•Spotlight on Shielding Gases

December 2004

•Spotlight on Shielding Gases •Developing an Effective Effectibe Web Web Site site •Weldability of Powder Metal Parts PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING AND ALLIED PROCESSES, INCLUDING JOINING, BRAZING, SOLDERING, CUTTING AND THERMAL SPRAYING

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Everything is bigger in Texas And the AWS Welding Show 2005 is the biggest of them all! Exhibiting at the AWS Welding Show 2005 is the most cost-effective way to gain broad exposure in a short time. As an AWS exhibitor, you will have the opportunity to meet those buyers who need your products. The AWS Welding Show has more to offer than any other show in the metal-fabricating and construction industries. Big benefits for exhibitors before, during, and after the Show. • Advance multi-media ad and direct mail campaign promoting the Show. • Local newspaper and media coverage. • Listing in the official Show Program and Buyers’ Guide distributed at the Show. • Use of the AWS Press Room. • Discounts on freight, car rentals, and room rates, as well as free shuttle buses from AWS-sponsored hotels to the Show.

• On-site staff to assist you during the Show and to help provide a hassle-free exit at the end. • AWS website, which is used as a year-round tool by manufacturers, distributors and end-users looking for products and services. • A targeted demographic attendee list will be available from Show management. • Our marketing staff will be available for consultation on lead follow-up and tracking.

Seven exciting Special Pavilions give attendees new reasons to come to the Show: ★ ★

★

★ ★ ★

To participate in any of the pavilions or for more information, please contact our Welding Show Exhibit Sales office at: 1-800-443-9353, ext. 295 or 242.

★

Gas Products Oilfield and Pipeline Equipment Cutting and Grinding Products Brazing and Soldering Resistance Welding Laser Welding and Cutting Nondestructive Testing and Inspection

April 26-28, Dallas, Texas DALLAS CONVENTION CENTER Circle No. 13 on Reader Info-Card © American Welding Society 2004

CON-1070

CONTENTS 26

December 2004 • Volume 83 • Number 12

Features 26

30

34

38

Bay Bridge Puts New Gas Mixtures to the Test

Departments Washington Watchword..........4

Challenging bridge project relied on advanced three-part gas mixtures B. O’Neil and M. E. Rodgers III

Press Time News..................6

How to Optimize Mild Steel GMAW

News of the Industry ............10

The right shielding gas can lead to reduced production costs and higher quality products R. Green

Aluminum Q & A ................16

Exploring the Weldability of Powder Metal Parts

New Products ....................20

The weldability of powder metal parts under a variety of manufacturing conditions was investigated A. Kurt et al.

Coming Events ..................44

Boot Camp for Battlefield Welders

Welding Workbook ..............54

Army, Air Force, and Marine welders prepare for battlefield welding at Aberdeen Proving Ground R. Hancock 41

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

Upgrade Your Web Site’s Usability Tips for making your Web site more useful

30

Editorial ............................8

CyberNotes ......................18

Navy Joining Center ............52

Society News ....................55 Tech Topics ......................61 Standards Errata Guide to AWS Services ........70 New Literature ..................72

Welding Research Supplement 319-S

Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: Nickel-based Alloys Nickel-based, gadolinium-enriched alloys showed improved hot ductility and cracking resistance compared to Gd-enriched stainless steels J. N. DuPont et al.

38 330-S

Personnel ........................74 Welding Journal Index..........76 Classifieds........................90 Advertiser Index ................92 Welding Consultants Directory ......................92

Numerical Simulation of Transient 3-D Surface Deformation of a Completely Penetrated GTA Weld A transient numerical model was developed to investigate the dynamic behavior of a completely penetrated GTAW joint C. S. Wu et al.

336-S

Signature Analysis for Quality Monitoring in Short-Circuit GMAW A time-frequency analysis method was developed to identify process stability and welding quality of short-circuit GMAW Y. X. Chu et al.

Cover photo courtesy of Craig Bratt, Fraunhofer USA. The hybrid laser beam welding process combines the traditional GMAW process with laser beam processing.

Welding Journal (ISSN 0043-2296) is published

monthly by the American Welding Society for $90.00 per year in the United States and possessions, $130 per year in foreign countries: $6.00 per single issue for AWS members and $8.00 per single issue for nonmembers. American Welding Society is located at 550 NW LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671. Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or resale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright.

WELDING JOURNAL

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WASHINGTON BY HUGH K. WEBSTER

WATCHWORD

AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE

OHSA Issues Final Rule on Shipyard Fire Protection The U.S. Occupational Safety and Health Administration (OSHA) has issued a final rule on Fire Protection in Shipyard Employment. The purpose of the standard, which becomes effective December 14, is to increase the protection of shipyard workers from fire hazards. According to OSHA, shipyard workers are subject to a risk of injury and death from fires and explosions during ship repair, shipbuilding, and shipbreaking. As well, many of the core tasks involved in shipyard employment, such as welding, can provide an ignition source for fires. The Bureau of Labor Statistics data show that there is an annual average of 1 fatality, 110 lost-workday “heat/burn” injuries, and more than 300 total injuries due to shipyard fires.

Congress Enacts Manufacturing Deduction As part of the American Jobs Creation Act of 2004, a new tax deduction will now be available for “U.S. production activities.” Ultimately, the deduction will be 9% of a manufacturer’s taxable income, though it will be phased in with 3% for 2005 and 2006, and 6% for 2007 through 2009. The deduction will be limited to 50% of W-2 wages plus certain elective income deferrals, and it will be allowed against the Alternative Minimum Tax.

Stricter Standard Proposed for Hexavalent Chromium The U.S. Occupational Safety and Health Administration (OSHA) has issued a Notice of Proposed Rulemaking for occupational exposure to hexavalent chromium. OSHA is proposing to lower its permissible exposure limit for hexavalent chromium from 52 to one µg/m3 of air as an eight-hour time-weighted average. The proposed rule also includes provisions for employee protection such as preferred methods for controlling exposure, respiratory protection, protective work clothing and equipment, hygiene areas and practices, medical surveillance, hazard communication, and record keeping. This proposal will affect all metal fabricators who join stainless steel or use electrodes containing chromium. Public comments will be accepted until January 3, 2005. In addition, OSHA plans to hold an informal public hearing in Washington, D.C., beginning February 1, 2005. A federal court order requires OSHA to publish a final rule by January 18, 2006. The OSHA Web site for submitting comments is http://ecomments.osha.gov. The entire proposed rule can be accessed at http://www.osha.gov/FedReg_osha_pdf/FED20041004.pdf.

H-1B Visas Reach Limit for Fiscal Year 2005 On October 1, 2004, the first day of fiscal year 2005, the Department of Homeland Security’s office of U.S. Citizenship and Immigration Services announced that it had already received enough petitions to account for all 65,000 H-1B visas allocated for the year. The H-1B program is designed to facilitate the hir4

DECEMBER 2004

ing of foreign highly skilled workers. This is the seventh time since 1997 that the H-1B cap was reached before the end of the fiscal year, but the first time that it was reached on the first day of the new year. Business groups have asked Congress to intervene by extending the 65,000 visa limit.

R&D Tax Credit Extended Congress has extended the Research and Development (R&D) tax credit for corporations through December 31, 2005. The extension is retroactive to June 2004, when the credit last expired. The R&D credit has expired 11 times since its creation, which has made long-term R&D planning difficult. The business community has tried to convince Congress to make the tax credit permanent.

OSHA Pursues More Cooperative Approach In recent years, the U.S. Occupational Safety and Health Administration (OSHA) has tried to accomplish i ts goals through more cooperative initiatives with industry, as a complement to its usual regulatory and enforcement activities. For example, the agency has formed 231 long-term alliances with trade associations and companies since 2002 that emphasize outreach, education, and sharing “best practices.” OSHA has also forged 214 active strategic partnerships that set safety goals involving 4762 employers, and there are 1153 voluntary protection program sites where companies with exemplary safety records forego routine inspections.

States Ranked for Their Small Business Climates The nonprofit Small Business & Entrepreneurship Council has issued a ranking of states based on their public policy climates for small businesses. The index is based on an analysis of 23 major government-imposed or government-related costs affecting small businesses and entrepreneurs, including an assortment of taxes and measures that reflect various regulatory costs such as worker’s compensation. The following are the top ten states: 1. South Dakota 2. Nevada 3. Wyoming 4. Washington 5. Florida 6. Michigan 7. Mississippi 8. Alabama 9. Colorado 10. Indiana

Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail [email protected] ; FAX (202) 835-0243.

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PRESS TIME NEWS

Mittal Steel Set to Become World’s Largest Steel Company Ispat International N.V. announced it has agreed to acquire LNM Holdings N.V. Following completion of this transaction, the company will be renamed Mittal Steel Co. N.V. Also, the board of directors from Is pat and International Steel Group, Inc. , have unanimously approved a definitive agreement to merge these two companies. The combined Mittal Steel will be the largest and most global steel c ompany in the world, with operations in 14 countries on four continents, and 165,000 employees. It will serve the major steel-consuming sectors, including automotive, appliance, machinery, and construction. For 2004, it expects pro forma revenues of more than $31.5 billion, and pro forma total steel shipments of approximately 57 million tons.

Oshkosh Developing Second-Generation Robotic Truck Oshkosh Truck Corp., Oshkosh, Wis., is d eveloping a second-generation vers ion of its self-navigating robotic TerraMax™truck to compete in the Pentagon-sponsored $2 million 2005 DARPA Grand Challenge. During this competition in the Mojave Desert, the sensor-data based TerraMax must make its own decisions on route planning, obstacle avoidance, and speed, without the aid of any human intervention once en route. The platform for the truck is the company’s Medium Tactical Vehicle Replacement, which is equipped with the Oshkosh TAK-4® independent suspension, Command Zone™ advanced electronics, and “on-the-go” central tire inflation. By 2015, the Pentagon hopes that the application of autonomous military vehicles will be able to help sav e the lives of military personnel who today are at risk when driving slow-moving supply convoys.

Report Reveals Business Conditions of Metalforming Companies According to the Precision Metalforming Association (PMA) Business Conditions Report from October, metalforming companies are feeling less optimistic about current and near-term business conditions than they were in September. When asked what they anticipated the general economic activity would be like over the next three months, 27% expected business c onditions to improve (down from 36% in September), 53% said activity would remain the same, and 20% thought it would decrease (compared to 15% in September). Also, expectations for incoming orders for the next three months were down, with 38% anticipating orders would rise (down from 42% in September), 37% predicting no change (the same number reported in September), and 25% indicating orders would decrease (up from 21%). The PMA, Cleveland, Ohio, conducts this monthly report as an economic indicator for manufacturing by sampling 172 metalforming companies in the United States and Canada.

Praxair Creates Web Site for Professional Welders Praxair Distribution, Inc., Danbury, Conn., has launched an all-in-one Web site, weld zone.praxair.com, to provide the latest information on products and services for the metal fabrication industry. Users can browse e-catalogs that contain more than 40,000 items. Other services include product-specific, safety, and technical information, welding gases and products, a welding equipment clearance center, on-line purchasing capabilities, and tips to improve welding and cutting operations. Users can also learn about upcoming welding demonstrations and events.

World’s Largest Solar-Powered Irrigation System Completed WorldWater & Power Corp., Pennington, N.J., recently announced the installation of a 200-hp, solar-powered irrigation system at a commercial citrus ranch in California. The company’s AquaMax™ solar motors are powering the $2 million water pumping installation. This is the largest solar-power system in California’s San Diego County, and it is the largest solar-driven irrigation system in the world. 6

DECEMBER 2004

Publisher Andrew Cullison Editorial Editor/Editorial Director Andrew Cullison Senior Editor Mary Ruth Johnsen Associate Editor Howard M. Woodward Assistant Editor Kristin Campbell Peer Review Coordinator Doreen Kubish

Publisher Emeritus Jeff Weber Graphics and Production Production Editor Zaida Chavez Production Assistant Brenda Flores Advertising National Sales Director Rob Saltzstein Advertising Sales Representative Lea Garrigan Advertising Production Frank Wilson Subscriptions Leidy Brigman [email protected] American Welding Society

550 NW LeJeune Rd., Miami, FL 33126 (305) 443-9353 or (800) 443-9353 Publications, Expositions, Marketing Committee G. O. Wilcox, Chair Thermadyne Industries D. L. Doench, Vice Chair Hobart Brothers Co. J. D. Weber, Secretary American Welding Society R. L. Arn, WELDtech International T. A. Barry, Miller Electric Mfg. Co. M. Balmforth, Sandia National Labs R. Durda, The Nordam Group J. R. Franklin, Sellstrom Mfg. Co. R. G. Pali, J. P. Nissen Co. L. Pierce, Cee Kay Supply J. F. Saenger, Jr., Edison Welding Institute R. D. Smith, The Lincoln Electric Co. S. Smith, Weld Aid Products. ., Sandia National Laboratories B. Damkroger, Ex Off J. E. Greer, Ex Off ., Moraine Valley College D. C. Klingman, Ex Off ., The Lincoln Electric Co. D. J. Landon, Ex Off ., Vermeer Mfg. Co. E. D. Levert , Ex Off ., Lockheed Martin E. C. Lipphardt, Ex Off., Consultant J. G. Postle, Ex Off ., Postle Industries R. W. Shook , Ex Off ., American Welding Society

Copyright © 2004 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.

MEMBER

VeronaFiere, 17-19 March 2005

www.saldat.it The Italian exhibition dedicated to welding and cutting technologies to stay in touch with the market and its key players After the success of the first edition, SALDAT is back. Sponsored by ANASTA, the Italian Association for Welding, Cutting, and Related Technology Companies, this biannual event has been designed for the trade operators and for all interested in the welding and cutting market. At SALDAT, end users, integrators, professionals, and dealers will learn about the new market trends, attend demonstrations and presentations and guided tours, get new contacts, find concrete offerings to improve their business. Thanks to ANASTA’s collaboration with organizations, associations, and universities, SALDAT will be rich with opportunities of discussing all of the latest issues, attending conferences on specific topics, and participating in training sessions for schools and professional institutes.

The exhibitors at SALDAT are exclusively Italian manufacturing firms, subsidiaries of multinational companies, distributors for the Italian market of trade brands and firms working in related industries. During the event, the most innovative solutions to the welding and cutting needs of the various industry segments will be presented, including: •manual oxy-gas welding, cutting and heating; •manual and semiautomatic arc and resistance welding and cutting; •consumables products; •automation of welding and cutting; •support machinery and accessories of welding and cutting.

Entrance is free For information: Exhibition Organization Tel. + 39 02 7002534 Italian Association for Welding, Cutting, and Related Technology Companies Circle No. 37 on Reader Info-Card

www.anasta.it • www.weld.it

EDITORIAL Founded in 1919 to Advance the Science, Technology and Application of Welding

A Place for Everyone Thoughout most of my business career, I have been employed in sales. I’ve sold all types of products, from cars to office supplies, from advertising to retail. I’ve been in distribution, and I’ve been a factory representative. I always believed that any product just needed to be “sold,” and that I could sell anything. Like the old saying goes, “I could sell ice cubes to Eskimos.” So 32 years ago I applied for a job in the welding and cutting industry with Chemetron Corporation (formerly NCG). Again, I thought, “Selling is selling…period. Just give me a company car and a commission, and I’ll do the rest.” I soon found that selling welding and cutting products and gases was different from what I was used to. For most products, all a salesperson needed was a quick training class. Selling welding products, however, required a lot more knowledge than what a simple training seminar could supply. I also soon learned that a sale represented something a lot more important than just a sale, because the products were being used to build something to last, something that would affect neighbo rhoods, cities, or even countries. I went back to college for more education on welding and metallurgy. I discovered the more I learned, the more I needed to learn. Never before had I been challenged by products, but now I was. That’s because in welding there are usually several ways to accomplish a job based on need or speed or specification. There’s not al ways one absolute “right” way. Alloy selection, process used, the design of the workpiece, and the way it is cut or shaped all influence the quality of the final product. That’s why, as I work with my customers, I always try to look at each project with fresh eyes and to consider several options. Within months of starting this new job, a wise colleague told me that if I was serious about the welding industry, I needed to attend the local AWS meetings. I went to my first Section meeting the very next Thursday night. Section meetings gave me an opportunity to meet customers, competitors, and people who gave back to their industry. The meetings helped me to grasp the enormous breadth of the industry and how it provides opportunities for many types of careers. Our industry has a history of shedding off good people who want to work, but who don’t succeed because they never quite saw the total picture. Becoming involved with AWS helped me view the big picture. I soon real ized that if you make an effort to learn, and you make it past the first few years, then you will have a career for life. While this may not always be the highest paying industry, to me it’s always challenging. During my welding sales career, I have been to so many interesting projects, from the Alaska pipeline to the Mercury nuclear test site in Nevada to standing on a 1000ft ship as it was being built. What other industry is so vast and constantly growing? Nowadays, when I have the opportunity to talk to students at colleges or vo-tech schools, I encourage them to try to achieve the highest level skills they can and to learn the AWS standards. Then when it’s time to put their education and skills on the market, they’ll have many options. My point is there’s room in welding and in the American Welding Society for many types of people. This is a career industry that needs architects, engineers, teachers, welders, and, yes, sales people such as myself.

Officers President James E. Greer Moraine Valley Community College

Vice President Damian J. Kotecki The Lincoln Electric Co. Vice President Gerald D. Uttrachi WA Technology, LLC Vice President Gene E. Lawson ESAB Welding & Cutting Products Treasurer Earl C. Lipphardt Consultant Executive Director Ray W. Shook American Welding Society Directors

T. R. Alberts (Dist. 4), New River Community College B. P. Albrecht (At Large), Miller Electric Mfg. Co. A. J. Badeaux, Sr. (Dist. 3), Charles Cty. Career & Tech. Center K. S. Baucher (Dist. 22), Technicon Engineering Services, Inc. M. D. Bell (At Large), Preventive Metallurgy J. C. Bruskotter (Dist. 9), Bruskotter Consulting Services C. F. Burg (Dist. 16), Ames Laboratory IPRT N. M. Carlson (Dist. 20), INEEL H. R. Castner (At Large), Edison Welding Institute N. A. Chapman (Dist. 6), Entergy Nuclear Northeast S. C. Chapple (At Large), Consultant N. C. Cole (At Large), NCC Engineering J. D. Compton (Dist. 21), College of the Canyons L. P. Connor (Dist. 5), Consultant J. R. Franklin (At Large), Sellstrom Mfg. Co. J. D. Heikkinen (Dist. 15), Spartan Sauna Heaters, Inc. W. E. Honey (Dist. 8), Anchor Research Corp. D. C. Howard (Dist. 7), Concurrent Technologies Corp.

J. L. Hunter (Dist. 13), Mitsubishi Motor Mfg. of America, Inc. M. D. Kersey (Dist. 12), The Lincoln Electric Co. E. D. Levert (Past President), Lockheed Martin Missiles &Fire Control V. Y. Matthews (Dist. 10), The Lincoln Electric Co. J. L. Mendoza (Dist. 18), City Public Service T. M. Mustaleski (Past President), BWXT Y-12, LLC R. L. Norris (Dist. 1), Merriam Graves Corp. T. C. Parker (Dist. 14), Miller Electric Mfg. Co. O. P. Reich (Dist. 17), Texas State Technical College at Waco E. Siradakis (Dist. 11), Airgas Great Lakes K. R. Stockton (Dist. 2), PSE&G, Maplewood Testing Serv.

Gene E. Lawson AWS Vice President

8

DECEMBER 2004

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


NEWS OF THE INDUSTRY to build and launch a spaceship able to carry three people to a height of 62.5 miles and return safely. The spaceship launched from its mother aircraft, White Knight, over the Mojave Desert in California and reached space three times; the team had to make two space flights with the same ship within two weeks to be the winner. SpaceShipOne has a hybrid motor that uses nitrous oxide as an oxidizer and hydroxy-terminated polybutadiene for fuel. Airgas, Inc., Radnor, Pa., provided the liquid nitrous oxide used to power it. Airgas West supplied air, nitrogen, carbon dioxide, and UHP nitrogen, along with gas regulators and fittings for managing the gas supply. “With this record-breaking achievement, the SpaceShipOne team has opened the door to exciting and challenging possibilities in the fields of aviation and aerospace,” said Martin Tupman, vice president and general manager of Airgas Nitrous Oxide.

Airgas Helps Fuel SpaceShipOne’s Ansari X Prize

Attendees of Shipbuilding Meeting See Welding Demonstrations SpaceShipOne , pict ured here sitting on the ramp on its landi ng gear, brought its team a place in history and a $10 million prize. Scaled Composites, LLC, Mojave, Calif., founded by Burt Rutan, led the SpaceShipOne team in winning the $10 million Ansari X Prize for commercial manned space flight on October 4. The team, privately financed by Paul G. Allen, became the first

The Laser Processing Division of ARL Penn State recently hosted a meeting of the National Shipbuilding Research Program’s SP-7 Welding Technology Panel. It attracted more th an 35 attendees from across the country, with representatives from the Navy and commercial shipyards, government and regulatory agencies, and a host of welding equipment suppliers. A tour of ARL Penn State’s Laser Processing Laboratory was


10

DECEMBER 2004

Meeting participants got a first-hand look at ARL Penn State’s Laser Processing Laboratory.

held after the meetings and presentations, with demonstrations of combined 4.5-kW Nd:YAG laser and gas metal arc welding to 1 join ⁄ 2-in.-thick steel in a single pass, and laser free forming (or cladding) of metal matrix composite materials.

U.S. Organizations to Establish Presence in China by Using Commerce Award The U.S. Commerce Department has announced it will make $399,500 available to establish an office in Beijing for China Standards and Conformity Assessment (CSCA). The CSCA office is Circle No. 5 on Reader Info-Card

Circle No. 31 on Reader Info-Card WELDING JOURNAL

11

an initiative by a four-member consortium: The American Society of Mechanical Engineers, The American Petroleum Institute, ASTM International, and CSA America. Through this Beijing office, the consortium will form relationships with peer agencies in China, monitor standards development, and promote acceptance of members’ standards and conformity assessment systems. Once established and staffed, they will prepare Chinese marketing materials and a Web site, obtain market and standards information of strategic importance, net work with government agencies and standards officials, and conduct training. The funds awarded to the consortium are made available through the Commerce Department’s Market Development Cooperator Program, and the consortium will match every federal dollar with two dollars of its own.

used to determine the beginning and completion of one or more phase transformations. As well, the practice can provi de data for computer models used in the control of steel manufacturing, forging, casting, heattreating, and welding processes.

Steel Sculpture Commemorates Wright Brothers’ Flight

Study on Steel Phase Transformations Results in New ASTM Standard A collaborative study on quantitative measurement of steel phase transformation by the American Iron and Steel Institute (AISI), West Conshohocken, Pa., in cooperation with more than a dozen companies, resulted in a recently approved new ASTM standard, A 1033, Practice for Quantitative Measurement and Re porting of Hypoeutectoid Carbon and Low-Alloys Steel Phase Trans formations . It was sponsored by the U.S. Department of Energy under AISI’s Technology Roadmap Project. In practice, dilatometer equipment is used to detect and measure the changes in dimension that occur as functions of both time and temperature during defined thermal cycles. The resulting data are converted to discrete values of strain for specific values of time and temperature during the thermal cycle that can be

This sculpture at the Raleigh-Durham Airport, commemorating the Wright brothers’ first powered flight, features an eliptical ring and a pair of intersecting wings atop a 50-ft tower.

Van Noorden Co., Franklin, Mass., recently built and erected a 40-ton sculpture for the Raleigh-Durham Airport that serves

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as an icon commemorating the 100th anniversary of the Wright brothers’ first powered flight. It evokes the Wright brothers’ spirit of invention and the circuitous nature of air travel involving time, movement, and return. 3 The 122-ft-long sculpture is fabricated from ⁄ 8-in. steel plate, and features an eliptical ring and a pair of intersecting wings atop a 50-ft tower. Architect Wellington Reiter of Urban I nstruments, Newton, Mass., designed the sculpture.

GAWDA Raises Money for HIV/AIDS Service Organization Golden Rainbow, Las Vegas, Nev., an HIV/AIDS service organization, has received $53,000 from the Philadelphia-based Gases and Welding Distributors Association (GAWDA) as this year’s recipient of the GAWDA Gives Back program. Each year for the past five years as part of its annual convention, GAWDA has chosen a charity in the convention’s host city to receive voluntary donations from the organization’s membership. “Our housing program is being threatened by freeway expansion in Las Vegas, and GAWDA’s incredible contribution will go a long way toward helping us s eek out or build new housing to continue our mission,” said Carol Hunter, Golden Rainbow president.

Deere & Co. to Build Tractor Factory in Brazil Deere & Co., Moline, Ill., recently announced it will build a new tractor factory in Brazil to increase its manufacturing capacity for farm tractors, combines, and seeding equipment in the South American agricultural equipment market. The new facility will manufacture farm tractors while the company’s existing factory there will focus on combines and planting equipment. In addition, the equipment manufactured in both places will be exported to other markets. Deere will invest $80 million to construct the new facility in Montenegro, Rio Grande do Sul, and expects it to be in full production by the second half of 2006.


Chairman Elected at Lincoln Electric Holdings, Inc. Lincoln Electric Holdings, Inc., Cleveland, Ohio, recently announced that its board of directors has elected J ohn M. Stropki as chairman of the board. He succeeds Anthony A. Massaro, who has retired afrer 11 years with the company. Stropki began his career at Lincoln 35 years ago, working in the company’s Cleveland factory while he was an engineering student at Purdue University. After graduation, he became a sales trainee and rose through the sales organization. In 1996, Stropki was the company’s executive vice president and president, North America, from May 2003 to June 2004 served as chief operating officer, and in June 2004 was named president and chief executive officer. He is a member of the American Welding Society, the Manufacturers Alliance/MAPI Presidents Council, and the Gases and Welding Distributors Association.

GE and Honda Establish Joint Venture to Market Jet Engine General Electric Co. and Honda Motor Co., Ltd., have established a new joint venture company, GE Honda Aero Engines, Circle No. 28 on Reader Info-Card WELDING JOURNAL

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LLC, to pursue launching of Honda’s HF118 turbofan engine in the jet engine market. The HF118 will enter service in the 1600-lb thrust class. Also, the engine has run more than 2400 h in ground tests and more than 450 h in flight tests to demonstrate reliability, long maintenance interval, and fuel economy. The 50/50 joint company will begin operating near the end of 2004 in Cincinnati, Ohio. It envisions a future market of approximately 200 or more of these business jets annually.

Northrop Grumman Awarded Contract for Nuclear-Powered Submarine

Maintenance work on the U SS Hyman G. Rickover is expected to be completed in March 2005.

Northrop Grumman Corp., Newport News, Va., has been awarded a contract valued at $36.5 million for the planning and

execution of dry-docking work on the nuclear-powered submarine USS Hyman G. Rickover . Maintenance work on the Rickover will be performed at the company’s Newport News sector. This includes blasting and painting the submarine’s internal and external tanks, removal and overhaul of various system valves, steering and diving gear inspection and repair, repairs to torpedo systems, and inspection and repairs to the sail, pressure, and nonpressure hulls. It will take approximately five months to complete and should be finished in March 2005.

Industry Notes • The Titan Corp., San Diego, Calif., has been awarded an indefinite delivery/indefinite quantity multiple award contract for engineering and technical services to the U.S. Navy’s NAVSEA Shipbuilding O ffice (NAVSHIPSO). As a multiple award five-year contract, with one base year and four one-year options, it has a potential ceiling value in excess of $1.05 billion. Titan will compete against seven other companies for task orders to provide NAVSHIPSO habitability, propulsion, electrical, auxiliary and electronics systems engineering, and technical services for ships and shore stations. • South Korean steelmaker Posco is in discussions with Brazilian iron-ore giant Companhia Vale do Rio Doce to participate in a joint venture to develop an $11.4 billion steel-manufacturing plant on Brazil’s north coast. This new slab-making operation would make Brazil one of the top steel producers in the world, according to a recent Wall Street Journal article. • Praxair, Inc., Danbury, Conn., announced that Praxair Distribution, a division of Praxair Canada, Inc., has signed an agreement to provide welding gases and hard goods to TSC Stores,

THE ANSWER FOR INDEPENDENT WELDING SHOPS! AWS AFFILIATE COMPANY MEMBERSHIP MEMBER BENEFITS: • Priceless exposure of your shop with free publicity on AWS’s 40,000-visitors-a-month website. • $50 OFF a job posting on AWS JobFind www.aws.org/jobfind, your connection to hundreds of welders, inspectors and other job seekers! • An AWS Individual Membership ($75 value), which includes need-to-know technical information through a FREE monthly subscription to the Welding Journal. WJ covers the latest trends, events, news and products guaranteed to make your job easier.

• Quick access to welding information through a personal library of AWS Pocket Handbooks: 1 . Everyday Pocket Handbook for Arc Welding Steel

2 . Everyday Pocket Handbook for Visual Inspection and Weld Discontinuities – Causes and Remedies 3 . Everyday Pocket Handbook for Gas Metal Arc and Flux-Cored Arc Welding

• A 62% discount on freight shipments with Yellow Transportation, Inc. • Practical information through The American Welder, a special section of the Welding Journal geared toward front-line welders.

To join, or for more information call: (800) 443-9353, ext. 480 or (305) 443-9353, ext. 480 Visit us on-line at www.aws.org Real-world business solutions for welding and fabricating shops Circle No. 16 on Reader Info-Card

• Exclusive usage of the AWS Affiliate Company Member logo on your business card and promotional material for a competitive edge. • Wall certificate to show your company’s affiliation with the world’s premier welding association. • Window decal to display on your shop’s storefront. • Free passes to the AWS Welding Show for you and your shop’s best employees. • Unmatched networking opportunities at local Section Meetings, the annual AWS Welding Show, as well as at AWS-sponsored educational events. • Professional development via discounts on worldrenowned and industry-wide AWS Certification programs, conferences and workshops. • Technical information through a 25% Members’only discount on 300+ industry-specific AWS Publications and technical standards.

Ltd., a London, Ont., Canada, based retailer that specializes in hardware and farm supplies. By the end of the year, Praxair’s industrial cylinders exchange program, which lets customers purchase new cylinders or exchange empties for full ones of Praxair’s Star™ gases and blends for welding and cutting, and the store-within-a-store program will be available at all of TSC Stores’ 25 retail outlets in southwestern and eastern O ntario. • Lime Rock Partners and SGAM/4D have announced the purchase of Serimer DASA, headquartered in Paris with a second facility in Villers-Cotterets, France, and Serimer DASA North America, with offices i n Hou ston, Tex., from Sto lt Of fshore. This is the first time Serimer DASA has not been a part of an offshore contractor group. David Williams will assume the position of chairman of the board. • United Rentals, Inc., Greenwich, Conn., recently purchased Atlantic Rental s, Ltd., of Woodstock, NB, Cana da. Atlan tic Rentals is the largest equipment rental company in Canada’s Maritime Provinces, with revenues of approximately $35 million. • IPG Laser GmbH, Burbach, Germany, has appointed HM Laser as a new distributor in China. HM Laser will provide training, support, and service to Chinese OEMs and systems manufacturers for IPG’s industrial fiber lasers. Correction

In the August Welding Journal on pg. 10, there was an announcement that Lincoln Electric Holdings, Inc., had acquired the controlling interest in a tungsten electrode factory in northern China. That item should have stated that the controlling interest was in a covered electrode factory. Circle No. 7 on Reader Info-Card

1-DAY Seminars Offered

Laser Welding and Processing This seminar provides a solid background on issues that influence laser processing with emphasis on laser welding. February 15, 2005

Robotic Arc Welding This seminar is designed for those considering automating welding operations with robotics. April 12, 2005

For more information or to register Call Today! 1-800-332-9448 or visit us at www.welding.org for more information. Some restrictions apply; please contact us for details. © 2004 Hobart Institute of Welding Technology, Troy, OH, St. of Ohio Reg. No. 70-12-0064HT Circle No. 33 on Reader Info-Card


WELDING JOURNAL

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ALUMINUM Q&A Q: I have heard, on occasion, reference made to some aluminum alloys as un weldable. What does this mean? Are there such aluminum alloys, and if so, what makes them unweldable?

A: I shall start by saying that the majority of aluminum-based alloys can be successfully arc welded when using the correct welding procedures. However, yes, there are some aluminum-based alloys that are sometimes referred to as unweldable. These groups of alloys are well known as being unsuitable for arc welding and, for this reason, are joined mechanically by riveting or bolting. Before we start examining the various reasons for the poor weldability of these alloys, we should start by considering the term “unweldable.” This is a nonstandard term that is sometimes used to describe aluminum alloys that can be difficult to arc weld without encountering problems during and/or after welding. These problems are usually associated with cracking, most often hot cracking, and on occasion, stress-corrosion cracking (SCC). When we consider the aluminum alloys that fall into this difficult-to-weld category, we can divide them into different groups. We will first consider the small selection of aluminum alloys that were designed for machineability, not weldability, such as 2011 and 6262 that contain 0.20–0.6 Bi, 0.20–0.6 Pb and 0.40–0.7 Bi, 0.40–0.07 Pb, respectively. The addition of these elements (bismuth and lead) to these materials greatly assists in chip formation in these free-machining alloys. However, because of the low solidification temperatures of these elements, they can seriously reduce the ability to successfully produce sound welds in these materials. There are a number of aluminum alloys that are quite susceptible to hot cracking if arc welded. These alloys are usually heat-treatable alloys and are most commonly found in the 2xxx-series, aluminum-copper (Al-Cu), and 7xxxseries, aluminum-zinc (Al-Zn) groups of materials. In order to understand why some of these alloys are unsuitable for arc welding (unweldable), we need to consider the reasons why some aluminum alloys can be more susceptible to hot cracking. Hot cracking, or solidification cracking, occurs in aluminum welds when high levels of thermal stress and solidification shrinkage are present while the weld is un-

16

DECEMBER 2004

BY TONY ANDERSON

dergoing various degrees of solidification. The hot-cracking sensitivity of any aluminum alloy is influenced by a combination of mechanical, thermal, and metallurgical factors. A number of high-performance, heattreatable aluminum alloys have been de veloped by combining various alloying elements in order to improve the materials’ mechanical properties. In some cases, the combination of the required alloying elements has produced materials with high hot-cracking sensitivity.

Coherence Range Perhaps the most important factor affecting the hot-crack sensitivity of aluminum welds is the temperature range of dendrite coherence and the type and amount of liquid available during the freezing process. Coherence is when the dendrites begin to interlock with one another to the point that the melted material begins to form a mushy stage. The coherence range is the temperature between the formation of coherent-interlocking dendrites and the solidus temperature; this could be referred to as the mushy range during solidification. The wider the coherence range, the more likely hot cracking will occur because of the accumulating strain of solidification between the interlocking dendrites.

The 2xxx-Series Alloys (Al-Cu) Hot-cracking sensitivity in the Al-Cu alloys increases as we add Cu up to approximately 3% Cu, and then decreases to a relatively low level at 4.5% Cu and above. Alloy 2219 with 6.3% Cu shows good resistance to hot cracking because of its relatively narrow coherence range. Alloy 2024 contain s approximately 4.5% Cu, which may initially encourage us to suppose that it would have relatively low crack sensitivity. However, Alloy 2024 also contains a small amount of magnesium (Mg). The small amount of Mg in this alloy depresses the solidus temperature, but it does not affect the coherence temperature; therefore, the coherence range is extended and the hot-cracking tendency is increased. The problem to be considered when welding 2024 is that the heat of the welding operation will allow segregation of the alloying constituents at the grain boundaries, and the presence of Mg, as stated above, will depress the solidus tempera-

ture. Because these alloying constituents have lower melting phases, the stress of solidification may cause cracking at the grain boundaries and/or establish the condition within the material conducive to stress-corrosion cracking later. High heat input during welding, repeated weld passes, and larger weld sizes can all increase the grain-boundary segregation problem (segregation is a time-temperature relationship) and subsequent cracking tendency.

The 7xxx-Series Alloys (Al-Zn) The 7xxx-series of alloys can also be separated into two groups as far as weldability is concerned. These are the Al-ZnMg and the Al-Zn-Mg-Cu types. The Al-Zn-Mg alloys, such as 7005, resist hot cracking better and exhibit better joint performance than the Al-Zn-Mg-Cu alloys, such as 7075. The Mg content in this group (Al-Zn-Mg) of alloys would generally increase the cracking sensitivity. However, zirconium is added to refine grain size, and this effectively reduces the cracking tendency. This alloy group is easily welded with the high-magnesium filler metals, such as 5356, which ensures the weld contains sufficient magnesium to prevent cracking. Silicon-based filler metals, such as 4043, are not generally recommended for these alloys because the excess Si introduced by the filler metal can result in the formation of excessive amounts of brittle Mg 2Si particles in the weld.

TONY ANDERSON is Director of Technical Training for ESAB North America. He is a Senior Member of the TWI and a Registered Chartered Engineer. He is Chairman of the Aluminum Association Technical Advisory Committee for Welding and Joining and holds numerous positions including Chairman, Vice Chairman and Member of various AWS technical committees. Questions may be sent to Mr. Anderson c/o Welding Journal, 550 NW LeJeune Rd., Miami ,

FL

33126

[email protected].

or

via

e-ma il

at

The Al-Zn-Mg-Cu alloys, such as 7075, have small amounts of Cu added. The small amounts of Cu, along with th e Mg, extend the coherence range and, therefore, increase the crack sensitivity. A similar situation can occur with these materials as with the 2024-type alloys. The stress of solidification may cause cracking at the grain boundaries and/or establish the condition within the material conducive to stress-corrosion cracking later. Be Aware It should be stressed that the problem of higher susceptibility to hot cracking from increasing the coherence range is not only confined to the welding of these more susceptible base alloys, such as 2024 and 7075. Crack sensitivity can be substantially increased when welding incompatible dissimilar base metals (which are normally easily welded to themselves) and/or through the selection of an incompatible filler metal. For example, by joining a perfectly weldable 2xxx series base metal to a perfectly weldable 5xxx series base metal, or by using a 5xxx series filler metal to weld a 2xxx series base metal, or a 2xxx series fill er metal on a 5xxx series base metal, we can create the same scenario. If we mix high Cu and high Mg, we can extend the coherence range and, therefore, increase the crack sensitivity.◆

HOTTEST WELDING BOOKS ON THE WEB www.aws.org/catalogs Circle No. 8 on Reader Info-Card


WELDING JOURNAL

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CYBERNOTES A COLLECTION OF INDUSTRY NEWS FROM THE INTERNET

Wolf Robotics Launches Web Site

Site Highlights Testing Services

Wolf Robotics. This new Web site offers information on the company, its products, services, and staff. Based in Fort Collins, Colo., the company is the former Welding Systems Division of ABB and still serves as its strategic partner for robotic arc welding and cutting systems in the United States. The site provides information on the company’s standard and custom products and optional accessories. It features a company history, contact information for specific business operations, a breakdown of sales territories, and directions to the manufacturing plant. In addition, it includes descriptions of a variety of training classes.

TÜV America, Inc. The company is an international, third-party testing and certification organization providing global conformity testing and certification services. Its Web site includes sections on the industries it serves, including aerospace/ defense, automotive, electrical and mechanical safety, management systems, medical, pressure equipment, semiconductor, and telecom. The site includes a “Breaking News and Events” section, an online store, a media center, a listing of company locations worldwide, and reference tools to provide visitors with information about TÜV’s accreditations, certification marks, and clients. That section also includes a list of industry-related links. Visitors can access the company’s TÜV Service News online newsletter.

www.wolfrobotics.com

Nilfisk-Advance America Adds E-Commerce Section

www.tuvamerica.com

Site Offers Comprehensive Materials Information

Nilfisk-Advance America. The company recently launched an e-commerce section on its Web site. Manufacturers can now purchase a select group of industrial vacuum cleaners, vacuum filters, and vacuum attachments directly from the site. The company’s most popular Nilfisk and CFM vacuum models, including portable, compressed air, and wet/dry vacuums, as well as several specialty vacuums are available. Visitors can also shop for a variety of filters, hoses, nozzles, brushes, wands, and other accessories. www.n-aa.com/info31

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DECEMBER 2004

ASM International. Although much of this site’s offerings are restricted to members only, a wide variety of materials information can be viewed by nonmembers. The site includes industry news, an online bookstore, standards information, descriptions of affiliate societies and links to their Web sites, an online newsletter, and a calendar of events. The “Ask ASM” section offers discussion groups in the following technical interest areas: general

discussion, chapter forum, heat treating, and failure analysis and testing. Visitors can also register for both on-site and online training, request brochures of various types, and download a free micrograph screen saver. The site’s “Materials Information” section consists of three main content areas: “ASM Handbooks Online,” which features the complete contents of 20 ASM Handbook volumes plus two ASM Desk Editions: “Alloy Center Online,” which features property data, performance charts, and processing guidelines for specific metals and alloys; and “Micrograph Center Online,” which includes more than 2500 micrographs for industrially important alloys. The “ASM Archive” lists thousands of articles published in the organization’s magazines, journals, and conference proceedings, including hundreds of articles related to materials testing and characterization, many of which are available in PDF format. ASM members can download two free PDF documents per year; they are available for purchase by nonmembers. www.asminternational.org

National Lab Site Details Engineering Solutions Idaho National Engineering and Environmental Laboratory (INEEL). In operation since 1949, this national laboratory located in Idaho Falls, Idaho, “is a science-based, applied engineering national laboratory dedicated to supporting the U.S. Department of Energy's missions in environment, energy, science, and national defense.” The lab’s Web site offers scientific and technical information that has been issued for unlimited distribution, including technical reports, conference papers, and bibliographic information about journal articles. Visitors can search by document number, author name, key words, and several other parameters. The site includes a news desk, feature articles about the work of INEEL and other government laboratories, an events calendar, and links to a variety of resources. A staff directory is also included. Transferring technology to the commercial sector is among the responsibilities of each DOE lab. Therefore, the site also includes a large amount of information regarding technology transfer and commercialization, including contact information. www.inel.gov

Get some career exposure. Get certified as an AWS Radiographic Interpreter. We’re proud to announce the AWS Radiographic Interpreter certification program. Designed for NDE professionals and current AWS Certified Welding Inspectors, this training and certification program assures employers and practitioners alike that the principles of radiographic interpretation are reliably applied to the examination of welds. If your job responsibilities include reading and interpretation of weld radiographs, this program is for you. You’ll learn proper film exposure, correct selection of penetrameters, characterization of indications and use of acceptance criteria as expressed in the AWS, API and ASME codes. For more information on the course, qualification requirements, certification exams and test locations, please visit our website at www.aws.org/certification/RI or call 1-800-443-9353 ext 273. Circle No. 10 on Reader Info-Card

AWS RADIOGRAPHIC INTERPRETER Training Seminar & Certification Exam 4 0 / 2 1 7 5 1 1 R E C 4 0 0 2 y t e i c o S g n i d l e W n a c i r e m A ©

Milwaukee, WI – May 2-7, 2005 Pittsburgh, PA PA – May May 23-28, 2005 Baton Rouge, LA – July 18-23, 2005

Founded in 1919 to Advance the Science, Technology an d Applic ation of Welding.

