ago I began a more concentrated study following the careers of 300

WAYNE WESTERN (westernw@ owatc.tec.ut.us) is a welding instructor at Ogden-Weber Applied Technology Cen- ter, Ogden, Utah.

welders in an effort to determine what the average welder is like. Following are the highlights of the profile of a welder I have developed.

• Did not like school. • Has not attended much college. • Is at least mildly antisocial. • Is a strong hands-on learner. • Competitive. • Not a great team player. • Twenty to thirty years old. • Has some issues with authority. Before anyone becomes defensive,

there are, of course, exceptions and these are not all negative tendencies. Still, these questions beg to be asked: "Why are welders like this?" and "Who will find this information useful?" The intent of this article is to help welders, their employers, those training prospective welders and anyone with a child in our nation's education system.

What Makes Welders The Way They Are?

Our schools became something of an issue to me as I began looking for the root causes for some of these behaviors, because I believe well-meaning but mis- guided educators begin directing us toward welding careers when we are young children. Does it surprise you that when you were a child with dreams of being a scientist, a doctor, or an as- tronaut, your teachers were, in fact, im- perceptibly steering you toward a life of melting metal? Does it shock you to think that may be happening to your children right now?

At this point, I have a mental image of my fourth grade teacher, Mrs. Cone, trying to reach out past the grave to whack me with a ruler. I am sure she would say she wanted me to succeed and


FIGURE 1: AVERAGE GROUP OF STUDENTS

I V'musl/A~:litory Learner ~ Tactile L a m e r Curriculum bas~l on icctu~ n ~ g , and ~ . Cumriculmn based on Imnds-on experiemc~

Group most likely to get good grades in school

i I I I

Group most likely to possess good welding skills

I Group most likely to be labeled as learning disabled

Fig. 1 - - The types o f learners in an average group o f students.

not be a burden on society by never passing fourth grade, but if her motives and the motives of most of the teachers that endured me as a student were pure, then what went wrong? Why wasn't I a more successful student? Over the last few years as I've developed this welder's profile, I've become a student of teaching methods and philosophies, and I believe many of the problems result from how different individuals learn.

Beginning the Learning Process

Let's look at how we all began the learning process. What happens when you hand something to a baby? It puts the object right in its mouth. It doesn't matter if it's candy or the cat's tail, a baby puts everything right into its mouth. That 's how we all began to learn, by using as many of our senses as we could to examine anything that was different or new to us. As we got older, and after being told thousands of times to not put stuff in our mouths, we learned to satisfy our curiosity by looking at and handling an object.

That is the basis for tactile learning. As we got older, society and our educational institutions began enforcing the artificial and unnatural method of learning exclusively by visual and auditory methods. Read, listen to me talk, but keep your hands to yourself!

Half the population is more or less successful at learning this way; the other half is more or less a failure at learning this way. If we were to chart an average

group of people, we would find a small group, perhaps 20%, who will succeed no matter what method is used or how bad the instruction is. My middle daugh- ter, Ann, is like that. She is on the high honor roll and will certainly have multiple college scholarships whether she has good teachers or not. The rest of us lean toward either learning with our eyes and ears or learning with our hands. This may seem like an oversimplification; in fact, studies commonly outline many different types of learners, but because the vast majority of successful welders are tactile learners and the vast majority of teachers are visual/auditory teachers, I have focused on these two. Figure 1 illustrates the visual/auditory learners and tactile learners in an average group of students. The illustrations are approxi- mations and are not intended to represent an exact numerical value.

Visual/Auditory vs. Tactile Learners

It would be tempting to say the learning style for any of the trades - - carpen- try, machinist, etc. - - would be the same as for welders, and, to some degree, it is. But welding is unique in the intense level of eye/hand coordination required. To be able to put on a helmet, block out the rest of the world and concentrate on creating uniform ripples in molten metal where any variation or loss of concentration is evident goes beyond the eye/hand demands of other trades.

This intense eye/hand coordination encourages welders to be strong hands-

on learners. By contrast, earning a teaching degree requires very little eye/hand coordination, yet demands a high degree of visual/auditory learning. This sets the stage for a natural conflict.

Can teachers teach math, reading and science using hands-on methods that our future welders can better understand? Yes, but it's harder and difficult for the teacher to relate to, so, instead, it's far more likely the student will be labeled "learning disabled." It's my personal opinion that most learning disabled students are not disabled at all but are victims of "teaching-disabled" instructors.

Let's face it, if my son gets an A+ in math and a D- in metal shop and your son gets a D - in math and an A + in metal shop, which child will more likely be labeled "learning disabled"? It sure won't be the kid with the A+ in math.

As these tactile learners progress through the grades, their options begin to narrow. Because so few teachers can teach any other way than visual/auditory, our future welders' chances of doing well in advanced math or science become less and less and so are their chances of going to college or on to the "professional" occupations.

You may think I'm being rather harsh in my assessment of teaching as a whole, but at our local high school's parent/ teacher conference last year, I listened in on a number of teachers as they coun- seled with parents. Over and over again, I heard teachers blaming their students for "not applying themselves enough" or "not working hard enough." I wanted to hear just one teacher say, "Your kid's okay, but as a teacher, I lack the talent and creativity to help him succeed." Of course, it didn't happen.

Good Students Don't Always Equal Good Employees

Perhaps the worst thing is the ten- dency for teachers and employers to assume good students equal good employees. This is not true for welding. In fact, as I've tracked dozens of high school seniors entering the welding field, those with poor attendance and below average grades actually have a slightly better chance of being a successful welder than the "~ ' student. School is school and work is work and one should not be used to judge the other.

Interestingly enough, once the welders-to-be have left school and become employed, they all do about as well on the job. The best 5% are more inclined to move into lead or supervisory positions, the worst 5% are more likely to work as welder helpers, the rest will be

46[ DECEMBER 2000

equally successful at maintaining a job regardless of their performance in school.

Whether it's called aptitude testing, career guidance, or counseling, the end result is to direct students to an occupation that best suits their aptitude and tal- ents. For many institutions, standard ap- t i tude tests include math, reading comprehension and, sometimes, eye/hand coordination. I have found after 20 years of teaching welding that these standardized tests are poor indica- tors of how successful a person will be as a welder.

If you think back to the items I listed in the welder's profile, it should become clear why certain behaviors are so common. It's only natural that an occupation as intensely dependent on eye/hand coordination as welding would attract the tactile learner. It's also logical that since most classes aren't taught in that way, these individuals will not enjoy school, and it is at school where many of our social interactions occur and our social skills are developed. Now we add to the mix the inclination many high schools have of "dumping" students who aren't doing well academically into the wood shop or welding shop or auto mechanics because they don't know where else to put them. It's sad, but with the average high school's fixation on sending everyone to college, the "blue collar" trades are considered somehow less important.

Becoming More Effective As educators or employers, what

does this mean to us? It means lots of reading, homework and lecture time will not be very effective for the average welding student. It means what's happening in the classroom needs to have an almost immediate connection to what is happening in the shop. It means a poor traditional student may well have a very successful, high-paid career as a welder.

What happens when the welder leaves high school and goes to work? Once welders have been out of school a few years and get over what it was like, some will return and a few will earn college degrees. Often this marks their exit from welding as a career.

What conclusion can we draw? The tendencies and abilities commonly present in a top-notch welder may, in fact, not be looked at as very positive in another situation. I find many students written off, labeled as failures when it should not have happened. Also, the importance of the teacher's attitude cannot be over- stated. Studies have shown hands-on learners are very good at reading body language. If the teacher has already decided they are a failure, they will know it.

FIGURE 2: AVERAGE WELDING EMPLOYEE

I Visual/Auditory Learner ~ Tactile Learner

Group able to learn both audiovisually and tactically

IGroup most likely to not stay long in welding [ [ Profile of most long-term welders I I

Fig. 2 - - Profile o f the average welding employee.

As an employer, it's tempting to try to hire from that middle 20% who can learn either way, and who are also better team players and prone to be better at a number of different tasks. It is not hard to tailor a company's hiring practices to ac- complish this. If a company testing for a new hire includes some fairly comprehensive written testing in math, blueprint reading, reading comprehension, as well as a difficult welding test, most of the successful applicants will be from the middle 20%.

However, depending on the company, this may not be such a good thing. The middle 20% are also more likely to use welding as a stepping stone to another career and to leave welding completely within a few years.

Using a very difficult weld test and eliminating any other criteria will shift our graph significantly to the right. These people will be good welders and more likely to stay in welding, but don't expect them to be great team players or take orders real well. You will find the people being considered are now more likely to resemble the average welders' profile discussed earlier. Figure 2 corre- lates the types of learners with their like- lihood of remaining welders.

After conducting hundreds of inter- views with welders and being involved with hundreds more, I have found if we look at a cross section of where those currently working as welders came from, about 25% had some basic welding in high school. This is rarely enough to make them job ready. About 5% gained some welding training or experience in the military, and 40% at tended some form of trade, vocational or other post- secondary welder training. The remain-

der learned "on the job" with no real formal training.

The typical welder enters the field at a young age, will work for several different companies and will pursue welding as a career for less than 10 years. As I've collected data, I've come to realize what a valuable commodity older (30+) welders are. They have spent years refining their skills and have stability and maturity not always found in younger welders. In much the same way experienced teachers are moved into administrative positions, taking their skills from the classroom, so, too, experienced welders often move into supervisory or supporting positions.

In both an official capacity and on my own, I have reviewed the welding programs at many high schools, vocational schools and colleges. These schools offer many different approaches to teaching welding and to structuring the curriculum. It is important to recognize what the actual objective is. Is it to introduce a person to welding, to teach welding as a support to a related degree or to train a job-ready welder? If the objective is to train job-ready welders, then several things are critical. First, training equipment must be equal to local industry. Second, industry expectations and quality standards need to be enforced in the training. The AWS S.E.N.S.E. program can be a valuable asset in establishing those standards. Lastly, students must get the maximum number of hours actually welding. Teaching welding theory is necessary and important, but job-ready welding skills are learned in the shop, not the classroom. And that works just fine for our hands-on learners. •


m m

I I

When the traditional education system can't produce what's needed, industry must rely on it own resources to train welders

BY D A V I D L A N D O N

~ A briskly growing Iowa economy I l k is expected to produce new jobs

at the rate of about 18,000 a year through 2005, state labor officials said. And about twice that number, 36,000 jobs, will open up annually in Iowa because workers retire or quit, the officials said. But here's the problem: Almost everyone in Iowa who wants a job already has a job. Iowa's unemployment rate has remained below 3% for more than year and a halL"

This was the opening paragraph to a news story that ran in The Des Moines Register in 1999. This is great news for those who are looking for work, but it 's a difficult challenge for a global equipment manufacturer based in Pella, Iowa, whose annual growth over the last seven years has been between 10 and 15%. For a company that has built its reputat ion on innovation and a strong work ethic, a challenge has never been something to shy away from.

Industry Needs Welders

Founded in 1948 by Gary Vermeer, a local farmer who invented a wagon hoist to make unloading shell corn easier, Ver- meer Manufacturing Co. has grown to become an international manufacturer of industrial construction and agricultural equipment. The company employs more than 2700 people with 1.4 million sq ft of manufacturing space under roof. Today, the company manufactures approximately 115 different models of industrial construction equipment with full lines of utility and t rack-mounted trenchers, horizontal directional drilling equipment, brush chipping, stump grinding and tub grinding equipment. Ver-

Fig. 1 - - A low student-to-instructor ratio ensures effective training when the time frame for instruction is limited.

meer also manufactures a full line of hay harvesting equipment.

Over the past seven years, Vermeer has experienced a period of tremendous growth. In 1992, the company employed 1200 people. Because the equipment consists of steel plate and shape construction, welding is vitally important . Almost one quarter of the hourly production employees at Vermeer are welders.

Training Comes In-House

Traditionally, industry relies upon the education system, whether it is high schools, community colleges or t rade

schools, to train and supply them with skilled welders. Unfortunately, these sources of training were unable to meet the demand for skilled welders or were not able to satisfactorily train those in their programs to meet the necessary requirements.

Because of these obstacles, the company decided to initiate its own in-house welder training program. The purpose of the program was to provide company- specific skills in gas metal arc welding (GMAW) to new employees in a timely fashion to facilitate the need for entry- level welders. This training program was not designed to take novice or unskilled welders and train them to become crafts-

DAVID LANDON is a Welding Engineer, Vermeer Manufacturing Co., Pella, Iowa.

48 J DECEMBER 2000

men in 80 hours. It was designed to take novice or unskilled welders and provide them with the basics in practical hands- on welding as well as blueprint reading. These basics are enough to allow the successful graduate to provide the company with value-added work on the first day of production.

Classroom and Hands-On Split the Time

The training program offers instruction in the G M A W process only. Al- though the capabil i ty is present to in- struct in other welding processes, more than 95% of all welding at Vermeer is GMAW. To provide this training in a timely fashion, a schedule of 80 contact hours was chosen. Of those 80 hours, 40 are in the classroom and 40 are actual welding time. The key to providing effective training in a concentra ted time frame is a proper student to instructor ratio - - Fig. 1. The company chose a ratio of six students to one instructor. Although, in a classroom setting, this ratio can be much higher, for practical hands-on welding, a maximum ratio of 6 to 1 is critical. Anything greater than this will not provide the one-on-one instruction necessary to learn the skills in a timely fashion.

The curriculum outline of the classroom training is broken down into four modules:

• Safety • Welding symbols and blueprint

reading • Welding fundamentals • Weld quality standards. The first hour of training is in weld-

ing and shop safety. This training covers job-specific personal protect ion equipment as well as typical welding hazards. The new employee receives general ori- entation and safety training prior to coming to welder training. In the general ori- entation, the new employee receives training in hazardous materials, emer- gency action plans and general personal protection equipment (safety glasses and steel- toed boots). The safety module provided in the welder training program includes arc radiation, electric shock, air contamination, fire and explosion, safe handling of compressed gases and other related hazards.

The welding symbols and blueprint reading module comprises approximately 30 hours in the classroom. This mater ial was developed by the Hobar t Insti tute of Welding Technology. The welding symbols and blueprint reading

Fig. 2 - - Hands-on welding comprises program.

courses are taught as two separate programmed learning sessions. These courses provide a simple yet complete method for students to learn and understand the principles of welding symbols and blueprint reading. Each course utilizes a self-paced student workbook sup- p lemented by instruction using video- tape. Each page of the workbook is designed to teach a small amount of information, which is reinforced through an action/problem, and self check.

Each page builds for the next as the student learns in an efficient and reward- ing manner. The symbols for the course are based on American National Stan- dards Institute/American Welding Soci- ety A2.4, s tandard Symbols for Welding Brazing and Nondestructive Examination. This system of communication provides the vital link between the designer and

a large portion of the training

the people responsible for producing and planning welding. The blueprint reading course contains valuable information on mathematics, the International System of Units (SI), blueprint reading for welders, setup tools and setup applications. The blueprint reading course is supplemented with actual production prints used at Vermeer Manufacturing.

The welding fundamentals module comprises approximately five hours in the classroom. This portion of the training is designed to supplement the practical hands-on welding port ion of the course. Topics of discussion are different welding electrodes and why they are used, different shielding gases and why they are used, and basic wire feed speed and voltage settings for short circuit, spray and pulsed arc transfer. The company has found that even for the entry-

WELDING JOURNAL 149

level welder, it is important to have not only an ability to perform the welding but also a basic understanding of the principles behind it.

The final module for classroom training consists of approximately four hours of instruction on the company's weld quality standards. This training intro- duces the student to the common weld discontinuities, the causes of the discontinuities, acceptance cri teria and the proper use of fillet weld gauges for measuring weld size. The core of this training utilizes a weld comparison replica developed by Caterpil lar , Inc., which is a three-dimensional representat ion of Vermeer ' s writ ten s tandard for weld quality. Its purpose is to clarify what is acceptable and provide a common reference for all those involved in judging weld appearance. Welders, welding inspectors and production supervisors are all trained in this module.

Hands-On Welding Curriculum

The hands-on welding portion of the training nominally consists of 40 hours - - Fig. 2. Vermeer has specified 12 competencies that are required to satisfactorily complete the training. Welders that enter the training with previous skills in welding frequently demonstrate the required competencies in less time than the specified 40 hours, while those who enter the training with little or no previous skills in welding may require up to 80 hours of hands-on training to demonstrate the required competencies. In either case, the minimum required time in this portion of training is 40 hours. If the requirements are completed early, the trainee is given light production work while still under the direction and supervision of the welding instructor.

The 12 competencies required for successful completion are straight fillet welds, circular fillet welds, edge welds, lap welds, three-corner intersections, cascade weld, welder performance qualification groove test for limited thickness in the flat position, welder performance qualification groove test for unlimited thickness in the flat position, welder performance qualification fillet weld test vertical position, welder performance qualification fillet weld test overhead position, proper setup and safe usage of oxyfuel cutting torch, and carbon air arc gouging.

In the training for the straight fillet welds, the student must learn how to properly size a fillet weld. The student must demonstra te competence in 3A6-, ~6-,3~-, and 'A-in. fillet welds. In addition, the student is trained in the proper con-

Since its inception in late 1993, more than 800

trainees have gone through the program.

The success completion rate is 83%.

tour and shape of an acceptable fillet weld.

In the training for circular fillet welds, the student must learn how to properly weld around tubing and round bar. Com- petency must be demonstrated in welding a horizontal fillet weld around a 1- in. tube, 2-in. tube or bar and 4-in. tube or bar, while maintaining proper weld bead contour and shape. Particular attention is given to weld tie-ins.

In the training for edge welds, the student is exposed to lighter gauge steels. For lap welds, the student learns the proper technique to successfully make the weld without excessive undercut or "cut edge" on the top plate. In the training for the three-corner intersection, the student learns the proper technique to successfully tie-in three welds that inter- sect from three different planes. For the cascade weld, the student learns the proper placement of each pass for multiple-pass fillet welds.

All of the performance qualification testing required for competency in the training program meets the requirements of the welder performance qualification testing of ANSI /AWS D14.3, Specification for Welding Earthmoving and Construction Equipment.

Evaluating the Results

This training program has been very successful. Each student evaluates the program and the instructors at the complet ion of the course. A common response to the evaluations is the outstanding knowledge of the instructors and the amount of material learned in a short time. The scores for the evaluations are consistently above average. In addition to a student evaluation, the plant welding supervisors are periodically asked to evaluate the students they have received from the training program. The students are evaluated based upon the competencies demonstrated in the training courses. These evaluations have been average to above average.

Since its inception in late 1993, more than 800 trainees have gone through the program. The success completion rate is 83%, proving it to be very successful over the years.

Going Back to High School

In September of 1999, Vermeer began a new endeavor in the area of weld training. The company teamed up with one of the local high schools to provide a product ion welding class for high school seniors.

In the spring of 1999, Pella Christian High School requested help to enhance the welding portion of its industrial arts classes. I went to the high school to evaluate the program, and I was amazed at the quality of instruction in the area of woodworking. But when it came to welding, all I saw was a small table and a couple of old buzz boxes. The thought of Vermeer providing training to a class of high school students occurred to me. The company has a world-class training program two miles down the road, so I thought who better to train for industrial welding than industry.

Student Curriculum

I developed a modified curriculum of the company's standard welder training course. The high school welder-training program consists of one semester of 90- minute sessions. As with the industrial welder training program, the high school program has both classroom and hands- on lab time. The high school program gives the student more than 90 hours of instruction in an actual manufacturing setting.

During the semester, seven high school students arrived at Vermeer and just like in an actual production environment, the students punch a time clock when they arrive and when they leave. Each day they spend 30 minutes in the classroom learning how to read and understand industrial blueprints and welding fundamentals. The last hour of the day, the students are issued the required personal protective equipment and weld various projects. In the shop, the students are under the direct supervision of the instructor. Each student must complete the same requirements the company expects from its product ion welders. In addition, the students are given a welder qualification test for 1G limited thickness.

After successful complet ion of the one-semester course, the students are eligible to participate in a school-to-work program, which allows the students to do actual product ion welding, earn high school credit and get paid.

Through the efforts of the welder training program and the company's welding department, Vermeer continues to meet or exceed customer expectations for quality and workmanship.~

50 J DECEMBER 2000

D a t a s h e e t 247a

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

Flash Welding Process Flash welding is a process that joins parts of similar cross

section. The weld is performed across the entire joint area without filler metal. It is a resistance welding process where- by the faying surfaces are brought into contact, heating is generated and pressure applied. The flashing action begins as the parts are moved together. A rapid upsetting completes the weld.

The joining process begins with the clamping of the two parts into dies, which also act as current-carrying electrodes. A resistance welding transformer is connected to the dies. As one part slowly approaches the stationary part, voltage is applied. Resistance heating occurs when the faying surfaces are brought into contact. High amperage causes melting and vaporization of the metal at the points of contact, and miniature arcs form. This action is called "flashing" as part temperature and metal loss increase. The increasing contact between the faying surfaces, the growing molten state of the metal and the flashing action all reach a critical stage at which a rapid "upset" force is applied. When the molten surfaces are in full contact, the weld is completed and the current terminated. The metal expelled from the interface at the upset stage is called flash.

Normally, the two parts should have the same cross section. When welding extruded or rolled shapes with different thicknesses within the cross section, the temperature distribution may vary during flashing. This situation can be sometimes counteracted through the proper design of the dies. With heavy sections, the beveling of one part end helps to start the flashing action.

Like all processes, flash welding has advantages and limitations. The advantages include the welding of shapes other than circular parts, such as H shapes, angles and rectangles. Parts of similar cross section can be welded with their axes aligned or at an angle to each other, within limits. The ejection of the molten metal at the interface during upset acts to remove impurities from the joint. Generally, preparation of the faying surfaces is not critical with this process.

Limitations of the process include the molten particles ejected at upset create a fire hazard and pose possible injury to the operator, as well as damage to shaft and bearings. The single-phase power demand produces an unbalanced condition with three-phase primary power lines. A secondary operation to remove flash and upset material is usually needed. Pieces with a small cross section are difficult to align.

Excerpted from Welding Handbook, Vol. 2, Eighth Edition.

(A)

(O)

Basic steps of the flash welding process. A - - The parts are positioned and clamped; B - - apply voltage and begin movement o f part; C - - flashing action; D - - upset force applied and current terminated.

WELDING JOURNAL I s~

Datasheet 247b

Flash Welding Process Applications and Equipment

D I E S - - ~

F,XEO I I MOVABLE PLATEN ~ PLATEN

TRANSFORMER (A) AXIALLY ALIGNED WELD

CROSS SECTION AFTER WELDING

TRANSFORMER


(B) MITER WELD

FIXED J ~ MOVABLE PLATEN PLATEN

TRANSFORMER (C) RING WELD


Common types of flash welds.

Both ferrous and nonferrous metals can be flash welded. Typically, carbon and low-alloy steels, stainless steel, aluminum, copper and nickel alloys all can be flash welded. Titanium can be joined with this process, but it is advisable to use an inert shielding gas at the joint to minimize the possibility of embrittlement.

Dissimilar metals with similar upset characteristics can be flash welded. Careful control of welding variables is needed, but aluminum to copper and nickel alloys to carbon steel have been successfully joined.

The automotive industry manufactures wheel rims from flash welded rings formed from flat cold-rolled stock. Motor and generator frames used in the electrical industry are flash welded, as well as cylindrical transformer cases and circular flanges. The aerospace industry makes use of flash welding in the fabrication of landing gear struts, hollow propeller blades, control assemblies, rocket casings and jet engine rings. Oil drilling pipe has fittings attached by flash welding and railroads have joined high-carbon steel rail with the process.

Flash welding equipment is primarily automatic or semiautomatic in operation, although there are also manual machines. The major components of flash welding equipment are a machine bed with platen ways attached, two clamping assemblies, a motion controller to move the platen, a welding transformer with adjustable taps and a controller to initiate flashing current.

With manual operation, the operator controls the speed of the platen from the time flashing is initiated to the completion of upset. With semiautomatic operation, the operator initiates flashing manually and then completes the job automatically. Automatic operation performs the welding cycle without the need of adjustment by an operator.

The platen motion may be initiated mechanically by a cam driven by an electric motor or through hydraulic or pneumatic means with the larger machines. Machine sequencing, current control and platen positioning during flashing and upsetting are all controlled by electrical means. Silicon-controlled rec- tifier (SCR) contactors are commonly used on machines that draw up to 1200 A from power lines. Preheat and postheat cycles are typically controlled by electronic timers.

The major variables with the process are dimensional, electrical, force and time. Good design should be concerned with heat balance in the part ends to ensure nearly equal compressive strength at the termination of the flashing time. Metal loss during flashing and upset must be designed into the overall length of the part. This is especially critical if the parts are at an angle, such as with a miter joint. Flashing should start at the center or in the central area of the parts being joined, and the ends should be designed to allow the flash material to escape easily.

52 J DECEMBER 2000

2001-2002 AWS CONGRESSIONAL FELLOW PROGRAM

I.

II .

PREFACE A. Technology is affecting society to an ever-increasing extent;

B. Public policy issues affecting a broad constituency are increasingly based on technological factors;

C. Informed decisions regarding public policy issues require the input of the engineering profession, among others;

D. The engineering professional constitutes one of the nation's most valuable resources, and

E. This resource should be applied in the public interest to matters having a technological content.

POLICY A. AWS declares that it is the continuing policy of the American Welding Society to

1. be sensitive to the public's interests; 2. provide government at all levels with advice on engineering matters and

policies affecting the public interest; and 3. maintain a climate of understanding and credibility that will foster

continuing dialogue with the government.

B. As one measure for furthering its policy, The Board of Directors establishes a Congressional Fellow Program to assist legislators and officials of the Congress in public policy deliberations. Each year, AWS will select a member, in a manner herein described, to serve as Congressional Fellow to assist legislators and other federal officials.

C. It is preferential that AWS and the Fellow's employer share the compensation and the expenses of the Fellow so that all parties have a financial interest in the program. However, a Fellow may serve with full employer support, provided that she or he is selected in accordance with this policy and she or he adheres to all AWS policies and guidelines of the program. AWS's share shall not exceed the amount annually budgeted. A Fellow may also participate with no employer support but recognizing the limited stipend.

D. Although the Congressional Fellow is sponsored by AWS, the Fellow's primary objective is to provide assistance to Congress while representing the welding engineering profession in objective fashion without bias or favor toward AWS or her or his employer.

In addition, AWS will help in furnishing whatever technical assistance a Congressional Fellow will request of the Society.

E. It is desirable that the Congressional Fellow be familiar with AWS operations and organizational structure in order to obtain assistance promptly and efficiently.

E Congressional Fellows must comply with the AWS policy on Conflict of Interest and any appropriate rules of ethics of the host federal office.

III. PROCEDURE A. Solicitation of applicants and Selection of Congressional Fellows

. AWS will solicit applicants through appropriate means, including letters to companies, announcements in the WeMingJournal, and appeals to the AWS leadership to identify candidates.

. The Candidate Review Committee shall a. Review applications; b. Interview highly marked applicants; c. Identify the best qualified among these for possible selection as a Congressional Fellow; d. Forward list of recommendations for the AWS Congressional Fellows and necessary support

documents to the Government Affairs Liaison Committee for final selection and approval.

. Individuals chosen to be Congressional Fellow(s) will be assisted by the AWS Washington Government Affairs Office in his or her placement with the staff of a Representative, Senator or a congressional committee.

4. The selection of the Fellow will be announced by the President of AWS.

B. Requirements

The requirements for the Congressional Fellow Program are as follows:

1. A Congressional Fellow's term shall be twelve months, beginning in September.

. Government Affairs Liaison Committee shall select the Fellow(s) using objective selection criteria, including a candidate's application, to determine a candidate's ability to communicate both orally and in written form, and such other attributes as the committee deems necessary for a candidate who will represent the welding profession.

. Sex, creed, race, ethnic background and political affiliation are expressly excluded as selection criteria for Congressional Fellows.

. Fellows shall hold at least the AWS grade of Member prior to submitting an application for Congressional Fellow.

5. Fellows shall be citizens of the United States of America.

Deadline for Receiving Applications is February 1, 2001.

For a complete application package, contact: Richard French Deputy Executive Director 1-800-443-WELD, ext. 218

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

Na e A MANTECH Center of Excellence r Operated by ~ ~

Friction Welding Increases Productivity for New Marine Corps Vehicle

T he Navy Joining Center (NJC) is applying a number of new technologies to improve productivity

and reduce the manufacturing costs for the Marine Corps ' new Advanced Am- phibious Assault Vehicle (AAAV). The development of friction stir welding and distortion control procedures were described in the March 2000 issue of the Welding Journal. Another project at the NJC is developing improved methods to weld appur tenances to the high- strength aluminum armor structure of this vehicle. This project is being conducted at Edison Welding Inst i tute (EWI) and involves the A A A V Team, which includes the Mar ine Corps and Genera l Dynamics Land Systems (GDLS.)

Appur tenances are th readed aluminum bosses that serve as at tachment points for a rmor panels , e lectronic components , seats and o ther equipment. The bosses range in size from 0.875 to 1.625-in. in diameter. There are approximately 1000 appurtenances that must be welded to 2519-T87 plates both inside and outside the vehicle. The present method is to manual ly gas metal arc weld (GMAW) each appurtenance in place, which is costly and t ime consuming. Savings in the product ion schedule and in costs could result from the development of mechanized or automated appur tenance welding procedures. The goal is to cut total welding t ime in half, while maintaining or improving weld strength.

Initially, the NJC evaluated three alternative welding processes for appurtenances: friction welding (FW), resistance project ion welding (RPW), and drawn-arc stud welding (SW). This study demons t ra ted friction welding and arc stud welding have productivity advantages for this appl icat ion compared to manual GMAW.

Frict ion welding of appur tenances has been successfully developed and demons t ra ted on a product ion pro totype A A A V structure. The procedure uses a modified, direct-drive Ram Stud T M friction welding machine with a hydraulic fluid motor. This machine was

specially modified to allow it to weld appurtenances up to 1.625 in. in diameter. Modifications involved adding a spr ing- loaded collet assembly to hold the appurtenances, and flywheels to increase energy output. The design of the appurtenance was adapted to accommodate friction welding. An optimum preweld cleaning method was developed to maximize joint strength. Mock- up parts were produced and successfully tested. Test data indicates friction welded appur tenances have between 25 and 30% greater strength than the current G M A W method and welds can be produced in about half the time using a mechanized gantry- positioning system.

Af ter refining the process, several appur tenances were recently friction welded on a prototype vehicle A A A V structure at the GDLS facility in Lima, OH. Six appurtenances were friction welded to the roof of the vehicle. Tests on this vehicle will permit a direct comparison of the performance of friction welded and gas metal arc welded appur tenances . Final project tasks will produce ballis- tic test panels, develop production process controls and transition the technology to GDLS. Technology transfer will include opera tor training and development of production equipment specifications.

The NJC is also developing the drawn-arc stud welding (SW) process for large d iameter aluminum appurtenances using a Silicon TM power source and weld head. Arc stud welding equipment is more por tab le and requires lower react ion loads during welding than friction welding. The weld head is more compact than FW or G M A W equipment , which permits welding in areas with l imited access. Initial feasibility tests on 0.5-in. diameter appurtenances showed weld strengths that are equivalent to the G M A W process. Arc stud welding of large d iameter aluminum appurtenances requires special

E x a m p h , oJ the al ) l )ur tenances t h a t serve as at- t a c h m e n t p o i n t s f o r a r m o r p a n e l s , e l e c t r o n i c c o m p o n e n t s , seats a n d o ther e q u i p m e n t on the M a r i n e Corps" n e w A d v a n c e d A m p h i b i o u s As- sau l t Vehicle (AAA V).

equipment to provide sufficient current and to control the weld upset.

These improved methods for attach- ing appurtenances support the goals for reduced acquisition and life cycle costs of the AAAV. The a l te rna te welding processes and procedures developed during this project will improve the performance, reduce distortion and reduce the fabrication cost of the AAAV.

For more information, contact Tim Trapp, NJC, at (614) 688-5231 or t im t rapp@ewi .org .

The Navy Joining Center 1250 Arthur E. Adams Dr.

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

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

www: http://www.ewLorg Contact: Harvey Castner


Conferences and Exhibitions

EuroBLECH 2000: 16th International Sheet Metal Working Technology Exposition. December 5-9, Hannover, Germany. Contact: Mack-Brooks Exhibitions Ltd., Forum Place, Hatfield Herts ALl0 0RN, U.K., +44 (0)1707 275641, FAX: +44 (0)1707 275544.

• ICAWT 2000, the International Conference on Advances in Welding Technology. December 7-8, Grosvenor Resort, Or- lando, Fla. Sponsored by the American Welding Society. Con- tact: AWS Conference Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552.

Second EPRI Corrosion and Degradation Conference. Decem- ber 11-14, Wyndham's Casa Marina Resort & Beach House, Key West, Fla. Cosponsored by EPRI and NACE. Contact: Brent Lancaster, CCM Conference Manager, EPRI, 1300 WT. Harris Blvd., Charlotte, NC 28262, (704) 547-6017, FAX: (704) 547-6168.

Orlando 2001 Advanced Productivity Exposition. January 16-18, 2001, Orange County Convention Center, Orlando, Fla. Contact Laura Heidrich, (313) 271-1500 ext. 1853 or e-maih heidlau @sme.org.

c L v e n t s • 5th Robotic Are Welding Conference and Exposition. Febru- ary 2-6, 2001, Grosvenor Resort, Orlando, Fla. 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.

NACE Northern Area Western Conference. February 26-28, 2001, Hilton Hotel, Anchorage, Alaska. Sponsored by NACE International, the Corrosion Society. Contact: Dan Powell, Co- chairman, (403) 235-6400, e-mail: [email protected].

International Laser Safety Conference. March 5-8, 2001, Cata- maran Resort Hotel, San Diego, Calif. Sponsored by the Laser Institute of America. Contact: LIA, 13501 Ingenuity Dr., Ste. 128, Orlando, FL 32826.

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

WESTEC 2001: Advanced Productivity Exposition. March 26-29, 2001, Los Angeles Convention Center, Los Angeles,

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

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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, 2001, IX Center, Cleveland, Ohio. Cohosted by the American Welding Society and The Pre- cision Metalforming Association, this collocated event is com- prised of The AWS International Welding and Fabricating Ex- position and Annual Conference and METALFORM ExpoSium. Contact: AWS Convention and Expositions Dept., 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 256 or (305) 443-9353 ext. 256, FAX: (305) 442-7451.

Tenth International JOM Jubilee Conference on the Joining of Materials, Jom-10. May 11-14, 2001, Helsingor-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, 2001, Minneapolis Convention Center, Minneapolis, Minn. Sponsored by the Society of Manufacturing Engineers (SME), America Machine Tool Distributors' Association (AMTDA) and The Association for Manufacturing Technology (AMT). Contact: SME Customer Service, (800) 733-4763 or (313) 271- 1500 ext. 1600 or visit the SME Web site at www.sme.org.

International Robots and Vision Show. June 5-7, 2001, Rose- mont Convention Center, Chicago. Sponsored by the Robotic Industries 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.

International Conference on Advances in Materials and Pro- cessing Technologies. September 18-21, 2001, Legan6s, Madrid, Spain. Contact: AMPT '01 Congress Secretariat, Fun- daci6n Universidad Carlos III, Congrega, Avda. de la Universi- dad, 30, 28911 Legan6s, Madrid, Spain, 34 91 624 91 42, FAX: 34 91 624 91 47, e-mail: [email protected].

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.

Educational Opportunities ASME Section IX: Welding and Brazing Qualifications Course. January 31-February 2, 2001, New Orleans, La. Conducted by the American Society of Mechanical 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].

CWI/CWE Training. January 29-February 9, 2001, Edison Welding Institute, Columbus, Ohio. Contact: Rich Green, (614) 688-5126, e-mail [email protected], or Candice Mahanay, (614) 688-5180, e-mail [email protected]. To register, EWI Registration Hotline (614) 688-5252. For information, www.ewi.org.

• ASME Section IX Seminar. January 4-5, 2001, Paper Valley Hotel and Conference Center, Appleton, Wis. Sponsored by the AWS Fox Valley Section. Contact: (920) 845-5992.

• DI.I: 2000 Structural Welding Code - - Steel. A five-day seminar. Sponsored by AWS. For more information and complete

- - cont#uted on page 59

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W E L D I N G IOURNAL I 57

Educational Opportunit ies

AWS Schedule - - CWI/CWE Prep Courses and Exams

E x a m app l i ca t i on m u s t be s u b m i t t e d six w e e k s b e f o r e e x a m da te . F o r e x a m i n f o r m a t i o n a n d app l i ca t ion , c o n t a c t t he A W S Cer t i f i ca t ion Dep t . , (800) 443-9353 ext. 273. Fo r exam p r e p cou r se i n fo rma t ion , con t ac t t he A W S E d u c a t i o n Dep t . , (800) 443-9353 ext. 229. D a t e s a re subjec t to change .

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

Jan. 22-26, 2001 Jan. 27, 2001 Anchorage, Alaska EXAM ONLY March 24, 2001 (API 1104 clinic also offered) Atlanta, Ga. Feb. 26-March 2, 2001 March 3, 2001 Miami, Fla. Dec. 4-8 Dec. 9

(API 1104 clinic also offered) Miami, Fla. EXAM ONLY Jan. 18, 2001 Birmingham, Ala. EXAM ONLY May 26, 2001 Buffalo, N.Y. EXAM ONLY Feb. 17, 2001 Miami, Fla. EXAM ONLY March 15, 2001 Charlotte, N.C. Feb. 12-16, 2001 Feb. 17, 2 0 0 1 Minneapolis, Minn. March 5-9, 2001 March 10, 2001 Chica~o, IlL April 30-May 4, 2001 May 5, 2001 Mobile, Ala. EXAM ONLY Feb. 17, 2001 Cleveland, Ohio Dec. 4-8 Dec. 9 Newark, N.J. EXAM ONLY Jan. 27, 2001 Columbus, Ohio EXAM ONLY March 3, 2001 Newark, N.J. March 12-16, 2001 March 17, 2001 Dallas, Tex. Jan. 29-Feb. 2, 2001 Feb. 3, 2001 Oklahoma City, Okla. Feb. 5-9, 2001 Feb. 10, 2001

(API 1104 clinic also offered) Perrysburg, Ohio EXAM ONLY March 24, 2001 Denver, Colo. Feb. 26-March 2, 2001 March 3, 2001 Portland, Maine April 2-6, 2001 April 7, 2001

Phoenix, Ariz. March 19-23, 2001 March 24, 2001 Fresno, Calif. EXAM ONLY Jan. 13, 2001 Gulfport, Miss. Feb. 19-23, 2001 Feb. 24, 2001 Salt Lake City, Utah Jan. 29-Feb. 2, 2001 Feb. 3, 2001 Houston, Tex. March 5-9, 2001 March 10, 2001 San Francisco, Ca. May 14-18, 2001 May 19, 2001

(API 1104 clinic/ Shreveport, La. Jan. 22-26, 2001 Jan. 27, 2001 SCWl also offered) Springfield, Mo. March 19-23, 2001 March 24, 2001

Knoxville, Tenn. March 12-16, 2001 March 17, 2001 Tampa, Fla. Jan. 29-Feb. 2, 2001 Feb. 3, 2001 (API 1104 clinic also offered)

(API 1104 clinic also offered) Tulsa, Okla. EXAM ONLY March 10, 2001 Las Vegas, Nev. EXAM ONLY Jan. 13, 2001 Las Vegas, Nev. April 23-27, 2001 April 28, 2001

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- - continued from page 57

schedule, contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 223, FAX: (305) 443-1552.

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.

Welding Skills Training Courses. Courses include weldability of ferrous and nonferrous metals, arc welding inspection and quality control, preparation for recertification of CWI and other courses. For complete schedule, contact: Hobart Institute of Welding Technology, 400 Trade Square E., Troy, OH 45373, (800) 332-9448, (937) 332-5000, FAX: (937) 332-5200.

Structural Welding: Design and Specification Seminars. Con- ducted by the Steel Structures Technology Center (SSTC). For 2000 schedule and locations, contact: SSTC, (248) 344-2910, FAX: (248) 344-2911.

Machine Safeguarding Seminars. Conducted by Rockford Sys- tems, Inc. For schedule and more information, contact: Rock- ford Systems, EO. Box 5525, Rockford, IL 61125, (800) 922- 7533, (815) 874-7891, FAX: (815) 874-6144.

ASME International m Section IX Welding Guide. Course #ZCD996. Introduction and review of Section IX welding information including welding documentation forms, review of Ar- ticles I and IV, sample WPS and review; sample PQR and review; testing and examination requirements for performance qualification; and other issues relating to Section IX. For information, www.asme.org/pro_dev.

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WELDING JOURNAL J 59

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

Q: Our new continuous brazing furnace has jus t been insta l led , and we are ex- periencing problems with it. The furnace is six ft long, plus the cooling zone, and it is equipped with a muffle for stainless steel parts. We are us ing bottled nitrogen and hydrogen and f lowing 800 ft3/h of ni trogen and 120 ft3/h of hydrogen. We do not have a dew-point instrument, nor do we have a water bubbler to change the dew-point atmosphere . Most of the t ime the copper does not mel t but instead sits on the part, as a fillet or blob, as it has been applied. When the copper does melt , it does not fill the bottom of the joint, and the bottom of the part that sets on the belt is d iscolored. Can you shed some light on this problem?

A: Since your nitrogen and hydrogen cylinders are undoubtedly filled from a cryogenic source, the dew point is going to be very low. In a low-dew-point atmosphere, the copper paste breaks down because the copper reacts as a catalyst and breaks down the binders into oxygen, hydrogen and carbon. The carbon coats all of the particles of copper, thus not allowing them to agglomerate after melting. Therefore, when the parts come out of the furnace, the copper is in the same form and location as when it was applied. To allow the copper, when melted, to join with other melted copper particles and flow into the joint, it is necessary to remove the carbon. This is done

by providing a sufficient amount of oxygen, in the form of moisture, to react with the carbon to form CO, which is a gas.

There are a number of methods used to increase the oxygen (dew point) in the furnace. One of the most common methods is to bubble some of the atmosphere through a water bath to pick up oxygen and mix it back into the furnace. Other methods consist of adding a controlled amount of CO 2 gas, or air, into the atmosphere line going into the hot zone of the furnace. A small quantity of the air will combine with hydrogen in the furnace to increase the dew point of the atmosphere. Similarly, some of the oxygen in the CO 2 will combine with the hydrogen at the brazing temperature to form the higher dew point.

Since you do not have the facilities to handle any one of these methods to increase the oxygen content in the furnace, an alternate method is to reduce the amount of atmosphere flowing into the furnace and allow the oxygen brought in with the parts and at the door opening to build up the dew point to a level that will burn off the carbon. This will allow the copper to agglomerate and flow into the joint.

To obtain satisfactory control of your brazing operation, it is important you have a dew-point instrument to measure the dew point of the atmosphere in the hot zone of the furnace. Most dew-point instruments can be a continuous operation and can be connected to a multiple- point temperature recorder or to a separate recorder to show the variation in dew point when starting up the furnace. This will give you an indication when the

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60 I DECEMBER 2000

atmosphere is suitable to start the brazing operation. It will also show any changes in the dew point as different parts are put into the furnace and door openings are adjusted for the parts.

Since your furnace is already built, a simple way of checking the dew point in the hot zone is to feed in a stainless steel tubing, approximately '/4 in. I.D., along side of the belt until it reaches the center of the hot zone. This can then be attached to the dew-point recorder. It will be necessary to use a small vacuum pump to suck the atmosphere out of the furnace, through the pipe and into the dew- point instrument. To obtain an accurate dew-point reading, you will not want to use plastic- or rubber-type tubing, or, if you must, use just enough tubing to make a connection. Thin-wall rubber and plastic tubing are porous. When the dew point and oxygen on the outside of the tubing are higher than on the inside, the oxygen and moisture will actually diffuse through the wall of the tubing, causing erroneous readings on the dew-point instruments.

The hydrogen of 2-5%, with nitrogen, is suitable atmosphere for brazing of the carbon steel parts with copper. As you vary the amount of nitrogen to control the influx of oxygen, the nitrogen/hydrogen ratio should be maintained. In your furnace, I suspect you could get by with around 150 ft3/h of nitrogen in order to allow enough oxygen to enter the furnace to raise your dew point enough to eliminate your carbon problem.

In reference to the parts being discol- ored on the bottom next to the belt, check if the belt speed is running so fast the furnace does not have an opportunity to heat both the belt and the part to the brazing temperature. Slowing down the belt speed should allow the belt to come up to the brazing temperature, thus allowing the bottom of the part to clean up and braze satisfactorily.

While I do not know of many furnaces using the atmosphere-flow rate to control the dew point, it is a very suitable method. A benefit of this method is the reduction of the atmosphere cost.t

R. L. P E A S L E E 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 Welding Journal, 550 N. W. LeJeune Rd., Miami, FL 33126.

N illions of t imes each day, Wolverine mee ts the needs of its cus tomers by p roduc ing the h ighes t quality, mos t innovat ive tubular and fabr icated p roduc t s in the world. Our hea t t ransfer p roduc t s are cons idered enabl ing technologies in many of the indust r ies w h e r e our cus tomers do business. Therefore, we are very sensit ive to the needs of our cus tomers and the markets tha t we serve and will only pu r sue those oppor tun i t i e s and bus inesses tha t suppo r t both .

Accordingly, we are del ighted to a n n o u n c e that Wolverine , SILVALOY has c o m p l e t e d its acquisi t ion of ..... ~ . . , . ~ ..... Engelhard 's joining p roduc t s [~ , ~'~'~,.,

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everyone. In fact, we will fill/'~r "~'~i'i~a~ar. :," "~ opera te the business as /////.~ ~">,i'#~;- Wolverine Jo in ing //// ', . . . . . , ' " Technologies , w h i c h / / / . under scores our c o m m i t m e n t to be ing a t echno logy leader and uniquely posi t ions us to be t t e r serve our cus tomers a round the globe.

Wolverine Jo in ing Technologies manufac tures all forms of silver and p h o s p h o r o u s brazing alloys and solder, as well as the supp lemen ta ry fluxes. These p roduc t s are industry-leading b rand names such as: Silvaloy'", Silvabrite, Silvabrite 100", Plymetal, Black Flux and Ultra Flux~L

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Circle No. 36 on Reader Info-Card WELDING JOURNAL I 61

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

Gas Detec t ing and Moni tor ing Products Cata log Published

This 76-page, full-color catalog and reference guide features the company's full line of portable and fixed gas monitors and systems. Also featured are single- and multi-,,as~ • portable monitors, confined

nent to construction and repair operations in many other fields including automotive restoration, antique auto parts, auto racing, aviation repairs, bicycle

space kits, fixed monitoring systems, and repair and rental information. Contained in the catalog are detailed specifications, calibration equipment, applicable accessories and pricing information.

Industrial Scientific Corp. 1001 Oakdale Rd., Oakdale, PA 15071-1500

120

Spill Control and Cleanup Catalog Helps Keep Workplaces Clean

This catalog presents 272 pages of spill control and cleanup products. In-

cluded are a large selection of sorbents, booms, pads, mats, kits and more. The company offers free technical support and fast shipping. If a client requires a product not listed in the catalog, the company will make every effort to get it for them.

Lab Safety and Supply Inc. P.O. Box 1368, Janesville, WI 53547-1368

121

Videos Highl ight Sheet Meta l and T u b e Fabricat ion

A series of videos combines film footage of the craftsmanship that played a major role in keeping World War II fighter planes in the air with an introduction to some of today's most diverse sheet metal tooling. Though the videos feature aircraft industry building, repair and welding operations - - the sheet metal and tube fabrication techniques demonstrated would be directly perti-

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building, motorcycle repairs, agricultural equipment, sheet metal and general industrial maintenance. Much of the video footage was adapted from actual World War II training films. Detailed operations include aluminum welding, precision frame alignment, tube straighten- ing, replacement and welding, safety procedures, fabric covering, undercoating and finish painting. Subjects of the his- toric original footage include the J3 Cub, the P-38 Lightning and the Hellcat fighter. The videos are a marriage of the old with the new, and culminate with some up-to-date tooling. Today's footage covers subjects such as modern sheet metal tooling for free-forming sheet metal parts. Demonstrations include stretching, shrinking, hammer/ buck forming and planishing with manual tools. Also shown are a series of specially designed air and electric motor- driven machines for shipping and planishing larger sheet steel parts.

TM Technologies 17167 Salmon Mine Rd., Nevada City, CA 95959

A l u m i n u m Brochure Provides Unique W e l d i n g Solutions

This 10-page, full-color aluminum welding brochure details the challenges and solutions to welding the lightweight but durable metal. Included are customer testimonials and specifications for the

62 I DECEMBER 2000

company's most appropriate welding and plasma arc cutting products used in light, medium and heavy duty, automated and high-tech aluminum welding applications.

Miller Electric Mfg. Co. 122 1635 W. Spencer St., P.O. Box 1079, Appleton, WI 54912

Hydrogen Genera tor Brochure Ideal for Gas Chromatography

This brochure describes the generators produced by this specialty gas manufacturer. These generators produce hydrogen at delivery pressures up to 200 lb/in. 2 (newer techniques require higher

gas pressure). The generators use deion- ized water to produce ultra-pure hydrogen, without using caustic electrolyte solutions.The Proton Exchange Mem- brane Technology used in the generators reduces impurities, and a specially designed palladium purifier removes water from the produced hydrogen without using dessicant cartridges. The brochure illustrates this technology and includes specifications, ordering information and information on optional accessories.

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Catalog Covers Hand Tools for Pipe We ld ing Tasks

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are covered in this 12-page buyers' guide. The brochure presents the company's full line of abrasive and wire brush hand tools specifically for pipeline weld preparation, cleaning and finishing tasks. The product categories include stringer bead, knot and encapsulated wire wheels; crimped, knot and encapsulated cup brushes; mini-grinder wheels and cups; scratch, dauber and welder's tooth brushes; pipeliner grinding and cut-off

wheels; and pipeline files, cones and plugs. Complete size and specification information is shown in easy-to-read tables along with pictures of the products and the recommended types of power tools that are applicable.

PFERD Inc. 124 30 Jytek Dr., Leominster, MA 01453



BY DAMIAN J. KOTECKI Q: I understand a little ferrite in a nominally austenitie stainless steel weld is helpful in preventing hot cracking. But why are there two measures - - percent ferrite and Ferrite Number? What is the difference? Does it matter which I specify?

A : Y o u are quite correct, a little ferrite in a nominally austenitic stainless steel weld metal, such as 308L or 316L, is very helpful in preventing hot cracking. So, of course, the various organizations involved in provision of a welding filler metal have a vested interest in how the ferrite requirements for a filler metal are specified. This has an important bearing on whether or not a given lot of filler metal is accepted for use.

By the time of World War II, the de- sirability of ferrite in nominally austenitic stainless steel welds as a means of preventing hot cracking was recognized. The ferrite was originally detected by metal lographic examination. The weld metal examined had to be cut into a specimen suitable for polishing, etched carefully to differentiate between ferrite and austenite and then some means of determining the volume fraction of ferrite had to be applied. Usually, this involved point counting, in which a grid of orthogonal intersecting lines would be overlaid on a photograph of the microstructure. Then, the percent ferrite would be obtained as the number of grid intersection points falling on ferrite as a percentage of the total number of grid

intersection points. The method of point counting to estimate volume percent of a given phase is defined in the ASTM E 562 standard. Manual point counting is laborious, but the job can be automated by using an image analyzing microscope, following the method of ASTM E 1245. A major drawback to point counting is that it is a destructive test - - the weld metal actually sampled usually can't be the weldment put into service. A second major drawback is that point counting results are very sensitive to the quality of the etching of the sample and to interpretation of points falling on boundaries between phases.

In 1949, Anton "Tony" Schaeffler published the well-known Schaeffler Di- agram that linked chemical composition to percent ferrite determined by metallographic methods (Metal Progress, 56(11): 680-680B). While the Schaeffier Diagram was originally conceived as a predict ing tool to provide guidance in filler metal design and selection, people started to apply it for specification, e.g., the filler metal shall provide 5 to 10% ferrite when its composit ion is plot ted on the Schaeffler Diagram. While simple in concept, this led to numerous problems. A major problem is there are usually several organizations concerned with the safety of a weldment that goes into, for example, a power plant. No one organization entirely trusts the other, so chemical analysis might be provided by the filler metal manufacturer , checked by the fabricator and rechecked by the master contractor. Not surprisingly, when three organizations independently perform chemical analysis on anything, they don't all arrive at the same conclusion. Therefore, they don't get the same predicted percent ferrite. Also, the cor-

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relation between chemical composition and percent ferrite is imperfect - - significant elements such as nitrogen were not part of the Schaeffler Diagram, and there are inaccuracies in any such diagram. For example, the Schaeffler Dia- gram is clearly incorrect in its treatment of manganese in the Nickel Equivalent.

Determination of ferrite by metallographic means turned out to be equally non reproducible. In the late 1960s and early 1970s, round robins of ferrite de- terminat ion by metal lographic means were run in the Welding Research Coun- cil, Subcommittee on Welding Stainless Steel, and in the International Institute of Welding, Commission II. These round robins showed, for example, that several laboratories might measure anywhere from 3 to 8% ferrite on a single sample of weld metal. So it was difficult for several organizations to agree that a specification like 5 to 10% ferrite was actually met. When they didn't agree, delays in construction resulted while the dis- agreeing parties a t tempted to resolve their differences.

Besides etching appearance, ferrite has another property that allows it to be differentiated from austenite - - ferrite is ferro-magnetic, while austenite is not. To a first approximation, the magnetic properties of a ferrite/austenite mixture of weld metal are proportional to the ferrite content. (There is also a compositional effect - - in general, ferrite higher in alloy content has a somewhat weaker magnetic response than lower alloy ferrite, but this effect is not important in in- terpreting the measurements.) A magnetic scale for ferrite determination was developed by the Welding Research Council, and was published as the AWS A4.2 standard in 1974. The A4.2 standard has been updated several times since 1974, and the latest edition was published in 1997. The magnetic method has become an international standard, ISO 8249, which was first published in 1985, and was updated in 2000. While the words in AWS A4.2 are not identical to the words in ISO 8249, the standards are technically identical, as are the test results obtained by following the two standards. The magnetic scale describes its measurements in terms of Ferrite Num- bers (FN), which were originally believed to numerically approximate percent ferrite. However, it is quite clear today that, at least at higher Ferr i te Numbers, the FN overstates the volume percent ferrite. From the point of view of whether or not

64 I DECEMBER 2000

a specification requirement is met, the exact amount by which the FN overstates the percent ferrite is unimportant. Of primary importance is that the various parties in the supply and consumption chain for weld metal can reproduce the ferrite measurement results, so there is no disagreement about whether or not the specification was met. And, of course, links must be established between the specified ferrite range and acceptable weld properties. After more than 25 years of experience with Ferr i te Numbers, the links between FN and properties are well established.

Round robin studies of FN determination by the Welding Research Council, and by the International Institute of Welding, for samples in the 5 to 10 FN range, demonstrated the reproducibility among a number of measuring laboratories is better than _+ 1 FN. So, the reproducibility of FN measurements is considerably better than that of percent ferrite determinations. In addition, FN measurement is non destructive. That is, the actual weldment can be evaluated, not only a prefabrication weld sample.

Predicting diagrams for welds, relating Ferrite Number to chemical composition, have been developed experimentally. The DeLong Diagram (Welding Journal 52(7): 281-s to 297-s) of 1973 was updated by the Welding Research Coun- cil in 1988 (Welding Journal 67(12): 289- s to 298-s), and again in 1992 (Welding Journal 71(5): 171-s to 178-s). Today, the WRC-1992 Diagram is the official method of the ASME Code, for predicting FN when FN cannot be measured. But FN measurement is preferred to prediction from a Diagram.

So, to summarize, Ferr i te Number measurement is more reproducible than ferri te percent measurement. Ferr i te Number is more conveniently measured than ferrite percent. And, because the Ferri te Number measurement is a nondestructive test, it is suitable for in-process quality assurance, while ferrite percent is generally not. Specification of a Ferr i te Number minimum, or of a FN range when necessary, is far preferable to specifying a percent ferrite minimum or range. For most weldments in nominally austenitic stainless steels, where the main concern is freedom from hot cracking sensitivity, specification of 3 FN minimum is all that is necessary. For 347 weld metal, and for some higher alloyed weld metals such as 317L and 309LMo, 5 FN minimum provides assurance of freedom from sensitivity to hot cracking. Where elevated tempera ture service and/or postweld heat treatment are to be applied, an upper limit of 10 or 15 FN is often appropr ia te to avoid embri t t le-

ment due to phase transformations at high temperature . And for duplex ferritic-austenitic stainless steel weld metals such as 2209, a specification range of 30 to 70 FN has been found to correlate well with good corrosion resistance and good mechanical properties.

The Welding Research Council, the Internat ional Insti tute of Welding and the ASME Code strongly recommend specification of ferrite in stainless steel weld metals by Ferr i te Number, not by percent ferr i te .4

DAMIAN J. KOTECKI 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 W S D1 Structural Welding Committee, Subcommittee on Stainless Steel Welding; and a member and past chair of the Welding Research Council Subcommittee on Welding Stainless Steels and Nickel Base Alloys. Questions may be sent to Mr. KotecM c/o Welding Journal, 550 N. W LeJeune Rd., Miami, FL 33126.

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LORS Machinery Names Chairman

Edward J. Onny [AWS], cofounder of LORS Machinery, Union, N.J., has been named chairman of the board. A machine designer with more than 700 resistance welder designs, he will continue to guide LORS' design engineering staff in addition to his corporate duties. Onny began his welding career as a machine designer with the Larkin Welder Com- pany in New York. He left Larkin to form the ONNY Pattern Works and, in 1960 he became a cofounder and director of LORS Machinery, Inc., where he headed the design engineering department. Onny is a Life Member of the American Welding Society.

LA-CO Industries Appoints President

La-Co Industries, Inc./Markal Co. appointed John F. Hardin president and chief operating officer. Before joining the company, Hardin spent ten years with Laporte plc, London, England.

Hardin

While there, he served as a divisional managing director in the company's Electronics Division. Hardin holds a B.S. in chemical engineering from the Uni- versity of Illinois and an M.B.A. from the University of Chicago. Hardin replaces Dan Kleiman, who was promoted to chairman and chief executive officer of the company.

Wall Colmonoy Names General Manager

Bruce H. Tifft was named general manager of the Wall Colmonoy, Madi- son Heights, Mich., Oklahoma City Fa- cility. Prior to joining the company, Tifft

Tifft

was the general manager of Tucker Technology. He has more than 20 years of experience in the aerospace industry and holds a B.S. in Industrial Technol- ogy from Northeastern State University.

HI TecMetal Group Announces Appointments

HI TecMetal Group (HTG), Cleve- land, Ohio, announced the following appointments:

Kim Catron was named vice president of operations. He has more than 25 years of experience in materials management, human resources and general account management. Catron will work with various Strategic Business Units to improve performance and assist with the newly acquired companies and future acquisitions.

Mark Emerson [AWS] was appointed HTG Aerobraze as operations manager. Emerson received his B.S. degree in metallurgical engineering from Purdue Uni- versity. He is a member of the American Welding Society, American Society for Materials, Society of Manufacturing En- gineers and is a voting member of the Heat Treating Task Group for National Aerospace and Defense Contractors Ac- creditation Program.

DE-STA-CO Appoints Managers

DE-STA-CO Industries, Madison Heights, Mich., a Dover Resources Com- pany, announced the following appointments:

Tom Stimac was named product manager for the company's Industrial Prod- uct Group. Stimac will manage all aspects of product development and launch, competitive and market analysis, pricing, promotion, sales and technical support.

Dennis Gustafson was appointed In- ternet and e-commerce business manager. He will be responsible for developing, implementing and managing a marketing plan for all U.S. Business units, evolving it into an Internet and electronic commerce presence. Gustafson was pre-

viously with Textron Automotive Co. where he managed and developed electronic business programs and strategy. He holds a B.S. from Oakland Univer- sity and a master's degree from Central Michigan University with concentrations in management information systems and economics.

Jane Isley joined the company as customer service manager. She will manage all customer activities for the company's automation and industrial product lines. Prior to joining the company, Isley was with ABT Building Prod- ucts Corp. She holds a B.A. degree from DePauw University.

ASM Honors Member

Richard E. Feigel [AWS] vice president of engineering at The Hartford Steam Boiler Inspection and Insurance Co., was honored by the American Soci- ety of Mechanical Engineers Interna- tional (ASME International) with the Melvin R. Green Codes and Standards Medal at the 2000 International Me- chanical Engineering Congress and Ex- position in Orlando, Fla. He was recognized for visionary achievements in the field of international standardization and advancing ASME's leadership role in the pressure equipment sector.

Feigel has been employed by The Hartford Steam Boiler Inspection and Insurance Co. since 1977. He is currently responsible for corporate quality initia- tives supporting the company's insurance and engineering consulting businesses. In previous positions, he was responsible for international inspection services business, including ASME code inspections. An early proponent of research and application of risk-informed methods, Feigel sponsored the company's support of the ASME Center for Re- search and Technology Development's projects that resulted in the development of widely used guidelines for risk-based inspection.

A member of ASME since 1978, Feigei played a pivotal role in the development of ASME codes and standards and has been instrumental in the effort to internationalize them. He was elected to the ASME International Board of Governors and assumed that responsibility in July 2000.

After receiving his B.A. in philosophy at Purdue University in 1968, Feigel went on to earn his master's and doctor- ate degrees at Pennsylvania State Uni- versity, University Park, in 1970 and 1984, respectively.

66 I DECEMBER 2000

/ N E W

By Susan Campbell

# 2 0 0 1 - 2 0 0 2 N a t i o n a l N o m i n e e s Annoulz(:ed

S

L e a d e r s h i p

Richard L. Arn Ernest D. Levert Thomas M. Mustaleski J a m e s L: Greer

T h e 2 0 0 1 - 2 0 0 2 N o m i n a t i n g C o m m i t t e e ha s an- n o u n c e d t h o s e c a n d i d a t e s w h o wi l l s t a n d for e l e c t i o n to AWS n a t i o n a l o f f i c e s fo r t h e 2 0 0 1 - 2 0 0 2 t e r m , w h i c h b e g i n s in J u n e 2001 .

N o m i n a t e d are t h e fo l lowing :

• For P r e s i d e n t : R i c h a r d L.Arn. • F o r V i c e P r e s i d e n t ( t h r e e to b e e l e c t e d ) : E r n e s t

D. L e v e r t , T h o m a s M. Mus ta l e sk i a n d J a m e s E. Greer . • For Di rec to r -a t -Large ( t w o to b e e l e c t e d ) : D a m i a n

J. Ko teck i a n d R icha r d Kel lum. T h e N a t i o n a l N o m i n a t i n g C o m m i t t e e w a s c h a i r e d

b y Pas t P r e s i d e n t S h i r l e y B o l l i n g e r . S e r v i n g w i t h Bo l l i nge r w e r e M. D. Bell, R. E. Blaisdel l , D. E Bovie , L. C. H e c k e n d o r n , J. L. H u n t e r , R. C. Lanier , V.Y. M a t t h e w s , R. C. P ie rce , G. H. P u t n a m , P .Torch io III a n d R. K .Wiswesse r . J o h n J. M c L a u g h l i n s e r v e d as s e c r e t a r y o f t h e c o m m i t - tee .

T h e N o m i n a t i n g C o m m i t t e e s fo r D i s t r i c t s 2, 5, 8, 11, 14, 17 a n d 20 h a v e s e l e c t e d t h e f o l l o w i n g c a n d i d a t e s for e l e c t i o n or r e e l e c t i o n as D i s t r i c t D i r e c t o r s for t h r e e - y e a r t e r m s b e g i n n i n g J u n e 1, 2 0 0 1 . T h e n o m i n e e s a r e D i s t r i c t 2 d i r ec to r , Al E Fleury; D i s t r i c t 5 d i r ec to r , Wayne J. E n g e r o n ; D i s t r i c t 8 d i r e c t o r , W a l l a c e E. H o n e y ; Dis-

t r i c t 11 d i r e c t o r , Sco t t C. C h a p p l e ; D i s t r i c t 14 d i r e c t o r , Hi l . J . Bax; D i s t r i c t 17 d i r e c t o r , O r e n P. R e i c h ; a n d Dis- t r i c t 20 d i r ec to r , J e s se A. G r a n t h a m .

T h e Di s t r i c t 9 N o m i n a t i n g C o m m i t t e e e l e c t e d J o h n B r u s k o t t e r to fulfi l l t h e r e m a i n i n g t e r m of D i s t r i c t 9 Di- r e c t o r O . J . T e m p l e t c o m m e n c i n g i m m e d i a t e l y t h r o u g h May 31, 2002

T h e Di s t r i c t 19 N o m i n a t i n g C o m m i t t e e e l e c t e d Phi l Z a m m i t to fulfi l l t h e r e m a i n i n g t e r m of t he la te D i s t r i c t 19 D i r e c t o r D o n De lk , c o m m e n c i n g i m m e d i a t e l y t h r o u g h May 31, 2003.

N o m i n a t e d f o r P r e s i d e n t R i c h a r d L. A r n

R i c h a r d L. A r n , w h o is c o m p l e t i n g h i s t h i r d t e r m as a n AWS v i c e p r e s i d e n t , is p r e s i d e n t o f T e l e t h e r m T e c h n o l o g i e s Inc . in Eas t L i v e r p o o l , O h i o . P r i o r to as- s u m i n g h i s c u r r e n t p o s i t i o n , h e h e l d t h e p o s i t i o n o f d i v i s i o n m a n a g e r o f t h e F a b r i c a t e d P r o d u c t s D i v i s i o n o f G l u n t I n d u s t r i e s , W a r r e n , O h i o . He a l so s e r v e d t h e c o m p a n y as c o r p o r a t e m a n a g e r of w e l d i n g t e c h n o l o g y c o n c u r r e n t l y w i t h h i s d i v i s i o n m a n a g e r p o s i t i o n .

WELDING JOURNAL [ 67

Prior to joining Glunt Industries as manager of we ld ing technology , Arn w o r k e d as a w e l d e r and welding technician for General American Transpor t a t ion Corp. , w e l d e r and weld ing foreman for the William B. Pol lock Co., we ld ing e n g i n e e r for P i t t sburgh Bridge and Iron Co., we ld ing e n g i n e e r for Youngs town Welding and Engineer ing Co., manager of fabricated products for Jefco Indust r ies and ope ra t ions manager for Machine Dynamics and Engi- neer ing Co.

Arn, w h o began his ca ree r as a ski l led craf tsman, is p ro f i c i en t at most arc welding processes and has passed ce r t i f i ca t ion tests in accordance with AWS,ASME,AAR,API and mi l i ta ry spec i f i ca t ions . He still enjoys spending time on the shop f loor t each ing up-and-coming c ra f t smen the art and sc ience of welding.

Having been an act ive m e m b e r of the Mahoning Valley Sect ion for 26 years, Arn still se rves his local s ec t ion as a m e m b e r of the Execu- tive Commit tee .As a third term vice p re s iden t of the Society, he se rves on the National Board of Directors , Execu t ive Commi t t ee , Compensa- t ion Commi t t ee , Role and Missions Commi t t e e , G o v e r n m e n t Affairs Li- aison Commit tee , Honorary-Meri to- r ious Awards C o m m i t t e e and is cha i rman of the Standards Council . Arn se rved on several Pres ident ia l Tasks Groups, both as a member and as chairman, and has been a member of Districts Council as District 10 director. He has served as chairman of the Dis t r ic ts Counci l , G o v e r n m e n t Affairs Liaison Commit tee , Commu- n ica t ions Counci l and TFPS. He is cur ren t ly a m e m b e r of the PEMCO, Product Deve lopment , Cert i f icat ion and Prayer Breakfast Committees.

Arn s tud ied bus iness adminis- t ra t ion and meta l lurg ica l eng ineer - ing at Youngs town State Univers i ty and we ld ing t e c h n o l o g y at the Ho- bart School of Welding Technology.

N o m i n a t e d f o r V ice P r e s i d e n t E r n e s t D. L e v e r t

Ernest D. Levert, an AWS Distin- guished Member, is present ly in his second term as vice president . He is employed as a senior staff manufac-

tu r ing e n g i n e e r for Lockheed Mar- tin Missiles and Fire Control in Dal- las,Tex. Lever t works in the Manu- fac tur ing Eng inee r ing D e p a r t m e n t on the In t e rna t iona l Space Stat ion Thermal Control Units Program, Pa- t r io t Advance Capabi l i ty (PAC-3) Army Tactical Missile System (ARMY TACMS), Line-of-Sight Missile Pro- gram (LOSAT), Jo in t Strike Fighter Program (JSF-F22),Advance Missile Programs and supports the X-33 Pro- ject and Multiple Launch Rocket Sys- tem. Previously, Levert w o r k e d for General Dynamics, Convair Division, in San Diego as a we ld ing eng inee r s u p p o r t i n g the Atlas Space Vehicle Program, Tomahawk Cruise Missile Program and Ground Launched Cruise Missile Program. Levert has more than 30 years in weld ing suppo r t i ng the ae rospace and de fense industries. He has presen ted several papers on welding of aerospace appl icat ion with emphasis on the elec- t ron beam weld ing process . He is a reg is te red profess iona l e n g i n e e r in the state of Texas and r e c e i v e d his B.S. in welding engineer ing f romThe Ohio State University.

Lever t is cu r ren t ly se rv ing on the AWS Board of Directors , Execu- tive Commit tee , Professional Devel- opment Council, Government Affairs Liaison Commit tee , National Educa- t ion Schola rsh ip Com m i t t e e , Gov- e rn ing Board Author i zed Nat ional Body, Prayer Breakfast Com m i t t e e , B1 Commit tee on Method of Inspec- tion and C7B Commit tee on Electron Beam Welding and Cutt ing. He is cha i rman of the Welding Indus t ry N e t w o r k i n g (WIN) C o m m i t t e e and a t rustee with the Federat ion of Ma- terials Societies (FMS). Levert represen ted the Uni ted States as a dele- gate for Commission IV, High-Energy Density Welding, at the 53rd Annual In t e rna t iona l Ins t i tu te of Welding (IIW) Assembly in Florence, Italy, and he served as the U.S. represen ta t ive on the Select Commit tee forAircraft Engineering.

Presently, Levert se rves on the Welding Advisory Boards of Texas State Technical Communi ty College, Waco,Tex.; Mountain View Commu- ni ty Col lege, Dallas, Tex.; Tarrant County College, Fort Worth,Tex.; and Lakeview Cen tenn ia l High School , Garland,Tex. He also serves on the Execu t ive Board of the AWS Nor th Texas Section.

Levert jo ined the AWS Nor th Texas Sect ion in 1986 and has held

several off ices , inc luding cha i rman (1991-1992) . He se rved on the Ex- ecu t ive Board of the San Diego Sec- t ion and was cha i rman of the AWS Student Chap te r at The Ohio State University.

Levert has r ece ived many awards for his work inc lud ing the H y p e r t h e r m Plasma Cut t ing Award (April 2000), the Lockheed Martin Vought Systems Pres iden t Perfor- mance Award Finalist for Employee of the Year (1999), Lockheed Martin Vought Systems Special Recogni t ion Award (1998), McDonne l l -Douglas Cer t i f icate of Apprec ia t ion for Out- s tanding Welding Engineer ing Sup- por t (1996) and the AWS Dis t r ic t Meritorious Award (1994).

N o m i n a t e d f o r Vice P r e s i d e n t T h o m a s M. M u s t a l e s k i

T h o m a s M. Mus ta l e sk i , who is cu r r en t ly se rv ing his first t e rm as v ice p res iden t , has been wi th the Oak Ridge Y-12 Plant of BWXT-Y12 LLC (former ly Lockheed Martin En- e rgy Systems, Inc.) , Oak Ridge, Tenn., s ince 1974. He is cur ren t ly a research staff m e m b e r in the Devel- o p m e n t Division. Mustaleski 's work is in the areas of welding metal lurgy and process and procedure development. He has been active in the technology transfer programs at the Oak Ridge Cen te r s for Manufac tur ing Technology. From 1980 to 1985, he se rved as g roup leader of the Join- ing Group. He had w o r k e d previously as a sen ior we ld ing e n g i n e e r at the A. O. Smith Corp. (1969-1974) and the Hami l ton Standard Div. of the United Aircraft Corp. as an elec- t ron beam welding appl ica t ions en- g ineer ( 1967-1969).

Mustaleski r e c e i v e d his under- graduate degree in metal lurgical en- g ineer ing at Rensselaer Polytechnic Ins t i tu te in 1967. He has done sub- sequen t graduate work in metal lurgical e n g i n e e r i n g at the Univers i ty of Wiscons in -Mi lwaukee and the University of Tennessee.

Mustaleski, who was designated a Dis t inguished Member of AWS in 1989, is currently complet ing his second term as director-at-large on the Board of Directors for the American Welding Society. While on the board, he has served on the Education,Tech- nical, Cert i f icat ion and Communica- t ions Counci ls and the Execut ive C o m m i t t e e (1995-1996) . He has

68 J DECEMBER 2000

b e e n a m e m b e r of a n u m b e r of pres- iden t i a l task g roups , i n c l u d i n g g r o u p s a d d r e s s i n g v o l u n t e e r r e c o g n i t i o n , re- o r g a n i z a t i o n , t he ANB, t h e Role & Mis- s i o n s C o m m i t t e e a n d T e c h n i c a l De- p a r t m e n t review.

M u s t a l e s k i h a s s e r v e d as a n of- f i c e r in t w o S e c t i o n s o f t h e A m e r i - c a n W e l d i n g Society. He r e l i n q u i s h e d his p o s t as f i r s t v i ce c h a i r m a n of t h e M i l w a u k e e S e c t i o n w h e n h e l e f t to a c c e p t e m p l o y m e n t in O ak Ridge , T e n n . A s a m e m b e r o f t h e N o r t h e a s t T e n n e s s e e S e c t i o n , h e t w i c e s e r v e d as c h a i r m a n ( 1 9 8 2 - 1 9 8 2 a n d 1 9 8 3 - 1 9 8 4 ) . He c o n t i n u e s to s e r v e t h e S e c t i o n as e d u c a t i o n c h a i r m a n a n d f o u n d a t i o n r e p r e s e n t a t i v e . He r e c e i v e d t h e D i s t r i c t M e r i t o r i o u s A w a r d in 1989 , a n d h e is o n t h e W e l d i n g A d v i s o r y C o m m i t t e e f o r Oak Ridge H igh School .

M u s t a l e s k i is c u r r e n t l y a m e m - b e r of t h e T e c h n i c a l P a p e r s C o m m i t - t e e a n d i ts P o s t e r S e s s i o n s a n d P e e r R e v i e w S u b c o m m i t t e e s , t h e P r o d u c t D e v e l o p m e n t C o m m i t t e e a n d t h e C o n s t i t u t i o n a n d Bylaws C o m m i t t e e . He is a lso a n a d v i s o r y m e m b e r of t h e C7 C o m m i t t e e o n H igh Ene rgy B e a m W e l d i n g a n d C u t t i n g a n d t h e C7B S u b c o m m i t t e e o n E l e c t r o n B e a m W e l d i n g a n d C u t t i n g . F r o m 1981 to 1995 , h e s e r v e d as t h e c h a i r m a n o f t h e C7 C o m m i t t e e , o f w h i c h h e is a f o u n d i n g m e m b e r , a n d s e r v e d as t h e f i r s t c h a i r m a n o f i t s C7B S u b c o m - m i t t e e . D u r i n g h is t e r m as c h a i r m a n o f t h e T e c h n i c a l A c t i v i t i e s C o m m i t - t e e ( 1 9 8 9 - 1 9 9 2 ) , h e w as an e x offi- c io m e m b e r of t h e Safety a n d H e a l t h C o m m i t t e e , t h e E d u c a t i o n C o m m i t - t e e a n d t h e T e c h n i c a l P a p e r s C o m - m i t t e e , a t t e n d i n g m e e t i n g s o f e a c h c o m m i t t e e . O n t h r e e o c c a s i o n s , h e ha s s e r v e d o n t h e N a t i o n a l N o m i n a t - ing C o m m i t t e e . He w a s also a pa r t i c - i p a n t at t h e AWS C o n c u r r o , F a s t i g i u m a n d C o n t i n u u m a n d t h e 1994 H e n n i k e r C o n f e r e n c e . M u s t a l e s k i h a s a l so b e e n a c o n t r i b - u t o r to t h e Weld ing H a n d b o o k .

M u s t a l e s k i is a m e m b e r o f t h e I n d u s t r i a l A d v i s o r y B o a r d ( IAB) o f t h e E d i s o n W e l d i n g I n s t i t u t e (EWI) , a n d h e c h a i r s t h e A e r o s p a c e I n d u s - t r y A d v i s o r y C o m m i t t e e for EWI. He is a l so a p a s t c h a i r m a n o f t h e De- p a r t m e n t o f E n e r g y I n t e r a g e n c y M a n u f a c t u r i n g O p e r a t i o n s G r o u p s ( I M O G ) J o i n i n g S u b g r o u p . He h a s p u b l i s h e d m o r e t h a n 20 p a p e r s in t h e f i e ld o f j o i n i n g r e s e a r c h a n d de- v e l o p m e n t , e m p h a s i z i n g w e l d a b i l i t y o f m e t a l s a n d al loys a n d t h e app l ica -

t i o n o f a d v a n c e d j o i n i n g p r o c e s s e s to i n d u s t r i a l n e e d s .

M u s t a l e s k i was t h e 1994 r ec ip i - e n t of t h e Wi l l i am I r r g a n g M e m o r i a l A w a r d f r o m t h e A m e r i c a n W e l d i n g Society. He ha s a lso r e c e i v e d seve ra l E n e r g y S y s t e m s a n d D e p a r t m e n t o f E n e r g y a w a r d s for Q u a l i t y I m p r o v e - m e n t s a n d T e c h n i c a l A c h i e v e m e n t s .

N o m i n a t e d f o r V i c e P r e s i d e n t

J a m e s E. G r e e r

J a m e s E. G r e e r h a s b e e n em- p l o y e d b y M o r a i n e Val ley C o m m u - n i t y Co l l ege for 25 yea r s a n d is cur- r e n t l y a p r o f e s s o r a n d c o o r d i n a t o r o f t h e w e l d i n g p r o g r a m . He is a l so p r e s i d e n t o f T e c h n o - W e l d W e l d i n g C o n s u l t a n t s . In h i s m o r e t h a n 20 yea r s as a c o n s u l t a n t , G r e e r ha s h a d n u m e r o u s e x p e r i e n c e s as a w e l d i n g t r a i n i n g s p e c i a l i s t a n d m a s t e r w e l d e r . He h a s w r i t t e n a n d s u p e r - v i s e d t h e q u a l i f i c a t i o n o f n u m e r o u s W e l d i n g P r o c e d u r e S p e c i f i c a t i o n s to v a r i o u s c o d e s w i t h m a n y p r o c e s s e s o n d i f f e r e n t t y p e s o f m a t e r i a l . P r i o r to j o i n i n g t h e c o l l e g e , G r e e r w a s c h i e f w e l d i n g e n g i n e e r fo r G e n e r a l R a i l r o a d Co. , Mar se i l l e s , Ill., a n d se- n i o r w e l d i n g s p e c i a l i s t for S t a n d a r d R e f r i g e r a t i o n Co. , M e l r o s e Park , I l l .He is a h a n d s - o n w e l d e r qua l i f i ed to AWS, API, ASME, MIL a n d DNV s p e c i f i c a t i o n s .

G r e e r h o l d s a n A.S. d e g r e e f r o m M o r a i n e Val ley C o m m u n i t y Col lege , a B.S. f r o m N o r t h e r n I l l ino is Unive r - s i ty a n d an M.S. f r o m C h i c a g o S ta te Univers i ty .

C u r r e n t l y , G r e e r is c h a i r m a n o f t h e AWS C e r t i f i c a t i o n C o m m i t t e e , f i rs t v i ce c h a i r of t h e A2 C o m m i t t e e o n W e l d i n g T e r m s a n d D e f i n i t i o n s a n d a m e m b e r o f t h e C e r t i f i c a t i o n , O p e r a t i o n s , F a b r i c a t i o n a n d Safe ty C o m m i t t e e f o r t h e A m e r i c a n Ins t i - t u t e of Steel c o n s t r u c t i o n . He is a lso t h e AWS r e p r e s e n t a t i v e to t h e S tee l C o n s t r u c t i o n R o u n d t a b l e .

G r e e r r e m a i n s ac t ive o n t h e Sec- t i o n a n d D i s t r i c t level . He is a m e m - b e r of t h e C h i c a g o S e c t i o n w h e r e h e ha s s e r v e d o n t h e Boa rd of D i r e c t o r s a n d w a s c h a i r m a n fo r t w o t e r m s ( 1 9 8 5 - 1 9 8 6 a n d 1 9 8 9 - 1 9 9 0 ) . G r e e r s e r v e d as D i s t r i c t 13 d i r e c t o r f r o m 1990 to 1997.

G r e e r h a s b e e n a w a r d e d t h e AWS Di s t r i c t M e r i t o r i o u s Award , t h e H o w a r d A t k i n s D i s t r i c t E d u c a t o r A w a r d a n d t h e D i s t r i c t CWI o f t h e Year Award .

DamiaH J. Kotecki

N o m i n a t e d f o r D i r e c t o r - a t - L a r g e

D a m i a n J . K o t e c k i

D a m i a n J . K o t e c k i r e c e i v e d his Ph.D. d e g r e e in m e c h a n i c a l e n g i n e e r - ing f rom the Un ive r s i t y o f Wiscons in - Mad i son . In 1989, h e j o i n e d T h e Lin- c o l n E l e c t r i c Co. , w h e r e h e is n o w t e c h n i c a l d i r e c t o r fo r s t a i n l e s s a n d h igh -a l l oy p r o d u c t d e v e l o p m e n t . He h a s b e e n a c t i v e in t h e d e v e l o p m e n t o f w e l d i n g f i l le r me t a l s , p a r t i c u l a r l y for s t a i n l e s s s t e e l s a n d h a r d f a c i n g , s ince 1974.

Kotecki is a m e m b e r of t he Amer- i c a n W e l d i n g S o c i e t y ' s (AWS) Na- t i o n a l B o a r d o f D i r e c t o r s . He is p a s t c h a i r of t h e AWS T e c h n i c a l Ac t iv i t i e s C o m m i t t e e , t h e AWS Fi l l e r M e t a l s C o m m i t t e e , t h e WRC S u b c o m m i t t e e o n W e l d i n g S t a i n l e s s S tee l s a n d t h e WRC S u b c o m m i t t e e o n H a r d f a c i n g a n d W e a r a n d is c u r r e n t l y an a c t i v e m e m b e r o f all four. In a d d i t i o n , h e is t h e c h a i r o f t h e I n t e r n a t i o n a l Ins t i - t u t e o f Weld ing (IIW), C o m m i s s i o n II, as we l l as U.S. D e l e g a t e to t h a t Com- m i s s i o n . He is a m e m b e r o f t h e AWS T e c h n i c a l Pape r s C o m m i t t e e , t h e IIW Select C o m m i t t e e o n S tandard iza t ion , I IW T e c h n i c a l C o m m i t t e e a n d ISO TC44 and its S u b c o m m i t t e e 3.

An AWS F e l l o w a n d r e g i s t e r e d p r o f e s s i o n a l e n g i n e e r , Ko teck i h o l d s s eve ra l p a t e n t s for arc w e l d i n g f i l le r me ta l s and is t he a u t h o r of n u m e r o u s t e c h n i c a l pape r s .

AWS p r e s e n t e d Koteck i w i t h t he J a m e s E L i n c o l n Go ld Meda l in 1979 and aga in in 1987; t he Wil l iam I r rgang A w a r d in 1987; t h e R. D. T h o m a s M e m o r i a l A w a r d in 1983; t h e R. D. T h o m a s , Jr. I n t e r n a t i o n a l L e c t u r e A w a r d in 1994; t h e Prof . Dr. R e n e W a s s e r m a n M e m o r i a l A w a r d in 1995 a n d 1997; t h e G e o r g e E. Will is A w a r d in 1995 , a n d t h e A. E Dav i s S i lver Medal in 1996. He was c h o s e n for t he I I W T h o m a s Medal in 1999.


Richard Kellum Alfred F. Fleury

N o m i n a t e d f o r D i r e c t o r - a t - L a r g e R i c h a r d K e l l u m

R i c h a r d K e l l u m p re sen t ly heads Wi l lamet te Welding Supply Co., a company he founded in 1984. Earlier he was employed in welding sales. He at tended Oregon State Uni- versity, whe re he s tudied chemis t ry and business. From 1968 to 1972, he served in the U.S. Navy, where he at- t ended the Nuclear Power Program and se rved in the Off ice of Secure Communicat ions.

Kellum jo ined AWS in 1979. Over the years, he has held many of- f icer posts in the Wi l lamet te Valley Section. Kellum served as District 19 director from 1994 to 2000.

Kel lum has se rved the Oregon Depar tment of Education as a member of the Reform C o m m i t t e e and the C o m m i t t e e on Appl ied Acade- mics. He has also been an indus t ry advisor to the Oregon House of Rep- resentatives.

N o m i n a t e d f o r D i r e c t o r D i s t r i c t 2

A l f r e d F. F l e u r y

A l f r e d F. F l e u r y , an AWS Dis- t i ngu i shed m e m b e r s ince 1989, began his we ld ing ca ree r in 1953 with the Welding Products Division of M.T. Chemicals , Inc. In 1972, he jo ined Tempil ° Division of Big Three Industries, Inc., which was later purchased by Air Liquide Amer ica , as general manager, and later served as sen ior bus iness advisor. F leury re- t i red f rom Tempi l ° in N o v e m b e r of 1997 and began his own consul t ing firm, A. Fleury and Associates, in Jan- uary of 1998.

Fleury has been an active member of the New Jersey Section since 1960.Among the many offices he has he ld are Dis t r ic t d i r ec to r (1986- 1992, 1998-2001) , t reasurer (1963,

~-~

Wayne J, Engeron Wallace L: Honey

1978-1980, 1996), secretary (1964), vice chai rman (1967) and chai rman (1966). He has been active on many c o m m i t t e e s inc lud ing the Member- ship Commi t t e e , Program and Edu- ca t iona l Lecture C o m m i t t e e s (in 1963, he es tab l i shed the Sec t ion ' s first Educational Lecture Series),Ad- vert is ing and Publici ty Commit tees , Picnic Commit tee , Hospital i ty Com- mi t t ee and the Execu t ive Commit- tee (1962, 1973-1984) . Nationally, he has served on the National Nom- inat ing and Nat ional M e m b e r s h i p Committees.

In addi t ion to be ing awarded AWS Life Member status in 1994, Fleury r e c e i v e d the AWS Dis t r ic t Meritorious Certificate in both 1997 and 1985.


W a y n e J . E n g e r o n

W a y n e J . E n g e r o n has b e e n nomina ted to serve as Distr ict 5 director. He has spent his entire working ca ree r in the meta l jo in ing indust ry .After 28 years as o w n e r of welding supply distr ibutorships, En- ge ron has been engaged in the op- e ra t ion of Eng inee red Alloys/Sys- tems & Supply in Tucker, Ga. Along with his sons, Engeron markets brazing, so lder ing and we ld ing f i l ler alloys and systems.

Engeron ea rned an assoc ia te ' s degree in industrial t echno logy and is a Certified Welding Educator.

Aside f rom AWS, Engeron is an act ive m e m b e r of ASM, SME and ASPE,ASHRAE.


W a l l a c e E. H o n e y

W a l l a c e E. H o n e y has been nomina ted to serve as Distr ic t 8 director . He is a sales r e p r e s e n t a t i v e

John Brz~skotter Scott C Chapple

fo rAnchor Research Corp. Honey rece ived his bache lo r ' s deg ree f rom Samford Universi ty, Bi rmingham, Ala., w h e r e he s tud ied human i t i e s and adminis t ra t ive services . Honey se rved in the U.S. Army Reserves from 1964 to 1970.

In 1998, Honey was awarded the District 8 Meritorious Certificate. He se rved as cha i rman of the AWS Nor theas t Mississippi Sec t ion for the 1999-2000 term.

E l e c t e d D i r e c t o r D i s t r i c t 9

J o h n B r u s k o t t e r

J o h n B r u s k o t t e r has b e e n e lec ted to fulfill the remaining term of Dis t r ic t 9 D i r ec to r O. J. Temple t for the t e rm c o m m e n c i n g immedi - ately through May 31, 2002.

Bruskotter is currently a pro jec t manager with Project Specialists Inc. From 1986 to 2000, he was employed with Houma Industr ies Inc., where his positions included fabrication and quali ty cont ro l manager and vice president of operat ions onshore, offshore fabr ica t ion and coat ings and warehousing and maintenance.

Bruskot ter jo ined the AWS New Orleans Sect ion in 1993 and served as t reasurer (1997-1998) , first v ice cha i rman ( 1 9 9 7 - 1 9 9 8 ) and chairman (1999-2000) . While chai rman, he also se rved as depu ty Dis t r ic t 9 director.


S c o t t C. C h a p p l e

Sco t t C h a p p l e has been a welding e n g i n e e r at Midway Produc t s Group, Monroe, Mich., s ince 1996. Midway Products Group is a tier one supp l i e r of fabr ica ted au tomot ive

?0 I DECEMBER 2000

p r o d u c t s f o r b o t h f o r e i g n a n d do- m e s t i c a u t o m a k e r s .

C h a p p l e is a m e m b e r of t h e AWS D8 C o m m i t t e e , D8C S u b c o m m i t t e e , W e l d i n g H a n d b o o k C o m m i t t e e , CIG, USA-TechnicalAdvisory G r o u p and the W e l d i n g E n g i n e e r i n g A d v i s o r y Coun- cil at Fer r i s Sta te Univers i ty , Big Rapids, Mich.

C h a p p l e is a n AWS C e r t i f i e d W e l d i n g I n s p e c t o r a n d w a s t h e 1 9 9 5 - 1 9 9 6 c h a i r m a n o f t h e W e s t M i c h i g a n S e c t i o n of AWS.

N o m i n a t e d f o r D i r e c t o r D i s t r i c t 1 4

H i l a r y J . B a x

H i l a r y " H i l " J . B a x , an AWS m e m b e r s i n c e 1979 , is d i r e c t o r o f t e c h n i c a l sa les at Cee Kay Supply, St. Louis, Mo.

W h i l e s e r v i n g o n t h e b o a r d o f d i r e c t o r s fo r t h e St. Lou i s S e c t i o n , Bax h a s h e l d s e v e r a l o f f i c e r s ' pos i - t i o n s i n c l u d i n g c h a i r m a n , v ice cha i r - m a n a n d sec re t a ry . His S e c t i o n com- m i t t e e c h a i r s i n c l u d e p r o g r a m a r r a n g e m e n t , a w a r d s a n d CWI act iv- i t i e s . Bax a l so s e r v e s as a C e r t i f i e d W e l d i n g I n s p e c t o r t e s t s u p e r v i s o r .


O r e n P. R e i c h

O r e n P. R e i c h is a n i n s t r u c t o r in I n d u s t r i a l M a i n t e n a n c e E n g i n e e r - i ng T e c h n o l o g y at Texas S ta te Tech - n ica l Co l l ege in Waco ,Tex . He ha s an a s s o c i a t e ' s d e g r e e in w e l d i n g . Re i ch h a s b e e n e m p l o y e d at T e x a s S t a t e T e c h n i c a l C o l l e g e s i n c e 1982 . In 1990, R e i c h f o u n d e d R e i c h S e r v i c e s C o m p a n y , a c o n s u l t i n g f i rm for sev- era l Texas c o m p a n i e s in qua l i t y con - t r o l a n d q u a l i t y a s s u r a n c e in t h e w e l d i n g f i e ld . R e i c h a l so w o r k e d w i t h l a rge Texas c o m p a n i e s t r a i n i n g t h e i r w o r k f o r c e s o n c o m p a n y s i t e s f r o m 1 9 8 2 - 1 9 9 5 .

Present ly , Re ich se rves o n t h e Ex- e c u t i v e B o a r d o f t h e C e n t r a l Texas S e c t i o n a n d is a j u d g e fo r t h e Skil ls USA S e c o n d a r y W e l d i n g C o n t e s t . He ha s h e l d s eve ra l AWS off ices , i nc lud - ing c h a i r m a n ( 1 9 8 5 - 1 9 8 7 , 1 9 8 7 - 1988 , 1 9 9 0 - 1 9 9 1 a n d 1 9 9 8 - 1 9 9 9 ) . R e i c h is a s u p p o r t e r of t h e AWS Stu- d e n t C h a p t e r at Texas State T e c h n i c a l

Hila r), j~ Bax Oren P. Reich

Col l ege .Among Re ich ' s a c h i e v e m e n t s a re t h e D i s t r i c t M e r i t o r i o u s Cer t i f i - ca te in 1993, Dis t r ic t E d u c a t o r A w a r d in 1992 a n d b e i n g s e l e c t e d to s e r v e as c h a i r m a n of t h e State of Texas VICA Weld ing C o n t e s t in 1985.

E l e c t e d D i r e c t o r D i s t r i c t 1 9

P h i l Z a m m i t

P h i l Z a m m i t h a s b e e n e l e c t e d to fu l f i l l t h e r e m a i n i n g t e r m of t h e l a t e D i s t r i c t 19 D i r e c t o r D o n De lk c o m m e n c i n g i m m e d i a t e l y t h r o u g h May 3 1 , 2 0 0 3 .

Z a m m i t was b o r n in Mal ta a n d b e g a n his w o r k i n g life in an in te l l ec - tual, r a t h e r t h a n technica l , career. After g radua t ion , he w o r k e d for t h r e e years as a cu s t om s officer. He t h e n left Malta for L o n d o n , Eng land , a n d w o r k e d in t h e Dep t . of H e a l t h a n d Social Secu- rity. Z a m m i t , h o w e v e r , f o u n d h e was u n h a p p y w i t h a p o s i t i o n t h a t r e l i ed solely on his in te l lect . He missed us ing h is h a n d s . He s o o n t r a d e d in h is su i t and tie for a pai r of coveral ls and work- b o o t s and p l u n g e d full t ime in to welding school . Eight m o n t h s later, Zammi t was w e l d i n g in a L o n d o n s h o p u s i n g mos t ly o x y a c e t y l e n e and gas t u n g s t e n arc we ld ing n o n f e r r o u s metals .

In 1978 , Z a m m i t m o v e d to t h e U n i t e d States and a c c e p t e d a p o s i t i o n as a f i t t e r / w e l d e r for R.A. H a n s o n Co. (RAHCO). D u r i n g t h a t t ime , h e c o n - t i n u e d h i s w e l d i n g e d u c a t i o n t h r o u g h s e l f - s t u d y a n d r e c e i v e d h i s CWI c e r t i f i c a t i o n in 1985. In 1998 , h e a c c e p t e d an o p p o r t u n i t y to s e rve as qua l i ty c o n t r o l i n s p e c t o r w i t h Red I r o n C o r p . ( n o w B r o o k l y n I r o n Works , Inc . , a n d B r o o k l y n I n d u s t r i a l C o a t i n g s , Inc . ) , a s t e e l f a b r i c a t i o n shop . Z a m m i t n o w se rves as QA man- a g e r for b o t h B r o o k l y n I r o n W o r k s a n d Brook lyn Indus t r i a l Coat ings .

Aside f rom AWS, Z a m m i t is ac t ive

Pbi l Z a m m i t

....

Jesse Gran tham

in t he Nat iona l Assoc ia t ion of Coa t ing E n g i n e e r s a n d t h e Pacif ic N o r t h w e s t Steel Fabr ica t ion Associat ion.

N o m i n a t e d f o r D i r e c t o r D i s t r i c t 2 0

J e s s e G r a n t h a m

J e s s e G r a n t h a m b e g a n h i s w e l d i n g c a r e e r in h i s g r a n d f a t h e r ' s r a d i a t o r r e p a i r s h o p a n d as a w e l d e r ' s h e l p e r in t h e o f f s h o r e oi l a n d gas i n d u s t r y . He h a s b e e n asso- c i a t e d w i t h f a b r i c a t i o n , i n s p e c t i o n a n d t e s t i n g l a b o r a t o r i e s s i n c e 1970. G r a n t h a m is w e l l - r e g a r d e d as an ex- p e r t o n m a t t e r s s u c h as t h e c u r r e n t p r a c t i c e s a n d a p p l i c a t i o n s o f w e l d - ing s c i e n c e for m a n a g e m e n t , me ta l - l u r g y a n d p r o c e s s e s u s e d in m a n u - f a c t u r i n g a n d f a b r i c a t i o n . He spe - c ia l izes in w e l d i n g m a n a g e m e n t a n d f o r e n s i c e n g i n e e r i n g .

G r a n t h a m ' s f o r m a l e d u c a t i o n in- c l u d e s a B.S. in i n d u s t r i a l e n g i n e e r - i ng a n d m a n a g e m e n t f r o m Okla- h o m a S ta t e U n i v e r s i t y in 1969 ; an M.B.A. f r o m U n i v e r s i t y o f S o u t h - w e s t e r n L o u i s i a n a w i t h s t u d i e s in m a n a g e m e n t , m a r k e t i n g a n d f i n a n c e in 1982 ; a n M.S. in w e l d i n g e n g i - n e e r i n g f r o m T h e O h i o Sta te Unive r - s i ty in 1988; and , in 1992, a Ph .D. in w e l d i n g e n g i n e e r i n g f r o m T h e O h i o Sta te Univers i ty .

G r a n t h a m is an a c t i v e m e m b e r o f a n u m b e r o f t e c h n i c a l a n d p ro fes - s i o n s o c i e t i e s a n d h a s h e l d o f f i c e s l o c a l l y a n d n a t i o n a l l y . He h a s re- c e i v e d m a n y AWS h o n o r s a n d h a s s e r v e d as c h a i r m a n of t h r e e A W S Sec- t i o n s . G r a n t h a m is a r e g i s t e r e d p ro - f e s s iona l e n g i n e e r in fou r s ta tes , a n d is c u r r e n t l y a m e m b e r o f C o l o r a d o P r o f e s s i o n a l E n g i n e e r s a n d t h e Na- t i o n a l A c a d e m y o f F o r e n s i c Engi- n e e r s . His p u b l i c a t i o n s a re p r i m a r - ily in t h e w e l d i n g c o n s u m a b l e s , testing a n d m a n a g e m e n t f ields. •

WELDING JOURNAL I ~l

• Sustaining Company Member Dues Update

r f fec t ive June 1, 2000, the fo l lowing ad jus tments have been imple- Company Members: Sustaining , ~ mented for AWS

Dues: The annual dues are $750, domest ic; $850, international; plus a $500 initiation fee.

Benefits: The e n h a n c e d AWS Sustaining Company Member benef i t s package includes one of the following primary offerings: 1) the complete library o f AWS p u b l i c a t i o n s ($5600 value), inc lud ing 130+ specif ica- tions, wi th compl imentary publicat ion updates included; or 2) a discount promotional p a c k a g e , inc lud ing a 5% d iscount on ads in the Welding Journal and a $4-per-sq-ft discount on booth space at the AWS/PMA Show; or 3) t e n a d d i t i o n a l AWS I n d i v i d u a l M e m b e r s h i p s for com pany employees or customers.

In addition,AWS Sustaining Company Members enjoy the following:

• Ten free Individual Memberships for company employees or customers.

• Publici ty of the company ' s name and p r o d u c t / s e r v i c e offer ings in the Welding Journal and on the AWS Web site.

• Company recogni t ion at the annual AWS/PMA Show.

• Usage of the AWS Sustaining Company Member logo on company letter- head and promotional material.

• AWS Sustaining Company engraved wall plaque.

• Free hyperl ink from the AWS Web site to the m e m b e r company ' s site.

For in format ion on b e c o m i n g an AWS Sustaining Company Member, contact the AWS Membership Dept. at (800) 443-9353 ext. 418, FAX (305) 443-5647 or wri te AWS, 550 N.W. LeJeune Rd., Miami, FL 33126. •

• Member Dues Adjus tment

T he AWS Board of Directors, acting on the recommendat ions made by the Membership Commit tee , approved a dues adjustment to $75 for the "Regular Member" classification effective June 1, 2000.

Upon joining, and every third membership year, Regular Members dues will include an expanded publ ica t ion cho ice of e i ther the latest Welding Handbook, Welding Metallurgy,Jefferson "s Welding Encyclopedia, Solder- ing Handbook or the Design and Planning Manual for Cost-Effective Weld- ing upon request. In addition,AWS members receive a monthly subscription to the award-winning Welding Journal. AWS-certified personnel also receive quarterly issues of Inspection Trends magazine.

AWS members enjoy access to widely respected technical information in the mater ia ls - jo ining indus t ry at d i s coun t ed rates. Members-only dis- counts apply to AWS technical publicat ions, as well as top-notch certifications, confe rences and o ther educat ional offerings. Members also benef i t f rom n e t w o r k i n g o p p o r t u n i t i e s at local Sec t ion m e e t i n g s and at the AWS/PMS Show.AWS members can choose be tween two value-added membership package offerings - - the Gold and the Platinum membersh ip packages - - for modes t fees.And, in the near future,AWS members will enjoy members-only access to special information and services on the AWS Web site, www. aws. org. •

A W S W E L C O M E S

N E W S U P P O R T I N G C O M P A N I E S

N e w S u p p o r t i n g Companies

Acropolis Steel Industries Ltd. 7555 51st Street S.E. Calgary, Alberta T2C 4At Canada

Work for Wisconsin 231 West Wisconsin Avenue, Ste. 200 Milwaukee,WI 53203

N e w E d u c a t i o n a l Institutions

Central Piedmont Community College P.O. Box 35009 Charlotte, NC 28235-5009

DALUS, S.A. DE C.V. Av. Lazaro Cardenas No. 2400 PTE. Edificio Losoles, Desp. C-14 Garza Garcia N.L. 66260 Mexico

Humphreys County Vocational Center

1327 Highway 70 West Waverly, TN 37185

Owens Community College P.O. Box 10000 Toledo, OH 43699

• S u s t a i n i n g M e ~ C o m p a n y

S COtt Manufactur ing, Inc. (SMI), specia l izes in cus tom metal fabrication. Special t ies

include small and large weldments of varying complexi t ies , laser and plasma cutting, CNC punching, roll forming of lengths up to 32 ft and comple t e machin ing capabil i t ies. SMI is currently pursuing ISO 9000 certification. •

72 J DECEMBER 2000

S A F E T Y A N D H E A L T H T O P I C S

• Electric and Magnetic Fields Fact S h e e t N o . 1

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

Elect r ic and m a g n e t i c f ields are o f t en r e f e r r ed to as "e lec t romagnet ic fields," or EMEThere is c o n c e r n that EMF may affect your heal th .

H o w i s EMF P r o d u c e d ?

Voltage is the di f ference in e lectr ic po ten t ia l b e t w e e n two po in t s .Th i s vol tage c rea tes an e lec t r ic field b e t w e e n those points . Now, suppose an electr ic c o n n e c t i o n is made b e t w e e n those two points , so t h e r e is an e lec t r ic cur ren t . This c u r r e n t p r o d u c e s a m a g n e t i c field. Magne t i c f ields occu r w h e n e v e r there is cu r ren t flow.

W h a t D o e s EMF do?

S u p e r i n t e n d e n t of D o c u m e n t s , U.S. G o v e r n m e n t P r in t ing Office,Washington, DC 20402.