NEW PRODUCTS

Transducer Measures Gas Flows in Real Time

FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMATION CARD.

of the gas in real-time. The output is linear over the flow range, and the device is contained in a rugged NEMA 4 housing. Proportion-Air, Inc.

System Monitors Bulk Storage Tank Product Status

100

P.O. Box 218, McCordsville, IN 46055

Manifold Monitors and Displays Pressure

The F-series flow transducer can measure gas flows as low as 2 ft 3 /h with a realtime output of 0–10 V or 4–20 mA. The pressure changes that occur when a gas is passed through a special venturi orifice is measured and used to determine the flow

The SG960 fully automatic switchover manifold for high-purity gases features an integrated circuit board that monitors and displays cylinder bank pressure and delivery pressure electronically. The need to manually reset levers or valves is eliminated because changeovers occur automatically. The system comes standard with an a udio /visu al alarm and optional on-site telemetry, and is designed to accommodate future cylinder expansion by adding header extensions. Harris Calorific, Inc. 2345 Murphy Blvd., Gainesville, GA 30504-6000


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DECEMBER 2004

101

The Freedom Telemetry and Management System for bulk storage tanks ensures that tanks will never run out. This system uses state-of-the-art microproces-


sor control technology. It features compatibility with most electronic gauges/pressure switches on bulk storage units and micro-bulk tanks; monitors for up to two gas units, two bulk storage tanks, or one bulk tank and one gas manifold; alerts at two levels (high and low) of product with input in percentages, gallons, liters, kilograms, pounds, or cubic feet; signals using 4–20 mA input; rugged stainless steel enclosure for severe weather conditions; Windows®-based software to allow information processing in an easyto-understand format; and software to e-mail information. Rexarc International, Inc.

1 in., and it can run at speeds of up to 4400 rpm. ¥

102 CGW-Camel Grinding Wheels, USA 103

35 E Third St., West Alexandria, OH 45381

7525 N Oak Park Ave., Niles, IL 60714

Chop Saw Blade Cuts Thick Metal Stock

Welding Carriage Operates on Battery Power

An angle iron/heavy bar, doub le-reinforced chop saw blade made with zirconia aluminum can be used for cutting all ferrous metals, especially thicker stock. The blade can be used on general angle iron, iron/steel bar, metal decking and cable, pipe line, wall studs, high tensile steel, stainless steel sheets, and stainless 3 steel bars. The size of the blade is 14 ¥ ⁄ 32

The Mini-Vert is a compact welding carriage with a four-wheel drive, batteryoperated fillet welding machine. It has a quick torch mount that allows the welding gun to be rapidly moved from one side of the machine to the other, enabling the operator to weld the entire workpiece from end to end. The tool features a 14.4-

V power supply, with a 3-A-h battery; 3 clearance of ⁄ 32 in.; manual torch adjust3 ment horizontally and vertically of ⁄ 4 in.; carrying capacity for walls vertically and horizontally of 15 lb, with flat position of 50 lb; speed of 3.9–39 in./min; dimensions of 13.5 ¥ 8.4 ¥ 10.6 in.; and a weight of 16 lb without the battery. Bug-O Systems

104

3001 W Carson St., P ittsburgh, PA 15204-1899

Portable Purge Monitor Detects Oxygen Levels The portable Argweld titanium purge monitor accurately measures oxygen con-

Get the gas that sets the

GOLD STANDARD in welding performance. A contaminated welding environment slows production and increases rejects and downtime, ultimately costing you money. Airgas Gold Gas premium shielding gases enhance weld atmosphere, performance and efficiency. Our welding process experts will help you determine which of our seven industry-leading mixes best fits your needs. ®

Airgas Gold Gas mixtures improve efficiency by:

Increasing weld speed — compared to “C25” and “C10” Reducing costs incurred from rejects and downtime Delivering uniformity, precision and high weld quality (low spatter, less overweld) Helping you comply with OSHA emission standards

You’ll find it with us.

SM

Call TOLL-FREE 1-866-924-7427 for the Airgas location nearest you, or visit our eCatalog at: www.airgas.com. Circle No. 3 on Reader Info-Card WELDING JOURNAL

21

tent down to 10 ppm and displays the results on an alphanumeric LED display that can also be switched to show oxygen content as a percentage. The unit can be interlocked to isolate welding equipment or a power supply to ensure that welding takes place only under the right conditions. Instructions are on the menu-driven display, and users can control the unit using a four-button layout. An internal alarm can be set to operate when minimum or maximum oxygen levels are reached, and only users with access to a security code number can change the settings. Oxygen levels are monitored continuously from the exhaust of the purge area via a tube and passed across the face of a sensor. The monitor measures 140 ¥ 8060 mm, operates from a 110- or 220-V, 50- or 60-Hz single-phase electricity supply, and has a serial port for connection to a PC; optional software can be used to provide traceability documents to confirm oxygen levels during welding operations. Huntingdon Fusion Techniques, Ltd.105 Stukeley Meadow, Burry Port, Carmarthenshire Wales, U.K. SA16 0BU

Air Cleaner Offers Multiple Attachments The TM 1000 TaskMaster offers shop

HIRE

ins to 208/230-V and 460-V three-phase outlets are available. Micro Air

Electronic Calipers Resist Coolant, Metal Chips

and plant air cleaning versatility. The user rolls the cleaner to where it is needed, plugs it into any 120-V single-phase outlet, and chooses the attachment needed. Attach ments i nclude articula ted sourc e capture arms in various sizes, dual articulated arms, downdraft table, backdraft hood, and long-reach flexible hose with hood; these make the unit capable of source capturing pollutants when grinding, welding, cutting, gluing, and painting. It is powered by a high-capacity motorblower assembly that provides 1000 1 ft3 /min, all within a 25 ⁄ 2 ¥ 35-in. footprint. Also, the unit has dual cartridge filters cleaned by the company’s Roto-Pulse™ cartridge cleaning system. Optional plug-

The 797 Electronic Caliper Series offer IP65 level protection in harsh manufacturing environments. They are resistant to coolant, water, dust, dirt, and metal chips. The calipers also feature a large, easy-to-read LCD with 0.310-in.-high characters, zero at any position, instant in./mm conversion, manual on/off with auto-off after four hours of nonuse, CR2032 battery with more than 3500 continuous hours of life, RS232 output port for collecting and outputting data to de vices, and a fitte d plastic case . Made of

JOB SEEKERS WHO STAND OUT

@ www.awsjobfind.com BETTER CANDIDATES, BETTER RESULTS AWS JobFind works better than other job sites because it specializes in the materials joining industry. Hire those hard-to-find Certified Welding Inspectors (CWIs), Welders, Engineers, Welding Managers, Consultants and more at www.awsjobfind.com You’ll find more than 2,000 résumés of top job seekers in the industry!

THE TOOLS TO DO MORE

AWS JOBFIND ENHANCE YOUR CANDIDATE SEARCH

www.awsjobfind.com

AWS JobFind provides companies with the tools to post, edit and manage their job listings easily and effectively, any day or time, have immediate access to an entire résumé database of qualified candidates, look for candidates who match their employment needs: full-time, part-time or contract employees, receive and respond to résumés, cover letters, etc. via e-mail. Circle No. 18 on Reader Info-Card

22

DECEMBER 2004

106

P.O. Box 1138, Wichita, KS 67201

hardened stainless steel, they are available in sizes from 0 to 6 in. with outside jaw 1 5 depth of 1 ⁄ 2 in. and inside jaw depth of ⁄ 8 7 in., 0–8 in. with outside jaw depth of 1 ⁄ in. 8 3 and inside jaw depth of ⁄ 4 in., and 0–12 in. 1 with outside jaw depth of 2 ⁄ 2 in. and inside 3 jaw depth of ⁄ 4 in. The L. S. Starrett Co.

107

121 Crescent St., Athol, MA 01331-1915

Beam Clamp’s Design Improved

The CADDY® BCISN beam clamp’s design features a finger close “smart nut” 3 that allows installation of a ⁄ 8-in. threaded rod for attachment to beam flanges up to 1 ⁄ 2 in. Without the use of tools or the need 3 for added nuts, it positions on a ⁄ 8 -in. threaded rod and allows for fine tuning and adjustment after the rod is locked in place. This product and the company’s standard beam clamps are reversible on flat flanges, and they both can be removed when needed. Erico®, Inc.


108

34600 Solon Rd., Solon, OH 44139

Portable Fume Extractor Works in Tight Spaces MiniFlex is a 33-lb, portable, high vacuum and low-volume system designed to filter welding fume. It is equipped with an automatic start/stop function, two parallel motors, and can be used in small spaces. The primary LongLife-H® and secondary HEPA filters handle most common light- and medium-duty arc welding applications, and have a filtering capacity of up to 99.9%. The standard wheel set makes this machine easy to move. Disassembly takes minutes for cleaning and maintenance. The Lincoln Electric Co.

109

22801 St. Clair Ave., Cleveland, OH 44117

Circle No. 23 on Reader Info-Card WELDING JOURNAL

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AWS FOUNDATION

The Mission of the AWS Foundation To meet the needs for education and research in the field of welding and related joining technologies. The Foundation deeply appreciates the hundreds of individuals and companies who support the industry’s future by contributing to the Foundation’s educational programs. These funds are awarded to students pursuing a career within welding or related materials joining sciences.

Highlights of 2004 The Foundation, along with Section support, surpassed $340,000 in scholarship and fellowship funding, serving nearly 350 students. The Foundation has established four additional scholarships this year. The Donald and Shirley Hastings which awards $2,500 to a student pursuing a four-year degree in welding engineering or welding engineering technology; the ITW Welding Companies Scholarship, which awards two $3,000 scholarships to students pursuing a four-year degree in welding engineering technology or welding engineering, with a preference for WET at Ferris State University; and the Robert L. Peaslee – Detroit Brazing & Soldering Division Scholarship which awards $2,500 to an individual pursuing a minimum four-year degree in welding engineering or welding engineering technology with an emphasis on Brazing and Soldering applications. Circle No. 15 on Reader Info-Card

Miller Electric Mfg. Co.—Sponsor of the World Skills Competition Scholarship The AWS Foundation is grateful to the Miller Electric Manufacturing Company, which is the proud sponsor of this $40,000 scholarship implemented in 1995. This award recognizes and provides financial assistance to contestants representing the United States in the World Skills Competition. To become eligible for this scholarship, the applicant must compete in the national SkillsUSA – VICA Competition for welding, and advance to the AWS Weld Trials at the AWS Welding Show, which is held on a biannual basis. Winners of the AWS Weld Trials then participate in the International Competition. Past recipients competing in the international competition are as follows: 2003 2001 1999 1997 1995 1993 1991

Miles Tilley Dien Tran Ray Connolly Glen Kay III Branden Muehlbrandt Nick Peterson* Robert Pope*

Bronze Medal Winner Bronze Medal Winner Gold Medal Winner International Finalist Silver Medal Winner Bronze Medal Winner Gold Medal Winner

*1991 and 1993 recipients received alternate scholarship funds, which were prior to the start of the Miller Scholarship.

Services and Programs Offered by the AWS Foundation

We would like to thank the following Major Donors who have supported the Foundation's activities:

NATIONAL SCHOLARSHIP PROGRAM

INDIVIDUALS

CORPORATIONS

Wilma J. Adkins Osama Al-Erhayem Richard Amirikian Richard L. Arn Roman F. Arnoldy Hil J. Bax D. Fred Bovie William A. and Ann M. Brothers Joseph M. and Debbie A. Cilli Donald E. and Jean Cleveland Jack and Jo Dammann Mr. and Mrs. J. F. Dammann Louis DeFreitas Frank G. DeLaurier William T. DeLong Richard D. French Glenn J. Gibson Joyce E. Harrison Donald F. and Shirley Hastings Robb F. Howell Jeffrey R. Hufsey Joseph R. Johnson Deborah H. Kurd J. J. McLaughlin L. William and Judy Myers Robert and Annette O’Brien Robert L. Peaslee Ronald C. Pierce Jerome L. Robinson Robert and Mitzie Roediger Ray W. Shook Myron and Ginny Stepath Charley A. Stoody R. D. Thomas, Jr. James A. Turner, Jr. Gerald and Christine Uttrachi Nelson Wall Amos O. and Marilyn Winsand Nannette Zapata

Airgas Air Liquide America Corporation Air Products and Chemicals, Inc. American Welding Society Caterpillar, Inc. Chemalloy Company, Inc. C-K Worldwide Cor-Met, Inc. ESAB Welding & Cutting Products Edison Welding Institute Eutetic Castolin The Fibre-Metal Products Company Gases and Welding Distributors Association Gibson Tube, Inc. Malcolm T. Gilliland, Inc. Gullco International, Inc. Harris Calorific, Inc. High Purity Gas Hobart Brothers Company - Corex - McKay Welding Products - Tri-Mark Hypertherm, Inc. Illinois Tool Works Companies Independent Can Company Inweld Corporation The Irene & George A. Davis Foundation J. W. Harris Company, Inc. Kirk Foundation Kobelco Welding of America, Inc. The Lincoln Electric Company The Lincoln Electric Foundation MK Products, Inc. Matsuo Bridge Co. Ltd. Miller Electric Mfg. Co. Mountain Enterprises, Inc. National Electric Mfg. Association National Welders Supply Company Navy Joining Center NORCO, Inc. ORS NASCO, Inc. OXO Welding Equipment Company Pferd, Inc. Praxair Distribution, Inc. Roberts Oxygen Company, Inc. Saf-T-Cart Select-Arc, Inc. SESCO Shell Chemical LP - WTC Thermadyne Holdings Corporation Trinity Industries, Inc. Uvex Safety, Inc. Webster, Chamberlain & Bean Welding Engineering Supply Co., Inc. Weldstar Company Wolverine Bronze Company

Howard E. Adkins Memorial Scholarship Airgas – Jerry Baker Scholarship Airgas – Terry Jarvis Memorial Scholarship Arsham Amirikian Engineering Scholarship Edward J. Brady Memorial Scholarship William A. and Ann M. Brothers Scholarship Donald F. Hastings Scholarship Donald and Shirley Hastings Scholarship William B. Howell Memorial Scholarship Hypertherm – International HyTech Leadership Scholarship ITW Welding Companies Scholarships John C. Lincoln Memorial Scholarship Matsuo Bridge Company, Ltd. of Japan Scholarship Miller Electric World Skills Competition Scholarship Praxair International Scholarship Robert L. Peaslee Brazing & Soldering Scholarship Jerry Robinson – Inweld Corporation Scholarship James A. Turner, Jr. Memorial Scholarship

SECTION NAMED SCHOLARSHIP Amos and Marilyn Winsand – Detroit Section Named Scholarship

SCHOLARSHIP PROGRAMS IN DEVELOPMENT Jack R. Barckhoff Scholarship Donald and Jean Cleveland-Willamette Valley Scholarship Gold Collar Scholarship Robert L. O’Brien Memorial Scholarship Ronald C. Pierce Scholarship Ted B. Jefferson Scholarship Thermadyne Industries Scholarship

AWS INTERNATIONAL SCHOLARSHIP GRADUATE RESEARCH FELLOWSHIPS Glenn J. Gibson Fellowship Miller Electric Fellowship Navy Joining Fellowship (2)

HISTORY OF WELDING CD This CD provides a story of welding history, stressing the importance of welding and the critical shortage of skilled manpower.

EDUCATIONAL TOOLS Engineering Your Future Welding So Hot It’s Cool Video/CD Hot Careers in Welding Video © American Welding Society 2004

FDN1150

Bay Bridge Puts New Gas Mixtures to the Test Many factors should be considered when selecting shielding gases

The new Bay Bridge is seen in this artist rendering. It is scheduled for completion in 2009. (Photo courtesy of CALTRANS.)

Since the creation of gas metal arc welding (GMAW) in the early 1920s and its implementation in 1948, shielding gas mixtures have played a critical role in the application and development of this important welding process. As related arc welding processes have progressed, flux cored and metal cored arc welding have evolved with literally hundreds of filler metal and gas mixture choices. One point has proved crucial with improvements in wire welding. The cylinder gas mixture quality and consistency have become as critical a component to these welding processes as the electricity provided from the power source. Without reliability in either one, the other doesn’t work very well. Manufacturers in the welding industry have experienced the evolution of these mixtures and the value they add to their BRYAN O’NEIL is U.S. Cylinder Business Development Manager, Air Liquide America, L.P., (713) 624-8000. MARVIN E. RODGERS III is Gener al Manager, Al liance Gas Products, Oakland, Calif., (510) 663-9353. 26

DECEMBER 2004

BY BRYAN O’NEIL AND MARVIN E. RODGERS III

processes over the last few decades. Certainly there are endless applications and special considerations that each indi vidual involved in making a gas choice must consider. The major gas companies and their distributors have developed through research, experience, and field trials a wide selection of products to meet these needs.

Making Sense of the Options So what can a fabricator do to make sense of all the choices available in shielding gas mixtures? Traditional components of the GMAW and flux cored arc welding (FCAW) processes have been argon and carbon dioxide for carbon steel. Today, advanced three-part mixtures include additions of oxygen, carbon dioxide, or helium with the balance gas being argon. These are increasingly used in the place of traditional single- or two-part mixtures. These changes have resulted in improved appearance, mechanical properties, and deposition rates as well as

increased travel speeds. Even newer developments are beginning to enter the market with small additions of nitrogen in specific mixtures. To maximize overall productivity, manufacturers are faced with numerous options with traditional GMAW or FCAW. This is where the right gas mixtures designed to optimize speed, appearance, and deposition rate in all positions have evolved for a given filler metal and diameter and weld size. While there is never a “one-size-fits-all” solution, combinations of optimized gas components have been developed to address the majority of concerns a fabricator may have in most welding situations. An example of a critical job where these criteria were taken into consideration was for the San Francisco Bay Bridge Project in California.

History of the Bridge Project You may remember the Loma Prieta earthquake that occurred in October

1989 during the World Series, or the horrific pictures and videos that were taken in the San Francisco and Oakland area of the collapsed Cypress Freeway. Although the Cypress Freeway has since been relocated and reconstructed, many people don’t realize that some 15 years later, the residents of the Bay area are still crossing the same bridge. After an extensive study of the span where a section collapsed in 1989, the California Department of Transportation (CALTRANS) determined that it was not feasible to simply retrofit the eastern span of the Bay Bridge to protect it from earthquake damage; instead, a new eastern span would need to be constructed. In a section of the country famous for majestic bridges and city skylines, the replacement span could not simply be another traditional trestle bridge. The successful design turned out to be a combination skyway and suspension bridge. The bridge will be the world’s first singletower, self-anchored suspension bridge. In addition, the new span, which features some of the largest and heaviest components ever seen in bridge building, needs to exceed the safety requirements set forth to become an earthquake-resistant bridge build.

Project Hits the Marketplace It’s not often that a supplier gets to participate in one of the most expensive public works projects ever undertaken in the United States, so when the San Francisco Bay Bridge general contracting joint venture of Kiewitt, Flatiron, and Manson (KFM, LLC) presented a request for a gas supply to the industrial gas and welding supply distributors in the San Francisco Bay Area, everyone took notice. To win this award, it would be necessary to address all of the unique challenges that KFM and the regulatory agencies were going to impose upon the successful gas supplier. This hurdle could not be met with traditional gas packages, mixtures, and tolerances. Alliance Gas Products of Oakland, Calif., had been supplying one of the Bay Bridge’s joint venture partners at another bridge project in Benicia, Calif., about 40 miles away. So when it received its bid package, Alliance Gas Products initially assumed it could use the one bridge project as a template for the other. However, the challenges and requirements for the two bridges were very different. It was initially assumed that the volumes of gas required for the welding operations would require a traditional method of gas supply (dewars) in conjunction with an on-site gas mixer. But, as the company tried to work through the requirements of the

project, it became increasingly apparent that a new approach would be needed.

The Challenges The 1993 Northridge earthquake in southern California raised many concerns regarding welding procedures for public works structures. The filler metal and construction industries have responded by creating new products and procedures to ensure mechanical integrity will exceed the design requirements. In addition, shielding gases have not been overlooked. CALTRANS has considered shielding gases just as important a contributor as any other material to the mechanical properties of the final weldment. To ensure repeatability and certification of weld procedures, CALTRANS set standards it would be willing to accept for gas purity and mixture tolerance. In addition, it wanted the welding gas “at the arc” to be traceable, and to also be certified for purity and mixture accuracy. There were logistics challenges as well. KFM needed to complete all of the work from barge platforms. All the gases had to be transported to the barge from the shore or supply barge via crane. Crane time was scarce, and gas movement could not be scheduled on a daily basis. Operationally, the company could not run out of product once welding started, so it needed a package that would hold product without venting for an indefinite period of time. More importantly, workers needed accuracy and traceability of contents to ensure KFM was receiving the product specified within the welding procedures.

A Special Consideration: Confined Space Welding What is most evident in the welding of piles and footings used to support the bridge is their mammoth diameter and the depth at which these components are set. A typical weld joint is 6 ft long and consists of a double-V partial-penetration joint detail. Approximately 35 weld passes take place on each joint, with more than 5000 joints to complete — Fig. 1. That means production of more than 30,000 ft of weld on thicker than 2-in. plate, welding uphill using semiautomatic FCAW equipment. Job completion relies on the expertise of a team of welders and welding engineers, like Dave Polette and Doug Silverwood from Flat Iron Constructors and General Construction. Both Polette and Silverwood oversee the day-to-day issues that arise as a result of confined space welding protocol — Figs. 2, 3. Each morning at the beginning of a shift and throughout the day, air monitors and air-

Fig. 1 — A welding operator monitors the uphill FCA welding with Blueshield within the internal section of bridge piling. This is one of more than 5000 weld joints requiring 35 or more passes each to be completed on the Bay Bridge project. The base material thickness is in excess of 2 in. in some joints. Preheating is done by electrical means. Gas quality is ensured at the welding gun for this complex application.

Fig. 2 — Working in confined spaces at the Bay Bridge site brought new challenges for welding teams, requiring calesthenics as part of their workday. Here, the Pier 16E night welding crew warms up before dropping into the cofferdam in May 2003. (Photo courtesy of KWT.)

Fig. 3 — A welder is hard at work inside a piling at the new Bay Bridge site. (Photo courtesy of KWT.)

WELDING JOURNAL

27

exchanging equipment are used to measure the oxygen content and replace the atmosphere with fresh air. Since there is little room for additional equipment, the construction group needed to choose an innovative package and mixture to assist in achieving the desired results. Alliance contacted its partner, Air Liquide, to address the needs of the specific customer requirements. Working together, both companies reviewed the stringent requirements of the contractors and governing agency. Looking at past success in similar applications, a unique patented assembly and high-quality cylinder brand name, Blueshield™, was chosen. This provided the features of innovative package design, safety in handling, reliability in service, and, most importantly, traceability of each package back to the original gas analysis at the fill plant. The value of a premium mixture used in combination with proper weld parameters provided the company with easy slag removal and higher travel speed out of position. Welding on the bridge commenced in April 2003 and is scheduled to end May 2005. With almost five miles of welding scheduled, innovative gas use will result in a much shorter welding time and more time spent depositing weld metal, with less time spent worrying about gas mixture quality and handling.

2005 Welding Journal Editorial Calendar Editorial Deadline January

• Resistance Welding Today • Trends in Welding Automation: Robots, Sensors, Equipment

Nov. 22

February

• Welding Thin Metals • Building Bridges with Better Processes and Techniques

Dec. 17

March

• Educating the Next Generation of Welders • Technology Transfer: From the Lab to the Shop Floor • Products for Metal Cutting

Jan. 17

April

• Preview of the 2005 AWS Show

Feb. 18

May

March 18

It is important for fabricators to undertake a thorough analysis of shielding gas mixtures that includes the following:

• Choosing the Right Filler Metal for the Job • Developments in Thermal Spraying • Bonus: The American Welder Supplement

June

• Technologies to Carry Joining into the Future • Pipe and Tube Welding

April 15

• Test the product being considered over a trial period in production and not just in a demonstration.

July

• Understanding the Heat-Affected Zone for Improved Quality • Developments in Power Supplies

May 16

August

• What’s New in Laser Welding and Cutting? • What Makes a Winning Weld: Tips from the Pros • Essen Welding Fair Preview

June 17

September

• Welding Customized Motorcycles • Preventing and Detecting Weld Cracking • Apparel for Safety and Productivity

July 15

October

• Special Emphasis: Brazing and Soldering • Bonus: The American Welder Supplement

Aug. 19

November

• Building Our Energy Infrastructure • Underwater Welding • AWS Welding Show/FABTECH preview

Sept. 16

December

• Marine Construction • Architectural and Ornamental Welding

Oct. 17

Conclusion

• Measure and track results. Also, make sure the packaging and quality process is in place, particularly when considering AWS and ASME codes and bridge and marine specifications. • Look for safety enhancements or handling advantages offered to improve the welder’s environment. • Lastly, ensure that you are meeting or exceeding the mechanical requirements of the gas and filler metal combination and a program is in place for traceability of the product purchased.◆

28

DECEMBER 2004

AWS Fellowships To: Professors Engaged in Joining Research Subject:

Request for Proposals for AWS Fellowships for the 2005-06 Academic Year

The American Welding Society (AWS) seeks to foster university research in joining and to recognize outstanding faculty and student talent. We are again requesting your proposals for consideration by AWS. 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 January 10, 2005 . New AWS Fellowships will be announced at the AWS Annual Meeting, April 26-28, 2005. 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 will be contingent on demonstration of reasonable progress in the research or in graduate studies. 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 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. DETAILS

The Proposal should include: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Executive Summary Annualized Breakdown of Funding Required and Purpose of Funds (Student Salary, Tuition, etc.) Matching Funding or Other Support for Intended Research Duration of Project Statement of Problem and Objectives Current Status of Relevant Research Technical Plan of Action Qualifications of Researchers Pertinent Literature References and Related Publications Special Equipment Required and Availability Statement of Critical Issues Which Will Influence Success or Failure of Research

In addition, the proposal must include: 1. 2. 3. 4.

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. Proposal should be sent electronically by January 10, 2005, to: Gricelda Manalich ( [email protected] ) Executive Assistant, Board Services/IIW American Welding Society

550 N.W. LeJeune Rd., Miami, FL 33126 Yours sincerely, Ray W. Shook Executive Director American Welding Society

How to Optimize Mild Steel GMAW

The hybrid laser beam welding process comb ines the traditional GMAW process with laser beam processing. (Photo courtesy of Craig Bratt, Fraunhofer USA.)

Make yourself more competitive globally through improved shielding gas selections BY RICHARD GREEN

30

DECEMBER 2004

T

wo dive rgent forces are hard at work in today’s business world: one is the constant updating of the latest and greatest technology, and the second is the ongoing political rhetoric about outsourcing jobs to lower-wage-paying countries. Inverter technology, for example, offers better power efficiency and, in some

cases, more stable arc characteristics. International competition, however, utilizes simpler technology coupled with lower overhead costs to put pressure on manufacturing jobs in the United States. Being pressured into making a capital investment of tens of thousands of dollars that may only achieve incremental cost savings over current optimized prac-

RICHARD GREEN ( richard.green@ concoa.com ) is Product Manager, CONCOA, Virginia Beach, Va.

Transfer Mode Current Range

.045” spray .045” globular .045” shortcircuiting arc .035” spray .035” globular .035” shortcircuiting arc

Fig. 1 — The approximate current ranges include the three modes of transfer for both 0.035- and 0.045-in.-diameter solid wire.

tices is obviously a pitfall to avoid. Instead, American business and its employees can offer the world the ingenuity it takes to produce quality weldments cost-competitively. What follows is a strategy for optimizing the cost to produce a mild steel gas metal arc weldment. This includes evaluating the mode of transfer as well as labor and overhead rates, deposition efficiency, electrode cost, and power consumption. It also shows the gas system required to obtain a competitive rate using existing assets. To begin, the three basic modes of metal transfer for a gas metal arc welding (GMAW) procedure as classified by current range need to be understood. Figure 1 illustrates the approximate current ranges for the three modes of transfer for both 0.035- and 0.045-in.-diameter solid wire. Short-circuiting arc occurs between 60 and 175 A for 0.035 wire, and 90 to 220 A for 0.045 wire. Short-circuiting arc welding offers low thermal input, which facilitates welding in all positions and reduces part distortion. Metallurgical properties are not adversely affected by the low energy input and subsequent dilution of the base material. Figure 2 illustrates the voltage and current relationship as the metal is transferred from the wire to the workpiece. As the wire is fed into the weld pool, the tip of the wire connected to the positive terminal of the power supply comes in contact with the workpiece that is connected to the negative terminal, and a short is created in the circuit. The welding machine output current rises to a minimum current level of 320 A for 0.035 wire, and 370 A for 0.045 wire, to separate it from the weld pool. The short-circuit process will occur 50 to 230 times per second depending on process design.

Fig. 2 — This graph illustrates voltage and current relationship through a short circuiting arc sequence transfer. (Reprinted from AWS C5.6-89R, Recommended Practices for Gas Metal Arc Welding , p. 6.)

Welding machine manufacturers have developed both fixed and variable slope welding power supplies to control the output voltage with increasing amperage. This limits the maximum energy available to separate the wire from the pool. If there is too much energy, the result is excessive spatter, which lowers the deposition efficiency; with too little energy, the wire piles up, resulting in incomplete fusion and poor weld quality. Secondly, welding equipment manufacturers have developed both fixed and variable inductance to control the rate of the current rise as illustrated by the current curve sequence A-B in Fig. 2. As inductance is increased, the amount of arcing time also increases as illustrated by the voltage curve sequence E-H in Fig. 2. The additional arc-on time produces a more fluid weld pool, which yields a flatter weld bead with better wetting at the edges. In turn, this affects the cosmetics and load-bearing capacity of the joint. The proper selection of shielding gas will drastically affect the energy transfer and deposition efficiency of the GMAW short-circuit transfer mode. Carbon dioxide was the first shielding gas used because of its availability and cost. The arc plasma has a narrow inner core and a low outer temperature envelope resulting from its low thermal conductivity that produces narrow and deep penetration. This presents problems for thin materials. More expensive GMAW wire containing higher amounts of deoxidizing elements is typically needed to balance the oxidizing nature of carbon dioxide. Also, because of centerline crowning and excessive spatter that result in 85 to 95% deposition efficiencies, manufacturers developed binary mixtures of argon and carbon dioxide. Additions of up to 80% argon (with the

balance being carbon dioxide) will produce less crowning, better edge tie-in, and 94 to 98% deposition efficiencies. Argon additions offer better arc ignition and stability based on argon’s low ionization potential. Argon has a low thermal conductivity that yields similar arc constriction but a shallower penetration profile than carbon dioxide. Plus, argon-carbon dioxide mixtures yield higher deposition rates with less spatt er, which is ideal for allposition welding and thin materials. As additional weldi ng current is applied, the end of the welding wire becomes overheated and balls up 1.5 to 3 times the wire di ameter. This establish es a longer arc length as illustrated in sequence F-H of Fig. 2. Gravity facilitates the metal transfer, which creates instability and excessive spatter. Deposition efficiency tends to fall between 80 and 90% depending on gas selection and processing parameters. For this reason and welding position limitations, it is wise to stay outside the globular transition range of 160 to 185 A for 0.035 wire, and 200 to 220 A for 0.045 wire. Depending on the gas selection, the minimum transition current for spray transfer occurs between 155 and 195 A for 0.035 wire, and 220 and 250 A for 0.045 wire. Above this transfer rang e, the end of the wire electrode develops a taper that emits fine droplets of metal across the arc with virtually no spatter, yielding 97 to 99% deposition efficiencies. The spray transfer yields higher travel speeds and deposition rates because of the superior arc stability and high droplet rate. However, the high heat input limits the weldment to the flat position. Choosing the optimal shielding gas for spray transfer takes some forethought to understand the application and effects each gas component will contribute to the

WELDING JOURNAL

31

Table 1 — Economic Comparison

Short-Circuiting Arc Labor and Overhead ($/h) 40 Deposition Rate (lb/h) 5.5 Duty Cycle (%) 0.4 Electrode Cost ($/lb) 0.8 Deposition Efficiency (%) 0.96 Gas Flow Rate (ft 3 /h) 35 Gas Cost (dollars per hundred cubic feet) 5.45 Electrical Cost (kWh) 0.06 Machine Volts 20 Machine Amps 200 Travel Speed (in./min) 9

Spray Transfer

On-Site Mixing Gas System

40 9.7 0.4 0.8 0.98 40 6.06 0.06 29 300 15

40 9.7 0.45 0.8 0.98 40 5.28 0.06 29 300 15

1.33 0.09 0.03 0.01 1.46

1.19 0.09 0.03 0.01 1.31

38.13%

44.59%

Cost per Foot of Weld

Labor and Overhead Wire Cost Shielding Gas Cost Power Cost Total Cost per Foot of Weld

2.22 0.09 0.04 0.01 2.36

Percent Cost Reduction

deposition efficiency and cost, environmental, and mechanical properties. Pure argon produces higher arc voltage and subsequent longer arc lengths, which create arc instability and excessive undercut at the edge of the welds. For this reason, 5 to 20% carbon dioxide is added to create an argon mixture that stabilizes the spray transfer. It is well documented that the lower the amount of carbon dioxide concentration, the lower the minimum spray transfer current and subsequent fume generation rates. It should also be noted that 8 to 15% carbon dioxide mixtures are flexible enough to facilitate both spray and shortcircuit transfer modes. In some cases, 1 to 5% oxygen may be added to argon to achieve superior arc stability and better tie-in (wetting) at the weld edge. Oxygen tends to provide a wider but shallower penetration profile, as compared to carbon dioxide mixtures, because of its lower ionization and higher thermal conductivity properties. Oxygen additions tend to yield better to ughness and s trengths because of the absence of carbon retention associated with carbon dioxide mixtures. Shielding gas development has led manufacturers to design three-component gas blends that offer the benefits of both carbon dioxide and oxygen additions to argon-based mild steel gas metal arc applications. As mentioned prev ious ly, each company must evaluate the incremental benefits of three-component mixtures as compared to two. In most cases, attention to quality and continually training personnel to meet the basic processing parame-

32

DECEMBER 2004

ters will yield the greatest return with minimal investment. For example, assume that the weld1 ment is a ⁄ 4-in. mild steel, 12-in. fillet weld requiring 0.106 lb/ft of welding wire. Current practice calls for a 0.045-in.-diameter wire using 75% argon balance carbon dioxide. It is assumed that the wire costs $0.80 per pound on a 33-lb spool, and the typical labor and overhead rate is $40/h. There is a total of ten weld stations each using a single “T-size” (330 ft3) high-pressure bottle. The company uses eight bottles per week at a cost of $18 each. The manual welding is performed utilizing conventional short-circuit parameters set at 20 V/200 A, yielding a deposition rate of 5.5 lb/h at 96% efficiency. In today’s market, it is also safe to assume that the company is receiving pricing pressure from international competitors. Utilizing existing equipment and pro viding the required training, the procedure is changed to a spray transfer with the following parameters listed below. The shielding gas is changed to 92% argon, balance carbon dioxide. The welding machine parameters are 29 V/300 A, which provide a deposition rate of 9.7 lb/h with a 98% efficiency. The economic results displayed in Table 1 show that a 38% cost reduction per foot of weld is achievable because of the higher deposition rate and efficiency of a spray transfer. As well, Table 1 illustrates that an additional 6% in cost savings can be realized by mixing the argon-carbon dioxide shielding gas on-site. Simple blending systems as illustrated in Fig. 3 enable the company to realize ad-

Fig. 3 — Simple blending systems allow for additional duty cycle or productivity savings by eliminating daily cylinder handling.

ditional duty cycle or productivity savings by eliminating daily cylinder handling. Finally, the on-site blending system enables the company to adjust the ratio of carbon dioxide in the shielding gas, which will have a positive effe ct on the weld ment’s mechanical properties and work environment. With American business facing so much competitive pressure today, it is necessary to look for the “lowest hanging fruit” to reduce production costs and enhance the quality of products. Getting back to the basics will further enhance the incremental cost savings of future investment in technology. To achieve such results, solutions as simple as evaluating the mode of transfer for a gas metal arc weld and the gas delivery system are important in the highly competitive global marketplace.◆

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CON 1071

Exploring the Weldability of Powder Metal Parts Experiments reveal the impact of powder metal characteristics on their weldability BY A. KURT, H. ATES, A. DURGUTLU, AND K. KARACIF

T

he development of unique materials for specific applications is expanding. Metal produced from powder metallurgy is one of those materials that is growing in use. Production by powder metallurgy entails sintering of metal powders mixed to give a desired chemical composition. They are pressed at room temperature into a die in the dimensions and the shape of the part to be manufactured, and then the piece is sub jected to a controlled high temperature. The advantages of powder metal materials compared to rolling and casting include the ability to manufacture complexshaped parts, the production of difficult alloys, density control, and economy (Refs. 1–5). This study investigates the weldabi lity of powder metal parts under various manufacturing conditions.

Characteristic Changes Due to Porosity The welding of powder metal materials is different from the welding of rolled or cast parts. The property that causes the most difference in their joining is porosity. Porosity volume and relative density affect welding and its characteristics. Porosity changes the properties of thermal conductivity and hardenability, and affects the welding process because of the oxides and impurities within the structure.

Fig. 1 — Macrophotography of powder metal welded sample.

Thermal conductivity not only depends upon the property of the material, but also the amount of porosity. As the volume of porosity changes, so does the heat transfer. The change in heat transfer naturally affects the welding parameters and properties such as hardenability. Since the porosity slows down the heat transfer through reduced thermal conductivity, the cooling rate of the material also slows during welding, reducing the hardening tendency (Refs. 6–10).

Plan before Proceeding with Powder Metal Parts The most important points to consider with powder metal p arts are design, material selection, and joining technique. First, it should be decided what characteristics are desired of the parts to be joined. For example, strength, dimension limitations, environmental factors, ap-

pearance, and economy should all be considered. Fusion and solid-state welding methods are used successfully to join powder metal parts. Fusion welding methods are preferred in the welding of mediumand high-density (>7.0 g/cm3) powder metals, whereas solid-state welding is used to weld low-density (<6.5 g/cm 3) powder metals (Ref. 7). In this study, the weldability of the powder metal iron parts have been examined using manual arc welding with the shielded metal arc process.

Materials and the Experimental Process In the experiments, Höganas AB 100 iron powders were used, some features of which are given in Table 1. Höganas AB 100 powders have been pressed unidirectionally under three different pressures (240, 265, and 300 MPa) in a volume of 50 ¥ 44 ¥ 5 mm. They were then sintered in an argon atmosphere at 1100°C for 45 min. The density changes before and after sintering are given in Table 2. The powder metal parts that were produced were cut into 50 ¥ 16 mm and welded with a 2.5-mm-diameter rutile electrode at 85 A. There was no root opening, and the welding was performed uphill. The chemical composition of the electrode is given in Table 3. The macrophotography of the

A. KURT, H. ATES, A. DURGUTLU, and K. KARACIF are with Gazi University, Technical Education Faculty, Dept. of Metallurgy Education, Besevler/Ankara, Turkey.

34

DECEMBER 2004

welded samples is presented in Fig. 1. Microstructure and hardness samples were prepared from vertically cut coupons right after the joint was welded. The samples were prepared for metallographic examination by grinding (200–1200), polishing (with Al2O3), and etching with 2% nital. Photographs of the microstructure were taken with an optical microscope showing the base metal, heat-affected zone, and weld metal. Vickers hardness values were taken using a 5-kg load from the regions shown in Fig. 2.

Fig. 2 — The regions where hardness values were taken.

A

A

B

B

C

C

Results of the Investigation Microstructure and Powder Metal Base Material

Density increases in powder metal parts as the pressure increases, although it is minimal after 90% of density is reached. At the lowest compaction pressure of 240 MPa, the density was measured as 68.35%, at 265 MPa the density was 73.01 %, and at 300 MPa it was 72.86%. The slight decrease in density observed at 300 MPa is probably the result the powder particles hardening with the increased compaction pressure. The hardened particles have a negative influence on density. No big decrease in density was observed after sintering, but a few factors do affect an increase in density from sintering. One of these is the outgassing of air from the cavities of porosity through the sintering process. Also, the weight of the sample diminished from the vaporization of low-melting-point elements. It was observed that factors like these do not have much effect since a lubricant such as Zn sterat was not added to the powders. If lubricants had been added, a density of more than 80% would have been realized. Lubricant was not added for the purpose of determining the weldability of powder metals with porosity. In the metallographic study, it was observed that porosity decreased as compaction pressure increased in the powder metal parts — Fig. 3. A great amount of porosity was observed in the microstructure of the sample compacted at 240 MPa — Fig. 3A. The material is denser at 265 MPa of pressure — Fig. 3B. It is observed in Fig. 3C that the den-

Fig. 3 — Microstructures (100¥ ) of the pow der m etal iron parts compacted wit h vari ous pressures. A — 240 MPa; B — 265 MPa; and C — 300 MPa.

Fig. 4 — Microstructures (50¥ ) of weld interface regions of powder metal iron parts compacted at various pressures. A — 240 MPa; B — 265 MPa; and C — 300 MPa.