Environmenta l Pro tec t ion Agency (EPA). Ques t ions and Answers abou t Electric and Magnet ic Fields. Nat ional Insti- tu te of Env i ronmen ta l Heal th Sciences (of Dept . of Heal th and H u m a n Services) and Dept . of Energy. Miles Kahn, P.O. Box 37133,Washington, DC 20013-7133.

U n i t e d States Congress , Off ice of Techno logyAsses s - ment . Biological Effects of Power Frequency Electric & Mag- ne t ic Fields -- Background Paper, Ota-BP-AE-63, May 1989. S u p e r i n t e n d e n t of D o c u m e n t s , U.S. G o v e r n m e n t P r in t ing Office,Washington, DC 20402.

Amer i can Confe rence of G o v e r n m e n t a l Industr ia l Hy- gienists (ACGIH).Threshold Limit Values for Chemical Sub- s t ance s and Physical Agents and Biological E x p o s u r e In- dices. ACGIH, Inc., 6500 G l e n w a y Ave., C inc inna t i , OH 45211.

National Electrical Manufacturers Association (NEMA). Q &A" Biological Effects of Elec t r ic and Magne t i c Fields. NEMA, 2101 L St., NW,,Washington, DC 20037 .0

EMF p r o d u c e s forces t ha t dr ive mos t of t he dev ices tha t we use every day. For examp |e , EMF is involved in light- ing our h o m e s and start ing our cars.

I s E M F H a r m f u l ?

Many scientific tests have b e e n and are still be ing conduc t ed by governmenta l and pr ivate agencies to de t e rmine if EMF is ha rmfu l to ou r hea l th . Most s tud ies to da te indica te t h e r e is n o e v i d e n c e of s ign i f ican t h e a l t h p r o b l e m s from EME

H o w D o I M i n i m i z e E x p o s u r e ?

• Do not p lace your body b e t w e e n the to rch and work cables. Route cables on the same side of your body.

• Route the weld ing cables close together. Secure t h e m wi th tape w h e n possible.

• C o n n e c t the work cable to the w o r k p i e c e as c lose to the weld as possible.

• Keep t he w e l d i n g p o w e r s o u r c e a n d cab les as far away from your body as possible.

• Never coil the to rch or work cable a round your body.

I n f o r m a t i o n S o u r c e s

O c c u p a t i o n a l Safety and Hea l th A d m i n i s t r a t i o n (OSHA). Code of Federal Regulat ions,Tit le 29 Labor, Chap- t e r XVII, Parts 1900 to 1910, O r d e r No. 869-019-00111-5.

The Safety and Health Fact Sheets, 2nd ed., cover all aspects o f safety and health applicable to welding and cutting. The Fact Sheets include 20 pages on subjects such as f u m e s and gases, radiation, noise and electrical hazards. Compiled in 1998. Price f o r AWS m e m b e r s is $27; nonmembers , $36. Copies of Safety and Health Fact Sheets can be ordered by calling AWS Publica- tion Sales at (800) 334-9353, or (305) 443-9353 ext. 280 outside the United States, Monday through Friday, 8 a.m. to 5 p.m. Eastern Standard Time.

• Tenth I n t e r n a t i o n a l JOM J u b i l e e C o n f e r e n c e

T h e I n s t i t u t e f o r t h e J o i n i n g o f M a t e r i a l s CIOM) h a s a n n o u n c e d t h e T e n t h I n t e r n a t i o n a l JOM Ju- b i l e e C o n f e r e n c e o n t h e J o i n i n g o f M a t e r i a l s ,

JOM-IO, May 1 1 - 1 4 , 2001 , in He ls ingor , D e n m a r k . T h e f o l l o w i n g are t h e m a i n t h e m e s of JOM-lO: • I n f o r m a t i o n t e c h n o l o g y , c a s e s in i t s e x p l o i t a -

t i o n as w e l l as p r e d i c t i o n o f i t s v a l u e fo r f u t u r e a n d p r e s e n t w e l d i n g f a b r i c a t i o n .

• R o b o t i z a t i o n a n d a u t o m a t i o n in w e l d i n g a n d a s s o c i a t e d p r o c e s s e s .

• Braz ing , s o l d e r i n g a n d a s s o c i a t e d p r o c e s s e s in n o n m e l t j o in ing .

JOM w e l c o m e s t h e a c t i v e s u p p o r t o f AWS to t h e J O M - 1 0 t h r o u g h s p e a k e r s a n d p a r t i c i p a n t s . AWS c o s p o n s o r e d p r e v i o u s JOM c o n f e r e n c e s 7 t h r o u g h 9.

For f u r t h e r i n fo rma t ion o n JOM-IO, c o n t a c t t he Insti- t u t e for t he Jo in ing of Materials , Kl in tehoj Vaenge 21, DK- 3460 Birkerod, Denmark; e-mail to jom_aws@post 10.tele.dk; t e l ephone 45 45 82 80 95; or FAX 45 45 94 08 55. •


• AWS Publ i ca t ions • E a r t h m o v i n g & C o n s t r u c t i o n E q u i p m e n t Welding i n a N e w A W S S p e c i f i c a t i o n

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) ha s c o m p l e t e d an u p d a t e d ver- s i on o f Speci f icat ion f o r Welding E a r t h m o v i n g a n d Cons truc t ion Equip- m e n t ( D 1 4 . 3 / D 1 4 . 3 M : 2 0 O O ) . A N S I - a p p r o v e d , t h i s g u i d e p r o v i d e s t h e s tan- d a r d s n e e d e d to p r o d u c e t h e s t r u c t u r a l w e l d s u s e d in t h e m a n u f a c t u r e o f c r a w l e r s , t r a c t o r s , l o a d e r s , p o w e r s h o v e l s , b a c k h o e s a n d o t h e r s e l f -p ro - p e l l e d m a c h i n e r y .

Specif ication f o r Welding E a r t h m o v i n g and Construct ion E q u i p m e n t p l a c e s a h e a v y e m p h a s i s o n w o r k m a n s h i p a n d w e l d e r q u a l i f i c a t i o n . In ad- d i t i on , t h e s p e c i f i c a t i o n also p r o v i d e s i l l u s t r a t i o n s of p r e q u a l i f i e d w e l d e d jo in t s for a va r i e ty of w e l d i n g p r o c e d u r e s .

P r e s e n t e d in t h e U.S. C u s t o m a r y a n d m e t r i c u n i t s , Spec i f i ca t ion f o r Welding E a r t h m o v i n g a n d Cons t ruc t ion E q u i p m e n t is 97 p a g e s a n d in- c l u d e s 41 f i g u r e s , 11 t a b l e s a n d f o u r a n n e x e s . Spec i f i ca t ion f o r Welding E a r t h m o v i n g a n d Cons truc t ion E q u i p m e n t is ava i l ab l e to AWS m e m b e r s for $54; $72 for n o n m e m b e r s .

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

C o p i e s of AWS p u b l i c a t i o n s c a n b e o r d e r e d by ca l l ing AWS P u b l i c a t i o n Sales at ( 8 0 0 ) 334-9353 , ( 3 0 5 ) 3 3 4 - 9 3 5 3 o u t s i d e t h e U n i t e d Sta tes , M o n d a y t h r o u g h Friday, 8 a .m. to 5 p . m . EST, o r t h r o u g h t h e AWS W e b s i t e at www.aws.org . A d d i t i o n a l i n f o r m a t i o n o n AWS's p r o g r a m s a n d p u b l i c a t i o n s c a n also b e f o u n d o n t he Web site. •

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

All AWS t echn i ca l c o m m i t t e e m e e t i n g s are open to the pub l i c . Persons w i s h i n g to a t t e n d a meeting s h o u l d con tac t the s t a f f secre- t a r y o f the c o m m i t t e e as l i s ted below a t AWS, 550 N. W LeJeune Rd., Miami , FL 33126; t e l ephone (305) 443-9353.

D e c e m b e r 7, G2E S u b c o m m i t t e e o n Sta in less Steel Alloys. Las Vegas, Nev. S t anda rds p r e p a r a t i o n m e e t i n g . Staff con tac t :T . R. Pot ter .

D e c e m b e r 8, G2C S u b c o m m i t t e e o n N i c k e l Al loys . Las Vegas , Nev. 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 :T . R. Pot ter .

D e c e m b e r 8, G2 C o m m i t t e e o n Join- ing Meta ls andAl loys . Las Vegas, Nev. G e n e r a l m e e t i n g . Staff c o n t a c t : T . R. Pot ter . •

• T e c h n i c a l T o p i c s

0 Errata forANSI/AWS B2.1-1-205-96, Carbon Steel Pr imari ly Pipe Appli- cations, SMAW Welding Procedure Specification.

Page 3, in the "Electrical Character is- t ics Table," c h a n g e "1.2.2.3." to r ead " 1 . 2 . 3 . 4 . " 0

• AWS MEMBERSHIP

Member A s o f G r a d e s N o v e m b e r 1, 2 0 0 0

Sustaining Companies ................ 312

Individual Members .............. 45,333

Student Members .................... 4,823

Total ............... 50 ,468

• A W S F o u n d a t i o n E l e c t s T r u s t e e

T h e A m e r i c a n Weld ing Socie ty (AWS) Founda t ion a n n o u n c e d t h e e l e c t i o n o f D. Fred Bovie

as Trus tee Emer i tus .A d i s t i ngu i shed A l u m n u s f r o m T h e O h i o Sta te Uni-

D I:ved Bot,ie

versity, Bovie has se rved the Society for m o r e t han 30 years. He will b r ing his years of e x p e r i e n c e in t he welding industry, inc lud ing work as pres- i d e n t a n d CEO of t he ESAB G r o u p , to t h e p h i l a n t h r o p i c e f fo r t s of t h e AWS Founda t ion .

In add i t i on to his c o m m i t m e n t to AWS and t he w e l d i n g i n d u s t r y as a w h o l e , Bovie is also a f o u n d i n g di- r e c t o r o f t h e A g r i c u l t u r a l a n d In- dust r ia l M u s e u m of York.

T h e AWS F o u n d a t i o n was f o u n d e d in 1989 a n d is d e d i c a t e d to s u p p o r t i n g r e s e a r c h a n d educa - t i o n in w e l d i n g a n d r e l a t e d t ech - n o l o g i e s . T h e F o u n d a t i o n a w a r d s m o r e t h a n $ 2 5 0 , 0 0 0 in u n d e r g r a d - ua te s c h o l a r s h i p s and g r a d u a t e fel- l o w s h i p s each year.

Fo r 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 u n d a t i o n s c h o l a r s h i p , f e l l o w s h i p a n d s t u d e n t l o a n p ro - g r a m s , v i s 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 w w w . a w s . o r g / f o u n d a t i o n / . •

• 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 tuden t C h a p t e r s are encou r - aged to s e n d r e p o r t s of t h e i r mee t - ings, activities and events, a long w i th p h o t o g r a p h s , for p u b l i c a t i o n in t he Welding Journal's Studen t Activit ies depar tmen t .

Send you r m e e t i n g / e v e n t re- por t s to Susan Campbell ,Asst . Editor, Weld ing Journa l , 550 N.W LeJeune Rd., Miami, FL 33126.

Repo r t s c an also b e f axed to (305) 443-4704 or e-mailed to camp- beU@aws, org. •

741 DECEMBER2000

I N E W S

AWS Presidenl Bill Myers, f i tr left in sport coal, and Maine Section members l i s tening to Russel l Van Bil l iard at the dedical ion o f the USS Alba- core s u b m a r i n e as an AWS Historical Welded Structure.

D I S T R I C T I D i r e c t o r : 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

• MAINE SEPTEMBER 12 Speaker: G e o f f P u t n a m , Dist r ic t 1 director. Af f i l ia t ion:The American Welding Society. Activity:The Section held a meeting to discuss Section and District activ- i t ies.The District Director 's Award was presented to Chairman Russ Norr is .

OCTOBER 3 Speaker: Bill Myers , president. Af f i l ia t ion:The American Welding Society, Miami, Fla. Act iv i ty: Pres iden t Myers presented a plaque dedicating the USS Albacore Research Submar ine an AWS Histor ical Welded Structure. Accep t ing the p laque was Prof. G e n e A l l m e d i n g e r , one of the submar ines or iginal des igners . Myers was p re sen ted with a book on the h i s tory of the submar ine and received a tour.

• BOSTON OCTOBER 2 Act iv i ty: The Sect ion was given demonstrat ions on plasma arc cutting, pulsed gas metal arc welding with synergic controls and oxyfuel metal spray p rocess using Ther- malarc, Miller and Eutect ic equipment . The demons t r a t i ons were given at the South Easton Regional Vocational Technical High School by instructors S teve F l o w e r s and D e r r i c k K n u d s e n and s tudents B i l l J a r r i d , Kr i s Creighton, Ryan G r o v e r , J e n n i f e r E l l i s and An- d r e w Cerc i .

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

• NEW JERSEY SEPTEMBER 19 Speaker: Pat D or r i s , director. Af f i l ia t ion: Welder Training and Testing Institute. Topic:Welder training, certif ication and inspection.

• LONG ISLAND OCTOBER 12 Speaker: H u g h C a l l a g h a n , district

District 1 Director GeoJfr{:l, Pltt- nam, left, presenting Maine Sec- tion Chairman Russ Norris with the District Director's Award.

Long I s land SeclioH speaker Hugh Cal laghan dur ing his pre- sentat ion in October.

sales manager. Affi l iat ion :Victor Equipment, New York and New England. Topic: Oxyfuel Welding, cu t t ing and heating.

D I S T R I C T 3 D i r e c t o r : C l a u d i a B o t t e n f i e l d

Phone: ( 7 1 7 ) 3 9 7 - 1 3 1 2

• LEHIGH V ~ SEPTEMBER 5 Speaker: Bob J o n e s , regional sales manager. Affiliation: Praxair TAFA Corp. Topic:Thermal spray coating

WELDING JOURNAL I ~s

S o u t h w e s t Virginia Sec t ion m e m b e r s and gues t speaker Bu tch Charlton, left, t ak ing a b reak f r o m the i r October tour to pose f o r a photo.

Southwest ViJ~inia SectioH (,'hctirma~t L:d Wyatt, right, presenting guest speaker Wal- ter Sperko with a speaker's gift.

Florida gt, st Coast Chairman Dar- ryl Jardine, right, present ing Mike Dortch with a speaker's gift.

From left are gues t speaker Chris P. Sacco, Joyce Sacco a n d York- Cen t ra l P e n n s y l v a n i a Sec t ion First Vice Cha i rman Mike Fink.

OCTOBER 3 Speaker: R o b e r t W i s w e s s e r , president. Af f i l i a t i on : Welder Training and Testing Inst i tute,Allentown, Pa. Topic: N o n d e s t r u c t i v e examination.

• YORK-CENTRAL PENNSYLVANIA OCTOBER 3 Speaker: C. P. Sacco, ret ired president. Af f i l i a t ion : Herr & Sacco, Lan- disville, Pa. Topic:Welding: It's not a job, it's an art.

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 : ( 9 1 9 ) 3 2 1 - 4 2 8 5

• SOUTHWEST VIRGINIA SEPTEMBER 20 Speaker: Wal te r J . Spe rko , P.E. Af f i l i a t ion : Sperko Engineer ing , Greensboro, N.C.

Lehigh Valley Section Chairmalz Rich Gallagher, right, present ing a speaker's g i f t to Bob Jones.

Topic: Welding meta l lu rgy of low carbon steels.

OCTOBER 18 Speaker: B u t c h C h a r l t o n , QA manager. Affi l iat ion: Roanoke Electric Steel. Topic:The Section rece ived a tour of the company's facilities.

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

Phone: ( 7 8 7 ) 8 8 3 - 8 3 8 3

• FLORIDA WEST COAST SEPTEMBER 13 Speaker: Mike D o r t c h . Aff i l iat ion: AlcoTec. Topic:Welding aluminum. Activi ty: D a r r y l J a r d i n e received the Di s t r i c t /Sec t ion Mer i to r ious Award. Industry Sponsor Recogni- t ion Awards were g iven to South- eas te rn Mechanica l Services and Ardaman and Associates.

Lehigh Vallej' Sect ion Pt tbl ic i ty Cha i rman Dave Marks, left, w i th gues t speaker Bob Wiswesser.

• SOUTH CAROLINA SEPTEMBER 21 Speaker: J e f f M a r t i n , sales and technical representative. Af f i l i a t ion : The Lincoln Electr ic Co. Topic: Surface tension transfer.

• SOUTH FLORIDA OCTOBER 19 Speaker: E r n e s t L e v e r t , s e n i o r s t a f f m a n u f a c t u r i n g e n g i n e e r and p r o j e c t m a n a g e r and AWS v i c e p r e s i d e n t . Aff i l ia t ion: L o c k h e e d M a r t i n Miss i l e s and Fire C o n t r o l , Dal- las, Tex. Topic: W e l d i n g t h e i n t e r n a - t i o n a l s p a c e s t a t i o n . A c t i v i t y : T h e S e c t i o n a l so h e l d E d u c a t i o n N i g h t . T h e e v e n t t o o k p l a c e at t he M c F a d d e r Vo- c a t i o n a l - T e c h n i c a l Schoo l .

D I S T R I C T 6 i

Director: Gerald R. Crawmer Phone: ( 5 1 8 ) 3 8 5 - 0 5 7 0

76 I DECEMBER 2000

District 7 Director RobertJ. "l}lber, tik, left, with AWS Vice President Richard Arn, center, and Columbus Section Chairman J im Worman.

Guest Speaker Lorne Weete,; &J?, accepting a speaker's gift f rom Colum- bus Section Vice Chairman and Trea- surer Tom Kuntzman.

Pascagoula Section Chairman Levis Carter, right, present ing guest speaker George Jones wi th a speaker's gift.

Topic: A dvancem en t s in Robot ic Welding.

D I S T R I C T 8 D i r e c t o r : H a r r e 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

• MEMPHIS SEPTEMBER 1 1 Speaker: H a r r e l l Benne t t , District 8 director. Activity: Members met to discuss re- organizing the Memphis Section as the West Tennessee Section.A new Executive Commit tee and officers were selected.

Greater I tuntsvi l le Seclion members pose fi~r a photograph during the Section's September meeting.

D I S T R I C T 7 Director : Robe r t J. Tabe rn ik

Phone: (614) 4 8 8 - 7 9 1 3

• PITTSBURGH JuLY 21 Speaker: D a v e D a u g h e r t y , technical sales representative. Af f i l i a t ion : The Lincoln Elect r ic Co. Act iv i ty : Section member s met to plan the u p c o m i n g year ' s mee t - ings and to approve an acceptab le budget.

SEPTEMBER 21 Speakers: S p e n c e r B u r n s i d e , fab- r ica t ing manager, and A d r i a n H i lbeck , training manager. Aff i l ia t ion: Pennsylvania Trans- former Tech., Inc., Cannonsburg, Pa.

Act iv i t y : The Sect ion toured this more than 1,000,000 f t 2 facility.

• COLUMBUS SEPTEMBER 14 Speaker: R o b e r t J . Tabern ik ,AWS District 7 director. Affi l iat ion:The Lincoln Electric Co. Topic:Waveform ControlTechnology. Activi ty: Vice President R i c h a r d A r n at tended the meet ing and discussed his rise from welding tech- nologist to vice president and in- coming president of AWS. Section- Vice Chairman/Treasurer T o m K u n t z m a n discussed his recent visit to AWS headquarters for the AWS Na- tional Leadership Symposium.

OCTOBER 14 Speaker: L o r n e Weeter , director of sales. Aff i l ia t ion: Motoman Inc., Troy, Ohio.

• PASCAGOULA SEPTEMBER 14 Speaker: William D o w d e n , director of safety. Affil iation: Nordeen Smith. Topic: Safety in the workplace.

OCTOBER 14 Speaker: G e o r g e J o n e s , construction superintendent. Affiliation: Ingalls Shipbuilding. Topic: Commercial shipbuilding. Act iv i t ies: The Pascagoula Sect ion has a Professional Welders Honor Program where two area welders (one from pipe and one from structural) are selected for excel lence in their profession. At this meet ing, Mr. S t r i n g f e l l o w , a weld ing instructor at Ingalls Shipbuilding, was honored as the best s t ructural welder at Ingalls. Cleo N icho l s was se lec ted as Ingalls 's best p ipe welder. S teve B r o w n received the District Di rec tor ' s Award for his work in put t ing toge ther the Pascagoula Sect ion 's annual golf tournament.


New Orleans Section Chairperson Marie I:l,gate and First Vice Chairman John Pajak, right, present guest speaker Patrick Hoyt, left, with a speaker's award.

• NORTHEAST MISSISSIPPI SEPTEMBER 21 Act iv i ty : R o b e r t B r e l a n d con - d u c t e d a t o u r o f t h e B e c h e t e l Red Hills P ro jec t p lan t .

• GREATER HUNTSVILLE SEPTEMBER 28 Speaker: H a r r e l l B e n n e t t , Dis t r ic t 8 director . Aff i l iat ion:American Weld ing Soci- ety. A c t i t i e s : J o e S m i t h w a s a w a r d e d t h e S e c t i o n E d u c a t o r A w a r d a n d a M e r i t o r i o u s Ce r t i f i c a t e b y D i s t r i c t 8 D i r e c t o r H a r r e l l B e n n e t t . Ben- n e t t p r e s e n t e d J i m T h o m s o n w i t h t h e D i s t r i c t E d u c a t o r A w a r d , t h e D a l t o n E. H a m i l t o n M e m o r i a l C W I A w a r d a n d t h e Dis t r i c t CWI of t h e Year Award .

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

• NEW ORLEANS SEPTEMBER 19 Speaker: P a t r i c k H o y t , c h i e f welding e n g i n e e r . Aff i l ia t ion: Li t ton A v o n d a l e Indus - t r ies , Avonda le , La. Topic:Titanium weld ing .

OCTOBER 17 Speaker: N a n c y M c A f e e , n a t i o n a l a c c o u n t r e p r e s e n t a t i v e . Aff i l iat ion: 3M Co., H o u s t o n , T e x . Topic: R e s p i r a t o r y h a z a r d s for we lders .

Cleveland Section Skills USA Repre- sentative and Education Chairman Dan Harrison, left, presenting Steve Houston with a speaker's gift.

• BATON ROUGE SEPTEMBER 20 Speaker: T o m H o w a r d , c h a i r m a n of s t u d e n t affairs. Af f i l ia t ion:AWS B a t o n R o u g e Sec- t i on a n d Air Liquide. Topic: Careers in weld ing . Act iv i ty: T h e S e c t i o n h e l d C a r e e r Night w i t h 59 h i g h s c h o o l s t u d e n t s f r o m f ive a rea s c h o o l s a t t e n d i n g . V e n d o r s h e l d d e m o n s t r a t i o n s a n d d i s t r i b u t e d i n f o r m a t i o n o n c a r e e r s in w e l d i n g to s t u d e n t s and pa ren t s . T h e e v e n t was s p o n s o r e d by t h e C e n t r a l High Schoo l , B a t o n Rouge S tuden t Chapter .

• MOBILE SEPTEMBER 21 Speaker: S i m o n T h o r n t o n , v i c e p r e s i d e n t , o p e r a t i o n s . Affi l iat ion: Austal USA. Topic:Austal's p l a n s for a n e w alu- m i n u m s h i p y a r d to b e c o n s t r u c t e d in Mobile .

Mobile Section Past Chairman Johnny Dedeaux, right, present ing guest speaker Simon Thornton with a speaker's plaque.

New Orleans Section Chairperson Marie Lygate, left, and First Vice Chairman John Pajak present guest speaker Nancy McAfee wi th a speaker's gift.

D I S T R I C T I 0 Director: Victor Y. Matthews

Phone: ( 2 1 6 ) 3 8 3 - 2 6 3 8

• CLEVELAND SEPTEMBER 12 Speaker: S t e v e H o u s t o n , t ra iner . Affi l iat ion: H o b a r t B r o t h e r s . Topic:The w e l d e r t r a i n i n g p r o g r a m d e v e l o p e d by Steve H o u s t o n for Ho- ba r t Bro thers . Activ i ty:The Sec t ion ' s n e w of f icers w e r e i n t r o d u c e d at a c l a m b a k e din- ner.

• NORTHWESTERN PENNSYLVANIA SEPTEMBER 14 Activity: T h e Sec t ion he ld its a n n u a l go l f o u t i n g at t h e C u l b e r t s o n Hills Gol f C o u r s e in Ed inbo ro , Pa. Eighty g o l f e r s a t t e n d e d t h e f o u r - m a n s c r a m b l e a n d d i n n e r . B o b K n e p - p e r , J a c k L u x , J i m W h i t e h i l l a n d I s r e a l S h a b t a i of G e n e r a l E lec t r i c w o n t he sc ramble .

78 J DECEMBER 2000

Detroit Sectiott 2000 academic sct~olarshi[) tvimters, bacL~ row, left to r~q,t~t, Joel Diller, Andrew Dake, Bill England, Jef f Albrecht, Jerome Meldrum, Jared Medler, f ron t row, left to right, Wesley Doneth, Chris Soule, Chad Schondehnayer, Troy Bittner, Chris Knaffle, Jeremy Purmala, Keven Fleming and Kyle Dockery.

St. Lottis Sect~oH members pose dl lDeir A'eptember ])laltt tour st/ the Hillsdale Fabricators facility, j~om left, J im Black, speaker Larry Ingram, Christine, Glenn Kayser and Mike Kamp.

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

• DETROIT SEPTEMBER 14 Speakers: J a m e s Ward , A a r o n Hausch i ld t , R ichard C a r l s o n and Er ic Urbas . Affiliations: General Motors Corp, Ford Motor Co., General Motors Corp. and Ford Motor Co., respectively. Topic: Life (Work!) - - the transformation to profitability. Activi ty: The Sect ion awarded $30,500 in academic scholarships to 15 outs tanding s tudents at Fer-

ris State Univers i ty and Washt- enau Com- m u n i t y C o l l e g e . W e s l e y D o n e t h of F e r r i s State was a w a r d e d the James W. Mitchell S c h o l a r - ship and J e r e m y P u r m a l a , also a stu-

dent at Ferris State, was awarded the Rober t L.Wilcox Scholarship. The Sect ion awarded more than $5300 in scho la r sh ips to the top finalists in the 2000 Detro i t Area High School Welding Contest . Scholarship winners included J e f f A l b r e c h t , J o e l D i l l e r , A n d r e w D a k e , J e r o m e M e l d r u m , Bi l l E n g l a n d , J a r e d M e d l e r , Chris Sou le , C h a d S c h o n d e l m a y e r , T r o y B i t t n e r , C h r i s K n a f f l e , K e v e n F l e m i n g and K y l e D o c k - ery .

• WESTERN MICHIGAN SEPTEMBER 25 Speaker: R o n Leibovi tz . Aff i l ia t ion: Unitrol Elec t ronics , Inc., Northbrook, Ill.

Three member s o f the w inn ing f o u r s o m e o f the Nor thwes tern Pennsylvania gol f scramble, f r o m left, Bob Knepper, Jack Lux and J im Whitehill.

Topic:The study of wa te r f low and temperature and its effects on resistance welding electrodes.

• FOX VALLEY OCTOBER 7 Act iv i ty:The Section held a Sport- ing Clay Shoot event at the J & H Hunting Club and Game Farm.After the clay rounds, a l uncheon was served in the clubhouse

OCTOBER 10 Speaker: D e n n i s Harwig , manager/principle engineer. Aff i l ia t ion: Edison Welding Insti- tute, Columbus, Ohio. Topic: An in tegra ted approach to arc welding optimization.

• NORTHWEST OHIO OCTOBER 10 Speaker: R i c h M e n z e l , publ ic re- lations. Aff i l ia t ion: North Star BHP Steel Co., Delta, Ohio. Activity: The Sect ion toured the North Star BHP Steel plant and saw everything from the melting of raw materials to casting billet slabs to the final coiled sheet steel product.

D I S T R I C T 1 2 D i r e c t o r : 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

• MILWAUKEE SEPTEMBER 14 Activi ty: One hundred and thi r ty members of the Section toured the nearly c o m p l e t e d Miller Park, wh ich will be the new h o m e for the Milwaukee Brewers w h e n it opens in April 2001.


Guest 3"pealeer Mike Anderson, center, accepting a speaker's award from Indiana Sec- tion Chairman Joe Daumeyer, left, and Vice Chairman Kevin Lynn.

Lexington Section Chairman P)-ank McKinley, left, presenting Wayne Reece with a speaker's gift.

• LAKESHORE OCTOBER 12 Speaker: Missy S p a r r o w s , wildlife biologist. Affi l iation: Dept . of Natural Re- sources. Topic: Wetlands conserva t ion programs and a wildl ife slide presentation.

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

• ST. LOUIS SEPTEMBER 14 Speaker: Lar ry I n g r a m . Affiliation: Hillsdale Fabricators. Topic: Structural steel fabrication.

Lexingto,t Section member and Welding Inslructor Alan Mattox, left, congratulating scholarship winners, from right, Jason Woolery, Jacob Bradford, and Jonathan Jones.

Activity: The Section toured the Hillsdale Fabricators facility.

• INDIANA SEPTEMBER 18 Speaker: Mike A n d e r s o n , welding instructor. Affiliation: New Castle Area Voca- tional School. Topic: Level 1 and Level 2 education and curr iculum in Indiana.

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

• NORTHWEST SEPTEMBER 20 Activity: The Section toured the Donaldson Company plant in Bald- win,Wis. Chuck Ash, plant manager of Donaldson, led the tour.

• MISSISSIPPI VALLEY SEPTEMBER 21 Activity:The Section held its Annual Fish Fry Social.

• TRI RIVER SEPTEMBER 21 Speaker: J o h n D u r b i n , Welding Depar tment and Section chairman. Affiliation: Ivy Tech State College, Evansville, Ind. Topic: Oxyace ty l ene cu t t ing and welding safety.

• LEXINGTON SEPTEMBER 28 Speaker: W a y n e R e e c e , dis t r ic t manager. Affiliation: Miller Electric Mfg. Co. Topic:The project car for Miller 31- Ford NASCAR weld ing . One hundred and twen ty peop le a t t ended the meeting.

OCTOBER 2 Activity: District scholarships were awarded to J o n a t h a n J o n e s , J a c o b B r a d f o r d and J a s o n Woole ry .

D I S T R I C T 16 D i r e c t o r : C. F. B u r g

P h o n e : ( 5 1 5 ) 2 9 4 - 5 4 2 8

• KANSAS CITY SEPTEMBER 14 Speaker: K e v i n J o h n s t o n , welding specialist. Affiliation: Kansas City Power and Light Company. Topic:The Section toured the new bo i le r units and cons t ruc t i on . Members d iscussed the failure of unit #5 and what caused it.

• SIOUXLAND SEPTEMBER 21 Speaker: Merle Meade, welding in- s t ruc tor and Regional Educator of the Year. Affiliation: Northeast Communi ty College, Norfolk, Neb. Topics: What is the American Weld- ing Society? And ten things industry can do to improve welder personnel re tent ion and recruitment.

80 I DECEMBER 2000

Northwest Section Chairman Mike Hanson, right, presenting a speaker's plaque to Chuck Ash.

Guest speaker Kevin./obnston addressing the Kansas City Section at the Kansas City Power and Light Company in September.

Sabine Section Clmirmalt Care 3, I~{,s- ley, left, presents a speaker's gift to Don Mills.

Activity: The Section toured Kol- berg-Pioneer in Yankton, S.D., cour- tesy of Section Chairman R o b e r t Olsen.

DISTRICT 17 D i r e c t o r : O r e n P. R e i c h P h o n e : ( 2 5 4 ) 8 6 7 - 2 2 0 3

• EAST TEXAS SEPTEMBER 14 Speaker:Jim Mumaw, staff engineer, Robotics and Automation Group. Af f i l ia t ion: The Lincoln Electric Co., Cleveland, Ohio. Topic: Robotics appl icat ion for welding

• OZARK SEPTEMBER 20 Speaker: Richa rd L. Ho ld ren , P.E. Topic: Future t rends in welding technology

Puget Sound &,ctioH Chairman A2,n Johnson, right, presenting Gordy Robertson with an AWS Outstand- ing Contributions Award.

DISTRICT 18 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

• SABINE SEPTEMBER 19 Speaker: D o n Mills , district manager. Aff i l ia t ion: Specialized Mainte- nance, Inc. Topic: Chemical cleaning of piping and equipment.

DISTRICT 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. 120

• PUGET SOUND OCTOBER 5 Speaker: A.J . Shenk .

San D i ~ o Section Chairman Mike Kitten presents a speaker's gif t to Bernard Mannion.

Af f i l ia t ion: In t e rcon Enterpr ises Inc. Topic: Pipe GTAW and the p rope r use of pu rg ing along wi th o ther GTAW pipe welding accessories by Intercon. Activity: Gordy Robe r t son was presented with the AWS Outstanding Contr ibut ions Award for his unfail- ing support for more than 26 years.

DISTRICT 20 Direc tor : Ne i l R. K ir sch

P h o n e : ( 9 7 0 ) 8 4 2 - 5 6 9 5

COLORADO SEPTEMBER 14 Speaker: D e n n i s Bart ley, sterilization facility manager. Affiliation: Cobe Labs Sterilization Services.


• F o x Val ley S e c t i o n to H o l d ASME S e c t i o n IX S e m i n a r

o n T h u r s d a y a n d Friday, J a n u a r y 4 a n d 5, 2 0 0 1 , t h e A W S Fox Val ley Sec t ion wil l h o l d a s e m i n a r d e v o t e d to ASME Sec t i on IX.This i n t en - s ive t w o - d a y s e m i n a r c o v e r s t h e r e q u i r e m e n t s of ASME Bo i l e r a n d

P r e s s u r e Vessel C o d e S e c t i o n I X . T h e o b j e c t i v e of t h e s e m i n a r is to i m p a r t t h e k n o w l e d g e a n d e x p e r i e n c e n e c e s s a r y to p r o p e r l y p r e p a r e w e l d i n g pro- c e d u r e s a n d qual i fy t h e p r o c e d u r e s a n d p e r s o n n e l .

Th i s c o m p r e h e n s i v e s e m i n a r f e a t u r e s t h e fo l lowing :

Day One • W r i t i n g a d e q u a t e a n d u n d e r s t a n d a b l e W e l d i n g P r o c e d u r e Speci f ica-

t ions . In a d d i t i o n to t he ASME IX, focus wil l be p l a c e d o n h o w to deal w i t h c o n s t r u c t i o n c o d e r e q u i r e m e n t s a n d o t h e r r e s t r i c t i o n s .

• R e v i e w of t h e c o m m o n m anua l , s e m i a u t o m a t i c a n d a u t o m a t i c welding p r o c e s s e s .

• H o w bas ic s tee l m e t a l l u r g y is a d d r e s s e d by t he Code. • H o w fi l ler m e t a l s are a d d r e s s e d by t h e Code. • P l a n n i n g , p r e p a r i n g , c o n d u c t i n g a n d d o c u m e n t i n g p r o c e d u r e qual i-

f i c a t i on tes ts . • N o t c h t o u g h n e s s a n d s u p p l e m e n t a r y e s sen t i a l var iab les .

Day Two • An o v e r v i e w of c h a n g e s to ASME IX. • R e v i e w of P e r f o r m a n c e Q u a l i f i c a t i o n v a r i a b l e s fo r m a n u a l , s emiau -

t oma t i c , m a c h i n e a n d a u t o m a t i c p r o c e s s e s . • Basic p e r f o r m a n c e qua l i f i c a t i on r e q u i r e m e n t s . • Planning, conduc t ing and d o c u m e n t i n g pe r fo rmance qualification tests. • C o n t i n u i t y and Qua l i f i c a t i on r e n e w a l s .

W e l d i n g p r o c e d u r e s a n d w e l d e r q u a l i f i c a t i o n s u s u a l l y p r e s e n t c o m - p l e x c h a l l e n g e s . A m o n g t h e p r o b l e m a reas a re f a i lu re to a d d r e s s all of t h e v a r i a b l e s , u n q u a l i f i e d p r o c e d u r e s for t h e j o b a n d / o r w e l d e r s n o t b e i n g qua l i f i ed for t h e p r o c e d u r e or t h e j o b . T h i s s e m i n a r wil l a d d r e s s all of t h e s e p r o b l e m s a n d wi l l p r o v i d e you w i t h s o l u t i o n s . In a d d i t i o n , t h e s e m i n a r m e e t s t h e c o n t i n u i n g e d u c a t i o n r e q u i r e m e n t s for CWI n i n e - y e a r r e n e w a l s . P a r t i c i p a n t s wi l l b e a w a r d e d a C e r t i f i c a t e o f C o m p l e t i o n c e r t i f i e d b y t h e p r e s e n t e r a n d t h e Fox Valley S e c t i o n ' s E d u c a t i o n C h a i r m a n .

T h e c o s t of t h e s e m i n a r is $425 for AWS m e m b e r s a n d $475 fo r n o n - m e m b e r s . T h e A S M E IX C o d e Book c a n b e p u r c h a s e d for an a d d i t i o n a l $225.

R e g i s t r a t i o n d e a d l i n e is D e c e m b e r 15 .To r e g i s t e r fo r t h e s e m i n a r o r fo r f u r t h e r i n f o r m a t i o n , w r i t e AWS S e m i n a r C o o r d i n a t o r , N 5 6 1 1 V e e s e r Lane, L u x e m b u r g , W I 54217 or cal l ( 9 2 0 ) 8 4 5 - 5 9 9 2 . 0

• Sect ion 106 Reorganized and Renamed West Tennessee Sect ion

s ec t ion 106, previously the Mem- ph i s Sect ion , has b e e n reorga- n i zed and is n o w the West Ten-

nessee Section. The West Tennessee Section will

be h e a d q u a r t e r e d in J ackson ,Tenn . , at t he Tennessee Techno logy Center. All AWS m e m b e r s are w e l c o m e and v e n d o r s are inv i t ed to a t t e n d mee t - ings w h e n t he m e e t i n g s c h e d u l e is announced . •

• District Director Awards

T Ihe D i s t r i c t D i r e c t o r A w a r d s p r o v i d e s a m e a n s for Dis t r ic t D i r e c t o r s to r e c o g n i z e indi -

v iduals w h o have c o n t r i b u t e d t h e i r t i m e a n d e f f o r t to t h e a f fa i r s o f t h e i r local Sec t ion a n d / o r Distr ict .

D i s t r i c t 17 D i r e c t o r O r e n Re ich , p r e s e n t e d t h e f o l l o w i n g in h is D i s t r i c t w i t h th i s award :

• Paul Morgan, Tulsa

• P h i l Walker, Ozark

• Richard H o f f m a n , Ozark

Activity: T h e S e c t i o n t o u r e d t h e s ta te-of- the-ar t s te r i l i za t ion facility.

SEPTEMBER 2 5 - 2 9 Speaker: R i c h C a m p b e l l , instructor. Activity:The S e c t i o n h e l d a n AWS s e m i n a r for CWI a n d CWE te s t i ng . T w e n t y - t h r e e s t u d e n t s a t t e n d e d t he seminar .

SEPTEMBER 30 Speaker: Galen Altman, SCWI and t e s t supe rv i so r .

Affiliation:American W e l d i n g So- ciety. Topic:AWS Tes t i ng for SCWI, CWI, CWE and CAWI. Activity: For ty m e n a n d w o m e n took t he CWI tes t in Denver .

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

• SAN D I E G O SEPTEMBER 13 Speaker: Bernard Mannion. Affiliation: P r o - F u s i o n T e c h n o l o -

gies, N e w b u r y Park, Calif. Topic: Orb i t a l a n d a u t o m a t i c we ld - ing la thes .

• HAWAII SEPTEMBER 20 Speaker: R a y J a b l o n s k i , S e c t i o n c h a i r m a n . Affilia tio n: AWS. Activity:The Dist r ic t C o n f e r e n c e in San Diego. •

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

82 J DECEMBER 2000

• 2000 -2001 Member-Get-A-Member Campaign Lis t ed b e l o w are the p e o p l e p a r t i c i p a t i n g in the 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 . For a l ist o f ru le s

a n d pr izes , p l ease see p a g e 83 o f this 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 cal l t he M e m b e r s h i p D e p a r t m e n t a t

(8(70) 443-9353 ext. 270.

W i n n e r ' s Circle (AWS Members sponsoring 20 or more

new members since June 1, 1999)

J. Compton, San Fernando Valley - - 6 8

E. H. Ezell, M o b i l e - - 35 B.A. Mikeska, H o u s t o n - - 24 W. L. Shreve, Fox Valley - - 22 J. Merzthal, P e r u - - 21 R. Wray, N e b r a s k a - - 21

Pres ident ' s Gui ld (AWS Ind iv idua l Members sponsoring

20 or more n e w I n d i v i d u a l Members

be tween J u n e 1, 2000, a n d May 31,

2001.)

J. Merzthal, Peru - - 21

Pres ident ' s R o u n d t a b l e (AWS Ind iv idua l Members sponsoring

11 -19 n e w I n d i v i d u a l Members be-

tween June 1, 2000, and May 31, 2001.)

A. O. Smith III, Tulsa - - 12 L.J. Smith, H o u s t o n - - 12

Pres ident ' s Club (AWS m e m b e r s sponsor ing 6 - 1 0 n e w

Ind i v idua l Members be tween J u n e 1,

2000, and May 31, 2001.)

J. Compton, San Fernando Valley - - 9

W. R. Beck, R o c h e s t e r - - 8

G.Taylor, P a s c a g o u l a - - 6

R. Buse, M o b i l e - - 6 D. Hatfield - - 6

Pres ident ' s H o n o r Rol l (AWS members sponsoring 1-5 new In-

d i v idua l Members be tween J u n e 1,

2000, a n d 21~ay 31, 2001. Only those

sponsor ing 2 or more AWS Ind iv idua l Members are listed.)

J.T. Blank, N o r t h e r n M i c h i g a n - - 5 H. E. Cable, Sr., P i t t s b u r g h - - 4

E Soto, N e w J e r s e y - - 4

C.-L.Tsai, C o l u m b u s - - 4

J. Rosado, P u e r t o Rico - - 3 J. Craft, Lou i sv i l l e - - 2

D. S. Dodds, P i t t s b u r g h - - 2 E. Ezell, M o b i l e - - 2

J. Gump, M a r y l a n d - - 2 R. H a n n a n , J A K - - 2

J. Koster, Western M i c h i g a n - - 2

E Larzabal, Corpus Chr is t i - - 2

M. Mott, Flor ida West Coas t - - 2 I. C. Pierre, N e w York - - 2

G.Teague, E a s t e r n Caro l i na - - 2

R.Teuscher, Colorado - - 2

M. W e e k s , S a b i n e - 2

G.Williams, S a n g a m o n Valley - - 2 D. Wright, K a n s a s - - 2

S t u d e n t S p o n s o r s (AWS m e m b e r s sponsor ing 3 or more

AWS Student Members are listed.)

G . W o o m e r J o h n s t o w n / A l t o o n a - - 20 P. Baldwin, Pe or ia - - 16 T. S t r i c k l a n d , A r i z o n a - - 13 C.AIonzo, San A n t o n i o - - 7

B. Patchett , N o r t h e r n M i c h i g a n - - 7 D. Hatfield - - 6 D. Nelson, P u g e t S o u n d - - 5

R. Rux, W y o m i n g - - 5 M.Tait, Los Ange l e s - - 4

J.T. Blank, N o r t h e r n M i c h i g a n - - 3

W. L. Galvary, Jr., L o n g B e a c h - - 3 R. Grays, K e r n - - 3 J. D. Sanders, H o u s t o n - - 3

J. H. Smith, M o b i l e - - 3 W. R. Beck, R o c h e s t e r - - 2 •

S E C T I O N E V E N T S

C A L E N D A R

• NEW JERSEY DECEMBER 19 A c t i v i t y : M a n u f a c t u r e r s ' Night .Al l ma jo r m a n u f a c t u r e r s wil l be in at- t endance .

JANUARY 16 Miller Electr ic . Topic :To be a n n o u n c e d .

FEBRUARY 20 Thermal Dynamics. Topic: Simple automation for plasma arc cutters.

• FOX VALLEY JANUARY 4 AND 5, 2001 A c t i v i t y : A S M E Sect ion IX Seminar. L o c a t i o n : P a p e r Valley H o t e l and C o n f e r e n c e Cen te r , (920) 733- 8000. For f u r t h e r i n f o r m a t i o n o r to register, call (920) 845-5992.

• ISO/TC44 Meet in Paris

M e m b e r s o f lhe ISO/TC4.t WeMing a n d Al l ied Processes C o m m i t t e e m e t a t the

I n s t i t u t de S o u d u r e in Paris , France , o n S e p t e m b e r 14 a n d 15. P i c t u r e d in

f r o n t o f the l n s t i t u t are, f r o m left to right, I n t e r n a t i o n a l S t a n d a r d s Ac t i v i t i e s C o m m i t t e e ( ISAC) C h a i r m a n W a i t e r Sperko , A WS T e c h n i c a l A c t i v i t i e s C o m -

m i t t e e (TAC) Chair N a n c y Cole, 1SAC Secretary A n d r e w Davis , ISAC Vice Chair-

m a n D a m i a n K o t e c k i a t zd I S O / T C 4 4 / S C 5 , Tes t ing a n d I n s p e c t i o n o f We lds C h a i r m a n H e n r y Hahn .

WELDING JOURNAL 18s

T A N A R N O T I C E S

S t a n d a r d s f o r P u b l i c R e v i e w

AWS was approved as an accredited s tandards-prepar ing organiza- t ion by the American National Stan- dards Institute (ANSI) in 1979. AWS rules, as approved by ANSI, requi re that all s tandards be open to public review for c o m m e n t during the approval process. This column also ad- vises of ANSI approval of documents. The fo l lowing standards are submitted for public review. A copy may be obta ined by s e n d i n g the a m o u n t shown to AWS Technica l Dept., 550 N.W. LeJeune Rd., Miami, FL 33126, or by call ing (800) 334-9353.

A5.7-84, Specif icat ion f o r Copper and Copper Alloy Bare Welding Rods and Electrodes. Reaffirmed standard. $4.50. [ANSI Publ ic Re- view expires December 19, 2000.]

c5 .2 :200x , R e c o m m e n d e d Prac- tices f o r Plasma Arc Cutt ing and Gouging. Revised standard. $18.00. [ANSI Publ ic Review expires Janu- ary 16, 2001.]

ISO D r a f t S t a n d a r d s f o r P u b l i c R e v i e w

Cop ies o f the f o l l o w i n g Draf t I n t e r n a t i o n a l S t a n d a r d s a r e a v a i l a b l e f o r r e v i e w a n d c o m - m e n t t h r o u g h y o u r n a t i o n a l s t a n d a r d s b o d y , w h i c h i n t h e U n i t e d Sta tes is ANSI, 11 West 4 2 n d S t r ee t , New York , NY 10036; t e l e p h o n e (212) 642- 4900 . A n y c o m m e n t s r e g a r d i n g ISO d o c u m e n t s s h o u l d be s e n t to y o u r n a t i o n a l s t a n d a r d s body .

I n t h e U n i t e d S ta tes , i f y o u w i s h to p a r t i c i p a t e i n t h e deve l - o p m e n t o f I n t e r n a t i o n a l S t an - d a r d s f o r w e l d i n g , c o n t a c t An- d r e w D a v i s a t AWS, 550 N.W. L e J e u n e Rd. , M i a m i , FL, 33126; t e l e p h o n e ( 3 0 5 ) 4 4 3 - 9 3 5 3 ex t . 466, e - m a i h a d a v i s @ a w s . o r g . O t h e r w i s e c o n t a c t y o u r n a t i o n a l s t a n d a r d s b o d y .

ISO/DIS 14345, Fatigue Testing o f Welded Components.

ISO/DIS 14373, Welding - - Resis- tance Spot Welds -- Procedure f o r Spot Welding o f Uncoated and Coated Low Carbon and High Strength Steels.

R e v i s e d S t a n d a r d A p p r o v e d b y ANSI

A5.13:2000, Specif icat ion f o r Sur- fac ing Electrodes f o r Shielded Metal Arc Welding. Approval date: September 7, 2000.

B2.1-1-210:2000, Standard Welding Procedure Specification (WPS) for Gas Tungsten Arc Welding wi th Consumable Inserts o f Carbon Steel (M-I/P-I/S-1, Group 1 or 2), % through 1% Inch Thick, INMs-1 and ER70S-2, As-Welded or PWHT Condition, Primari ly Pipe Applica- tions. Approval date: Oc tobe r 9, 2000.

B2.1-1-211:2000, Standard Welding Procedure Specification (WPS) fo r Gas Tungsten Arc Welding wi th Consumable Inserts Followed by Shielded Metal Arc Welding o f Car- bon Steel (M-I/P-I/S-1, Group 1 or 2), % through 1 '/2 Inch Thick, INNs- 1, ER70S-2, and E7018, As-Welded or PWHT Condition, Primari ly Pipe Appl icat ions. Approval date: Octo- ber 9, 2000.

B2.1-8-024:2000, Standard Welding Procedure Specification (WPS) fo r Gas Tungsten Arc Welding o f Aus ten i t i c Stainless Steel (M-8/P- 8/S-8, Group 1), %through 1~ Inch Thick, As-Welded Condit ion. Ap- proval date: October 9, 2000.

B2.1-8-025:2000, Standard Welding Procedure Specification (WPS) fo r Gas Tungsten Arc Welding Followed by Shielded Metal Arc Welding o f Aus ten i t i c Stainless Steel (M-8/P- 8/S-8, Group 1), % through 1'/2 Inch Thick, As-Welded Condit ion. Ap- proval Date: October 9, 2000.

B2.1-8-212:2000, Standard Welding Procedure Specification (WPS) fo r Gas Tungsten Arc Welding o f Aus ten i t i c Stainless Steel (M-8/P- 8/S-8, Group 1), % through 1~ Inch Thick, ER3XX, As-Welded Condi- tion, Pr imar i ly Pipe Applicat ions. Approval date: October 9, 2000.

B2.1-8-214:2000, Standard Welding Procedure Specification (WPS) ) for Gas Tungsten Arc Welding Followed by Shielded Metal Arc Welding o f Aus ten i t i c Stainless Steel (M-8/P- 8/S-8, Group 1), % through 1½Inch Thick, ER3XX, E3XX-XX, As-Welded Condition, Primari ly Pipe Applica- tions. Approval date: Oc tobe r 9, 2000.

B2.1-8-215:2000, Standard Welding Procedure Specification (WPS) fo r Gas Tungsten Arc Welding wi th Consumable Inser t o f Aus ten i t i c Stainless Steel (M-8/P-8/S-8, Group 1), % through 1'/-, Inch Thick, IN3XX and ER3XX, As-Welded Condition, Pr imar i l y Pipe Appl icat ions . Ap- proval date: October 9, 2000.

B2.1-8-216:2000, Standard Welding Procedure Specification (WPS) fo r Gas Tungsten Arc Welding wi th Consumable Inser t Followed by Shielded Metal Arc Welding o f Aus ten i t i c Stainless Steel (M-8/P- 8/S-8, Group 1), % through 1¼ Inch Thick, IN3XX, ER3XXX, and E3XX- XX, As-Welded Condition, Primarily Pipe Appl ica t ions . Approval date: October 9, 2000. •

• Visit AWS o n t h e Web

The world of AWS is as just a click of the mouse away.While visiting the American Welding Society's Web site, you can renew your membership, buy books and standards, get scholarship applications and even look for a new job.To see what's on the AWS Web site for you, visit http:/www.aws.org. •

86 J DECEMBER 2000

• Sustaining Member Companies

A. O. Smith Corp. Milwaukee,Wis.

ABA Industries, Inc. Pinellas Park, Fla.

ABB Flexible Automation & Welding Systems Division Fort Collins, Colo.

ADB Industries Burbank, Calif.

A.E.E. Destructive & Non Destructive Testing Ltd. Kwai Tak Chung, Hong Kong

ABBALSTOM Power-Brazil Taubate, Brazil

AGA Gas Inc. Cleveland, Ohio

AGA General Gases San Juan, Puerto Rico

AGA S.A. Ecuador

AGA S.A. Peru

AK Steel Corp. Middletown, Ohio

Accudata, Inc. Clarklake, Mich.

Acute Technological Services, Inc. Houston,Tex.

Air Liquide America Corp. Walnut Creek, Calif.

Air Products & Chemicals, Inc. Memphis,Tenn.

Aker Gulf Marine Ingleside,Tex.

Alabama Shipyard, Inc. Mobile,Ala.

Aladdin Welding Products, Inc. Grand Rapids, Mich.

Alcoa Massena, N.Y.

Alcoa Rockdale,Tex.

Alcoa Cressona Operation Cressona, Pa.

Alcotec Wire Corp. Traverse City, Mich.

Alexander Binzel Corp. Frederick, Md.

Algoma Steel Inc. Ontario, Canada

All Star Bleachers Mfg., Inc. Lakeland, Fla.

Alpine Steel, LLC Las Vegas, Nev.

Aluminum Company of America Alcoa Center, Pa.

Aluminum Company of America Davenport, Iowa

Aluminum Company of America Wenatchee,Wash.

American Bureau of Shipping Paramus, N.J.

American Filler Metals Co. Houston,Tex.

American Torch Tip Co. Bradenton, Fla.

AMET Inc. Rexburg, Idaho

Arc Machines, Inc. Pacoima, Calif.

ARCONE,a Division of A.C.E. International Co., Inc. Taunton, Mass.

Arcos Alloys Mt. Carmel, Pa.

Arcsmith, Inc. Pittsburgh, Pa.

Arctec Alloys Ltd. Alberta, Canada

Artisan Industries, Inc. Waltham, Mass.

Arvin Industries Columbus, Ind.

Askaynak Istanbul,Turkey

Atlantic Marine, Inc. Mobile,Ala.

Atlantic Marine Holding Co. Jacksonville, Fla.

Atlas Welding Accessories, Inc. Troy, Mich.

Auburn Mfg., Inc. Mechanic Falls, Maine

Avondale Shipyards, Inc. New Orleans, La.

AZCO, Inc. Appleton,Wis.

BP Amoco Middlesex, England

Base Line Data, Inc. Portland,Tex.

Bath Iron Works Bath, Maine.

Beaird Industries Inc. Shreveport, La.

Bechtel Corp. San Francisco, Calif.

Belmont Technical College St. Clairsville, Ohio

Bender Shipbuilding & Repair Co. Mobile,Ala.

Benteler Automotive Galesburg, Mich.

Bethlehem Steel Corp. Bethlehem, Pa.

Bishop State Communi ty College Mobfle,Ala.

Black & Decker Hunt Valley, Md.

BMS, inc. Pearland,Tex.

BOC Gases Murray Hill, N.J.

Bohler Thyssen Welding USA, Inc. Stafford,Tex.

Bombardier Concarril S.A. de C.V. Estado Hidalgo, Mexico

Bortech Corp. Keene, N.H.

Boss Mfg. Co. Kewanee, Ill.

Brown and Root, Inc. Houston,Tex.

Browne Dreyfus Int'l, Ltd. New York, N.Y.

Bug-O Systems Pittsburgh, Pa.

Burco Welding & Cutting Products, Inc. Burlington, N.C.

CK Worldwide Inc. Auburn, Wash.

CNH Global N.V. Racine,Wis.

CRC-Evans Automatic Welding Houston,Tex.

C-Spec Pleasant Hill, Calif.

Carolina Steel Corp. Greensboro, N.C.

Caterpillar, Inc. Peoria, Ill.

Cee Kay Supply Inc. St. Louis, Mo.

Cement Industries, Inc. Ft. Myers, Fla.

Centerline,Windsor Ltd. Detroit, Mich.

Centricut, LLC West Lebanon, N.H.

Cerbaco Ltd. Brooklyn N.Y.

Certanium Alloys & Research Co. Cleveland, Ohio

Certified Welding Bureau Chicago, Ill.

Chart, Inc. Burnsville, Minn.

Charles E. Daily Welding & Management Consultant Kirkland, Wash.

Chasma Nuclear Power Project lslamabad, Pakistan

Chicago Bridge & Iron Houston,Tex.

Chevron Research & Technology Co. Richmond, Calif.


Cigweld Victoria,Australia

College of the Canyons Valencia, Calif.

College of Eastern Utah Price, Utah

Columbia Energy Group Herndon,Va.

Communi ty College of Southern Nevada Henderson, Nev.

Concurrent Technologies Corp. Johnstown, Pa.

Conoco, Inc. Houston,Tex.

Controls Corp. of America Virginia Beach,Va.

Cooperheat Inc. Piscataway, N.J.

COR-MET Inc. Brighton, Mich.

DaimlerChrysler Corp. Auburn Hills, Mich.

Cranfield University, Welding Engineering Research Center Bedfordshire, United Kingdom

DBI, Inc. Milford, Neb.

Detroit Edison Co. Detroit, Mich.

Devasco Int'l Inc. Houston,Tex.

Dickson GMP Int'l Belle Chase, La.

Dimet rics-Merric/Taliey Industries Davison, N.C.

Direct Wire & Cable Denver, Pa.

Dixie Metal Products Inc. Ft. Lauderdale, Fla.

Conaldson Co., Inc. Bloomington, Minn.

Doosan Mfg. Co. Ltd. Kyung, Korea

DOVATECH Ltd. Beecher, Ill.

Dow Chemical Co. Freeport,Tex.

Dresser Rand-Turbo Products Div. Olean, N.Y.

Eagle Bending Machines, Inc. Stapleton,Ala.

Eastman Chemical Co. Kingsport,Tenn.

Eastman Kodak Co. Rochester, N.Y.

Edison Welding Institute Columbus, Ohio

Edison Welding Insti tute- Technical Div. Columbus, Ohio

E.G. HeUer's Son Inc. Tarzana, Calif.

E. H.Wachs Co. Wheeling, Ill.

ELCO Enterprises, Inc. Clarklake, Mich.

Electrodos Oerlikon Colombia Bogota, Columbia

Electron Beam Technologies, Inc. Kankakee, Ill.

Electronics Research, Inc. Chandler, Ind.

Emhart Fastening Teknologies- a Black & Decker Company New Haven, Conn.

Emirates Building Systems, LLC Dubai, U.A.E.

Empresas Hopsa, S.A. Republic of Panama

Engineering & Materials Group Columbus, Ohio

Erlikon Metal Mfg. Co. S.A. Athens, Greece

ESAB Welding & Cutting Products Hanover, Pa.

ESAB Group, Inc. Equipment-Automation Florence, S.C.

Essex Group, Inc.- Division of Superior Essex Ft.Wayne, Ind.

Estructuras de Acero, D-G, S.A. Republic of Panama

Eutectic Corp. Charlotte, N.C.

EXSA, S.A. Lima, Peru

Exxon Research & Engineering Co. Florham Park, N.J.

Exxon Upstream Div. Co. Houston,Tex.

FTV Proclad,V.A.E., LLC Abu Dhabi, U.A.E.

FANUC Robotics North America Auburn Hills, Mich.

Federal Aviation Administration Oklahoma City, Okla.

Fibre-Metal Products Co. Concordville, Pa.

Filler Metals Inc. Pottstown, Pa.

Fisher Tank Co. Chester, Pa.

Florida Pneumatic Mfg. Co. Jupiter, Fla.

Florida Power & Light Co. Juno Beach, Fla.

Folsom State Prison- Dept. of Corrections Represa, Calif.

Franklin Electric Co. Bluffton, Ind.

Fraunhoffer Institut for Laser Technology Ann Arbor, Mich.

Friede Goldman Offshore Pascagoula, Miss.

Fuller and Co., Inc. Houston,Tex.

G.E.Aircraft Engines Evendale, Ohio

G. M. Powertrain Flint, Mich.

GSE Construction Co., Inc. Livermore, Calif.

GSI Lumonics Ontario, Canada

Gateway Amsafe, Inc. Cleveland, Ohio

Gauld Equipment Co. Theodore,Ala.

General Dynamics Land Systems Sterling Heights, Mont.

Genesis Systems Group Davenport, Iowa

Gibson Tube Co. North Branch, NJ.

Global Engineering Documents Irvine, Calif.

88 I DECEMBER 2000

Goss Inc. Glenshaw, Pa.

Greystone Adult School Vocational Welding P.I.A. Represa, Calif.

Grupo Zeta El Paso,Tex.

Gulf States Airgas Theodore,Ala.

Gullco Int'l Inc. Cleveland, Ohio

H20 2000 Corp. Clearwater, Fla.

Hacienda la Puenta Unified Saugus, Calif.

Harbert 's Products Inc./ Allied Flux Reclaiming Ltd. Greencastle, Pa.

Harnischfeger Industries P&H Mining Equipment Milwaukee, Wis.

Harris Calorific Div. Gainesville, Fla.

Harris/Welco King Mountain, N.C.

Henderson Mfg. Inc. Manchester, Iowa

Herrick Corp. Pleasanton, Calif.

H & H Sales Co., Inc. Hunter town, Ind.

H & M Pipe Beveling Machine Co., Inc. Tulsa, Okla.

Hornell Speedglas, Inc. Twinsburg, Ohio

Hougen Mfg. Inc. Swartz Creek, Mich.

Houma Industries, Inc. Harvey, La.

Hyd-Mech Saws Ontario, Canada

Hypertherm, Inc. Hanover, N.H.

ICM, Inc. Colwich, Kans.

IGM Robotic Systems, Inc. Menomonee Falls,Wis.

IQC Training & Services Privated Ltd. Chennai, India

ITF Engineered Valves Amory, Miss.

ICESA/MODICON Tlainepantla, Mexico

Idaho Testing & Inspection, Inc. Nampa, Ind.

Illinois Tools Works Piqua, Ohio

Inco Alloys Int'l Huntington,W.Va.

Indura S.A. Industria y Comercio Santiago, Chile

Industrial Gas Products & Supply Co. Bristol,Tenn.

Ingalls Shipbuilding Pascagoula, Miss.

International Training Inst. Alexandria,Va.

Interstate Welding Sales Corp. Appleton,Wis.

Inversiones Arco Metal, S.A. Aragua,Venezuela

Inweld Corp. Rod Factory Ambridge, Pa.

Ipsco Steel Alabama, Inc. Axis,Ala.

J & S Machine, Inc. Ellsworth,Wis.

J.A.Jones Construction Co. Charlotte, N.C.

J. P Nissen Co. Glenside, Pa.

J.W~ Harris Co., Inc. Cincinnati, Ohio

J.Walter Inc. Hartford, Conn.

Jackson Products, Inc. Chesterfield, Mo.

James Morton, Inc. Batavia, N.Y.

Jancy Engineering Co. Davenport, Iowa

Jeffboat Div.,A.C.M.S. Jeffersonville, Ind.

Jetline Engineering Inc. lrvine, Calif.

John Deere Co. Moline, Ill.

Johnson Controls, Inc. Plymouth, Mich.

KAPL, Inc. Schenectady, N.Y.

Kaplan Industries, Inc. Maple Shade, N.J.

Kawasaki Robotics, USA, Inc. Wixom, Mich.

Kayo Products Co. Ltd. Taiwan, P. R. of China

Kedman Co. Salt Lake City, Utah

Kellogg Brown & Root, Inc. Mobile,Ala.

Kemper USA, Inc. Atlanta, Ga.

Kennametal Inc. Latrobe, Pa.

Keystone Fastening Technologies, Inc. Pittsburgh, Pa.

Kimura Denyoki, Inc. Carson, Calif.

K & K Welding Products Lake Zurich, Ill.

Klingspor Abrasives, Inc. Hickory, N.C.

Kobelco Welding of America Inc. Houston,Tex.

Koike Aronson, Inc. Arcade, N.Y.

Komatsu Mining Systems, Inc. Peoria, Ill.

LA-CO Industries Inc. Markal Co. Chicago, Ill.

Lake Washington Technical College Kirkland, Wash.

Le Tourneau University Longview, Tex.

Liburdi Pulsweld Corp. Ontario, Canada

The Lincoln Electric Co. Cleveland, Ohio

The Lincoln Electric Co. Texas Sales Houston,Tex.

Link-Belt Construction Equipment Lexington, Ky.

Lockheed Martin Astronautics Group Denver, Colo.

Lockheed Martin Missiles & Fire Control Dallas,Tex.

Los Angeles Dept. of Water Los Angeles, Calif.

Lucas-Milhaupt Inc. Cudahy, Wis.

Machinery & Welder Corp. Menomonee Falls,Wis.

Mack Products Cleveland, Ohio

Madison Area Technical College Madison,Wis.

Magnatech-The DSD Co. East Granby, Conn.

MajorTool and Machine, Inc. Indianapolis, Ind.

Manitowoc Cranes, Inc. Manitowoc,Wis.

Marathon Oil Co. Houston,Tex.

MarionTesting & Inspection Collinsville, Conn.

Martinez Refining Co. Equilon Ent. Martlnez, Calif.

Mathey Dearman Tulsa, Okla.

Mauritzon, Inc. Chicago, Ill.

Matsuo Bridge Co. Ltd. Osaka,Japan

McDermott Int'l Inc. New Orleans, La.

McMahon Steel, Inc. San Diego, Calif.

McNeilusTruck and Mfg. Dodge Center, Minn.

Mechanical Contractos, S.A. Balboa, Republic of Panama


Meritor Automotive Troy, Mich.

Messer Welding Products Menomonee Falls,Wis.

Metal Industries Co., Ltd. Trinidad &Tobago West Indies

Metal Industries Development Center Kaohsuing, China

Metal Processing Systems, Inc. Schaumburg, IlL

Midstates Wire Crawfordsville, Ind.

Miller Electric Mfg. Co. Appleton, is.

Miller Electric Mfg. Co. Equipment Technology Ctr. Appleton,Wis.

Minnesota Depar tment of Transportation- Bridges and Structures St. Paul, Minn.

Mitsubishi Materials Corp. Irvine, Calif.

M K Products Inc. Irvine Calif.

Mohave Generating Station Laughlin, Nev.

Moltech Gainesville, Fla.

Motoman, Inc. West Carrollton, Ohio

Municipal Testing Hicksville, N.Y.

Nacco Materials Handling GRP Berea, Ky.

Nassau Research Corp. Aliquippa, Pa.

National Certified Pipe Welding Bureau Rockville, Md.

National Energy Skills Center La Romaine,Trinidad

National Standard Co. Niles, Mich.

Naval Surface Warfare Center Carderock Div. West Bethesda, Md.

Naylor Pipe Co. Chicago, Ill.

Nederman Inc. Westland, Mich.

Nelson Stud Welding Inc. Elyria, Ohio

Newcor Bay City Bay City Mich.

New Orleans Pipe Trades Metairie, La.

Newpor t News Shipbuilding & Dry Dock Co. Newport News,Va.

The Nippert Co. Delaware, Ohio

Nooter Corp. St. Louis, Mo.

Nordan SmithWelding Supplies Pascagoula, Miss.

Norfolk Southern Corp. Roanoke,Va.

Norris Cylinder Co. Longview, Tex.

Norton Co. Niagara Falls, N.Y.

OCI Wyoming LP Green River, Wyo.

Oshkosh Truck Corp. Oshkosh,Wis.

Osram Sylvania Inc. Towanda, Pa.

OTC America Inc. Charlotte, N.C.

Otis Elevator Co. Bloomington, Ind.

Ozarks Technical College Springfield, Mo.

PRL Industries Inc. Cornwall, Pa.

Pacific Technical Services Torrance, Calif.

Panasouic FactoryAutomation Franklin Park, Ill.

Pandjiris Inc. St. Louis, Mo.

Pangborn Corp. Hagerstown, Md.

Pennsylvania Power & Light Co. Allentown, Pa.

Penton Publishing, a Subsidiary of Pittway Corp. Cleveland, Ohio

PFERD Inc. Leominster, Mass.

Phillips Petroleum Co. Bartlesville, Okla.

Phoenix Int'l, Inc. Milwaukee,Wis.

Pinney Machinery & Supply Florence, Ky.

Plant Maintenance Service Memphis,Tenn.

Plymovent Corp. Edison, N.J.

Postle Industries Cleveland, Ohio

Potomac Airgas Inc. Linthicum, Md.

Pratt & Whitney East Hartford, Conn.

Praxair, Ankeny, Iowa

Praxair Inc. Tarrytown, N.Y

Praxair Inc. Hudson, Ohio

Praxair S.A. Peru

Precision Componen ts Corp. York, Pa.

Preston-Eastin, Inc. Tulsa, Okla.

Products Mexicanos Flex-Arc Lerma, Mexico

Public Transport Corp. Melbourne,Australia

Quality Inspect ion Services, Inc. Buffalo, N.Y.

Ransome Co. Houston,Tex.

Revco Industries Inc., Black Stallion Paramount, Calif.

Robinson Industries, Inc. Zelienople, Pa.

Roman Mfg., Inc. Grand Rapids, Mich.

Roy Smith Co. Detroit, Mich.

Saf-T-Cart, Inc. Clardsdale, Miss.

Salinas Valley State Prison Soledad, Calif.

Salvino Steel & Iron Works, Inc. Franconia, Pa.

Sandvik Steel Scranton, Pa.

Sciaky Inc. Chicago, Ill.

Selectrode Industries, Inc. Hunt ington Station, N.Y.

Sellstrom Mfg. Co. Palatine, Ill.

Serra Soldadura, S.A. Barcelona, Spain

Sewage & Water Board of New Orleans New Orleans, La.

Servo-Robot, Inc. Quebec, Canada

SGL Carbon Group Valencia, Calif.

Shanghai Grand Tower Steel Structure Co., Ltd. Shanghai, P. R. of China

Sheet Metal & Air Conditioning Chantllly, Va.

Siemens Westinghouse Power Corp. Orlando, Fla.

Smith Equipment Mfg. Co. LLC Watertown, S.D.

Soldadura Movil, S.A. Panama, Republic of Panama

Springs Fabrication, Inc. Colorado Springs, Colo.

Stoody Co. Bowling Green, Ky.

Stupp Brothers Bridge & Iron Co. St. Louis, Mo.

Superior Products, Inc. Cleveland, Ohio

Syncro Vac, Inc. Elgin,Tex.

90 [ DECEMBER 2000

Tatras, Inc., DBA Thermacut Claremont, N.H.

Taylor-Wharton Theodore,Ala.

Technalloy Co. Inc. Baltimore Div. Baltimore, Md.

TechniWeld Products Corp./RobinsonTech Ontario, Canada

Technostyle Ltd. Kaminia, Greece

Tempil Inc. South Plainfield, N.J.

Testwell Laboratories, Inc. Ossining, N.Y.

Texas Eastman Co. Longview, Tex.

Thermadyne Industries St. Louis, Mo.

Thrall Car mfg. Co. Cartersville, Ga.

Thrall Car Mfg. Co. Chicago Heights, Ill.

Thrall Car Mfg. Co. Clinton, Ill.

Thrall Car Mfg. Co. Winder Georgia Facility Winder, Ga.

Thrall Europe York, United Kingdom

TienTai Electrode Co. Ltd. Taiwan, P. R. of China

Tower Automotive Milwaukee, Wis.

Tregaskiss Ltd. Ontario, Canada

Triangle Engineering Inc. West Hanover, Ma.

Trinity Industries, Inc. Longview, Tex.

Trinity Industries, inc. Longview, Tex.

Tri Tool Inc. Rancho Cordova, Calif.

Underwater Engineering Services, Inc. Port St. Lucie, Fla.

UNICOR Littleton, Colo.

Union Tank Car Co. East Chicago, Ind.

United Abrasives, Inc. Willimantic, Conn.

United Airlines MOC San Francisco, Calif.

United States Air Force Cataloging & Standardization Center Battle Creek, Mich.

United States Army Tank- Automotive & Armaments Command Warren, Mich.

United States Department of Energy Albuquerque, N. Mex.

United States Welding, Inc. Denver, Colo.

United Welding & Supplies Co. Ltd. Jeddah, Saudi Arabia

Uniweld Products Inc. Ft. Lauderdale, Fla.

U.S. Steel Corp.-Tech Center Monroeville, Pa.

UT Automotive Dearborn, Mich.

UTP Brasileira de Soldas Ltda. Sao Pauio, Brazil

Valley State Prison for Women Chowchilla, Calif.

Vermeer Mfg. Co. Pella, Iowa

Viking Steel Erectors, Inc. Phoenix,Ariz.

Webb Corp. Dallas,Tex.

Weiler Corp. Cresco, Pa.

Weld-Aid Products, Inc. Detroit, Mich.

Weldcoa Northlake, Ill.

Weld Mold Co. Brighton, Mich.

Weld Wire Co., inc. King of Prussia, Pa.

Welding Consultants Inc. Columbus, Ohio

Welding Engineering Supply Co. Prichard,Ala.

Welding Research Council New York, N.Y.

The Welding Rod Factory, a Subsidiary of Nassau Research Corp. Aliquippa, Pa.

Weldco, Inc. Mobile,Ala.

Weldsale Co. Div. Of J.A. Cunningham Philadelphia, Pa.

Wellex Industries Ltd. New Plymouth, New Zealand

Western Enterprises Westlake, Ohio

Westinghouse Government Services Group-Electro Mechanical Div. Cheswick, Pa.

The Wheelabrator Corp. Shenandoah, Ga.

Williams Enterprises of Georgia, Inc. Smyrna, Ga.

Wilson Industries, Inc. Pomona, Calif.

Worthington Industries Columbus, Ohio

X-Ergon Irving,Tex.

O 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 your Sect ion ' s mee t ings and training p rog rams wi th f ree listings in the Sect ion Meet- ing Calendar co lumn of Society News.

Useful informat ion inc ludes your Sect ion name; activity date, t ime and location; speaker ' s name, title, affiliation and subject; and not ices of golf outings, seminars, contests and other special Section activities.

If s o m e of your m e e t i n g p lans are sketchy, s e n d the n a m e and p h o n e n u m b e r of a pe r son to contact for more information.

Send your n e w ca lendar to Susan Campbel l ,Associa te Editor, Welding Journal Dept.,AWS, 550 N.W. LeJeune Rd., Miami, FL 33126; FAX: (305) 443-7404.0

• 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 w a n t to r ecogn ize the ef for ts o f your c o m m i t t e e and inform our r eader s o f its a c c o m p l i s h m e n t s . Send a b r i e f prof i le o f its act ivi t ies and recen t accompl i shments , along wi th a m e m b e r ros ter and co n t ac t n u m b e r s , and we will pub l i sh it in t he Weld- ing Journal's Society News sect ion.

Send your submiss ions to

Susan Campbel l ,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: campbell@ aws.orgO

WELDING JOURNAL I 9t

G U I D E T O A W S S E R V I C E S 550 N.W. L e J e u n e Rd. , Miami , FL 3 3 1 2 6

Phone (800) 443-9353; Telex 51-9245; (888) WELDING FAX ( 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.WilliamMyers 482WolfRun Road

Cuba, NY14727

ADMINISTRATION

Executive Director Frank G. DeLaurier, CAE (210)

Deputy Executive Directors Richard D. French (218) Jeffrey R. Hnfsey (264)

John J. McLaughlin (235)

Assistant Executive Director Dehbie A. Cadavid (222)

Director of Quality Management Systems Linda K. Williams (298)

Corporate Director of Finance/Comptroller Frank R.Tarafa (252)

INFORMATION SERVICES

Corporate Director Joe Cilli (258)

HUMAN RESOURCES

Director Luisa Hernandez (266)

INTERNATIONAL INSTITUTE OF WELDING

Information (294)

Provides l ia ison act iv i t ies invo lv ing o t h e r profess ional soc ie t i es and s tandards orga- nizat ions, nat ional ly and internationally.

GOVERNMENT LIAISON SERVICES

Hugh K.Webster Webster, Chamberlain & Bean

Washington, D.C. (202) 466-2976

FAX (202) 835-0243

Identifies sources of funding for welding education and research & development. Moni- tors legislative and regulatory issues important to the industry.

WELDING EQUIPMENT M A N U F A ~ R S COMMrlTEE

Associate Executive Director Richard L.Alley (217)

INDUSTRY ACTION COMMITrEE

Associate Executive Director Charles R. Fassinger (297)

COMMUNICATIONS

Corporate Director, Communications Nannette M. Zapata (308)

Corporate Director of Administrative Services Jim Lankford (214)

Corporate Director of Marketing Technical Services Division

Debrah C.Weir (279)

P romotes Society p r o g r a m s and ac t iv i t ies to AWS m e m b e r s , t he w e l d i n g c o m m u - nity and the genera l publ ic .

CONVENTION & E X P O S m O N S Exhibiting Infurmation (221, 256)

Managing Director Tom L. Davis (231)

Organ izes the w e e k - l o n g annua l AWS In- t e r n a t i o n a l Weld ing and 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 . R e g u l a t e s s p a c e a s s i g n m e n t s , r e g i s t r a t i o n ma te r i - als and o t h e r Expo act ivi t ies .

PUBLICATION SERVICES Division Information (348)

Managing Director JeffWeber (246)

WELDING JOURNAL

Publisher JeffWeber (246)

Editor Andrew Cullison (249)

National Sales Director Rob Saltzstein (243)

WELDING HANDBOOK

Welding Handbook Editor Annette O'Brien (303)

P u b l i s h e s AWS's m o n t h l y m a g a z i n e , the Wel d i ng J o u r n a l , w h i c h p r o v i d e s infor- m a t i o n on the s t a t e of t he w e l d i n g industry, its t e c h n o l o g y and Socie ty activi- t ies . P u b l i s h e s t he W e l d i n g H a n d b o o k and books on genera l w e l d i n g subjec ts .

MEMBER SERVICES

Department Information (261)

Managing Director Cassie R. Burrell (253)

Director Rhenda A. Mayo (260)

Serves as a liaison between Section members and AWS headquarters. Informs members about AWS benefits and other activities of interest.

CERTIFICATION PROGRAMS/ BUSINESS DEVELOPMENT

Director of Int'l Business Development Walter Herrera (475)

For customized certification and educational programs to industry and government.

EDUCATION

Director James R. Cunningham (219)

Information on education products, projects and programs. CWI, SCWl and o ther seminars designed for assistance in Certification. Responsible for the S.E.N.S.E. beg inn ing welder program and disseminat ion of education information on the Web.

CONFERENCES

Director Giselle 1. Rodriguez (278)

Responsible for national and local conferences/exhibi t ions and seminars on industry topics ranging from the basics to the leading edge of technology.

CERTIFICATION OPERATIONS Information and appl ica t ion materials on cert ifying welders, welding inspectors and educators. (273)

Managing Director Wendy S. Reeve (215)

Awards & Fellows

Managing Director Wendy S. Reeve (215)

Coordinates awards and AWS Felk)w nominees.

TELEWELD

FAX:(305) 443-5951

For information about AWS technical publications, contact the Technical Services personnel listed below.

TECHNICAL SERVICES

Department Information (340)

Managing Director Leonard P. Connor (299)

Qualification, Inspection, Food Processing Equipment

Andrew R. Davis (466) International Standards Program Manager, Welding in Marine

Construction

Stephen P. Hedrick (305) Safety and Health Manager, Symlx)ls and Definitions

Engineers

Hardy H. Campbell III (300) Structural

Rakesh Gupta (301) Filler Metals

Christopher B. Pollock (304) Braziog, Soldering Testing, Railroads, C~mputetization,

Insmm'tentation

Tim Potter (309) Robotics,Joining of Metals and Alloys, Piping and Tubing,

Friction Welding

Melvin O. Kulp (314) Oxyfuel GasWelding & Cutting,Arc Welding and Cutting, Machinery

and Equipment,Welding Iron Castings

John L Ccayler (472) Metric Pmcticcs, Sheet Metal, Plastics and Composites, Perstmnd Qualification

92 J DECEMBER 2000

PUBLICATION SALES (800) 334-9353 (305) 443-9353

Pub l i c a t i on o rde r s . S e m i n a r a n d c o n f e r e n c e

reg i s t r a t ions .

Ed E Mitchell (254)Thermal Spray, High- Energy Beam Welding and Cutting, Re-

sistance Welding, Automotive, Aerospace

Senior Publications Coordinator

Rosalinda O'Neill (451)

AWS publishes more than 160 volumes of material, including standards that are used throughout the industry.

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 behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

It is the intent o f the American Weld- ing Society to bui ld the Society to the highest qual i ty standards possible. We, welcome any suggestions you may hat~.

Please contact any o f the s ta f f listed on the previous page or A WS President L. William Myers, Welding Engineer, Dresser-Rand, Olean Operations, p.o. Box 560, Paul Clark Dr, Olean, NY 14760.

A W S F O U N D A T I O N , I N C ,

550 N.W. LeJeune Rd. Miami , FL 3 3 1 2 6 (305) 4 4 5 - 6 6 2 8

(800 ) 443-9353 , ext . 293 O r e-mail: b o b w @ a w s . o r g

C h a i r m a n , Board o f T r u s t e e s R o n a l d C. P ie rce

E x e c u t i v e D i r e c t o r Frank G. DeLaur ier , CAE

D i r e c t o r o f D e v e l o p m e n t R o b e r t B .Wi the re l l

T h e A W S F o u n d a t i o n is a n o 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 - f i s h e d t o p r o v i d e s u p p o r t f o 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 Soc i e ty . 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 a v a i l a b l e u p o n r e q u e s t .

• N o m i n e e s f o r N a t i o n a l O f f i c e

On l y S u s t a i n i n g M e m b e r s , M e m b e r s , H o n o r a r y M e m b e r s , Life M e m b e r s o r Re- t i red M e m b e r s w h o have b e e n m e m b e r s for a pe r i od o f at least t h r ee years shall be eligible for e lec t ion as a Di rec tor o r Nat ional Officer.

It is the duty of the National Nomina t ing Commi t t e e to nomina t e candidates for national off ice.The commi t t e e shall hold an o p e n meet ing , preferably at the Annual Meet- ing, at w h i c h m e m b e r s may a p p e a r to p r e s e n t and d i scuss t he eligibility o f all candidates.

To be cons idered a candidate for pos i t ions of President ,Vice Pres ident ,Treasurer or Director-at-Large, the following qualifications and condi t ions apply:

P res iden t :To be el igible to h o l d t he off ice o f Pres iden t , an ind iv idua l m u s t hav e se rved as a Vice Pres iden t for at least o n e year.

Vice P re s iden t :To be el igible to ho ld t h e of f ice o f Vice P re s iden t , an ind iv idua l m u s t have s e rved at least o n e year as a Director , o t h e r t h a n Execu t ive Di rec to r an d Secretary.

T reasu re r :To be el igible to ho ld t h e of f ice o f Treasurer , an ind iv idua l m u s t be a m e m b e r o f t he Society, o t h e r t h a n a S tuden t Member , m u s t be f r e q u e n t l y avai lable to t h e Na t i ona l Of f i c e a n d s h o u l d be o f e x e c u t i v e s t a t u s in b u s i n e s s o r i n d u s t r y w i t h e x p e r i e n c e in f inancial affairs.

Director-at-Large:To be el igible for e l e c t i on as a Director-at-Large, an ind iv idua l sha l l p r e v i o u s l y h a v e h e l d of f ice as C h a i r m a n o f a Sec t ion ; as C h a i r m a n o r Vice C h a i r m a n o f a s t and ing , t e chn ica l o r spec ia l c o m m i t t e e o f t he Society; o r as Distr ic t Director.

I n t e r e s t e d p a r t i e s a re to s e n d a l e t t e r s t a t i n g w h i c h p a r t i c u l a r o f f ice t h e y a re seeking , i nc lud ing a s t a t e m e n t o f qual i f icat ions, the i r w i l l i ngness and ability to se rve if n o m i n a t e d and e l ec t ed and 20 cop i e s o f the i r b iographica l ske tch .

Th i s mate r ia l s h o u l d be s en t to Rober t J .Teuscher , C h a i r m a n , Nat ional Nomina t - ing C o m m i t t e e , A m e r i c a n Weld ing Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

T h e n e x t m e e t i n g o f t h e Na t iona l N o m i n a t i n g C o m m i t t e e is c u r r e n t l y s c h e d - u l ed for May 1 ,2001 , in C leve land , O h i o . T h e t e r m s o f o f f ice for c a n d i d a t e s n o m i - na t ed at this m e e t i n g will c o m m e n c e J u n e 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 Commit tee has the duty to make recommendat ions regarding nominees presented for Honorary Membership, National Meritorious Certificate, William Irrgang Memorial and the George E. Willis Awards. These awards are presented in conjunct ion with the AWS Exposition and Convention held each spr ing.The descriptions of these awards follnw, 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. McLaughlin, Secretary, Honorary-Meritorious Awards Committee, 550 N.W LeJeune Road, Miami, FL 33126.

N a t i o n a l M e r i t o r i o u s Cer t i f ica te Award : This award is g iven in r e cogn i t i on o f the cand ida te ' s counse l , loyalty and devo t ion to the affairs o f t he Society, a s s i s t ance in p r o m o t i n g cordial relat ions wi th indus t ry and o t h e r o rgan iza t ions , and for t he con- t r i bu t ion o f t ime and effor t on b e h a l f o f the Society.

W i l l i a m I r r g a n g M e m o r i a l A w a r d : This award is administered by theAmericanWeld- ing Society and sponsored by The Lincoln Electric Company to hono r the late William Irrgang. It is awarded each year to the individual w h o has done the mos t to e n h a n c e the Amer ican Welding Society's goal o f ad- vanc ing the s c i ence and t e c h n o l o g y of welding over the past five-year period.

G e o r g e E. W i l l i s A w a r d : Th i s award is admin is te red by the Amer ican Welding So- ciety and s p o n s o r e d b y T h e Lincoln Elec- tric C o m p a n y to h o n o r George E.Willis. It is awarded each year to an individual for p r o m o t i n g t he a d v a n c e m e n t o f w e l d i n g in t e rna t iona l ly by fo s t e r ing c o o p e r a t i v e par t ic ipa t ion in areas s u c h as t e c h n o l o g y transfer, s tandards rationalization and pro- mo t i on o f industr ial 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 Cert i f i - c a t e A w a r d : T h i s a w a r d is g i v e n in r e c o g n i t i o n o f t h e c a n d i d a t e ' s s ign i f i - c a n t c o n t r i b u t i o n s to t h e w o r l d w i d e w e l d i n g i n d u s t r y . T h i s a w a r d s h o u l d re- f l e c t " S e r v i c e to t h e I n t e r n a t i o n a l Weld- ing C o m m u n i t y " in t h e b r o a d e s t t e r m s . T h e a w a r d e e is n o t r e q u i r e d to be a m e m b e r o f t h e A m e r i c a n W e l d i n g So- ciety. Mul t ip le a w a r d s c a n be g i v e n p e r y e a r as t h e s i t u a t i o n d i c t a t e s . T h e a w a r d c o n s i s t s o f a c e r t i f i c a t e to b e p r e s e n t e d at t h e a w a r d ' s l u n c h e o n o r at a n o t h e r t i m e 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 t h e AWS P r e s i d e n t ' s t r ave l i t i n e r a r y , a n d , i f a p p r o p r i a t e , a o n e - y e a r 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 M e m b e r shal l be a p e r s o n o f a c k n o w l e d g e d e m i n e n c e in t h e we ld - i ng 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 t h e d e v e l o p m e n t o f t h e w e l d i n g ar t , u p o n w h o m t h e A m e r i c a n W e l d i n g So- c i e ty s e e s fit to c o n 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 s h a l l h a v e full r i gh t s o f m e m b e r s h i p . •

WELDING JOURNAL J 93

WELDING JOURNAL INDEX

V O L U M E 79 m 2000

PUBLISHED BY THE AMERICAN WELDING SOCIETY, 550 N.W. LEJEUNE RD., MIAMI, FL 33126

Part 1 - - W E L D I N G J O U R N A L

SUBJECT INDEX

Advancements Push Pipeline Welding Productivity, Tech- nology - - S. A. Blackman and D. V. Dorling, 39 (Aug)

Airport Expansion, Welding Lends Architectural Flair to - - 43 (Oct)

Architectural Flair to Airport Expansion, Welding Lends - - 43 (Oct)

Assessing Arc Welding Performance and Quality, A Wise Method for - - D. D. Harwig, 35(Dec)

Assessing Deterioration Conditions in Coke Drums - - J. A .

Penso, C. L. Tsai, D. G. Howden and W. O. Soboyejo, 45 (Aug)

Auto Industry Gears Up for Aluminum, The - - B. Irving, 63 (Nov).

Automotive Industry, Electron Beam Welding: A Useful Tool for the - - D. Powers and G. Schubert, 35 (Feb)

Alkaline Cleaning, Back to Basics: A Guide to - - G. Sanko, 49 (Jul)

Back to Basics: A Guide to Alkaline Cleaning - - G. Sanko, 49 (Jul)

Backscattered Electron Diffraction to Understand Weldabil- ity, Using--J. N. Dupont, J. R. Michael and C. V. Robino, 43 (Mar)

Basics: A Guide to Alkaline Cleaning, Back to - - G. Sanko, 49 (Jul)

Boiler Tubing, Cladding Operation Doubles Life o f - - T. He- ston, 45 (Jul)

Brazing Flux Breakthroughs, Manufacturers Capitalize on - - S. A. Urban, 37 (Sep)

Bridge Construction, Electroslag Welding Stands Poised for a Comeback in - - M. R. Johnsen, 39 (Feb)

Caterpillar, Robotic Arc Welding Is Off and Running at - - B. Iving, 55 (Apr)

Cell with Its Own Web Site, A Welding-- T. P. Quinn, J. D. Gilsinn and W. Rippey, 46 (Jan)

Chicago: There's a Whole Lot of Welding Going On - - M. R. Johnsen and T. Heston, 48 (Apr)

Choose Brazing, Ten Reasons to - - W. D. Kay, 33 (Sep) Chrome Plating, Thermal Spray Coatings as an Alternative to

Hard - - B. D. Sartwell, 39 (Jul) Cladding Operation Doubles Life of Boiler Tubing - - T. He-

ston, 45 (Jul) Coast Guard Always Ready, Weld Shop Keep U. S. - - 31

(May) Coatings as an Alternative to Hard Chrome Plating, Thermal

Spray - - B. D. Sartwell, 39 (Jul) Coke Drums, Assessing Deterioration Conditions in - -J. A .


Companies Enter into the Judiciary System, From Naivet~ to Desperation: When Small - - J. A. Miller, 35 (Oct)

Company Embraces Automatic Laser Gas Supply System - - F. Steele, 61 (Apr)

Consolidates Cutting Operations to Cut Costs, Steel Center - - 41 (May)

Cost Effective, Repairing an Offshore Jacket Structure Proves - - J. R. Still and V. Blackwood, 43 (May)

Cost of GMAW Gun Ownership, Calculating the Total - - H. Shah, 49 (Oct)

Contact-Tube Performance through Cryogenics, Improving - - J. Villafuerte, 45 (Oct)

Critical for Offshore Oil Production Vessels, Hull Weld Qual i ty--J. R. Still and J. B. Speck, 33 (Aug)

Cutting Operations to Cut Costs, Steel Center Consolidates - - 41 (May)

Densities of Many Thermal Sprayed Coatings, HVIF Process Improves - - B. Irving, 42 (Feb)

Desk to the Desktop, Moving Weld Management from the - - A. D. Brightmore and M. Bernasek, 43 (Jan)

Desperation: When Small Companies Enter into the Judi- ciary System,From Naivet6 t o - J. A. Miller, 35 (Oct)

Deterioration Conditions in Coke Drums, Assessing- J. A .


Development of Titanium Weld Color Inspection Tools --J. Talkington, D. Harwig, H. Castner and G. Mitchell, 35 (Mar)

Diffraction to Understand Weldability, Using Backscattered Electron --J. N. DuPont, J. R. Michael and C. V. Robino, 43 (Mar)

Drawn Arc Stud Welding: Crossing Over from Steel to Alu- minum - - S. Ramasamy, 35 (Jan)

Electron Beam Welding: A Useful Tool for the Automotive Industry - - D. Powers and G. Schubert, 35 (Feb)

Electroslag Welding Stands Poised for a Comeback in Bridge Construction - - M. R. Johnsen, 39 (Feb)

Entry-Level Welders, Program Answers Industry's Call f o r - M. R. Johnsen, 29 (Dec)

Equipment Industry, Survey Reflects Stability in W e l d i n g - A. Cullison, 65 (Apr)

Filler Metal for Welding Aluminum, How to Select the Best - -T . Anderson, 69 (Nov)

Forcing Adjustments in Welding and Cladding, Petrochem-

94 J DECEMBER 2000

ical Requirements Are - - B. Irving, 53 (Aug) Flux Breakthroughs, Manufacturers Capitalize on Brazing--

S. A. Urban, 37 (Sep) Flux-Free Ultrasonic Soldering, A New Look at, H. R. Faridi,

J. H Devletian and H. P. Le, 41 (Sep) GTA Welding Machines Improve Fabrication, Inverter-Based

- - M . Sammons, 35 (May) Future, Training for the - - D. Landon, 40 (Dec) Gas Supply System, Company Embraces Automatic Laser--

F. Steele, 61 (Apr) Gears Up for Aluminum, The Auto Industry - - B. Irving, 63

(Nov). GMAW Gun Ownership, Calculating the Total Cost o f - - H.

Shah, 49 (Oct) Great Master's Horse Returns Home after 500 Years, The - -

44 (Apr) HVlF Process Improves Densities of Many Thermal Sprayed

Coatings - - B. Irving, 42 (Feb) Heavy Weldments, Metal Cored Welding Wire Comes

Through on - - D. Phillips, 52 (Mar) Horse Returns Home after 500 Years, The Great Master's - -

44 (Apr) Hull Weld Quality Critical for Offshore Oil Production Ves-

sels - - J. R. Still and J. B. Speck, 33 (Aug) Inspection Tools, Development of Titanium Weld Color - -

J. Talkington, D. Harwig, H. Castner and G. Mitchell, 35 (Mar)

Inspects Pipe Welds, Portable Video Probe - - 73 (Nov) Inverter-Based GTA Welding Machines Improve Fabrication

- - M . Sammons, 35 (May) Japan's High-Speed Trains on Track, Advanced Welding

Technology Keeps - - S. Yamada and K. Masubuchi, 48 (Nov).

Judiciary System, From Naivet6 to Desperation: When Small Companies Enter into the - - J. A. Miller, 35 (Oct)

Laser Gas Supply System, Company Embraces Automatic - - F. Steele, 61 (Apr)

Machines Improve Fabrication, Inverter-Based GTA Welding - - M. Sammons, 35 (May)

Management from the Desk to the Desktop, Moving Weld - - A. D. Brightmore and M. Bernasek, 43 (Jan)

Master's Horse Returns Home after 500 Years, The Great - - 44 (Apr)

Metal Cored Welding Wire Comes Through on Heavy Weld- ments - - D. Phillips, 52 (Mar)

Methods of Weld Root Purging for Pipe Welding - - R. Sewell, 57 (Aug)

Mexico, Training Welders in - - A. Hill Price, 41 (Dec) Moving Weld Management from the Desk to the Desktop - -

A. D. Brightmore and M. Bernasek, 43 (Jan) National Landmark, Preserving a - - T. Siewert, C. Mc-

Cowan, R. Bushey, B. Robinson, T. Christ and K. Hilde- brand, 54 (Nov).

Networking of Welding Applications: A Tutorial - - T. P. Quinn, J. D. Gilsinn and W. Rippey, 49 (Jan)

New Approach to Powder Spraying, A - - V. Bogachek, 45 (Feb)

OSHA Inspection, Respiratory Protection: Preparing for an - - C. E. Colton, 49 (Mar)

Offshore Jacket Structure Proves Cost Effective, Repairing an - -J . R. Still and V. Blackwood, 43 (May)

Oil Production Vessels, Hull Weld Quality Critical for Off- shore - - J. R. Still and J. B. Speck, 33 (Aug)

Operation Doubles Life of Boiler Tubing, Cladding-- T. He- ston, 45 (Jul)

Pathway to the Stars, Welding a - - M. R. Johnsen, 39 (Oct) Performance through Cryogenics, Improving Contact-Tube

- - J . Villafuerte, 45 (Oct) Pipe Production and Reduce Cost, Two New Technologies

May Increase - - T. McGaughy, 65 (Aug) Pipe Welding, Methods of Weld Root Purging for - - R.

Sewell, 57 (Aug) Pipeline Welding Productivity, Technology Advancements

Push - - S. A. Blackman and D. V. Dorling, 39 (Aug) Petrochemical Requirements Are Forcing Adjustments in

Welding and Cladding - - B. Irving, 53 (Aug) Powder Spraying, A New Approach to - - V. Bogachek, 45

(Feb) Program Answers Industy's call for Entry-Level Welders - -

M. R. Johnsen, 29 (Dec) Protection: Preparing for an OSHA Inspection, Respiratory

- - C. E. Colton, 49 (Mar) Purging for Pipe Welding, Methods of Weld Root- - 57 (Aug) Repairing an Offshore Jacket Structure Proves Cost Effective

- - J . R. Still and V. Blackwood, 43 (May) Respiratory Protection: Preparing for an OSHA Inspection - -

C. E. Colton, 49 (Mar) Robotic Arc Welding Is Off and Running at Caterpillar - - B.

Irving, 55 (Apr) Safety Programs, Too, Small Shops Need - - 39 (Mar) Select the Best Filler Metal for Welding Aluminum, How to

- - 69 (Nov) Shop Keeps U. S. Coast Guard Always Ready, Weld - - 31

(May) Small Shops Need Safety Programs, Too - - 39 (Mar) Sprayed Coatings, HVIF Process Improves Densities of Many

T h e r m a l - B. Irving, 42 (Feb) Stability in Welding Equipment Industry, Survey Reflects - -

A. Cullison, 65 (Apr) Steel Center Consolidates Cutting Operations to Cut Costs

- - 41 (May) Steel to Aluminum, Drawn Arc Stud Welding: Crossing Over

from - - S. Ramasamy, 35 (Jan) Stud Welding: Crossing Over from Steel to Aluminum,

Drawn Arc - - S. Ramasamy, 35 (Jan) Survey Reflects Stability in Welding Equipment Industry - -

A. Cullison, 65 (Apt) Technologies May Increase Pipe Production and Reduce

Cost, Two New - - T. McGaughy, 65 (Aug) Technology Advancements Push Pipeline Welding Produc-

tivity - - S. A. Blackman and D. V. Dorling, 33 (Aug) Technology Stars at 2000 AWS Exposition, Welding - - A.

Cullison and M. R. Johnsen, 33 (Jul) Thermal Spray Coatings as an Alternative to Hard Chrome

Plating - - B. D. Sartwell, 39 (Jul) Titanium Weld Color Inspection Tools, Development o f - -

J. Talkington, D. Harwig, H. Castner and G. Mitchell, 35 (Mar)

Trains on Track, Advanced Welding Technology Keeps Japan's High-Speed - - S. Yamada and K. Masubuchi, 48 (Nov).

Tube-to-Tubsheet Joints, Improving the Reliability of - - H. W. Ebert, 47 (Sep)

Two New Technologies May Increase Pipe Production and Reduce Cost - - T. McGaughy, 65 (Aug)

Ultrasonic Soldering, A New Look at Flux-Free, H. R. Faridi, J. H Devletian and H. P. Le 41 (Sep)

Using Backscattered Electron Diffraction to Understand Weldabil i ty - - J. N. Dupont, J. R. Michael and C. V. Robino, 43 (Mar)

Video Probe Inspects Pipe Welds, Portable - - 73 (Nov) Web Site, A Welding Cell with Its Own - - T. P. Quinn, J. D.

Gilsinn and W. Rippey, 46 (Jan) Weld Root Purging for Pipe Welding, Methods of - - R.

W E L D I N G J O U R N A L I 9 S

Sewell, 57 (Aug) Weld Shop Keeps U. S. Coast Guard Always Ready - - 31

(May) Welder?, Who Will Become a - - W. Western, 45 (Dec) Welders in Mexico, Train ing-- A. Hill Price, 41 (Dec) Welders, Program Answers Industry's Call for Entry-Level - -

M. R. Johnsen, 29 (Dec) Welding: A Useful Tool for the Automotive Industry, Electron

Beam - - D. Powers and G. Schubert, 35 (Feb) Welding Aluminum, How to Select the Best Filler Metal for

- - T. Anderson, 69 (Nov) Welding Aluminum, What You Should Know about - - 54

(Jan) Welding Applications: A Tutorial, Networking of - - W.

Rippey, T. P. Quinn and J. D. Gilsinn, 49 (Jan) Welding Cell with Its Own Web Site, A - - T. P. Quinn, J. D.

Gilsinn and W. Rippey, 46 (Jan) Welding and Cladding, Petrochemical Requirements Are

Forcing Adjustments in - - B. Irving, 53 (Aug) Welding Going On, Chicago: There's a Whole Lot o f - M.

R. Johnsen and T. Heston, 48 (Apr) Welding Is Off and Running at Caterpillar, Robotic Arc - - B.

Irving, 55 (Apr) Welding Performance and Quality, A Wise Method for As-

sessing Arc - - D. D. Harwig, 35 (Dec) Welding Stands Poised for a Comeback in Bridge Construc-

tion, Electroslag - - M. R. Johnsen, 39 (Feb) Welding Technology Stars at 2000 AWS Exposition - - A.

Cullison and M. R. Johnsen, 33 (Jul) Welding Technology Keeps Japan's High-Speed Trains on

Track, Advanced - - S. Yamada and K. Masubuchi, 48 (Nov).