Table 1 — Features of Höganas AB 100 Iron Powders

Particle size range (µm) ≈ 20–180

Apparent density (g/cm3) 3.04

Flow (s/50 g) 24

H 2 loss (%) 0.10

C (%) <

0.10

Green Strength (N/mm2) at 600 MPa 33

Compressibility (g/cm3) at 4.2 t/cm2 at 600 MPa 6.72 7.17

WELDING JOURNAL

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Table 2 — Density Changes of Powder Metal Parts

Compacting Pressure (MPa) 240 265 300

Table 3 — Chemical Composition of Wire Used in Experiments (wt-%)

Weight before Sintering (g)

Weight after Sintering (g)

Green Density (%)

72.907 75.097 73.548

72.902 75.021 73.540

68.35 73.01 72.86

Sintered Density (%) 68.34 72.93 72.84

C

Mn

Si

0.08

0.50

0.40

Table 4 — Hardness Values Obtained from Samples (HV 5)

Regions where hardness was obtained

Fig. 5 — Weld metal microstructures (50¥ ) of powder metal i ron parts compacted at various pressures. Top — 240 MPa; and bottom — 300 MPa.

sity is less than the other compacted sample and its porosity is greater. This is probably due to the hardening of the powders caused by the increased pressure. Weld Metal and Transition Zone

When the weld metal microstructure of the sample compacted at 265 MPa pressure is observed, it appears similar to the microstructure of rolled low-carbon steel. It was observed that the weld interface at the base material solidified as an epitaxial, with solidification starting from the dense grain of the powder iron material growing to the weld center — Fig. 4B. In the samples compacted at 240 MPa pressure, the weld interface is observed clearly, and the irregularity of the solidified grain is seen in Fig. 4A. The microstructure of the sample compacted at 300 MPa is much better than that compacted at 240 MPa; besides, the microstructure of the compacted sample in 36

DECEMBER 2004

Compaction Pressure (MPa)

1

2

3

4

240 265 300

55 60 68

65 69 76

70 74 84

160 155 140

Fig. 6 — Result of hardness test.

265 MPa does not display a regular fusion-solidification as it does in the structure of the compacted sample in 265 MPa in Fig. 4C. In fusion welding, weld metal is a combination of base metal and welding electrode. It is known that in single-pass welding, two-thirds of the weld metal comes from the welding electrode and one-third of the weld metal comes from the base metal. For this study, it can be said that the base metal ratio of weld metal is less than one-third because of the porosity structure of the base metal. Thus, the electrode controls the composition of the weld metal — Fig. 5. Results of Hardness Test

Table 4 and Fig. 6 show the hardness values of fusion welded powder metal iron materials. From Fig. 6, it can be seen that there is a hardness increase transition from base metal to weld metal. For the

lowest compaction pressure of 240 MPa, hardness values were measured as 55, 65, 70, and 160 HV for the base metal, heataffected zone, base metal-weld metal transition zone, and weld metal, respectively. At 265 MPa, these values were measured as 60, 69, 7 4, and 155 HV, and they were measured as 68, 76, 84, and 140 HV, respectively, at 300 MPa. It is seen from Fig. 6 that increasing the density of the base metal increases the base metal hardness and decreases the weld metal hardness. This can be contributed to the ratio of electrode metal to base metal. In the low-density powder metal samples, the quantity of base metal in the weld metal will be low, and the amount of electrode metal in the weld metal will be high. Consequently, the hardness is dominantly controlled by the electrode metal. In powder metal samples, increasing density of the mixing rate of powder metal materials to weld metal increases, therefore electrode metal rate decreases. As a

result of this, base metal hardness increases with increasing density, while weld metal hardness decreases with increasing density. Conclusions

In this experimental study, the joinablity of powder metal iron parts using a manual arc welding method have been in vestigated with the following results. 1. The porosity of powder metal materials decreased with increased compacting pressure. 2. Iron-based materials produced by powder metallurgy were successfully joined using a manual welding method. 3. Aluminum powder metal materials showed more porosity and surface oxides than other metallic materials. 4. The rate of density did not change more than the critical density (73%).® References

1. Saritas, S. 1995. Powder steel forging. METU Journal of Applied Research, 3 (11): 1–26 ( in Turkish). 2. Demir, A., Saritas, S. 1993. Mechanical properties of powder metal steels. AU Isparta Journal of Mechanical Engineering, Vol. 7, pp. 1–13 ( in Turkish). 3. German, R. M., and Dangelo, K. A. 1984. Enhanced sintering treatments for ferrous powders. Int. Metals Rev., Vol. 29, pp. 249–272. 4. Metals Handbook, 9th Ed., Vol. 7. 1984. Powder Metallurgy, pp. 23–99. Materials Park, Ohio: ASM International. 5. German, R. M. 1984. Powder metal lurgy science , pp. 9–55. Princeton, N.J.: Metal Powder Industries Federation. 6. Hamill, J. A. 1991. PM joining processes materials and techniques. The Int. J. of Powder Metal lurgy, 27 (4): 363–371. 7. Kurt, A., Gülenç, B., and Durgutlu, A. 1999. Investigation of HAZ in Roll ePM Cu materials joined by fusion welding methods. Second National Powder Met allur gy Conference Proce edings , pp. 565–570 (in Turkish). 8. Kurt, A., Gülenç, B., and Türker, M. 1996. Investigation of weldability of PM parts compacted pure iron powder to lowcarbon steel by MIG-MAG welding. First National Powder Metallurgy Confe rence Proceedings, pp. 595–602 ( in Turkish). 9. Hamil, J. A. Jr. 1993. What are the joining processes, materi als and techniques for powder metal parts? Welding Journal 72(2): 37–45. 10. Dudas, J. H., and Dean, W. A. 1969. The production of precision aluminum P/M parts, Progress i n Powder Metallurgy, Conference Proceedings, MPIF, Vol. 25, pp. 101 –129.



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Boot Camp for Battlefield Welders

Welding stations used by Army and Marine trainees.

Sgt. Corley shows a Marine Corps mobile welding unit to Education Committee Chair Dennis Klingman. Klingman said the unique tour was an excellent example of t he ben efits gained by volunteering for AWS committees.

America’s warriors learn to weld at Aberdeen Proving Ground

BY ROSS HANCOCK

ROSS HANCOCK ( [email protected] ) is an AWS Technical Committee Secretary.

38

DECEMBER 2004

Military recruits learn how welding can protect a nation in an unassuming industrial building on the 72,500-acre campus of the Aberdeen Proving Ground in Aberdeen, Md. Aberdeen, one of the nation’s most secretive military installations, recently opened its gates to volunteer members of the AWS Education Committee so they could take a rare look at how soldiers prepare for battlefield welding. Their tour “behind the wall” of this topsecret facility left the committee members with a huge respect for the challeng es of welding in hostile territory, and an equally great respect for the men and women who train their comrades to work in harm’s way. A tour of the U.S. Army Ordnance Mechanical Maintenance School (OMMS) was conducted by Marine Sgt. Brian Corley, Air Force Sgt. Jason Ratliff, and Army Sgt. Jeffrey Bruckshaw. Bruckshaw is well known at AWS headquarters, where he was deployed last year to expand and share his expertise. Bruckshaw was instrumental in helping incorporate AWS’s

Sgt. Bruckshaw shows an educational dis play at the Army’s Ordnance Mechan ical Maintenance School.

S.E.N.S.E. educational program into the Army. Three branches of the military share the OMMS facility. (The Navy and Coast Guard, with their unique needs, share two other welding training centers — one on each coast.) Service personnel from the Army, Air Force, and Marines also share some of a 13-week curriculum. “We give them the basics, and hopefully when they get to their field units, they’ll have a good NCO (noncommissioned officer) to give them more,” said Bruckshaw. Training starts with a four-day module on theory and identification of metals (primarily steel and brass). Recruits also master welding symbols and the use of hand tools, and learn a respect for safety matters. The recruits then spend about two weeks in a 50-student lab learning oxyacetylene welding, plasma cutting, soldering, and brazing. The third phase involves another 50-student lab equipped with SMAW (shielded metal arc welding) booths. The

Army and Marines train toget her with Miller 350 LX machines, while the Air Force trains separately with Lincoln Power MIG 300 machines and place more emphasis on fleet vehicles and aircraft, as opposed to mechanized armor. The Air Force detachment utilizes very sophisticated welding booths that incorporate high-resolution, close-up cameras that record the welder’s actions and display multiple angles on wide-screen LCD displays for replay and review. The Marines and Army personnel proceed to a module on GMAW (gas metal arc welding) of aluminum and stainless steel, including butt-joint and complete joint-penetration welding. Soldiers learn how to troubleshoot wire feeders in the field. The Marines take an additional month of training that includes welding titanium and often leads to AWS certification, while the Army personnel practice using field equipment to repair breeched armor, and learn such tasks as dye penetrant testing and plasma arc gouging. “We have a different theory from the Army on armor repair,” said Corley . He showed the visitors the Marine’s mobile trailer for field repair of mechanized armor and artillery. The Army recruits learn other skills that could be useful in the field, such as auto body and glass repair, fuel tank and radiator maintenance, and riveting patches over bullet holes on Humvee fenders. Welders in the line of fire can provide a strategic advantage for a military force if they can keep damaged tanks and other equipment operational. They may be working in difficult terrain, in bad weather (such as 115°F heat in Iraq), and under intense pressure. Maybe bullets are flying. In addition to hostile forces, military welders contend with vehicles that are armored with very hard, exotic metals, ceramics, and composite materials. The vehicles usually contain explosive weaponry that could kill a welder, and sophisticated electronics that can be damaged if the welder makes a mistake. Among environmental hazards are depleted uranium, which is used to strengthen armaments, and the CART (chemical agent retardant technology) paint used on tanks, which can have dangerous health effects to a welder. “We’re fighting to see that our welders in the field are taken care of,” said Army SFC Jim Abels. “There’s enough people trying to kill them. We don’t want to kill them ourselves.” Field welders are trained to wear grounding wrist straps to reduce damage to electronics from static electricity. “Anytime you weld, you have to download the ammo,” Abels pointed out.

An A ir Force we lding booth i s eq uippe d with plasma display panels that show close -up images of welding.

Abels has helped develop strategies to reduce the risk to battlefield welders from hostile actions and environmental risks. He showed the AWS visitors some armored vehicle “first-aid kits” that include high-tech Belzona® polymeric adhesives for patching armor. These materials consist of packets or tubes of base and solidifier chemicals that can be mixed on a ration kit or a piece of cardboard to attach

a armor patch. This provides a strong temporary repair until the armored vehicle can be safely welded. Abels said Aberdeen is under a Congressional mandate to test all armored equipment under live fire. “It’s mandatory that you take it over the fence and shoot at it,” he said. “Then 86% of the time we’re able to ‘MacGyver’ the stuff and return it to work.” ◆

Aberdeen Proving Ground features many fields displaying historic armaments from various nations. Aberdeen i s also home to the U.S. Ar my Ordnance Museum, which i s open to the public.

WELDING JOURNAL

39

Since 1919, we’ve established the standards that guide welding. Doesn’t it make sense to let us guide you to getting certified? SIGN UP FOR THE AWS CWI OR CWE SEMINARS, AND PREP WITH THE EXPERTS. We offer five and a half days of intensive seminars that help prepare you to pass the AWS certification tests. Our experienced teachers help you learn the material you need to know fast, and show you how to use and understand the latest standards. AWS seminars are an excellent value, saving you time and literally hundreds of dollars, by supplying you with many of the books you need FREE . Seminar topics include D1.1 Code, API 1104 Code, Welding Inspection and Technology, and Visual Inspection, followed by the certification exam at the end of the week. By grouping the preparation with the test, you can attend AWS seminars with less time off from the job and less travel expense. When it comes to preparing for an exam that proves you’re one of the best, then take it from the people who know it best—AWS. FIND THE AWS SEMINAR NEAREST YOU. LOCATION

SEMINAR DATES

MIAMI, FL (EXAM ONLY)

EXAM DATES

LOCATION

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EXAM DATES

1/20/2005

HOUSTON, TX

3/13-18

3/19/2005

3/13-18

3/19/2005

BATON ROUGE, LA

1/23-28

1/29/2005

NEW ORLEANS, LA

BOSTON, MA

1/23-28

1/29/2005

MOBILE, AL (EXAM ONLY)

3/19/2005

DENVER, CO

1/30–2/4

2/5/2005

YORK, PA (EXAM ONLY)

3/26/2005

SEATTLE, WA

1/30–2/4

2/5/2005

SAN FRANCISCO, CA

3/20-25

3/26/2005

ONTARIO, CA

1/30–2/4

2/5/2005

ANCHORAGE, AK

3/20-25

3/26/2005

BIRMINGHAM, AL

2/6-11

2/12/2005

CORPUS CHRISTI, TX (EXAM ONLY)

4/16/2005

2/17/2005


4/21/2005

MIAMI, FL (EXAM ONLY) CORPUS CHRISTI, TX

2/19/2005

PORTLAND, ME

4/17-22

4/23/2005

NORFOLK, VA

2/20-25

2/26/2005

ROANOKE, VA

4/17-22

4/23/2005

HARTFORD, CT

2/27-3/4

3/5/2005

BAKERSFIELD, CA

4/24-29

4/30/2005

LAS VEGAS, NV

3/6-11

3/12/2005

COLUMBUS, OH (AT NBBPVI)* 4/25-29

4/30/2005

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3/6-11

3/12/2005

WACO,TX

5/7/2005

PERRYSBURG, OH (EXAM ONLY)

3/12/2005

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5/1-6

5/7/2005

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3/12/2005

NEWARK, NJ

5/1-6

5/7/2005


3/17/2005

SPOKANE, WA

5/1-6

5/7/2005

(EXAM ONLY)

(EXAM ONLY)

For more information, call 1-800-443-9353, Ext. 449

Founded in 1919 to Advance the Science, Technology an d Applic ation of Welding.


To become an AWS member, call 800-443-9353, ext. 480, or visit our website athttp://www.aws.org

4 0 / 2 1 9 2 1 1 F N C 4 0 0 2 y t e i c o S g n i d l e W n a c i r e m A ©

Upgrade Your Web Site’s Usability Over the last ten years, the Internet has become an essential part of the way America does business. These days, it’s as important to have a Web site as it is to have a phone book listing. Unfortunately, many Web sites are riddled with perplexing navigation and unclear priorities that leave many users confused and frustrated. So, what’s the solution? It’s time to review your site to see if it fits today’s standards of usability. “In short, usability is the ease with which someone can use your Web site to do a particular task and get the expected results based on what they currently know,” said Mary Elges, a creative designer with Tallán, a custom IT solution company headquartered in Glastonbury,

This might also be a good time to show this user monthly specials. By identifying, profiling, and creating user scenarios, you will gain foresight on how to develop tasks, web flow, and the most likely ways this user intuitively navigates and views page components to complete the given task effectively,” she explained.

Identify the Purpose and Goals What is the overall goal of the Web site? Is it simply to provide information about your fabricating company, or are you selling welding supplies via an online catalog? The site may even be a mixed

Follow these navigation and content tips to make your Web site a more effective marketing tool Conn. “In other words, the site has to be intuitive.” According to Elges, usability is probably one of the most important aspects of your Web site. It not only will save you time and money, it will also drastically increase the effectiveness of your Web site, whether it exists as a brochure , e-commerce, or somewhere in between. Below are five simple steps to help your business ensure its Web site offers good usability.

Identify the Users

Based on information from Tallán, Glaston bury, Conn. For more information, contact Mary Elges at [email protected].

“You need to know who your users will be. Pinpoint their ages, sex, education, computer experience, and what technologies they will most likely be using. Once you have identified your users, you can then create user scenarios to ensure that the priority tasks they will perform on your Web site will be intu itive,” Elges stated. “Let’s say your business is selling welding supplies. In one of your user scenarios, you profile a 32-year-old male user purchasing supplies for his shop. After de veloping a profile on this user , crea te a scenario of how he would most likely approach the task of buying the supplies.

brochure and catalog. By defining the purpose and goals, you can ensure the correct selection of site navigation, prioritize tasks appropriately, and get the correct message out about what your company does that is of value to your user. In addition, your purpose an d goals aid in the choice of the appropriate navigation style, page layout, graphics utilization, and what technologies should be used.

Identify the Tasks “Write down all of the tasks on the site and then rank them by priority, frequency, and what type of flow would be best suited for the task at hand,” Elges said. This is also an excellent time to start usability testing to see if users are comprehending the information. “Usability testing at this stage identifies many pitfalls before development even starts. This saves both time and money and, oftentimes, a future rewrite.”

Identify the Environmental Challenges If you know that some users will face environmental challenges, you need to

WELDING JOURNAL

41

make sure that your site is accessible with the equipment your target audience will have at hand. Will some visitors be handicapped or need to use screen readers? This will affect the overall design of your site.

Identify the Technology “When deciding what to put on your Web site, consider what technologies your target audience will be using. Most businesses are using DSL or a cable modem. But if you expect to have visitors from the general population, most are still accessing the Internet via dial up,” Elges stated. “This means animation and streaming video wil l be e xcruciatingly slo w to view and can cause these potential customers to visit a competitor. You can build a site that lets the user select the preferred bandwidth to view pages, but if this isn’t cost effective, design your Web site for the lowest common bandwidth and sacrifice flash for usability.” Once you’ve completed these tasks, you will be rea dy to consi der other ways to improve your Web site’s usability. Elges offers the following tips to improve usability when you start the redesign or creation of your site.


42

DECEMBER 2004

Navigation Tips System navigation should not be tricky or confusing. Elges suggests the following: • Determine the Appropriate Navigation Structure. This can be done by considering navigation complexity, the tasks at hand, and the depth of the site to minimize the path of action traveled. • Determine How Your Users Like to Navigate. Do they prefer images instead of buttons or text? • Ensure Your Links Look Clickable. • Utilize Page Identifiers. Let the visitor

know where they are currently located in the site. • Show Navigation State. Utilize style sheets and variations of graphics to show visited links and currently active page links.

Content Tips As for content, Elges said the rule of thumb is to make the site easily understandable. • Use the User’s Language. • Use Labels that Users Already Recognize. For example, use a “Contact Us”

page, not “Give Us a Yell.” • Write Clearly. Create content that is

readable at a glance. Use bullets, introduction summaries, and clear labeling and titles. • Ensure Text Is Legible. Ensure all of your fonts are from the same font family and are at least ten points. Ensure there is good contrast between the page background and the font color, and remember white background with black text is still the most legible for your users. In addition, align your text to the left, and avoid using all capital letters and italics in large bodies of text. • Use Color to Your Advantage. Color can be used for grouping, dividing, showing relationships, or to draw attention. But if you overuse color, it becomes more of a distraction than a marketing tool. My rule of thumb is to use no more than three colors throughout a site. “If users visit your site and can’t figure out how to find information or how to order a product, they’re going to go some where else and not come back,” Elges explained. “This is why companies can’t put off making sure that their sites are up to par for usability. If your site has never been reviewed for usability, do it now. Every day that your company goes by with an ineffective Web site means another day of lost business.”◆


INTERNATIONAL OPPORTUNITIES IN WELDING & CUTTING SALES AWAIT YOU! Be a part of new trade missions. Exhibit at major trade shows. Join AWS/WEMCO and prospect for new sales in the growing international arena. Make new contacts, put your products in front of new purchasers, and position your company to take advantage of the turning economic tide.

NEW 2005 TRADE MISSIONS— Mission #1— Saudi Arabia, Dubai, Libya, Kuwait Mission #2— Russia, Poland, Czech Republic, Slovakia Mission #3— Argentina, Chile, Brazil, Venezuela INTERNATIONAL TRADE SHOWS— Exhibit in the AWS/WEMCO-SPONSORED AMERICAN PAVILION at these shows. EXPO MANUFACTURA February 22-24, 2005 Monterrey, Mexico “SCHWEISSEN & SCHNEIDEN”— The International Essen Welding Fair September 12-17, 2005 Essen, Germany

BENEFITS INCLUDE: • Exhibit space discounts • Shipping, logistics and customs assistance • Exclusive exhibitors’ lounge • Booth packages • Interpreters • Contacts at the best hotels • Exhibitor receptions FIND OUT MORE. Join us at the WEMCO Annual Meeting at the Loews Ventana Canyon Resort in Tucson, Arizona, January 20-22, 2005. Learn more about Trade Missions and Exhibitions—and participate in some of the finest networking in the industry. Circle No. 21 on Reader Info-Card

For more information, contact Mary Ellen Mills (800) 443-9353, ext. 444 or [email protected].

© American Welding Society 2004

WEM1156

COMING EVENTS

NOTE: A DIAMOND ( ®) DENOTES AN AWS-SPONSORED EVENT.

Jan. 25–28, David Inter-Continental Hotel, Tel Aviv, Israel. Sponsored by AWS Israeli International Section, Israeli National Welding Committee, and Association of Engineers and Architects in Israel. Cosponsored by AWS, IIW, and DVS. Contact: www.bgu.ac.il/me/convention/welding/welding2005.html. ® Welding & Joining 2005, Frontiers of Materials Joining.

International Laser Safety Conference. March 7–10, Marriott

Hotel, Marina Del Rey, Calif. Sponsored by the Laser Institute of America. Contact: (407) 380-1553; www.laseri nsti tute .org ; [email protected] .

Weldmex 2005 Welding Show and Symposium. Jan. 25–27, World

JOM-12, Twelfth International Conference on the Joining of Materials, and Fourth International Conference on Education in Welding. March 20–23, Helsingör, Denmark. Contact Institute

Trade Center, Mexico City, Mexico. Symposium to include resistance, arc, laser beam, and spot welding, and welding stainless steels. Contact: www.weldmex.com; [email protected].

Metalform 2005 Symposium. March 20–23, Donald E. Stephens

Advanced Materials Conference — Ship and Ground Vehicle Applications. Feb. 1–2, Rosen Centre Hotel, Orlando, Fla. Concur-

rent Technologies Corp., facilitated by National Center for Excellence in Metalworking Technology. Contact: www.ncemt.ctc.com. ® 5th Weld Cracking Conference. Feb. 15–16, Monteleone Hotel,

New Orleans, La. Sixteen experts will discuss the elements of hot and cold cracking, weld repair, lamellar tearing, stress corrosion cracking, toughness testing, and heat treating. Contact American Welding Society, www.aws.org/conferences; (800/305) 443-9353, ext. 449. HOUSTEX® APEX (Advanced Productivity Exposition). March

1–3, George R. Brown Convention Center, Houston, Tex. Contact Society of Manufacturing Engineers, (313) 425-3155; www.sme.org/events.

for the Joining of Metals, [email protected]. Convention Center, Rosemont, Ill. Sponsored by the Precision Metalforming Assn. Contact Precision Metalforming Assn., 6363 Oak Tree Blvd., Independence, OH 44131; (216) 901-8800; www.metalforming.com. WESTEC® APEX (Adv ance d P roductivity Expositi on). April

4–7, Los Angeles Convention Center, Los Angeles, Calif. Contact Society of Manufacturing Engineers, (313) 425-3155; www.sme.org/events. ® AWS

Welding Show. April 26–28, Dallas Convention Center, Dallas, Tex. Featuring gas products, oilfield and pipeline equipment, cutting and grinding products, brazing and soldering, resistance welding, laser beam welding and cutting, nondestructive testing and inspection, the SkillsUSA national student welding competition, and 35th International Brazing and Soldering Symposium. To exhibit, contact Susan Hopkins at (800) 443-9353, ext. 295. For more information, visit www.aws.org/expo.

WELDING AUTOMATION POSITIONERS TURNING ROLLS

w w w . g e n s t a r t e c h . c o m


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DECEMBER 2004


Twin Cities APEX (Advanced Productivity Exposition). May 3–5,

CWI/CWE Course and Exam. This 10-day program designed to

Minneapolis Convention Center, Minneapolis, Minn. Contact Society of Manufacturing Engineers, (313) 425-3155; www.sme.org/events. Rapid Prototyping & Manufacturing. May 10–12, Hyatt Regency

prepare students for taking the AWS-certified CWI/CWE exam is presented in Troy, Ohio. The exam is presented on the last day. For schedule and entry requirements, contact Hobart Ins titute of Welding Technology, (800) 332-9448; www.welding.org ; [email protected] .

Dearborn, Dearborn, Mich. Contact Society of Manufacturing Engineers, (313) 425-3155; www.sme.org/events.

T.E.S.T. NDT, Inc., Courses. CWI preparation, ultrasonic, eddy

XXXVI Steelmaking Seminar International. May 16–18, Vitõria,

E.S., Brazil. Contact: sandr a.feraccini@abmbr asil.com.br ; www.abmbrasil.com.br/seminarios/fusao/index.shtml. EASTEC® APEX (Advanced Productivity Exposition). May

24–25, Eastern States Exposition Grounds, West Springfield, Mass. Contact Society of Manufacturing Engineers, (313) 4253155; www.sme.org/events. Cleveland APEX (Advanced Productivity Exposition). June 7–9,

I-X Center, Cleveland, Ohio. Contact Society of Manufacturing Engineers, (313) 425-3155; www.sme.org/events. EMO Hannover: The World of Machine Tools & Metalworking.

Sept. 14–21, Fairgrounds, Hannover, Germany. Contacts: www.emo-hannover.de; Hannover Fairs USA, Angela Dessables, at [email protected]. FABTECH International 2005. Nov. 13–16, McCormick Place

South, Chicago, Ill. Contact Society of Manufacturing Engineers, (313) 425-3155; www.sme.org/events. FabForm 2005. Dec. 6–8, Exhibition Center, Nuremberg, Ger-

many. Encompasses key sectors of sheet metal forming and fabricating technologies. Contact, www.fabform.de.

Educational Opportunities Motorsports Welding School. Basic Course: Jan. 17–21, Feb.

21–25, March 14–18, April 25–29, May 23–27, June 13–17, Aug. 1–5, Sept. 12–16, Sept. 26–30, Oct. 10–14, Nov. 14–18, Dec. 5–9. Advanced Course: March 21–25, May 2–6, Sept. 19–23, Oct. 17–21. The Lincoln Electric Co., Cleveland, Ohio. Contact: (216) 383-2461; www.lincolnelectric.com. Laser Welding and Processing Seminar. Feb. 15. A seven-hour

seminar discusses Nd:YAG, CO2, disk, and fiber lasers, including basics, metallurgy, joint design, and safety. Registration is $1050. Contact: Hobart Institute of Welding Technology, www.welding.org ; e-mail: [email protected] ; (800) 332-9448, ext. 5300. Engineering Effective Team Management & Practice Seminar.

Feb. 16–18, Aug. 15–17. Troy, Mich. Designed for managers at all levels, including those preparing to take on management responsibilities for the first time. Fees, including lunch and refreshments, are $1235, $1135 for members of the Society of Automotive Engineers (SAE). Contact: SAE International, (877) 606-7323; [email protected]. Robotic Arc Welding Seminar. April 12. This one-day seminar

covers robotic equipment, systems, applications, and economic justifications for implementation. Presented by instructors from Edison Welding Institute. Registration is $1050. Contact: Hobart Institute of Welding Technology, www.welding.org ; e-mail: [email protected] ; (800) 332-9448, ext. 5300.

current, radiography, dye penetrant, magnetic particle, and visual at Levels 1, 2, and 3. Meet SNT-TC-1A and NAS-410 requirements. On-site training available. T.E.S.T. NDT, Inc., 193 Viking Ave., Brea, CA 92821; (714) 255-1500; FAX (714) 255-1580; e-mail: [email protected]; www.testndt.com. Boiler and Pressure Vessel Inspectors Training Courses and Seminars. Courses and seminars cover such topics as ASME

Code Sections I, IV, V, VIII (Division 1), IX, and B31.1; Writing Welding Procedures; Repairing Pressure Relief Valves; Understanding How Boilers and Pressure Vessels Are Constructed and Inspected; and others. To obtain the 2004 schedule of training courses and seminars offered by the National Board of Boiler and Pressure Vessel Inspectors at its Training and Conference Center in Columbus, Ohio, contact: Richard McGuire, Manager of Training, (614) 888-8320, e-mail: [email protected] ; www.nationalboard.org . Welding Introduction for Robot Operators and P rogrammers.

This one-week course is offered at the Troy, Ohio, facility; or presented at a corporate location tailored to specific needs. Contact Hobart Institute of Welding Technology, (800) 3329448, ext. 5603; Web site: www.welding.org . Unitek Miyachi Corp. Training Services. Unitek Miyachi’s Applicati ons Lab offers personaliz ed training services on resistance and laser beam welding and laser marking. For information, contact (626) 303-5676 or e-mail info@unitekmiy achi.com; www.unitekmiyachi.com . CWI Preparatory and Visual Weld Inspection Courses. Classes

presented in Pascagoula, Miss., Houston, Tex., Houma, La., and Sulphur, La. Course lengths range from 40 to 80 hours. Contact Real Educational Services, Inc., (800) 489-2890; or e-mail to [email protected]. EPRI NDE Training Seminars. EPRI offers NDE technical skills

training in visual examination, ultrasonic examination, ASME Section XI, and UT operator training. For information, contact Sherryl Stogner, (704) 547-6174, e-mail: [email protected]. Free Home Study Internet-based GTAW Training Course for Welding Engineers and Beginners. This three-month-long cer-

tificate course requires 2–3 h study/week. Presented by Huntingdon Fusion Techniques. For complete details, send an e-mail to [email protected]. Victor 2004 Training Seminars. Victor Equipment Co. offers

training programs for gas apparatus and service repair technicians, end users, and sales personnel. For the 2004 schedule, contact Aaron Flippen, (940) 381-1217; www.victorequip.com. The Fabricators & Manufacturers Association, International (FMA), and the Tube and Pipe Association, International (TPA), Courses. For the course schedule, call (815) 399-8775; e-mail:

[email protected] ; www.fmametalfab.org .

WELDING JOURNAL

45

Educational Opportunities AWS 2005 Schedule CWI/CWE Prep Courses and Exams Exam applications must be submitted six weeks before the exam date. For exam information, contact Certification Dept., (800) 443-9353, ext. 273. For information on prep courses, contact Education Dept., (800) 443-9353, ext. 229.

City

Exam Prep Course

Anchorage, Alaska

CWI/CWE Exam

March 20–25 March 26 (API 1104 Clinic also offered) Atlanta, Ga. May 15–20 May 21 (API 1104 Clinic also offered) Bakersfield, Calif. April 24–29 April 30 (API 1104 Clinic also offered) Baton Rouge, La. Jan. 23–28 Jan. 29 (API 1104 Clinic also offered) Beaumont, Tex. June 5–10 June 11 (API 1104 Clinic also offered) Birmingham, Ala. Feb. 6–11 Feb. 12 (API 1104 Clinic also offered) Birmingham, Ala. EXAM ONLY May 28 Boston, Mass. Jan. 23–28 Jan. 29 (API 1104 Clinic also offered) Boston, Mass. EXAM ONLY May 14 Columbus, Ohio April 25–29 April 30 (NBBPVI) Corpus Christi, Tex. EXAM ONLY Feb. 16 Corpus Christi, Tex. EXAM ONLY April 16 Corpus Christi, Tex. EXAM ONLY May 21 Dallas, Tex. Jan. 9–14 Jan. 15 (API 1104 Clinic also offered) Dallas, Tex. March 21–26 No Test 9-Year Recertification Course Denver, Colo. Jan. 30–Feb. 4 Feb. 5 (API 1104 Clinic also offered) Denver, Colo. Feb. 21–26 No Test 9-Year Recertification Course Fargo, N.Dak. June 5–10 June 11 (API 1104 Clinic also offered) Fresno, Calif. Jan. 9–14 Jan. 15 (API 1104 Clinic also offered) Hartford, Conn. Feb. 27–Mar. 4 March 5 (API 1104 Clinic also offered) Houston, Tex. March 13–18 March 19 (API 1104 Clinic also offered) Knoxville, Tenn. EXAM ONLY Jan. 15 Las Vegas, Nev. March 6–11 March 12 (API 1104 Clinic also offered) Long Beach, Calif. May 22–27 May 28 (API 1104 Clinic also offered) Miami, Fla. EXAM ONLY Jan. 20 Miami, Fla. EXAM ONLY Feb. 17 Miami, Fla. EXAM ONLY March 17 Miami, Fla. EXAM ONLY April 21 Miami, Fla. May 15–20 May 21 (API 1104 Clinic also offered) Miami, Fla. EXAM ONLY June 16 Mobile, Ala. EXAM ONLY March 19 Milwaukee, Wis. May 1–6 May 7 (API 1104 Clinic also offered) Nashville, Tenn. March 6–11 March 12 (API 1104 Clinic also offered) Newark, N.J. May 1–6 May 7 (API 1104 Clinic also offered) 46

DECEMBER 2004

City

Exam Prep Course

CWI/CWE Exam

New Orleans, La.

Jan. 24–29 No Test 9-Year Recertification Course New Orleans, La. March 13–18 March 19 (API 1104 Clinic also offered) Norfolk, Va. Feb. 20–25 Feb. 26 (API 1104 Clinic also offered) Ontario, Calif. Jan. 30–Feb. 4 Feb. 5 (API 1104 Clinic also offered) Perrysburg, Ohio EXAM ONLY March 12 Pittsburgh, Pa. May 22–27 May 28 (API 1104 Clinic also offered) Pittsburgh, Pa. June 27–July 2 No Test 9-Year Recertification Course Portland, Maine April 17–22 Apr. 23 (API 1104 Clinic also offered) Roanoke, Va. April 17–22 Apr. 23 (API 1104 Clinic also offered) Rochester, N.Y. EXAM ONLY March 12 Sacramento, Calif. April 4–9 No Test 9-Year Recertification Course Sacramento, Calif. June 5–10 June 11 (API 1104 Clinic also offered) St. Louis, Mo. May 15–20 May 21 (API 1104 Clinic also offered) San Juan, P.R. May 22–27 May 28 (API 1104 Clinic also offered) San Francisco, Calif. March 20–25 March 26 (API 1104 Clinic also offered) Seattle, Wash. Jan. 30–Feb. 4 Feb. 5 (API 1104 Clinic also offered) Spokane, Wash. May 1–6 May 7 (API 1104 Clinic also offered) Waco, Tex. EXAM ONLY May 7 York, Pa. EXAM ONLY March 26

INTERNATIONAL COURSES The Mexico training and testing location is DALUS, S.A. de C.V., Monterrey, N.L. Contact: Lorena Garza at [email protected]. DALUS is an AWS-accredited training and testing facility. It employs the S.E.N.S.E. (Schools Excelling Through Skill Standards Education) programs.

Monterrey, Mex. Monterrey, Mex.

April 11–15 July 11–15

April 16 July 16

Will ISO welding standards include U.S. practices? You decide. ISO welding standards are important. In the long run, they will be used worldwide. Within the next few years, the U.S. will begin using ISO filler metal standards. Thanks to U.S. volunteer efforts, those standards will contain U.S. standard practices and methods. Without continuing U.S. volunteer participation — without being “at the table” when future ISO committee work is being done — additional ISO standards will be based on practices and methods other than those currently used in the U.S. Without U.S. volunteer participation, the industry will have to learn a whole new and expensive set of welding standards, rewrite thousands of WPSs, and requalify tens of thousands of welders. ISO Welding committee meetings take place all over the world. U.S. volunteers donate considerable time to attend. AWS assists by providing up to $1,000 a year to defray travel expenses — but our support fund is low.

Your contribution is important and will make a difference. To make contributing easy — and to provide you with advertising and recognition in return — we’re selling ads in a special International Section of the Welding Journal . These ads will reach 50,000 readers, all potential buyers of your products. All proceeds will go directly to the ISO Participation fund, administered by the AWS International Standards Activities Committee.

Show your support for US participation in ISO. A small, two-column inch ad in one Welding Journal issue is just $500. Discounts are available if you buy more than two months of advertising at a time. Send your check, payable to AWS ISO Participation Fund, with 25 words of copy to: AWS ISO Participation Fund American Welding Society 550 NW LeJeune Road Miami, FL 33126 These ads will appear in future issues of Welding Journal , beginning in the spring of 2005. a 4 . 4 2 1 1 C E T 4 0 0 2 y t e i c o S g n i d l e W n a c i r e m A ©

For more information on contributing, call Bob Bishopric, Director of Marketing, at 800-443-9353, ext. 213 or email [email protected] . To volunteer for work on ISO or other AWS standards, call Andrew Davis at ext. 466 or email [email protected] . Circle No. 19 on Reader Info-Card

Founded in 1919 to Advance the Science, Technology and Application of Welding

Learn About Welding in Your Pajamas

Whatever you wear and wherever you are, WeldAcademy puts welding knowledge at your fingertips. Just log your computer onto this convenient Internet-based introductory professional-development course. For in-service training and expanding your personal knowledge, WeldAcademy is precisely what you need. Engineers and others interested in welding technology and the welding industry will find it ideal for individual or corporate use. WeldAcademy offers a great entry point if you’re new to welding, or an engaging refresher course to confirm previous knowledge. Its ten modules cover the basics, including safety, welding processes, welding inspection, and metallurgy. Over 30 pre- and post-assessment questions for each module reinforce key learning objectives. Teach yourself at your own pace, and earn up to 40 Professional Development Hours of American Welding Society continuing-education credits. In a corporate setting, WeldAcademy’s tracking-management system lets instructors rate module-users’ progress. For a demonstration, skill test, and licensing information, visit www.weldacademy.com You can enroll online or call 888-344-0609 toll-free.

Nonmembers: AWS Members:

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© American Welding Society 2004

EDU 1146

NAVY JOINING CENTER

A MANTECH CENTER OF EXCELLENCE OPERATED BY EWI

NJC Explores Product-Centered Manufacturing for Submarine Construction

The Virginia Class submarine is one candidate for design-for-manufacturing methods being developed by the Navy Joining Center.

T

he Navy Joining Center (NJC) is leading a project to develop novel design-for-manufacturing methods (DFM) and welding automation to support product-centered structural fabrication at General Dynamics Electric Boat (GDEB). The project team is combining the welding process and automation expertise of Edison Welding Institute (EWI) and the manufacturing systems design talents of the Institute for Manufacturing and Sustainment Technology (iMAST) to assist GDEB in planning a new state-of-theart fabrication facility that will feature product-centered manufacturing. At the onset of this project, the team identified a family of tank components in the Virginia Class submarine as candidates for DFM principles. The tanks identified were for feed water, bilge water, and lube oil. These tanks are complex structures requiring more than 15,000 worker-hours to fabricate. To facilitate making these tanks, state-of-the-art welding automation technologies have been evaluated for GDEB production welding operations. The most appropriate welding process and portable automation solutions have been determined, and the functional requirements have been established for a comprehensive flexible fixture design. 52

DECEMBER 2004

The primary purposes of any welding fixture are to ensure accurate positioning of components for production welding, and to provide minimal interference to the welder (or automation device) during the welding process. Even with an optimum welding fixture, the ability to produce a final component meeting all of the dimensional requirements will be limited unless consideration is given to the sequence in which individual pieces, or subassemblies, are introduced and included into the final welded structure being fabricated. Toward that end, the project team is currently selecting automation methods and developing new fixturing technology. Fixtures are also being designed to accommodate the access and positioning requirements dictated by optimized welding procedures and automation welding systems. A Weldin g Procedure Estimator™ is also under development to accurately predict welding fabrication time. This tool will assist in making production work assignments and enable GDEB to easily compare the economic benefits of multiple welding processes, or to compare the advantages of semiautomatic vs. automated deployment of a single welding process. The key to exploiting product-centered

manufacturing is to improve productivity across all production operations. Electric Boat has already achieved significant advancements in cutting, forming, marking, and surface-preparation processes. Without first developing the requisite infrastructure to support product-centered manufacturing, the potential of these enhanced capabilities cannot be fully realized. Thus far, the project has been successful and work will continue during the next year to apply flexiblefixture approaches employing DFM principles to applications for fabrication of foundation tanks in the Virginia Class submarine. For more information, contact Nancy Porter, Navy Joining Center, at 614-6885194 or e-mail to [email protected] .

Operated by

The Navy Joining Center 1250 Arthur E. Adams Dr. Columbus, OH 43221 Phone: (614) 688-5010 FAX: (614) 688-5001 e-mail: [email protected] www: http://www.ewi.org Contact: Larry Brown

If you don’t have this, you don’t have the latest welding requirements for quality fabrication. The industry reference since 1928, the 2004 edition covers: • Design of Welded Connections • Pre-qualification of Welding Procedure Specifications • Qualification for Procedures and Personnel • Fabrication • Inspection • Stud Welding • Strengthening and Repair of Existing Structures

NEW for 2004 • Clarifies when an engineer’s approval is needed • Details newest allowable stress range formulae • Latest restrictions on pre-qualified FCAW and GMAW power sources • Most current tolerances for PJP and CJP groove welds • Adjusts welder qualification essential variables • Adjusts pre-qualification figure details • Latest revision of the pre-qualified base metal list

Order today. Call us at 800.854.7179 or visit global.ihs.com to get your copy. NON- MEMBER

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D1.1/D1.1M COMBO (Web Order Code: D1.1/D1.1M Combo) Buy the hardcopy D1.1 and companion CD ROM and SAVE. Sales, fulfillment and customer service managed by Global Enginering Documents © American Welding Society 2004

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Founded in 1919 to Advance the Science, Technology and Application of Welding. To become an AWS member, call 800.854.7179 or visit our website at http://www.aws.org Circle No. 20 on Reader Info-Card

WELDING WORKBOOK

Datasheet 262a

Controlling Dilution in Weld Surfacing Surfacing is the process of depositing a material onto a base metal to obtain desired properties or dimensions. Probably the single greatest difference between welding a joint and depositing surfacing material is the concern about dilution. Figure 1 shows dilution as a function of the amounts of base metal melted (B) and surfacing metal added (A). The properties of the surfacing material are strongly influenced by dilution. For example, when surfacing a low-alloy or carbon steel with stainless steel using an E308 electrode (19% chromium-9% nickel) at 30% dilution, a first-layer deposit would consist of only 70% surfacing alloy, and therefore, contain about 13% chromium and 6% nickel. On the other hand, if an E309 electrode (25% chromium-12% nickel) was used under the same conditions, a deposit containing about 17% chromium and 8% nickel would be obtained, providing better corrosion resistance. It is important to know the effect each electrode and welding variable has on dilution. The variables below need to be closely controlled when surfacing because they affect dilution. Amperage. Increasing amperage increases dilution. The arc becomes hotter and stiffer, penetrating deeper and melting more base metal. Polarity. Direct current electrode negative (DCEN) gives less penetration and, hence, lower dilution than direct current electrode positive (DCEP). Alternating current (AC) gives penetration intermediate between the two. Electrode Size. Smaller electrodes, as a rule, mean lower amperages, and therefore lower dilution. In gas metal arc welding, for a given amperage, larger electrodes mean lower dilution if they result in globular transfer. Electrode Extension. A long electrode extension decreases dilution. Conversely, a short electrode extension increases dilution, within limits. Bead Spacing or Pitching. Tight bead spacing (more overlap) reduces dilution because more of the previously deposited bead is remelted and added to the weld pool, and less base metal

is melted and incorporated into the pool. Wider bead spacing increases dilution. Electrode Oscillation. Greater width of electrode oscillation reduces dilution. The stringer bead gives maximum dilution. As a rule, the higher the frequency of oscillation the lower the dilution. The three basic oscillation patterns are shown in Fig. 2. Pendulum oscillation, characterized by a slight hesitation at both sides of the bead, produces slightly greater penetration and somewhat higher dilution. The arc length is continually changing with this type of oscillation. Straight-line oscillation is similar to pendulum, except that the arc length is maintained constant. Straight-line constant velocity oscillation produces the lowest level of dilution and provides for movement on a horizontal path so that arc length remains constant. Ideally it should be programmed to have no hesitation at the sides of the bead, eliminating deep penetration at the sides. Travel Speed. A decrease in travel speed increases the amount of surfacing metal added, per unit time or distance, thus decreasing dilution.This reduction is the result of changes in bead shape and thickness, and the arc force is expended on the weld pool rather than the base metal. Welding Position. Depending on the welding position or work inclination, gravity will cause the pool to run ahead of, remain under, or run behind the arc. The more the pool stays ahead or under the arc, the less penetration i nto the base metal and the lower the dilution. Arc Shield ing. The shielding medium influences the extent to which the weld metal will wet the base metal and blend in along the edges of the bead. It also affects the welding current that is required. In general, the order of decreasing dilution for various shielding media are as follows: helium (highest), granular flux without alloy additions, carbon dioxide, argon, granular flux with alloy additions (lowest).