What You Should Know about Welding Aluminum - - 54 (Jan)

Wire Comes Through on Heavy Weldments, Metal Cored Welding - - D. Phillips, 52 (Mar)

AUTHORS FOR FEATURE ARTICLES

Anderson, T. - - How to Select the Best Filler Metal for Weld- ing Aluminum, 69 (Nov)

Bernasek, M. and Brightmore, A. D. - - Moving Weld Man- agement from the Desk to the Desktop, 43 (Jan)

Blackman, S. A. and Dorling, D. V. - - Technology Ad- vancements Push Pipeline Welding Productivity, 39 (Aug)

Blackwood, V. and Still, J. R. - - Repairing an Offshore Jacket Structure Proves Cost Effective, 43 (May)

Bogachek, V. - - A New Approach to Powder Spraying, 45 (Feb)

Brightmore, A. D. and Bernasek, M. - - Moving Weld Man- agement from the Desk to the Desktop, 43 (Jan)

Bushey, R., Robinson, B., Christ, T., Hildebrand, K., Siewert, T. and McCowan, C. - - Preserving a National Landmark, 54 (Nov)

Castner, H., Mitchell, G., Talkington, J. and Harwig, D. - - Development of Titanium Weld Color Inspection Tools, 35 (Mar)

Christ, T., Hildebrand, K., Siewert, T., McCowan, C., Bushey, R. and Robinson, B. - - Preserving a National Landmark, 54 (Nov)

Colton, C. E. - - Respiratory Protection: Preparing for an OSHA Inspection, 49 (Mar)

Cullison, A. - - Survey Reflects Stability in Welding Equip- ment Industry, 65 (Apr)

Cullison, A. and Johnsen, M. R.- -Welding Technology Stars at 2000 AWS Exposition, 33 (Jul)

Devletian, J. H. Le, H. P. and Faridi, H. R., - - A New Look at Flux-Free Soldering, 41 (Sep)

Dorling, D. V. and Blackman, S. A. - - Technology Ad- vancements Push Pipeline Welding Productivity, 39 (Aug

DuPont, J. N., Michael, J. R. and Robino, C. V. - - Using Backscattered Electron Diffraction to Understand Weld- ability, 43 (Mar)

Ebert, H. W., - - Improving the Reliability of Tube to Tub- sheet Joints, 47 (Sep)

Faridi, H. R., Devletian, J. H. and Le, H. P. - - A New Look at Flux-Free Soldering, 41 (Sep)

Flitter, L., Rippey, W. and Gilsinn, J. - - Networking of Weld- ing Applications: A Tutorial, 49 (Jan)

Gilsinn, J. D., Rippey, W. and Quinn, T. P . - -A Welding Cell with Its Own Web Site, 46 (Jan)

Gilsinn, J., Flitter, L. and Rippey, W. - - Networking of Weld-

ing Applications: A Tutorial, 49 (Jan) Harwig, D. D. - - Assessing Arc Welding Performance and

Quality, A Wise Method for, 35 (Dec) Harwig, D., Castner, H., Mitchell, G. and Talkington, J. - -

Development of Titanium Weld Color Inspection Tools, 35 (Mar)

Heston, T. - - Cladding Operation Doubles Life of Boiler Tubing, 45 (Jul)

Heston, T. and Johnsen, M. R. - - Chicago: There's a Whole Lot of Welding Going On, 48 (Apr)

Hildebrand, K., Siewert, T., McCowan, C., Bushey, R., Robinson, B. and Christ, T. - - Preserving a National Land- mark, 54 (Nov)

Howden, D. G., Soboyejo, W. O., Penso, J. A. and Tsai, C. L. - - Assessing Deterioration Conditions in Coke Drums, 45 (Aug)

Irving, B. - - HVlF Process Improves Densities of Many Ther- mal Sprayed Coatings, 42 (Feb)

Irving, B. - - Petrochemical Requirements Are Forcing Ad- justments in Welding and Cladding, 53 (Aug)

Irving, B. - - Robotic Arc Welding Is Off and Running at Caterpillar, 55 (Apr)

Irving, B. - - The Auto Industry Gears Up for Aluminum, 63 (Nov)

Johnsen, M. R. - - Program Answers Industry's Call for Entry- Level Welders, 29 (Dec)

Johnsen, M. R. - - Welding a Pathway to the Stars, 39 (Oct) Johnsen, M. R. and Cullison, A . - Welding Technology Stars

at 2000 AWS Exposition, 33 (Jul) Johnsen, M. R. and Heston, T. - - Chicago: There's a Whole

Lot of Welding Going On, 48 (Apr) Johnsen, M. R. - - Electroslag Welding Stands Poised for a

Comeback in Bridge Construction, 39 (Feb) Kay, W. D. - - Ten Reasons to Choose Brazing, 33 (Sep) Landon, D. - - Training for the Future, 48 (Dec) Le, H. P., Faridi, H. R., and Devletian, J. H. - - A New Look

at Flux-Free Soldering, 41 (Sep) Masubuchi, K. and Yamada, S. - - Advanced Welding Tech-

nology Keeps Japan's High-Speed Trains on Track, 48 (Nov)

McCowan, C., Bushey, R., Robinson, B., Christ, T., Hilde- brand, K., and Siewert, T. - - Preserving a National Land- mark, 54 (Nov)

96 I DECEMBER 2000

McGaughy, T. - - Two New Technologies May Increase Pipe Production and Reduce Cost, 65 (Aug)

Michael, J. R., Robino, C. V. and DuPont, J. N. - - Using Backscattered Electron Diffraction to Understand Weld- ability, 43 (Mar)

Miller, J. A., - - From Naivet~ to Desperation: When Small Companies Enter into the Judiciary System, 35 (Oct)

Mitchell, G., Talkington, J., Harwig, D. and Castner, H. - - Development of Titanium Weld Color Inspection Tools, 35 (Mar)

Penso, J. A., Tsai, C. L., Howden, D. G. and Soboyejo, W. O . - Assessing Deterioration Conditions in Coke Drums, 45 (Aug)

Phillips, D. - - Metal Cored Welding Wire Comes Through on Heavy Weldments, 52 (Mar)

Powers, D. and Schubert, G. - - Electron Beam Welding: A Useful Tool for the Automotive Industry, 35 (Feb)

Price, A. H. - - Training Welders in Mexico, 41 (Dec) Quinn, T. R, Gilsinn, J. D. and Rippey, W . - A Welding Cell

with Its Own Web Site, 46 (Jan) Ramasamy, S. - - Drawn Arc Stud Welding: Crossing Over

from Steel to Aluminum, 35 (Jan) Robino, C. V., DuPont, J. N. and Michael, J. R. - - Using

Backscattered Electron Diffraction to Understand Weld- ability, 43 (Mar)

Rippey, W., Quinn, T. P. and Gilsinn, J. D. - - A Welding Cell with Its Own Web Site, 49 (Jan)

Rippey, W., Gilsinn, J. and Flitter, L. - - Networking of Weld- ing Applications: A Tutorial, 54 (Jan)

Robinson, B., Christ, T., Hildebrand, K., Siewert, T., Mc- Cowan, C. and Bushey, R. - - Preserving a National Land- mark, 54 (Nov)

Sammons, M. - - Inverter-Based GTA Welding Machines Im- prove Fabrication, 35 (May)

Sanko, G. - - Back to Basics: A Guide to Alkaline Cleaning, 49 (Jul)

Sartwell, B. D. - - Thermal Spray Coatings as an Alternative to Hard Chrome Plating, 39 (Jul)

Schubert, G. and Powers, D. - - Electron Beam Welding: A Useful Tool for the Automotive Industry, 35 (Feb)

Sewell, R. - - Methods of Weld Root Purging for Pipe Weld- ing, 57 (Aug)

Shah, H. - - Calculating the Total Cost of GMAW Gun Own- ership, 49 (Oct)

Siewert, T., McCowan, C., Bushey, R., Robinson, B., Christ, T. and Hildebrand, K . - Preserving a National Landmark, 54 (Nov)

Soboyejo, W. O., Penso, J. A., Tsai, C. L. and Howden, D. G . - Assessing Deterioration Conditions in Coke Drums, 45 (Aug)

Speck, J. B. and Still, J. R. - - Hull Weld Quality Critical for Offshore Oil Production Vessels, 33 (Aug)

Steele, F. - - Company Embraces Automatic Laser Gas Sup- ply System, 61 (Apr)

Still, J. R. and Blackwood, V. - - Repairing an Offshore Jacket Structure Proves Cost Effective, 43 (May)

Still, J. R. and Speck, J. B. - - Hull Weld Quality Critical for Offshore Oil Production Vessels, 33 (Aug)

Talkington, J., Harwig, D., Castner, C and Mitchell, G. - - De- velopment of Titanium Weld Color Inspection Tools, 35 (Mar)

Tsai, C. L., Howden, D. G., Soboyejo, W. O. and Penso, J. A . - Assessing Deterioration Conditions in Coke Drums, 45 (Aug)

Urban, S.A. Manufacturers Capitalize on Brazing Flux Breakthroughs, 37 (Sep)

Villafuerte, J . - Improving Contact-Tube Performance through Cryogenics, 45 (Oct)

Western, W. - - Who Will Become a Welder?, 45 (Dec) Yamada, S. and Masubuchi, Koichi - - Advanced Welding

Technology Keeps Japan's High-Speed Trains on Track, 48 (Nov)

PART 2 - RESEARCH SUPPLEMENT

SUBJECT INDEX Aluminum Alloy AA5754, Cracking in Spot Welding - - J.

Senkara and H. Zhang, 194-s (Jul) Aluminum Alloys, A Method for Studying Weld Fusion

Boundary Microstructure Evolution in - - A. Kostrivas and J. C. Lippold, 1-s (Jan)

Aluminum Alloys Using the Front Weld Pool Image Signal, Control of Weld Penetration in VPPAW of - - B. Zheng, H. J. Wang, Q. I. Wang and R. Kovacevic, 363-s (Dec)

Aluminum During Diffusion Welding, Interfacial Reactions of Titanium and - - J-G Luo and V. L. Acoff, 239-s (Sep)

Aluminum Resistance Spot Welding Processes Using Cou- pled Finite Element Procedures, Analysis o f - - X. Sun and R Dong, 215-s (Aug)

Aluminum Welds - - Liquation Mechanism and Directional Soldification, Partially Melted Zone in - - C. Huang and S. Kou, 113-s (May)

Analysis of Aluminum Resistance Spot Welding Processes Using Coupled Finite Element Procedures - - X. Sun and P. Dong, 215-s (Aug)

Approximate Stress Intensity Factor and Notch Stress for Spot Welds - - S. Zhang, 54-s (Feb)

Basicity of a FCAW Consumable - - Part 1 : Solidified Slag Composition of a FCAW Consumable as a Basicity Indi- cator, Reconsidering the - - E. Baun6, C. Bonnet and S. Liu, 57-s (Mar)

Basicity of a FCAW Consumable-- Part 2: Verification of the Flux/Slag Analysis Methodology for Weld Metal Oxygen Control, Reconsidering t h e - - E. Baun6, C. Bonnet and S. Liu, 66-s (Mar)

Bead Volume for the Submerged Arc Process - - Part 1, Pre- diction and Optimization of Weld - - V. Gunaraj and N. Murugan 268-s (Oct)

Bead Volume for the Submerged Arc Process - - Part 2, Pre- diction and Optimization of Weld - - V. Gunaraj and N. Murugan, 331-s (Nov)

Beam Welding of Magnesium AZ91 D Plates, Electron - - A. Munitz, C. Cotler, H. Shaham and G. Kohn, 202-s (Jul)

Brazed Alumina Tensile Specimens, Microstructural and


Mechanical Characterization of Actively - - F. M. Hosk- ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, P. T. Vianco and C. A. Walker, 222-s (Aug)

Brazed Joints, A New Approach to Improving the Properties o f - - B. Zorc and L. Kosec, 24-s (Jan)

Brazed Joints, Model Equation for Predicting the Tensile Strenght of Resistance- - - K. Takeshita, 261 -s (Sep)

Characteristics of Resistance Spot Welding of Steels, Force - - H. Tang, W. Hou, S. J. Hu and H. Zhang, 175-s (Jul)

Characterization of C-Mn Steel Laser Beam Welded Joints with Powder Filler Metal, Structural - - S. Missori and A. Sill, 31 7-s (Nov).

Construction Diagram, A New Ferritic-Martensitic Stainless Steel - - M. C. Balmforth and J. C. Lippold, 339-s (Dec)

Consumable as a Basicity Indicator, Reconsidering the Ba- sicity of a FCAW Consumable - - Part 1: Solidified Slag Composition of a FCAW - - E. Baun6, C. Bonnet and S. Liu, 57-s (Mar)

Convection in Simulated Weld Pools Containing a Surface- Active Agent, Visualization of Marangoni - - C. Limma- neevichitr and S. Kou, 324-s (Nov)

Convection in Simulated Weld Pools, Visualization of Marangoni - - C. Limmaneevichitr and S. Kou, 126-s (May)

Convection on Weld Pool Shape, Experiments to Simulate Effect of Marangoni - - C. Limmaneevichitr and S. Kou, 231 -s (Aug)

Cracking in Spot Welding Aluminum Alloy AA5754 - - J. Senkara and H. Zhang, 194-s (Jul)

Cracking Susceptibility of a New Ferritic Steel - - Part 1: Sin- gle-Pass Heat-Affected Zone Simulations, The Stress-Re- l i e f - J. G. Nawrocki, J. N. Dupont, C. V. Robino, and A. R. Marder, 355-s (Dec)

Defect Formation in Friction Welded Aluminum, Spiral - - K. Uenishi, Y. Zhai, T. H. North and G. J. Bendzsak, 184-s (Jul)

Diffusion Welding, Interfacial Reactions of Titanium and Aluminum Dur ing--J-G Luo and V. L. Acoff, 239-s (Sep)

Dissimilar Metal Welds - - Part 2: On-Cooling Transfroma- tions, Nature and Evolution of the Fusion Boundary in Ferritic-Austenitic - - T. W. Nelson, J. C. Lippold and M. J. Mills, 267-s (Oct)

Electron Beam Welding of Magnesium AZ91 D Plates - - A. Muniz, C. Cotler, H. Shaham and G. Kohn, 202-s (Jul)

Evolution of Titanium Arc Weldment Macro and Mi- crostructures - - Modeling and Real Time Mapping of Phases - - Z. Yang, J. W. Elmer, J. Wong and T. DebRoy, 97-s (Apr)

FCAW Consumable - - Part 1: Solidified Slag Composition of a FCAW Consumable as a Basicity Indicator, Recon- sidering the Basicity of a - - E. Baun6, C. Bonnet and S. Liu, 57-s (Mar)

FCAW Consumable - - Part 2: Verification of the Flux/Slag Analysis Methodology for Weld Metal Oxygen Control, Reconsidering the Basicity of a - - E. Baun6, C. Bonnet and S. Liu, 66-s (Mar)

Fatigue Assessment of Spot Welds Based on Local Stress Pa- rame te rs - D. Radaj, 51-s (Feb)

Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks-- Part 1 : Neural Network De- velopment, Improved - -J . M. Vitek, Y. S. Iskander and E. M. Oblow, 33-s (Feb)

Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural N e t w o r k s - Part 2: Neural Network Re- sults, Improved - - J. M. Vitek, Y. S. Iskander and E. M. Oblow, 41-s (Feb)

Ferritic Steel - - Part 1 : Single-Pass Heat-Affected Zone Sim-

ulations, Cracking Susceptibil i ty of a New - - J. G . Nawrocki, J. N. Dupont, C. V. Robino, and A. R. Marder, 355-s (Dec)

Ferritic-Austenitic Dissimilar Metal Welds - - Part 2: On- Cooling Transfromations, Nature and Evouliton of the Fu- sion Boundary in - - T. W. Nelson, J. C. Lippold and M. J. Mills, 267-s (Oct)

Ferritic Steel - - Part 1 : Single-Pass Heat-Affected Zone Sim- ulations, Cracking Susceptibil ity of a News - - J. G . Nawrock, J. N. Dupont, C. V. Robino, and A. R. Marder, 355-s (Dec)

Filler Metal, Structural Characterization of C-Mn Steel Laser Beam Welded Joints with Powder-- S. Missori and A. Sill, 317-s (Nov)

Finite Element Analyses, Modeling of Projection Welding Processes Using Coupled - - X. Sun, 244-s (Sep)

Finite Element Analysis of Heat Flow in Single-Pass Arc W e l d s - E. A. Bonifaz, 121-s (May)

Finite Element Procedures, Analysis of Aluminum Resis- tance Spot Welding Processes Using Coupled - - X. Sun and P. Dong, 215-s (Aug)

Fluid Physical Properties on Weld Qualification for In-Ser- vice Pipelines, The Influence of Working - - R. J. Belanger and B. M. Patchett, 209-s (Aug)

Fluoride Additions in Welding Flux Hydrogen Control in Steel Weld Metal by Means o f - M. Matsushita and S. Liu, 295-s (Oct)

Flux/Slag Analysis Methodology for Weld Metal Oxygen Control, Reconsidering the Basicity of a FCAW Consum- able - - Part 2 Verification of the - - E. Baun~, C. Bonnet and S. Liu, 66-s (Mar)

Force Characteristics of Resistance Spot Welding of Steels-- H. Tang, W. Hou, S. J. Hu and H. Zhang, 175-s (Jul)

Friction Welded Aluminum, Spiral Defect Formation in - - K. Uenishi, Y. Zhai, T. H. North and G. J. Bendzsak, 184-s (Jul)

Fusion Boundary in Ferritic-Austenitic Dissimilar Metal Welds- - Part 2: On-Cooling Transformations, Nature and Evolution, Nelson, T. W., Lippold, J. C. and Mills, M. J., 267-s (Oct)

Fusion Boundary Microstructure Evolution in Aluminum Al- loys, A Method for Studying Weld - - A. Kostrivas and J. C. Lippold, 1-s (Jan)

GTAW Process Light Mechanism and Its Application in Sens- ing of the - - P. J. Li and Y. M Zhang, 252-s (Sep)

Heat-Affected Zone Simulations, The Stress-Relief Cracking Susceptibility of a New Ferritic Steel - - Part 1 : Single-Pass - - J. G. Nawrocki, J. N. Dupont, C. V. Robino, and A. R. Marder, 355-s (Dec)

Heat Flow in Single-Pass Arc Welds, Finite Element Analy- sis o f - E. A. Bonifaz, 121-s (May)

High-Strength Aluminum Alloy, A Hot-Cracking Mitigation Technique for Welding - - Y. P. Yang, P. Dong, J. Zhang and X. Tian, 9-s (Jan)

Hot-Cracking Mit igation Technique for Welding High- Strength Aluminum Alloy, A - - Y. P. Yang, P. Dong, J. Zhang and X Tian, 9-s (Jan)

HSLA-100 Welds Fabricated with New Ultra-Low-Carbon Weld Comsumables, Microhardness Variations in, D. W. Moon, R. W. Fonda and G. Spanos, 278-s (Oct)

Image-Based Penetration Monitoring of CO 2 Laser Beam Weld ing- - R. K. Holbert, R. W. Richardson, D. F. Farson and C. E. Albright, 89-s (Apr)

Image Signal, Control of Weld Penetration in VPPAW of, Alu- minum Alloys Using the Front Weld Pool - - B. Zheng, H. J. Wang, Q. I. Wang and R. Kovacevic, 346-s (Dec)

Improved Ferrite Number Prediction in Stainless Steel Arc

98 I DECEMBER 2000

Welds Using Artificial Neural Networks - - Part 1 : Neural Network Development - - J. M. Vitek, Y. S. Iskander and E. M. Oblow, 33-s (Feb)

Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 2: Neural Network Results - - J. M. Vitek, Y. S. Iskander and E. M. Oblow, 41-s (Feb)

Influence of Working Fluid Physical Properties on Weld Qualification for In-Service Pipelines, The - - R. J. Be- langer and B. M. Patchett, 209-s (Aug)

Interaction of a Molten Droplet with a Liquid Weld Pool Sur- face: A Computational and Experimental Approach, An Investigation of the - - M. H. Davies, M. Wahab and M. J. Painter, 18-s (Jan)

Investigation of the Interaction of a Molten Droplet with a Liquid Weld Pool Surface: A Computational and Experi- mental Approach, An - - M. H. Davies, M. Wahab and M. J. Painter, 18-s (Jan)

Laser Beam Welded Joints with Powder Filler Metal, Struc- tural Characterization of C-Mn Steel - - S. Missori and A. Sill, 317-s (Nov)

Laser Beam Welding, Image-Based Penetration Monitoring of CO 2 - R. K. Holbert, R. W. Richardson, D. F. Farson and C. E. Albright, 89-s (Apr)

Laser Beam Welding, Magneto-Fluid Dynamic Control of Seam Quality in CO 2 - - M . Kern, P. Berger and H. HL~gel, 72-s (Mar)

Light Mechanism and Its Application in Sensing of the GTAW Process - - P. J. Li and Y. M Zhang, 252-s (Sep)

Liquation Mechanism and Directional Melted Zone in Alu- minum Welds - - C. Huang and S. Kou, 113-s (May)

Magnesium AZ91 D Plates, Electron Beam Welding o f - - A. Munitz, C. Cotler, H. Shaham and G. Kohn, 202-s (Jul)

Magneto-Fluid Dynamic Control of Seam Quality in CO 2 Laser Beam Welding - - M. Kern, P. Berger and H. HL~gel, 72-s (Mar)

Marangoni Convection in Simulated Weld Pools, Visualiza- tion of - - C. Limmaneevichitr and S. Kou, 126-s (May)

Martensite Boundary on the WRC-1992 Diagram - - Part 2: The Effect of Manganese - - A, D. J. Kotecki 346-s (Dec)

Mechanical Characterization of Actively Brazed Alumina Tensile Specimens, Microstructural and - - F. M. Hosk- ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, P. T. Vianco and C. A. Walker, 222-s (Aug)

Mechanical Properties of Titanium Welds, Oxygen Equip- ment Effects on the - - D. D. Harwig, C. Fountain, W. It- tiwattana and H. Castner, 305-s (Nov)

Method for Studying Weld Fusion Boundary Microstructure Evolution in Aluminum Alloys, A - - A . Kostrivas andJ. C. Lippold, 1-s (Jan

Microstructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens - - F. M. Hosk- ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, P. T. Vianco and C. A. Walker, 222-s (Aug)

Microstructure Evolution in Aluminum Alloys, A Method for Studying Weld Fusion Boundary - - A. Kostrivas and J. C. Lippold, 1-s (Jan)

Microstructures - - Modeling and Real Time Mapping of Phases, Evolution of Titanium Arc Weldment Macro and - - Z. Yang, J. W. Elmer, J. Wong and T. DebRoy, 97-s (Apt)

Mitigation Technique for Welding High-Strength Aluminum Alloy, A Hot-Cracking-- Y. P. Yang, P. Dong, J. Zhang and X. Tian, 9-s (Jan)

Molten Droplet with a Liquid Weld Pool Surface: A Com- putational and Experimental Approach, An Investigation of the Interaction of a - - M. H. Davies, M. Wahab and M. J. Painter, 18-s (Jan)

Neural Networks - - Part 1: Neural Network Development, Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial - -J . M. Vitek, Y. S. Iskander and E. M. Oblow, 33-s (Feb)

Neural Network Results, Improved Ferrite Number Predic- tion in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 2 - - J. M. Vitek, Y. S. Iskander and E. M. Oblow, 41-s (Feb)

New Approach to Improving the Properties of Brazed Joints, A - - B. Zorc and L. Kosec, 24-s (Jan)

On-Cooling Transformations, Nature and Evolution of the Fusion Boundary in Ferritic-Austenitic Dissimilar Metal Welds - - Part 2: Nelson, T. W., Lippold, J. C. and Mills, M. J., 267-s (Oct)

Optimization of Weld Bead Volume for the Submerged Arc Process - - Part 2, Prediction and - - V. Gunaraj and N. Murugan, 331-s (Nov)

Oxygen Control, Reconsidering the Basicity of a FCAW Consumable-- Part 2: Verification of the Flux/Slag Analy- sis Methodology for Weld Metal - - E. Baun6, C. Bonnet and S. Liu, 66-s (Mar)

Partially Melted Zone in Aluminum Welds - - Liquation Mechanism and Directional Soldification - - C. Huang and S. Kou, 113-s (May)

Penetration Monitoring of CO 2 Laser Beam Welding, Image- Based - - R. K. Holbert, R. W. Richardson, D. F. Farson and C. E. Albright, 89-s (Apr)

Penetration in VPPAW of Aluminum Alloys Using the Front Weld Pool Image Signal, Control of Weld - - B. Zheng, H. J. Wang, Q. I. Wang and R. Kovacevic, 363-s (Dec)

Pool Shape, Experiments to Simulate Effect of Marangoni Convection on Weld - - C. Limmaneevichitr and S. Kou 231-s (Aug)

Pools Containing a Surface-Active Agent, Visualization of Marangoni Convection in Simulated Weld - - C. Limma- neevichitr and S. Kou, 324-s (Nov)

Predicting the Tensile Strength of Resistance-Brazed Joints, Model Equation for - - K. Takeshita, 261-s (Sep)

Preheat, The Welding of Structural Steels w i thou t - - A.J. Kin- sey, 79-s (Apr)

Projection Welding Processes Using Coupled Finite Element Analyses, Modeling o f - - X. Sun, 244-s (Sep)

Properties of Brazed Joints, A New Approach to Improving the - - B. Zorc and L. Kosec, 24-s (Jan)

Properties on Weld Qualification for In-Service Pipelines, The Influence of Working Fluid Physical - - R. J. Belanger and B. M. Patchett, 209-s (Aug)

Quali f ication for In-Service Pipelines, The Influence of Working Fluid Physical Properties on Weld - - R. J. Be- langer and B. M. Patchett, 209-s (Aug)

Real Time Mapping of Phases, Evolution of Titanium Arc Weldment Macro and Microstructures - - Model ing and-- Z. Yang, J. W. Elmer, J. Wong and T. DebRoy, 97-s (Apr)

Reconsidering the Basicity of a FCAW Consumable - - Part 1: Solidified Slag Composition of a FCAW Consumable As a Basicity Indicator - - E. Baun~, C. Bonnet and S. Liu, 57-s (Mar)

Reconsidering the Basicity of a FCAW Consumable - - Part 2: Verification of the Flux/Slag Analysis Methodology for Weld Metal Oxygen Control - - E. Baun6, C. Bonnet and S. Liu, 66-s (Mar)

Seam Quality in CO 2 Laser Beam Welding, Magneto-Fluid Dynamic Control o f - - M. Kern, P. Berger and H. HL~gel, 72-s (Mar)

Sensing of the GTAW Process, Analysis of an Arc Light Mechanism and Its Application in - - P. J. Li and Y. M


Zhang, 252-s (Sep) Simulate Effects of Marangoni Convection on Weld Pool

Shape, Experiments to - - C. Limmaneevichitr and S. Kou 231-s (Aug)

Single-Pass Arc Welds, Finite Element Analysis of Heat Flow in - - E. A. Bonifaz, 121-s (May)

Slag Composition of a FCAW Consumable as a Basicity In- dicator, Reconsidering the Basicity of a FCAW Consum- able - - Part 1 : Solidified - - E. Baun6, C. Bonnet and S. Liu, 57-s (Mar)

Spiral Defect Formation in Friction Welded Aluminum - - K. Uenishi, Y. Zhai, T. H. North and G. J. Bendzsak, 184-s (Jul)

Spot Welds, Approximate Stress Intensity Factor and Notch Stress for - - S. Zhang, 54-s (Feb)

Spot Welds Based on Local Stress Parameters, Fatigue As- sessment o f - D. Radaj, 51-s (Feb)

Spot Welding Aluminum Alloy AA5754, Cracking in - - J. Senkara and H. Zhang, 194-s (Jul)

Spot Welding of Steels, Force Characteristics of Resistance - - H. Tang, W. Hou, S. J. Hu and H. Zhang, 175-s (Jul)

Spot Welding Processes Using Coupled Finite Element Pro- cedures, Analysis of Aluminum Resistance - - X. Sun and P. Dong, 215-s (Aug)

Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 1 : Neural Network Development, Improved Fer- rite Prediction in - - J. M. Vitek, Y. S. Iskander and E. M. Oblow, 33-s (Feb)

Stainless Steel Arc Welds Using Artificial Neural Networks --Part 2: Neural Network Results, Improved Ferrite Num- ber Prediction in - - J. M. Vitek, Y. S. Iskander and E. M. Oblow, 41-s (Feb)

Stainless Steel Constitution Diagram, A New Ferritic- Martensitic - - M. C. Balmforth and J. C. Lippold, 339-s (Dec)

Stress Intensity Factor and Notch Stress for Spot Welds, Ap- proximate - - S. Zhang, 54-s (Feb)

Stress Parameters, Fatigue Assessment of Spot Welds Based on Local - - D. Radaj, 51-s (Feb)

Structural Steels without Preheat, The Welding o f - A. J. Kinsey, 79-s (Apt)

Submerged Arc Process - - Part 1, Prediction and Optimiza-

tion of Weld Bead Volume for the - - V. Gunaraj and N. Murugan 268-s (Oct)

Submerged Arc Process - - Part 2, Prediction and Optimiza- tion of Weld Bead Volume for the - - V. Gunaraj and N. Murugan, 331-s (Nov)

Surface-Active Agent, Visualization of Marangoni Convec- tion in Simulated Weld Pools Containing a - - C. Limma- neevichitr and S. Kou, 324-s (Nov)

Tensile Specimens, Microstructural and Mechanical Char- acterization of Actively Brazed Alumina - - F. M. Hosk- ing, C. H. Cadden, N. Y. C. Yang, S. J. Glass, J. J. Stephens, P. T. Vianco and C. A. Walker, 222-s (Aug)

Tensile Strength of Resistance-Brazed Joints, Model Equa- tion for Predicting the - - K. Takeshita, 261 -s (Sep)

Titanium and Aluminum During Diffusion Welding, Interfa- cial Reactions o f - - J-G Luo and V. L. Acoff, 239-s (Sep)

Titanium Arc Weldment Macro and Microstructures - - Modeling and Real Time Mapping of Phases, Evolution of - - Z. Yang, J. W. Elmer, J. Wong, and T. DebRoy, 97-s (Apr)

Titanium Welds, Oxygen Equivalent Effects on the Mechan- ical Properties - - D. D. Harwig, C. Fountain, W. Ittiwat- tana, and H. Castner, 305-s (Nov)

Ultra-Low-Carbon Weld Comsumables, Microhardness Variations in HSLA-100 Welds Fabricated with New - - D. W. Moon, R. W. Fonda and G. Spanos, 278-s (Oct)

Visualization of Marangoni Convection in Simulated Weld Pools - - C. Limmaneevichitr and S. Kou, 126-s (May)

VPPAW of Aluminum Alloys Using the Front Weld Pool Image Signal, Control of Weld Penetration i n - B. Zheng, H. J. Wang, Q. I. Wang and R. Kovacevic, 363-s (Dec)

Weld Metal by Means of Fluoride Additions in Welding Flux Hydrogen Control in Steel - - M. Matsushita and S. Liu, 295-s (Oct)

Weld Pool Surface: A Computational and Experimental Ap- proach, An Investigation of the Interaction of a Molten Droplet with a Liquid - - M. H. Davies, M. Wahab and M. J. Painter, 18-s (Jan)

Welding of Structural Steels without Preheat, The - - A.J. Kinsey, 79-s (Apr)

WRC-1992 Diagram - - Part 2: The Effect of Manganese, A Martensite Boundary on the - - D. J. Kotecki 346-s (Dec)

AUTHORS FOR RESEARCH SUPPLEMENTS

Acoff, V. L. and Luo, J-G. - - Interfacial Reactions of Tita- nium and Aluminum During Diffusion Welding, 239-s (Sep)

Albright, C. E., Holbert, R. K., Richardson, R. W. and Farson, D. F. - - Image-Based Penetration Monitoring of CO 2 Laser Beam Welding, 89-s (Apr)

Ahmadi, G., Aidun, D. K. and Domey, J. J. - - Effect on High Gravity on Weld Fusion Zone Shape, 145-s (Jun)

Aidun, D. K., Domey, J. J. and Ahmadi, G. - - Effect of High Gravity on Weld Fusion Zone Shape, 145-s (Jun)

Balmforth, M. C. and Lippold, J. C. - - Construction Dia- gram, A New Ferritic-Martensitic Stailess Steel, 339-s (Dec)

Baun(~, E., Bonnet, C. and Liu, S. - - Reconsidering the Ba- sicity of a FCAW Consumable - - Part 1: Solidified Slag Composition of a Consumable as a Basicity Indicator,

57-s (Mar) Baun~, E., Bonnet, C. and Liu, S. - - Reconsidering the Ba-

sicity of a FCAW Consumable - - Part 2: Verification of the Flux/Slag Analysis Methodology for Weld Metal Oxy- gen Control, 66-s (Mar)

Belanger, R. J., Patchett, B. M., - - The Influence of Working Fluid Physical Properties on Weld Qualification for In- Service Pipelines, 209-s (Aug)

Bendzsak, G. J., Uenishi, K., Zhai, Y. and North, T. H. - - Spiral Defect Formation in Friction Welded Aluminum, 184-s (Jul)

Berger, P. Hi, igel, H. and Kern, M. - - Magneto-Fluid Dy- namic Control of Seam Quality in CO 2 Laser Beam Weld- ing, 72-s (Mar)

Bonifaz, E. A. - - Finite Element Analysis of Heat Flow in Sin- gle-Pass Arc Welds, 121 -s (May)

100 J DECEMBER 2000

Bonnet, C, Liu, S. and Baun6, E. - - Reconsidering the Ba- sicity of a FCAW Consumable - - Part 1: Solidified Slag Composition of a ECAW Consumable as a Basicity Indi- cator, 57-s (Mar)

Bonnet, C, Liu, S. and Baun6, E. - - Reconsidering the Ba- sicity of a FCAW Consumable - - Part 2: Verification of the Flux/Slag Analysis Methodology for Weld Metal Oxy- gen Control, 66-s (Mar)

Cadden, C. H., Yang, N. Y. C., Glass, S. J., Stephens, J. J., Vianco, P. T., Walker, C. A., Hosking, F. M. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Castner, H.,Harwig, D. D., Fountain, C. and Ittiwattana, W. Oxygen Equivalent Effects on the Mechanical Proper-

ties of Titanium Welds, 305-s (Nov) Chen, S. B., Lou, Y. J., Wu, L. and Zhao, D. B. - - Intelligent

Methodology for Sensing, Model ing and Control of Pulsed GTAW: Part 1 - - Bead-on-Plate Welding, 151-s (Jun)

Chen, S. B., Zhao, D. B., Wu, L. and Lou, Y. J. - - Intelligent Methodology for Sensing, Model ing and Control of Pulsed GTAW: Part 2 - - Butt Joint Welding, 164-s (Jun)

Cotler, C., Shaham, H., Kohn, G. and Munitz, A . - Electron Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul)

Davies, M. H., Wahab, M. and Painter, M.J. An Investi- gation of the Interaction of a Molten Droplet with a Liq- uid Weld Pool Surface: A Computational and Experi- mental Approach, 18-s (Jan)

DebRoy, T., Yang, Z., Elmer, J. W. and Wong, J. Evolution of Titanium Arc Weldment Macro and Microstructures Modeling and Real Time Mapping of Phases, 97-s (Apr)

Dong, E, Sun, X., Analysis of Aluminum Resistance Spot Welding Processes Using Coupled Finite Element Proce- dures, 215-s (Aug)

Dong, P., Zhang, J., Tian, X. and Yang, Y.P. A Hot-Crack- ing Mitigation Technique for Welding High-Strength Alu- minum Alloys, 9-s (Jan)

Dupont, J. N., Robino, C. V., Marder, A. R., and Nawrocki, J. G. - - The Stress-Relief Cracking Susceptibility of a New Ferritic Steel Part 1: Single-Pass Heat-Affected Zone Simulations, 355-s (Dec)

Elmer, J. W., Wong, J., DebRoy, T. and Yang, Z. - - Evolution of Titanium Arc Weldment Macro and Microstructures - - Modeling and Real Time Mapping of Phases, 97-s (Apr)

Farson, D. F., Albright, C. E., Holbert, R. K. and Richardson, R. W. - - Image-Based Penetration Monitoring of CO 2 Laser Beam Welding, 89-s (Apr)

Fonda, R. W., Spanos, G. and Moon, T.W. Microhard- ness Variations in HSLA-100 Welds Fabricated with New Ultra-Low-Carbon Weld Consumables, 278-s (Oct)

Fountain, C., Ittiwattana, W., Castner, H. and Harwig, D. D. - - Oxygen Equivalent Effects on the Mechanical Proper- ties of Titanium Welds, 305-s (Nov)

Glass, S. J., Stephens, J. J., Vianco, P. T., Walker, C. A., Hosk- ing, E. M., Cadden and C. H., and Yang, N. Y. C. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Gunaraj V., and Murugan, N. - - Prediction and Optimiza- tion of Weld Bead Volume for the Submerged Arc Process - - Part 1,286-s (Oct)

Gunaraj, V. and Murugan, N. - - Prediction and Optimiza- tion of Weld Bead W)lume for the Submerged Arc Process - - Part 2, 331 -s (Nov)

Harwig, D. D., Fountain, C., Ittiwattana, W., and Castner, H. - - Oxygen Equivalent Effects on the Mechanical Proper- ties of Titanium Welds, 305-s (Nov)

Holbert, R. K., Richardson, R. W., Farson, D. F. and AIbright,

C . E . Image-Based Penetration Monitoring of CO 2 Laser Beam Welding, 89-s (Apr)

Hosking, F. M., Cadden, C. H., Yang, N. Y. C., Glass, S. J., Stephens, J. J., Vianco, P. T., and Walker, C. A. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Hou, W., Hu, S. J., Zhang, H. and Tang, H. Force Char- acteristics of Resistance Spot Welding of Steels, 175-s (Jul)

Hu, S. J., Zhang, H., Tang, H. and Hou, W. - - Force Char- acteristics of Resistance Spot Welding of Steels, 175-s (Jul)

Huang, C. and Kou, S. - - Partially Melted Zone in Aluminum Welds - - Liquation Mechanism and Directional Solidifi- cation, 113-s (May)

HL)gel, H., Kern, M. and Berger, P. - - Magneto-Fluid Dy- namic Control of Seam Quality in CO 2 Laser Beam Weld- ing, 72-s (Mar)

Iskander, Y. S., Oblow, E. M. and Vitek, J. M. - - Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks Part 1 : Neural Net- work Development, 33-s (Feb)

Iskander, Y. S., Oblow, E. M. and Vitek, J. M. - - Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 2: Neural Net- work Results, 41-s (Feb)

Ittiwattana, W., Castner, H.,Harwig, D. D. and Fountain, C. - - Oxygen Equivalent Effects on the Mechanical Proper- ties of Titanium Welds, 305-s (Nov)

Kinsey, A. J. - - The Welding of Structural Steels without Pre- heat, 79-s (Apr)

Kern, M., Berger, P. and HQgel, H . - Magneto-Fluid Dy- namic Control of Seam Quality in CO 2 Laser Beam Weld- ing, 72-s (Mar)

Kohn, G., Munitz, A., Cotler, C. and Shaham, H. - - Electron Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul)

Kosec, L. and Zorc, B. A New Approach to Improving the Properties of Brazed Joints, 24-s (Jan)

Kostrivas, A. and Lippold, J. C. - - A Method for Studying Weld Fusion Boundary Microstructure Evolution in Alu- minum Alloys, 1-s (Jan)

Kotecki, D. J . , - - A Martensite Boundary on the WRC-1992 Diagram Part 2: The Effect of Manganese, 346-s (Dec)

Kou, S. and Huang, C. - - Partially Melted Zone in Aluminum Welds - - Liquation Mechanism and Directional Solidifi- cation, ] 13-s (May)

Kou, S., and Limmaneevichitr, C. - - Experiments to Simu- late Effect of Marangoni Convection on Weld Pool Shape, 231-s (Aug)

Kou, S. and Limmaneevichitr, C. - - Visualization of Marangoni Convection in Simulated Weld Pools, 126-s (May)

Kou, S. and Limmaneevichitr, C. - - Visualization of Marangoni Convection in Simulated Weld Pools Con- taining a Surface-Active Agent, 324-s (Nov)

Kovacevic, R., Zheng, B, Wang, H. J., and Wang, Q. I., - - Control of Weld Penetration in VPPAW of Aluminum Al- loys Using the Front Weld Pool Image Signal, 363-s (Dec)

Li, P. J. and Zhang, M. Y., - - Analysis of an Arc Light Mech- anism and Its Application in Sensing of the GTAW Process, 252-s (Sep)

Li, L. and Messier, Jr., R. W. - - Stress Relaxation Study of HAZ Reheat Cracking in Type 347 Stainless Steel, 137-s (lun)

Limmaneevichitr, C. and Kou, S. - - Experiments to Simulate Effect of Marangoni Convection on Weld Pool Shape, 231-s (Aug)

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

Limmaneevichitr, C. and Kou, S.--Visualization of Marangoni Convection in Simulated Weld Pools, 126-s (May)

Limmaneevichitr, C. and Kou, S . - Visualization of Marangoni Convection in Simulated Weld Pools Con- taining a Surface-Active Agent, 324-s (Nov)

Lippold, J. C. and Balmforth, M. C. - - A New Ferritic- Martensitic Stainless Steel Construction Diagram 339-s (Dec)

Lippold, J. C. and Kostrivas, A. - - A Method for Studying Weld Fusion Boundary Microstructure Evolution in Alu- minum Alloys, 1-s (Jan)

Lippold, J. C. and Mills, M. J. and Nelson, T. W. - - Nature and Evolution of the Fusion Boundary in Ferritic- Austenitic Dissimilar Metal Welds - - Part 2: On-Cooling Transformations, 267-s (Oct)

Liu, S., Baun~, E. and Bonnet, C. - - Reconsidering the Ba- sicity of a FCAW Consumable - - Part 1: Solidified Slag Composition of a FCAW Consumable as a Basicity Indi- cator, 57-s (Mar)

Liu, S., Baun~, E. and Bonnet, C. - - Reconsidering the Ba- sicity of a FCAW Consumable - - Part 2: Verification of the Flux/Slag Analysis Methodology for Weld Metal Oxy- gen Control, 66-s (Mar)

Liu, S. and Matsushita, M. - - Hydrogen Control in Steel Weld Metal by Means of Fluoride Additions in Welding Flux, 295-s (Oct)

Lou, Y. J., Wu, L., Zhao, D. B. and Chen, S. B. - - Intelligent Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 1 - - Bead-on-Plate Welding, 151-s (Jun)

Lou, Y. J., Chen, S. B., Zhao, D. B. and Chen, S. B. - - Intel- ligent Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 2 - - Butt Joint Welding, 164-s (Jun)

Luo, J-G. and Acoff, V. L. - - Interfacial Reactions of Titanium and Aluminum During Diffusion Welding, 239-s (Sep)

Marder, A. R., Nawrocki, J. G., Dupont, J. N., and Robino, C. V., - - The Stress-Relief Cracking Susceptibility of a New Ferritic Steel - - Part 1: Single-Pass Heat-Affected Zone Simulations, 355-s (Dec)

Matsushita, M and Liu, S., - - Hydrogen Control in Steel Weld Metal by Means of Fluoride Additions in Welding Flux, 295-s (Oct)

Messier, Jr., R. W. and Li, L. - - Stress Relaxation Study of HAZ Reheat Cracking in Type 347 Stainless Steel, 137-s (Jun)

Mills, M. J. and Nelson, T. W. and Lippold, J. C. - - Nature and Evolution of the Fusion Boundary in Ferritic- Austenitic Dissimilar Metal Welds - - Part 2: On-Cooling Transformations, 267-s (Oct)

Missori, S. and Sill, A. - - Structural Characterization of C- Mn Steel Laser Beam Welded Joints with Powder Filler Metal, 317-s (Nov)

Moon, T. W., Fonda, R. W., and Spanos, G., - - Microhard- ness Variations in HSLA-100 Welds Fabricated with New Ultra-Low-Carbon Weld Consumables, 278-s (Oct)

Munitz, A., Cotler, C., Shaham, H. and Kohn, G. - - Electron Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul)

Murugan, N. and Gunaraj V. - - Prediction and Optimiza- tion of Weld Bead Volume for the Submerged Arc Process - - Part 1,286-s (Oct)

Murugan, N. and Gunaraj, V. - - Prediction and Optimiza- tion of Weld Bead Volume for the Submerged Arc Process - - Part 2,331-s (Nov)

Nawrocki, J. G., Dupont, J. N., Robino, C. V., and Marder, A. R. - - The Stress-Relief Cracking Susceptibility of a New Ferritic Steel - - Part 1: Single-pass Heat-Affected Zone Simulations, 355-s (Dec)

Nelson, T. W., Lippold, J. C. and Mills, M. J. - - Nature and Evolution of the Fusion Boundary in Ferritic-Austenitic

Dissimilar Metal Welds - - Part 2: On-Cooling Transfor- mations, 267-s (Oct)

North, T. H., Bendzsak, G. J., Uenishi, K. and Zhai, Y. - - Spi- ral Defect Formation in Friction Welded Aluminum, 184-s 0ul)

Oblow, E. M., Vitek, J. M. and Iskander, Y. S. - - Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 1: Neural Net- work Development, 33-s (Feb)

Oblow, E. M., Vitek, J. M. and Iskander, Y. S. - - Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 2: Neural Net- work Results, 41-s (Feb)

Painter, M. J., Davies, M. H. and Wahab, M. - - An Investi- gation of the Interaction of a Molten Droplet with a Liq- uid Weld Pool Surface: A Computational and Experi- mental Approach, 18-s (Jan)

Patchett, B. M., Belanger, R. J. - - The Influence of Working Fluid Physical Properties on Weld Qualification for In- Service Pipelines, 209-s (Aug)

Radaj, D. - - Fatigue Assessment of Spot Welds Based on Local Stress Parameters, 51-s (Feb)

Richardson, R. W., Farson, D. F., Albright, C. E. and Holbert, R. K. - - Image-Based Penetration Monitoring of CO 2 Laser Beam Welding, 89-s (Apr)

Robino, C. V., Marder, A. R.,Nawrocki, J. G., and Dupont, J. N. - - The Stress-Relief Cracking Susceptibility of a New Ferritic Steel - - Part 1: Single-Pass Heat-Affected Zone Simulations, 355-s (Dec)

Senkara, J. and Zhang, H. - - Cracking in Spot Welding Alu- minum Alloy AA5754, 194-s (Jul)

Shaham, H., Kohn, G., Munitz, A. and Cotler, C. - - Electron Beam Welding of Magnesium AZ91 D Plates, 202-s (Jul)

Sill, A. and Missori, S. - - Structural Characterization of C- Mn Steel Laser Beam Welded Joints with Powder Filler Metal, 317-s (Nov)

Spanos, G. and Moon, T. W. and Fonda, R. W. - - Micro- hardness Variations in HSLA-100 Welds Fabricated with New Ultra-Low-Carbon Weld Consumables, 278-s (Oct)

Stephens, J. J., Vianco, P. T., Walker, C. A., Hosking, F. M., Cadden, C. H., Yang, N. Y. C., and Glass, S. J. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Sun, X. - - Modeling of Projection Welding Processes Using Coupled Finite Element Analyses, 244 (Sep)

Sun, X., and Dong, P. - - Analysis of Aluminum Resistance Spot Welding Processes Using Coupled Finite Element Procedures, 209-s (Aug)

Takeshita, K. - - Model Equation for Predicting the Tensile Strength of Resistance-Brazed Joints, 261-s (Sep)

Tang, H., Hou, W., Hu, S. J. and Zhang, H. - - Force Char- acteristics of Resistance Spot Welding of Steels, 175-s (Jul)

Tian, X., Yang, Y. if, Dong, P. and Zhang, J. - - A Hot-Crack- ing Mitigation Technique for Welding High-Strength Alu- minum Alloy, 9-s (Jan)

Uenishi, K., Zhai, Y., North, T. H. and Bendzsak, G. J. - - Spi- ral Defect Formation in Friction Welded Aluminum, t 84-s 0ul)

Vianco, P. T., Walker, C. A., Hosking, F. M., Cadden, C. H., Yang, N. Y. C., Glass, S. J., and Stephens, J. J. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Vitek, J. M., Iskander, Y. S. and Oblow, E. M. - - Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 1 : Neural Net- work Development, 33-s (Feb)

102. I DECEMBER 2000

Vitek, J. M., Iskander, Y. S. and Oblow, E. M. - - Improved Ferrite Number Prediction in Stainless Steel Arc Welds Using Artificial Neural Networks - - Part 2: Neural Net- work Results, 41-s (Feb)

Wahab, M., Painter, M. J. and Davies, M. H. - - An Investi- gation of the Interaction of a Molten Droplet with a Liq- uid Weld Pool Surface: A Computational and Experi- mental Approach, 18-s (Jan)

Walker, C. A., Hosking, F. M., Cadden, C. H., Yang, N. Y. C., Glass, S. J., Stephens, J. J., and Vianco, P. T. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Wang, H. J., Wang, Q. I., Kovacevic, R., and Zheng, B - - Control of Weld Penetration in VPPAW of Aluminum Al- loys Using the Front Weld Pool Image Signal, 363-s (Dec)

Wang, Q. I., Kovacevic, R., Zheng, B, and Wang, H. J., - - Control of Weld Penetration in VPPAW of Aluminum Al- loys Using the Front Weld Pool Image Signal, 363-s (Dec)

Wong, J., DebRoy, T., Yang, Z. and Elmer, J. W. - - Evolution of Titanium Arc Weldment Macro and Microstructures - - Modeling and Real Time Mapping of Phases, 97-s (Apr)

Wu, L., Zhao, D. B., Chen, S. B. and Lou, Y. J. - - Intelligent Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 1 - - Bead-on-Plate Welding, 151-s (Jun)

Wu, L., Lou, Y. J., Chen, S. B. and Zhao, D. B. - - Intelligent Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 2 - - Butt Joint Welding, 164-s (Jun)

Yang, N. Y. C., Glass, S. J., Stephens, J. J., Vianco, P. T., Walker, C. A., Hosking, F. M. and Cadden, C. H. - - Mi- crostructural and Mechanical Characterization of Ac- tively Brazed Alumina Tensile Specimens, 222-s (Aug)

Yang, Y. P., Dong, P., Zhang, J. and Tian, X. - - A Hot-Crack-

ing Mitigation Technique for Welding High-Strength Alu- minum Alloy, 9-s (Jan)

Yang, Z., Elmer, J. W., Wong, J. and DebRoy, T. - - Evolution of Titanium Arc Weldment Macro and Microstructures - - Modeling and Real Time Mapping of Phases, 97-s (Apr)

Zhai, Y., North, T. H., Bendzsak, G. J. and Uenishi, K. - - Spi- ral Defect Formation in Friction Welded Aluminum, 184-s (Jul)

Zhang, H. and Senkara, J. - - Cracking in Spot Welding Alu- minum Alloy AA5754, 194-s (Jul)

Zhang, H., Tang, H., Hou, W. and Hu, S. J. - - Force Charac- teristics of Resistance Spot Welding of Steels, 175-s (Jul)

Zhang, J., Tian, X., Yang, Y. P. and Dong, P. - - A Hot-Crack- ing Mitigation Technique for Welding High-Strength Alu- minum Alloy, 9-s (Jan)

Zhang, M. Y. and Li, P. J. - - Analysis of an Arc Light Mech- anism and Its Application in Sensing of the GTAW Process, 252-s (Sep)

Zhang, S. - - Approximate Stress Intensity Factor and Notch Stress for Spot Welds, 54-s (Feb)

Zhao, D. B., Wu, L., Lou, Y. J. and Chen, S. B. - - Intelligent Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 1 - - Bead-on-Plate Welding, 151-s (Jun)

Zhao, D. B., Wu, L., Lou, Y. J. and Chen, S. B. - - Intelligent Methodology for Sensing, Modeling and Control of Pulsed GTAW: Part 2 - - Butt Joint Welding, 164-s (Jun)

Zheng, B., Wang, H. J., Wang, Q. I., and Kovacevic, R. - - Control of Weld Penetration in VPPAW of Aluminum Al- loys Using the Front Weld Pool Image Signal, 363-s (Dec)

Zorc, B. and Kosec, L. - - A New Approach to Improving the Properties of Brazed Joints, 24-s (Jan)

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CALL FOR PAPERS

Eleventh International Conference on Computer Technology in Welding

September 19 and 20, 2001 m Columbus, Ohio

This is the eleventh in a series of computer conferences designed to provide the welding industry with the latest information regarding the use of computers for welding. This conference, jointly sponsored by the American Welding Society, The Welding Institute and the National Institute of Standards and Technology, will be held September 19 and 20, 2001, in Columbus, Ohio. Authors from around the world are strongly encouraged to submit an abstract, as attendance from an international audience will be encouraged.

Authors should submit the Author Form (on reverse side), together with an abstract of no more than 500 words to American Welding Society, Conference Department, 550 NW LeJeune Road, Miami, FL 33126, by January 31, 2001. The abstract should be sufficiently descriptive to give a clear idea of the content of the proposed paper. Authors will be notified of acceptance by March 5, 2001. Completed manuscripts will be required from selected speakers by May 1, 2001.

Authors are not limited to any specific topics, except that papers should be appropriate for the conference subject. Contributions are encouraged in the following areas:

• 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

To ensure your paper's consideration for the conference, your abstract must be postmarked no later than January 31, 2001

Author Application Form

Eleventh International Conference on Computer Technology in Welding September 19-20, 2001 m Columbus, Ohio

Date Mailed

Author's Name: Please check how you are addressed: Title or Position:

Mr. Ms. Dr. Other

Organization: Mailing Address: City: State: Zip Code: Country Telephone: Fax:

For joint authorship, give names. (if more than two coauthors, please use separate sheet.