Fig. 1 — Calculating weld metal dilution .

Fig. 2 — Surf acing oscillation techniques and bead configurations.

Excerpted from the Welding Handbook, Vol. 4, eighth edition. 54

DECEMBER 2004

SOCIETYNEWS BY HOWARD M. WOODWARD

Candidates Named for Election to Key AWS Posts

Damian J. Kotecki president

Gerald D. Uttrachi vice president

T

he 2003–2004 Nominating Committee has announced its slate of candidates who will stand for election to AWS national offices for the 2005–2006 term, which begins June 1, 2005. Nominated are the following: Damian J. Kotecki for president Gerald D. Uttrachi for vice president Gene E. Lawson for vice president Victor Y. Matthews for vice president

(Three vice presidents to be elected.) Osama Al-Erhayem for director-at-large William A. Rice, Jr., for director-at-large

(Two directors-at-large to be elected.)

The National Nominating Committee was chaired by Past President Ernest D. Levert. Serving on the committee with Levert were Nancy C. Cole, Wayne J. Engeron, Alfred F. Fleury, Jesse A. Grantham, Wallace E. Honey, Robert J. Teuscher, Dave L. McQuaid, Dave J. Nangle, Tully C . Parke r, Geo ffrey H. Putnam, Oren P. Reich, and Eftihios Siradakis. Jack McLaughlin served as secretary.

The Nominating Committees for Districts 3, 6, 9, 12, 15, 18, and 21 have selected the following candidates for election or reelection as District directors for the three-year terms June 1, 2005, through May 31, 2008. The nominees are Alan J. B adeaux, Sr., District 3 director; Neal A. Chapman, District 6 director; John Brus kotter, District 9 director; Sean

Gene E. Lawson vice president

Victor Y. Matthews vice president

Moran, District 12 director; Mace Harris , District 15 director; John Me ndoza , District 18 director; and Jack Co mpton , District 21 director. Don Howard, District 7 director, is

fulfilling the June 1, 2004, through May 31, 2006, term vacated by the previous director. Nominated for President Damian J. Kotecki Damian J. Kotecki is currently complet-

ing his third year as an AWS vice president. He joined The Lincoln Electric Co. in 1989 where he serves as technical directo r for stainless and high-alloy product development. Kotecki has been active in the development of stainless steel welding filler metals since 1974. Kotecki holds a Ph.D. in mechanical engineering from the University of Wisconsin-Madison. Kotecki is past chair of the AWS Technical Activities Committee, the A5 Committee on Filler Metals and Allied Materials, the WRC Subcommittee on Welding Stainless Steels, and the WRC Subcommittee on Hardfacing and Wear. In addition, he is past chair of the International Institute of Welding (IIW), Commission II, as well as U.S. delegate to that commission. This year, he was elected vice president of the IIW. He is a member of the AWS Technical Papers Committee, the IIW Select Committee on Standardization, IIW Technical Committee, and ISO TC44 and its Subcommittee 3.

Osama Al-Erhayem director-at-large

William A. Rice, Jr. director-at-large

— Kotecki continued on page 58

WELDING JOURNAL

55

All Aboard! Flying Yankee Is an AWS Historical Welded Structure

H

eaping praise upon the 69-yearold “shot-welded” stainless steel Flying Yankee diesel-electric three-passenger-car train was easy for the celebrants who met October 8 at the New Hampshire Dept. of Transportation headquarters in Concord. Commissioner Carol A. Murray accepted the AWS Historical Welded Structure Award on behalf of the train’s owner, the state of New Hampshire. A follow-up public presentation of the award and tours of the train took place October 9 at the Claremont Concord Railroad in Claremont, N.H., where the Flyi ng Yankee has been undergoing a complete restoration since November 1997. Participating in the two-day ceremonies were AWS President 1960–1961 R. David Thomas, Jr., District 1 Director Russ Norris , and Jose ph Tokarski of the Green & White Mountains Section. Other dignitaries included Lisa Jamen representing Governor Benson’s office, R. Stoning Morrell, president, and George Howard, treasurer, of the nonprofit Flying Yankee Restoration Group, Inc., members of the Robert S. Morrell family who founded the Flying Yankee Restoration Group, Inc., and noted train historian Dick Gassett who narrated a slide presentation documenting the history of the Flying Yankee.

Shown leaving the Edward G. Budd Mfg. Co. in 1935, the Flying Yankee starts out on what will become a 22-year-long history-making journey.

R. David Thomas, Jr., explained

during his presentation speech, October 9, “The AWS Pas t Pre sidents Committee meets once a year to revie w the nominations for the AWS Historical Welded Structure Award and vote on its Dave Thomas selections. “I, for one, was tremendously impressed with this welded structure, representing the only historical structure we had yet recognized that made use of the electric resistance welding process. In this process, the surge of power to make the weld nugget in ad jacent sheet steel components is measured in milliseconds to minimize the heat that would otherwise damage the strength and corrosion-resistant properties of the stainless steel. 56

DECEMBER 2004

Shown during the formal presentation of the AWS Historical Welded Structure Award October 8, are (from left) Joseph Tokarski; Lisa Jamen representing Governor Benson's office; George Howard, treasurer, Flying Yankee Restoration Group; Carol A. Murray, commissioner, N.H. DOT; and AWS District 1 Director Russ Norris. Taken at the New Hampshire Department of Transportation (NHDOT) headquarters in Concord. (NHDOT photo) “A patent was issued in 1931 for the welding process which, because of its extremely short time interval, has since been termed ‘shot welding.’ “On behalf of the officers of the

American Welding Society, I a m privi leged to make this award to be displayed with the train to railroad buffs, tourists, and other visitors to this exhibit.” The inscription on the plaque reads:

Romanticized in this 1935 E. G. Budd Mfg. Co. advert iseme isement, nt, the Flying Yankee no doubt raised hopes for a brighter future for millions of Americans emerging from the depths of the Great Depression.

The American Welding Society Historical Welded Welded Structure Award Is ho no r ab ly be st ow ed up on th e Flying Flyi ng Yankee. Yankee. In recogniti rec ogniti on of the advanced technology and innovative weldi ng tech techniqu niquee known as ‘sho ‘shott weldi ng’ that was deve developed loped by the Edwar d G. Budd Manufa ctur cturing ing Company to join stainless steel throughoutt this train. This process throughou created crea ted a ligh lighter ter and fast faster er trai n, thereby revolutionizing American rail travel. The Flying Yankee remains one of o f the th e technol te chnologic ogical al marvel m arvel s of the modern world, and a testament to the quality of work undertaken by the welders and engineers who con structed it. October 8, 2004.

The AWS Historical Welded Structure Award honors structures that are at least 35 years old and have had a significant impact on history. Previous recipients include the St. Louis Arch, Hoover Dam, USS Intrepid aircraft carrier, and USS Nautilus submarine. George Howard said, “The Flyi ng Yankee not only pushed the limits of technology when it was built in 1935 at the end of the Great Depression, it also gave the American people the confidence they could dream again.” Engineered with eye-popping Art Deco good looks and innovative features guaranteed to dazzle, it covered intermediate distances quickly with its Winton 201 diesel-electric locomotive — the first longer-distance train not

The Flying Yankee drew crowds in Nashua, N.H., March 1935, during the innovative streamliner’s inaugural run. (Photo from the collection of Ted Polinski.) Polinski.)

powered by steam. It was the first train with fixed fi xed windows wi ndows becau se it was w as also al so the first train with air conditioning. True, it had no dining car, but food was prepared in a galley and served to passengers on trays affixed to the seat in front — the forerunner of the trays used today on all airlines. It was the first of the streamliners constructed of welded lightweight stainless steel throughout. Edward G. Budd Mfg. Co., Philadelphia, Pa., delivered the Flying Yankee Yankee on February 10, 1935, to the B&M Railroad, Mechanicville, N.Y. For the next several weeks, the train train went on tour over the entire B&M-MEC Railroad system. In Nashua, N.H., 10,000 people came to see it, while 20,000 reportedly showed up to marvel over it in Boston. On April 1, 1935, the Flyi Flying ng Yankee was chri christe stened ned (wit (with h a bottl bottlee of wate r from Lake Sebago, Maine) and began service on its rigorous daily route: Portland to Boston to Portland to Bangor to Portland to Boston and back to Portland — 750 miles/day, 6 days a week. (Maintenance was performed every Sunday.) The train was successful beyond expectations. It reliably served for 22 years until May 7, 1957, when service was discontinued. The train set was donated by B&M to the Edaville Rail Road in Carver, Mass., where it languished almost 40 years until a visionary, Robert S. Morrell, purchased the train and moved it to New Hampshire to begin its restoration to operating condition — as an example of American ingenuity in the face of adversity. He stored the train in Glen, N.H., until 1997 when it was moved to the Claremont Concord Railroad facility at Claremont Junction, N.H. There the Flyi ng Yankee is being restored to operate again some day as Mr. Morrell envis ioned. To To view many more photographs and interesting information visit, www www.flying .flying yankee.com.

A Snow Goose? Yes, the sleek aerody namic front end of the Flying Yankee unfortunately scooped snow up over the windows — obscuring obscuring the engineer’s view of the tracks. It took some more Yankee ingenuity to invent and retrofit this Snow Goose, whose wide-spread stainless steel “wings” deflected the white stuff off to the sides of the train.

Als o, you Also, y ou might m ight want to fe tch your November 1934 issue of Welding Jour nal to read M. B. Butler, Jr.’s, article detailing how E. G. Budd Mfg. Co. used the shot-weld process to produce light weight stainless steel truck bodies. The Flyi ng Yankee ’s restoration to operating condition, now about twothirds completed, will cost about $4 million and require another two years of work. But stimulated by her designation as an AWS Historical Welded Structure, the future looks brighter for this shot welded stainless st ainless steel s teel grand old lady to once again hear the “All aboard!” then fire-up her engine, head down the tracks, and start flying once more.® WELDING JOURNAL

57

— Kotecki continued from page 55

An AWS Fello Fellow w and a reg ist istered ered Professional Engineer, Kotecki holds several patents for arc welding filler metals. He has authored numerous technical papers and writes the Welding Journal’s “Stainless Q&A” column. AWS present pre sent ed Kotec K otec ki wi th t he James F. Lincoln Gold Medal in 1979 and again in 1987; the William Irrgang Award in 1987 ; the R. D. Tho Thomas mas Memorial Award in 1983; the R. D. Thomas, Jr. International Lecture Award in 1994 ; the Prof Prof.. Dr. Rene Wasserman Memorial Award in 1995 and 1997; the George E. Willis Award in 1995; and the A. F. Davis Silver Medal in 1996. He was awarded the IIW Thomas Medal in 1999. He was selected by AWS to present the 1996 Comfort A. Adams Memor ial Lec Lecture ture tit titled led “Ferrite Determination in Stainless Steel Welds — Advances since 1974.” Nominated for Vice President Gerald D. Uttrachi Gerald D. Uttrachi , an AWS Life

Member, is currently completing his second year as an AWS vice president. Uttrachi is president of his company, WA Technology, Technology, LLC. The f irm sells his invention, a recently patented device that effects major cost savings during welding by minimizing shielding gas losses. Previously, he served as a development engineer, project engineer, welding materials materi als laboratory laborato ry manager, and director of welding market development with Linde Division of Union Carbide Corp. He was vice president of marketing for L-TEC Welding & Cutting Systems, then vice president of equipment marketing for ESAB Welding & Cutting Products. Throughout his 39-year career in the welding industry, Uttrachi has been involved with the development of automatic welding processes and welding materials. He has published numerous technical papers on welding processes and filler metals. Uttrachi holds master’s degrees in mechanical engineering and in business management from New Jersey Institute of Technology. Uttrachi has served on various filler metals committees, the Welding Handbook Committee, Technical Papers Committee, and has chaired the Marketing and PEMCO Committees. He has also acted as representative to IIW Committees on Filler Metals Specifications. Uttrachi is currently chairman of the AWS Metric Practices Committee, a member of the Conference Committee, and is an AWS Foundation trustee. 58

DECEMBER 2004

Nominated for Vice President Gene E. Lawson Gene E. Lawson is currently completing his first year as an AWS vice president. An AWS member since 1974, he received a degree in commercial art/advertising from Colorado Institute of Art. He continued his education at Denver Community College specializing in welding and metallurgy. At Chemet C hemetron ron Corp. Corp.,, he speci alized in sales of welding consumables and equipment. In 1975, he moved to southern California as Chemetron’s regional sales manager. Although Chemetron later became Alloy Rods Corp., and is now ESAB Welding Welding & Cutting Cuttin g Products, Lawson remains its representative as territory sales manager for southern California, Arizona, and Hawaii. Lawson has served several terms as chairman of the Los Angeles Section, served three years as a director-at-large director-at-large,, and two terms as District 21 director. He has taken the CWI preparation course and proctored CWI examinations. In 1990, he served on the Steering Committee for the AWS National Convention held in Anaheim, Calif. He also served on the Liaison Committee in 1996 for the Los Angeles show. Lawson has been been a member of the Product Development, Prayer Breakfast, Membership, and Executive committees, and served on the Government Affairss Liaison, Affair Liais on, National Nati onal Nominati No minating, ng, and Convention Site Committees. He has sat on the Board of Directors and Districts, Communications, and Marketing Councils. Lawson also serves on the advisory board at Orange Coast College.

Nominated for Vice President Victor Y. Matthews Victor Vict or Y. Matthe Ma tthews ws, a member of

the Cleveland Section for 37 years, began his career at The Lincoln Electric Co. in 1963 as a bend brake operator. He attended Lincoln’s welding school and earned all of the diplomas it had to offer. He progressed to work in the Electrode Research and Development group for 13 years years where his work and name are recorded on patents in eight countries. Matthews moved to the manufacturing facility as Plant Welding Engineer where he worked for 12 years. He automated many workstations and put into production the company’s firstever welding robot for piecework. In 1990, he joined the Service Department with resp responsi onsibili bility ty for engi engine-d ne-driven riven weldi ng machine mac hines. s. In 1 992, h e was asas signed responsibility for Clevelandmanufactured consumable products worldwide. Currently, he is responsible

for consumables, GTA and SMA welding machines, plasma arc cutting machines, inverters under 300 A, and is liaison to the Italian subsidiaries. Lincoln recognized him with its Man of the Year Award in 1995. He is the past president president of the Lincoln Electric Employee’s Association and Sick Benefit Fund. Matthews also is a past chairman of the Cleveland Section. He served as national chairman of the Liaison Committee for the 1995 Welding Show held at the Cleveland IX-Center. Currently, he is District 10 Director and serves on the Prayer Breakfast Committee, Standards Council, Districts Council, and the Membership Committee. He served eight years on PEMCO, the Executive Committee, the Professional Development Council, TFPS, and Government Affairs Liaison Committee. Nominated for Director-at-Large Osama Al-Erhayem Osama Al-Erhayem founded the Institute for Joining of Materials (JOM) in Denmark in 1979 to enhance training and research and development in weldingg technology weldin techn ology.. The Institute Inst itute curcur rently publishes a journal for its members residing in 40 countries. Al-Erhayem left his native Iraq following high school to study mechanical engineering in Germany. He earned his Ph.D. at the Technical University at Hannover in 1966. The topic of his dissertation was submerged arc welding of high-strength steels in shipbuilding. He moved to Denmark in 1966 and received Danish citizenship in 1973. He chartered and has chaired the AWS International Scandinavia Section in Denmark serving AWS members in Sweden, Norway, Finland, and Denmark. From 1969 until 1996, Al-Erhayem was a lecturer in weldi ng and materi als techn olog ologyy at Polytechnic, Elsinore, Denmark, and from 1996 until 2001 he was an associate professor at Denmark Technical University. From 1986 until the present he has served as an executive for the JOM Institute. Al-Erhayem has published widely and has been invited to present his papers in Egypt, Europe, Korea, and Scandinavia. He has received numerous awards, including the AWS A WS International Meritorious Meritorious Award, Award, the AWS Leaders of Excellence Award, and the Distinguished Member Award.

Nominated for Director-at-Large William A. Rice, Jr. William A. Rice, Jr Jr.., holds the AWS

Silver Award for 25 years of membership in the Society. Now semiretired, he serves as a part-time CEO for OKI Bering Supply, and is a member of the

Alan J. Badeaux, Sr. Sr.

Neal A. Chapman

boards of trustees for several health and financial organizations in West Virginia. Rice worked for Airgas, Inc., from 1993 to 2001, where he served as its president and COO. From 1971 to 1992, he was president of Virginia Welding Welding Supply Co., and president of several other welding-r weldi ng-r elate elated d compa companies nies,, whic which h he later sold to Airgas. He served as chairman of the state VICA welding contests 1979–1983. Rice earned his degree in business marketing from West Virginia University with postgraduate studies in journalism, public relations, psychology, and labor relations. He has completed numerous welding-related courses presented by AWS, Hobart Brothers, Union Carbide, Stellite Hardfacing School, Stoody, The Lincoln Electric Co., and Thermal Dynamics. Nominated for Director District 3 Alan J. Badeaux, Sr. Alan Badea Badeaux ux , an AWS member for 24 years, has been nominated for reelection as District 3 director. Badeaux has 24 years of experience as a welding instructor in the public school system training students to become certified welders welde rs and an d fab ricat ricators ors using u sing feder federal, al, state, and industry guidelines and procedures to comply with OSHA and MOSHA regulations. Currently with Charles County Career Technology Center, where he has taught since 2001, he previously taught for 22 years at Crossland High School in Maryland. He chaired the Washington, D.C., Section 2001–2002, and served as advisor for many years for the Crossland High School and the Washington, D.C., Student Chapters. A graduate of the Uni versity versi ty of Maryl Maryland, and, he hold s an ad vanced profess p rofessional ional certif certificatio icatio n from the state of Maryland, is a certified highpressure-vessel pipe welder, and is certified as a structural steel welder.

Donald C. Howard

Nominated for Director District 6 Neal A. Chapman

John C. Bruskotter

Nominated for Director District 9 John C. Bruskotter

Neal Chapman is a welding engi-

John Brus kott kotter er has been nomi-

neer for Entergy Nuclear Northeast, where he is responsible for the development and administration of the site welding program. program. He previously previously did engineering work at New York Power Authority in Scriba, N.Y., and as a corporate welding/quality engineer for J. P. Bell and Sons in Rocheste Rochester, r, N.Y. Chapman has served served as treasurer and technical representative for the Syracuse Section, and sits on the national level Certification Committee Committee and the Ethics Subcommittee.. He has chaired the SubSubcommittee committee on Certified Welding Engineers. He holds a degree in welding technology from Community College of Beaver County in Monaca, Pa., with continuing studies at the State University of New York at Oswego.

nated for reelection as District 9 director. He currently operates Bruskotter Consulting Services working for an independent oil and gas operator. Previously, he worked for several years as a project manager with Dynamic Industries, Inc. From 1986–2000, Bruskotter was employed employ ed with Houma Ho uma Industries, Indust ries, Inc., where his positions included fabrication and quality control manager, vice president of operations onshore, offshore fabrication and coatings and warehousing and and maintenance. maintenance. Bruskotter joined the AWS New Orleans Section in 1993 where he served as its treasurer and vice chair. From 1999 to 2000, he served as both the Section chairman and District 9 deputy Director.

Nominated for Director District 7 Donald C. Howard

Nominated for Director District 12 Sean P. Moran

Don Howard is currently fulfilling

Sean Moran is currently a product

the term vacated by the previous director: June 1, 2004, through May 31, 2006. He is a technical staff member at Concurrent Technologies Technologies Corp., a nonprofit applied research and development company in Johnstown, Pa., where he has worked in the Advanced Materials department since 1990. His area of interest is the welding of high-strength low-alloy (HSLA) steels for use in shipbuilding. His published reports concern the characteristics of HSLA steels. Prior to joining the company, he worked as a welderr in a truck welde tru ck body bo dy manufac ma nufacturi turing ng plant, and welding and fabrication as part of a building construction crew. Howard received his welding engineering technologies degree from Westmoreland County Community College, where he serve servess as a s an adjun adjunct ct facul faculty ty member, teaching courses in its welding program.

manager for Miller Electric Mfg. Co. He join ed the compan joined c ompan y in 1999 19 99 as a wel ding engineer in the Arc Research group. His prior experience includes ten years as a welding instructor for secondary and postsecondary levels at public and private institutions. His teaching credentials were earned at the University of North Texas. He earned his engineering degree at The Ohio State University and his master’s in engineering management from Milwaukee School of Engineering. He is a Certified Welding Inspector (CWI) and a Certifi ed Welding Educator (CWE). He served on the AWS Welding Handbook Volume 2 Committee as chair of the Chapter Committee on Arc Welding Power Sources. He currently serves as a member of the Welding Handbook Volume 3 Committee on Welding Processes, with oversight for WELDING JOURNAL

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Sean P. Moran

Chapters 1, 3, and 5. He has served on the Education Scholarship Committee and is currently a member of the Educators Committee. Moran received the AWS District Educator Award, and also the Donald Hastings and the Hypertherm Hytech awards for leadership and scholarship. Nominated for Director District 15 Mace Harris Mace Harris joined Reynolds Welding Supply in 1988, where he currently serves as a route salesman. Earlier, he worked as a mechanic and a welder for ten years. A member of AWS since 1990 with the Northwest Section, he worked his way though the chairs and served as chairman 1999–2000. He has served on various Section committees. Currently, he is the cochair of the scholarship committee, a position he has held for six years. He also plays a leadership role in the SkillsUSA/VICA welding contests in Minnesota.

Mace Harris

John L. Mendoza

Nominated for Director District 18 John L. Mendoza

Nominated for Director District 21 Jack D. Compton

John Mend oza is currently completing his first three-year term as District 18 director and has been nominated for reelection. Mendoza has served the City Public Service in San Antonio’s gas and electric utility for 30 years. He is qualified to ASME Section IX in SMA and GTA welding, an d has performed power plant maintenance for more than 20 years. He joined AWS in 1991 and has held several offices in the San Antonio Section, including chairman 1997–1999. As an AWS Certified Welding Inspector and a Certified Welding Educator, he has served as a supervisor for the CWI and CWE exams. Mendoza has received the District Dalton E. Hamilton Memorial CWI of the Year Award.

Jack Compton learned the basics of welding from his father, who did a lot of welding, soldering and brazing, and sheet metal work. After he graduated high school, he worked as a welder at an aerospace company in Burbank, Calif. He performed welding in the U.S. Army where h e served as a comb at engineer in Vietnam. Following discharge, he welded at nig ht and s tudied civil engi neering and industrial arts in the daytime. He earned his associate’s degree from Pierce College, and later his bachelor’s from California State University at Los Angeles, doing welding jobs to pay his tuition. In 1976, he started teaching full time at College of the Canyons and Wm. S. Hart High School. He is the author and publisher of Guide to Certi fied Welder Examinations, which has sold 14,000+ copies. Today he does what he enjoys most — teaches welding at College of the Canyons. ®

Neizel Membership Awards Announced

T

he Corpus Christi Section (District 18), has been awarded the Henry C. Neizel National Membership Award for the greatest net nu merical increase in membership for the 2003–2004 year. The Fresno Section (District 22), earned the award for the greatest net perce ntage increase in membership. Listed below is the Section in each District achieving the greatest percentage increase in membership during the year. Green & White Mountains (1) Central Pennsylvania (3) Charlotte (4) North Central Florida (5) Mid-Ohio Valley (7) 60

DECEMBER 2004

Jack D. Compton

Greater Huntsville (8) Morgan City (9) Drake Well (10) Detroit (11) Upper Peninsula (12) Illinois Valley (13) Louisville (14) Siouxland (16) Ozark (17) Sabine (18) Puget Sound (19) Albuquerque (20) Hawaii (21) Fresno (22).

District Director Award Presented

D

istrict Director Awards pro vide a means for District directors to recognize individuals who h ave co ntributed their time and effort to the affairs of their local Section and/or District. Victor Matthews, District 10 Direc-

tor, has nominated the following member for this award for 2003–2004. Guy Euliano

Northwestern Pennsylvania Section. Districts 2, 6, and 15 have no Sections qualifying for this award.®

Tech Topics technical committee meetings

A

WS technical committee meetings are open to the public. To attend a meeting, contact the staff secretary of the committee as listed in the Guide to AWS Services, on page 70 of this issue of Welding Journa l. No technical committee meetings are listed at this time.

standards notices one standard for PINS Development work has begun on the following revised standard. Materially affected individuals are invited to contribute to its development. Contact the staff secretary Harold Ellison, ext. 299, for more information. Participation on AWS Technical Committees and Subcommittees is open to all persons. AWS

C4.2:200X, Recomm ended

Pract ices for Safe Oxyfuel Gas Cutt ing Torch Operation. The new revised man-

ual for oxyfuel gas cutting includes the latest procedures to be used in conjunction with oxyfuel gas cutting equipment. The manual also includes the latest safety requirements. Complete lists of

Membership Counts Member Grades

As of 11/1/04

Sustaining companies ......................414 Supporting companies* ....................199 Educational institutions ....................322 Affiliate companies............................257 Welding distributor companies ........ 51 Total corporate members .................. 1,243

*Supporting Company members identi fied as welding distributors have been upgraded to the Welding distributor com panies category.

Individual members......................42,947 Student + transitional members ........4,439 Total members.............................. 47,386

equipment are available from individual manufacturers. Stakeholders: This document will be used by oxyfuel gas cutters (operators) involved with steel plate cutting, tooling fabrication, manufacturers of equipment, and building construction. Re vised standard: Harold Ellison ext. 299.

Standard for public review AWS was approved as an accredited standards-preparing organization by the American National Standards Institute (ANSI) in 1979. AWS rules, as approved by ANSI, require that all standards be open to public review for comment during the approval process. This column also advises of ANSI approval of documents. The following standard is submitted for public review. A draft copy may be obtained from Rosalinda O’Neill, AWS, Technical Services Business Unit, 550 NW LeJeune Rd., Miami, FL 33126; telephone (800/305) 4439353, ext. 451, e-mail: [email protected] .

ERRATA in a published standard An incorrect UNS number is recorded in the following AWS specification: ANSI/AWS A5.7-84R , Specification

for Copper and Copper Alloy Bare Welding Rods and Electrodes.

Page 3, Table 1, ti tled Chemica l composition requirements, percent In second column, change UNS Number for ERCuNi to C71581.

merged Arc Welding . Extension granted

to 9/25/06. A5.20-95 , Specification for Carbon Steel

Electrod es for Flux Cored Arc Welding .

Extension granted to 8/18/05.

D14.3/D14.3M:200X, Specification for Welding Earthmoving, Construct ion, and Agri cultural Equipment . Revised

A5.23/A5.23M:1997, Specification for

standard — $8.00. ANSI Public review expires 12/7/2004.

Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding . Extension

Standards extensions approved by ANSI

A5.24-90R , Specification for Zirconium

A5.15-90R , Specification for Welding

Elect rodes and Rods for Cast Iron. Extension granted to 9/25/06. A5.17/A5.17M-97, Specification for Car bon Steel Electrodes and Fluxes for Sub-

granted to 9/25/06. and Zirconium Alloy Welding Electrodes and Rods. Extension granted to 8/11/06. A5.30-97, Specification for Consumable

Inserts. Extension granted to 8/11/06. ®

New AWS Supporters Affiliate Companies

Bill Lykens & Son Welding Co., Inc. 1500 4th Ave. S Birmingham, AL 35233

Detronic Industries, Inc. 35800 Beattie Dr. Sterling Heights, MI 48312

Cryomech 113 Falso Dr. Syracuse, NY 13211

Fred’s Welding Service, Inc. 2401 N Main Cleburne, TX 76033

Dan’s Welding & Machine 1320 E Glendale Ave. Sparks, NV 89431 David Garza Jr. Welding Service 1808 N Main McAllen, TX 78501 Delta Welding Corp. 80 Oak St. Brooklyn, NY 11222

Hagerman Welding, Inc. 428 Elnora Dr. Fort Wayne, IN 46825 IMM, Inc. P.O. Box 747 Grayling, MI 49738 — Supporters continued on next page

WELDING JOURNAL

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— Supporters from previous page

Affiliate Companies (continued ) K. K. Welding, Inc. 107 Providence St., Hyde Park Boston, MA 02136

King Fabrication, LLC 19300 W Hardy Rd. Houston, TX 77073 M. K. Enterprises, Inc. DBA Van Grouw Welding 430 W Main St., Wyckoff, NJ 07481 Metal Sartigan, Inc. 1000 40th St., St. Georges QC G5Y 6V2 Canada

Nick’s Welding, Inc. 1625 Main St. Lewiston, ID 83501 Suncoast Industries of Florida 11385 Ranchette Rd. Fort Myers, FL 33912 Sygometal Kokkinis D & Co. 15 Athinon Ave. 10447 Athens, Hellas 108657 Greece Wayne’s, Inc. P.O. Box 187 Morgan, MN 56266

Mingo Aerospace, LLC 8141 N 116th East Ave. Owasso, OK 74055

Supporting Companies F. A. Wilhelm Construction, Inc. 3914 Prospect St. Indianapolis, IN 46206-0516

NI Welding Supply, LLC P.O. Box 11335 New Iberia, LA 70562

STADCO 1931 N Broadway Los Angeles, CA 90031

Distributor Member Best Welder’s Supply, Inc. 1824 SW Blvd. Tulsa, OK 74107 Educational Institutions College of the North Atlantic Box 370, Burin Bay Arm Newfoundland, Canada A0E 1G0

GEICO Auto Damage School 1690 Old Meadow Rd. McLean, VA 22102 Ivy Tech State College Region 14 200 Daniels Way Bloomington, IN 47404 Lurleen B. Wallace Community College MacArthur Campus 1708 N Main St. Opp, AL 36467 ®

Member-Get-a-Member Campaign

L

isted are the members participating in the 2004–2005 campaign. For rules and a prize list, see page 67 of this Welding Journal. For questions regarding your member proposer points, call the Membership Dept. at (800) 443-9353, ext. 480. Winner’s Circle (Members who have sponsored 20 or more new Individual Members, per year, since June 1, 1999.) J. Compton, San Fernando Valley (4) E. H. Ezell, Mobile (2) J. Merzthal, Peru (2) B. A. Mikeska, Houston (1) R. L. Peaslee, Detroit (1) W. L. Shreve, Fox Valley (1) G. Taylor, Pascagoula (2) S. McGill, Northeast Tennessee (1) T. Weaver, Johnstown/Altoona (1) G. Woomer, Johnstown/Altoona (1) R. Wray, Nebraska (1) ( ) Denotes the number of times the member has achieved Winner’s Circle status. Status will be reviewed at the close of each membership campaign year. President’s Guild (Members sponsoring 20 or more new Individual Members between June 1, 2004, and May 31, 2005.) M. Karagoulis, Detroit — 43

62

DECEMBER 2004

President’s Club (Members sponsoring 6–10 new Individual Members between June 1, 2004, and May 31, 2005.) W. M. Shreve, Fox Valley — 8 J. Compton, San Fernando Valley — 7 President’s Honor Roll (Members sponsoring 1–5 new Individual Members between June 1, 2004, and May 31, 2005. Only those sponsoring 2 or more are listed.) M. Tryon, Utah — 5 D. Guthrie, Tulsa — 4 B. Franklin, Mobile — 3 G. Taylor, Pascagoula — 3 A. Baughman, Stark Central — 2 J. Campbell, Racine-Kenosha — 2 J. Cantlin, Southern Colorado — 2 J. Carney, Western Michigan — 2 J. Emmerson, Connecticut — 2 K. Erickson, Florida West Coast — 2 E. Ezell, Mobile — 2 G. Fudala, Philadelphia — 2 G. Garner, St. Louis — 2 P. Harper, Baton Rouge — 2 J. Jaeger, Kansas — 2 D. Kensrue, Long Beach/Orange Cty. — 2 J. Krall, Dayton — 2 P. Layola, International — 2 R. Robles, Corpus Christi — 2 S. Salamon, New Jersey — 2 G. Schroeter, Puget Sound — 2 T. Shirk, Tidewater — 2 O. Templet, Baton Rouge — 2

Student Sponsors (Members sponsoring 3 or more new Student Members between June 1, 2004, and May 31, 2005.) H. Hughes, Mahoning Valley — 27 A. Baughman, Stark Central — 22 D. Scott, Peoria — 21 G. Euliano, Northwestern Pa. — 20 C. Daily, Puget Sound — 19 J. Fox, Northwest Ohio — 17 D. Newman, Ozark — 16 N. Carlson, E. Idaho/Montana — 11 R. Collins, New York — 11 J. Davis, Maryland — 11 D. Combs, Santa Clara Valley — 10 S. Robeson, Cumberland Valley — 10 A. Badeaux, Washington, D.C. — 9 G. Seese, Pittsburgh — 8 J. Crosby, Atlanta — 7 L. Davis, New Orleans — 7 D. Hatfield, Tulsa — 6 M. Hill, Lexington — 6 M. Tait, L.A./Inland Empire — 6 T. Alberts, Southwest Virginia — 5 J. Boyer, Lancaster — 5 J. Carney, Western Michigan — 5 J. Pelster, Southeast Nebraska — 5 D. Zabel, Southeast Nebraska — 5 T. Buchanan, Mid-Ohio Valley — 4 T. Shirk, Tidewater — 4 B. Taves, Puget Sound — 4 R. Theiss, Houston — 4 R. Palovcsik, St. Louis — 3 D. Vranich, North Florida — 3 ®

SECTIONNEWS SECTIONNEWS

Shown at the Boston Section program are John Scholl (left) and and Ralph Fatieger Fatieger..

DISTRICT 1 Director: Russ Norris Phone: (603) 433-0855

BOSTON OCTOBER 4 Speaker: John Scholl, welding g instrucinstruc S choll, weldin tor Affiliation: Engineers Local No. 4 Topic: Specification used for the repair of earthmoving equipment Activity: Activit y: The Sectio Section n members mem bers toured t oured the Operating Engineers Training Center at the Hoisting and Portable Engineers Local No. 4, led by welding instructors Ralph Fatieger and John Scholl.

CONNECTICUT JUNE 15 Activity: Activ ity: The Sect ion tour toured ed the t he Fou r Horsemen Motor Company in Preston, Conn., to study the designing, engineering, and fabrication of custom-made motorcycles. Steve Raymond, partner, conducted the tour. UGUST 10 A UGUST Activity: The Connecticut Connecticut Section members joined members of the ASM International Hartford Chapter for a jointly sponsored golf tournament held at Blackridge Country Club. The event attracted 140 participants.

DISTRICT 2 Director: Kenneth R. Stockton Phone: (732) 787-0805

Shown at the Lancaster Section board meeting are (from left) Michael Sebergandio, Claudia Bottenfield, Russ Ross, John Boyer, Chairman John Ament, Trina Siegrist, Joe Taylor, and Tim Siegrist.

NEW JERSEY SEPTEMBER 21 Speaker: Dennis Sullivan, regional manager Affiliation: ESAB Welding Welding & Cutting Topic: Flux cored wire and welding Activi ty: The Sect Section ion hono red Bill Miller , a past chairman, on his retirement as a welding instructor at Somerset Count Countyy Vo-Tech. Ed Jones, Somerset County Cou nty Vo-T Vo-Tech principal, pri ncipal, attended the program. October 19 Speaker: Tim Gittens , marketing manager Affiliation: Praxair Topic: Shielding gases and mixing mixi ng techniques Activi ty: The T he progr p rogram am was w as he ld at a t the L’Affai re Restaur Restaurant ant in Mountainside, Mountainsid e, N.J., the New Jersey Section’s regular meeting place.

Reti ree Bill Mill Retiree Miller er ( righ right) t) i s shown sh own with w ith Ed Jones, principal, Somerset Somerset County VoVoTech, at the September New Jersey Section program.

DISTRICT 3 Director: Alan J. Badeaux, Sr. Phone: (301) 934-9061

LANCASTER SEPTEMBER 28 Activi ty: The exe executi cutive ve boar board d met to plan the Section’s 2004–2005 calendar.

YORK CENTR CENTRAL AL PA. OCTOBER 7 Speakers: Robert Blauser, Mike Fink Topic: Welding motorcycle structures

Shown at the October meeting of the New Jersey Section are Vince Murray (left) (left) and speaker Tim Gittens. Activity: Brian T. Yarrison, advisor, and members of the York County School of Technology Student Chapter were guests at the program.

DISTRICT 4 Director: Ted Alberts Phone: (540) 674-3600, ext. 4314 WELDING JOURNAL

63

Southwest Virginia Section Chair Bill Rhodes (left) is shown shown with speaker Dave Dave Waskey (center) and member Robert Gilbert at the September program.

DISTRICT 5 Director: Leonard P. Connor Phone: (954) 981-3977

Shown at the York Central Pennsylvania Section pr ogram are York County School of Technology Student Chapter members (front, from left) Andy Flory and Frank Ot; (rear, from left) Kurt Strauble, S hawn Mowery, Advisor Brian Yarrison, Yarrison, Kevin Woolridge, and Matt Wheeler. Wheeler.

DISTRICT 6 Director: Neal A. Chapman Phone: (315) 349-6960

NIAGARA NIAGA RA FRONT FRONTIER IER SEPTEMBER 23 Activity: Activit y: The Secti Section on met me t at Sw agelo agelok k Biopharm Services Co. nea r Rochester, N.Y., to study the high-purity orbital welding and inspection procedures procedures used by the company. Ray Borawski led the tour of the facility. Ed Wolf made a presentation on precision orbital welding. Ron Kinz discussed the company’s weld quality inspection procedures. Shown at the September Niagara Frontier Section program are (from left) Ed Wolf, Ray Borawski, Chairman Tom Tom Matecki, and Ron Kinz.

NORTHERN NEW YORK OCTOBER 5 Activity: Twenty Twenty four Section S ection members memb ers toured the Flach Crane/Gould Erectors, Inc., facilities in Glenmont, N.Y. The presenters included Hank Digester, president, Gould Erectors, Inc.; John Flach, president, Flach Crane; and Chris Walton , operations manager for Total Facility Solutions, Inc. The topics included welding of stainless tubing and welding plastic piping. The pizza dinner was provided pr ovided by Ravena Raven a Welding SupSu pply Co.

Shown at the Southwest Virginia Section program are (standing, from left) instructor Larry Johnston, Johnston , and his students st udents Doug Slusher, S lusher, Erica Franklin, Marc us Martin, Casey R. Campbel Campbell, l, George Ge orge Evans, Ev ans, and an d Robert Day; (front (f ront row, r ow, from left) lef t) Chr is Robertson, Rober tson, Clayton Mays, Clinton Mays, and Casey K . Campbell.

SOUTHWEST VIRGINIA SEPTEMBER

23 Activity : The Secti Activity: Section on members mem bers toured t oured the Areva/Framatome facility near Roanoke, Va., to study its steam generator area and technical training areas for performing remote welding opera64

DECEMBER 2004

tions during a nuclear power plant malfunction. The tour was conducted by Dave Waskey, welding department manager. Amherst County High School welding instructor i nstructor Larry Johnston and ten of his welding students attended the program.

DISTRICT 7 Director: Don Howard Phone: (814) 269-2895

CINCINNATI OCTOBER 19 Speaker: Gordon Smith, ASNT Level III Affiliation: H. C. Nutting Co. Topic: Inspection techniques Activi ty: The mee meeting ting was held at Corinthian Restaurant in Cincinnati, Ohio.

DISTRICT 8 Director: Wallace E. Honey Phone: (256) 332-3366

CHATTANOOGA SEPTEMBER 21 Activi ty: Follow Following ing dinn er at Durty Nelly’s Pub, the Section toured the Tennessee Rand Co.’s new 100,000-sq-ft facility in downtown Chattanooga, Tenn. Highlights included the company’s engineering and CNC machine shops.

GREATER HUNTSVILLE UGUST 19 A UGUST Activity:: The Section Activity Sect ion members membe rs toured the Taylor-Wharton Coyne facility in Huntsville, Ala., to study its methods for producing cylinders of oxygen, acetylene, and mixed gases.

Shown at the New Orleans Section’s tour are (from left) Ron Fryou, Bob Bartlett, John Schexnayder, Jim Greer, John Gerrets, and John Bruskotter.

SEPTEMBER 23 Activi ty: Great Greater er Hunts Huntsvill villee Sect Section ion Chair Larry Smith , a welding instructor at Blount County AVC, led the Section members on a tour of the school’s shops to observe students engaged in ironworking and welding projects.

HOLSTON VALLEY OCTOBER 5 Activi ty: The Secti on held its soci social al evening at Holiday Lanes Bowling in Johnson City, Tenn.

NASHVILLE SEPTEMBER 11 Activity: The Section Section hosted its 10th annual golf tournament at Farm Lakes Golf Course. OCTOBER 12 Activi ty: The Nashv Nashville ille Sect Section ion members toured the Bobby Hamilton Racing facility in Mt. Juliet, Tenn.

DISTRICT 9 Director: John Bruskotter Phone: (504) 394-0812

MOBILE SEPTEMBER 9 Speaker: Barbara Estes, president Affil iati iation: on: Asso Associate ciated d Build ers and Contractors Topic: Area construction projects Activi ty: Christine Farmer , a welder and mechanic at Christ Steam Plant in Pensacola, Fla., described how welding improved her life. She learned the skills she needed to obtain satisfying work at George Stone Vocational School. She attends evening college classes and makes presentations to students on the value of caree careers rs in weldi ng. The pro-

Gordon Smith (left) accepts a speaker plaque from Uwe Aschemeier Aschemeier,, Cincinnati Section secretary, at the October meeting.

Speaker Barbara Estes poses with Lavon Mill s, Mobil Mills, Mobilee Secti S ecti on c hair, at the September program.

gram was held at Cock of the Walk Restaurant in Mobile, Ala.

NEW ORLEANS SEPTEMBER Activity: Gabe Signorelli conducted the Section on a tour of the New Orleans Sewage and Water Board. Jim Gree Greerr , AWS presiden t, and John Brus Bruskotte kotte r, District 9 director, participated, along with 60 members members and guests. guests.

Christine Farmer is shown with Lavon Mill s, Mobil Mills, Mobilee Secti S ecti on c hair, at the September meeting.

PASCAGOULA SEPTEMBER 30 Speaker: Mickey Holmes, technical representative Affiliation: Lincoln Motor Motor Sports Topic: Job opportunities for welders at NASCAR Activi ty: This stude student nt nigh t prog program ram was held at Missi Mississip ssippi pi Gulf Coast Community College (MGCCC). Students received door prizes including free tickets to the Talladega Winston Cup Race, donated by Lincoln Electric. Chairman Willi William am Harr Harris is from MGCCC presided over this meeting.

Mick ey Holm Mickey Holmes es (lef (left) t) is shown with William Harris, Pascagoula Section chair, at the September meeting. WELDING JOURNAL

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DISTRICT 10 Director: Victor Y. Matthews Phone: (216) 383-2638

DISTRICT 11 Director: Eftihios Siradakis Phone: (989) 894-4101

DETROIT Speaker Pat Pollock (right) accepts a speaker gift from Detroit Vice Chair Ray Roberts at the October meeting.

OCTOBER 14 Speaker: Pat Pollock , vice president Affiliation: Genesis Systems Group Topic: Managing variations in robotic welding applications

NORTHERN MICHIGAN

Shown at the September Lakeshore Section program are (from left) speaker Mag nus Carlsson, Ben Mueller, and Jim Hoff mann.

SEPTEMBER 30 Activity: The Section mem bers toured the Great Lakes Maritime Academy in Traverse City, Mich. Highlights included a tour of the ship State of Michi gan, new academy building, and parts of the Northwestern Michigan College Acade my of Mari time and Culi nary Arts campus. Jerry Williams conducted the tour.

WESTERN MICHIGAN SEPTEMBER 20 Speaker: Mike Soter, vice president Affiliation: Rollan Engineering Services Topic: The art and science of resistance weld verification Activity: The Section made plans for its upcoming golf outing. The meeting was held at O’Mally’s Grill and Pub in Grand Rapids, Mich.

DISTRICT 12 Director: Michael D. Kersey Phone: (262) 650-9364 At the Chicago Section program, speaker Dennis Klingman (above, left) is shown with Chair man Jeff Stanczak. Below, Craig Ticheler (left) accepts his achieve ment award from Jesse Hunter, Distr ict 13 director.

LAKESHORE SEPTEMBER 23 Speaker: Magnus Carlsson, manager Affiliation: SSAB, Oxelösund, Sweden Topic: Working high-strength steels Activity: Carlsson detailed the methods used at SSAB to weld, cut, form, and machine the company’s Hardox brand of quenched and tempered wear-resistant steel. The program was held at the Coach Light Inn in Manitowoc, Wisc.

DISTRICT 13 Director: Jesse L. Hunter Phone: (309) 359-8358 66

DECEMBER 2004

CHICAGO OCTOBER 13 Speaker: Dennis Klingman, manager, technical training Affiliation: The Lincoln Electric Co. Topic: Motorsports welding Activity: Craig Ticheler and Walt Stein received awards for their outstanding service from Jesse Hun ter , District 13 director. Jim Greer, AWS president, spoke on items of general interest about the Society. The program was held at Baby Joe’s Barbecue.

DISTRICT 14 Director: Tully C. Parker Phone: (618) 667-7744

INDIANA SEPTEMBER 8, 9 Activity: Gary Dugger and Mike Anderson manned the Section’s booth at the Solutions Expo 2004 presented by Praxair Distribution, Inc., in Indianapolis, Ind. SEPTEMBER 20 Activity: The Indiana Section membe rs participated in demonstrations of soldering, brazing, and oxyacetylene procedures emphasizing safety. The program, held at Starweld in Rushville, Ind., was led by Bob Richwine from Ivy Tech State College, Muncie, Ind.

ST. LOUIS SEPTEMBER 23 Activity: Following an introductory program by Mark Kohler , vice president, manufacturing, the group toured the Gundlach division of JMJ Industries, Inc. The facility does everything inhouse from oxygen cutting to robotic application of hardfacing materials.

DISTRICT 15 Director: J. D. Heikkinen Phone: (800) 249-2774

DISTRICT 16 Director: Charles F. Burg Phone: (515) 233-1333

KANSAS CITY OCTOBER 14 Speaker: David Craig Affiliation: Computer Engineering, Inc. Topic: Welding computer programs Activity: The program was held at Hay ward’s Barbecue.

DISTRICT 17 Director: Oren P. Reich Phone: (254) 867-2203

DISTRICT 18 Director: John L. Mendoza Phone: (210) 353-3679

SABINE SEPTEMBER 21 Speakers: Ashley Madray, Jason Willingham, and Carl Chance Affiliation: Gas Innovations/WWS, Inc. Topic: Flux cored wire advantages and gas cylinder inspections Activi ty: The program was held at L a Hacienda Restaurant in Port Arthur, Tex., for 56 attendees.

Shown working the Indiana Section’s booth at Solutions Expo 2004 are (from left) Gary Dugger and Mike Anderson.

DISTRICT 19 Director: Phil Zammit Phone: (509) 468-2310 ext. 120

DISTRICT 20

Bob Palovcsik (fr ont, left ), St. Louis Section Chair, presents a gift to Mark Kohler fol lowing the Section’s tour of the Gundlach facilities.

Director: Nancy M. Carlson Phone: (208) 526-6302

DISTRICT 21 Director: Jack D. Compton Phone: (661) 362-3218

DISTRICT 22 Director: Kent S. Baucher Phone: (559) 276-9311

Shown at the Sabine Section program are (from left) Ashley Madray, Section Chair Tom Holt, Jason Willingham, and Carl Chance.

David Craig discussed welding software at the Kansas City Section meeting Octo ber 14.

INTERNATIONAL SECTION RIO DE LA PLATA SEPTEMBER 10 Activi ty: The Internat iona l Sect ion sponsored a national technical program named 8th FECOL Expo, attended by more than 200 visitors. Chairman Carlos Nozralah was a featured speaker. The Section also planned the 2nd IAS Conference on Uses of Steel, scheduled for November 3–5 at Hotel Colonial San Nicolas in San Nicolas, Buenos Aires, Argentina.

Shown at the Rio de la Plata Section Expo are (from left) Roberto Pieklo, Expo or ganizer; Heriberto Weiberlen, vice chair; Daniel Bottero, secretar y; and Sect ion Chairman Carlos Nozralah.

Dick Alley (left), AWS past president (1989–90), and presenter Bob Richwine (right) are shown at the Indiana Section September 20 program.

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Guide to AWS Services 550 NW LeJeune Rd., Miami, FL 33126 Phone (800) 443-9353; (888) WELDING; FAX (305) 443-7559 Internet: www.aws.org Phone extensions appear in parentheses. AWS PRESIDENT James E. Greer ................ [email protected] Moraine Valley Community College 248 Circlegate Rd., New Lenox, IL 60451

PUBLICATION SERVICES Department Information ........................(275) Managing Director Andrew Cullison . [email protected] ......(249) .

ADMINISTRATION Executive Director Ray W. Shook . [email protected] ............(210) .

Welding Journal Publisher/Editor Andrew Cullison . [email protected] ......(249)

CERTIFICATION OPERATIONS Director Terry Perez .. [email protected] ..................(470) Information and application materials on certifying welders, inspectors, and educators..(273)

INTERNATIONAL BUSINESS DEVELOPMENT Director Walter Herrera.. [email protected] ............(475) AWS AWARDS, FELLOWS, and COUNSELORS Managing Director Wendy S. Reeve.. [email protected] ........(293) Coordinates AWS awards and AWS Fellow and Counselor nominees.

.

CFO/Deputy Executive Director Frank R. Tarafa.. [email protected] ..........(252) Deputy Executive Director Jeffrey R. Hufsey .. [email protected] ....(264) Associate Executive Director Cassie R. Burrell.. c [email protected] ....(253) Corporate Director Business Management Systems Linda K. Henderson.. [email protected] (298) Executive Assistant for Board Services Gricelda Manalich.. [email protected] ..(294)

COMPENSATION + BENEFITS Director Luisa Hernandez .. [email protected] ..........(266) DATABASE ADMINISTRATION Corporate Director Jim Lankford .. [email protected] ..................(214) INT’L INSTITUTE OF WELDING Senior Coordinator Sissibeth Lopez .. [email protected] ............(319) Provides liaison activities involving other professional societies and standards organizations, nationally and internationally.

GOVERNMENT LIAISON SERVICES Hugh K. Webster .......... [email protected] Webster, Chamberlain & Bean Washington, D.C. (202) 466-2976; FAX (202) 835-0243

National Sales Director Rob Saltzstein.. [email protected] ..............(243)

Welding Handbook Welding Handbook Editor Annette O’Brien.. [email protected] ......(303)

Managing Director Andrew R. Davis.. [email protected] ......(466) International Standards Activities, American Council of the International Institute of Welding (IIW)

Publishes the Society’s monthly magazine, Welding Journal, which provides information on the state of the welding industry, its technology, and Society activities. Publishes Inspection Trends, the Welding Handbook, and books on general welding subjects.

Director, National Standards Activities Peter Howe.. [email protected] ................(309) Machinery and Equipment Welding, Robotic and Automatic Welding, Computerization of Welding Information.

MARKETING Corporate Director Bob Bishopric.. [email protected] ..............(213) Plans and coordinates marketing of AWS products and services.

Marketing Communications Senior Manager George Leposky .. [email protected] ....(416) Manager Amy Nathan.. [email protected] . .............(308)

MEMBER SERVICES Department Information ........................(480) Associate Executive Director Cassie R. Burrell .. c [email protected] ....(253) Director Rhenda A. Mayo.. [email protected] ......(260)

BRAZING AND SOLDERING MANUFACTURERS’ COMMITTEE

Jeff Weber.. [email protected] ..................(246)

WEMCO-WELDING EQUIPMENT MANUFACTURERS’ COMMITTEE Mary Ellen Mills.. [email protected] ......(444) WIN-WELDING INDUSTRY NETWORK

Mary Ellen Mills.. [email protected] ......(444)

CONVENTION & EXPOSITIONS Exhibiting Information .................. (242, 295) Associate Executive Director/Sales Director Jeff Weber.. [email protected] ..................(246) Director of Convention & Expositions John Ospina.. [email protected] ..............(462) Organizes the annual AWS Welding Show and Convention. Regulates space assignments, registration materials, and other Expo activities.

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DECEMBER 2004

Manager, Safety and Health Stephen P. Hedrick .. [email protected] (305) Metric Practice, Personnel and Facilities Qualification, Safety and Health, Joining of Plastics and Composites. Technical Committee Secretaries Harold P. Ellison.. [email protected] .....(299) Welding in Sanitary Applications, Automotive Welding, Resistance Welding, High-Energy Beam Welding, Aircraft and Aerospace, Oxyfuel Gas Welding and Cutting. John L. Gayler .. [email protected] ..........(472) Structural Welding, Welding Iron Castings. Rakesh Gupta. . [email protected] ..........(301) Filler Metals and Allied Materials, International Filler Metals, Instr umentation for Welding. Ross Hancock. . [email protected] ....(226) Welding Qualification, Friction Welding, Railroad Welding, Joining of Metals and Alloys.

Serves as a liaison between Section members and AWS headq uarte rs. Infor ms membe rs abou t AWS benefits and activities.

Cynthia Jenney .. [email protected] ....(304) Definitions and Symbols, Brazing and Soldering, Brazing Filler Metals and Fluxes, Technical Editing.

PROFESSIONAL INSTRUCTION SERVICES Managing Director Debrah C. Weir.. [email protected] ............(482)

Brian McGrath . [email protected] ......(311) Methods of Inspection, Mechanical Testing of Welds, Thermal Spray, Arc Welding and Cutting, Welding in Marine Construction, Piping and Tubing, Titanium and Zirconium Filler Metals, Filler Metals for Naval Vessels.

.

Identifies funding sources for welding education, research, and development. Monitors legislative and regulatory issues of importance to the industry.

TECHNICAL SERVICES Department Information ........................(340)

Proposes new products and services. Researches effectiveness of existing programs.

Educational Product Development Director Christopher Pollock .. [email protected] (219) Responsible for tracking the effectiveness of existing programs and for the orchestration of new product and service development. Coordinates in-plant seminars and workshops. Administers the S.E.N.S.E. program. Assists Government Liaison Committee with advocacy efforts. Works with Education Committees to disseminate information on careers, national education and training trends, and schools that offer welding training, certificates or degrees.

Conferences and Seminars Director Giselle I. Hufsey .. [email protected] ........(278) Responsible for conferences, exhibitions, and seminars on topics ranging from the basics to the leading edge of technology. Organizes CWI, SCWI, and 9-Year Renewal certificationdriven seminars.

Note: Offi cial inter pretation s of AWS standards may be obtained only by sending a request in writing to th e Managing Director, Technical Services. Oral opinions on AWS standards may be ren dered. However, such opinions represent only the person al op inions of t he pa rtic ular indiv iduals givi ng them . These i ndivi duals do n ot speak on behalf of AWS, no r do thes e oral opi nions con stitute off icial or unoff icial opinions or i nterpretations of AWS. In addition, oral opinions are in formal and should not be used as a substitute for an official interpretation.

Technical Publications Senior Manager, Rosalinda O’Neill.. [email protected] ....(451) AWS publishes more than 200 technical standards and publications widely used in the welding industry.

WEB SITE ADMINISTRATION Director Keith Thompson.. [email protected] ........(414)

Nominees for National Office Only Sustaining Members, Members, Honorary Members, Life Members, or Retired Members who have been members for a period of at least three years shall be eligible for election as a Director or National Officer. It is the duty of the National Nominating Committee to nominate candidates for national office. The committee shall hold an open meeting, preferably at the Annual Meeting, at which members may appear to present and discuss the eligibility of all candidates. To be considered a candidate for positions of President, Vice President, Treasurer, or Director-at-Large, the following qualifications and conditions apply: President: To be eligible to hold the office of President, an individual must have served as a Vice President for at least one year. Vice President: To be eligible to hold the office of Vice President, an individual must have served at least one year as a Director, other than Executive Director and Secretary. Treasurer: To be eligible to hold the office of Treasurer, an indivi dual must be a member of the Society, other than

a Student Member, must be frequently available to the National Office, and should be of executive status in business or industry with experience in financial affairs. Director-at-Large: To be eligible for election as a Director-at-Large, an indi vid ual shall prev ious ly have held office as Chairman of a Section; as Chairman or Vice Chairman of a standing, technical or special committee of the Society; or as District Director. Interested parties are to send a letter stating which particular office they are seeking, including a statement of qualifications, their willingness and ability to serve if nominated and elected, and 20 copies of their biographical sketch. This material should be sent to Thomas M. Mustaleski, Chairman, National Nominating Committee, American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126. The next meeting of the National Nominating Committee is currently scheduled for April 2005. The term of office for candidates nominated at this meeting will commence June 1, 2006. ®

Honorary-Meritorious Awards The Honorary-Meritorious Awards Committee makes recommendations for the nominees presented for Honorary Membership, National Meritorious Certificate, William Irrgang Memorial, and the George E. Willis Awards. These awards are presented during the AWS Exposition and Convention held each spring. The deadline for submissions is July 1 prior to the year of awards presentations. Send candidate materials to Wendy Sue Reeve, Secretary, Honorary-Meritorious Awards Committee, 550 NW LeJeune Rd., Miami, FL 33126. A description of the awards follow.

National Meritorious Certificate Award: This award is given in recognition of the candidate’s counsel, loyalty, and de votion to the affairs of the Society, assistance in promoting cordial relations with industry and other organizations, and for the contribution of time and effort on behalf of the Society. William Irrgang Memorial Award: This award is administered by the American

Welding Society and sponsored by The Lincoln Electric Co. to honor the late William Irrgang. It is awarded each year to the indi vidual who has done the most to enhance the American Welding Society’s goal of ad vancing the science and technology of welding over the past five-year period. George E. Willis Award: This award is administered by the American Welding Society and sponsored by The Lincoln Electric Co. to honor George E. Willis. It is awarded each year to an individual for promoting the advancement of welding internationally by fostering cooperative participation in areas such as technology transfer, standards rationalization, and promotion of industrial goodwill.

International Meritorious Certificate Award: This award is given in recognition of the candidate’s significant contributions to the worldwide welding industry. This award should reflect “Service to the International Welding Community” in the broadest terms. The awardee is not required to be a member of the American Welding Society. Multiple awards can be given per year as the situation dictates. The award consists of a certificate to be presented at the awards luncheon or at another time as appropriate in conjunction with the AWS President’s travel itinerary, and, if appropriate, a one-year membership in the American Welding Society.

TeleWeld FAX:

(305) 443-5951

Publications Sales/Orders Global Engineering Documents (800) 854-7179 or (303) 397-7956, or online at www.global.ihs.com.

Reprints Order quality custom reprints from Claudia Stachowiak, FosteReprints, telephone (866) 879-9144 ext. 121, or e-mail at [email protected].

AWS Mission Statement The mission of the American Welding Soci ety is to adva nce the sci enc e, technology, and application of welding and all ied pro ces ses , inc lud ing joi nin g, bra zin g, sol der ing , cutting, and thermal spray.

It is the intent of the American Welding Society to build AWS to the highest quality standards possible. The Society welcomes your suggestions. Please contact any of the staff listed on the previous page or AWS President James E . Greer, Mora ine Valley Community College, 248 Circlegate Rd., New Lenox, IL 60451.

AWS Foundation, Inc. 550 NW LeJeune Rd., Miami, FL 33126 (305) 445-6628; (800) 443-9353 ext. 293 e-mail: [email protected] general information (800) 443-9353, ext. 689 Chairman, Board of Trustees Ronald C. Pierce

Executive Director Ray W. Shook

Managing Director Wendy S. Reeve

The AWS Foundation is a not-for-profit corporation established to provide support for educational and scientific endeavors of the American Welding Society. Information on gift-giving programs is available upon request.

Honorary Membership Award: An Honorary Member shall be a person of acknowledged eminence in the welding profession, or who is accredited with exceptional accomplishments in the development of the welding art, upon whom the American Welding Society sees fit to confer an honorary distinction. An Honorary Member shall have full rights of membership.® WELDING JOURNAL

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NEW LITERATURE

English Translations of DIN Standards Released The 2004 Catalog of DIN Translations, issued as volume 3 of the DIN Catalog of Technical Rules, lists English translations of nearly 14,500 DIN, DIN EN, and DIN ISO standards. The 468-page, soft cover volume covers such diverse fiel ds as gauges, fasteners, steel and nonferrous metal products, compression couplings, building construction contract procedures, insulating materials, materials testing, etc. The 17,700 documents, classified according to subject group, are presented with date of issue a nd a k eyword index. For more information, e-mail foreignsales @beuth.de, or visit www.beuth.de.

Gas Delivery Systems Pictured

FOR MORE INFORMATION, CIRCLE NUMBER ON READER INFORMATION CARD.

ment for a wide array of applications in the industrial laser materials processing industry. The applications range from cutting sheet metal to laser beam welding. Systems and equipment are designed to meet the specific requirements of major laser manufacturers including Bystronic, Tanaka, Mitsubishi, and Trumpf. Information is grouped according to specific systems that supply mixtures of gases to CO 2 and solid-state lasers with demanding requirements for purity, pressure, and flow. CONCOA

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1501 Harpers Rd., Virginia Beach, VA 23454

Cutting Tools Detailed in General Catalog A catalog features the company’s complete line of products for turning, boring, milling, drilling, grooving, threading, and cut-off applications. New products include insert grades of CVD-coated carbides for ductile iron, and supermicro-grain cermets, and CBN inserts with chip breakers, PCD grades, and others. Detailed is the indexable Magic Drill, the multifunction Ultra Drill Mill, and antivibration Strong Bar in sizes up to 1 in. in diameter. Kyocera Industrial Ceramics Corp. 111

Detailed are a crushproof thermoplastic polyurethane hose reinforced with a urethane helix, drag-resistant types, light weight PVC, heavy 60-mil urethane hose, vacuum hoses, and blower hoses. Hi-Tech Hose, Inc.

112

400 E. Main St., Georgetown, MA 01833

Metallurgy Text on Alloys The text, The Growth of the Alloy Tree, is intended as a reference for metallurgists and materials engineers. Using a narrative style, it shows the interrelationships between the main alloy groups. Ten chapters describe how stainless steels, nickel alloys, and some low-alloy steels have evolved from plain carbon steel. Each chapter explains the background, development, key properties, and applications of the alloy types. Abbreviations, specifications, product forms, alloying costs, and types of corrosion are covered in extensive appendixes. Price is $125 plus shipping. Published by Woodhead Publishing Ltd., Abington Hall, Abington, Cambridge, CB1 6AH, U.K. For details, visit www.woodhead-publishing.com.

Portable Electric Tools Depicted in Catalog

100 Industrial Pk. Rd., Mountain Home, NC 28758

New Flexible Hoses and Ducting Illustrated

A 48-p age cata log displays gasdelivery systems and gas control equip-

A 16-page catalog pictures and describes flexible hoses and ducting. Featured are ten new products including crushproof, vapor-recovery, extremetemperature, and variations on stock hoses in new sizes up to 24 in. ID.

An 18-page, full-color cata log features the company’s lines of professionalgrade portable electric power tools and abrasives for industrial construction and welding applications. Among the new and enhanced tools displayed are a rotary hammer, reciprocating saw, masonry bits, jig saw, variable -spe ed poli sher, and a number of new accessories including a cordless battery pack, paint-remover Circle No. 25 on Reader Info-Card

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DECEMBER 2004

accessory, and new 5- and 6-in. random orbit sanding discs. Metabo

113

1231 Wilson Dr., West Chester, PA 19380

Eye and Face Safety Standard Updated The recently updated American national standard, ANSI Z87.1-2003, Occu-

Explore alternatives - Find practical solutions Specify least – cost Welding Procedures

WPS – Designer 3.0

pational and Educational Personal Eye and Face Protect ion Devices , states the mini-

mum performance requirements for welding helmets and hand shields, spectacles, goggles, face shields, and respirators. It also includes guidelines for the selection, use, and maintenance of these devices. The 67-page standard features numerous illustrations and includes a pull-out selection chart that can be posted in the workplace to provide guidance for various hazard exposures that require eye and face protection. A reproducible Eye Injury Report Form is included. The single copy price is $53, with discounts available on bulk orders. Contact International Safety Equipment Association (ISEA), 1901 N Moore St., Ste. 808, Arlington, VA 22209; jbradley@safet yequipment.org ; or visit www.safetyequipment.org.

Literature Pictures Updated Plasma Torches

Buildings - Bridges •

Compliance with AWS D1.1:2004 / AWS D1.5:2002

•

Prequalified Joint Details - Base Metals - Filler Metals

•

Preheat Tables / PWHT Information

•

Deposition Rate Equations

•

Weld Metal – Welding Time - Welding Cost Estimating

•

Standard Joints for Pipe Welding

•

Automatically Create WPS’s / PQR’s with minimum typing

•

English / Spanish WPS Reports

•

High Level and Accuracy of Code - Checking

•

U.S Customary – International System of Units

IWE-Consulting, Inc. Phone: 954-432 -2655 E-mail: [email protected]

Check new features !

www.iweconsulting.com


A well-illustrated brochure de scribes the company’s FineCut™ consumables and new line of plasma torches for cutting 10- to 24-gauge mild and stainless steels. Shown are examples of the cuts displaying decreased heat-affected zone, narrower kerf width, and improved cut angularity, with minimal dross. Also detailed are several FineCut starter kits for use with the comp any’ s MAX™ and Powermax™ series of manual cutting systems. Detailed are the part numbers and descriptions of the consumables with exploded views of the assemblies. An operating data chart displays typical parameters for cutting mild and stainless steels, including thicknesses, torch standoff distances, arc current and voltage settings, and travel speeds. Hypertherm, Inc.

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21 Great Hollow Rd., Hanover, NH 03755

Welding and Metallurgy Courses Offered on DVDs A meta llurgy course and two S.E.N.S.E.-based welding courses are offered in the DVD “courseware” format to assist instructors teaching basic weldability of carbon steel, aluminum, and stainless steel, and the basics of the shielded — continued on page 74


WELDING JOURNAL

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PERSONNEL NEW LITERATURE

Lincoln Names Asia Pacific Head Lincoln Electric Holdings, Inc., has announced the promotion of Thomas A. Floh n to president of Lincoln Electric Asia Pacific, effective January 1. He will succeed Michael J. F. Thomas A. Flohn Gillespie. Until he retires at the end of the 2005 first quarter, Gillespie will become vice president and special assistant to the president of Asia Pacific. Flohn, with the company for 21 years, is presently vice president, sales and marketing.

has named Alle n J. (Jeff) Clay III as southern region sales manager, responsible for shielding gas systems and acetylene cylinders in Alabama, Florida, Georgia, Louisiana, Missis Allen J. Clay III sippi, South Carolina, and Texas. Clay previously was national marketing manager for Airgas Nitrous Oxide.

Hypertherm Designates California Sales Manager

Two Named to Robotics Board Innova Holdings, Inc., Fort Myers, Fla., announced that Ron Fukui and Tom Helzerman have joined the board of directors of Robotic Workspace Technologies, Inc. (RWT), a wholly owned subsidiary of Innova. Fukui, currently president and co-owner of Amiteq International LLC, will serve as chief technology officer. Helzerman, with 36 years of experience in vehicle operations engineering at Ford Motor Co., joined RWT in 2002 as president and COO.

ASTM Presents Its Award of Merit The American Society for Testing and Materials (ASTM International), Conshohocken, Pa., has conferred its 2004 Award of Merit and title of fell ow to Andrew David McCrindle, a retired metallurgist with GenFast Manufacturing, Bantford, Ont., Canada. The society’s highest honor was presented to McCrindle in recognition of his achievements in de veloping technical standards and his leadership serving as chair of Committee F16 on Fasteners for six years.

Harsco GasServ Selects Sales Manager Harsco GasServ, Mechanicsburg, Pa.,

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DECEMBER 2004

Kris Scherm

Hypertherm, Inc., Hanover, N.H., has appointed Kris Scherm as its district sales manager for southern California. Scherm previously served the company in various key sales positions for the past ten years.

— continued from page 73

metal arc welding (SMAW) and gas metal arc welding (GMAW) processes. The video action is organized in a modular menu-driven format that corresponds with the skills-based student workbooks and comprehensive Instructor Guides. Displayed are dynamic welding videos and close-up views of the weld pool, with all of the amenities of the digital video disc technology including, slow motion, freeze frame, and both English and Spanish sound tracks. For more information and price schedules, contact Training Materials Dept., Hobart Institute of Welding Technology, 400 Trade Square East, Troy, OH 45373; (800) 332-9448, ext. 5433; e-mail [email protected] .

Air Plasma Cutting System Illustrated in Brochure

Obituary Robert (Bob) J. Keller Robert J. Keller, 92, died December 18, 2003. Mr. Keller, a lifelong supporter of the American Welding Society, was born in southern Indiana. He graduated from Hanover College in 1933 with ma jors in chemistry an d physics. Mr. Keller moved to Milwaukee, Wis., with his wife, Nellie, to work in the A. O. Smith Corp. weldi ng research laboratory. There, he moved up into management positions in the welding research division, which was subsequently sold to Harnishfager, and then to Chemetron. After retiring from Chemetron, Hanover, Pa., he returned to southern Indiana where he took a job selling welding supply contracts for Welding Therapy in Columbus, Ind. Mr. Keller later started his own consulting company serving clients in Australia, Germany, and the U.S.

A 4-page, full-color brochure provides details on the Cutmaster™ 101 air plasma cutting system for non-high-frequency start automation applications. Described is the advanced torch connector (ATC™) for quick disconnects. This system is rated for 3 1 ⁄ 8-in. production cut capacity and 1 ⁄ 4-in. edge start capacity for use on aluminum, stainless steel, and mild steel including thingauge production fabrications. Thermal Dynamics Corp.

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Ste. 300, 16052 Swingley Ridge Rd., Chesterfield, MO 63017


WELDING JOURNAL INDEX

Part 1 — WELDING JOURNAL SUBJECT INDEX Abrasive Wheels, Save Time and Money with the Right Abrasive Wheels — C. Karpac, K. Honaker, and T. Fogarty, 38 (May) Airline Millions, Weld Repair Saves — M. R. Johnsen, 28 (Aug) Aluminum Breaks Out of the Vacuum, EBW of — K. Schulze and D. E. Powers, 32 (Feb) Aluminum Cuts Energy Costs by 99%, Friction Welding of — R. Hancock, 40 (Feb) Alumi num Shipbuil ding, New Developme nts in — T. Anderson, 28 (Feb) Aluminum Space Frames Speeds Introduction of Sports Car, Robotic Welding of — C. Occhialini, 24 (Feb) Atmospheres for Bright Brazing, Controlled — P. F. Stratton and A. McCracken, 25 (Oct) Atomiz ation, Manufacture of Brazed and Solder Alloy Powders by — D. Fortuna, 40 (Oct) Automating Materials Handling — 33 (Aug) Auto Parts Maker Goes Ductless — 36 (Sept) Battlefield Welders, Boot Camp for — R. Hancock, 38 (Dec) Brazed and Solder Alloy Powders by Atomization, Manufacture of — D. Fortuna, 40 (Oct) Brazing, Controlled Atmospheres for Bright — P. F. Stratton and A. McCracken, 25 (Oct) Brazing of Stainless Steel, Modern — S. L. Feldbauer, 30 (Oct) Bridge Puts New Gas Mixtures to the Test, Bay — B. O’Neil and M. E. Rodgers III, 26 (Dec) Chicago, Spend Four Profitable Days in — M. R. Johnsen, 38 (Jan) Coke Drums, Vertical Plate Technology Extends the Life of Coke Drums — C. Stewart, 34 (Apr) Costs by 99%, Friction Welding of Aluminum Cuts Energy — R. Hancock, 40 (Feb) Cleveland, Fabtech Comes to — 51 (Oct) Cutting Tips, Tips for Selecting Qxyfuel — J. Jones, 71 (Sept) Daughters Bond through Welding, Dads and — R. H ancock, 91 (Apr) Distortion, Understanding — D. McGowan, 76 (Sept) Electrodes Improve GMAW Heat Input Control, Double — Y. M. Zhang, M. Jiang, and W. Lu, 39 (Nov) Ferritic Welds, Understanding Hydrogen Failures of — J. R. Still, 26 (Jan) Filler Metal Review, Nickel Alloy — H.W. Ebert, 60 (July) Fires?, How Do We Prevent Hot Work — M. Blank, 26 (Sept) Force-Guided Relays Add Extra Measure of Safety — R. Harris, 38 (Sept) Frames Speeds Introduction of Sports Car, Robotic Welding of Aluminum Space — C. Occhialini, 24 (Feb) Gas Mixtures to the Test, Bay Bridge Puts New — B. O’Neil and M. E. Rodgers III, 26 (Dec) Gas Platforms, Now Made in USA: Spar Hulls for Oil and — R. Hancock, 38 (Apr) Girls, Welding Sparks Self-Esteem for — R. Hancock, 73 (Sept)

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Guns and Torches, Developments in — R. Hancock and M. R. Johnsen, 29 (May) GMAW Heat Input Control, Double Electrodes Improve — Y. M. Zhang, M. Jiang, and W. Lu, 39 (Nov) GMAW, How to Optimize Mild Steel— Richard Green, 30 (Dec) Heat Treatment Is Critical to Refurbishing a Wellhead Housing, Postweld — J. R. Still and V. Blackwood, 34 (Oct) Heat Input Control, Double Electrodes Improve GMAW — Y. M. Zhang, M. Jiang, and W. Lu, 39 (Nov) Hermetic Sealing, Optimizing Projection Welding for — T. E. Salzer, 42 (March) High-Purity Water Systems Rely on Orbital Welding — 39 (Aug) Hollywood Bowl, A New Tune for the — R. Aday, 54 (July) How Do We Prevent Hot Work Fires? — M. Blank, 26 (Sept) Hydrogen Failures of Ferritic Welds, Understanding — J. R. Still, 26 (Jan) Hybrid Welding?, What’s Next for — R. W. Messler, Jr., 30 (March) Hybrid Welding of Ships, Laser- — S. Herbert, 39 (June) Insert Metal, Friction Welding Using — H. Ochi, K. Ogawa, Y. Yamamoto, and Y. Suga, 36 (March) Ironworkers New Skills, Dinosaur Project Teaches — N. Borchert, 42 (Nov) Job Shops, Tips for — M. R. Johnsen, 45 (June) Life of Coke Drums, Vertical Plate Technology Extends the — C. Stewart, 34 (Apr) Materials Handling, Automating — 33 (Aug) Mild Steel GMAW, How to Optimize — Richard Green, 30 (Dec) Mixtures to the Test, Bay Bridge Puts New Gas — B. O’Neil and M. E. Rodgers III, 26 (Dec) Money with the Right Abrasive Wheels, Save Time and — C. Karpac, K. Honaker, and T. Fogarty, 38 (May) Nickel Steel, Electrodes for Welding 9% — J. Hilkes, F. Neesen, and S. Caballero, 30 (Jan) Nuclear Power Plant Benefits from Innovative Repair Technology — N. Chapman, 36 (Aug) Oil and Gas Platforms, Now Made in USA: Spar Hulls — R. Hancock, 38 (Apr) Orbital Welding, High-Purity Water Systems Rely on — 39 (Aug) Qxyfuel Cutting Tips, Tips for Selecting — J. Jones, 71 (Sept) Parts Maker Goes Ductless, Auto — 36 (Sept) P91, Welding Root Beads — C. Patrick, T. Ferguson, and J. Maitlen, 38 (July) Pipeline, Maintenance Welding on the Trans-Alaska — W. A. Bruce and A. S. Beckett, 48 (July) Pipelines, Weld Metal Properties of Reeled — J. R. Still, 42 (July) Plate Technology Extends the Life of Coke Drums, Vertical — C. Stewart, 34 (Apr) Powder Metal Parts, Exploring the Weldability of — A. Kurt,

H. Ates, A. Durgutlu, and K. Karacif, 34 (Dec) Power Plant Benefits From Innovative Repair Technology, Nuclear — N. Chapman, 36 (Aug) Pressure Vessel Challenge, Vertical Welding Solves a — J. Ferrell and P. Formento, 48 (Nov) Profitable Days in Chicago, Spend Four — M. R. Johnsen, 38 (Jan) Projection Welding for Hermetic Sealing, Optimizing — T. E. Salzer, 42 (March) Properties of Reeled Pipelines, Weld Metal — J. R. Still, 42 (July) Protect Your Most Valuable Asset — Yourself — M. Schifsky, 30 (Sept) Protection, Volunteer Welders Give Troops a Ton of — R. Hancock, 83 (Apr) Repair Technology, Nuclear Power Plant Benefits from Innovative — N. Chapman, 36 (Aug) Repair Saves Airline Millions, Weld — M. R. Johnsen, 28 (Aug) Root Beads in P91, Welding — C. Patrick, T. Ferguson, and J. Maitlen, 38 (July) Safety, Force-Guided Relays Add Extra Measure of — R. Harris, 38 (Sept) Shipbuilding, New Developments in Aluminum — T. Anderson, 28 (Feb) Ships, Laser-Hybrid Welding of — S. Herbert, 39 (June) Show, A Look at the AWS Welding — A. Cullison, R. Hancock, and M. R. Johnsen, 33 (June) Skills, Dinosaur Project Teaches Ironworkers New — N. Borchert, 42 (Nov) Society Turns 85, The American Welding — A. Cullison, 50 (June) Solder Alloy Powders by Atomization, Manufacture of Brazed and — D. Fortuna, 40 (Oct) Spar Hulls for Oil and Gas Platforms, Now Made in USA: — R. Hancock, 38 (Apr) Sports Car, Robotic Welding of Aluminum Space Frames Speeds Introduction of — C. Occhialini, 24 (Feb) Stainless Steel, Modern Brazing of — S. L. Feldbauer, 30 (Oct) Strongest Linepipe in Arctic Conditions, Welding the World’s — R. Hancock, 58 (July) Success, Dressed for — R. Hancock, 29 (Apr) Thermoplastics, Welding of — D. Ziegler, 45 (Oct) Tips for Selecting Qxyfuel Cutting Tips — J. Jones, 71 (Sept)

Titanium Specification Revised, Update: — J. A. McMaster and R. C. Sutherlin, 43 (May) Toolbox?, What’s in Your — A. Cullison, R. Hancock, and M. R. Johnsen, 34 (May) Torches, Developments in Guns and — R. Hancock and M. R. Johnsen, 29 (May) Trans-Alaska Pipeline, Maintenance Welding on the — W. A. Bruce and A. S. Beckett, 48 (July) Troops a Ton of Protection, Volunteer Welders Give — R. Hancock, 83 (April) Understanding Distortion — D. McGowan, 76 (Sept) Usability, Upgrade Your Web Site’s — 41 (Dec) Vacuum, EBW of Aluminum Breaks Out of the — K. Schulze and D. E. Powers, 32 (Feb) Web Site’s Usability, Upgrade Your — 41 (Dec) Weldability of Powder Metal Parts, Exploring the — A. Kurt, H. Ates, A. Durgutlu, and K. Karacif, 34 (Dec) Welders Give Troops a Ton of Protection, Volunteer — R. Hancock, 83 (Apr) Welding, Dads and Daughters Bond through — R. Hanock, 91 (Apr) Welding 9% Nickel Steel, Electrodes for — J. Hilkes, F. Neesen, and S. Caballero, 30 (Jan) Weld Repair Saves Airline Millions — M. R. Johns en, 28 (Aug) Welding Show, A Look at the AWS — A. Cullison, R. Hancock, and M. R. Johnsen, 33 (June) Welding Society Turns 85, The American — A. Cullison, 50 (June) Welding Solves a Pressure Vessel Challenge, Vertical — J. Ferrell and P. Formento, 48 (Nov) Welding Sparks Self-Esteem for Girls — R. Hancock, 73 (Sept) Welding Using Insert Metal, Friction — H. Ochi, K. Ogawa, Y. Yamamoto, and Y. Suga, 36 (March) Welding?, What’s Next for Hybrid — R. W. Messler, Jr., 30 (March) Wellhead Housing, Postweld Heat Treatment Is Critical to Refurbishing a — J. R. Still and V. Blackwood, 34 (Oct) Wheels, Save Time and Money with the Right Abrasive — C. Karpac, K. Honaker, and T. Fogarty, 38 (May) Workplace Safety: The Human Factor — M. Pankratz and D. Dorn, 32 (Sept) World Now, They’re in the Real — M. R. Johnsen, 87 (Apr) World Trade Center Site, Construction Begins at the — B. Sommer, 36 (Nov)