Name: Name: Organization: Organization: Address: Address:

PROPOSED TITLE (10 words or less):

ABSTRACT: • Typed, double-spaced, 250-500 words, attached to this form. • Be sure to give information to provide a clear idea of content of the proposed paper. • If completed manuscript is available now, in addition to abstract, attach copy to this form. • Application form and abstract must be postmarked no later than January 31, 2001.

MANUSCRIPT DEADLINE: • All manuscripts must be submitted no later than May 1, 2001. • Guidelines for submission of manuscripts will be provided to authors selected for the

program.

PRESENTATION AND PUBLICATION OF PAPERS: Has material in this paper been previously published or presented at any meeting?

Yes No When? Where?

Return to AWS postmarked no later than January 31, 2001, to the following address:

Conferences American Welding Society 550 N.W. LeJeune Road Miami, Florida 33126 Phone: 800/443-9353, Ext. 223, or 305/443-9353, Ext. 223 Fax: 305/443-1552

AWS FELLOWSHIPS AND WRC GRANTS-IN-AID

To: Professors Engaged in Joining Research

Subject: Request for Proposals for AWS Fellowships and for WRC Grants-in-Aid for the 2001-02 Academic Year

The American Welding Society (AWS) and the Welding Research Council (WRC) seek to foster university research in joining and to recognize outstanding faculty and student talent. Each of these two organizations has its own programs to channel funding into graduate research programs at universities. In recent years, AWS and WRC have coordinated their award programs and have made their respective selections based on responses to a joint Request for Proposals. We are again requesting your proposals for consideration by AWS and WRC.

Please note that AWS and WRC have separate selection committees, criteria and objectives as described below. However, if you wish, you need only provide a single proposal for consideration by the two organizations in their respective evaluation activities. Of course, only one award, a Fellowship to the Student (from AWS) or a Grant (from WRC) will be made for any one program of research at a university.

With both organizations, it is expected that the winning researchers will take advantage of the opportunity to work with industry committees interested in the research topics and report work in progress.

Please note, there are important changes in the schedule which you must follow in order to enable the awards to be made in a timely fashion. Proposals must be received at American Welding Society by February 5, 2001. New AWS Fellowships will be announced at the AWS Annual Meeting, May 6-10, 2001. WRC will notify applicants for its Grants by mail by June 1,2001.

THE AWARDS

The Fellowships or Grants are to be in amounts of up to $25,000 per year, renewable for up to three years of research. However, progress reports and requests for renewal must be submitted for the second and third years. Renewal by AWS or WRC will be contingent on demonstration of reasonable progress in the research or in graduate studies. WRC expects awardees to interact with any of its committees working in related areas of research.

The AWS Fellowship is awarded to the student for graduate research toward a Masters or Ph.D Degree under a sponsoring professor at a North American University. The qualifications of the Graduate Student are the key elements to be considered in the award. The academic credentials, plans and research history (if any) of the student should be provided. The student must prepare the proposal for the AWS Fellowship. However, the proposal must be under the auspices of a professor and accompanied by one or more letters of recommendation from the sponsoring professor or others acquainted with the student's technical capabilities. Topics for the AWS Fellowship may span the full range of the joining industry. Should the student selected by AWS be unable to accept the Fellowship or continue with the research at any time during the period of the award, the award will be forfeited and no (further) funding provided by AWS. The bulk of AWS funding should be for student support. AWS reserves the right not to make awards in the event that its Committee finds all candidates unsatisfactory.

The WRC Grant is to the university and professor for support of research in the defined area. The student need not be identified for consideration by WRC. Thus, if WRC makes the award for a proposal in which the student has been identified a change may be made at any time without loss of the Grant from WRC. It is hoped that the WRC funds will seed broader programs and any such plans to obtain follow-on or supplementary support should be mentioned in the Proposal. Proposals may be for innovative research in new areas or for research of interest to current WRC Committees. Subjects of interest to WRC Committees include underwater welding, linepipe welding, evaluating susceptibility to hydrogen cracking, corrosion resisting alloys such as duplex or other high alloy steels, high-strength welding consumables, hardfacing, automation or other timely subjects.

All proposals received will be considered for an award by WRC. Only those proposals containing suitable supporting information about the student and identified as having been prepared by the student will be considered by AWS. Please clearly specify in your cover letter if you intend AWS consideration.

SELECTION

The AWS and WRC selection committees operate separately, AWS may award up to six Fellowships. WRC will award as many Grants as funding permits. The number will depend on the size of the requests and the number of renewals from last year's group. Topics selected by WRC's group in recent years have been:

(a) Underwater Welding Consumables Research (b) Joining of Particulate Reinforced Metal Matrix Composites (c) Residual Stresses in Weldments (d) Fundamental Studies on Metallurgical Causes for Reheat Cracking (e) Analysis of Transient Liquid Phase (TLP) Diffusion Bonding (f) Hydrogen Effects on Cracking of Duplex Steel Welds (g) Brazing Alloys for Ceramic Substrates (h) On-Line Underwater Welding Control and Inspection by Ultrasonics (i) Weld Pool Geometry (j) Microstructure and Property Development of HSLA 100 and 130 Steel (k) Crack Growth in Weldments (I) Causes of Hot Cracking (m) Corrosion Behavior of Welds

DETAILS

The Proposal should include:

1. Annualized Breakdown of Funding Required and Purpose of Funds (Student Salary, Tuition, etc.) 2. Matching Funding or Other Support for Intended Research 3. Duration of Project 4. Statement of Problem and Objectives 5. Current Status of Relevant Research 6. Technical Plan of Action 7. Qualifications of Researchers 8. Pertinent Literature References and Related Publications 9. Special Equipment Required and Availability 10. Statement of Critical Issues Which Will Influence Success or Failure of Research

In addition, for the AWS Fellowship:

.

2. 3.

.

Student's Academic History, Resume and Transcript Recommendation(s) Indicating Qualifications for Research Brief Section or Commentary on Importance of Research to the Welding Community and to AWS, Including Technical Merit, National Need, Long Term Benefits, etc. Statement Regarding Probability of Success

The technical portion of the Proposal should be about ten typewritten pages. Four copies should be sent by February 5, 2001, to:

Richard D. French Deputy Executive Director American Welding Society 550 N. W. LeJeune Rd. Miami, FL 33126

Yours sincerely,

Frank G. DeLaurier Executive Director American Welding Society

Martin Prager Executive Director Welding Research Council

;las : :

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American Welding & Engineering, LLC, has an opportunity available in its sales and marketing department. American Welding & En- gineering is a well-established producer of contract fabrications and burned plate. The right individual for this position will be highly energetic, well organized and have a seasoned knowledge of the fabrication and burned plate industry.

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I

Atlas Foundry, located in the Pacific Northwest, has an immediate opening for a Welding Engineer to assist shop personnel in managing welding and fabrication functions as well as weld fil ler material control operations. This person ensures that the Welding Dept. complies with all codes, standards and customer requirements. In addition, you wi l l support Sales in resolving welding/metallurgical issues and quotations. Qualified candidate wi l l be PC literate and familiar with Microsoft Word, Excel, Access and have CAD skills. EOE. Send resume to

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108 [ DECEMBER 2000

E M P L O Y M E N T O P P O R T U N I T I E S

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A b i c o r B inze l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 All Fab C o r p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 A m e r i c a n T o r c h T ip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A W S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 , 27 ,28 ,40

B u g - O S y s t e m s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,61

C o r - M e t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ,43 C y p r e s s We ld i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

D i a m o n d G r o u n d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 D C T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 D ivers A c a d e m y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Ed i son We ld i ng Ins t i tu te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 E n e r p r o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 E S A B We ld i ng & Cut t ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 , O B C

F & M M a f c o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

G . A . L G a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 G e n e r i c o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

H o b a r t Ins t i tu te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

IPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

J .P . N i ssen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Je t l ine E n g i n e e r i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Ko i ke A r o n s o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

L inco ln E lect r ic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

M a c k P r o d u c t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 M e t o r e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Na t i ona l S t a n d a r d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

P a n a m e t r i c s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Scha f f I n te rna t i ona l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Se lec t A rc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC S t ress Re l ie f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

T.J. C la rk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 T e c n a r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 T h e r m c o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 T o c c o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

We ld H u g g e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 W e l d c r a f t P r o d u c t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC W o l v e r i n e T u b e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

I F C = Inside F r o n t C o v e r I B C = Inside B a c k C o v e r O B C = O u t s i d e B a c k C o v e r

W E L D I N G J O U R N A L I I 13

A W S Peer Review Panel All papers published in the Welding Journal's Welding Research Supplement undergo Peer Review before publication for: 1) originality of the contribution; 2) technical value to the welding community; 3) prior publication of the material being reviewed; 4) proper credit to others working in the same area; and 5) justification of the conclusions, based on the work performed. The following individuals serve on the AWS Peer Review Panel and are experts in specific technical areas. All are volunteers in the program.

D. Abson E Hall D. K. Aidun D.L. Hallum G. A. Andreano I .D. Harris D. G. Atteridge D.A. Hartman R. E. Avery R.T. Hemzacek S. S. Babu M.J. Higgins D. J. Ball T. Hikido W. L. Ballis J .E. Hinkel R Banerjee J. E Hinrichs T. S. Bannos T. R Hirthe R. E. Beal R Hochanadel E R. Beckman D.G. Howden S. S. Bhargava R Howe B. Bjorneklett C. Hsu O. Blodgett J.P. Hurley R. J. Bowers D.L. Isenhour J. E. M. Braid J .R. Jachna K. L. Brown J. Jaeger S. B. Brown B.A. Jones J. Bundy J .E. Jones S. N. Burchett W. Kanne M. L. Callabresi B. Kapadia D. A. Canonico A. Kar K. W. Carlson D.D. Kautz N. M. Carlson H.W. Kerr C. L. Chan D.S. Kim Y. J. Chao J. E King C. C. Chen S. Kolli J. C. Chennat P.J. Konkol B. A. Chin S. Kou G. E. Cook J.J. Kozelski R. E. Cook H .G. Kraus R. A. Daemen K.W. Kramer S. Daniewicz J.J. Kwiatkowski J. C. Danko E Lake J. DeLoach J .D. Landes G. den Ouden J.W. Lee X. Deng A. Lesnewich P. J. Ditzel G.K. Lewis R. J. Dybas M.V. Li H. W. Ebert T.J. Lienert G. M. Evans M.J. Lucas R. G. Fairbanks R.O. Lund D. A. Fink K.A. Lyttle D. W. Fitting B. Madigan W. R. Frick M.C. Maguire E. Friedman A.K. Majumdar Y. P. Gao M. Manohar J. A. Gianetto A. E Manz E E. Gibbs K. Masubuchi

Principal Reviewers

Y. Adonyi P.W. Fuerschbach D.W. Meyer C. E. Albright W. E Gale J.O. Milewski J. A. Brooks J.M. Gerken K.W. Mitchiner H. R. Castner D.D. Harwig P.E. Murray M. J. Cieslak D. Hauser T.M. Mustaleski M. J. Cola G.K. Hicken D.L. Olson C. E. Cross J.E. Indacochea B.M. Patchett C. B. Dallam J.L. Jellison T.P. Quinn B. Damkroger M.Q. Johnson A. Rabinkin V. R. Dav~ R.R. Kapoor B. Radhakrishnan S. A. David T.J. Kelly W.G. Reuter T. DebRoy G.A. Knorovsky R.W. Richardson J. H. Devletian D.J. Kotecki J. E Saenger R. D. Dixon R. Kovacevic M.L. Santella P. Dong E V. Lawrence, Jr. S.D. Sheppard J. N. DuPont W. Lin H.B. Smartt T. W. Eagar J.C. Lippold B.R. Somers G. R. Edwards S. Liu C.L. Tsai J. W. Elmer H.W. Ludewig G.D. Uttrachi D. E Farson R.P. Martukanitz D.R. White Z. Feng R. Menon T. Zacharia S. R. Fiore S.J. Merrick Y. Zhou L. H. Flasche R.W. Messier, Jr.

J. Mazumder M. Prager J.J. Vagi V. E. Merchant D.D. Rager T.L. VanderWert M. T. Merlo K. E Rao I. Varol W. C. Mohr W. Ridgway R T. Vianco A. J. Moorhead A. Ritter K.K. Wang T. Morrissett M.N. Ruoff D.K. Watney L. W. Mott D.J. Rybicki M.M. Weir C. G. Mukira E. E Rybicki C.E. Wirsing K. Mundra K. Sampath C.E. Witherell O. Myhr J.M. Sawhill, Jr. W.E. Wood K. Nagarathnam A.P. Seidler J. Xie R Nagy L.R. Shockley Y.P. Yang S. Nasla L.E. Shoemaker H. Zhang T. W. Nelson M. Sierdzinski J. Zhang J. L. Novak T.A. Siewert S. Zhang A. Ortega S.D. Smith Y.M. Zhang M. Parekh T.M. Sparschu R. A. Patterson W.J. Sperko R. L. Peaslee D.E. Spindler D. D. Peter J .E. Stallmeyer E. Pfender R.J. Steele M. Piltch E L. Sturgill L. E. Pope D.W. Trees N. Potluri A.J. Turner

114 J DECEMBER 2000

W E L D I N G R E S E A R C H

SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 2000 Sponsored by the American Welding Society and the Welding Research Council

A New Ferritic-Martensitic Stainless Steel Constitution Diagram

New equivalency relationships improve the accuracy for predicting weld metal microstructure

BY M. C. BALMFORTH A N D J. C. LIPPOLD

ABSTRACT. A new constitution diagram that more accurately predicts the microstructure of ferritic and martensitic stainless steel weld deposits has been developed. This diagram represents an improved version of the diagram presented by the authors in the January 1998 welding Journal Research Supplement. Button melting and quantitative metallography techniques were used to produce additional microstructures, which supplied information about specific alloying element effects and provided microstructures near the phase boundaries, including the boundary for austenite formation. Using the entire database and linear regression analysis techniques, new equivalency formulae were developed and compared with existing formulae. Using the new equivalency formulae and iso- ferrite contour maps, a new ferritic- martensitic stainless steel constitution diagram was developed. Based on arc welds made using commercial martensitic and ferritic stainless steels, this diagram has proven to be extremely accurate in predicting weld metal microstructure within the composition limits of the diagram.

Introduction

The increasing popularity of ferritic and martensitic stainless steels in engineering applications over the past

M. C. BALMFORTH is with Dept. of Materials Science and Engineering, Massachusetts Insti- tute of Technology, and was formerly with the Welding and Joining Metallurgy Group, The Ohio State University. J. C. LIPPOLD is with Weldin~ and Joining Metallurgy Group, The Ohio State University, Columbus, Ohio.

decade has focused considerable attention on the weldability of these alloys. The mechanical properties of the weld zone are very sensitive to microstructure, and poor microstructure control can limit their application. These microstructural effects, including the presence of ferrite in martensitic welds and martensite in ferritic welds, were summarized in a previous paper by the authors (Ref. 1 ).

Historically, constitution diagrams using chromium and nickel equivalents for the elements present in the alloy have served as road maps for determining weld deposit microstructure (or constitution). Most of the diagrams currently available, such as the WRC-1992 diagram, do not represent the constitution region for ferritic and martensitic stainless steels. Those that include the ferrite plus martensite region, such as the Schaeffler diagram, do not accurately predict microstructure. The objective of the work reported here was to develop a constitution diagram over a composition range that predicts weld deposit microstructures for ferritic and martensitic stainless steels with a higher degree of accuracy.

KEY WORDS

Constitution Diagram Stainless Steel Ferritic-Martensitic M icrostructure Weld Metal WRC-1992 Equivalency Formulas

As the compositional influence on weld microstructure is understood, greater confidence in utilizing ferritic and martensitic stainless steels will be possible. Development of a diagram that allows more accurate prediction of the compositional influence on weld microstructure will facilitate both alloy development and selection for welded applications and the choice of filler metals.

In an earlier paper (Ref. 1), a preliminary ferritic-martensitic stainless steel constitution was proposed. This diagram was based on an initial database produced by quantitative metallography and a large number of samples produced using a button melting technique. The preliminary diagram provided a rough estimate of weld metal microstructure, but further experimentation and evaluation were needed. The results reported here include a larger number of compositions that were produced by button melting in an effort to improve the accuracy of the preliminary diagram.

Experimental Approach and Procedures

The previous paper (Ref. 1) provides the details of the experimental procedures used to develop this diagram. The following sections are a summary of the procedures used.

Production of Alloy Buttons

Materials for this study included conventional, commercially available ferritic and martensitic stainless steels, along with other ferritic materials and grades of stainless steels. Some experimental compositions were also used. All of the chem-

WELDING RESEARCH SUPPLEMENT J 339-s

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Fig. I - - Button melt vol-% data plotted using the Schaeffler equivalents.

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alents.

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Fig. 3 Button mel t vo l -% data p lo t ted using the Kaltenhauser

equivalents.

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equivalents.

ical compositions for the materials used were provided by the producers and are listed in Table 1. These base materials were combined in different dilutions in order to produce a range of microstructures. Other materials were used, in addition to the ferritic and martensitic stainless steels, in order to create combinations containing various amounts of alloying elements and microstructures bordering the duplex ferrite plus martensite constitution region.

Combinations of the base metals that would transect the duplex ferrite plus martensite constitution region were selected and mixed in different dilutions using a button melting technique. The button melts, which were used to simulate weld metal for microstructural data, were made by melting four grams of material, (e.g., 3 g of one type of stainless steel with 1 g of another) in a water- cooled copper crucible using the GTAW process. It was confirmed in the earlier paper (Ref. 1) the button melting tech-

nique is a highly efficient and reliable method for simulation of weld metal and developing constitution diagrams.

The alloys were melted and allowed to cool under a high-purity argon-shielding atmosphere. Initially, dilutions of 25, 50 and 75% of each base metal were prepared. Button melts of the undiluted base metals were also made. Later, intermedi- ate dilutions, such as 12.5%, were made in order to fill in appropriate areas on the diagram. The compositions of the individual buttons were estimated by dilution calculations based on the chemical compositions of the base materials. For example, if 1 g of Alloy A was combined with 3 g of Alloy B, the carbon content could be estimated by the following equation:

Cbutton 4

where Cbut ton = the carbon content of the button, C A = the carbon content of alloy A and C B = the carbon content of alloy B.

Character iza t ion Techniques

Button melt specimens were sectioned in half using an abrasive wafering saw and ground and polished through colloidal silica. Three different etching techniques were employed to reveal the two-phase microstructures of these alloys. Most of the alloys responded well to an electrolytic etch using 10% oxalic acid in distilled water at 6 V for times up to 2 min. Some of the martensitic alloys were more easily characterized when im- mersed in Vilella's reagent (5 mL HCI, 1 g picric acid, 100 mL ethanol) for 3-4 s, and, in some of the two-phase alloys, martensite was much more visible, as a dark phase within light-colored ferrite, when swabbed for 1 2 s using Fry's reagent (5 g CuCI 2, 40 mL HCI, 30 mL water, 25 mL ethanol).

A colloidal suspension of Fe304 particles, known as ferro-fluid (Ref. 2), was used to determine whether austenite existed in specimens near the triplex austen-

340-S J DECEMBER 2000

Table I - - Chemical Compositions of the Materials Used in This Study

Composition, wt-% Alloy C Mn Si Cr Ni P S AI Mo Cu Nb Ti N

Ferrite Stainless Steels 409 0.018 0.28 0.49 11.54 0.14 0.023 0.001 . . . . 0.18 - - 444 0.02 0.36 0.23 17.85 0.37 0.031 0.001 - - 1.92 0.33 0.33 0.019 430-A 0.046 0.45 0.38 16.48 0.27 0.026 0.003 0.005 0.09 0.08 - - 0.003 0.046 430-B 0.036 0.47 0.31 16.1 0.11 - - - - - - 0.02 0.08 - - 0.035 430-C 0.04 0.44 0.42 16.6 0.21 0.024 0.001 0.003 0.17 0.08 0.017 - - 0.035 439-A 0.02 0.3 0.4 17.89 0.2 - - - - - - 0.04 0.07 0.48 0.41 439-B 0.012 0.27 0.28 17.32 0.32 0.031 0.001 0.064 0.039 0.074 0.01 0.33 0.012 409Ni 0.01 0.64 0.36 10.99 0.8 0.023 0.001 0.049 0.027 0.074 0.01 0.19 0.008 405 0.019 0.46 0.76 13.21 0.17 0.019 - - 0.23 O. 13 0.05 0.007 0.002 0.002

Martensitic Stainless Steels 403-A 0.11 0.37 0.35 12.38 0.28 0.015 0.004 0.003 0.069 0.099 0.008 0.002 0.028 403-B 0.089 0.65 0.33 12.15 0.32 0.019 0.002 0.003 0.036 0.08 0.003 0.002 0.029 410 0.106 0.38 0.37 12.52 0.23 0.022 0.025 - - {).02 - - 0.053 410Cb 0.122 0.24 0.29 12.0 0.17 0.023 0.007 - - 0.03 0.09 0.174 0.002 0.008 410K 0.1 0.6 0.5 16.7 2.1 0.01 0.01 - - 1.0 - - - - HT9 0.22 0.52 0.38 11.3 0.5 0.019 0.006 - - 0.85 - - - - - - 0.27 CC8 0.024 0.46 0.48 8.13 0.22 0.012 0.004 - - 0.31 0.04 - - - - 0.018 13Cr 0.031 0.389 0.155 12.88 3.96 0.012 0.002 - - 1.01 - - - - - - 0.02

Other Materials Fe 0.02 0.32 0.01 - - - - 0.01 0.013 - - - - - - A36 0.088 0.627 0.236 - - - - 0.005 0.025 . . . . . . 304L 0.023 1.79 0.58 18.12 8.09 0.023 0.006 - - - - 0.069 312 0.05 1.75 0.51 30.4 8.36 0.021 0.002 - - 0.01 0.04 - - - - - - 2205 0.014 1.46 0.48 22.16 5.64 0.028 0.001 - - 3.04 0.18 21-6-9 0.067 8.31 0.29 20.16 7.03 0.017 0.003 0.018 0.22 0.072 0 . 0 0 1 0.002 0.197

ite-ferrite-martensite constitution region. Because the particles are ferromagnetic, they adhere to ferrite and martensite, giving a blue or brown color, whi le leaving austenite unaffected and white when observed with an optical microscope.

To determine the volume fraction of ferrite or martensite in the microstructures of the specimens, quantitative analysis was performed using the point-counting method according to ASTM E562.

Data Analysis

To determine which elements and their coefficients should be used in the new equivalency relat ionships for the predict ion of volume-percent ferrite in ferrit ic and martensit ic stainless steel welds, two linear regression techniques were used. Mul t ip le l inear regression, which analyzes relationships between one dependent variable and one or more independent variables, was used to determine the ini t ial equations. Volume- percent ferrite was defined as the dependent variable, whi le the elements affecting ferrite content, such as nickel, chromium, nitrogen, etc., were defined as the independent variables. This process produces linear equations of the form:

vol-% ferrite = C 0 + C I(E I )+C2(E2)+...+Ci(E i) (1)

where C o is a constant, the C i t e r m s are coefficients and the E i t e r m s are the ele-

ments included in the regression. Ele- ments chosen for inclusion in the regression were based on previous equivalency formulae, experience and whether or not sufficient data existed for the element. Various combinations of elements were chosen, which produced a variety of equivalency relationships.

The various coeff icients produced were evaluated using statistical methods, such as the standard deviation, T-value, P-value, R-squared value, and by examining the correlation matrix of the coefficients. Once the initial regressions were completed, ridge regression was used to improve the predict ions for the coefficients. Ridge regression uses a ridge parameter (theta) to modi fy the least squares regression procedure to help avoid problems caused by highly coll inear independent variables. As theta increases, biases in the coefficients increase, but the coefficients may be more precise. The goal is to find a small value of theta beyond which the estimates change slowly.

Chromium and nickel equivalent formulae developed during the regression analysis were then used to plot the volume-percent ferrite data. By plott ing the various relat ionships and determin ing best-fit lines for the data, an iso-ferrite contour map was produced. The lines were drawn wi thout curvature and were al lowed to be nonparallel and non-equispaced.

Results and Discussion

Development of the New Diagram

After the preliminary diagram was proposed, more button melt samples were made in an attempt to fill in gaps where more microstructural data was needed. The data from these microstructures was then added to the existing database. All of the data from this work, including dilutions and phase ratios, are listed in the primary author's thesis (Ref. 3). The expanded data set was plotted, using existing equivalency formulae, as shown in Figs. 1 through 4. Only the equivalency relationships from the Schaeffler (Ref. 4), DeLong (Ref. 5), Kaltenhauser (Ref. 6) and WRC-1992 (Ref. 7) diagrams were used in these plots; the microstructure boundary lines from the original diagrams were not used. The boundary lines separating the martensite and ferrite regions from the two-phase region in the Figs. 1-4 were determined optimally. It is apparent boundary lines for determining 100% ferrite or martensite formation are possible using any of these equivalency relationships.

If guaranteeing either a fully ferritic or fully martensitic microstructure is all that is required, any of the diagrams in Figs. 1 through 4 would be sufficient. However, the addit ion of iso-ferrite lines to the diagram requires further analysis because the data is not distributed in a smooth transition from 0 to 100% within the two-

WELDING RESEARCH SUPPLEMENT J 341-s

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Cr+ 4Si + 4Ti + 2Mo + 69A1+ 2Mn

Fig. 5 - - Button melt vol-% data plotted using experimental equivalents developed by linear regression analysis including the 0% and 100% data.

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Cr + 8Si + 4Ti + 2Mo + 85AI

Fig. 6 - - Button melt vol-% data plotted using experimental equivalents developed by l inear regression analysis using only the two-phase data.

phase region. Using linear regression analysis, few

experimental equivalency relationships were determined, and the data was plotted, with these values for the axes, in Figs. 5 and 6. The equivalency relationships in Fig. 5 were determined using the complete data set, including the 0 and 100 vol-% ferrite data, while the equivalency relationships in Fig. 6 were determined using only the data from the two-phase microstructural region. It was felt that it was better to use only the two-phase data for the development of the constitution diagram. This is because the 0 and 100 vol-% data could be assigned to an entire region, not a specific point on the diagram, thus making this data less useful for the linear regression analysis. The equivalency relationships in Fig. 6 are similar to the Kaltenhauser factors, if the Kaltenhauser nickel relationship ( 40[C + N] + 2Mn + 4Ni ) is divided by four, and with the exception of the overly large coefficient for aluminum.

At this point, the data analysis led to the conclusion that a diagram could be developed using new equivalency relationships developed with linear regression analysis. Also, by using the new equivalency relationships, iso-ferrite lines could be added within the two-phase region to provide a means of predicting weld metal constitution accurately within the ferrite plus martensite region.

Specific Alloying Element Effects

To resolve concerns over terms such as the coefficient for aluminum in Fig. 6, several buttons were made with specific alloying elements in mind. Alloys such as the nitrogen-strengthened austenitic stainless steel Nitronic 40 (21Cr-6Ni- 9Mn-0.2 N) and the duplex stainless steel

2205 were combined with the ferritic and martensitic stainless steels, as well as with pure iron and A36 structural steel, to create button melt samples with a range of nitrogen, manganese, aluminum and nickel contents. It was hy- pothesized that by producing a wider range of compositions, a more applicable coefficient could be determined for the element in question.

Austenite Formation

Another objective in the development of the diagram was to identify the boundary for austenite formation on the upper right side of the diagram. To do this, microstructures containing austenite were required. These were produced by mix- ing various alloys, such as austenitic Type 304L and duplex Type 312, mainly with ferritic stainless steels. Some austenite was also present in mixtures of 2205 with both ferritic and martensitic alloys. In collecting the microstructural data, a note was made if a microstructure was found to contain austenite, and this data was not used in the regression analysis. This data was later applied to the completed diagram in order to determine a boundary above which austenite can be expected to form in the weld metal.

These microstructures presented a challenge in determining whether austenite was present or whether the austenite had transformed to martensite on cooling. Some of the microstructures appeared very similar when etched using standard procedures. Alloys possessing a duplex ferritic/martensitic microstructure sometimes appear very similar to alloys with a duplex ferritic/austenitic microstructure. To determine whether austenite was present in these alloys, ferro-fluid color metallographic techniques were used (Ref. 2).

Because austenite is not ferromagnetic, the iron particles in the ferro-fluid do not attach to it, and it appears white when observed under an optical microscope, while ferrite and martensite are colored blue or brown. The ferro-fluid technique was thus determined to be an efficient and reliable method for determining whether austenite was present in the microstructure.

Equivalency Relationships

With the addition of the new button melt data to the database, statistical predictions were improved significantly. Compositional ranges for the data were as follows: 7-20 Cr, 0.1-8 Ni, 0.01-0.6 Si, 0.01-0.22 C, 0.3-1.8 Mn, 0-0.23 AI, 0-0.33 Ti, 0-0.48 Nb, 0-3 Mo and 0-0.2 N. A total of 125 button melt samples were included in the database used for regression analysis. Multiple linear regression analysis was used to evaluate the alloying element effects on weld metal volume-percent ferrite. One of the predictive equations, developed using the same elements Kaltenhauser included in his ferrite factor, is given in the following:

vol-% ferrite =-109 + 14.3(Cr + 2 [Si + Mo] + 9[AI + 1]])-21.7(Ni + 20C + 10N + 0.3 Mn)

(2) The chromium and nickel equivalency relationships are the terms in parenthe- ses. Various combinations of elements were chosen, based on previous equivalency formulae, experience and whether or not sufficient data existed for the element, producing a variety of equivalency relationships. From these regressions, coefficients were determined for several of the elements in the chromium and nickel equivalency formulae.

3 4 2 - s J D E C E M B E R 2000

The coefficient of 2 for molybdenum was consistent throughout the regressions on various combinations of elements. Aluminum and titanium also had coefficients consistently in the 8 to 10 range. In most of the trials, carbon was stronger as an austenite stabilizer than nitrogen. The C:N ratio of around 1:5 found in the development of the WRC- 1988 diagram (Ref. 8) seemed to apply here also. Coefficients of around 20 for carbon and 12 for nitrogen were common. Coefficients determined for chromium and nickel were statistically significant, with relatively small standard deviations. Chromium and carbon always showed the strongest effect on volume-percent ferrite.

Coefficients for manganese and silicon were not as consistent and left a degree of uncertainty. Each of these had small coefficients, and thus effects, on the volume-percent ferrite. Also, each was present in both the chromium and nickel equivalency relationships when included in various combinations with other elements. A very surprising finding was that niobium ended up with a negative coefficient, suggesting it acted as an austenite stabilizer, with values ranging from 2 to 8. A coefficient for copper was also investigated, but insufficient data and uncertain results precluded its inclusion in the equivalency relationships.

Because of these uncertainties and in- consistencies with other equivalency formulae, further evaluation was needed for some of the coefficients. Using the combinations of elements that made the most sense from the previous analysis, the correlation matrix of coefficients was examined. It was determined that some of the estimates of coefficients could have errors that were inflated from correlation with other element effect estimates. For example, niobium was strongly corre- lated to the titanium effect estimate. This means the coefficient for niobium was masked by the effect of titanium. This is a possible explanation why niobium seemed to have a negative coefficient. Nickel and molybdenum also showed possible inflation of the standard deviation error due to correlation with other effect estimates.

To evaluate these compositional effects further, ridge regression was employed. This technique, which improves the coefficient estimates by helping to avoid problems caused by highly collinear independent variables, was used to look for coefficients for niobium, silicon and manganese, and to determine if there was inflation of errors for nickel and molybdenum. This analysis showed a coefficient for niobium could not be determined with this data set. Coefficients

z o 4 -I-

(J 3 in tv~ 4- ~ 2

MART INSIT~ / / / / / / / ~ .F

/~~/~~~FERRITE j / / / / / / / ,

I , i i 10 12 14 16 18 20 22

Cr + 2Mo + IO(AI +Ti)

Fig. 7 - - New territic-martensitic stainless steel constitution diagram, which contains a boundary for austenite formation. Iso-ferrite lines are in vol-% ferrite.

6

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Fig. 8 GTA weld vol-% ferrite data plotted on the new diagram.

for silicon and manganese were still uncertain. Also, the coefficients for nickel and possibly molybdenum could be reduced slightly. Reducing the nickel coefficient would have the effect of increasing the coefficients for carbon and nitrogen and other austenite stabilizers in the nickel equivalent relationships.

Plotting the Data

Using the above information, several potential equivalency relationships were determined, and the chromium and nickel equivalent values were calculated for the button melt samples. The chromium and nickel equivalent values were then plotted with the volume- percent ferrite as the data label for each

point. By plotting the various relationships and determining best-fit lines for the data, iso-ferrite contour maps were produced. If only the equations developed using linear regression analysis were used, they would produce a diagram with equispaced and parallel lines. The contour maps had lines that were not parallel or equispaced and that were based on actual data, thus potentially increasing the predictive accuracy. The iso-ferrite contour maps were then used to determine the best equivalency relationships.

On the basis of these evaluations, the best nickel and chromium equivalent equations were the following:

Creq = Cr + 2Mo + 10IAI + Ti] (3)

W E L D I N G RESEARCH SUPPLEMENT J 343-s

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Cr + 2 M o + 10(AI + Ti)

28 30

Fig. 9 - - New ferrit ic-martensit ic stainless steel consti tut ion diagram wi th sl ight ly extended axes.

and and nitrogen were chosen, and it was felt

Nieq = Ni + 35C + 20N (4)

Although only the two-phase volume- percent ferrite data was used in the linear regression analysis, the data for 0 and 100 vol-% ferrite were included in plotting the diagram. This allowed boundary lines to be determined accurately, along with iso-ferrite lines within the two- phase region. All of the iso-ferrite lines were approximated as straight lines.

Austenite Boundary

Some of the button melt samples were mixed in dilutions that would form austenite in the microstructure. These data points were plotted using the new equivalency relationships, and a boundary where austenite begins to form was added to the diagram. Most of the data for austenite formation fell outside the region of volume-percent data and was thus not useful for inclusion in the new diagram. However, enough data existed to add a boundary to the upper right corner of the diagram.

it would be best to have the diagram as much in agreement with the WRC equivalents as possible.

The shape of the martensite plus ferrite region is similar to the Schaeffler diagram (Ref. 4). The martensite boundary has a steeper slope than the ferrite boundary line. This trend also carries over from the Lefevre diagram (Ref. 9) and Lippold's ferritic stainless steel constitution diagram (Ref. 10). The iso-ferrite lines gradually change from steeper to lower slope as volume-percent ferrite increases.

For higher alloyed stainless steels where austenite formation is a possibility, an austenite boundary line has been included.

New Diagram

The ferritic-martensitic stainless steel constitution diagram developed in this study is presented in Fig. 7. The iso-ferrite lines are in volume-percent ferrite. The equivalents were developed based on linear regression analysis and previous experience and intuition. Notice the nickel equivalent is identical to the WRC-1988 nickel equivalent (Ref. 8). Because the ridge regression technique suggested lowering the coefficient for nickel, the larger coefficients for carbon

Evaluation of the New Diagram

Verification with Actual Welds

To check the accuracy of the new ferritic-martensitic stainless steel constitution diagram, autogenous GTA welds were made in all of the base metals used in this study, and volume-percent ferrite was determined for each. An autogenous square-groove weld was also made between Types 410Cb and 409Ni, giving a 50% dilution weld. This procedure helped verify the point counting technique for determining volume-percent ferrite in these alloys, as several of the button melt samples and actual welds were found to contain the same fraction of ferrite in the microstructure by point counting. In the plate materials, heat inputs of 20 and 40 kJ/in, were used. This, combined with the low heat inputs used for the sheet materials, ensured that the range of conventional arc welding heat inputs was represented. It was found that,

within this range, the heat input did not greatly affect the volume-percent ferrite, and hence the predictive capability of the new diagram.

The weld data was then plotted on the new diagram, as shown in Fig. 8. It can be seen the weld metal volume-percent ferrite is predicted with a reasonable degree of accuracy by the new diagram. Further verification should be conducted using welds in alloys not used for production of button melt samples, but all of the available alloys were used in this study. It is felt, however, the microstructures of most conventional ferritic and martensitic stainless steel welds can be predicted accurately with the new diagram.

Practical Imolications

The new ferritic-martensitic stainless steel constitution diagram provides a significant improvement over existing methods for predicting weld metal volume percent ferrite in these alloys. The database used in its development was more extensive than that used by Lefevre (Ref. 9) or Lippold (Ref. 10), and the alloys were from the microstructure region of interest, unlike the Schaeffler diagram (Ref. 4), which was developed using austenitic alloys.

Because most constitution diagrams have been developed based on measured chemical compositions, there was a question whether using composition values based on dilution calculations would be accurate. As a check, the actual chemical compositions of several of the button melt samples were measured. A simple investigation, using the measured nitrogen values in place of the nitrogen values estimated by dilution calculations for the nickel equivalent values, was performed. It was determined the slight differences between measured values and estimated values were negligible in determining the volume-percent ferrite predicted by the diagram. When using the new diagram, the final microstructure of a dissimilar weld or weld with filler metal can be predicted by estimating the dilution and using the chemical composition of the base materials to calculate the final weld metal composition with dilution calculations.

Table 2 provides a comparison of weld metal constitution (volume-percent ferrite) between the Schaeffler diagram and the new diagram, and that determined metallographically for autogenous welds in Type 409 and Type 410 and a dissimilar combination between A36 and Type 430. It is evident the new diagram predicts weld metal microstructure much more accurately than the Schaeffler diagram in the ferrite plus martensite region.

3 4 4 - s J DECEMBER 2000

Table 2 - - Predicted vs. Actual Volume Percent Ferrite

Alloy

410 409 635 430 + 37% A36

Phrase Vol-% Vol-% Vol-% Field Ferrite Ferrite Ferrite (New

(Schaeffler) (Schaeffler) (Actual) Diagram)

M+F 30 8 8 M + F 90 99 96 M+F 20 0 0

It is felt the boundary lines for 100% ferrite and martensite on the new diagram are highly accurate, while the iso- ferrite lines are more qualitatively accurate. Also, the austenite formation boundary is considered qualitative. The diagram can be used with a high level of confidence to determine whether or not a second phase will form when welding the ferritic and martensitic stainless steels, and provides an accurate estimate of the actual volume-percent of the second phase. Figure 9 shows the new diagram with slightly extended axes. This was done to allow the diagram to be used when welding alloys, such as the 25Cr ferritics, whose base metal compositions fall outside the initial boundaries. Pre- diction of weld metal volume-percent ferrite or martensite above Nieq = 6 should be considered qualitative.

Limitations

The new diagram should only be applied to alloys welded with conventional arc welding processes. High-energy- density (HED) processes, such as laser beam welding (LBW) or electron beam welding (EBW), produce high solidification and cooling rates. Under these conditions, both the solidification and phase transformation behavior may be altered relative to arc welds. This may result in different proportions of ferrite and martensite and could promote the retention of austenite in some alloys.

Extrapolation of the lines on the diagram outside the boundary regions shown in Fig. 9 is not recommended. The microstructure database used in the development of the diagram is represented by the axes of the diagram; therefore, errors may be introduced by predicting microstructures outside the boundaries of the diagram. Prediction below Nie~ = 0.5 is also not recommended. Microstruc- tures of alloys containing very low carbon contents may not be accurately predicted by the new diagram. The diagram is very accurate within the compositional limits of conventional ferritic and martensitic stainless steels. A compositional range of confidence is listed in Table 3. The differences between the compositional values listed in Table 3

and those previously listed in the Equiv- alency Relationships section are due to the wide range of experimental data. The previously listed ranges were from the specific compositions of the experimental button melts, which included other types of stainless alloys and some non- stainless alloys. The compositional ranges listed in Table 3 are based more on commercially available ferritic and martensitic stainless steels.

Conclusions

1) A new ferritic-martensitic stainless steel constitution diagram is proposed that uses compositional factors developed using linear regression analysis. This new diagram includes iso-ferrite lines within the martensite plus ferrite region. A boundary for austenite formation is also proposed.

2) The diagram provides improved predictive accuracy over currently available methods for predicting ferritic and martensitic stainless steel weld metal microstructure. The boundary lines for 100% ferrite and martensite on the new diagram are highly accurate, while the iso-ferrite lines and austenite formation boundary are qualitatively predictive.

3) The new diagram should be applied only to alloys welded with conventional arc welding processes. The use of high- energy-density processes, such as laser and electron beam welding, may result in different proportions of ferrite and martensite and could promote the retention of austenite.

Acknowledgments

The authors acknowledge the Ameri- can Welding Society, which provided principal funding for this project through an AWS graduate research fellowship. We are grateful to Damian Kotecki of The Lincoln Electric Co., who provided assistance and expert advice during the project. Thanks also to Paul Lovejoy, formerly with Allegheny Ludlum, for providing materials and advice, and others who provided materials, including Mauro Losz at Armco Research, Terry DeBold at Carpenter Technologies, Bryan O'Neal at Air Liquide and Ravi

Table 3 - - Compositional Range of Confidence for the New Diagram

Element Compositional Range (wt-%)

Cr 11-30 Ni 0.1-3.0 Si 0.3-1.0 C 0.07-0.2 Mn 0.3-1.8 Mo 0-2.0 AI 0-0.3 Ti 0-0.5 N 0-0.25

Menon at Stoody Company. We are ap- preciative of the Edison Welding Institute for allowing the use of the button melting equipment. We are also indebted to Pro- fessor Theodore T. Allen at The Ohio State University for his help with statistical analysis and interpretation.

References

1. Balmforth, M. C., and Lippold, J. C. 1998. A preliminary ferritic-martensitic stainless steel constitution diagram. Welding Jour- nal 77(1 ): 1 -s to 7-s.

2.1989. ASM Handbook, Volume 9, Met- allography and Microstructures, John Newby, Ed. ASM International, Materials Park, Ohio.

3. Balmforth, M. C. 1998. Development of a ferritic-martensitic stainless steel constitution diagram. Master's thesis. Columbus, Ohio, The Ohio State University.

4. Schaeffler, A. L. 1949. Constitution diagram for stainless steel weld metal. Metal Progress 56(11 ): 680-680B.

5. DeLong, W. T., Ostrom, G. A., and Szu- machowski, E. R. 1956. Measurement and calculation of ferrite in stainless steel weld metal. Welding Journal 35(11 ): 521 -s to 528-s.

6. Kaltenhauser, R. H. 1971. Improving the engineering properties of ferritic stainless steels. Metals Engineering Quarterly 11 (2): 41-47.

7. Kotecki, D. J., and Siewert, T. A. 1992. WRC-1992 constitution diagram for stainless steel weld metals: a modification of the WRC- 1988 diagram. Welding Journal71 (5): 171 -s to 178-s.

8. Siewert, T. A., McCowan, C. N., and Olson, D. L. 1988. Ferrite number prediction to 100 FN in stainless steel weld metal, welding Journal 67(12): 289-s to 298-s.

9. Lefevre, J., Tricot, R., and Castro, R. 1973. Noveaux aciers inoxyables a 12% de chrome. Revue de Metallurgie 70(4): 259.

10. Lippold, J. C. 1991. A review of the welding metallurgy and weldability of ferritic stainless steels. EWl Research Brief B9101, Columbus, Ohio.

W E L D I N G RESEARCH SUPPLEMENT I 345 -s

A Martensite Boundary on the WRC-1 992 Diagram Part 2: The Effect of Manganese

Manganese is found to be more powerful than nickel in stabilizing austenite with respect to transformation to martensite

BY D. J. KOTECKI

ABSTRACT. The upper boundary for martensite appearance in stainless steel weld metals on the Schaeffler Diagram is shown to be overly conservative, it also does not predict a manganese effect beyond its coefficient in the nickel equivalent. A modification to the WRC-1992 Diagram is proposed, which takes variation of manganese into account. The martensite boundary is based upon magnetic measurements and 2T longitudinal face bend tests of numerous submerged arc weld claddings. Separate boundaries are offered for 1%, 4% and 10% Mn.

Introduction

The Schaeffler Diagram (Ref. 1), now fifty years old, is well outdated for ferrite prediction in stainless steel welds. It was supplanted in large part by the DeLong Diagram (Ref. 2), which has in turn been supplanted by the WRC-1992 Diagram (Ref. 3). The newer diagrams make predictions in terms of Ferrite Number (FN) instead of ferrite percent (FP). FN is more reproducible than FP, and it is obtained nondestructively, by magnetic means. Since 1995, the WRC-1992 Diagram has been the recommended method of ferrite prediction in the ASME Code (Ref. 4). However, the WRC-1992 Diagram did not take martensite formation into account. Because the Schaeffler Diagram does make martensite predictions, it tends still to be referenced in stainless steel weld cladding and dissimilar metal joining situations.

Since the WRC-1992 Diagram is recommended for ferrite prediction, it is rather awkward to still rely on the Schaef- tier Diagram for martensite prediction.

D. J. KOTECKI is with The Lincoln Electric Co., Cleveland, Ohio.

Accordingly, a study was undertaken to allow placement of a martensite boundary on the WRC-1992 Diagram. The first part of this study concentrated on compositions containing nominally 1% Mn, and showed the upper martensite boundary on the Schaeffler Diagram does not agree well with the experimental results (Ref. 5). Using results of magnetic measurements and 2T longitudinal face bend tests, an upper martensite boundary, for 1% Mn compositions, was proposed for the WRC-1992 Diagram.

However, it must be recognized there are a number of stainless steel weld filler metal compositions of appreciably more than 1% Mn content. Such compositions include AWS Type 307 (typically around 4% Mn), the European 18 8 Mn (typically around 6% Mn) and the AWS Type 219 (typically around 10% Mn). These filler metals are often used as cladding or buffer layers, or for dissimilar metal joining. Manganese has been shown to have a negligible effect on solidification of stainless steel weld metals as regards formation of ferrite or austenite at high temperature (Ref. 6). But manganese has a very important effect of stabilizing austenite as regards transformation to martensite at low temperatures (Ref. 7). So it is of interest to extend the earlier

KEY WORDS

Stainless Steel Manganese Weld Cladding Martensite WRC-1992 Diagram Bend Test

work to consider higher Mn levels than 1%, and to examine how higher Mn levels in the weld metal affect the position of the upper martensite boundary on the WRC-1992 Diagram.

Experimental Materials

Numerous chromium-nickel stainless steel single-pass deposits were produced by submerged arc welding on carbon steel plate. All of the wires employed in Part 2 of this study were ~g2-in. (2.4-mm) diameter tubular metal cored wires. Two series of wires were specially fabricated, one to obtain single-pass deposit compositions on ASTM A36 steel of about 4% Mn, and the second to obtain single-pass deposit compositions of about 10% Mn. The wire compositions were all designed to produce deposits of about 0.1% C, 0.5% Si and 0.02% N, with no significant Mo or Nb content. The compositional variables, then, were Mn, Cr and Ni. Table 1 lists the nominal wire compositions, based upon calculation from the fill formulation. Since dilution from the A36 steel is not taken into account in these calculated wire compositions, and since some loss of manganese during welding was expected, the nominal wire compositions are appreciably higher in Mn than the 4% and 10% targets for the weld deposits, it is the deposit composition that is important.

Only unalloyed high basicity fluxes were used in this part of the study. They are standard commercial products.

Experimental Welds and Evaluation

Each wire was used to make deposits under several welding conditions, primarily varying wire feed speed (current), with corresponding change in travel speed to obtain more-or-less consistent

346-s J DECEMBER 2000

Table 1 - - Ca lcu la ted W i r e Composi t ions

Wire C Mn Number

1761 0.119 7.65 1762 0.031 8.57 1775 0.122 8.57 1776 0.109 6.65 1777 0.103 6.64 1786 0.102 7.18 1787 0.111 7.19 1791 0.112 7.72 1792 0.102 7.18

Calculated Wire Composition (wt-%)

S Si Cr Ni

Wires Producing Diluted Deposits of about 4% Manganese

Mo Nb N

0.007 0.006 0.06 5.61 11.32 0.00 0.00 0.0004 0.015 0.010 0.33 27.39 6.29 0.16 0.00 0.027 0.015 0.012 0.30 21.89 10.48 0.16 0.00 0.027 0.008 0.008 0.46 7.28 19.63 0.00 0.00 0.0004 0.010 0.005 0.58 24.54 2.93 0.00 0.00 0.0004 0.008 0.006 0.49 27.55 2.70 0.00 0.00 0.0004 0.008 0.009 0.42 7.19 20.71 0.00 0.00 0.0004 0.007 0.009 0.41 6.53 22.06 0.00 0.00 0.0004 0.008 0.006 0.46 28.76 2.70 0.00 0.00 0.0004

1793 0.111 19.28 1794 0.110 19.28 1795 0.111 19.28

Wires Producing Diluted Deposits of about 10% Manganese

0.008 0.009 0.41 6.56 9.00 0.00 0.00 0.008 0.008 0.49 14.81 3.65 0.00 0.00 0.007 0.008 0.46 14.90 4.55 0.00 0.00

0.001 0.001 0.001

weld deposit weight per unit length, but varying di lut ion so a number of different compositions could be obtained with a single wire. In the early part of the study, weld deposits were stringer beads. Later in the study, 1-in. (25-mm) osci l lat ion was employed to produce a wider deposit that was more easily chemically analyzed by spectrographic methods. In all cases, the base metal was ASTM A36 carbon steel of approximately 0.15% C, '~ in. (12.7 mm) thick and 3 in. (75 ram) wide. The weld deposits were about 14 in. (355 mm) long, so that bending in the longitudinal direction did not include the arc start or crater area. Except for intro- ducing oscillation, the approach is the same as during the first part of the study, as reported in Ref. 5.

Two methods were used to evaluate the presence of martensite in the as- welded condition. The first was a magnetic measurement of "FN" in the as- deposited condit ion after l ightly grinding the weld centerline smooth. "FN" is used in quotation marks here to indicate that, wh i le the instrument is calibrated according to AWS A4.2 for FN measurements, that which is being measured can be ferrite and/or martensite, since both microstructures are ferromagnetic. The measured "FN" was compared with the FN calculated from the WRC-1992 Dia- gram, extrapolating the iso-ferrite lines in the diagram if necessary. Then the presence of martensite is indicated by the measured "FN" exceeding the calculated FN by more than 1.0. Conversely, the absence of martensite is indicated by the measured "FN" being nearly equal to, or less than, the calculated FN.

The second method used to evaluate the presence of martensite was to perform a longi tud inal face bend test around a mandrel whose radius was

32

' 2 8

+

g 2o

+

~ 12 |1

w

• 4

t t . . . . ~ - ~Jpp_erMartpnsltl / / / L ~ Z - ~ - o % - s°~

Boundary ~ccordlng / ~uste te I | I I ~ i ~ , / i

,/. ' . i _ i [ . . . . !.. / | [ x g " / ~ j 1 0 % '< I I I ~ r ,-~,,~.,,~,,- E I I / " [ / " S t

__ ~ - ~ [e : ~ i Bo..,4ry [ I Y - ~ - J l ~ L _

I - - - / , -" . . . . . . 8o~

"~v,,. "T~.I)'>C. / / ~ " iD.~ I,..r-~I ; ! l .

\ Mai tens l te | / I ~ / x / ~ 1 / I ~F ~ - ' I. ;

! r • i •

0 4 8 12 t 6 20 24 28 32 36

C r Equ iv . = % C r + % M o + 1 . 5 ( % S i ) + 0 . 5 ( % N b )

f

S

J

I

40

Fig. 1 - - Martensite-free 4% Mn compositions on the Schaeffler Diagram. Many 4% Mn compositions, indicated by solid circles, are below the 1% Mn martensite-free boundary.

twice the thickness of the base metal (a test commonly referred to as a "2T" bend test). This test requires at least 20% tensile elongation in the weld metal to pass the test wi thout cracking. A given weld then either passes the test, or it cracks. Cracking is taken to be evidence of martensite, which is brittle, in the as- deposited condit ion.