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AUTHORS FOR FEATURE ARTICLES Aday, R. — A New Tune for the Hollywood Bowl, 54 (Jul y) Ander son, T. — New Developments in Alumi num Shipbuilding, 28 (Feb) Ates, H., Durgutlu, A., Karacif, K., and Kurt, A. — Exploring the Weldability of Powder Metal Parts, 34 (Dec) Beckett, A. S., and Bruce, W. A. — Maintenance Welding on the Trans-Alaska Pipeline, 48 (July) Blackwood, V., and Still, J. R. — Postweld Heat Treatment Is Critical to Refurbishing a Wellhead Housing, 34 (Oct) Blank, M. — How Do We Prevent Hot Work Fires?, 26, (Sept) Borchert, N. — Dinosaur Project Teaches Ironworkers New Skills, 42 (Nov) Bruce, W. A., and Beckett, A. S. — Maintenance Welding on the Trans-Alaska Pipeline, 48 (July) Chapman, N. — Nuclear Power Plant Benefits from Innovative Repair Technology, 36 (Aug) Cullison, A. — The American Welding Society Turns 85, 50 (June) Cullison, A., Hancock, R., and Johnsen, M. R. — What’s in Your Toolbox?, 34 (May) Cullison, A., Hancock, R., and Johnsen, M. R. — A L ook at the AWS Welding Show, 33 (June) Caballero, S., Hilkes, J., and Neesen, F. — Electrodes for Welding 9% Nickel Steel, 30 (Jan) Dorn, D., and Pankratz, M. — Workplace Safety: The Human Factor, 32 (Sept) Durgutlu, A., Karacif, K., Kurt, A., and Ates, H. — Exploring the Weldability of Powder Metal Parts, 34 (Dec) Ebert, H. W. — Nickel Alloy Filler Metal Review, 60 (July) Ferguson, T., Maitlen, J., and Patrick, C. — Welding Root Beads in P91, 38 (July) Feldbauer, S. L. — Modern Brazing of Stainless Steel, 30 (Oct) Ferrell, J., and Formento, P. — Vertical Welding Solves a Pressure Vessel Challenge, 48 (Nov) Fogarty, T., Karpac, C., and Honaker, K. — Save Time and Money with the Right Abrasive Wheels, 38 (May) Formento, P., and Ferrell, J. — Vertical Welding Solves a Pressure Vessel Challenge, 48 (Nov) Fortuna, D. — Manufacture of Brazed and Solder Alloy Powders by Atomization, 40 (Oct) Green, R. — How to Optimize Mild Steel GMAW, 30 (Dec) Hancock, R., Johnsen, M. R., and Cullison, A. — A L ook at the AWS Welding Show, 33 (June) Hancock, R. — Dads and Daughters Bond through Welding, 91 (Apr) Hancock, R., and Johnsen, M. R. — Developments in Guns and Torches, 29 (May) Hancock, R. — Dressed for Success, 29 (Apr) Hancock, R. — Friction Welding of Aluminum Cuts Energy Costs by 99%, 40 (Feb) Hancock, R. — Now Made in USA: Spar Hulls for Oil and Gas Platforms, 38 (Apr) Hancock, R. — Volunteer Welders Give Troops a Ton of Protection, 83 (Apr) Hancock, R. — Welding Sparks Self-Esteem for Girls, 73 (Sept) Hancock, R., Johnsen, M. R. and Cullison, A. — What’s in Your Toolbox?, 34 (May) Hancock, R. — Boot Camp for Battlefield Welders, 38 (Dec) Harris, R. — Force-Guided Relays Add Extra Measure of

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Safety, 38 (Sept) Herbert, S. — Laser-Hybrid Welding of Ships, 39 (June) Hilkes, J., Neesen, F., and Caballero, S. — Electrodes for Welding 9% Nickel Steel, 30 (Jan) Honaker, K., Fogarty, T., and Karpac, C. — Save Time and Money with the Right Abrasive Wheels, 38 (May) Jiang, M., Zhang, Y. M., and Lu, W. — Double Electrodes Improve GMAW Heat Input Control, 39 (Nov) Johnsen, M. R., Cullison, A., and Hancock, R. — A Look at the AWS Welding Show, 33 (June) Johnsen, M. R., and Hancock, R. — Developments in Guns and Torches, 29 (May) Johnsen, M. R., Hancock, R., and Cullison, A. — What’s in Your Toolbox?, 34 (May) Johnsen, M. R. — Spend Four Profitable Days in Chicago, 38 (Jan) Johnsen, M. R. — They’re in the Real World Now, 87 (Apr) Johnsen, M. R. –– Weld Repair Saves Airline Millions, 28 (Aug) Johnsen, M. R. — Tips for Job Shops, 45 (June) Jones, J. — Tips for Selecting Qxyfuel Cutting Tips, 71 (Sept) Karacif, K., Kurt, A., Ates, H., and Durgutlu, A. — Exploring the Weldability of Powder Metal Parts, 34 (Dec) Karpac, C., Honaker, K., and Fogarty, T. — Save Time and Money with the Right Abrasive Wheels, 38 (May) Kurt, A., Ates, H., Durgutlu, A., and Karacif, K. — Exploring the Weldability of Powder Metal Parts, 34 (Dec) Kvaale, P. E., Van Der Eijk, C., Akselsen, O.M., and Rorvik, G. — Microstructure-Property Relationships in HAZ of New 13% Cr Martensitic Stainless Steels, 160-S (May) Lu, W., Zhang, Y. M., and Jiang, M. — Double Electrodes Improve GMAW Heat Input Control, 39 (Nov) Maitlen, J., Patrick, C., and Ferguson, T. — Welding Root Beads in P91, 38 (July) McCracken, A., and Stratton, P. F. — Controlled Atmospheres for Bright Brazing, 25 (Oct) McGowan, D. — Understanding Distortion, 76 (Sept) McMaster, J. A., and Sutherlin, R.C. — Update: Titamium Specification Revised, 43 (May) Messler, Jr., R. W. — What’s Next for Hybrid Welding?, 30 (March) Neesen, F., Caballero, S., and Hilkes, J. — Electrodes for Welding 9% Nickel Steel, 30 (Jan) Occhialini, C. — Robotic Welding of Aluminum Space Frames Speeds Introduction of Sports Car, 24 (Feb) Ochi, H., Ogawa, K., Yamamoto, Y., and Suga, Y. — Friction Welding Using Insert Metal, 36 (March) Ogawa, K., Yamamoto, Y., Suga, Y., and Ochi, H. — Friction Welding Using Insert Metal, 36 (March) O’Neil, B., and Rodgers III, M. E. — Bay Bridge Puts New Gas Mixtures to the Test, 26 (Dec) Powers, D. E., and Schulze, K. — EBW of Aluminum Breaks Out of the Vacuum, 32 (Feb) Pankratz, M., and Dorn, D. — Workplace Safety: The Human Factor, 32 (Sept) Patrick, C., Ferguson, T., and Maitlen, J. — Welding Root Beads in P91, 38 (July) Rodgers III, M. E., and O’Neil, B. — Bay Bridge Puts New Gas Mixtures to the Test, 26 (Dec) Salzer, T. E. — Optimizing Projection Welding for Hermetic

Sealing, 42 (March) Schifsky, M. — Protect Your Most Valuable Asset — Yourself, 30 (Sept) Schulze, K. and Powers, D. E. — EBW of Aluminum Breaks Out of the Vacuum, 32 (Feb) Sommer, B. — Construction Begi ns at the World Trade Center Site, 36 (Nov) Stewart, C. — Vertical Plate Technology Extends the Life of Coke Drums, 34 (Apr) Still, J. R. — Understanding Hydrogen Failures of Ferritic Welds, 26 (Jan) Still, J. R. — Weld Metal Properties of Reeled Pipelines, 42 (July)

Still, J. R., and Blackwood, V. — Postweld Heat Treatment Is Critical to Refurbishing a Wellhead Housing, 34 (Oct) Stratton, P. F., and McCracken, A. — Controlled Atmospheres for Bright Brazing, 25 (Oct) Suga, Y., Ochi, H., Ogawa, K., and Yamamoto, Y. — Friction Welding Using Insert Metal, 36 (March) Sutherlin, R. C., and McMaster, J. A. — Update: Titanium Specification Revised, 43 (May) Yamamoto, Y., Suga, Y., Ochi, H., and Ogawa, K. — Friction Welding Using Insert Metal, 36 (March) Ziegler, D. — Welding of Thermoplastics, 45 (Oct) Zhang,Y. M., Jiang, M., and Lu, W. — Double Electrodes Improve GMAW Heat Input Control, 39 (Nov)

Part 2 — RESEARCH SUPPLEMENT SUBJECT INDEX Al-Cu Welds, Liquation Cracking in Full-Penetration — C. Huang and S. Kou, 50-S (Feb) Aluminum Alloys, ‘Kissing Bond’ Phenomena in Solid-State Welds of — A. Oosterkamp, L. Djapic Oosterkamp, and A. Nordeide, 225-S (Aug) Aluminum Alloy to Steel with Transition Material — From Process to Performance — Part I: Experimental Study, Resistance Spot Welding of — X. Sun, E.V. Stephens, M. A. Khaleel, H. Sao, and M. Kimchi, 188-S (June) Aluminum Alloy to Steel with Transition Material — Part II: Finite Element Analyses of Nugget Growth, Resistance Spot Welding of — X. Sun and M. A. Khaleel, 197-S (July) Aluminum Alloy 5052 and Low-Carbon Steel by Laser Roll Welding, Joining of — M. J. Rathod and M. Kutsuna, 16-S (Jan) Aluminum Alloy Subjected to an External Electrostatic Field, Metallurgical Characterization of a Friction Welded — L. Fu and S. G. Du, 232-S (Aug) Aluminum Alloy to Steel, Friction Stir Welding of — K. Kimapong and T. Watanabe, 277-S (Oct) Aluminum Brazed Joints, Prediction of the Fillet Mass and Topology of — D. P. Sekulic, F. Gao, H. Zhao, B. Zellmer, and Y. Y. Qian, 102-S (March) Aluminum Resistance Spot Welds, Effects of Fusion Zone Size on Failure Modes and Static Strength of — X. Sun, E. V. Stephens, R. W. Davies, M. A. Khaleel, and D. J. Spinella, 308-S (Nov) Austenitic Alloys for Spent Nuclear Fuel Applicatons — Part I: Stainless Steel Alloys, Physical and Welding Metallurgy of Gd-Enriched — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, 289-S (Nov) Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: Nickel-based Alloys, Physical and Welding Metallurgy of Gd-enriched — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, 319-S (Dec) Bead Geometry, The Influence of Various Hybrid Welding Parameters on — M. El Rayes, C. Walz, and G. Sepold, 147-S (May)

Beam Measurement for Spot Welding Lasers, Development and Evaluation of an In-Situ Beam Measurement for Spot Welding Lasers — P. W. Fuerschbach, J. T. Norris, R. C. Dykhuizen, and A. R. Mahoney, 154-S (May) Brazed Joints, Prediction of the Fillet Mass and Topology of Aluminum — D. P. Sekulic, F. Gao, H. Zhao, B. Zellmer, and Y. Y. Qian, 102-S (March) Brazing Technology for Manufacture of Titanium Honeycomb Structures — A Statstical Study, Activated Diffusion — X. Huang and N. L. Richards, 73-S (March) Boundary Character in Alloy 690 and Ductility-Dip Cracking Susceptibility, Grain — V. R. Dave, M. J. Cola, M. Kumar, A. J. Schwartz, and G. N. A. Hussen, 1-S (Jan) Brazed Joints — Part 1, Flaw Tolerance in Lap Shear — Y. Flom amd L. Wang, 32-S (Jan) Charpy Toughness, Optimization of Shielded Metal Arc Weld Metal Composition for — M. Murugananth, S. S. Babu, and S. A. David, 267-S (Oct) Clad Steel Plate, Single-Pass Laser Beam Welding of — S. Missori, F. Murdolo, and A. Sili, 65-S (Feb) Cored Arc Weld Metal Deposits, The Effect of Welding Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 Flux — H. G. Svoboda, N. M. Ramini De Rissone, L. A. De Veida, and E. S. Surian, 301-S (Nov) Crack Propagation Behavior of Stainless Steel Welds, The Influence of Microstructure on Fatigue — C. S. Kusko, J. N. DuPont, and A. R. Marder, 6-S (Jan) Crack Propagation Behavior of Stainles s Steel Welds, Influence of Stress Ratio on Fatigue — C. S. Kusko, J. N. DuPont, and A. R. Marder, 59-S (Feb) Cracking in Full-Penetration Al-Cu Welds, Liquation — C. Huang and S. Kou, 50-S (Feb) Cracking in Full-Penetration Al-Mg-Si Welds, Liquation — C. Huang and S. Kou, 111-S (Apr) Cracking in Nickel-Based Weld Meals — Part III, An Investigation of Ductility-Dip — M. G. Collins, A. J. Ramirez, and J. C. Lippold, 39-S (Feb) Cracking Susceptibility, Grain Boundary Character in Alloy WELDING JOURNAL

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690 and Ductility-Dip — V. R. Dave, M. J. Cola, M. Kumar, A. J. Schwartz, and G. N. A. Hussen, 1-S (Jan) Deformation and Fracture of Weld-Bonded Joints, CohesiveZone Modeling of the — M. N. Cavalli, M. D. Thouless, and Q. D. Yang, 133-S (Apr) Deformation of a Completely Penetrated GTA Weld, Numerical Simulation of Transient 3-D Surface — C. S. Wu, P. C. Zhao, and Y. M. Zhang, 330-S (Dec) Direct Observations of Ausentite, Bainite, and Martensite Formation during Arc Welding of 1045 Steel Using TimeResolved X-ray Diffraction — J. W. Elmer, T. A. Palmer, S. S. Babu, W. Zhang, and T. DebRoy, 244-S (Sept) Distortion Analysis for Fillet Welded Thin-Plate T-joints, Plasticity-Based — G. H. Jung and C. L. Tsai, 177-S (June) Distortion Control Plans on Angular Distortion in Fillet Welded T-Joints — G. H. Jung and C. L. Tsai, 213-S (July) Ductility-Dip Cracking in Nickel-Based Weld Metals — Part III, An Investigation of — M. G. Col lins, A. J. Ramirez, and J. C. Lippold, 39-S (Feb) Ellipsodial Heat Source in Finite Thick Plate, Analytical Approximate Solution for Double — N. T. Nguyen, Y. -W. Mai, S. Simpson, and A. Ohta, 82-S (March) Failure Modes and Static Strength of Aluminum Resistance Spot Welds, Effects of Fusion Zone Size on — X. Sun, E. V. Stephens, R. W. Davies, M. A. Khaleel, and D. J. Spinella, 308-S (Nov) Filler Metals, The Kinetics of Nitrogen Absorption by ArcMelted Fe-C-Mn-Type Filler Metals — A. Gruszczyk, 94-S (March) Fillet Mass and Topology of Aluminum Brazed Joints, Prediction of the — D. P. Sekulic, F. Gao, H. Zhao, B. Zellmer, and Y. Y. Qian, 102-S (March) Fillet Welded Thin-Plate T-joints, Plasticity-Based Distortion Analysis for — G. H. Jung and C. L. Tsai, 177-S (June) Fillet Welded T-Joints, Fundamental Studies on the Effect of Distortion Control Plans on Angular Distortion in — G. H. Jung and C. L. Tsai, 213-S (July) Finite Element Analyses of Nugget Growth, Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material — X. Sun and M. A. Khaleel, 197-S (July) Flux Cored Arc Weld Metal Deposits, The Effect of Welding Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 — H. G. Svoboda, N. M. Ramini De Rissone, L. A. De Veida, and E. S. Surian, 301-S (Nov) Fracture of Weld-Bonded Joints, Cohesive-Zone Modeling of the Deformation and — M. N. Cavalli, M. D. Thouless, and Q. D. Yang, 133-S (April) Friction Welded Aluminum Alloy Subjected to an External Electrostatic Field, Metallurgical Characterization of a — L. Fu and S. G. Du, 232-S (Aug) Full-Penetration Al-Mg-Si-Welds, Liquation Cracking in — C. Huang and S. Kou, 111-S (April) Fusion Zone Size on Failure Modes and Static Strength of Aluminum Resistance Spot Welds, Effects of — X. Sun, E. V. Stephens, R. W. Davies, M. A. Khaleel, and D. J. Spinella, 308-S (Nov) Gases in GTA Welding of a Wrought AZ80 Magnesium Alloy, An Investigation on the Effects of — M. Marya, G. R. Edwards, and S. Liu, 203-S (July) GMA Weld Pool with Free Surface, Three Dimensional Simulation of Transient — Z. Cao, Z. Yang, and X. L. Chen, 169-S (June) GTA Welding of a Wrought AZ80 Magnesium Alloy, An 80

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Investigation on the Effects of Gases in — M. Marya, G. R. Edwards, and S. Liu, 203-S (July) GTA Weld, Numerical Simulation of Transient 3-D Surface Deformation of a Completely Penetrated — C. S. Wu, P. C. Zhao, and Y. M. Zhang, 330-S (Dec) HAZ of New 13% Cr Martensitic Stainless Steels, Microstructure-Property Relationships in — O. M. Askelsen, G. Rorvik, P. E. Kvaale, and C. Van Der Eijk, 160S (May) Heat Source in Finite Thick Plate, Analytical Approximate Solution for Double Ellipsodial — N. T. Nguyen, Y. -W. Mai, S. Simpson, and A. Ohta, 82-S (March) High-Frequency Electric Resistance Welding, Penetrator Formation Mechanisms during — J. -H. Choi, Y. S. Chang, C. -M. Kim, J.-S. Oh, and Y. -S. Kim, 27-S (Jan) Honeycomb Structures — A Statistical, Activated Diffusion Brazing Technology for Manufacture of Titanium — X. Huang and N. L. Richards, 73-S (March) HSLA Steel Welds, Yttrium Hydrogen Trapping to Manage Hydrogen in — C. A. Lensing, Y. D. Park, I. S. Maroeff, and D. L. Olson, 254-S (Sept) Hybrid Welding Parameters on Bead Geometry, The Influence of Various — M. El Rayes, C. Walz, and G. Sepold, 147-S (May) Hydrogen in HSLA Steel Welds, Yttrium Hydrogen Trapping to Manage — C. A. Lensing, Y. D. Park, I. S. Maroeff, and D. L. Olson, 254-S (Sept) Kinetics of Nitrogen Absorption by Arc-Melted Fe-C-Mn-Type Filler Metals, The — A. Gruszczyk, 94-S (March) ‘Kissing Bond’ Phenomena in Solid-State Welds of Aluminum Alloys — A. Oosterkamp, L. Djapic Oosterkamp, and A. Nordeide, 225-S (Aug) Lance, Flame-Focusing Modification of a Wire-Core Thermal — H. Wang, P. Pranda, and V. Hlavacek, 283-S (Oct) Laser Beam Welding of Clad Steel Plate, Single-Pass — S. Missori, F. Murdolo, and A. Sili, 65-S (Feb) Lasers, Development and Evaluation of an In-Situ Beam Measurement for Spot Welding — P. W. Fuerschbach, J. T. Norris, R.C. Dykhuizen, and A. R. Mahoney, 154-S (May) Laser Roll Welding, Joining of Aluminum Alloy 5052 and Low-Carbon Steel by — M. J. Rathod and M. Kutsuna, 16S (Jan) Low-Carbon Steel by Laser Roll Welding, Joining of Aluminum Alloy 5052 and — M. J. Rathod and M. Kutsuna, 16-S (Jan) Magnesium Alloy, An Investigation on the Effects of Gases in GTA Welding of Wrought AZ80 — M. Marya, G. R. Edwards, and S. Liu, 203-S (July) Martensitic Stainless Steels, Microstructure-Property Relationships in HAZ of New 13% Cr — O. M. Askelsen, G. Rorvik, P. E. Kvaale, and C. Van Der Eijk, 160-S (May) Mechanisms during High-Frequency Electric Resistance Welding, Penetrator Formation — J. -H. Choi, Y. S. Chang, C. -M. Kim, J. -S. Oh, and Y. -S. Kim, 27-S (Jan) Metallurgical Characterization of a Friction Welded Aluminum Alloy Subjected to an External Electrostatic Field — L. Fu and S. G. Du, 232-S (Aug) Metallurgy of Gd-Enriched Austenitic Alloys for Spent Nuclear Fuel Applicatons — Part I: Stainless Steel Alloys, Physical and Welding — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, 289-S (Nov) Metallurgy of Gd-enriched Austenitic Alloys for Spent

Nuclear Fuel Applications — Part II: Nickel-based Alloys, Physical and Welding — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, 319-S (Dec) Microstructure and Property Calculations, Reliability of Weld — H. K. D. H. Bhadeshia, 237-S (Sept) Modeling of the Deformation and Fracture of Weld-Bonded Joints, Cohesive-Zone — M. N. Cavalli , M. D. Thouless, and Q.D. Yang, 133-S (Apr) Modeling of Ultrasonic Welding, Mechanical — C. Doumanidis and Y. Gao, 140-S (Apr) Monitoring in Short-Circuit GMAW, Signature Analysis for Quality — Y. X. Chu, S. J. Hu, W. K. Hou, P. C. Wang, and S. P. Marin, 336-S (Dec) Microstructure on Fatigue Crack Propagation Behavior of Stainless Steel Welds, The Influence of — C. S. Kusko, J. N. DuPont, and A. R. Marder, 6-S (Jan) Nickel-Based Weld Metals — Part III, An Investigation of Ductility-Dip Cracking in — M. G. Collins, A. J. Ramirez, and J. C Lippold, 39-S (Feb) Nickel-based Alloys, Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, XX (Dec) Nitrogen Absorption by Arc-Melted Fe-C-Mn-Type Filler Metals, The Kinetics of — A. Gruszczyk, 94-S (Mar) Nuclear Fuel Applicatons — Part I: Stainless Steel Alloys, Physical and Welding Metallurgy of Gd-enriched Austenitic Alloys for Spent — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, 289-S (Nov) Nuclear Fuel Applications — Part II: Nickel-based Alloys, Physical and Welding Metallurgy of Gd-enriched Austenitic Alloys for Spent — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, XX (Dec) Nugget Growth, Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material — Part II: Finite Element Analyses of Nugget Growth — X. Sun and M. A. Khaleel, 197-S (July) Penetrated GTA Weld, Numerical Simulation of Transient 3-D Surface Deformation of a Completely — C. S. Wu, P. C. Zhao, and Y. M. Zhang, 330-S (Dec) Penetration Al-Mg-Si Welds, Liquation Cracking in Full — C. Huang and S. Kou, 111-S (Apr) Penetration Al-Cu Welds, Liquation Cracking in Full — C. Huang and S. Kou, 50-S (Feb) Plate, Analytical Approximate Solution for Double Ellipsodial Heat Source in Finite Thick— N. T. Nguyen, Y. -W. Mai, S. Simpson, and A. Ohta, 82-S (March) Plate, Single-Pass Laser Beam Welding of Clad Steel — S. Missori, F. Murdolo, and A. Sili, 65-S (Feb) Pool with Free Surface, Three- Dimensional Simulation of Transient GMA Weld — Z. Cao, Z. Yang, and X. L. Chen, 169-S (June) Prediction in Resistance Spot Welding, Expulsion — J. Senkara, H. Zhang, and S. J. Hu, 123-S (Apr) Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 Flux Cored Arc Weld Metal Deposits, The Effect of Welding — H. G. Svoboda, N. M. Ramini De Rissone, L. A. De Veida, and E. S. Surian, 301-S (Nov) Reliability of Weld Microstructure and Property Calculations — H. K. D. H. Bhadeshia, 237-S (Sept) Resistance Welding, Penetrator Formation Mechanisms during High-Frequency Electric — J. -H. Choi, Y. S. Chang, C. -M. Kim, J. -S. Oh, and Y. -S. Kim, 27-S (Jan)

Shear Brazed Joints — Part 1, Flaw Tolerance in Lap — Y. Flom and L. Wang, 32-S (Jan) Shielded Metal Arc Weld Metal Composition for Charpy Toughness, Optimization of — M. Murugananth, S. S. Babu, and S. A. David, 267-S (Oct) Short-Circuit GMAW, Signature Analysis for Quality Monitoring in — Y. X. Chu, S. J. Hu, W. K. Hou, P. C. Wang, and S. P. Marin, XX (Dec) Simulation of Tranient GMA Weld Pool with Free Surface, Three Dimensional — Z. Cao. Z. Yang, and X.L. Chen, 169S (Jun) Simulation of Transient 3-D Surface Deformation of a Completely Penetrated GTA Weld, Numerical — C. S. Wu, P. C. Zhao, and Y. M. Zhang, 330-S (Dec) Solid-State Weld of Aluminum Alloys, ‘Kissing Bond’ Phenomena in — A. Oosterkamp, L. Djapic Oosterkamp, and A. Nordeide, 225-S (Aug) Spot Welds, Effects of Fusion Zone Size on Failure Modes and Static Strenght of Aluminum Resistance — X. Sun, E. V. Stephens, R. W. Davies, M. A. Khaleel, and D. J. Spinella, 308-S (Nov) Spot Welding of Aluminum Alloy to Steel with Transition Material — From Process to Performance — Part I: Experimental Study — X. Sun, E.V. Stephens, M.A. Khaleel, H. Sao, and M. Kimchi, 188-S (June) Spot Welding, Expulsion Prediction in Resistance — J. Senakara, H. Zhang, and S. J. Hu, 123-S (Apr) Spot Welding Lasers, Development and Evaluation of an InSitu Beam Measurement for — P. W. Fuerschbach, J. T. Norris, R.C. Dykhuizen, and A. R. Mahoney, 154-S (May) Spot Welding of Aluminum Alloy to Steel with Transition Material — Part II: Finite Element Analyses of Nugget Growth, Resistance — X. Sun and M. A. Khaleel, 197-S (July) Stainless Steel Alloys, Physical and Welding Metallurgy of GdEnriched Austenitic Alloys for Spent Nuclear Fuel Applicatons — Part I — J. N. DuPont, C. V. Robino, J. R. Michael, R. E. Mizia, and D. B. Williams, 289-S (Nov) Stainless Steels, Microstructure-Property Relationships in HAZ of Ne 13% Cr Martensitic — O. M. Akelesen, G. Rorvik, P .E. Kvaale, and C. Van Der Eijk, 160-S (May) Stainless Steel Welds, The Influence of Microstructure on Fatigue Crack Propagation Behavior of — C. S. Kusko, J. N. Dupont, and A. R. Marder, 6-S (Jan) Stainless Steel Welds, Influence of Stress Ratio on Fatigue Crack Propagation Behavior of — C. S. Kusko, J. N. Dupont, and A. R. Marder, 59-S (Feb) Statistical Study, Activated Diffusion Brazing Technology for Manufacture of Titanium Honeycomb Structures — A — X. Huang and N. L Richards, 73-S (March) Steel Using Time-Resolved X-ray Diffraction, Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 — J. W. Elmer, T. A. Palmer, S. S. Babu, W. Zhang, and T. DebRoy, 244-S (Sept) Stir Welding of Aluminum Alloy to Steel, Friction — K. Kimapong and T. Wantanabe, 277-S (Oct) Stress Ratio on Fatigue Crack Propagation Behavior of Stainless Steel Welds, Influence of — C. S. Kusko, J. N. DuPont, and A. R. Marder, 59-S (Feb) Susceptibility, Grain Boundary Character in Alloy 690 and Ductility-Dip Cracking — V. R. Dave, M. J. Cola, M. Kumar, A. J. Schwartz, and G. N. A. Hussen, 1-S (Jan) Titanium Honeycomb Structures — A Statistical Study,

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Activated Diffusion Brazing Technology for Manufacture of — X. Huang and N. L. Richards, 73-S (March) T-joints, Plasticity-Based Distortion Analysis for Fillet Welded Thin-Plate T-joints — G.H. Jung and C. L. Tsai, 177-S (June) T-Joints, Fundamental Studies on the Effect of Distortion Control Plans on Angular Distortion in Fillet Welded — G. H. Jung and C. L. Tsai, 213-S (July) Tolerance in Lap Shear Brazed Joints — Part 1, Flaw — Y. Flom and L. Wang, 32-S (Jan) Topology of Aluminum Brazed Joints, Prediction of the Fillet Mass and — D. P. Sekulic, F. Gao, H. Zhao, B. Zell mer, and Y. Y. Qian, 102-S (March) Transition Material — From Process to Performance — Part I: Experimental Study, Resistance Spot Welding of Aluminum Alloy to Steel with — X. Sun, E. V. Stephens, M. A. Khaleel, H. Sao, and M. Kimchi, 188-S (June)

Ultrasonic Welding, Mechanical Modeling of — C. Doumanidis and Y. Gao, 140-S (Apr) Weld-Bonded Joints, Cohesive-Zone Modeling of the Deformation and Fracture of — M. N. Cavalli, M. D. Thouless, and Q.D. Yang, 133-S (Apr) Weld Metal Composition for Charpy Toughness, Optimization of Shielded Metal Arc — M. Murugananth, S. S. Babu, and S. A. David, 267-S (Oct) Wire-Core Thermal Lance, Flame-Focusing Modification of a — H. Wang, P. Pranda, and V. Hlavacek, 283-S (Oct) X-ray Diffraction, Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 Steel Using Time-Resolved — J. W. Elmer, T. A. Palmer, S. S. Babu, W. Zhang, and T. D EBroy, 244-S (Sept) Yttrium Hydrogen Trapping to Manage Hydrogen in HSLA Steel Welds — C. A. Lensing, Y. D. Park, I. S. Maroeff, and D. L. Olson, 254-S (Sept)

AUTHORS FOR RESEARCH SUPPLEMENTS Akelesen, O. M., Rorvik, G., Kvaale, P .E., and Van Der Eijk, C. — Microstructure-Property Relationships in HAZ of New 13% Cr Martensitic Stainless Steels, 160-S (May) Babu, S. S., Zhang, W., DebRoy, T. J., Elmer, W., and Palmer, T. A. — Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 Steel Using Time-Resolved X-ray Diffraction, 244-S (Sept) Babu, S. S., David, S. A. and Murugananth, M. — Opti mization of Shielded Metal Arc Weld Metal Composition for Charpy Toughness, 267-S (Oct) Bhadeshia, H. K. D. H. — Reliability of Weld Microstructure and Property Calculations, 237-S (Sept) Blank, M. — How Do We Prevent Hot Work Fires?, 26 (Sept) Cao, Z., Yang, Z., and Chen, X. L. — Three- Dimensional Simulation of Transient GMA Weld Pool with Free Sur face, 169-S (June) Cavalli, M. N., Thouless, M. D., and Yang, Q. D. — CohesiveZone Modeling of the Deformation and Fracture of WeldBonded Joints, 133-S (Apr) Chen, X. L., Cao, Z., and Yang, Z. — Three-Dimensional Simulation of Transient GMA Weld Pool with Free Sur face, 169-S (June) Cola, M. J., Kumar, M., Schwartz, A. J., Hussen, G. N. A., and Dave, V. R. — Grain Boundary Character in Alloy 690 and Ductility-Dip Cracking Susceptibility, 1-S (Jan) Collins, M. G., Ramirez, A. J., and Lippold, J. C. — An Investigation of Ductility-Dip Cracking in Nickel-Based Weld Metals — Part III, 39-S (Feb) Chang, Y. S., Kim, C. -M., Oh, J. -S., Kim,Y. -S., and Choi, J. H. — Penetrator Formation Mechanisms during HighFrequency Electric Resistance Welding, 27-S (Jan) Choi, J. -H., Chang, Y. S., Kim, C. -M., Oh, J. -S., and Kim, Y. -S. — Penetrator Formation Mechanisms during HighFrequency Electric Resistance Welding, 27-S (Jan) Chu, Y. X., Hu, S. J., Hou, W. K., Wang, P. C., and Marin, S. P.

82

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— Monitoring in Short-Circuit GMAW, Signature Analysis for Quality, XX (Dec) Davé, V. R., Cola, M. J., Kumar, M., Schwartz, A. J., and Hussen, G. N. A. — Grain Boundary Character in Alloy 690 and Ductility-Dip Cracking Susceptibility, 1-S (Jan) David, S. A., Murugananth, M., and Babu, S. S. — Optimization of Shielded Metal Arc Weld Metal Composition for Charpy Toughness, 267-S (Oct) Davies, R. W., Khaleel, M. A., Spinella, D. J., Sun, X. and Stephens, E. V. — Effects of Fusion Zone Size on Failure Modes and Static Strength of Aluminum Resistance Spot Welds, 308-S (Nov) De Veida, L. A., Surian, E. S., Svoboda, H. G., and Ramini De Rissone, N. M. — The Effect of Welding Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 Flux Cored Arc Weld Metal Deposits, 301-S (Nov) DebRoy, T., Elmer, J. W., Palmer, T. A., Babu, S. S., and Zhang, W. — Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 Steel Using Time-Resolved X-ray Diffraction, 244-S (Sept) Doumanidis, C. and Gao, Y. — Mechanical Modeling of Ultrasonic Welding, 140-S (Apr) Du, S. G. and Fu, L. — Metallurgical Characterization of a Friction Welded Aluminum Alloy Subjected to an External Electrostatic Field, 232-S (Aug) DuPont, J. N., Marder, A. R., and Kusko, C. S. — The Influence of Microstructure on Fatigue Crack Propagation Behavior of Stainless Steel Welds, 6-S (Jan) DuPont, J. N., Marder, A. R., and Kusko, C. S. — Influence of Stress Ratio on Fatigue Crack Propagation Behavior of Stainless Steel Welds, 59-S (Feb) DuPont, J. N., Robino, C. V., Michael, J. R., Mizia, R. E., and Williams, D. B. — Physical and Welding Metallurgy of GdEnriched Austenitic Alloys for Spent Nuclear Fuel

Applicatons — Part I: Stainless Steel Alloys, 289-S (Nov) DuPont, J. N., Robino, C. V., Michael, J. R., Mizia, R. E., and Williams, D. B. — Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: — Nickel-based Alloys, 319-S(Dec) Dykhuizen, R. C., Mahoney, A. R., Fuerschbach, P. W., and Norris, J. T — Development and Evaluation of an In-Situ Beam Measurement for Spot Welding Lasers, 154-S (May) Edwards, G. R., Liu, S. and Marya, M.— An Investigation on the Effects of Gases in GTA Welding of a Wrought AZ80 Magnesium Alloy, 203-S (July) Elmer, J. W., Palmer, T. A., Babu, S. S., Zhang, W., and Debroy, T. — Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 Steel Using Time-Resolved X-ray Diffraction, 244-S (Sept) Flom, Y. and Wang, L. — Flaw toletance in Lap Shear Brazed Joints — Part 1, 32-S (Jan) Fuerschbach, P. W., Norris, J. T., Dykhuizen, R. C., and Mahoney, A. R. — Development and Evaluation of an InSitu Beam Measurement for Spot Welding Lasers, 154-S (May) Fu, L. and Du, S. G. — Metallurgical Characterization of a Friction Welded Aluminum Alloy Subjected to an External Electrostatic Field, 232-S (Aug) Gao, Y. and Doumanidis, C. — Mechanical Modeling of Ultrasonic Welding, 140-S (Apr) Gao, F., Zhao, H., Zellmer, B., Qian, Y. Y., and Sekulic, D. P. — Predicton of the Filler Mass and Topology of Aluminum Brazed Joints, 102-S (March) Gruszczyk, A. — The Kinetics of Nitrogen Absorption by ArcMelted Fe-C-Mn-Type Filler Metals, 94-S (March) Hlavacek V., Wang, H. and Pranda, P. — Flame-Focusing Modification of a Wire-Core Thermal Lance, 283-S (Oct) Hou, W. K., Wang, P. C., Marin, S. P., Chu, Y. X., and Hu, S. J. — Signature Analysis for Quality Monitoring in ShortCircuit GMAW, 336-S (Dec) Huang, C. and Kou, S. — Liquation Cracking in FullPenetration Al-Cu Welds, 50-S (Feb) Huang, C. and Kou, S. — Liquation Cracking in FullPenetration Al-Mg-Si Welds, 111-S (Apr) Huang, X. and Richards, N. L. — Activated Diffusion Brazing Technology for Manufacture of Titanium Honeycomb Structures — A Statistical Study, 73-S (Mar) Hussen, N. A., Dave, V. R., Cola, M. J., Kumar, M., and Schwartz, A. J. — Grain Boundary Character in Alloy 690 and Ductility-Dip Cracking Susceptibility, 1-S (Jan) Hu, S. J., Senkara, J., and Zhang, H. — Expulsion Prediction in Resistance Spot Welding, 123-S (Apr) Hu, S. J., Hou, W. K., Wang, P. C., Marin, S. P., and Chu, Y. X. — Monitoring in Short-Circuit GMAW, Signature Analysis for Quality, XX (Dec) Jung, G. H. and Tsai, C. L. — Plasticity-Based Distortion Analysis for Fillet Welded Thin-Plate T-joints, 177-S (June) Jung, G. H. and Tsai, C. L. — Fundamental Studies on the Effect of Distortion Control Plans on Angular Distortion in Fillet Welded T-Joints, 213-S (July) Khaleel, M.A., Shao, H., Kimchi, M., Sun, X., and Stephens, V. E. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - From Process to Performance Part 1: Experimental Study, 188-S (June) Khaleel, M. A. and Sun, X. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material — Part II: Finite Element Analyses of Nugget Growth, 197-S (July) Khaleel, M. A., Spinella, D. J., Sun, X., Stephens, E. V., and

Davies, R. W.— Effects of Fusion Zone Size on Failure Modes and Static Strenght of Aluminum Resistance Spot Welds, 308-S (Nov) Kim, C. -M., Oh, J. -S., Kim, Y. -S., Choi, J. -H, and Chang, Y. S. — Penetrator Formation Mechanisms during High Frequency Electric Resistance Welding, 27-S (Jan) Kim, Y. -S., Choi, J. -H., Chang, Y. S., Kim, C. -M., and Oh, J.S. — Penetrator Formation Mechanisms during High Frequency Electric Resistance Welding, 27-S (Jan) Kimapong, K. and Watanabe, T. — Friction Stir Welding of Aluminum Alloy to Steel, 277-S (Oct) Kimchi, M., Sun, X., Stephens, E. V., Khaleel, M. A., Shao, H., and Kimchi, M. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - From Process to Performance - Part 1: Experimental Study, 188-S (June) Kou, S. and Huang, C. — Liquation Cracking in FullPenetration Al-Cu Welds, 50-S (Feb) Kou, S. and Huang, C. — Liquation Cracking in FullPenetration Al-Mg-Si Welds, 111-S (Apr) Kumar, M., Schwartz, A. J., Hus sen, G. N. A., Dave, V. R., and Cola, M. J. — Grain Boundary Character in Alloy 690 and Ductility-Dip Cracking Susceptibility, 1-S (Jan) Kusko, C. S., DuPont, J. N., and Marder, A. R. — The Influence of Microstructure on Fatigue Crack Propagation Behavior of Stainless Steel Welds, 6-S (Jan) Kusko, C. S., DuPont, J. N., and Marder, A. R. — Influence of Stress Ratio on Fatigue Crack Propagation Behavior of Stainless Steel Welds, 59-S (Feb) Kutsuna, M., and Rathod, M. J. — Joining of Aluminum Alloy 5052 and Low-Carbon Steel by Laser Roll Welding, 16-S (Jan) Lippold, J. C., Collins, M. G., and Ramirez, A. J. — An Investigation of Ductility-Dip Cracking in Nickel-Based Weld Metals — Part III, 39-S (Feb) Liu, S., Marya, M., and Edwards, G. R. — An Investigation on the Effects of Gases in GTA Welding of a Wrought AZ80 Magnesium Alloy, 203-S (July) Mai, Y. -W., Simpson, S., Ohta, A., and Nyugen, N. T. — Analytical Approxiamte Solution for Double Ellipsodial Heat Source in Finite Thick Plate, 82-S (March) Mahoney, A. R., Fuerschbach, P. W., Norris, J. T. and Dykhuizen, R. C. — Development and Evaluation of an InSitu Beam Measurement for Spot Welding Lasers, 154-S (May) Marder, A. R., Kusko, C. S., and DuPont, J. N. — The Influence of Microstructure on Fatigue Crack Propagation Behavior of Stainless Steel Welds, 6-S (Jan) Marder, A. R., Kusko, C. S., and DuPont, J. N. — Influence of Stress Ratio on Fatigue Crack Propagation Behavior of Stainless Steel Welds, 59-S (Feb) Marin, S. P., Chu, Y. X., Hu, S. J., Hou, W. K., and Wang, P. C. — Monitoring in Short-Circuit GMAW, Signature Analysis for Quality, XX (Dec) Marya, M., Edwards, G. R. and Liu, S. — An Investigation on the Effects of Gases in GTA Welding of a Wrought AZ80 Magnesium Alloy, 203-S (July) Michael, J. R., Mizia, R. E., Williams, D. B., DuPont, J. N., and Robino, C. V. — Physical and Welding Metallurgy of GdEnriched Austenitic Alloys for Spent Nuclear Fuel Applicatons — Part I: Stainless Steel Alloys, 289-S (Nov) Michael, J. R., Williams, D. B., DuPont, J. N., Robino, C. V., and Mizia, R. E.— Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: — Nickel-based Alloys, 319-S (Dec) WELDING JOURNAL

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Missori, S., Murdolo, F., and Sili, A. — Single Pass L aser Beam Welding of Clad Steel Plate, 65-S (Feb) Mizia, R. E., Williams, D. B., DuPont, J. N., Robino, C. V., and Michael, J. R. — Physical and Welding Metallurgy of GdEnriched Austenitic Alloys for Spent Nuclear Fuel Applicatons — Part I: Stainless Steel Alloys, 289-S (Nov) Mizia, R. E., Michael, J. R., Williams, D. B., DuPont, J. N., and Robino, C. V. — Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: — Nickel-based Alloys, XX (Dec) Murdolo, F., Sili, A., and Missori, S. — Single-Pass Laser Beam Welding of Clad Steel Plate, 65-S (Feb) Murugananth, M., Babu, S. S., and David, S. A. — Optimization of Shielded Metal Arc Weld Metal Composition for Charpy Toughness, 267-S (Oct) Nordeide, A., Oosterkamp, A., and Oosterkamp, L. Djapic — ‘Kissing Bond’ Phenomena in Solid-State Weld of Aluminum Alloys, 225-S (Aug) Norris, J. T., Dykhuizen, R. C., Mahoney, A. R., and Fuerschbach, P. W. — Development and Evaluation of an InSitu Beam Measurement for Spot Welding Lasers, 154-S (May) Nyugen, N. T., Mai, Y. -W., Simpson, S., and Ohta, A. — Analytical Approxiamte Solution for Double Ellipsodial Heat Source in Finite Thick Plate, 82-S (March) Oh, J. -S., Kim, Y. -S., Choi, J. -H., Chang, Y. S., and Kim, C. M. — Penetrator Formation Mechanisms during HighFrequency Electric Resistance Welding, 27-S (Jan) Ohta, A., Nyugen, N. T., Mai, Y. -W., and Simpson, S. — Analytical Approxiamte Solution for Double Ellipsodial Heat Source in Finite Thick Plate, 82-S (March) Oosterkamp, A., Oosterkamp, L. Djapic, and Nordeide, A. — ‘Kissing Bond’ Phenomena in Solid-State Weld of Aluminum Alloys, 225-S (Aug) Oosterkamp, L. Djapic, Oosterkamp, A., and Nordeide, A. — ‘Kissing Bond’ Phenomena in Solid-State Weld of Aluminum Alloys,225-S (Aug) Pranda, P., Hlavacek, V., and Wang, H. — Flame-Focusing Modification of a Wire-Core Thermal Lance, 283-S (Oct) Palmer, T. A., Babu, S. S., Zhang, W., DebRoy, T., and Elmer, J. W. — Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 Steel Using Time-Resolved X-ray Diffraction, 244-S (Sept) Qian, Y. Y., Sekulic, D. P., Gao, F., Zhao, H., and Zellmer, B. — Prediction of the Fillet Mass and Topology of Aluminum Brazed Joints, 102-S (March) Ramini De Rissone, N. M., De Veida, L. A., Surian, E. S., and Svoboda, H. G. — The Effect of Welding Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 Flux Cored Arc Weld Metal Deposits, 301-S (Nov) Ramirez, A. J., Lippold, J. C., and Collins, M. G. — An Investigation of Ductility-Dip Cracking in Nickel-Based Weld Metals — Part III, 39-S (Feb) Rathod, M. J. and Kutsuna, M. — Joining of Aluminum Alloy 5052 and Low-Carbon Steel by Laser Roll Welding, 16-S (Jan) Rayes, M. El, Walz, C., and Sepold, G. — The Influence of Various Hybrid Welding Parameters on Bead Geomety, 147-S (May) Richards, N. L. and Huang, X. — Activated Diffusion Brazing Technology for Manufacture of Titanium Honeycomb Structures — A Statistical Study, 73-S (March) Robino, C. V., Michael, J. R., Mizia, R. E., Williams, D. B., and DuPont, J. N. — Physical and Welding Metallurgy of Gd-

Enriched Austenitic Alloys for Spent Nuclear Fuel Applicatons — Part I Stainless Steel Alloys, 289-S (Nov) Robino, C. V., Mizia, R. E., Michael, J. R., Williams, D. B., and DuPont, J. N. — Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: — Nickel-based Alloys, 319-S (Dec) Rorvik, G., Kvaale, P. E., Van Der Eijk, C., and Akelesen, O.M. — Microstructure-Property Relationships in HAZ of New 13% Cr Martensitic Stainless Steels, 160-S (May) Shao, H. E., Kimchi, M., Sun, X., Stephens, V., and Khaleel, M. A. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material — From Process to Performance — Part I: Experimental Study, 188-S (June) Schwartz, A. J., Hussen, G. N. A., Davé, V. R., Cola, M. J., and Kumar, M. — Grain Boundary Character in Alloy 690 and Ductility-Dip Cracking Susceptibility, 1-S (Jan) Sekulic, D. P., Gao, F., Zhao, H., Zellmer, B., and Qian, Y. Y. — Prediction of the Fillet Mass and Topology of Aluminum Brazed Joints, 102-S (March) Senkara, J., Zhang, H., and Hu, S. J. — Expulsion Prediction in Resistance Spot Welding, 123-S (Apr) Sepold, G., El Rayes, M., and Walz, C. — The Influence of Various Hybrid Welding Parameters on Bead Geometry, 147-S (May) Sili, A., Missori, S., and Murdolo, F. — Single-Pass Laser Beam Welding of Clad Steel Plate, 65-S (Feb) Simpson, S., Ohta, A., Nyugen, N. T., and Mai, Y. -W. — Analytical Approxiamte Solution for Double Ellipsodial Heat Source in Finite Thick Plate, 82-S (March) Spinella, D. J., Sun, X., Stephens, E. V., Davies, R.W., and Khaleel, M. A. — Effects of Fusion Zone Size on Failure Modes and Static Strenght of Aluminum Resistance Spot Welds, 308-S (Nov) Stephens, E. V., Khaleel, M.A., Shao, H., Kimchi, M., and Sun, X. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - From Process to Performance Part 1: Experimental Study, 188-S (June) Stephens, E. V., Davies, R. W., Khaleel, M. A., Spinella, D. J., and Sun, X. — Effects of Fusion Zone Size on Failure Modes and Static Strength of Aluminum Resistance Spot Welds, 308-S (Nov) Sun, X., Stephens, E. V., Khaleel, M. A., Shao, H., and Kimchi, M. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material - From Process to PerformancePart I: Experimental Study, 188-S (June) Sun, X. and Khaleel, M. A. — Resistance Spot Welding of Aluminum Alloy to Steel with Transition Material — Part II: Finite Element Analyses of Nugget Growth, 197-S, (July) Sun, X., Stephens, E. V., Davies, R. W., Khaleel, M. A., and Spinella, D. J. — Effects of Fusion Zone Size on Failure Modes and Static Strength of Aluminum Resistance Spot Welds, 308-S (Nov) Surian, E. S., Svoboda, H. G., Ramini De Rissone, N. M., and De Veida, L. A. — The Effect of Welding Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 Flux Cored Arc Weld Metal Deposits, 301-S (Nov) Svoboda, H. G., Ramini De Rissone, N. M., De Veida, L. A., and Surian, E. S. — The Effect of Welding Procedure on ANSI/AWS A5.29-98 E81T1-Ni1 Flux Cored Arc Weld Metal Deposits, 301-S (Nov) Thouless, M. D., Yang, Q., and Cavalli, M. N. — CohesiveZone Modeling of the Deformation and Fracture of WeldBonded Joints, 133-S (Apr) Tsai, C. L. and Jung, G. H. — Plasticity-Based Distortion WELDING JOURNAL

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Analysis for Fillet Welded Thin-Plate T-joints, 177-S, (June) Tsai, C. L. and Jung, G. H. — Fundamental Studies on the Effect of Distortion Control Plans on Angular Distortion in Fillet Welded T-Joints, 213-S (July) Van Der Eijk, C., Akelesen, O. M., Rorvik, G., and Kvaale, P. E. — Microstructure-Property Relationships in HAZ of New 13% Cr Martensitic Stainless Steels, 160-S (May) Walz, C., Sepold, G., and El Rayes, M. — The Influence of Various Hybrid Welding Parameters on Bead Geometry, 147-S (May) Wang, L. and Flom, Y.— Flaw Toletance in Lap Shear Brazed Joints — Part 1, 32-S (Jan) Wang, H., Pranda, P., and Hlavacek, V. — Flame-Focusing Modification of a Wire-Core Thermal Lance, 283-S (Oct) Wang, P. C., Marin, S. P., Chu, Y. X., Hu, S. J., and Hou,W. K. — Monitoring in Short-Circuit GMAW, Signature Analysis for Quality, XX (Dec) Watanabe, T. and Kimapong, K. — Friction Stir Welding of Aluminum Alloy to Steel, 277-S (Oct) Williams, D. B., DuPont, J. N., Robino, C. V., Michael, J. R., and Mizia, R. E. — Physical and Welding Metallurgy of GdEnriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part I: Stainless Steel Alloys, 289-S (Nov) Williams, D. B., DuPont, J. N., Robino, C. V., Mizia, R. E., and Michael, J. R. — Physical and Welding Metallurgy of Gdenriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: — Nickel-based Alloys, 319-S (Dec)

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Wu, C. S., Zhao, P. C., and Zhang, Y. M. — Numerical Simulation of Transient 3-D Surface Deformation of a Completely Penetrated GTA Weld, 330-S (Dec) Yang, Q. D., Cavalli, M. N., and Thouless, M. D. — CohesiveZone Modeling of the Deformation and Fracture of WeldBonded Joints, 133-S (Apr) Yang, Z., Chen, X. L., and Cao, Z. — Three- Dimensional Simulation of Transient GMA Weld Pool with Free Sur face, 169-S (Jun) Zellmer, B., Qian, Y. Y., Sekulic, D. P., Gao, F., and Zhao, H. — Prediction of the Fillet Mass and Topology of Aluminum Brazed Joints, 102-S (March) Zhang, H., Senkara, J., and Hu, S. J. — Expulsion Prediction in Resistance Spot Welding, 123-S (Apr) Zhang, W., DebRoy, T., Elmer, J. W., Palmer, T. A., and Babu, S. S. — Direct Observations of Ausentite, Bainite, and Martensite Formation During Arc Welding of 1045 Steel Using Time-Resolved X-ray Diffraction, 244-S (Sept) Zhang, Y. M., Wu, C. S., and Zhao, P. C. — Numerical Simulation of Transient 3-D Surface Deformation of a Completely Penetrated GTA Weld, 330-S (Dec) Zhao, H., Zellmer, B., Qian, Y. Y., Sekulic, D. P., and Gao, F. — Prediction of the Fillet Mass and Topology of Aluminum Brazed Joints, 102-S (March) Zhao, P. C., Zhang, Y. M., and Wu, C. S. — Numerical Simulation of Transient 3-D Surface Deformation of a Completely Penetrated GTA Weld, 330-S (Dec)

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WANTED Independent Sales Reps to demonstrate welding alloys to end users. -Consumables Market -Repeat Customers -Complements Industrial Rep’s present line(s) of products. Very unique opportunity. Contact Christopher Biggar Vulcan Systems, Inc. (800) 642-9885 WELDING ENGR/QC MGR Komline-Sanderson an Int’l leader in design, fabrication and installation of dryers, filters, wastewater treatment filtration equipment, seeks a hands on, degreed engineer to develop weld procedures/techniques. Sound knowledge of metallurgy and welding methods to minimize fatigue failure in rotating shafts a must. Responsible for implementing and maintaining quality system to ASME Code including weld procedures/qualifications; Supervise in-house & vendor Inspection; qualify vendors to provide manufacturing support for Code and non-Code contracts. Minimum 15 years experience a MUST. Domestic/Int’l travel required. NDT Level III a plus/PE helpful. [email protected] EOE-M/F

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ADVERTISER INDEX Abicor Binzel................................................www.binzel-abicor.com ......................IBC

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92

DECEMBER 2004

WELDING RESEARCH SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 2004

Sponsored by the American Welding Society and the Welding Research Council

Physical and Welding Metallurgy of Gd-enriched Austenitic Alloys for Spent Nuclear Fuel Applications — Part II: Nickel-based Alloys Tests proved Gd-enriched Ni-based alloys are excellent candidates for use in storing spent nuclear fuels J. N. DUPONT, C. V. ROBINO, J. R. MICHAEL, R. E. MIZIA, AND D. B. WILLIAMS

ABSTRACT. The physical and welding metallurgy of gadolinium- (Gd-) enriched Ni-based alloys has been examined using a combination of differential thermal analysis, hot ductility testing, Varestraint testing, and various microstructural characterization techniques. Three different matrix compositions were chosen that were similar to commercial Ni-Cr-Mo base alloys (UNS N06455, N06022, and N06059). A ternary Ni-Cr-Gd alloy was also examined. The Gd level of each alloy was ~2 wt-%. All the alloys initiated solidification by formation of primary austenite and terminated solidification by a Liquid g + Ni5Gd eutectictype reaction at ~1270°C. The solidification temperature ranges of the alloys varied from ~100° to 130°C (depending on alloy composition). This is a substantial reduction compared to the solidification temperature range of Gd-enriched stainless steels (360° to 400°C) that terminate solidification by a peritectic reaction at ~1060°C. The higher-temperature eutectic reaction that occurs in the Ni-based alloys is accompanied by significant improvements in hot ductility and solidification cracking resistance. The results of this research demonstrate that Gd-enriched Ni-based alloys are excellent candidate materials for nuclear criticality control in spent nuclear fuel storage applications that require production →

J. N. DU PONT is Associate Professor and D. B. WILLIAMS is Vice Provost for Research and a Professor, Department of Materials Science & En gineering, Lehigh University, Bethlehem, Pa. C. V. ROBINO is with the Technical Staff, Joinin g and Coating Department, and J. R. MICHAEL is with the Technical Staff, Materials Characterization Dept .,Sa ndia Nati onal Lab orat orie s, Albu querque, N.Mex. R. E. MIZIA is Engineering Fel low, Energy and Engineering Technology, Idaho National Engineering and Env ironmental Labo ratory, Idaho Falls, Idaho.

and fabrication of large amounts of material through conventional ingot metallurgy and fusion welding techniques.

Introduction Part 1 of this research article (Ref. 1) summarized results on development of Gd-enriched stainless steel alloys for nuclear criticality control in spent nuclear fuel storage applications. In that work, it was shown that Gd additions to a 316Ltype matrix leads to the formation of an intermetallic (Fe,Ni,Cr) 3Gd phase that produces a very large solidification temperature range (360° to 400°C, depending on Gd concentration) and se verely limits the hot ductility and weldability of these alloys to a point where commercial production is not practical. As shown by the binary Fe-Gd phase diagram in Fig. 1A (Ref. 2), Fe-Gd alloys with low Gd concentrations exhibit a primary delta solidification mode that is followed by a brief region of austenite solidification. Under nonequilibrium solidification conditions in which solute diffusion in the solid is negligible, austenite formation is followed by a series of cascading peritectic reactions before solidification terminates at 845°C by a terminal KEYWORDS

Gadolinium-Enriched Nickel-Based Alloys Austenitic Alloys Differential Thermal Analysis Hot Ductility Testing Varestraint Testing Solidification Cracking Eutectic Reaction

eutectic reaction involving the Fe 2Gd intermetallic. Thus, the solidification temperature range of simple Fe-Gd alloys is also very large under nonequilibrium solidification conditions. In multicomponent Gd-enriched stainless steels, solidification starts with primary delta and terminates by a peritectic reaction involving the (Fe,Ni,Cr)3Gd phase at ~1060°C, which also produces a very large solidification temperature range. Thus, although there are significant differences between simple Fe-Gd alloys and multicomponent Fe-Ni-Cr-Mo-Gd stainless steels, the alloys are similar in that a low-temperature peritectic reaction is responsible for producing a very large solidification temperature range in each system. As mentioned previously, this severely limits the hot ductility and weldability of these alloys. Comparison of the Ni-Gd (Fig. 1B) and Fe-Gd systems reveals some significant differences in the solidification behavior of alloys with low Gd concentrations. In particular, Ni-Gd alloys with less than about 13 wt-% Gd exhibit a simple two step solidification sequence consisting of primary austenite (Ni) formation followed by a terminal eutectic reaction at 1275°C involving the Ni17Gd2 intermetallic. The presence of the high-temperature eutectic reaction in the Ni-Gd system significantly decreases the solidification temperature range compared to Fe-Gd alloys. Thus, in general, it appears that the solidification behavior of the multicomponent Gd-enriched stainless steels mimics the Fe-Gd system more closely than the NiGd system. From a technical standpoint, it is highly desirable to identify alloying strategies that could be utilized to modify the solidification behavior of the commercial-type Gd-enriched alloys so that solidification more closely follows that of the WELDING JOURNAL

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WELDING RESEARCH Fe-Gd

A

Ni-Gd

B

Fig. 1 — Binary phase diagrams. A — Fe-Gd; B — Ni-Gd.

Table 1 — Chemical Compositions of Small- Scale Alloys Used for Prelimi nary Experiments (All values in wt-%)

Alloy E-1 E-2

Gd 6.0 2.0

Fe Bal 2.8

Ni 19.8 Bal

Cr 13.9 20.9

Mo 2.3 12.5

Mn 1.4 <0.5

Si 0.13 <0.08

Table 2 — Compositions (wt-%) for the Trial Ni-based Alloys(a)

Element Gd Mo Cr Fe W Co C Si Mn V P S Ti Al Cu N O Ni

N06455-Gd 1.58 14.16 16.21 0.147 0.014 <0.10 0.011 0.033 0.104 0.007 <0.010 0.0018 0.004 0.042 0.004 0.0046 0.0129 bal

N06022-Gd 1.98 12.01 21.27 2.02 2.98 0.085 0.006 0.036 0.101 0.012 <0.010 0.0012 0.004 0.056 0.003 0.0068 0.0140 bal

N06059-Gd

Ni-Cr-Gd

1.82 15.02 22.64 0.163 0.125 0.008 0.010 0.040 0.103 0.009 <0.010 0.0019 0.005 0.303 0.030 0.0074 0.0209 bal

1.93 0.57 22.33 0.087 0.005 <0.10 0.009 0.053 0.098 0.009 <0.010 0.0019 0.003 0.055 0.055 0.0067 0.0191 bal

(a) Values shown are averages of three determinations at each of three laboratories. Fig. 2 — SEM photomicrograph and EB SP analysis of high-Ni stainless steel Alloy E-1 with Gd addition.

Ni-Gd system. In particular, it is of interest to develop alloying strategies that would lead to replacement of the lowtemperature peritectic reaction with a higher temperature terminal eutectic reaction. This could potentially produce a significant reduction in the solidification temperature range and concomitant improvements in weldability and hot ductil320 -S

DECEMBER 2004

ity. The most obvious approach to accomplish this modification would be to increase the Ni content of the matrix. Thus, the objective of this research is to investigate the use of Ni-based alloys for improving the hot ductility and weldability of Gd-enriched austenitic alloys for spent nuclear fuel applications.

Experimental Procedure Preliminary Alloy Experiments

The solidification responses of two small-scale (2.3 kg) alloys were first evaluated in the as-cast condition before larger scale heats were prepared. The composi-

WELDING RESEARCH

A

B

Fig. 3 — DTA traces for as-cast high-Ni stainless steel Alloy E-1 with Gd addition . A — Heating trace; B — cooli ng trace.

A

B

Fig. 4 — Light optical photomicrographs of high-Ni stainless steel Alloy E-1 wi th Gd addition after DTA analysis.

tions of the two experimental alloys are shown in Table 1. Alloy E-1 was based on a stainless steel type composition with high Ni, while Alloy E-2 is a Ni-based alloy with a matrix composition similar to the commercial alloy UNS #N06022. Alloy E1 was examined to determine if an increased Ni content could be used to significantly modify the solidification behavior in a favorable way, while still maintaining a stainless-steel-type matrix composition. The N06022 alloy heat was examined to determine if higher Ni contents were needed in the matrix in order to produce the desired result. The N06022 matrix composition was chosen because this commercial alloy is already being considered for spent nuclear fuel applications. Each alloy was characterized by differential thermal analysis (DTA) and microstructural characterization techniques as described in Part 1 (Ref. 1). Large-Scale Alloy Experiments

Results from the preliminary alloy optimization experiments showed that desirable results were obtained by adding Gd to

a N06022-type matrix. Thus, four larger scale heats of Ni-based alloys were prepared for more detailed investigations using the same techniques described in Part 1. The compositions of the four alloys are summarized in Table 2. Three of the alloys were chosen to provide matrix compositions similar to highly corrosionresistant Ni-Cr-Mo alloys (UNS #N06455, UNS #N06022, and UNS #N06059), which will provide the proper long-term corrosion resistance under storage conditions. As with the stainless steel alloys, in order to achieve the desired matrix composition, modifications to the nominal alloy composition were required to account for Ni depletion and Cr enrichment of the matrix due to formation of Gd-rich intermetallics (Ref. 3), and these were based on the measured composition of the intermetallic in the small-scale N06022-Gd trial heat. The fourth alloy is a simplified ternary Ni-Cr-Gd alloy that was included as a basis for comparison. Although previous work (Ref. 1) considered Gd additions up to 6 wt-%, recent experiments performed at the Los Alamos National Laboratory Criticality Experiments

Facility (Ref. 4) indicate that, for the most highly enriched spent nuclear fuel and the current repository container design, a Gd level of 2 wt-% should be adequate to meet criticality control needs. Thus, target Gd levels were set at 2 wt-%. The values shown in Table 2 are averages of three determinations each at three independent laboratories (nine total measurements). For the four alloys, the standard deviation in the Gd determinations, expressed as a fraction of the average value, ranged from 4.4 to 10.7% of the average for the nine measurements. In general, values for the other major elements were in reasonable agreement, with a single standard deviation of approximately 5% of the average value for that element. The same experimental techniques utilized in Part 1 (DTA, hot ductility, Varestraint weldability, microstructural characterization) were conducted on the large scale Ni-based alloys with the following exceptions. The Ni-based alloys were melted by vacuum induction heating, cast into 10-cm-diameter, 11.3-kg ingots, homogenized at 1160°C for 16 h, and hot rolled at 1160°C with moderate reductions WELDING JOURNAL

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WELDING RESEARCH

Fig. 5 — Light optical photomicrograph of Ni-based Alloy E -2 with Gd addition.

Fig. 6 — DTA result for the Ni-based Alloy E-2 with Gd addition.

B

A

Fig. 7 — EPMA results acquired from Ni -based Alloy E -2 with Gd addition. A — SEM photomicrograph showing location of EPMA trac e; B — EPMA results.

(3–6 mm) per pass to 14-mm-thick by 15.2-cm-wide plate. Frequent reheating was used to maintain the rolling temperature near 1150°C. Following rolling, the alloys were annealed in an argon atmosphere at 1150°C for 4 h and quenched with chilled flowing argon. Varestraint weldability tests were conducted on the N06455-Gd and Ni-Cr-Gd plate. The Varestraint tests were conducted on 165 ¥ 25.4 ¥ 3-mm subsize samples with a current, voltage, and travel speed of 100 A, 9 V, and 3 mm/s, respectively. Augmented strain levels of 1.0% and 3.5% were used. Simple autogeneous welds were also made on the N06455-Gd alloy plate using electron beam welding (EBW) and gas tungsten arc welding (GTAW). The electron beam welds were made at sharp focus, an accelerating voltage of 100 kV, various beam currents between 6 and 40 mA, and travel speeds ranging from 6 to 25 mm/s. Sharp focus was defined as the focus setti ng that

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DECEMBER 2004

yielded the maximum visible heating of a tungsten block at the appropriate beam current, voltage, and final lens-to-work distance. This produced welds ranging in penetration from 1.5 to 3.2 mm. The autogeneous GTA weld was made at a voltage of 14 V, a current of 120 A, and a travel speed of 3.4 mm/s.

Results Preliminary Alloy Optimization Experiments

An SEM photomicrograph of the highNi stainless steel heat (Alloy E-1) in the as-cast condition is shown in Fig. 2 along with EBSP patterns of the phases observed in the microstructure. The lack of retained ferrite in the dendrite cores is apparent, as is the absence of the thin (Fe,Ni,Cr) 3Gd rim and terminal ferrite constituents around the interdendritic (Ni,Fe)3Gd phase that were observed in

316L-type stainless steels enriched in Gd (Ref. 1). With the increased Ni content, solidification appears to initiate by the formation of austenite dendrites and terminate by a peritectic-like reaction, since Fe3Gd and Ni3Gd both form by peritectic reactions in the Fe-Gd and Ni-Gd systems, and the (Fe,Ni,Cr) 3Gd phase forms peritectically in Gd-enriched 316L stainless steel. Differential thermal analysis of the Ni modified heat is shown in Fig. 3. During heating, liquation of the (Ni,Fe) 3Gd phase initiates at 1127°C — Fig. 3A. Thus, the liquation temperature of the (Ni,Fe)3Gd phase in this alloy is raised by about 65°C compared to that in the 316Ltype alloys, which liquates at ~1060°C (Ref. 1). The cooling portion of the DTA trace indicates that, for the cooling rate used for the DTA analysis (5°C/min), solidification terminates with the formation of two constituents. The microstructure of the DTA samples is shown in Fig. 4 and in-

WELDING RESEARCH A

B

C

D

Fig. 8 — Backscattered elec tron SEM photomicrographs of four Ni-based alloys with Gd additions. A — N06455-Gd; B — N06022-Gd; C — N06059-Gd; D — Ni-Cr-Gd.

Table 3 — Compositions (All Values in wt-%) of Ni5Gd-Type Phase O bserved in As-Cast Ingots

Alloy N06455-Gd N06022-Gd N06059-Gd Ni-Cr-Gd

Ni

Cr

Mo

Mn

Fe

W

Al

Si

63.13 60.50 61.72 61.41

2.00 2.35 2.82 2.52

0.69 0.53 0.84 0.04

0.00 0.00 0.00 0.00

0.04 0.52 0.00 0.04

0.00 0.00 0.00 0.00

0.00 0.02 0.50 0.00

0.08 0.10 0.11 0.04

Table 4 — Summary of On-Heating DTA Results

Sample N06455-Gd N06022-Gd N06059-Gd Ni-Cr-Gd

Eutectic Type L Æg + Ni5Gd Temperature, °C 1290, 1290 1272, 1276 1265, 1269 1291, 1294

dicates that at least two constituents are associated with the interdendritic regions. Although these constituents have not yet been identified, consideration of the Fe-

Liquidus Temperature, °C 1400, 1402 1379, 1381 1370, 1369 1423, 1423

Average Melting Temperature Range, °C 110 106 103 131

Gd and Ni-Gd phase diagrams, and the established tendency of these alloys to form Gd-rich intermetallics (Ref. 2), implies that the intermetallic phases are probably

Gd 35.26 34.93 35.50 34.23

based on the Ni 3Gd and Ni 7Gd2 structures. The presence of two distinct Gd intermetallic phases was not apparent in either the microstructural analysis or heating DTA response of the alloy in the as-cast condition, so it is clear that the cooling rate through the solidification temperature range is an important factor that affects microstructural development in this alloy. In any case, although the solidification temperature range of the Nimodified alloy has been reduced by ~65°C, the solidification temperature range is still almost 300°C and would not be expected to significantly improve the weldability and hot ductility. The as-cast microstructure of Alloy E-2

WELDING JOURNAL 323 -S

WELDING RESEARCH A

B

Fig. 9 — Bac ksca tter ed diff ract ion resu lts for Alloy Fig. 10 — DTA scans from Alloy N06455-Gd that were typical for all the alloys: A — Heating; B — N06022-Gd that were typical for all the alloys. cooling.

Fig. 11 — DTA microst ructu re of Alloy N06455- Gd showin g primary austenite cells and an intercellular g /Ni 5Gd eutectic-type constituent.

is shown in Fig. 5. The eutectic constituent in the microstructure is clearly visible, and it is evident that the primary austenite is continuous with the austenite in the eutectic constituent. The results of the differential thermal analysis are shown in Fig. 6. On heating, a single liquation event initiates at approximately 1285°C and melting is complete near 1391°C. On cooling, some undercooling is apparent, with solidification initiating at 1374°C and terminating with the formation of a single constituent at 1255°C. The single terminal solidification peak is consistent with the LOM photomicrograph shown in Fig. 5 in which a single eutectic-like constituent was observed. Figure 7 shows the results of an electron probe microanalysis (EPMA) scan conducted across the cellular substructure of this alloy. The line shown in Fig. 7A denotes the location of the EPMA scan. As with the stainless-steel-type alloys, the intermetallic is high in Gd, and there is essentially no Gd

324 -S

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Fig. 12 — Hot ductility results of Ni-based a lloys with Gd additions.

dissolved in the austenite matrix. Based on the results presented above, the Ni-based alloy provides the desirable solidification characteristics in which solidification terminates by a high-temperature eutectic-type reaction instead of a low-temperature peritectic reaction. Comparison of the DTA traces with those for the initial 316L-type heats and the Nimodified alloy indicates that the melting temperature range for this Ni-based alloy is significantly smaller, i.e., ~100°C for the Ni-based alloy vs. 300–400°C for the stainless steel alloys. Thus, based on these initial results, a full series of experiments was conducted on several commercialtype Ni-based alloys with Gd additions (compositions shown in Table 2). Full-Scale Experiments on Ni-based Alloys

Figure 8 shows typical backscattered

electron images of the large-scale alloys in the as-cast condition. All of the alloys exhibited a cellular substructure with an intercellular secondary constituent. Figure 9 shows a representative backscattered diffraction result, which shows that the matrix is austenite and the secondary phase within the eutectic constituent is a Ni5Gd-type intermetallic. Gadolinium oxides were also observed. These results were consistent among all the alloys. The compositions of the Ni 5Gd-type phases observed in each alloy are summarized in Table 3. The composition of the phase is consistent with the Ni 5Gd stoichiometry, with small amounts of dissolved Cr, Mo, Fe, and Al. Figure 10A shows a DTA heating scan and Fig. 10B shows a cooling scan from Alloy N06455-Gd that was typical for all the alloys. On heating, the alloy exhibits an endothermic peak at 1290°C associated with liquation of the g /Ni 5Gd eutectic-

WELDING RESEARCH A

B

Fig. 13 — Typical photomicrographs of hot ductilit y samples that failed: A — Outside of the hot zone; B — inside the hot zone.

A

B

A

B

C

Fig. 14 — Light op tical micrographs of rolled and annealed N06455-Gd p late in the following orientations: A — Longitudinal; B — transverse; an d C — rolling plane. Rolling direct ion i s right to left in A and C and plate thickness is vertical in B. Elongated gray features are the Ni 5Gd intermetallic, and small spherical black features are Gd oxides.

type constituent, and the austenite matrix is fully molten at 1400°C. On cooling, the primary austenite phase begins to solidify at 1400°C, and the terminal Liquid g + Ni5Gd eutectic-type reaction occurs at 1272°C (18°C undercooling). These peaks are consistent with the initial alloy microstructures and DTA microstructures (Fig. 11), which exhibit a primary austenite phase and intercellular g /Ni5Gd eutectic-type constituent. Table 4 summarizes the on-heating DTA data. Results are shown for two separate tests conducted on each alloy, and the reproducibility is always within 4°C. The melting temperature range for the alloys varies between →

103° and 131°C, which is a substantial reduction compared to the original Gdenriched stainless steels considered (360°–400°C) (Ref. 1). Figure 12 shows hot ductility results. In general, each alloy exhibits reasonably good ductility up to a temperature of 1200°C. The ductility is lost at 1250°C, which is near the liquation temperature of the eutectic constituent. The N06022-Gd alloy generally exhibited the lowest ductility while the Ni-Cr-Gd and N06455-Gd alloys typically exhibited the highest ductility at each test temperature. At the lower temperatures of 900° and 1000°C, the samples often failed outside the hot

Fig. 15 — Light optical photomicrographs of the autogeneous electron beam weld made on Alloy N06455-Gd in the following conditions: A — As polished; B — etched.

zone. Samples that failed both within and outside of the hot zone were examined using light optical microscopy to determine the location and mode of failure — Fig. 13. The samples that failed within the hot zone (Fig. 13B) generally exhibited significant plastic deformation of both the matrix and Ni 5Gd intermetallic. In contrast, samples that failed outside the hot zone (Fig. 13A) exhibited little ductility and significant cracking of the intermetallic phase. The intermetallic cracks were always approximately normal to the tensile axis. The microstructure of the hot rolled N06455-Gd plate in the three principal WELDING JOURNAL 325 -S

WELDING RESEARCH A

B

cracks or other defects were observed in this or C the other electron beam welds produced in this study. Figure 16 shows the structure of an autogeneous GTA weld. The weld exhibits a microstructure similar to that of the ingots (primary austenite cells with intercellular /Ni 5Gd eutectic-type g constituent). The cell spacing and secondary phase is much finer than the ingots due to the higher cooling rates Fig. 16 — Lig ht optical p hotomicrographs of an autogeneous GTA weld in the weld. A partially made on the Alloy N06455-Gd. The weld exhibits a microstructure simi- melted zone (PMZ) is lar to that of the ingots (primary austenite cells with intercellular g /Ni 5Gd clearly distinguishable eutectic-type constitue nt). outside of the fusion zone (FZ). This PMZ bounds temperatures between the liquidus at plate orientations is shown in Fig. 14, and the PMZ/FZ interface and the Liquid Æ g is representative of that observed in all + Ni5Gd eutectic-type temperature at the the alloys. As shown, the gadolinide disPMZ/HAZ interface. Within this region, tribution is substantially changed during the g /Ni 5Gd constituent will liquate, as rolling. At the hot rolling temperature shown in Fig. 16C. The PMZ is often a reused (1150°C), the gadolinides appear to gion where liquation cracking will occur in be relatively soft and ductile, and this alloys with wide solidification temperaresults in a gadolinide morphology that is ture ranges. However, the solidification elongated in the rolling direction and flattemperature range in this alloy is relatened out in the rolling plane. In a mantively narrow (110°C) and comparable to ner similar to the as-cast microstructure other nickel-based alloys that are readily of Fig. 9, the rolled plate also contains weldable. Thus, liquation cracking is gensmall spherical Gd oxides that are apparerally not expected except, as described ently distributed throughout the austenbelow, under conditions of high restraint ite matrix as well as within the Ni 5Gd or where macrosegregation is persistent. intermetallic. Figure 17 shows light optical photomiFigure 15 shows light optical photomicrographs of an isolated region of a GTA crographs of an autogeneous electron weld that contained a crack. Inspection of beam weld made on the N06455-Gd alloy the cracked region at slightly higher magin the as-polished and etched conditions. nification (Fig. 17B) shows that a relaThe weld exhibits columnar grains that tively large amount of the g /Ni5Gd congrow epitaxially from the base metal, and stituent exists at the edge of the crack. The this grain morphology is typically oblarge amount of g /Ni5Gd in this area can served in fusion welds. No solidification

326 -S DECEMBER 2004

be attributed to macrosegregation from the original ingot, and this form of cracking should be easily avoided when macrosegregation in the original ingot is prevented by a secondary refining step such as vacuum arc remelting. Figure 18 shows the Varestraint hot cracking results for the N06455-Gd and Ni-Cr-Gd alloys. Results are shown for the total and maximum crack length. As a basis for comparison, Fig. 19 shows Varestraint hot cracking results for the stainless steel alloys (Ref. 1). The results for the stainless steel alloys were acquired as a function of Gd concentration at a fixed strain level of 3.5%. The stainless steel samples were 0.25 in. thick while the Nibased samples were 0.125 in. thick. The Varestraint welding parameters were identical for each alloy system. The weld size produced on the stainless steel samples was similar to the welds produced on the Ni-based samples. Although direct comparisons cannot be made between the results for the stainless steels and Nibased alloys due to differences in sample size, the very large difference in maximum and total crack length values clearly shows the significant level of improvement in weldabili ty for the Ni-based alloys. In terms of maximum crack length (MCL), the stainless steel alloys with comparable Gd levels (1.9 wt-%) exhibited MCL values near 5 mm, which is significantly higher than that of the Ni-based alloys of 1 to 1.2 mm. Similar results were obtained when total crack length (TCL) was used as the cracking susceptibility indicator. The TCL value for the stainless steel alloy with 1.9 wt-% Gd was 50 mm, which is significantly higher than the TCL value of 5.7 to 7.5 mm for the Ni-based alloys. Discussion

The results of this research show that the solidification behavior and resultant hot ductility and weldability of Gd-

WELDING RESEARCH

Fig. 17 — Light optical photomicrographs of an isolated region of the GTA weld in Alloy N06455-Gd that contained a c rack. A

B

Fig. 18 — Varestraint hot cracking results for the Ni-Cr-Gd and N06455-Gd alloys. Results are shown for the following: A — Maximum crack length; B — total crack length.

enriched austenitic alloys depends strongly on the matrix composition. In particular, stainless-steel-type matrix compositions form a low-temperature (Fe,Ni,Cr)3Gd-type intermetallic by a peritectic reaction. This undesirable reaction sequence and concomitantly large melting temperature range can be avoided by the use of austenitic alloys with a Nibased matrix. The DTA results from the Ni-based alloys indicated that, in the absence of undercooling, solidification initiates at the liquidus temperature (in the range of ~1370°–1420°C depending on alloy composition) by the formation of primary g -austenite. Essentially no Gd is dissolved in the austenite matrix. Thus, as solidification proceeds, the liquid becomes increasingly enriched in Gd until the Liquid Æ g + Ni5Gd eutectic-type reaction is reached, at which point solidification is terminated by the eutectic reaction. This

reaction sequence and temperature range is generally similar to that expected in the binary Ni-Gd system. Simple binary NiGd alloys with less than about 13 wt-% Gd exhibit a similar two-step solidification sequence consisting of primary austenite formation followed by a terminal eutectic involving the Ni17 Gd 2 intermetallic at 1275°C (Ref. 2). By comparison, the multicomponent Ni-Cr-Mo-Gd alloys terminate solidification in the range of 1260°–1290°C by a terminal eutectic-type reaction involving the Ni5Gd intermetallic. Thus, although the secondary phase within the terminal eutectic constituent is different in each case, the terminal reaction temperatures are very similar. The Gleeble hot ductility test results confirm that the reduced melting temperature range provides improved hot workability (relative to the Gd-stainless alloys) at temperatures above ~1000°C. As

shown in Fig. 12, the hot ductility of the alloys over the temperature range of 900°– 1200°C can be roughly grouped into highest ductility (N06455-Gd and Ni-Cr-Gd), intermediate ductility (N06059-Gd), and lowest ductility (N06022-Gd). Qualitatively, this response can be rationalized in terms of the concentrations of major alloying elements (Cr, Mo, Fe, W) and gadolinide volume fraction (Gd level) (Table 2). The Ni-Cr-Gd alloy has the lowest substitutional alloying element level, while the N06455-Gd alloy has an appreciably lower Gd concentration (and intermetallic volume fraction) than the other alloys. Conversely, the N06022-Gd alloy has both the highest alloying element level and highest intermetallic volume fraction, while the N06059-Gd alloy is intermediate by these measures. At temperatures below 900°C, the fracture process initiates by localized cracking in the brittle Ni 5Gd WELDING JOURNAL 327 -S

WELDING RESEARCH A

B

Fig. 19 — Varestraint hot cracking results for the sta inless ste el alloys. Results are shown a s a function of Gd conce ntration at a fixed strai n lev el of 3.5%. A — Maximum crack lengths; B — total crack lengths.

phase, while ductility at the higher temperature (~1250°C) appears to be limited by liquation of the Ni 5Gd phase. In any case, all the alloys were successfully reduced to plate by hot rolling at temperatures near 1150°C. For these working conditions, the Ni 5Gd intermetallic constituent appears to be relatively soft and ductile, and an elongated pancakelike morphology is developed. This morphology is likely not optimal from a mechanical properties perspective, but no attempt was made in the current investigation to optimize either the hot working procedures or the resultant microstructure. Such efforts are, however, ongoing. The significant improvement in solidification cracking resistance of the Nibased alloys compared to the Gd-modified stainless steel alloys can also be attributed to the large reduction in solidification temperature range. The N06455Gd and Ni-Cr-Gd alloys exhibit a solidification temperature range of 110°C and 131°C, respectively. In comparison, the Gd-stainless steel alloys exhibited a solidification temperature range of 360°–400°C. For a given set of welding parameters (i.e., temperature gradient), the size of the crack-susceptible two-phase solid + liquid region behind the fully molten weld pool increases as the solidification temperature range increases. Thus, the distance a solidification crack can propagate in the two-phase region also increases, resulting in higher MCL and TCL values (i.e., higher cracking susceptibility). Note that the cracking susceptibility is also dependent on the volume fraction of the terminal liquid, but the comparisons between the Gd-stainless alloys and the GdNi alloys were made at similar Gd levels 328 -S DECEMBER 2004

(and thus similar volume fractions of terminal constituents). Comparisons can also be made to commercial Ni-based alloys in which a history of weldability has been established through practical applications. For example, Alloys IN718 and IN625 tested with equivalent size samples and welding parameters at strain level of 2.5% exhibit MCL values of ~1.6 and 1.2 mm, respectively (Ref. 5). These MCL values are comparable to those observed here, and these commercial alloys are known to be readily weldable in typical applications where the level of restraint is not large. Thus, based on the solidification temperature range and Varestraint data acquired here, the Ni-based alloys are expected to be readily weldable under most applications where the level of restraint is not very high. Preliminary conformation of this was provided in the electron beam and GTA welds that were generally crack free. The isolated region of cracking observed in one GTA weld was confined to a region where a local increase in the amount of the /Ni5Gd constituent (relative to the nomig nal g /Ni 5Gd content) existed due to macrosegregation. The g /Ni 5Gd constituent was present as liquid just prior to the end of solidification. In places where the liquid exists in large quantities, it can promote solidification cracking by interfering with the formation of solid/solid boundaries across cells and grains. This continuous grain boundary/intercellular liquid film cannot support solidification shrinkage strains at the terminal stages of solidification, and hot tears form as a result. It is considered that solidification cracking in this alloy should not be a major problem when macrosegregation has been reduced by an intermediate processing

step such as vacuum arc remelting. It should be noted that ongoing work, which includes more extensive welding trials and weld schedule development, has not encountered any difficulties with HAZ cracking in narrow gap cold wire feed GTA butt joint welds. Work is in progress to evaluate this issue in more detail and will be presented in a future article. Conclusions

The influence of Gd additions on the solidification behavior, hot ductility, and weldability of Ni-based alloys has been in vestigated. The following conclusions can be drawn from this research. 1. The addition of 6 wt-% Gd to a nominal 20Ni-14Cr-2Mo stainless-steel-type alloy results in a primary austenite solidification mode and formation of a Gd-rich interdendritic constituent at ~1130°C. The resulting solidification temperature range of this high-Ni stainless steel is still rather large (300°C) and not significantly different than that previously observed in Type 316L stainless steel alloys with Gd additions (360° to 400°C). 2. The Ni-based alloys with ~2 wt-% Gd initiated solidification by primary austenite and terminated solidification by a Liquid Æ g + Ni5Gd eutectic-type reaction at ~1270°C. The solidification temperature range of these alloys (100° to 130°C) is significantly smaller compared to that of Gd-enriched 316L-type stainless steels that terminate solidification by a peritectic reaction at ~1060°C. 3. The higher temperature eutectic reaction that occurs in the Ni-based alloys is accompanied by significant improvements in hot ductility and solidification cracking

WELDING RESEARCH resistance. These alloys therefore show considerable potential in terms of primary processing by conventional ingot metallurgy and hot working, and secondary fabrication by fusion welding. Acknowledgments

This work was supported by the U.S. Department of Energy, Assistant Secretary for Environmental Management, under DOE Idaho Operations Office Contract No. DE-AC07-99ID13727. This work was performed at Lehigh University, Sandia National Laboratories, and Idaho National Engineering and Environmental Laboratory through support from the Na-

tional Spent Nuclear Fuel Program. Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin company, for the U.S. Department of Energy under Contract DE-AC0494AL8500. References

1. DuPont, J. N., Robino, C. V., Michael, J. R., Mizia, R. E., and Williams, D. B. 2004. Physical and welding metallurgy of Gd-enriched austenitic alloys for spent nuclear fuel applications, Part I: Stainless steel alloys. Welding Jour nal 83(11): 289-s to 300-s. 2. Binary Alloy Phase Diagrams, Vol. 3. 1992. Materials Park, Ohio: ASM International. 3. Robino, C. V., DuPont, J. N., Mizia, R. E.,

Michael, J. R., Williams, D. B., and Shaber, E. 2003. Development of Gd-enriched alloys for spent nuclear fuel applications — Part I: Preliminary characterization of small scale Gdenriched stainless steels. Journal of Material s Engineering and Performance 12(2): 206–214. 4. Loaiza, D. J., Sanchez, R., Wachs, G., and Mizia, R. E. 2003. Critical experiment analysis of a neutron absorbing nickel-chromiummolybdenum-gadolinium alloy being considered for the disposal of spent nuclear fuel. Jour nal of Nuclear Materials Ma nagement 32(1). 5. DuPont, J. N., Robino, C. V., and Marder, A. R. 1998. Solidification and weldability of Nbbearing superalloys, Welding Journal 77(10): 417-s to 431-s.