Metal lographic examinat ion had been used in the first part of this study to verify martensite was indeed present in certain samples. Given the excellent correlation of metal lographic determinations with magnetic measurements and bend test results, it was not considered necessary to perform more than a few

metallographic examinations, and none are reported herein.

After the "FN" measurement and bend test, the sample was bent back flat. Then the region of the apex of the bend was prepared for chemical analysis. Chips were machined for C, S and N by fusion analysis. The remainder of the analysis was performed by optical emission spectrophotometry and/or X-ray flu- orescence, with a limited number of wet analyses done also as checks on the spectrographic methods. From the chemical analysis data, chromium and nickel equivalents according to both the Schaeffler and the WRC-1992 Diagrams were calculated. These were then plot-

W E L D I N G R E S E A R C H S U P P L E M E N T I 3 4 7 - s

Table 2 - - Experimental Results

Test Weld Number

1761-1 1761-2 1761-3 1761-4 1761-5 1761-6 1761-7 1761-8 1761-9 1762-1

C Mn P S

0.107 4.80 0.018 0.013 0.106 4.10 0.017 0.015 0.117 4.05 0.017 0.014 0.111 3.85 0,017 0.015 0.117 4.15 0.017 0.015 0.115 4.00 0.017 0.015 0.101 3.99 0.016 0.016 0.110 4.36 0.015 0,015 0.112 4.39 0.019 0.018 0.065 4.85 0.023 0.007

Deposits Composition, % Si Cr Ni Mo Cu Nb N Measure WRC Schaeffler

"FN" FN % Ferrite

0.34 9.58 10.25 0.10 0.16 N.D '(al 0.022 0.0 0.0 0.0 0.29 8.93 9.31 0.08 0.15 N.D. 0.021 0.0 0.0 0.0 0.25 6.49 9.14 0.10 0.14 N.D. 0.021 0.0 0.0 0.0 0.27 7.87 8.80 0.08 0.15 N.D. 0.021 0.8 0.0 0.0 0.26 7.78 9.20 0.08 0.14 N.D. 0.020 0.4 0.0 0.0 0.25 7.50 8.35 0.08 0.14 N.D. 0.020 2.7 0.0 0.0 0.38 8.80 8.73 0.12 0.16 N.D. 0.021 0.1 0.0 0.0 0.40 8.86 9.19 0.12 0.15 N.D. 0.020 0.0 0.0 0.0 0.49 8.72 8.83 0.13 0.16 N.D. 0,020 0.0 0.0 0.0 0.48 15.45 4.52 0,13 0.18 N.D. 0.044 25.5 6.2 3.9

1762-2 1762-3 1762-4 1762-5 1762-6 1762-7 1775-1 1775-2 1775-3 1775-4

0.064 4.85 0.022 0.010 0.46 16.05 4.23 0.13 0.17 N.D. 0.071 4.55 0.020 0.011 0.44 15.45 3.97 0.12 0.16 N.D. 0.073 4.40 0.019 0.014 0.38 15.38 3.79 0.12 0.16 N.D. 0.075 4.15 0.018 0.011 0.33 14.51 3.64 0.10 0.15 N.D. 0.072 4.20 0.017 0.014 0.56 14.16 3.76 0.13 0.17 N.D. 0.079 4.06 0.020 0.015 0.69 12.56 3.51 0.13 0.17 N.D. 0.102 4.25 0.017 0.019 0.47 11,12 5.77 0.14 0.17 N.D. 0.101 3.90 0.017 0.018 0.47 10.86 5.34 0.12 0.17 N.D. 0.098 3.75 0.018 0.014 0.54 11.61 5.67 0.13 0.17 N.D. 0.108 4.22 0.017 0.016 0.50 10.589 5.53 0.13 0.16 N.D.

0.036 14.7 11.3 7.4 0.032 8.1 8.9 6.0 0.031 11.0 9.0 6.1 0.030 14.4 4.9 2.3 0.027 11.4 3.6 2.1 0.025 54.3 0.0 0.0 0.023 3.1 0.0 0.0 0.023 36.3 0.0 0.0 0.024 19.0 0.0 0.0 0.024 7.4 0.0 0.0

1775-5 1775-6 1775-7 1775-8 1776-1 1776-2 1776-3 1776-4 1776-5 1777-1

0,103 4.84 0.019 0.014 0.67 12.98 6.64 0.15 0.18 N.D. 0.105 3.95 0.019 0.016 0.59 10.75 5.40 0.13 0.17 N.D. 0.099 4.07 0.021 0.014 0.61 11.16 5.63 0.13 0.17 N.D. 0.103 4.45 0.025 0.020 0.85 12.18 5.93 0.15 0.17 N.D. 0.080 3.76 0.021 0.014 0.81 4.90 12.57 0.02 0.05 N.D. 0.092 3.30 0.017 0,015 0.61 4.34 10.26 0.01 0.06 N.D. 0.084 3.72 0.020 0.011 0.70 5.08 I3.35 0.01 0.03 N.D. 0.086 3.36 0.034 0.023 0.43 4.22 11.06 0.03 0.09 N.D. 0.082 3.62 0.018 0.023 0.72 5.04 11.77 0.02 0.04 N.D. 0.098 3.55 0.018 0.013 0.83 14.46 1.73 0.02 0.04 N.D.

0,027 0.0 0.0 0.0 0.024 9.0 0.0 0.0 0.024 4.2 0.0 0.0 0.026 0.0 0.0 0.0 0.010 23.2 0.0 0.0 0.011 74.1 0.0 0.0 0.011 0.5 0.0 0.0 0.012 57.5 0.0 0.0 0.013 23.6 0.0 0.0 0.020 77.2 10.7 11.7

1777-2 1777-3 1777-4 1777-5 1777-6 1786-I 1786-2 1786-3 1787-I 1 787-2

0.106 3.11 0.019 0.016 0.82 11.88 1.53 0.02 0.06 N.D. 0.107 3.33 0.027 0,016 0.54 13.77 1.73 0.03 0.06 N.D. 0.112 3.56 0.018 0.022 0.78 15.71 2.07 0.03 0.04 N,D. 0.106 3.32 0.019 0.022 0.89 15.54 2.08 0.03 0.05 N.D. 0.123 4.04 0.020 0.020 0.91 14.99 2.15 0.02 0.05 N.D. 0.125 4.15 0.015 0.011 0.76 10.89 2.26 0.02 0.04 N.D. 0.144 3.94 0.018 0.016 0.69 8.77 1.60 0.02 0.06 N.D. 0.125 3.86 0.017 0.010 0.79 9.76 1.78 0.02 0.05 N.D. 0.089 4.24 0.012 0,017 0.61 5.27 13.33 0.02 0.04 N.D. 0.113 3.15 0.0014 0.019 0.48 3.40 8.98 0.01 0.05 N.D.

0.018 79.4 0.3 0.0 0.020 76.7 5.2 6.7 0.025 49.5 12.2 13.1 0.024 52.7 12.5 15.0 0.026 44.8 6.6 8.2 0.019 75.3 0.0 0.0 0.016 80.6 0.0 0.0 0.019 76.2 0.0 0.0 0.012 2.5 0.0 0.0 0.011 74.2 0.0 0.0

1787-3 0,106 3.41 0.015 0.017 0.57 3.86 10.11 0.01 0.05 N.D. 1787-4 0.099 3.42 0.014 0.018 0.57 3.96 11.06 0.02 0.05 N.D. 1791-1 0.082 4.00 0,012 0.014 0.58 4.54 13.48 0.01 0.03 N.D. 1791-126 0.073 5.40 0.014 0.009 0.73 5.61 17.62 0.01 0.03 N.D. 1791-128 0.074 4.88 0.015 0.011 0.80 5.18 16.40 0.01 0.03 N.D. 1791-2 0.101 3.19 0.011 0.017 0.35 2.97 9.60 0.01 0.07 N.D. 1791-3 0.085 4.58 0.013 0.012 0.63 5.01 15.62 0.01 0.03 N.D. 1791-4 0.079 4.30 0.013 0.011 0.60 4.60 14.91 0.01 0.03 N.D. 1792-1 0.115 3.36 0.012 0.011 0.65 15.98 1.57 0.01 0.04 N.D. 1792-2 0,121 2.79 0,014 0.016 0.41 11.51 1.23 0.01 0.04 N.D.

0.011 77.8 0.0 0.0 0.011 56.2 0.0 0.0 0.015 26.1 0.0 0.0 0.012 0.0 0.0 0.0 0.012 0.0 0.0 0.0 0.014 84.0 0.0 0.0 0.016 0.0 0.0 0.0 0.015 0.0 0.0 0.0 0.019 68.9 17.3 16.6 0.018 81.2 0.0 0.0

1792-3 1792-4 1792-5 1793-1 1793-2 1793-3 1793-4 1793-5 1793-6 1793-7

0.111 3.99 0.011 0.010 0.I 09 4.49 0.012 0.011 0.102 4.28 0.012 0.012 0.112 11.66 0,012 0.010 0.110 9.22 0.010 0.014 0.101 11.33 0.011 0.010 0.109 9.31 0.011 0.013 0,110 9.49 0.011 0.014 0.103 10.47 0.015 0.010 0.103 9.78 0.018 0.011

0.67 19.15 2.08 0.01 0.03 N.D. 0.70 20.30 1.94 0.01 0.03 N.D. 0.68 20.26 2.01 0.01 0.03 N.D. 0.80 4.95 6.61 0.02 0.03 N.D. 0.42 3.51 4.76 0.01 0.05 N.D. 0.71 4.75 6.35 0.01 0.04 N.D. 0.54 3.70 4.97 0.01 0.04 N.D. 0.47 3.63 5.14 0.01 0.05 N.D. 0.71 4.23 5.68 0.01 0.07 N.D. 0.76 3.81 5.14 0.01 0.08 N.D.

0.022 67.9 76.4 33.3 0.022 66.8 >100 44.9 0.025 78.7 >100 48.1 0.018 0.0 0.0 0.0 0.012 17.2 0.0 0.0 0.021 0.0 0.0 0.0 0.010 11.6 0.0 0.0 0,012 4.0 0.0 0.0 0.012 0.1 0.0 0.0 0.012 4.3 0.0 0.0

1794-1 0.102 11.72 0.015 0.008 0.97 11.25 2.73 0.01 0.05 N.D. 1794-2 0.099 11.68 0.018 0.008 0.99 10.50 2.70 0,01 0.06 N.D. 1794-3 0.108 9.21 0.013 0.011 0.77 8.91 2.06 0.01 0.08 N.D. 1794-4 0.105 8.60 0.019 0.012 0.81 7.47 1.90 0.01 0.08 N.D. 1794-5 0.111 9.81 0.015 0.013 0.66 8.34 2.15 0.01 0.09 N.D. 1795-1 0.108 11.04 0,012 0.009 0.80 9.91 3.06 0.01 0.04 0.00 1795-1R 0.104 11.25 0.013 0.009 0.79 10.77 3.36 0.01 0.03 0.00 1795-2 0.109 10.36 0.013 0.010 0.63 9.27 2.94 0.01 0.04 0.00 1795-3 0.111 9.90 0.013 0.016 0.60 8.88 2.77 0.01 0.04 0.00 1795-4 0.115 9.92 0.013 0.013 0.55 8.58 2.69 0.01 0.04 0.00 1795-5 0.116 9.38 0.012 0.015 0.49 8.09 2.48 0.01 0.04 0.00

0.025 4.1 0.0 0.0 0.021 + 5.7 0.0 0.0 0.017 12.6 0.0 0.0 0.016 25.9 0.0 0.0 0.017 21.6 0,0 0.0 0.020 0.8 0.0 0.0 0.020 0.7 0.0 0.0 0.018 4.5 0.0 0.0 0.016 9.3 0.0 0.0 0.016 10.2 0.0 0.0 0.015 14.0 0.0 0.0

(a) N.D. = Not Determined. (b) Some bending before crack.

348-s I DECEMBER 2000

Table 2 - - Cont inued

WRC- 1992 Bend Measured Creq Nieq

"FN" after bend

ok 2.5 9.68 14.48 ok 21.1 9.01 13.48 ok 21.0 8.59 13.69 ok 32.8 7.95 13.14 ok 35.9 7.86 13.73 crack 44.9 7.58 12.81 ok 26.8 8.92 12.73 ok 25.7 8.97 13.48 ok 22.8 8.85 13.19 ok 33.2 15.58 7.72

Schaeffler

Crc~ I

10.19 9.45 8.97 8.36 8.25 7.96 9.49 9.58 9.58

16.30

Ni~

15.86 14.54 14.68 14.06 14.79 13.80 13.76 14.67 14.39 8.90

Wire Feed,

in./min

2OO 24O 280 28O 3OO 320 24O 28O 32O

9O

ok 42.6 16.18 7.23 16.87 8.58 120 ok 63.8 15.57 7.14 16.23 8.38 150 ok 63.2 15.48 7.01 16.05 8.18 180 c~ck 80.0 14.61 6.90 15.11 7.97 210 crack 82.2 14.29 6.86 15.12 8.02 180 crack 82.7 12.69 6.81 13.73 7.91 220 c~ck (b) 46.0 11.26 9.84 11.96 10.96 240 crack 76.7 10.98 9.38 11.69 10.32 280 c~ck Ib) 83.0 11.74 9.62 12.54 10.49 200 crack 70.3 11.02 9.83 11.77 10.88 180

ok 16.3 13.13 10.82 14.13 12.15 160 crack (b~ 53.7 10.87 9.60 11.75 10.52 170 crack {b~ 54.6 11.28 9.62 12.19 10.64 165 ok 33.4 12.33 10.10 13.60 11.25 160 crack {b~ 64.8 4.92 15.58 6.14 16.85 150 crack 82.5 4.35 13.71 5.27 14.77 200 ok 34.3 5.10 16.51 6.15 17.72 120 crack Ibl 81.7 4.25 14.33 4.90 15.32 130 crack (b) 43.8 5.06 14.91 6.15 16.04 130 crack 84.2 14.48 5.57 15.73 6.45 150

crack 81.0 11.90 5.61 13.13 6.27 200 crack 80.5 13.80 5.89 14.61 6.60 120 crack 72.0 15.73 6.50 16.90 7.21 100 crack 69.4 15.57 6.28 16.90 6.91 80 crack 72.1 15.02 6.99 16.38 7.86 120 crack 77.0 10.91 7.02 12.05 8.08 100 crack 81.2 8.79 6.97 9.83 7.89 200 crack 80.8 9.78 6.54 10.96 7.46 80 ok 26.9 5.29 16.69 6.21 18.12 100 crack 84.2 3.41 13.17 4.13 13.95 200

Travel Speed, in.lmin

20 24 28 28 28 30

8 9

10 12

Volts DCEP

34 34 34 38 40 40 30 30 30 34

Amps

N.D. N.D. IN.D. N.D. N.D. N.D. N.D.

49O 515 N.D.

15 18 21 24

6 7 8 9 8 7

34 N.D. 34 N.D. 34 N.D. 34 N.D. 30 370 30 415 30 N.D. 30 N.D. 30 N.D. 30 375

6 30 355 6.5 30 360 6 30 345 5 30 350 4 30 360 6.5 30 415 4 30 310 5 30 340 4 30 340 4 30 360

6.5 30 410 4 30 300 4 30 340 4 3O 22O 4 30 280 4 30 270 8 3O 34O 4 30 175 4 30 270 8 30 435

Electrical Extension

in.

17., 1 1

Welding Technique

stringer stringer stringer stringer stringer stringer

oscillation oscillation oscillation

stringer

stringer stringer stringer stringer

oscillation oscillation oscillation oscillation oscillation oscillation

oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation


crack 86.8 3.88 14.05 4.73 14.99 150 c~ck 77.6 3.98 14.76 4.84 15.74 125 c~ck (b~ 65.9 4.55 16.66 5.43 17.94 100 ok 0.0 5.62 20.43 6.71 22.51 100 ok 0.4 5.19 19.24 6.38 21.06 100 c~ck 86.1 2.98 13.44 3.50 14.23 200 ok 0.3 5.02 18.92 5.97 20.46 100 ok 11.5 4.61 17.99 5.50 19.43 100 c~ck 76.9 15.99 5.98 16.96 6.70 100 crack 81.7 11.52 5.83 12.13 6.25 200

6 30 375 1 5 30 345 1 4 30 295 1 4 26 N.D. 1 4 28 265 1 8 30 465 1 4 30 250 1~ 4 30 265 1~ 4 3O 285 I 8 30 445 1


crack ~N 69.7 19.17 6.41 20.16 7.40 100 crack d~l 66.6 20.30 6.20 21.35 7.45 100 crack ~b~ 77.6 20.27 6.09 21.29 7.21 100 ok 11.1 4.97 10.90 6.17 15.80 100 crack (h) 65.8 3.52 8.86 4.15 12.67 200 ok 12.8 4.76 10.31 5.82 15.05 125 crack Ibl 55.2 3.71 9.00 4.52 12.90 150 crack Ib) 56.7 3.64 9.24 4.35 13.18 175 ok 31.5 4.24 9.55 5.30 14.01 150 crack ~h~ 50.2 3.82 9.00 4.95 13.12 175

c~ck ~b) 34.5 11.26 6.82 12.72 11.65 100 c~ck Ib; 50.2 10.51 6.60 12.00 11.51 125 crack 50.9 8.91 6.20 10.07 9.90 150 crack 45.4 7.47 5.91 8.69 9.35 175 crack 61.7 8.35 6.39 9.34 10.38 200 ok 30.0 9.92 7.25 11.13 11.82 100 ok 23.6 10.78 7.41 11.98 12.10 100 crack Ibl 38.6 9.28 7.12 10.22 11.39 125 ok 50.9 8.89 6.98 9.78 11.05 150 c~ck ~b) 53.6 8.59 7.05 9.41 11.10 175 crack Ib) 64.4 8.10 6.85 8.83 10.65 200

3O 240 30 210 30 245 30 265 30 425 30 315 30 365 30 390 28 355 28 390

17-, 2 1¼

28 265 28 315 28 330 28 360 28 395 28 295 28 295 28 345 28 370 28 400 28 445


oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation oscillation

WELDING RESEARCH SUPPLEMENT I 349-s

18

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12

10

8

6

0 2 . 4 6 8 10 12 14 16 18 20 22 24 26 28 30

Cr Equiv. = %Cr + %Mo + 0.7(%Nb)

Fig. 2 - - Martensite-free 4% Mn compositions on the WRC-1992 Diagram. Many 4 % Mn compositions, indicated by solid circles, are below and left of the 1% Mn martensite-free boundary. A 4% Mn martensite-free boundary, based on magnetic measurements, is indicated.

I i I I : / --I .4/- A..,e.,,. ' Z ' I - - ' . X , i . "

• " " "

~ 12 !_ .a: , ~ ~ [ ~ L ! "~ 8 lO%

0 4O

Sl + (

Fig. 3 - - Bend~break results at 4% Mn on the 5chaeffler Diagram. Compositions that passed the 2T bend test are shown as solid circles. Compositions that cracked during bending are shown as open squares.

ted on the diagrams in two ways. First, only compositions whose measured "FN" was less than the calculated FN plus 1 were plotted on each diagram to find the lower left boundary of such compositions. Then, all the results were plotted on each diagram, with a different symbol for those that passed the bend test than for those that cracked, in order to find a boundary dividing the two types of bend test behavior.

E x p e r i m e n t a l Resul ts

Table 2 lists all the experimental weld compositions in this phase of the study, along with the welding conditions employed in making each weld, calculated nickel and chromium equivalents, 2T longitudinal face bend test results, and measured "FN" before and after bending. In many cases, the measured "FN" after bending is much higher than before

bending, which indicates considerable transformation of austenite to martensite during bending, which is to be expected. It is the presence or absence of martensite before bending that is of interest. More than 50 compositions were examined at the nominal level of 4% Mn, and 18 were examined at the nominal level of 10% Mn.

4% Mn Compositions

Figure 1 plots the magnetically determined martensite-free 4% Mn compositions, from Table 2, on the Schaeffler Di- agram. No lower left boundary for martensite-free compositions is offered for 4% Mn compositions because it is not the intent to propose a correction to the Schaeffler Diagram. Despite the fact the Schaeffler Diagram includes manganese in the nickel equivalent, it can be qualitatively seen that, for 4% Mn, the magnetically determined limit of martensite- free compositions has shifted leftward and somewhat counterclockwise relative to the 1% Mn boundary observed in Part 1 of this study.

Figure 2 plots the same composition data on the WRC-1992 Diagram. A boundary line for 4% Mn compositions is indicated in this figure. Without manganese in the nickel equivalent, the leftward and counterclockwise shift of the magnetically determined martensite boundary from 1 to 4% Mn is more pro- nounced in this diagram than in the Schaeffler Diagram.

Figure 3 plots the bend test results on the Schaeffler Diagram. As was noted in the first part of this study where 1% Mn compositions were considered, there is a transition region of mixed pass-fail results. Above and to the right of this mixed zone, all compositions, except three very high in ferrite, pass the 2T bend test. The failure of the high ferrite compositions to pass the bend test can be attributed to excessive ferrite, not to martensite. In a study of duplex ferritic-austenitic stainless steel weld metals, it was found (Ref. 8) that ferrite above 60 FN resulted in reduced ductility in the weld metal, so this is not unexpected. Below and to the left of this mixed bend test zone, all compositions fail the 2T bend test. Again, the magnetically determined martensite boundary lies within the zone of mixed bend test results.

Figure 4 plots these same bend test results on the WRC-1992 Diagram. Com- positions in the upper right portion of the diagram all bent, except for the three high ferrite compositions, as noted above. These three compositions are calculated, by extrapolating the iso-ferrite lines of the WRC-1992 Diagram, to have


10% Mn Compositions

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30


Figure 5 plots the magnetically determined martensite-free compositions of nominally 10% Mn on the Schaeffler Di- agram. Further leftward shift of martensite-free compositions can be seen as compared to 4% and 1% Mn compositions. In particular, a composition can be seen that is entirely martensite-free but lies within the region of the Schaeffler Di- agram predicted to be completely martensite. Clearly, the Schaeffler Dia- gram is inadequate for predicting martensite in these high manganese compositions.

Figure 6 plots the magnetically determined martensite-free 10% Mn compositions on the WRC-1992 Diagram, with a lower-left boundary for such compositions. It should be noted there are not a lot of compositions available to act as a basis for this boundary, so there must be considerable uncertainty attached to it. However, leftward shift and counterclockwise rotation of the boundary compared to that for the 4% and 1% Mn compositions is evident.

Figure 7 plots the 2T bend test data at 10% Mn on the Schaeffler Diagram. As in the case of the 4% Mn results, there is no attempt to draw boundaries for compositions that all bend, or all break, because there is no intention to propose a correction to the Schaeffler Diagram. It can be noted there are two compositions in the zone predicted by the diagram to consist of 100% martensite that passed the bend test.

Figure 8 plots the 2T bend test data at 10% Mn on the WRC-1992 Diagram. Once again, there is a transition zone, indicated by heavy parallel lines, of mixed bend test behavior, and the magnetically determined martensite-free boundary lies within this zone of mixed bend test behavior. Compositions above and to the right of this transition zone all bend. Compositions below and to the left of this transition zone all break during the bend test. A further leftward shift and counterclockwise rotation of the transition zone, as compared to that for 4% Mn, is evident.

18

16

14

12

10

8

6

4

2

0

more than 75 FN each. Compositions in the lower left portion of the diagram all broke. And there is a transition zone, indicated by a pair of heavy parallel lines, of mixed behavior in bending. The magnetically determined martensite boundary is within this transition zone. This zone of mixed bending behavior is shifted leftward and rotated counterclockwise from the similar zone for 1% Mn compositions, as determined in the first part of this study.

Fig. 4 - - Bend~break results at4% Mn on the WRC-1992 Diagram. Compositions that passed the 2 T bend test are shown as solid circles. Compositions that cracked during bending are shown as open squares. Between the two parallel heavy lines, some compositions bent and some cracked. Above and to the right of these two lines, all compositions bent, except for a few very high ferrite compositions. Below and to the left of these two lines, all compositions cracked in bending.

32 , L I ' I : I : [ ~ °°1° _S°/, ~" 28 [ Uooe~ Marl msit I • poundary, ~cor ling uste ,ire / " / I / 7 ~ '

- i u ~. m ~ , ,~ \ , , / ! I

+ k / I . , 4 " I i / Ised )n F! =m,,,,,,,,,~. I ~ . / I 1 2 o ~ - -

,, 12 L I - . - d

• g 8 Y < : : ' v . - ' . . / 1 " I I ..lOO~" UJ M te , 1 ~ + . . . . / ~ ~ ~ ~ 4 : \ 1 1 [ , , . .

o ! : 2 " i I .. IT i i : 1 0 4 8 12 16 20 24 28 32 36 40

Cr Equiv. = %Cr + %Mo + 1.5(%Si) + 0.5(%Nb)

Fig. 5 - - Martensite-free 10% Mn compositions on the 5chaeffler Diagram. Note one of these compositions is within the area considered to be 100% martensite according to the diagram, but it is martensite-free.

D i s c u s s i o n o f Resul ts

Three levels of manganese have been considered in stainless steel weld deposits. The 1% Mn level, from the previous part of this study, is normal for most common austenitic stainless steel weld claddings. The 4% Mn level, considered herein, might be encountered when producing buffer layers using 18 8 Mn or 307

filler metal. And the 10% Mn level might be encountered when using stainless steel filler metals high in manganese (the AWS 200 series filler metals). In all three cases, the Schaeffler Diagram has been shown to predict martensite in compositions that were magnetically determined to be martensite-free, and which pass the 2T bend test. The disagreement between the Schaeffler predictions and the exper-


18

16

14

12

10

i 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30


Fig. 6 - - Martensite-free 10% Mn compositions on the WRC- 1992 Diagram. Many 10% Mn compositions, indicated by solid circles, are below and left of the 4% Mn boundary obtained by magnetic measurements. A 10% Mn martensite-free boundary is indicated.

32 I " Mart tniItl 0% 5%

28 PounPe~i:~Zccol~llng laLllltellltll J• ~/~ ! 7 f

+ ~4 /B;l led')nF~ / . / i / I /

~ / @11%'1n / " / i I ' ~ ' "

i"' ..,,,,,.t.o !\ I / I l + / / I

4 8 12 16 20 24 28 32 36 40

Cr Equiv. = % C r + % M o + 1.S(%SI) + 0 . t i (%Nb)

Fig. 7 - - Bend~break results at 10% Mn on the 5chaeffler Diagram. Compositions that passed the 2T bend test are shown as solid circles. Compositions that cracked are shown as open squares.

imental results becomes greater at higher manganese levels.

There is no reason to expect that manganese should have exactly the same effect (weighting factor relative to nickel) on martensite formation at low temperatures as it has on ferrite formation at high temperatures. The Schaeffler Diagram, with a coefficient of 0.5 for Mn in the Nickel Equivalent, proposes that Mn is both half as powerful as Ni in stabilizing austenite with respect to ferrite formation at high

temperatures, and half as powerful as Ni in stabilizing austenite relative to martensite formation at low temperatures. The WRC-1992 Diagram does not include manganese in the Nickel Equivalent at all, which means that manganese has no effect on ferrite formation at high temperatures. So the way is clear to provide different martensite boundaries for different manganese levels. These are shown in Fig. 9 as shaded zones. Each shaded boundary zone includes the magnetically

determined martensite-free boundary and the lines bounding the extremes of the transition zone between bend and break behavior in the 2T bend test.

The three shaded boundary zones, corresponding to three manganese levels, are each drawn with parallel sides as a practical matter. If the sides were not parallel, the edges would cross at some point, which is absurd from a realistic point of view. The uncertainty associated with the width of each shaded zone is considered to be due mainly to uncertainty in chemical analysis. If a single sample of weld metal is analyzed repeat- edly, on successive days, the results reported from one day to the next for each element will vary. Then the calculated chromium equivalent and nickel equivalent will vary as well. So one cannot say with certainty what the exact chromium equivalent and nickel equivalent are for a given weld sample. This uncertainty is reflected in the width of the shaded boundary zone. In the case of the 10% manganese compositions, there are fewer data points, so the uncertainty (shaded boundary width) is indicated to be greater than that for the other two manganese levels.

The strength of manganese relative to that of nickel, with respect to stabilizing austenite against transformation to martensite, can be estimated from the vertical displacement of the martensite boundary obtained by increasing the Mn content from 1 to 4%. It can be seen from Fig. 9 that this vertical displacement due to the additional 3% Mn amounts to about 4 nickel equivalent near the right end of the 4% Mn martensite boundary (i.e., at a chromium equivalent of 16). This would mean a coefficient for manganese in the nickel equivalent of about 1.3 (4 nickel equivalent divided by 3% Mn) at 16% Cr. Near the left end of the 1% Mn martensite boundary (i.e., at a chromium equivalent of 10), the vertical displacement due to the additional 3% Mn amounts to about 5 nickel equivalent. This would mean a coefficient for manganese in the nickel equivalent of about 1.7 (5 nickel equivalent divided by 3% Mn) at 10% Cr. So manganese is more powerful than nickel in stabilizing austenite with respect to transformation to martensite, not half as powerful as proposed by the Schaeffler Diagram, and the power of manganese increases with decreasing chromium content.

The observed leftward shifting and counterclockwise rotation of the martensite boundary as the manganese content increases is not really surprising. Self, et al. (Ref. 7), predicted this shifting and rotation graphically, based upon the equations of Andrews (Ref. 9). Self, et al., pro-


pose a coefficient for manganese in the Nickel Equivalent with respect to austenite transformation to martensite that increases with decreasing chromium content, as given in Equation 1 below.

Coefficient for Mn = 1/(0.083x%Cr + 0.5) (1)

The prediction of Self, et al. Ref. 7), can be tested against the observed shift in the martensite boundary. At 16% Cr, Equation 1 proposes the coefficient for Mn to be 0.547, vs. the observed value of 1.3. And at 10% Cr, Equation 1 proposes the coefficient to be 0.752, vs. the observed value of 1.7. There appears, therefore, to be qualitative agreement between the predictions of Self, et al., in that the coefficient for manganese increases with decreasing chromium content. However, there is not quantitative agreement - - the observed coefficients are about 2.3 times as large as predicted by Self, et al. (Ref. 7).

In a later review of microstructure prediction in austenitic stainless steel weld metal, Olson (Ref. 10) reproduces a martensite-start temperature relationship from Self, et al. (Ref. 11), that indicates manganese to be 1.7 times as powerful as nickel in stabilizing austenite, which is much more consistent with the 1.3 to 1.7 factor observed herein.

It must be recognized there is a degree of uncertainty in the exact location of the martensite boundary at any manganese level. At all three manganese levels examined, this degree of uncertainty is indicated by presenting the martensite boundary as a shaded zone. This shaded boundary zone is on the order of 1.5 chromium equivalent, or 1.5 nickel equivalent, wide (more in the case of the 10% Mn level). Above and to the right of each martensite boundary zone, all compositions at the given manganese level are martensite-free in the as-welded condition, and these compositions pass a 2T bend test unless they contain excessive ferrite. Below and to the left of each martensite boundary zone, all compositions at the given manganese level contain martensite in the as-deposited condition and fail a 2T bend test. Within the shaded martensite boundary zone, the behavior is unpredictable.

C o n c l u s i o n s

An experimentally determined modification of the WRC-1992 Diagram has been developed, as shown in Fig. 9. This now provides the possibility to predict whether or not stainless steel clad layers, over nonalloy or low-alloy steels, will be free of martensite and will pass a 2T bend

32 I

~ 2 8 ,nsltq 2 4 ~ ~ ~ ling ~s!el ,,te

+ "~ [//B' sed ' ,n FN[ /

g l . + - - -

_, £ / /

0 12 16 20 24 28

0% _ 5% --

/ / / ~ % "

J / . J f

I i i " ~ / . . . 100%

i Fer t te

32 36 40

Cr Equiv. = %Cr + %Mo + 1.5(%Si) + 0.5(%Nb)

Fig. 8 - - Bend~break results at 10% Mn on the WRC-1992 Diagram. Compositions that passed the 2T bend test are shown as solid circles. Compositions that cracked during bending are shown as open squares. Between the two parallel heavy lines, some compositions bent and some cracked. Above and to the right of the heavy lines, all compositions bent. Below and to the left of the heavy lines, all compositions cracked in bending.

18

16

14

12

10

8

6

4

2

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30


Fig. 9 - - The WRC-1992 Diagram, with martensite boundaries for I, 4 and 10% Mn. The boundaries are shown as shaded bands to indicate a degree of uncertainty in their positions. Each boundary includes the extreme of martensite-free compositions as determined by magnetic measurements, and the limits of mixed bend~break behavior in the 2T bend test.

test. With the modified WRC-1992 Dia- gram, the graphical methods used for predicting ferrite in cladding or dissimilar metal joining (Ref. 3) can now be applied also to predicting martensite.

F u t u r e W o r k

Part 3 of this study will examine the ef-

fects of carbon, nitrogen and molybdenum on the position of the martensite boundary in the WRC-1992 Diagram.

Acknowledgments

The author is grateful to The Lincoln Electric Co. for the opportunity to pursue this interest and for the laboratory sup-

WELDING RESEARCH SUPPLEMENT I 3 5 3 - s

port necessary. Bill Spang was especially helpful in preparing the test welds and extracting test pieces.

References

1. Schaeffler, A. L. 1949. Constitution diagram for stainless steel weld metal. Metal Progress 56(11): 680 to 680B.

2. DeLong, W. T. 1974. Ferrite in austenitic stainless steel weld metal. Welding Journal 53(7): 273-s to 286-s.

3. Kotecki, D. J., and Siewert, T. A. 1992. WRC-1992 constitution diagram for stainless steel weld metals: a modification of the WRC- 1988 diagram. Welding Journal 71 (5): 171 -s to 178-s.

4. ASME Boiler and Pressure Vessel Code, 1995 Edition, Section II1, Division I, Figure

NB-2433.1-1. The American Society of Me- chanical Engineers, N.Y.

5. Kotecki, D. J. 1999. A martensite boundary on the WRC-1992 Diagram. Welding Jour- nal 78(5): 180-s to 192-s.

6. Szumachowski, E. R., and Kotecki, D. J. 1984. Effect of manganese on stainless steel weld metal ferrite. Welding Journal 63(5):156-s to 161-s.

7. Self, J. A., Matlock, D. K., and Olson, D. L. 1984. An evaluation of austenitic Fe- Mn-Ni weld metal for dissimilar metal welding. Welding Journal 63(9): 282-s to 288-s.

8. Kotecki, D. J. 1986. Ferrite control in duplex stainless steel weld metal. Welding Jour- nal 65(10): 273-s to 278-s.

9. Andrews, K. 1965. Empirical formulae for the calculation of some transformation temperatures. Jl51203:721 to 727.

10. Olson, D. L. 1985. Prediction of austenitic weld metal microstructure and properties. Welding Journal 64(10): 281 -s to 295-s.

11. Self, J. A., Olson, D. L., and Edwards, G. R. July 1984. The stability of austenitic weld metal. Proc. oflMCC, Kiev, Ukraine.

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• 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 material along the following 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.

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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 consideration 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 the abstract only 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.

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~¢A_~ I I~I:CI:MRI:R ")1"1(10

The Stress-Relief Cracking Susceptibility of a New Ferritic Steel Part 1: Single-Pass Heat-

Affected Zone Simulations

The effects of energy input and postweld heat treatment temperature on the stress-

relief cracking susceptibility of a new ferritic steel were investigated and compared

to conventional 2.25Cr- 1Mo steel

BY J. G. NAWROCKI, J. N. DUPONT, C. V. ROBINO A N D A. R. MARDER

ABSTRACT. The stress-relief cracking (SRC) susceptibility of single-pass welds in a new ferritic steel, HCM2S, has been evaluated and compared to 2.25Cr-1Mo steel using Gleeble thermal simulation techniques. HCM2S was found to be more susceptible to stress-relief cracking than 2.25Cr-1Mo steel. Simulated coarse-grained heat-affected zones (CGHAZ) were produced that correspond to the thermal cycles expected when depositing single-pass welds using a range of energy inputs and tested at various simulated postweld heat treatment (PWHT) temperatures. Both alloys were tested at a stress of 325 MPa. The 2.25Cr- 1Mo steel was also tested at 270 MPa to normalize for the difference in yield strength between the two materials. Light optical and scanning electron microscopy were used to characterize the simulated CGHAZ microstructures. The simulated as-welded CGHAZ of each alloy consisted of lath martensite or bainite and had approximately equal prior austenite grain sizes. The as-welded hardness of the simulated 2.25Cr-1Mo steel CGHAZ was significantly higher than that of the HCM2S alloy. Over the range studied, energy input had little effect on the as-welded microstructure or hardness of either alloy. The energy input also had no effect on the stress-relief cracking susceptibility of either material. Both alloys failed intergranularly along prior austenite grain boundaries under all test conditions. The 2.25Cr-1Mo steel samples experienced significant macro-

J. G. NAWROCKI, J. N. DUPONT and A. R. MARDER are with the Department of Materi- als Science and Engineering, Lehigh Univer- sity, Bethlehem, Pa. C V. ROBINO is with Ma- terials Joining Dept., Sandia National Laboratories, Albuquerque, N. Mex.

ductility and some microductility when tested at 325 MPa. The ductility decreased significantly when tested at 270 MPa, but it was still higher than that of HCM2S at each test condition. The stress- relief cracking susceptibility was based on the ductility and resultant microstructures. Using these criteria, HCM2S is considered "extremely" to "highly susceptible" to stress-relief cracking at each energy input and postweld heat treatment, whereas 2.25Cr-lMo steel would only be considered "slightly susceptible" tested at 325 MPa. The 2.25Cr-1Mo steel samples tested at 270 MPa are considered "slightly" to "highly susceptible" to stress-relief cracking at each PWHT temperature. The time to failure decreased with increasing PWHT temperature for each material. There was no significant difference in the times to failure between the two materials. Varying energy input and stress had no effect on the time to failure. The ductility, as measured by reduction in area, increased with increasing PWHT temperature for 2.25Cr-1Mo steel tested at both initial stress levels. However, PWHT temperature had no ef-

KEY WORDS

Stress-Relief Cracking Ferritic Steel Coarse-Grained HAZ Alloy HCM2S Thermal Cycles Postweld Heat Treat Chrome-Moly Power Plant

fect on the ductility of HCM2S. The hardness of the CGHAZ for 2.25Cr-1Mo steel decreased significantly after PWHT, but it remained constant for HCM2S. The differences in stress-relief cracking response are discussed in terms of the differences in composition and expected carbide precipitation sequence for each alloy during PWHT.

Introduction

2.25Cr-1Mo steel is commonly used for high-temperature applications in steam generators and pressure vessels for chemical and fossil power plants. Many components in these power plants operate at temperatures of approximately 300-600°C. New components fabricated from 2.25Cr-1Mo steel may require welding at both the fabrication and installation stages, and in-service material may be welded during repairs. In such applications, preheat and/or postweld heat treatment (PWHT) are often required to improve heat-affected zone (HAZ) mechanical properties and reduce susceptibility to hydrogen cracking. These preheat and PWHT steps represent a significant fraction of the overall fabrication/repair costs.

Recently, a new ferritic steel, denoted as HCM2S, was developed. HCM2S has been reported to exhibit improved mechanical properties and resistance to hydrogen cold cracking compared to conventional 2.25Cr-1Mo steel (Refs. 1-3). Table 1 compares the allowable composition ranges of both 2.25Cr-1Mo and the HCM2S alloy (Refs. 1, 4). The lowered carbon content improves weldability by reducing hardenability and the as- welded hardness of the HAZ. Although the carbon content of HCM2S and


,?'++'?,iI~ + I I I

1400

1200

= 800

600 g~

400 [..

200

. . . . . Stress Profile ~ Temperature Profile , , , , , , , 400

Peak Temp. 131~C 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

,,' 300 • " PWh ' [T S inn l h l t i on 250

• " + 200 ~ ." / ~ Simulation 100

,m Onset of Stress ~ / 50 , 'A~' AppUeation ~ /

m~ l l I I ~ I I I I 0 50 100 150 200 250 300 350 400

Time (seconds)

Fig. 1 - - Schemat ic i l lus t ra t ion o f a stress-rel ief c rack ing test cycle.

Table I - - Allowable Composition Range of HCM2S and 2.25Cr-1Mo Steel (wt-%)

Element H C M 2 S 2.25Cr-1Mo (Ref. 1) (Ref. 5)

C 0.04-0.10 <0.15 Cr 1.90-2.602.00-2.50 Mo <0.30 0.90-1.10 W 1.45-1.75 - - V 0.20-0.30 - - Nb 0.02-0.08 - - B ~O.OO6 - - AI <0.03 - - Si ~0.50 0.20-0.50 Mn 0.30-0.600.30-0.60 P nO.030 <0.035 S ~0.010 ~0.035

~ , L7 / •

: =-~ T'¢

Fig. 2 - - Representa t ive coarse-grained heat-

a f f e c t e d z o n e m i c r o s t r u c t u r e in the as-

w e l d e d condi t ion . A - - 2 .25 Cr-I Mo; B - -

HCM25.

2.25Cr-1Mo can be identical, HCM2S is typically produced with a carbon content of -0.06 wt-%, which is much lower than the typical carbon content of 2.25Cr-

1Mo steel (Refs. 1-3, 5). In addition, the maximum allowable C content is 0.1 and 0.15 wt-% for HCM2S and 2.25Cr-1Mo steel, respectively. The creep rupture strength is improved by the substitution of Mo with W that acts as a solid-solution strengthening element. Vanadium and niobium are added to improve creep strength by way of carbide precipitation strengthening. Boron is also added to improve creep strength. It has recently been suggested that the improved weldability from these composition modifications may permit elimination of costly preheat and/or PWHT requirements. Although HCM2S has been shown to exhibit excellent mechanical properties and resistance to hydrogen cracking, the stress- relief cracking susceptibility had yetto be investigated.

Many low-alloy, creep-resistant steels such as 2.25Cr-1Mo steel are known to be susceptible to stress-relief cracking (Ref. 6). Stress-relief cracking is defined as intergranular cracking in the heat- affected zone or weld metal that occurs during exposure of welded assemblies to postweld heat treatments or high-temperature service (Ref. 7). Stress-relief cracking occurs primarily in the CGHAZ of a weldment. The general mechanism of stress-relief cracking is well docu- mented in the literature and has been explained for low-alloy steels (Refs. 6-10). During typical fusion welding processes, the unmelted base material surrounding the weld pool is heated to a temperature very high in the austenite phase field. During this time, pre-existing carbides either dissolve or coarsen and austenite grain growth occurs. Due to the fast cooling rates during fusion welding, supersat- uration of microalloying elements occurs as the austenite transforms to martensite (provided the alloy has sufficient hardenability). When the newly formed CGHAZ is exposed to elevated temperatures,

alloy carbides (e.g. VC, NbC) preferen- tially precipitate at dislocations in the prior austenite grain interiors, thereby causing considerable strengthening. These carbides retard dislocation movement and do not allow residual stresses to relax through plastic deformation of the grains. The microstructure may also contain precipitate-free denuded zones adjacent to prior austenite grain boundaries. These denuded zones may be due to grain boundary carbides that have de- pleted the adjacent matrix of carbon and alloying elements (Refs. 11, 12)or the formation of a second phase during cooling after welding (Ref. 13). Along with this, classical temper embrittlement can occur, which is the segregation of tramp elements to prior austenite grain boundaries during cooling or elevated temperature exposure. These segregants lower the cohesive strength of the boundaries and, together with the presence of a denuded zone, can lead to brittle intergranular failure.

Previous work has been conducted to understand the stress-relief cracki ng susceptibility of 2.25Cr-1Mo steel. How- ever, the stress-relief cracking response of this HCM2S alloy is currently unknown. Therefore, the objective of this work is to evaluate the stress-relief cracking susceptibility of HCM2S relative to 2.25Cr-1Mo steel expected in single pass welds deposited with a range of heat inputs and several PWHT temperatures. The results may be useful for determining the conditions under which HCM2S may be used in the pressure vessel and utility industries.

E x p e r i m e n t a l P r o c e d u r e

Stress-Relief Cracking Tests

The alloy compositions of the 2.25Cr- 1Mo and HCM2S steels used in this re-

3 5 6 - S I DECEMBER 2000

search are summarized in Table 2. Stress- relief cracking tests were performed using a Gleeble 1000 thermomechanical simulator. Unnotched, cylindrical test samples (105 mm long and 10 mm diameter) with threaded ends were used. A schematic illustration of the stress-relief cracking thermomechanical test cycle can be seen in Fig. 1. Samples were subjected to single-pass weld thermal simulation cycles representative of 2, 3 and 4 kJ/mm energy inputs with a peak temperature of 1315°C and a preheat temperature of 93°C. The thermal cycles are based on actual data from SMA welds on carbon steel (Refs. 14, 15). A tensile stress was imposed on the sample during cooling and held for the duration of the test to simulate the residual stresses present in an actual weldment. After cooling to room temperature, the sample was then subjected to a simulated programmed postweld heat treatment temperature and held at constant temperature and load (that corresponds to the initial stress level) until failure. The load is actually constant and not the stress because the stress will change as the cross-sectional area of the specimen changes. Therefore, when the stress level is mentioned here- after, it corresponds to the initial stress level. The simulated postweld heat treatment temperatures ranged from 575-725°C. Both materials were tested at a stress of 325 MPa and the 2.25Cr- 1Mo steel was also tested at a stress of 270 MPa. The initial stress levels (325 MPa for HCM2S and 270 MPa for 2.25Cr- 1Mo) were chosen based on the yield strength of the alloys at -650°C. The yield strengths of the CGHAZ of these al-

Ioys at the test temperatures used in this research are unavailable and therefore the above values were chosen because 650°C is near the middle of the test temperature range. The 2.25Cr-1Mo steel samples tested at 270 MPa were produced using an energy input of 2 kJ/mm. The maximum residual stress present in a weldment is typically at or near the yield strength (Ref. 16). Therefore, the lower stress was used because the yield strength of HCM2S is typically higher than that of 2.25Cr-1Mo steel and lowering the stress serves to help normalize the yield strength differences between the two materials. A constant load test is more severe than a constant displacement or stress relaxation test because the load is not allowed to relax and the sample is often taken to failure. However, the mechanism of stress-relief cracking was effectively simulated and the constant load test is relatively easy to perform. These tests were performed under a vacuum of approximately 100 millitorr to prevent decarburization and oxidation of the samples as well as decoherence of the thermocouples. The time to failure was taken to be the time when the PWHT temperature was reached to the time of rupture. The ductility was determined as the reduction in area during PWHT.

One half of each fractured sample was reserved for fractographic examination by scanning electron microscopy (SEM). The remaining half was electroless Ni- coated to provide edge retention of the fracture surface. Longitudinal cross-sectional samples were then polished to a 0.04 pm finish using colloidal silica. Mi- crohardness traverses were performed on

Table 2 - - Chemical Composition of HCM2S and 2.25Cro1Mo Steels (wt-%)

Element H C M 2 S 2.25Cr-1Mo (Ref. 1) (Ref. 5)

C 0.06 0.13 Si 0.25 O.2 Mn 0.48 0.5 P 0.013 O.OO8 S 0.006 0.001 Cr 2.4 2.3 Mo 0.09 1.04 W 1.5 NM V 0.24 0.004 Nb 0.050 0.001 B 0.0036 NM AI 0.013 NM Sn 0.01 0.01 Sb 0.01 <0.001 As 0.01 0.006 Fe balance balance

NM: not measured

samples in the as-welded condition and after SRC testing using a Knoop indenter and a 500-g load. Samples were etched using either 2% Nital or Vilella's reagent and observed using light optical microscopy (LOM). Prior austenite grain size measurements were made in accordance with ASTM E112-84.

Results

Stress-Relief Cracking Tests

Typical as-welded CGHAZ microstructures of each alloy are shown in Fig. 2. Each thermal cycle produced a microstructure consisting of lath martensite and/or bainite with similar prior austenite grain sizes (-50 pm). Hardness tra-

Base Metal I ~ gnth-e HAZ-- ~ Base Metal

4'°1,oo

200 0 S Distaln0ce (ram) IS 20

HCM2S, 3 kJ/mm 2.2SCr-IMo, 3 ItJImm

Fig. 3 - - Microhardness traverse across simulated heat-affected zones. The traverse was across the sample between the jaws o f the Gleeble.

7 5 0

7 0 0

~ 650

eL

600

550 1

O 2.25Cr-lMo, 2 kJ/mm [] 2.25Cr-lMo, 3 k J/ram

2.25CrolMo, 4 k J/ram • HCM2S, 2 kJ/mm • HCM2S, 3 k J/ram • HCM2S, 4 kJ /mm

• E~R ,<E D

ODDI~

O

i l O~U~)

10 100 1000

Time to Failure (sec.)

O B

10 4 l 0 s

Fig. 4 - - Postweld heat treatment temperature vs. t ime to failure at various energy inputs.

W E L D I N G RESEARCH SUPPLEMENT [ 357-s

i

~ I

~ I

~ 1

I

~ I

t

W:!I

N

W:

750

~ 700

E 650

600

550

• HCM2S(325MPa) G 2.25Cr-lMo(325 MPa) • 2.25Cr-lMo (270 MPa)

. . . . . . . . . . . . . , . . . . . . . . i . . . . . . . . . . . . . . . .

2 Z5Cr-IMo Did|not fai

V e B

10 100 1000 10 4 10 s

Time to fai lure (sec.)

;o . . . . . . . . . . . . . . . . . . .

~o

~o

~o

o

6 550

| • , W . .

600

<>

• I a ! 650 700 750

PWHT (°C)

Q 2.25Cr-lMo, 2 k J/ram [] 2 .25Cr- lMo,3 kJ/mm

2.25Cr-lMo, 4 kJ/mm I) HCM2S, 2 kJ/mm II HCM2S, 3 kJ/mm

HCM2S, 4 k J/ram

Fig. 5 - - Postweld heat treatment temperature vs. time to failure for an energy input of 2 kJ/mm along with lowered stress values for 2.25Cr- 1Mo steel.

Fig. 6 - - Reduction in area as a function of PWHT temperature at various energy inputs.

40

35

30

25

20

15

10

5

0600 650 700

• H C M 2 S ( 3 2 5 MPa)

• 2 . 2 5 C r - l M o (325 MPa)

C~ 2 , 2 5 C r - l M o (270 MPa) . . . . . . . . . i . . . . . . . . . t . . . . . . . . . .

|

,25 o

© o ~

"/5O

Temperature (°C)

Fig. 7 - Reduction in area as a function of PWHT temperature for an energy input of 2 kJ/mm along with lowered stress values for 2.25Cr- 1Mo steel.

"as-welded" 2-25Cr-1Mo,~A '

"as-welded'~450 HCM2S %

400

350

300

250

200

0 2

~ ] , ~ - - - B a s e M l t a l - - - ~ 0 2.25Cr.iMo, 2kJ/mm, 675°C

~GHA~' I l / • HCM2S, 2U/mm, 67S°C

4 6 8 10 12 14 16

Distance from Fracture Surface (mm)

Fig. 8 - - Microhardness traces acquired from HAZ samples (2 kJ/mm) after failure during a PWHT of 675°C.

verses from each alloy in the as welded condition (energy input of 3 kJ/mm) are presented in Fig. 3. These traverses are across the entire region between the jaws of the Gleeble and represent the entire HAZ along with unaffected base material. Although the base metal hardness of each alloy is similar (-225 HKN), the 2.25Cr-1Mo steel has a much higher peak hardness in the CGHAZ (-470 HKN) than HCM2S (-375 HKN) due to the higher C content. The CGHAZ extends from approximately 6.5 mm to 13.5 mm in Fig. 3. The hardness of the simulated CGHAZ of HCM2S corresponds well with hardness values of actual welds taken for comparison (-370 HKN). The microstructure of the CGHAZ

is more likely to be martensite than bainite due to the large effect of carbon content on the as-welded hardness of the CGHAZ. Figure 4 shows the postweld heat treatment temperature vs. time to failure for both alloys tested under an initial stress of 325 MPa and various energy inputs and postweld heat treatments. It is important to note every failure occurred in the CGHAZ. In general, as the PWHT temperature increased, the time to failure decreased for both materials. There is no discernable difference between the two materials, and the change in energy input is shown to have very little effect. Vary- ing energy input also had no discernable effect on the CGHAZ peak hardness, im- plying the cooling rate (for 100% marten-

site formation) in these simulations was faster than the critical cooling rate for these materials. Figure 5 compares the time to failure for both alloys tested at an energy input of 2 kJlmm and an initial stress of 325 MPa as well as 2.25Cr-I Mo steel tested at an initial stress of 270 MPa. It can be seen the change in stress had no effect on the time to failure for the 2.25Cr-1Mo alloy. The 2.25Cr-1Mo samples tested at 575°C (325 and 270 MPa) did not fail after six hours and the tests were stopped. Figure 6 shows the variation in reduction in area as a function of postweld heat treatment temperature at various energy inputs for each alloy tested at 325 MPa. For 2.25Cr-1Mo, the ductility increased considerably with in-


Fig. 9 - - Scanning electron microscopy photomicrographs of fracture surfaces. Samples produced using an energy input of 2 kJ/mm and tested at a PWHT temperature of 675°C. A - - HCM2S; B - - 2.25Cr-IMo tested at 325 MPa; C - - 2.25Cr- 1Mo tested at 270 MPa.

I Z I I 1,1.1 I I 1 1 I L l I O I

I ILII I I ~ I I ILII, I l a I

It,.P I I ~ I I @ I

I ~ r J I I I.LI I

creasing PWHT temperature. In contrast, HCM2S shows no clear variation in ductility with PWHT temperature. Again, there is no clear correlation between the ductility and the energy input for a given PWHT. Figure 7 shows the variation in reduction in area as a function of PWHT for both alloys tested at an energy input of 2 kJ/mm and a stress of 325 MPa as well as 2.25Cr-1Mo steel tested at 270 MPa. The reduction in area at 270 MPa is much lower than the reduction in area at 325 MPa at each PWHT temperature for the 2.25Cr-1Mo steel. Figure 8 compares typical hardness traverses acquired from each material after being subjected to an energy input of 2 kJ/mm, a PWHT of 675°C and a stress of 325 MPa. The original CGHAZ extends approximately 3.5 mm from the fracture surface. The hardness of the HCM2S is constant across the CGHAZ, but the hardness increases near the end of the CGHAZ in 2.25Cr-1Mo steel. It is unclear as to why this occurs, but it may be due to the increased elongation of the 2.25Cr-1 Mo samples. Neck- ing during the test may cause a temperature gradient to form, thereby causing the variation in hardness with distance. The peak hardness of the CGHAZ in the 2.25Cr-1Mo steel was considerably higher than HCM2S in the as-welded condition. However, the hardness of the 2.25 Cr- lMo steel decreased considerably after PWHT (from 470 HKN to -325 HKN), while the HCM2S hardness exhibits no detectable change although the times to failure (time of exposure to PWHT) were equivalent. This behavior was typical of each sample tested at 325 MPa.

The HCM2S alloy generally showed more evidence of brittle intergranular failure. Figure 9 shows SEM photomicrographs of samples produced using a thermal cycle representative of an energy input of 2 kJ/mm and tested at 675°C. The samples represented in Fig. 9A (HCM2S) and 9B (2.25Cr-1Mo) were tested at a

stress of 325 MPa and the sample shown in Fig. 9C was tested at 270 MPa (2.25Cr- 1Mo). Each of the samples failed intergranularly along prior austenite grain boundaries. These microstructural features indicate the test conditions properly simulate the stress-relief cracking mechanism. In comparing the two samples tested at 325 MPa, the 2.25Cr-1Mo steel exhibits some microductility on grain surfaces (Fig. 9B), whereas the HCM2S sample has primarily smooth, featureless grain surfaces - - Fig. 9A. However, the 2.25Cr-1Mo steel sample tested at 270 MPa shows little signs of microductility and closely resembles the HCM2S sample - - Fig. 9C. Figure 10 shows typical cross-sectional LOM photomicrographs acquired from fractured samples of each alloy corresponding to the samples in Fig. 9. The white layer on the fracture edge is an electroless Ni-coating used to preserve the microstructural features near the edge of the sample. Each sample failed intergranularly along prior austenite grain boundaries. Secondary cracks are present behind the fracture surface, with each being approximately normal to the tensile axis. These samples are representative of all energy inputs and PWHT used in this investigation. The cracks in the 2.25Cr-1Mo steel samples tested at 325 MPa (Fig. 10B) appear to have more elongated features as opposed to the relatively undeformed grains seen for the HCM2S in Fig. 10A and the 2.25Cr-lMo sample tested at 270 MPa - - Fig. 10C. This corresponds well with the ductility values presented in Fig. 7.

Discussion

Ductility has been found to be a reliable indicator of stress relief cracking susceptibility when Gleeble simulation techniques are used to compare alloys (Ref. 17). In general, alloys that can appreciably soften during PWHT are capable of relieving residual stresses by

Table 3 - - Steel-Rel ief Cracking Susceptibil i ty Cr i ter ia Deve loped by Vinckier and Pense (Ref. 18)

Susceptibility to % Reduction Stress-Relief Cracking in Area

Extremely susceptible <5% Highly susceptible 5-10% Slightly susceptible 10-15% Not susceptible >20%

macroscopic yielding. On the other hand, alloys that retain their strength at high temperatures and/or become locally embrittled at the grain boundaries are susceptible to low-ductil ity fracture along the prior austenite grain boundaries during stress relief. Vinckier and Pense (Ref. 18) developed a criteria for the susceptibility to stress-relief cracking of steels based on the percent reduction in area of specimens subjected to HAZ simulations and tested at elevated temperatures (Table 3). The criteria were found to agree with test results by Lundin, et al. (Ref. 16), on low-alloy steels.

The susceptibility criteria discussed above are to be used as a general guide for well-controlled laboratory experiments. Using these criteria, HCM2S is considered "extremely" to "highly susceptible" to stress-relief cracking at each energy input and postweld heat treatment, whereas, 2.25Cr-1Mo steel would only be considered "slightly susceptible" tested at 325 MPa. The 2.25Cr-1Mo steel samples tested at 270 MPa are considered "slightly" to "highly susceptible" to stress-relief cracking at each PWHT temperature.

The reason for the decrease in ductility of 2.25Cr-1Mo steel when using a lower stress is that a higher stress corresponds to a greater initial strain. In other words, during a constant stress test, the material is initially (prior to the time

W E L D I N G R E S E A R C H S U P P L E M E N T I 3 5 9 - s

I I L l I

t m i

I ~ I B I

I 1,1.1 I

i w i

I L I . I I

I i i i I

[ i i i

t

L B

i , M

I.LI i!

O U.I

Ll, I

- r t ~ re'

I~1 ¸ i

1.1,1

L

Fig. 10 - - Light optical microscopy photomicrographs of cross-sectioned failed samples produced using an energy input of 2 kJ/mm and tested at a PWHT temperature of 675°C. A - - HCM2S; B - - 2.25Cr- 1Mo tested at 325 MPa; C - - 2.25Cr-1Mo tested at 270 MPa.

when embrittlement mechanisms are ac- tivated) elongated an amount that corresponds to the stress and then the test essentially becomes a creep test. Therefore, the use of a higher stress at a given temperature wil l initially produce more strain and the apparent ductility increases. Figure 11 is a plot of displacement vs. time for each material/stress test combination at a PWHT temperature of 625°C. The data represents the time at which the PWHT was reached to the time of failure. The increase in stress in the 2.25Cr-1Mo steel has caused an increase in the slope of the steady-state portion of the curve. This is similar to the result of increasing the stress in a creep test. While the elongation initially increases rapidly in each sample, only the 2.25Cr-1Mo steel sample tested at 325 MPa continues to significantly elongate during the remainder of the test. The 2.25Cr-1Mo sample tested at 270 MPa and the HCM2S sample reach a given displacement, then the displacement essentially remains constant. In contrast, the 2.25Cr- 1Mo sample tested at 325 MPa continues to elongate and always had a greater rate of elongation than the other samples at all PWHT temperatures. The rate of elongation also increased with increasing PWHT temperature similar to a conventional creep test. Therefore, even though each sample failed due to stress-relief cracking, the 2.25Cr-1 Mo samples tested at 325 MPa exhibited high reductions in area and continued to elongate throughout the test. The 2.25Cr-1Mo samples tested at 270 MPa and HCM2S samples experienced some elongation before maintaining a constant displacement and then elongated a small amount before failing due to stress-relief cracking. It is important to note HCM2S should be compared to the 2.25Cr-1Mo samples

tested at 270 MPa since, as discussed above, a stress of 325 MPa for 2.25Cr- 1Mo steel induces an artificial reduction in area. The lower stress is a more accurate representation of the stress state the 2.25Cr-1Mo steel would experience in an actual weldment because it is closer to the yield strength at the PWHT temperatures used in this study. The result is 2.25Cr-lMo steel appears to be slightly less susceptible to stress-relief cracking than HCM2S based on the criteria of Vinckier and Pense (Ref. 18). This is especially true since the reduction in area increased as the PWHT temperature increased, but PWHT had no effect on the ductility of HCM2S.

Low ductility intergranular failure in the CGHAZ during PWHT can occur by two general mechanisms: 1) tramp element segregation to prior austenite grain boundaries and/or 2) precipitation strengthening of grain interiors and denuded zone formation near the grain boundaries (Ref. 6). In the former case, the presence of tramp elements (P, S, Sn, As and Sb) along the prior austenite grain boundaries lowers the cohesive strength across the boundaries and leads to brittle, intergranular fracture. In the latter case, alloy carbides (e.g. VC, NbC) pref- erentially precipitate in the prior austenite grain interiors on dislocations and cause considerable strengthening. Along with this, some carbides may precipitate in the prior austenite grain boundaries. These carbides can deplete the adjacent material of carbon leaving a thin precipitate-free denuded zone (Refs. 11, 12). Therefore, any stress will be concentrated in these relatively soft zones leading to intergranular failure. Thus, the operable cracking mechanism of each alloy can be understood by examining the influence of chemical composition on the charac-

teristics of elemental segregation and carbide precipitation and how these processes, in turn, affect the tempering response and fracture modes during stress relief.

Tramp element segregation (temper embrittlement) typically occurs in carbon and low-alloy steels when slowly cooled or isothermally aged in the temperature range of approximately 350-600°C (Ref. 19). When temper embrittled steels are reheated to temperatures above approximately 600°C and cooled rapidly, embrittlement is reversed (Refs. 19, 20). Therefore, with the exception of the samples tested at 575 and 625°C, failure was unlikely to be associated with tramp element segregation.

The CGHAZ of the 2.25Cr-1Mo steel experienced significant softening during postweld heat treatment at 325 MPa whereas the hardness of the CGHAZ of each HCM2S sample after PWHT was essentially identical to the hardness in the as-welded condition. The reason for this difference can be explained by examining the chemical composition and the expected carbide precipitation sequences of these alloys. Baker and Nutting (Ref. 21) studied the carbide precipitation sequence during tempering of 2.25Cr-1 Mo steel for a broad range of tempering temperatures (400-750°C) and times (0.5-1000 h). Their findings are illustrated in Fig. 12. The following general carbide precipitation sequence was determined:

~-carbide "--~" M3 C

(M02C + M3C) ~ M23C 6 ~ M6C

* t Cr7C3

where the M stands for Fe or Cr.


0.4

0.39

~ 0.38

0,37 u

J

0.34

0

2.25Cr-iMa 3IS MI~ 62,5 de

f / f /

f

/

~. .c j 2.,lSCr 1Mo,2"70 MI:'n,( IS del lnm C

|

EIC34~ 3 ~ M]F L, fg,5 dellmm C

500 1000 1500 2000

Time (w.onds)

• _ ~ .-~'--..~.~.£"~

° ° r

~ i ~ , ~ h CLoq sca~)

Fig. 11 - - Displacement as a function of time during a PWHT of 625°C

Fig. 12 - - Isothermal diagram showing the sequence of carbide formation on tempering of a quenched 2.25Cr-1Mo steel (Ref. 21).

For the temperature range 400-725°C, E-carbide and/or M3C always precedes the formation of any Cr- or Mo-based carbides. From these results, it can be estimated that, due to the short times, cementite should be the only carbide to form in the 2.25Cr-1Mo steel samples under the conditions of this study. Therefore, the material should soften relative to the as-welded condition because the mechanism of softening is the release of carbon from the supersaturated matrix and concomitant relaxation of lattice strain (Ref. 22). This would account for the significant increase in ductility observed with increasing PWHT temperature and the low susceptibility to stress relief cracking. This is also consistent with the hardness results in Fig. 8. Because the material could soften appreciably during tempering, the stress would be relieved by macroscopic yielding rather than the concentration of strain at the prior austenite grain boundaries.

The carbide precipitation sequence during the tempering of HCM2S is expected to differ from 2.25Cr-lMo steel due to the presence of V and Nb, which are strong carbide forming elements. Pi- grova (Ref. 23), in a study on quenched and tempered Cr-Mo-V steels, found M3C (Fe and Cr-rich) and MC (V-rich) carbides to be present after tempering from 450-700°C for up to 1000 h (depending on the temperature). Previous work has shown normalized and tempered HCM2S steel exhibits a fine dispersion of MC along with some M7C 3 inside the grains and M23C 6 along grain boundaries (Ref. 24). The MC carbide was found to be V-rich with some Nb present. After aging for 1000 h at 600°C, MC remained stable, but M23C 6 and M7C 3 transformed to M6C (Ref. 24). Calculation of phase equilibria at 600°C using Thermo-Calc routine for the C-Cr-1.6W-0.1 Mo-0.25V-

0.05 Nb-0.006N-0.5Mn-0.004B system (Ref. 24) indicated the stable phases at 2.5 wt-%-Cr and 0.06%C are ~ + VC + M6C. This is consistent with the long- term aging results. The relatively high susceptibility of HCM2S to stress-relief cracking is likely due to a combination of vanadium carbide precipitation strengthening within the grain interiors and possibly the formation of denuded zones in the grain boundary regions. Denuded zones formed in low-alloy steels are typically only up to a few hundred nanome- ters wide (Ref. 13). Therefore, even if denuded zones had formed, the detectability is limited to transmission electron microscopy. Vanadium carbide is well-known to promote stress-relief cracking by forming a fine, uniform dispersion of very stable carbides (Refs. 25, 26). Grain interior strengthening by VC would resist stress relaxation by macroscopic yielding and lead to stress intensi- fication along the relatively weak prior austenite grain boundaries that may contain denuded zones. This proposed process would account for the retained hardness of the HCM2S after postweld heat treatment and the relatively high susceptibility to stress relief cracking.

Another possible factor is the presence of B and AI in the HCM2S alloy. Ad- ditions of AI (Refs. 13, 27, 28) and B (Refs. 10, 13, 29) to low-alloy steels have been shown to greatly increase the susceptibility to stress-relief cracking and promote the formation of a denuded zone (Ref. 13), although the exact mechanisms by which AI and B promote stress- relief cracking are unclear. Therefore, the differences in composition between 2.25Cr-1Mo steel and HCM2S and their effect on the carbide precipitation kinet- ics and grain boundary characteristics apparently are the reason for the contrast in the stress-relief cracking behavior.

Work is now in progress using analytical and transmission electron microscopy to examine the microstructures so the precise failure mechanisms can be understood in more detail.

Conclusions

The stress relief cracking response of conventional 2.25Cr-1Mo and HCM2S steels was investigated by Gleeble HAZ simulation techniques. The HCM2S alloy was shown to be more susceptible to stress-relief cracking than 2.25Cr-1Mo steel over the range of weld thermal simulations and postweld heat treatment schedules used in this research for single- pass weld CGHAZ simulation samples. HCM2S experienced brittle intergranular failure along prior austenite grain boundaries under each set of test conditions. The 2.25Cr-1Mo steel also failed intergranularly along prior austenite grain boundaries, but exhibited significant macroductility when tested at a stress of 325 MPa. Lowering the applied stress in the 2.25Cr-1Mo steel samples to normalize for the yield strength resulted in lower ductility values from the stress-relief cracking tests. Increasing the postweld heat treatment temperature increased the ductility for 2.25Cr-1Mo steel, but had no significant effect on HCM2S. The as- quenched hardness of the CGHAZ produced at each energy input for 2.25Cr- 1Mo steel was -470 HKN and for HCM2S was -375 HKN. This difference in as-quenched hardness was attributed to the higher carbon content of the 2.25Cr-1Mo steel. The hardness of the CGHAZ after tempering decreased to -325 HKN for 2.25Cr-lMo steel, but remained the same as the as-quenched hardness of the CGHAZ for HCM2S. With the tempering temperatures and times used in this study, E-carbide and

W E L D I N G RESEARCH SUPPLEMENT I 361-s

Fe3C are expected to precipitate in 2.25Cr-1Mo steel. The concomitant release of carbon from the supersaturated structure and precipitation of Fe3C results in a decrease in lattice strain and softening of the CGHAZ. In HCM2S, V-rich MC is expected to form, which retards softening and ultimately leads to the higher SRC susceptibility.

Acknowledgments

The authors would like to gratefully acknowledge the sponsors of this research including Sumitomo Metal Corp., Mitsubishi Heavy Industries, Ltd., Foster Wheeler Development Corp. and Penn- sylvania Power and Light Co. The authors would also like to thank Dr. Bruce Lind- sley for his contributions to this research.

References

1. Masuyama, E, Yokoyama, 1-., Sawaragi, Y., and Iseda, A. 1994. Materials for Advanced Power Engineering. D. Coutsouradis, et al. eds., Part 1. Kluwer Academic Publishers, Netherlands, pp. 173-181.

2. Masuyama, E, Yokoyama, T., Sawaragi, Y., and Iseda, A. 1994. Service Exposure and Reliability Improvement: Nuclear, Fossil, and Petrochemical Plants, PVP, Vol. 288. ASME, pp.141-146.

3. Prager, M., and Masuyama, F. 1994. Conference Proceedings Maintenance and Repair Welding in Power Plants V. Orlando, Fla., EPRI and AWS, pp. 16-30.

4. Metals Handbook, 8th ed., Vol. 1. ASM International, Materials Park, Ohio.

5. Creep Rupture Data of HCM25 Steel Tubes, Pipes, Forgings and Plates. 1997. Sum- itomo Metal Industries, Ltd. and Mitsubishi Heavy Industries, Ltd.

6. Meitzner, C. F. 1975. WRC Bulletin 211 pp. 1-17.

7. Dhooge, A., and Vinckier, A. 1992. Welding in the World 30: 44-71.

8. Swift, R. A. 1971. Welding Journal50(5): 195-s to 200-s.

9. Swift, R. A., and Rogers, H. C., Welding Journal 50(5): 357-s to 373-s.

10. McPherson, R. 1980. Metals Forum 3(3): 175-186.

11. Asbury, F. E., Mitchell, B., and Tort, L. H. 1960. British Welding Journal (11 ): 667-678.

12. Irvine, K. J., Murray, J. D., and Picker- ing, F. B. 1960. Journal of the Iron and Steel In- stitute (10): 166-179.

13. Edwards, R. H., Barbaro, F. J., and Gunn, K. W. 1982. Metals Forum 5(2): 119-129.

14. Nippes, E. F., Merrill, L. L., and Savage, W. F. 1949. Welding Journal (28): 556-s to 564-s.

15. Nippes, E. F., and Nelson, E. C. 1958. Welding Journal (37): 289-s to 294-s.

16. Welding Handbook, 8th ed., Vol. 1. 1991. American Welding Society, Miami, Fla.

17. Lundin, C. D., Liu, P., Qiao, C. Y. P.,

Zhou, G., Khan, K. K., and Prager, M. 1996. WRC, Bulletin 411, pp. 1-215.

18. Vinckier, A. G., and Pense, A. W. 1974. WRC Bulletin 197.

19. Steven, W., and Balajiva, K. 1959. Jour- nal of the Iron and Steel Institute 193: 141-147.

20. Pugh, S. F. 1991. An Introduction to Grain Boundary Fracture, The Institute of Met- als, London.

21. Baker, R. G. and Nutting, M. A. 1959. Journal of the Iron and Steel Institute (7): 257-268.

22. Honeycombe, R. W. K., and Bhadeshia, H. K. D. H. 1996. Steels: Mi- crostructure and Properties, 2rid ed. Halstead Press, New York, N.Y.

23. Pigrova, G. D. 1996. Metallurgical Transactions A, 27A(2): 498-502.

24. Miyata, K., Igarashi, M., and Sawaragi, Y. 1997. ICOPE-97, Tokyo, Japan, pp.13-17.

25. Bentley, K. P. 1964. British Welding Journal (10): 507-515.

26. Stone, P. G., and Murray, J. D. 1965. Journal of the Iron and Steel Institute (11 ): 1094-1107.

27. Viswanathan, R., and Beck, C. G. 1975. Metallurgical and Materials Transac- tions A 6A(11 ): 1997-2003.

28. Ratliff, J. L., and Brown, R. M. 1967. Transactions of the ASM 60:176-186.

29. Presser, R. I., and McPherson, R. 1977. Scripta Metallurgica 11 : 745-749.

Call for Papers

The 6th International Seminar on Numerical Analysis of Weldability will be held October 1-3, 2001, in Graz, Austria. This seminar is held under the sponsorship of IIW Commission IX, Working Group "Mathematical Modeling of Weld Phenomena." Papers are invited on the following topics:

• Melt Pool and Arc Phenomena • Solidification • Microstructural Modeling in Weld Metal and HAZ • Microstructure and Mechanical Properties • Influence of Postweld Heat Treatment • Crack Phenomena and Testing Methods • Residual Stresses and Distortion • Modeling Tools and Computer Programs

Individuals interested in presenting a paper should prepare an abstract no more than a half page in length. Include the title of the paper, name of the author(s) and affiliation. Deadline for abstract submission is April 1, 2001. Send it to Bernhard Schaffernak, TU Graz, Institute for Materials Science, Welding and Forming, Kopernikusgasse 24, A-8010 Graz, Austria; FAX +43 316 873 7187; e-mail [email protected].


Control for Weld Penetration in VPPAW of Aluminum Alloys Using the Front

Weld Pool Image Signal The study shows the feasibility of implementing weld formation control of VPPAW

of aluminum in real time

BY B. ZHENG, H. J. WANG, Q. I. WANG AND R. KOVACEVIC

Abstract. This paper presents a technique for real-time, closed-loop feedback control of weld penetration based on the front image signal of the weld pool in variable polarity plasma arc welding (VPPAW) of aluminum alloys. The formation of an image can be acquired when the arc light reflects off the concave, mirror-like surface of the depressed keyhole weld pool and passes through a band-pass filter onto the image sensor. The image of the visual keyhole (nominal keyhole) is a two-dimensional projected picture of the actual keyhole weld pool. The determination of the geometrical size of the nominal keyhole is also described according to the consecutive frames of the image. The variation in size of the nominal keyhole is closely corre- lated to the bottom diameter of a keyhole. A model of the relationship between the bottom diameter of a keyhole and the geometrical size of the nominal keyhole weld pool in the image is established and examined using the BP artificial neural network theory. A cutting or a keyhole collapse phenomenon is successfully avoided and uniform weld formation is obtained in a welding process using the model to control both the wire feed and the welding current when the thermal conditions of the butt-jointed workpieces are changed. The results achieved show a feasible way to implement the real-time weld formation control into the aluminum VPPAW.

Introduction

Variable polarity plasma arc welding (VPPAW) of aluminum alloys in the keyhole mode has been used successfully in production, such as in fabricating the space shuttle external tanks (Refs. 1-4).

B. ZHENG, H. J. WANG and R. KOVACEVIC are with Southern Methodist University, Dal- las, Tex. Q. I. WANG is with Harbin Institute of Technology,, Harbin, P. R. China.

Compared with other welding processes, VPPAW can generate high weld quality and high productivity at relatively low cost. These attractive features are attributed mainly to a fully penetrated keyhole-mode weld pool, inside which hydrogen cannot be trapped, and to the removal of tenacious oxide film on the workpiece surface, which guarantees better fluidity of the metal in the weld pool. However, keyhole collapse and melt-through may occur during a welding process if disturbances such as abruptly varying thermal conditions exist, especially when welding plates ranging from 4.0 to 25.4 mm. Thus, selecting process parameters and providing control of the stability of weld formation during welding to produce a satisfactory weld remains a challenge.

One effective approach is to monitor the keyhole weld pool. Recently, it was found the presence or absence of a keyhole could be determined by measuring the ratio of hydrogen to argon in the plasma arc column with an optical spectrometer (Ref. 5). However, the size of the keyhole cannot be determined and the welding process cannot be distinguished from the cutting process according to the signal. At present, two difficult problems are associated with front-face sensing of the keyhole weld pool in plasma arc

Key Words

Aluminum Alloys VPPAW Front Image Sensing Weld Pool Keyhole Diameter Neural Networks Model Penetration Control Weld Formation

welding (PAW): inaccessibility of the weld pool because of the limited torch stand-off distance and the interference of the arc radiation. PAW technology in the one-keyhole-per-pulse mode can be fairly well applied to steels, so the arc sound or the arc efflux light from the back side of the workpiece can be used to detect the size of the keyhole. Based on this principle, a full-penetration weld bead has been guaranteed in real-time feedback control (Refs. 6-9). However, this type of technology is not applicable to aluminum alloys. Also, detecting the keyhole from the back side of the workpiece is not feasible in some cases, such as in the welding of pressure vessels. To date, constant parameter open-loop control of weld formation is still being used in PAW of aluminum alloys by the keyhole mode.

In recent years, welding researchers have focused on using machine vision systems to sense the weld pool for controlling the full penetration state in gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) (Refs. 10-15). The arc light filtering solution has been investigated through coaxial viewing of the weld pool in GTAW (Ref. 16). These approaches are based on the principle the diffuse reflection of arc light from the mirror-like weld pool surface is weaker than that from the surrounding area. Thus, in the image, the weld pool produces a dark area, while the solid part of the workpiece appears as a bright area. Some researchers used a pulsating laser synchronized with a high-shutter-speed camera to overcome the arc light interference in GTAW of stainless steel (Refs. 17-19). With this approach, a clear image of the weld pool is captured and the weld pool boundary is calculated in real time using a developed image- processing algorithm. The geometrical appearance of the weld pool is characterized by the rear angles and the length


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of the weld pool. For the full-penetration case, the back weld bead width could be related to the geometrical features of the front side of the weld pool. Infrared ther- mography has also been extensively investigated (Refs. 20-22). It was found the interference of the bright arc light could be prevented, and the depth of the joint penetration could be determined using the characteristics of the temperature profiles of steel in GTAW. The instanta- neous decrease of the welding current has also been used to weaken the intensity of the arc light in order to capture a clear weld pool image during welding (Ref. 23). However, in some cases, this approach may not be acceptable because of the poor weld bead that occurs, such as in PAW of aluminum alloys using the keyhole mode.

Besides the inaccessibility of the weld pool and the arc radiation interference in PAW, a common problem existing in the welding of aluminum alloys is that nearly no color change occurs when the plate is melted. Consequently, the weld pool cannot be easily distinguished from the solid base metal using the visible spectrum range. Thus, processing a weld pool image in the case of aluminum alloys is much more difficult than in the case of steel welding.

Another problem in the welding of aluminum alloys is the tenacious oxide film on aluminum strongly impedes the flow of the weld pool in the welding process so that a very poor weld formation with oxide inclusion is easily generated. A cutting process with an oxidizing surface cut may also occur if the plates are melted through in a plasma arc welding process by the keyhole mode. Actu- ally, the main representation of an unstable weld formation in VPPAW of

aluminum alloys is the transition from a keyhole welding process to a cutting process or to a melt-in-mode welding process without a keyhole. Although lots of factors influence the stability of the weld formation, variation in thermal conditions of the workpiece (which is an un- controllable factor in application) is mainly responsible for the transition if the optimized welding parameters are applied. Therefore, to avoid this transition, the guarantee of the dynamic presence of a keyhole weld pool in a plasma arc welding process with a varied thermal condition is one of the biggest challenges in the control of a quality weld.

Currently, the real-time feedback control of the weld formation using a keyhole signal in PAW of aluminum alloys is still not available, despite its applications to some key products. Therefore, explo- ration of this research issue is crucial to achieving a quality weld. This paper will focus on front imaging the weld pool to achieve the required signal of a keyhole; establishing the model of the relationship between the bottom diameter of a keyhole and the geometrical size of a weld pool in the image and implementing the real-time feedback control of the weld penetration.

Experimental Procedure

Experimental System

The image sensing system used is shown in Fig. 1. It consists of a commercial CCD camera (15 mm in diameter and 100 mm in length) with a band-pass filter, a monitor, an image processing card, a PC-Pentium computer and a video recorder. The parameters of the filter are the following: center wave length 658 nm, half wave width 10 nm, trans- missivity 27% and background depth of field 1/1000. These specific filter parameters are selected because the intensity of the arc light when using argon as the shielding gas is much weaker within the above spectrum. The welding system also shown in Fig. 1 consists of a variable-polarity welding power source, programmable sequence controller, plasma gas controller, CNC positioning system, computer-controlled wire feeder and plasma arc torch. The camera is attached to and positioned in front of the plasma arc torch with its axis at an angle

(43 deg) from the workpiece surface plane.

Experimental Conditions

Variations in the keyhole size can be effected by changing some of the welding conditions such as the welding cur-


rent, the wire feed speed and the thermal conditions of the plates (the shape of the workpiece, for instance). Since variation in the thermal conditions is crucial to stability of weld formation in the welding of aluminum products, all the experiments were conducted using workpieces with varied thermal conditions, except the experiments done for comparison. Butt-joint welds were made with wire feeding. Two shapes of 5-mm- thick 2024 aluminum plates are shown in Fig. 2. The welding current in the start- up segment reaches 80-90 A within 5 s, which increases up to 90-120 A within 5-10 s from the termination of this segment to the beginning of the main body segment. Other parameters have the following values: a direct current electrode negative (DCEN) to direct current electrode positive (DCEP) time ratio of 22 to 3.0 ms, DCEN current 80-100 A, DCEP current 110-120 A, pilot arc current 15 A, plasma gas f low rate 4.5 L/min, shielding gas flow rate 6 L/min, welding speed 100 mm/min, torch stand-off distance 5 mm, angle of workpiece surface plane to the horizontal plane equal to 85 deg, orifice diameter 3.2 mm, orifice length 3.5 mm and a tungsten electrode setback of 3.2 mm.

Image Features of the Keyhole Weld Pool

Keyhole Profile

To better understand a keyhole image, a three-dimensional schematic of a keyhole is shown in Fig. 3. The keyhole is actually a cavity through the weld pool, with a profile resembling a trumpet. The cross section of this cavity varies both in diameter and shape (irregular ellipse). The maximum cross-sectional diameter occurs at the top surface of the workpiece (top section diameter). The cross section with the smallest diameter is located about 1.5-2.5 mm up from the bottom surface of the workpiece (throat section diameter). The diameter of the cross section on the bottom surface of the workpiece is larger than the throat diameter but less than the top section diameter. In uphill welding without wire feeding, the shape of a back-side weld bead is concave-downward along the entire weld path - - Fig. 4. Therefore, the keyhole weld pool is a deformed weld pool, and is much different from a weld pool in GTAW and GMAW (Refs. 17-19). How- ever, with wire feeding, the concave- downward shape in the back side of a weld bead will be filled into the convex shape that is a normal full-penetration weld bead.

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Image Features

A schematic of a keyhole weld pool without wire feeding and with wire feeding is shown in Fig. 5. The main features of the image are as follows:

1) The images are two-dimensional profiles of the keyhole weld pools projected onto the target plane of the camera, which is defined in this paper as the visual (nominal) keyhole weld pool. This means only a single viewpoint of the keyhole weld pool can be captured by the camera, and the curves in the image are generally in different spatial planes. The pattern of the keyhole weld pool in the image is deformed with respect to the pattern of the actual keyhole weld pool.

2) The front periphery (S) of the nominal keyhole weld pool is clear, but the portion of it at the location with the largest weld bead width cannot be clearly distinguished from the solid area of the base metal. The rear periphery of the nominal keyhole weld pool cannot be seen in the image.

3) The lines L and R are projected lines of the actual periphery of the keyhole. They may be the periphery of the keyhole throat (at the throat cross section [Fig. 3]). However, the periphery S is on the workpiece surface. So, actually, the three

curves (L, R and S) are not in the same spatial plane (L and R are not parallel to the workpiece surface). The area bounded by lines L and R and the periphery S is a type of keyhole area through which the plasma arc passes. This area is defined in this paper as the nominal keyhole. With wire feeding, the lines L and R become a smooth curve, and the middle segment of the periphery S is blocked by the cold wire.

4) A highlighted area behind the nominal keyhole exists in the image during a normal welding process. The highlighted area is not the image of the bright arc, but the reflected light from the arc on the rear surface of the weld pool. The area of the nominal keyhole will increase with an increase in the welding current, but the highlighted area will decrease with an increase in welding current. This is because the size of the actual keyhole increases. The area of the nominal keyhole increases to a maximum until the highlighted area vanishes (because there is no surface to reflect the arc light) when the welding process becomes the cutting process.

5) The bright arc cone cannot be seen directly from the image because of the shielding of the torch gas cup.

6) Besides other dimensions of the


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Fig. 8 - - Back side photographs o f weld beads in butt jo ints with wire feed. A - - Ordinary workpiece; B - - varied heat sink workpiece.

nominal keyhole, there are three characteristic points with coordinates (X,, YL), (XR, YR) and (Xo, Yo) in the image.

7) The quantity of the molten metal in the weld pool with wire feeding is much more than in the case of no wire feeding, so the bottom weld bead profile is convex. This will make the highlighted area in the image become larger than that in the case with wire feeding. However, the image is not as clear as in the case without wire feeding.

Extract ing the N o m i n a l Keyhole Per iphery

Without Wire Feeding

Because the image of the nominal keyhole weld pool is clear and the difference in grayness between the periphery of the nominal keyhole and the other area is large, no image preprocessing is needed in the case of no wire feed. The characteristic points and the lines of the nominal keyhole can be directly ex-

tracted, as shown in Fig. 6A. The periphery of the nominal keyhole

is determined as follows: • Find the vertical centerline of the

highlighted area in the image. • Determine the starting point for

tracing the periphery of the nominal keyhole.

• Trace the periphery of the nominal keyhole.

• Determine the front periphery of the nominal weld pool.

With Wire Feeding

To process the image of a nominal keyhole weld pool, one buffered area of the RAM in the computer is preserved for storing the data of a whole frame of the image sampled per second. The same size area of RAM is preserved for a copy of the data stored in the area of buffer 1. During the data processing of a new sampled image, the data in buffer 1 are changed, but the data in buffer 2 are kept as the initial value. The following simpli-

fied algorithm is taken to acquire the area of a nominal keyhole:

1) Within the predefined window, an image frame is divided into two areas separated by the dotted line ab, which is shown in Fig. 6B. The data points to the left of line ab are processed in a sequence from left to right and from top to bottom. In buffer 1, if the gray of a point (x, y) is greater than fifty and the gray difference between this point and the other point (x+5, y+5) is between zero and ten, the gray of the point (x, y) is changed to zero. Otherwise, the original gray of the point (x, y) is saved. The same operation for the data points to the right of line ab is done, but the sequence is from right to left and from top to bottom.

2) The first point with a gray value of zero in each column is searched by scanning the image frame from top to bottom. The left intersecting point between curve S and the nominal keyhole periphery arc L can be located according to the following: to the left of line ab in the image frame, if the ordinates y of the points with


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Fig. 10 - - Error comparison o f the BP neural networks.

the gray value of zero consecutively decrease and the last point among these points has the same abscissa as that of line ab, the first point (xu YL) among these points is the left terminal point of the nominal keyhole periphery L. The right terminal point (xR, YR) of the nominal keyhole periphery R can also be acquired by the same method.

3) A straight line Yu with ordinate YL to the left of line ab and perpendicular to the Y axis, is drawn. Another straight line, YR, can be drawn in a similar way. The area I, surrounded by lines ab, L and YL, and the area il, surrounded by lines ab, R and YR, are added together to represent the nominal keyhole area.

The other geometrical size (width and length) of a nominal keyhole and the coordinates of the points (Xu YL), (XR, YR) and (Xo, Xo) can also be calculated according to their number of pixels and their corresponding gray values in the image frame.

Variat ion of a Keyhole

Many factors - - arc stability, energy input of a workpiece, flow rates of gases, position and speed stability of the wire feed, thermal condition variations generated by the workpiece structure and heat buildup because of the continuous welding process i t s e l f - may influence the transition from a normal keyhole welding process to a cutting process or a melt-in mode welding process. The variation in thermal conditions is the most crucial and complex among these factors because of its variability, immeasur- ability and uncontrollability. In keyhole welding, the cutting process usually occurs more easily than in the melting-in mode welding process. Once a cutting process occurs, the weld bead is not acceptable and must be repaired. Thus, avoiding a cutting process resulting mainly from a variation in thermal conditions is a high priority. This is also one

of the prerequisites for achieving a uniform and stable weld formation.

In essence, the reason for generating a cutting process is that not enough metal exists in the weld pool and too much energy is deposited in the workpiece. The experiments reported in this paper show that under constant energy input, when the thermal condition of a workpiece is changed due to the buildup of heat, the keyhole size becomes larger as the weld pool becomes wider. When the keyhole size is larger than a certain value, a cutting process will be generated. To avoid this melt-through mode cutting process, the quantity of the filler metal should be increased, which will decrease the size of the keyhole even though the width of the weld bead generated will probably be larger than that of a normal keyhole weld bead. Figure 7 shows the relationship of the bottom diameter of a keyhole and the nominal keyhole size to the time using the workpieces shown in Fig. 2, in which the origin of the time axis represents the instant when the work-

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WELDING RESEARCH SUPPLEMENT [ 367-s

Table I - - Welding Parameters Keyhole with Wire Feeding

for BP Neural Network Modeling of the Bottom Diameter of a

Number of Slot length Welding current Wire feed speed experiment (ram) (A) (mm/s)

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Fig. 12 - - Control model of the bottom diameter of a keyhole.

piece movement is initiated after the keyhole size reaches a certain value. Be- cause it is not currently possible to syn- chronously measure the bottom diameter of a keyhole in a welding process, the off- line measured width between the bottom oxide films along a weld bead, which is the trace of the arc efflux, is used for representing the bottom diameter of a keyhole. To accurately acquire the data, marks with an interval of 1.0 mm are made on the top and bottom faces along the butt-jointed workpieces before welding. The cycle of image sampling is 1.0 s and the welding speed is 6.48 m/h. Therefore, the measuring interval is 1.8 mm. Associated with the corresponding photos given in Fig. 8, the following results were obtained:

1 ) The bottom diameter of the keyhole on the ordinary workpiece increases with time during the first 20 s - - Fig. 7A. How- ever, at the nearby origin, it is about 4.5-5.0 mm because of the arc preheat at the start location, and then decreases to 3.8 mm because of the better heat transfer conditions of the workpiece after torch motion is initiated. From that instant, the bottom is nearly constant in the range of 3.8 to4.0 mm up until 90 s. From about 90 s, it increases to 4.5 mm because of the heat buildup and maintains 4.5 mm after 110 s. Therefore, the keyhole welding process can enter a stable state after 20 s from the start, during which the variation of the keyhole diameter is 0.2 mm up to 100 s. For the varied heat sink workpiece, it can also be seen the keyhole diameter has nearly the same variation as that of the ordinary workpiece up until 30 s, even though there exists a small difference during the first 10 s. Because the thermal condition is getting worse after 30 s (the arc is reaching the area with a slot machined on each workpiece), the variation of the keyhole diameter rapidly increases to more than 6.8 mm at the instant of 72 s. After that, the keyhole welding process becomes

the cutting process. 2) The geometrical size (the

area, width and height are shown, respectively, in Fig. 7B-D) of the nominal keyhole in an image has the same trend as the bottom diameter of the keyhole, for both the ordinary and the varied heat sink workpiece, even though there are some slight differences between them. The change in the area shows the largest variation among these characteristic sizes. How- ever, all this size data cannot represent the variation in the bottom diameter of a keyhole, which is actually a measurement of the full- penetration state. Thus, to avoid the cutting process, the bottom diameter of a keyhole should be cor- related with the geometrical size of the nominal keyhole.

3) The allowable magnitude of the variation in the bottom diameter of a keyhole is not large (+ 2.0 mm). The time interval required for the welding process to become the cutting process for nominal welding velocities of 100 mm/min shows the response time for both acquiring and processing the image and for controlling the full weld penetration should be less than 20 s.

0.24

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0.22 3 6 g 12 15 18

PE number of the hidden layer

Fig. 13 - - Training error of the BP neural network.

Fig. 14 - - Output of the controlling model of the wire feed speed. (Note: curve I is the output of the model using the data from open-loop control experiments; curve 2 is the output of the model using the data from closed-loop control experiments.)

M o d e l i n g t h e K e y h o l e D i a m e t e r

The fol lowing experiments were made for mapping the relationship of the bottom diameter of a keyhole with the geometrical size of the corresponding nominal keyhole in an image:

1) Ordinary workpiece with constant welding parameters.

2) Varied heat sink workpiece with constant welding parameters.

3) Varied heat sink workpiece with a variation in wire feed speed.

4) Varied heat sink workpiece with a variation in welding current.

5) Varied heat sink workpiece with variations in both the welding current and the wire feed speed.

The purpose of the variations in the welding current and/or the wire feed speed is to maintain a continuous welding process and prevent an occurrence of a cutting process. The parameters applied are shown in Table 1. As an example of experiment 4, the welding current is maintained at an initial value of 97 A until the area with the varied heat sink is

368-s [ DECEMBER 2000

reached. Then the welding current is stepped down to 87 A. When the area with the varied heat sink is passed, the welding current is stepped up again to 97 A. In experiment 6, the initial wire feed speed is maintained at a value of 15 cm/s until the area with the varied heat sink is reached. Then it is increased to a maximum value of 17 cm/s according to a slope at the middle location of the area with the varied heat sink. After that, it is decreased to the initial value of 15 cm/s according to a slope. Every experiment is repeated four times. The first three of the same four experiments are used for model recognition, and the last experiment is for verifying the accuracy of the model established based on the three experiments. Every group of parameters associated with the results of the image processing is recorded once a second, 20 seconds after the weld initiation. From the three groups of experiments in Table 1 (from 1 to 4, 5 to 8 and 9 to 12), 3855 groups of data were acquired.

An artificial BP neural network of three layers with nine parameters as inputs and the bottom diameter of a keyhole as an output, which can implement any map from m dimensions to n dimensions, was used to model the system - - Fig. 9. As the number of hidden layers is not easily determined using current the- ories, the BP models with one hidden layer consisting of elements of 3, 6, 9, 12, 15 and 18 are respectively examined using the Gauss initiation procedure and the Delta rule (Ref. 24). Figure 10 shows the error comparison of the models with different layers. A comparison of the neural network output with the measured results is given in Fig. 11. It can be seen the training error of the model is the smallest value of 6.77%, and the corresponding error of the experiment examined is 6.64% when the number of the hidden layer element is selected as six. Also, the corresponding curves measured and output from the model agree well with each other. Thus, the model with a six-element hidden layer was selected as the mapping model between the bottom diameter of a keyhole and the geometrical size of a corresponding nominal keyhole, as well as the three pairs of coordinates in the image schematically shown in Fig. 5. However, the model should be retrained using new experimental data if the thickness of a workpiece and different welding parameters are applied.

R e a l - t i m e Feedback C o n t r o l o f the Full W e l d Penet ra t ion

As stated above, the reason for the occurrence of a cutting phenomenon is not enough metal is inside the weld pool. To

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Fig. 15 - - Block diagram of the program for closed loop control o f ful l penetration in butt-jointed plates.

guarantee full penetration control and achieve a uniform weld bead, the quantity of the weld pool metal should be controlled. Based on the fact the keyhole size may be regulated by adjusting the wire feed speed and the heat input may be control led by changing the welding current, the wire feeding speed was selected as the first control ling variable for full weld penetration.

Controlling Model

To model the relationship between the wire feed speed and the bottom diameter of a keyhole by the black- box method, the artificial BP neural network theory was applied. Because the welding process is a time delay process (the response of the weld pool status to the adjustment of the controlling parameters takes a longer

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Fig. 16 - - Bottom diameter o f a keyhole and wire feed speed vs. the time in the ful l penetration control of a weld bead in a butt jo int using wire feed speed as a control variable.

Fig. 17 - - A weld bead with closed loop control of ful l penetration in a butt jo int using wire feed speed as a controll ing variable. A - - Top face; B - - bottom face.

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time), the previous data values for the input should be utilized in the establish- ment of a model using current data value. A model of three layered BP neural networks was established, with the current wire feed speed as the output and the current and previous bottom diameters of the keyholes as the input. The number of hidden layer elements is selected from the experiments. In the beginning, the training sample data are acquired from the experiments in Table 1 when the wire feed speed was changed. So, two categories of data (associated with the varied heat sink workpiece and the ordinary workpiece, respectively) are selected according to the standard: there is no apparent concave or undercut in a weld bead. The bottom diameter of a keyhole, which is the input for the controlling model shown in Fig. 12, is the output in Fig. 9. From the comparison of the output results of the neural networks model with the training sample data, illustrated in Fig. 13, it can be seen the model with three elements in the hidden layer has the smallest error. Also, the difference between the output results of the neural networks model and the training sample data is large. The reason for this is the changes in the wire feed speed are limited and the standard for an acceptable weld bead is not very strict. Conse- quently, contradictory data are included in the training data sample collection.

In Fig. 14, curve 1 is the model output of the wire feed speed regulator based on the above data sample collection used for training the model. The corresponding initial and terminal data values, as well as the increment value of the bottom diameter of a keyhole are respectively 3.0, 8.0 and 0.1 mm. Curve 2 is the output of the same regulator trained using the new data sample collection acquired from the feedback experiments done under the condition of the varied heat sink according to curve 1. These experiments are divided into three groups: the

first four experiments are for constant weld- ~ ~ ~ . ~ ing current; the second . ,~ four experiments are for a decrease in welding current by 5 A when the area with a slot is reached; the last four experiments are for a decrease in weld- I ~ ~'~ -::, ing current by 10 A ~ : : i when the heat sink of ~ [ ' ~ -~ thecreased.Workpieces is in- ~ . ~ - T ~

According to the feedback control the- ,~,~:~Z~ ory, it can be seen the ~.~ regulator in Fig. 12 can regulate the wire feed speed to change the keyhole size depending on the variation in the keyhole diameter, so an occurrence of the cutting process may be avoided.

Full Penetration Control

Fig. 20 - - A weld bead in a butt jo in t with the closed-loop control of weld formation using both wire feed and welding current as controll ing variables• A - - Top face; B - - bottom face.

The block diagram of the program for controlling full penetration of a weld bead for the butt-joint plates is shown in Fig. 15. Because a welding process needs about 20 s to enter the stable main body segment from the start-up segment, the control process of the full penetration begins at the 20th cycle of the image sampling (i.e., the control strategy is applied after the variable I equals 19 s in Fig. 15).

The wire feed speed and the bottom diameter of a keyhole are recorded, measured and calculated, the relationships of which, versus time, are shown in Fig. 16. The corresponding photograph of a weld bead is given in Fig. 17. It shows the following:

• The cutting process can be avoided reliably using the wire feed speed as a controlling variable in the real-time closed loop control of the full weld pen-

etration when the thermal condition of the workpiece changes•

• In the areas with a poorer heat sink because of the slots, the width and height of the bottom weld bead are apparently wider and higher than those in other areas with a better heat sink. The corresponding width of the top bead is a little wider and the corresponding height of the top bead is a little reduced. However, there are no concave or undercut defects in the weld bead.

• The weld formation is not uniform.

Opt imizat ion of the Weld Formation

To achieve a uniform weld formation during the full weld penetration control process, the welding current should be control led for regulating the heat input to the workpiece. Although the experiments show the cutting process can also be avoided by adjusting only the welding current, there often exist undercut and concave defects in the top weld bead.


A solution that includes the regulation of the wire feed speed is shown in Fig. 18. Three thresholds of the bottom keyhole diameters of 4.3, 4.6 and 5.1 mm are respectively matched with the welding current of 97, 92 and 87 A. The changing mode of the welding current is designed into the following:

1 ) When the bottom diameter of a keyhole increases to a threshold, the welding current is decreased according to the top downstairs-shaped curve in Fig. 18.

2) When the bottom diameter of a keyhole decreases to a threshold, the welding current is increased according to the bottom upstairs-shaped curve.

3) When the bottom diameter of a keyhole changes between the two neigh- boring thresholds and does not reach those thresholds, the welding current is held constant. To weaken the influence of any noise during an on-line control process, an average-weighted fi l tering method is applied to the determination of the bottom diameter of a keyhole: the weighted coefficients are 0.5, 0.3 and 0.2, respectively, for the current diameter, the former diameter and the diameter before the former diameter.

Figure 19 shows the responses of the welding current and the wire feed speed to the variation in the bottom diameter of a keyhole during a real-time feedback control process. Compared with the results in Fig. 1 6, it can be seen the bottom diameter becomes significantly smaller in area with a poorer heat sink because of the slots and the quantity of wire feed is decreased to avoid a cutting process. The corresponding photograph of the weld bead (Fig. 20) also shows the bead is more uniform than that in Fig. 17. Therefore, a combination of the wire feed regulation with welding current adjustment can further improve the weld formation in VPPAW of aluminum alloys by the keyhole mode.

Conclusions

The fol lowing conclusions can be made based on the results of this study:

1 ) A clear image of the keyhole weld pool can be obtained using a band-pass filtering method. The nominal keyhole in the image is a part of the actual keyhole, the geometrical features of which can reflect the variation in the bottom diameter of a keyhole regardless of whether there is wire feed or not.

2) The main reason for an occurrence of a cutting phenomenon is not enough metal is appropriately added to the weld pool during a welding process. The development of a cutting process from a keyhole welding process takes some time, which allows full weld penetration control.

3) The model, established between the bottom diameter of a keyhole and the geometrical size of a nominal keyhole weld pool in the image, effectively and accurately reflects the keyhole variation. The bottom diameter of a keyhole can be used as a characteristic parameter to monitor and control the full weld penetration.

4) The model for controlling the full weld penetration can be applied to a welding process using the wire feed speed as a control variable to reliably avoid an occurrence of a cutting process or a melt-in mode. However, a uniform weld bead may not be obtained by using only the wire feed speed as a single controlling variable.

5) Uniform weld formation can be achieved using a combination of the wire feed speed regulation with welding current adjustment according to the variation in the bottom diameter of a keyhole in the full weld penetration control of a weld bead.

6) The approach used in this paper should be further explored when thicker materials are applied. The influence of the arc light intensity should be a greater condition when designing a filtering system under the condition of a high welding current.

Acknowledgments

The authors wish to acknowledge the financial support from the National Key Laboratory of Advanced Welding Pro- duction Technology at Harbin Institute of Technology, P. R. China, and from the National Science Foundation (Project Nos. DMI-9900011 and DMI-9700102).

References

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3. Torres, M. R. 1992. Gas contamination effects in variable polarity plasma arc welded aluminum. Welding Journal 71(4): 123-s to 130-s.

4. Martinez, L. F. 1994. Effect of weld gases on melt zone size in VPPA welding of A12219. Welding Journal 73(10): 50-s to 55-s.

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6. Steffens, H. D. 1972. Automatic control for plasma arc welding with constant keyhole. Welding Journal 51 (6): 40-s to 45-s.

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Study on arc sound in TIG and plasma processes. IIW Doc. 212-610-85.

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