Preparation of Manuscripts for Submission to the Welding Journal Research Supplement All authors should address themselves to the following questions when writing papers for submission to the Welding Research Supplement: ◆ Why was the work done? ◆ What was done? ◆ What was found? ◆ What is the significance of your results? ◆ What are your most important conclusions? With those questions in mind, most authors can logically organize their 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. 2) Introduction. A short statement giving relevant background, purpose, and scope to help orient the reader. Do not duplicate the abstract. 3) Experimental Procedure, Materials, Equipment. 4) Results, Discussion. The facts or data obtained and their evaluation. 5) Conclusion. An evaluation and interpretation of your results. Most often, this is what the readers remember.

6) Acknowledgment, References and Appendix. Keep in mind that proper use of terms, abbreviations, and symbols are important considerations in processing a manuscript for publication. For welding terminology, the Welding Journal adheres to AWS A3.0:2001, 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 1 2 x 11-in. or A4 paper) of the manuscript. A on 8 ⁄ manuscript submission form should accompany the manuscript. Tables and figures should be separate from the manuscript copy and only high-quality figures will be published. Figures should be original line art or glossy photos. Special instructions are required if figures are submitted by electronic means. To receive complete instructions and the manuscript submission form, please contact the Peer Review Coordinator, Doreen Kubish, at (305) 443-9353, ext. 275; FAX 305-443-7404; or write to the American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126.

WELDING JOURNAL

329 -S

WELDING RESEARCH

Numerical Simulation of Transient 3-D Surface Deformation of a Completely Penetrated GTA Weld An analytical model that explores the dynamic behavior of a weld pool will help in the development of a sensor that detects complete joint penetration in gas tungsten arc welding BY C. S. WU, P. C. ZHAO, AND Y. M. ZHANG

ABSTRACT. By establishing the correlation between transient behavior of a weld pool surface deformation and workpiece penetration, and quantitatively analyzing the surface deformation at the top and bottom surfaces at the moment the pool penetrates and their dynamic responses to welding process parameters will provide basic data for the development of topside vision -based penetration control in gas tungsten arc welding (GTAW). A transient numerical model was developed to investigate the dynamic behavior of a completely penetrated GTAW joint. A complete and comprehensive scheme was used in which many factors, such as moving arc, 3-D fluid and heat flow fields, transient state, completely penetrated weld, and surface deformation at both the top and bottom surfaces were considered. The transient development of 3-D surface deformation and shape of a weld pool during the period from partial penetration to complete penetration is predicted. The simulated results showed that the ratio curves of the maximum depression to the length and width at the top surface of the weld pool at different times clearly indicated basic information on penetration. Therefore, the relation of the ratios vs. time can be used as an indicator to judge whether the joint is penetrated.

Introduction Gas tungsten arc welding (GTAW) is the most used arc welding process for critical and accurate joining. For this process, 100% complete joint penetration must be ensured without melt-through or overpenetration (Ref. 1). To this end, autoC. S. WU and P. C. ZHAO are with Institute of Materi als Joini ng, Shando ng Unive rsity, Jinan , China, [email protected] . Y. M. ZHANG is with Center for Manufacturing and Department of Electrical an d Computer Engineering, University of Kentucky, Lexington, Ky.

330 -S

DECEMBER 2004

mated sensing and control of the GTAW process must be realized (Ref. 2). In practice, the backside weld bead width is usually employed to determine the extent of penetration. Although the backside bead width can be sensed by a backside sensor, there are limitations of access and coordinating the motion between the torch and sensor, and it is often necessary that the sensor be attached to and moved with the torch to form a weld-face or topside sensor. However, the invisibility of the backside and the strong arc light radiation together cause tremendous difficulties for such sensors. To find a feasible sensor for automated control, various methods have been studied, including pool oscillation (Ref. 3), ultrasound (Ref. 4), and an infrared sensor (Ref. 5). Although significant progress has been made, practical applications are still restricted. Weld pool behavior contains enough information on penetration. The pool surface is deformed because of the plasma impingement. Previous researchers have found that the resultant depression of the weld pool surface correlates to the penetration depth of the weld pool (Refs. 6–8), but there is a lack of quantitative analysis of such a correlation. Establishing the correlation between dynamic behavior of weld pool surface deformation and the penetration information, while quantitatively analyzing the surface deformation at the top and bottom surfaces when the joint

KEY WORDS

Weld Pool Surface Deformation Penetration Correlation Numerical Simulation

is penetrated and their dynamic response to welding process parameters will pro vide much basic data for the realization of a topside vision-based penetration control for the GTAW process. Thus, numerical simulation of the surface deformation and its dynamic behavior to the GTAW process is of great significance for designing the process control algorithm. Although there have been significant advances in the numerical simulation of the GTAW process (Refs. 9–24), little attention has been paid to the transient dynamics of the 3-D weld pool surface deformation at both the topside and backside of a fully penetrated weld pool and its correlation to the extent of penetration. Previous studies have shown that the pool depression has a direct effect on the penetration (Refs. 6–8). In fact, the weld pool surfaces at both the front and back are depressed when there is complete penetration, and the amplitude of such depression could be a reflection of the extent of penetration (Refs. 25, 26). For dynamic control, quantitative analysis is required to reveal how the process variables (weld pool geometry and surface depression) change with the welding parameters (welding current and velocity). In this paper, a numerical model is developed to describe the transient behavior of a 3-D GTA weld pool with complete penetration and surface deformation, and the quantitative relationship between the pool surface depression at the front side and the extent of penetration.

Formulation In order to describe the development of weld pool shape, surface deformation, thermal field, and fluid flow field, a GTAW arc is considered to be impinging on the workpiece along the z direction and it moves in the x direction at a constant speed u0. A moving ( x, y, z) coordinate sys-

WELDING RESEARCH tem is so chosen that its origin is located at the intersection between the arc centerline and the workpiece surface. For such a three-dimensional transient problem, the governing equations include the energy, momentum, and continuity equations. Because of the surface deformations at both topside and backside of the weld pool, some new boundaries appeared at both top and bottom surfaces, and their positions changed with time. Therefore, the calculation domain is no longer a regular rectangular one, which causes some boundary conditions to be difficult to deal with. To represent the irregular boundaries, a coordinate transformation is adopted. The independent variable in transformed space ( z*) is related to the vertical coordinate in physical space ( z) according to z *

(

Table 1 — Other Thermophysical Properties and Parameters Used in the Calculation

Property or Parameter

Symbol

Value

Melting point Ambient temperature Density Latent heat of vaporization Gravitational acceleration Surface radiation emissivity Magnetic permeability Surface tension Temperature coefficient of surface tension Thermal expansion coefficient Current density distribution parameter Heat flux distribution parameter Arc power efficiency Plate thickness

T m T ∞

1763 K 293 K 7200 kg m–3 73.43 ¥ 105 J kg–1 9.8 m s–2 0.4 1.66 ¥ 10–6 H m–1 1.0 N m–1 –1.12 ¥ 10–4 N m–1K –1 10–4 1.5 mm 2.25 mm 0.65 3 mm

— s =

)

z - F x , y , t

=

(

∂ ∂ ∂ i + j + S k ∂ x ∂ y ∂ z * r

) - F( x , y ,t)

m w l = V ◊ —z * - — 2 z * r

(1)

wt

where F ( x,y,t) and B( x,y,t) are functions that define the upper and lower surfaces of the weld pool, respectively. The transformation maps the irregularly shaped regions into rectangular computational domains in which the two curvilinear surfaces are stationary during any given time interval, and are defined by z* = 0 and z* = 1. Then, the governing equations describing the fluid flow and heat transfer phenomena in a weld pool are expressed as: r

(7)

= V ◊—z * -

k

r c p

— 2 z * (9)

È Ê ∂V ˆ ˘ ˙ ◊— xy z * C v = 2 m Í— xy Á ˜ ÍÎ Ë ∂ z * ¯ ˙˚ È Ê ∂T ˆ ˘ * CT = 2 m Í— xy Á ˜ ˙ ◊— z ÍÎ Ë ∂ z * ¯ ˙˚ xy r

r

— xy =

∂ ∂ i + j ∂ x ∂ y r

(10)

(11)

r

(12)

r

(2)

= J ¥ Bm - rb g(T - T • ) r

F b

r

r

(13)

r

∂V + r (V l ◊—* )V = F b ∂t Ê ˆ ∂p 2 * Á — p + * ◊— z ˜ + m — s V + Cv Ë ¯ ∂ z (3) Ê ∂T ˆ r c p Á + Vt ◊—*T ˜ = — s ( k— sT ) + kCT Ë ∂t ¯ (4) r

r

r

r

r

r

where V is the fluid velocity vector with the components (u, v, w) in x, y, and z directions, V l is the fluid velocity vector with the components (u, v, w l) in x, y, and z directions, V t is the fluid velocity vector with the components (u, v, wt) in x, y, and z directions, r is the density, c p is the specific heat, p is the pressure, m is the viscosity, k is the thermal conductivity, and other symbols are defined as follows:

∂ ∂ ∂ — = i + j + k ∂ x ∂ y ∂ z ∂ ∂ ∂ —* = i + j + k ∂ x ∂ y ∂ z * r

r

r

r

m

j

q

H

(

r

J

¥ B m ) = r

z

r

(5)

r

(6)

where b is the volume expansion coefficient, g is the acceleration of gravity, T ∞ is the ambient temperature, and the electromagnetic force J ¥ B m is calculated based on Wu’s analytical solutions (Refs. 12 and 15) expressed as follows:

( J ¥ B ) r

r

m

x

=

Ê 2 ˆ r ˜ expÁ Á 2s 2 ˜ 4p 2 s j2 r Ë j ¯ 2 È Ê ˆ ˘ Í1 - expÁ - r 2 ˜ ˙Ê 1 - z ˆ x Í Á 2s 2 ˜ ˙ÁË H ˜ ¯ r ÍÎ Ë j ¯ ˙˚ m m I 2

(

r

J

4p 2 Hr 2

È Ê ˆ ˘ Í1 - expÁ - r 2 ˜ ˙ Ê 1 - z ˆ Á ˜ Í 2 ˜ ˙ Ë H ¯ Á s 2 ÍÎ Ë j ¯ ˙ ˚

(16)

where m m is the magnetic permeability, I is the welding current, s j is the effective radius of the current distribution in Gaussian form, H is the thickness of the workpiece, and r =√ x 2 + y2. When the workpiece is not completely penetrated, the weld pool has only one free surface F ( x,y,t), which is deformed under the combined action of arc pressure, hydrostatic force, and surface tension. If the workpiece is completely penetrated, the weld pool has two free surfaces, i.e., the upper surface F ( x,y,t ) and the lower surface B( x,y,t). Under the condition of partial penetration, the shape of weld pool surface F ( x,y,t) can be described by the following equation:

Ê ˆ — F 5 ˜ p a - rgF + C1 = g — Á ÁÁ — F ˜ Ë s ˜ ¯

(17)

where p a is the plasma arc pressure, C1 the Langrangian constant, g the surface tension, and F s = z – F(x,y,t) = 0. The arc pressure p a can be described by (Ref. 27) (14)

¥ B m ) =

P arc

r

=

y

Ê 2 ˆ r ˜ expÁ 4p 2s j2 r ÁË 2s 2j ˜ ¯ 2 È Ê ˆ ˘ Í1 - expÁ - r 2 ˜ ˙Ê 1 - z ˆ y Á ˜ Í 2 ˜ ˙Ë H ¯ r Á s 2 ÍÎ Ë j ¯ ˙˚

m m I 2 2

(8)

For the body force term,

∂V * ◊— z = 0 * ∂ z r

e m g ∂g / ∂T b s s h

r

r

r

r

L b g

r

B x , y , t

—V +

r

m m I 2

m m IJ

(18)

4p

where J is the current density at the workpiece surface, which can be assumed to be in Gaussian distribution (Ref. 28)

(

)=

J r

(15)

I

2ps j2

Ê

ˆ ˜ Á 2s 2 ˜ Ë j ¯

expÁ -

r 2

(19)


WELDING RESEARCH Table 2 — Comparison of the Maximum Depression at Top Surface

Predicted Weld Depression width (mm) (mm) Top 5.4 side Bottom 1.9 side

Measured Weld Depression width (mm) (mm)

0.14

6.5

0.12

0.27

1.7

0.30

(SS304 workpiece, thickness 3 mm, 110 A, 12 V, 125 mm/min)

Fig. 1 — The surface deformation vs. time (workpiece, SS304; thickness, 3 mm; 100 A; 14 V; 125 mm/min).

Equation 17 should satisfy with the constraint condition

ÚÚ F dxdy = 0

- k

S T

(20) where St is the area of fusion zone at the workpiece’s upper surface ( z = 0), i.e., the domain of F(x,y,t) at the plane z = 0. The Langrangian constant C1 can be determined by using Equation 20. If the workpiece is completely penetrated, the upper surface F(x,y,t) and the lower surface B(x,y,t) of the weld pool can be expressed as p a

- rgF + C 2

( B - F ) + C2

r g

Ê — F = g — ÁÁ s ÁË — F s

ˆ ˜ ˜ ˜ ¯

Ê — B = g — ÁÁ s ÁË — B s

ˆ ˜ ˜ ˜ ¯

(22)

( x - u t) ≥ 0 , q ( x , y) = 0

arc

(24) (25)

r

∂V ∂T =0, =0 ∂ y ∂ y

(34)

In the solid, V = 0

6h EI

(b1 + b2 )

(28)

6h EI

(b1 + b2 )

(29)

= hcr (T - T • )

(30)

t = 0, T(x,y,z,0 ) = T ∞ , F(x,y,0 ) = 0, B(x,y,0 ) = 0

log( m ev) = A – B/T – 0.5logT

(38)

Methods of Solution

(31)

where a(b1 + b2 ) = 12s2 q, a = 1.87s q , b1 = 2.51s q, b2 = 3.91s q, h the arc power efficiency, E the arc voltage, and s q the distribution parameter of arc heat flux. In this research, h cr is the combined heat transfer coefficient for the convection and radiation boundary, T ∞ is the ambient temperature, L b is the latent heat of evaporation, and m er is the evaporation mass rate. For a metal such as steel, h cr and m ev can be written as (Refs. 29, 30) h cr = 24.1 ¥ 10–4 eT 1.61

(37)

For the initial conditions:

p a

= mer Lb

For the points at the melting zone boundary on the oxz-plane,

∂ F ∂ B =0, =0 ∂ x ∂ x

È 2˘ Í 3( x - u0 t) ˙ Ê 3 y 2 ˆ ˙ expÁ expÍ˜ 2 Í ˙ ÁË a 2 ˜ b2 ¯ Í ˙ Î ˚ q cr

(35)

The boundary conditions for Equations 19, 21, and 22 are written as: For the domain outside the melting zone, (36) F = 0, B = 0

p a

È 2˘ Í 3( x - u0 t) ˙ Ê 3 y 2 ˆ ˙ expÁ expÍ˜ Á 2 2 ˜ Í ˙ b1 Í ˙ Ë a ¯ ˚ Î

q evp

(23)

For the symmetric plane ( y = 0),

r

arc

m


(27)

when,

( x - u0t) < 0 , q ( x , y) =

where S B is the area of the fusion zone at the workpiece’s lower surface ( z = H ), i.e., the domain of B(x,y,t) at the plane z = H . In transient state, the weld pool geometry changes with time t, so the domains ST and S B also vary with time. In this way, the variations of F(x,y,t) and B(x,y,t) with time t are described. The boundary conditions for solving the governing Equations 2–4 are as follows: For the free surface of weld pool,

∂u ∂ z * ∂g ∂T =∂T ∂ x ∂ z * ∂ z * ∂ v ∂ z ∂g ∂T m =* ∂T ∂ y ∂ z ∂ z

∂T ∂ z * = q arc - qcr - qevp * ∂ z ∂ z

(21)

ÚÚ Fdxdy - ÚÚ Bdxdy = 0 S B

(26)

when,

where B s = z – B(x,y,t) = 0, and C2 is the Langranian constant, to make Equations 21 and 22 satisfactory with the constraint condition

S T

w = 0

(32) (33)

where e is the emissivity of the workpiece surface, and A and B are constants ( A = 8.641, B = 18836).

The governing equations and boundary conditions are solved by means of the finite difference technique. The scheme of differences has a high degree of nonlinearity, as the characteristic values for the material are taken as temperaturedependent. Coupling occurs between and within the relevant aspects of the problem. Thus, a special iterative procedure is necessitated. The program first calculates the temperature field in the solid workpiece. Once the melt zone emerges, the whole domain is divided into two regions, i.e., the fluid flow zone in the weld pool and the solid zone outside the pool. The calculations of fluid flow and heat transfer inside the pool and the conductive heat transfer outside the pool are conducted simultaneously. Then, the shape of the weld pool surface is calculated according to the pressure and energy equilibrium conditions. The liquid-solid boundary is determined by the enthalpy at the melting point. Based

WELDING RESEARCH A

B

C

D

Fig. 2 — The transient development of weld pool surface deformation (workpiece, SS304; thickness, 3 mm; 100 A; 14 V; 125 mm/min). A — Deformation at top surface (side view, enlarged in z direction); B — deformation at bottom surface (side view, enlarged in z direction); C — deformation at top surface (front view, enlarged in z direction); D — deformation at bot tom surface (front view, enlarged in z direction).

on the deformed pool surface, the fluid flow and temperature fields are recalculated. Then, the configuration of the weld pool surface and geometry is adjusted, and a repeated calculation procedure commences. Once the workpiece is completely penetrated, the appropriate equilibrium conditions of pressure are applied to determine the shape of the weld pool and its surface deformation at both topside and bottom side. The fluid flow and heat transfer within the pool are recalculated, and the pool geometry is modified. Iterations are performed until the selected convergence criterion is satisfied. The overall algorithm consists of individual procedures which are performed iteratively. The iterative calculations for the transient problems are carried out. At each time step, all physical subprocesses are solved numerically until the convergence criterion is met, and then time is incremented and the calculation procedure is repeated. The additional source term method is utilized to transform both energy and momentum boundary conditions into discrete forms, and the discrete governing equations in body-fitted coordinates are established. Nonuniform grids are used with finer spacing inside the weld pool and coarser away from it to improve the simulation accuracy and speed up the convergence. Various subprocess problems are calculated separately and improved by turns during the whole iterative procedure. In this way, the strongly coupling problems are solved effectively and successfully.

Results

Numerical simulations are performed for GTAW on stainless steel 304. A half workpiece with a welding domain of 200 ¥ 50 ¥ 3 mm are divided into the mesh of 352 ¥ 60 ¥ 10 grid points. For the 304 material, the specific heat c p, dynamic viscosity µ, and thermal conductivity k are temperature dependent, which can be expressed as follows (Ref. 31): Ï10 .717 + 0.014955T T £ 780 K Ô -1 -1 Ô12 .0 76 + 0.0 13213T W m K 780 K £ T £ 1672 K k = Ì Ô217.12 - 0.1094T 1672 K £ T £ 1727 K Ô 1727 £ T Ó8 .278 + 0.0115T

(

)

(39) Ï 37 .203 - 0 .0176T 1713 K £ T £ 1743 K Ô - 3 -1 -1 Ô 20 .354 - 0 .008 T 10 kg m s 1743 K £ T £ 1763 K m = Ì Ô 34 .849 - 0 .0162T 1763 K £ T £ 1853 K Ô 1853 K £ T £ 1873 K Ó13 .129 - 0.0045 T

(

)

(40) Ï438 .95 + 0.198T T £ 773 K Ô -1 773 K £ T £ 873 K Ô137 .93 + 0.59T J kg C p = Ì Ô871 .25 - 0.25T 873 K £ T £ 973 K Ô 973 K £ T Ó 555 .2 + 0.0775T

(

)

(41)

Other thermophysical properties and parameters used in the calculation are summarized in Table 1. The development of the weld pool includes the following stages: weld pool forming after the arc ignition, the pool expanding, and the pool reaching quasi-

steady state. The welding conditions were as follows: 1) Test piece was 304 stainless steel with 250 mm length, 60 mm width, and 3 mm thickness. 2) The welding current was 100 A. 3) The arc voltage was 14 V. 4) The welding speed was 125 mm/min. The figures and tables denote conditions as workpiece, SS304; thickness, 3 mm; 100 A; 14 V; and 125 mm/s. For the welding conditions used, the weld pool emerges at t = 0.82 s, then expands continuously, gets fully penetrated at t = 3.54 s, and reaches the quasi-steady state at t = 4.24 s. Figure 1 shows the transient development of the pool surface deformation, i.e., the maximum values of the depression at both sides and the hump at the topside vs. time. After the weld pool is formed at t = 0.82 s, the pool surface deformation is produced. As the pool volume expands with increasing time, the extent of the pool surface deformation gets bigger, and both maximum depression and hump at topside increase with time. The test plate is completely penetrated t = 3.54 s. In the mean time, the bottom surface of the weld pool starts to deform, so the whole weld pool is depressed. Then, the hump at topside decreases, while the depressions at both sides rise at a higher rate. When the thermal process reaches the quasi-steady state at t = 4.24 s, the weld pool geometry keeps constant, the hump at the topside becomes zero, and the depressions of the weld pool at both sides attain their maxi-


WELDING RESEARCH A

B

Fig. 3 — The ratios of Dd max /W and Dd max /L vs. time (workpiece, SS304; thickness, 3 mm; 100 A; 14 V; 125 mm/min). A — The ratio of the maximum de pression to the pool width; B — the ratio of the maximum depression to the po ol length.

mum and do not vary anymore with time. It can be seen that the increasing rate of the pool surface depressions is quite different before and after the pool is completely penetrated. Figure 2 illustrates the transient development of weld pool surface deformation at both the top and bottom sides of the weld pool. In this figure, A and B are the longitudinal sections (side view), while C and D are the transverse cross sections (front view). Compared to the top surface of the weld pool, the bottom surface gets depressed more seriously and quickly. The maximum depression at the bottom surface increases from 0 mm at t = 3.54 s (the moment when the pool is just completely penetrated) to 0.26 mm at t = 4.24 s (the instant when the quasi-steady state is reached). The increasing rate is 0.371 mm/s. As shown in Fig. 2D, there is a minor oscillation of the pool surface deformation at the bottom side after the weld pool geometry reaches quasisteady state. But the amplitude of such oscillation is so low that the bottom surface contours at t = 4.2 s and t = 4.4 s are nearly identical with each other. For the top surface depression, the increasing rates of maximum depression are 0.031 mm/s before complete penetration (from 0 mm at t = 0.82 s to 0.098 mm at t = 4.0 s) and 0.117 mm/s after complete penetration (from 0.098 mm at t = 4.0 s to 0.126 mm at t = 4.24 s), respectively. Since the variation rate of the top surface depression of the weld pool has a marked increase after the pool is completely penetrated, it can be taken as an indicator to judge whether the plate is penetrated or not. On the other hand, the pool length and width at the topside are also changed after complete penetration is achieved. To quantitatively describe the correlation of the topside surface depression with the extent of penetration, two characteristic variables are used to reflect the variation of the whole weld pool geometry, i.e., the ratio of the maximum de-


pression Ddmax to the pool width W ( Ddmax / W) , and the ratio of Ddmax to the pool length L ( Ddmax / L). Figure 3 shows the ratios of Ddmax / W and Ddmax / L vs. time. The three-segment curves of such ratios reflect the information on the penetration. During the expanding of the nonpenetrated weld pool, the values of Dd max / W and Ddmax / L rise slowly with time. At the moment the weld pool is fully penetrated (t = 3.54 s), the rising rates of Ddmax / W and Ddmax / L are suddenly increased, i.e., the slopes of two curves increase in a marked way. The first kink point on the curves corresponds to the moment when the weld pool gets fully penetrated. When the quasi-steady state is obtained at t = 4.24 s, the weld pool geometry is in a relatively stable condition, Ddmax / W and Ddmax / L are nearly constant, so the curves are just straight lines after 4.24 s. The second kink point on the curves corresponds to the moment when the weld pool reaches the quasi-steady state. Because the depression of the weld pool surface at the topside has the characteristics mentioned above, it can be employed as an indicator of weld penetration extent. In practice, the topside sensor can be developed to measure the weld pool surface depression for weld penetration control. Experimental measurements are made to verify the model. After welding, a macrograph of a weld cross section is made to measure the weld dimension. Table 2 is the comparison between the predicted and experimental weld depressions on a weld cross section. They are in agreement with each other. Conclusions

1) A 3-D transient numerical model is developed for investigating the dynamic behavior of the weld pool geometry, surface deformation, heat transfer, and fluid flow in a full-joint penetrated GTA weld pool. Based on the model, the weld pool

emerges at t = 0.82 s, then it expands continuously, gets fully penetrated at t = 3.54 s, and reaches the quasi-steady state at t = 4.24 s, for the welding conditions used (workpiece, SS304; thickness, 3 mm; 100 A; 14 V; 125 mm/s). 2) For the top surface depression, the increasing rates of maximum depression are 0.031 mm/s before complete penetration (from 0 mm at t = 0.82 s to 0.098 mm at t = 4.0 s) and 0.117 mm/s after complete penetration (from 0.098 mm at t = 4.0 s to 0.126 mm at t = 4.24 s), respectively. Compared to the top surface of the weld pool, the bottom surface gets depressed more seriously and quickly, with the maximum depression of 0.26 mm and the increasing rate of 0.371 mm/s. 3) The variation rate of the ratios of the maximum pool surface depression at the topside to the pool width, and to the pool length, can be described if the plate is completely penetrated. The simulation results lay a foundation for topside sensor-based process control of the GTAW process. Acknowledgments

The authors are grateful for the financial support for this project from United States National Science Foundation under Grant No. DMI-0114982, and The National Natural Science Foundation of China under Grant No. 50475131. They would like to thank T. T. Feng, M. X. Zhang, and J. K. Hu for their help in experiments, and H. G. Wang for his help in graph drawing. References

1. Swaim, W. 1998. Gas tungsten arc welding made easy. Welding Journal 77(9): 51–52. 2. Zhang, Y. M., Kovacevic, R., and Lin., L. 1996. Adaptive control of full penetration GTA welding. IEEE Trans. on Control Systems Tech nology 4(4): 394–403.

WELDING RESEARCH 3. Xiao, Y. X., and Ouden, G. den 1993. Weld pool oscillation during GTA welding of mild steel. Welding Journal 72(8): 428-s to 434-s. 4. Carlson, N. M., and Johnson, J. A. 1988. Ultrasonic sensing of weld pool penetration. Welding Journal 67(11): 239-s to 246-s. 5. Wikle, H. C., Kottilingam, S., Zee, R. H., and Chen, B. A. 2001. Infrared sensing techniques for penetration depth control of the submerged arc welding process. Journal of Ma teri als Processing Technology, 113: 228–233. 6. Friedman, E. 1978. Analysis of weld puddle distortion and its effect on penetration. Welding Journal 57(6): 161-s to 166-s. 7. Lin, M. L., and Eagar, T. W. 1985. Influence of arc pressure on weld pool geometry. Welding Journal 64(6): 163-s to 169-s. 8. Rokhlin, S. I., and Guu, A. C. 1993. A study of arc force, pool depression, and weld penetration during gas tungsten arc welding. Welding Journal 72(8): 381-s to 390-s. 9. Oreper, G. M., and Szekely, J. 1984. Heatand fluid-flow phenomena in weld pools. Jour nal of Fluid Mechanics, 147(10): 53–79. 10. Oreper, G. M., Szekely, J., and Eagar, T. W. 1986. The role of transient convection in the melting and solidification in arc weldpools. Metall. Trans. B, 17: 735–744. 11. Kou, S., and Wang, Y. H. 1986. Computer simulation of convection in moving arc weld pools. Metall. Trans. A, 17 (12): 2271–2277. 12. Tsao, K. C., and Wu, C. S. 1988. Fluid flow and heat transfer in GMA weld pools. Welding Journal 67(3): 70-s to 75-s. 13. Zacharia, T., David, S. A., Vitek, J. M., and Debroy, T. 1989. Weld pool development during GTA and laser beam welding of type 304 stainless steel, part I — theoretical analysis. Welding Journal 68: 499-s to 509-s.

14. Zacharia, T., Eraslan, A. H., Aidun, D. K., and David, S. A. 1989. Three-dimensional transient model for arc welding process. Metall. Trans. B, 20(10): 645–659. 15. Wu, C. S., and Tsao, K. C. 1990. Modelling the three-dimensional fluid flow and heat transfer in a moving weld pool. Engi neer ing Computations 7(3): 241–248. 16. Zacharia, T., David, S. A., Vitek, J. M., and Debroy, T. 1990. Modeling of interfacial phenomena in welding. Metall. Trans. B, 21(6): 600–603. 17. Choo, R. T. C., Szekely, J., and Westhoff, R. C. 1991. Modeling of high-current arcs with emphasis on free surface phenomena in the weld pool. Welding Journal 69(9): 346-s to 361-s. 18. Choo, R. T. C., Szekely, J., and David, S. A. 1992. On the calculation of the free surface temperature of gas-tungsten-arc weld pools from first principles: part II modeling the weld pool and comparison with experiments. Metall. Trans. B, 23(6): 371–384. 19. Wu, C. S., and Dorn, L. 1994. Computer simulation of fluid dynamics and heat transfer in full-penertrated TIG weld pools with surface depression. Computational Materials Science, 2: 341–349. 20. Domey, J., Aidun, D. K., Ahmadi, G., Regel, L., and Wilcox, W. R. 1995. Numerical simulation of the effect of gravity on weld pool shape. Welding Journal 74(8): 263-s to 268-s. 21. Wu, C. S., and Zheng, W. 1997. Analysis of fluid flow and heat transfer in a moving pulsed TIG weld pool. International Journal for the Joining of Materials, 9: 166–170. 22. Wu, C. S., Sun, J. S. 1998. Determining the distribution of the heat content of filler metal droplet transferred into GMA weld pools. Proc Instn Mech Engrs, Part B: Journal of

Engineering Manufacture, Vol. 212B, 525–531.

23. Ko, S. H., Choi, S. K., and Yoo, C. D. 2001. Effects of surface depression on pool con vecti on and geometry in stationary GTAW. Welding Journal 80: 39-s to 45-s. 24. Wu, C. S., and Yan, F. 2004. Numerical simulation of transient development and diminution of weld pool in gas tungsten arc welding. Modeling and Simulation in Materials Science and Engineering , 12: 13–20. 25. Kovacevic, R., and Zhang, Y. M. 1997. Real-time image processing for monitoring of free weld pool surface. ASME Journal of Manufacturing Science and Engineering , 119: 161–169. 26. Saeed, G., and Zhang, Y. M. 2003. Mathematical formulation and simulation of specular reflection based measurement system for gas tungsten arc weld pool surface. Mea sure ment Scie nce and Techn olog y, 14: 1671–1682. 27. Lin, M. L., and Eagar, T. W. 1986. Pressure produced by gas tungsten arcs. Meta ll. Trans. B, 17(9): 601–607. 28. Tsai, N. S., and Eagar, T. W. 1985. Distribution of the heat and current fluxes in gas tungsten arcs. Metall. Trans. B, 16(4): 841–846. 29. Goldak, J., Bibby, M., Moore, J., and Patel, B. 1986. Computer modeling of heat flow in welds. Metall. Trans., 17B: 587–600. 30. Choi, M., and Greif, R. 1987. A study of heat transfer during welding with applications to pure metals or alloys and low or high boiling temperature materials. Numerical Heat Trans fer , 11: 477–489. 31. Wu, C. S. Computer simulation of threedimensional convection in traveling MIG weld pools. 1992. Engin eerin g Comput ation s, 9(5): 529–537.

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Signature Analysis for Quality Monitoring in Short-Circuit GMAW An effective method has been developed to identify the process stability and weld quality of short-circuit GMAW BY Y. X. CHU, S. J. HU, W. K. HOU, P. C. WANG AND S. P. MARIN ABSTRACT. An efficient approach is presented to identify the stability and quality of short-circuit gas metal arc welding (GMAW) by using power spectral analysis and time-frequency spectral analysis methods. A systematic analysis based on experimental data shows that the shortcircuiting frequency is a determining factor on weld process stability. The relationship between the short-circuiting frequency and the process stability is established. Moreover, using the timefrequency analysis method, some disturbances and unpredictable variation of welding conditions, which contributes to an instable process, can be easily identified and weld defects can be located. A set of experiments with designed disturbances was conducted to verify the method. The results show that it is possible to evaluate the process stability and detect weld defects automatically during the welding process. The time-frequency analysis method is also useful in tuning or refining a welding procedure to obtain the greatest level of stability.

Introduction Gas metal arc welding (GMAW) is widely applied in various industries because of its high productivity, flexibility, and low cost. It can be operated in semiautomatic and automatic modes and can be utilized particularly well in a high volume productio n environment. In GMAW, there are three major modes of metal transfer from the electrode wire to the weld pool: globular transfer, spray transfer, and short-circuiting transfer. Short-circuit GMAW employs the lowest range of welding current, low voltage, and small wire diameters, thus producing low heat input and a small, fast-freezing weld pool. The low heat input minimizes distortion of the welded structure. Therefore, short-circuit GMAW is highly suited Y. X. CHU, S . J. HU, and W. K. HOU are with the Department of Mechanical Engineering, Univer sity of Michigan at Ann Arbor. P. C. WANG and S. P. MARIN are with M anufacturing Systems Re search Lab, General Motors Corp.

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for welding thin sheet metals. Recent trends toward fabricating hydroformed parts for vehicle structures have led to the implementation of short-circuit GMAW for thin sheets in the automotive industry. Short-circuit GMAW is characterized by periodic contacts between the electrode wire and the weld pool. This causes periodic changes in its welding current and voltage. Therefore, there must be a relationship between the electrical signals, welding process stability, and weld quality (since the weld joint with good quality can only be produced by a stable welding process). Signal processing and analysis techniques, which are widely used in process monitoring and control, may be employed to analyze the complex shortcircuit processes of GMAW. Using these methods, weld joint quality and welding stability corresponding to different short- circuit welding processes can be investigated. The stability of the arc in the shortcircuit process affects the quality — such as surface finish, penetration, and amount of spatter — of the weld. This means that stable arcs can result in stable welding processes and good weld quality. But even given a set of good welding parameters, the process may be disturbed by some unpredictable variation of welding conditions, causing unstable welding processes and leading to a greater probability of spatter, nonuniform weld bead, and other fusion defects. Thus, the goal of industrial welding to consistently produce high quality is quite difficult. However, traditional methods of monitoring welding processes and weld quality are heavily dependent on the knowledge, skill, and experience of welders. This is typically labor intensive, may be unreliable, and may also increase KEYWORDS

GMAW Process Stability Short-Circuiting Frequency Quality Monitoring Defect Detection

manufacturing cost. Therefore, a method of on-line monitoring of weld stability and weld quality by analyzing the signatures of the GMAW process would be highly desirable. In the last few years, much effort has been put into the study of weld stability and weld quality. The related research (Refs. 1–8) uses the welding voltage and current to analyze the stability or regularity of metal transfer in welding processes. Standard deviation is computed with arc and short-circuiting time, short-circuiting peak current, mean current, and voltage to assess the process stability. However, little research attention has been paid to the frequency domain or the time-frequency analysis of the welding processes to consider time-varying frequencies corresponding to unstable welding processes. Most existing studies have been focused on the time domain. There is no systematic study on the relationship between short-circuiting frequencies, welding process stability, welding parameters, and weld quality. It was reported (Refs. 1, 2) that in the short-circuiting welding mode, optimal stability occurs when the shortcircuit frequency equals the oscillation frequency of the weld pool and reaches its maximum. But measuring the weld pool oscillations is not practically possible in GMAW, in particular because of the impact of droplets entering the weld pool. Some monitoring systems are based on the visual analysis of weld quality after welding and normally employ visual information from the weld joint geometry, weld pool, and/or from the weld bead geometry (Ref. 9). However, visual systems are not always reliable where used in a production environment because the intensive disturbance from the electric arc interferes with the visual sensor system. The objective of this paper is to analyze the signatures of a welding process for welding stability and weld quality using power spectral density and timefrequency analysis methods. By analyzing the welding voltage and current in the frequency domain, the relationship between short-circuiting frequency and process stability and other welding parameters,

WELDING RESEARCH

Fig. 1 — The captured images of a metal transfer in short-circuit GMAW and Fig. 2 — Schematic diagram of GMAW principle with data acquisition. the corresponding welding current and voltage.

such as travel speed, wire feed rate, and welding voltage, is discussed and established. Signatures of welding processes for weld quality are analyzed and identified. The time-frequency analysis is used to identify the stability of a process at a specific time (or point). A systematic study based on experimental data shows that the power spectral analysis and timefrequency analysis methods are efficient approaches for stability and quality analysis of the GMAW process. This paper is organized as follows: the next section describes the short-circuit GMAW process, while the subsequent section presents signature analysis methodology, results and discussion, and a final summary.

Short-Circuit GMAW Process Short-circuit GMAW is characterized by periodic contacts between the electrode wire and the weld pool. As shown in Fig. 1, the electrode wire melts and the molten droplet is formed at the electrode tip during the arcing period T a. When the molten droplet touches the surface of the weld pool, short-circuiting transfer occurs, which extin guish es the arc. During the short-circuiting period T s, the welding voltage decreases to its minimum value, and the current increases to its maximum value. Once the contact bridge breaks, the arc is reignited, and another short-circuiting cycle starts. Therefore, the shortcircuiting frequency of the welding voltage and current corresponds to the characteristics of the molten metal transfer of a short-circuiting process. The GMAW process employs a consumable wire electrode passing through a copper contact tube, as shown in Fig. 2. The welding voltage is measured between the electrode wire applied to the contact tube and the conducting worktable that

serves as a reference. A Hall sensor is used to measure the welding current. After signal conditioning, the current and voltage are sampled by a data acquisition system with the sample frequency 4.0 kHz. The data are transferred to and stored in the computer. While the computer starts collecting current and voltage signals, a trigger signal is sent to a high-speed video camera to take images of the shortcircuiting transfer process in a synchronous way. Thus, the real image description of a short-circuiting transfer process, as shown in Fig. 1, can be observed to correspond with the periodic changes with current and voltage signals.

Signature Analysis of Welding Processes In this research, the welding voltage and current are used as main characteristic signals for signature analysis of the welding process. Since one cycle of welding current or voltage waveform corresponds to the transfer of one molten droplet in the short-circuiting process, the variation of the short-circuiting frequency of the current and voltage represents irregularity of metal transfer (i.e., the stability of the process). The following subsections will discuss the relationship between the short-circuiting frequencies, process stability, and weld quality by the power spectral density analysis and timefrequency analysis methods. First, the power spectral density and timefrequency functions are described. Next, the experimental results and computational analyses are presented. Power Spectral Density Function

Power spectral density is a frequencydomain function. It is most directly inter-

preted as a measure of the frequency distribution of the mean square value of the data. For the sequence of a sampled signal with a finite interval N, x(n), n=0,1,…, N –1, the power spectral density is the discrete Fourier transformation of the autocorrelation function as follows (Ref. 10):

()

N - 1

Â rxx (k)e - j 2 fk

P xx f =

p

(1)

k = – N + 1

where f is the frequency, r xx(k) is the autocorrelation function of a signal x(n) given by

()

r xx k =

1

N - k - 1

N

Â

n = 0

( )(

)

x n x n + k ,

k = 0,1, L , N - 1.

(2)

It can also be viewed in terms of direct Fourier transformation of the original data by

P xx

È 1 Í N - 1 f = x k e - j 2 N Í k = 0 Î

()

Â

()

˘

2

p kf ˙

˙ ˚

(3)

The function P xx(f) defined in Equation 1 is equivalent to the corresponding function defined in Equation 3. Thus, spectral density functions can be estimated either through finite Fourier transformations of the correlation’s functions, or through finite Fourier transformations of the original time history signals.

Time-Frequency Spectrum Function The time-frequency analysis describes

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Fig. 3 — Power spectral densit y analysis for diffe rent wire feed rates (bare steel): A — 50 in./min; B — 70 in./min; C — 90 in./min; D — 110 in./min; E — 130 in./min; and F — 150 in./min. Welding speed = 0.51 m/min, voltage = 15 V, and CTWD = 13.97 mm (0.55 in.).

how the frequency content of a signal is changed in time. There are several ways to theoretically describe the spectra of time varying signals, including the short-time Fourier transformation, the generalized spectrum, the evolutionary spectrum, the instantaneous autospectrum, and physical spectrum. The wavelet waveform can also be used to analyze nonstationary signals. The short-time Fourier transformation method is one of the simplest and most commonly used time-frequency representations and is employed in this study to analyze the time-frequency properties of the welding signals. A brief description of this method follows. The basic idea is to first select, by means of a “window” function, a small piece of the signal about a time of interest. A standard Fourier analysis of this windowed signal is then used to infer frequency content at the selected time. We illustrate as follows: Consider x(t) a time-varying signal, h(t) a window function. Let t be the time of interest and t the running time, then the window function h( t) can be designed to emphasize the times around the time of interest t–t. Multiplying the signal x(t) by the window function h(t–t), centered on the time of interest t–t obtains the weighted signal x h

( - t) = x( )h( - t) . t

t

(4)

t

Considering this signal as a function of t and taking the spectrum of it yields the short-time Fourier transform (Ref. 11)

( )

S f ,t =

=

1

•

Ú -• x h ( )e - j2 f d

2p • 1 2p

p t

t

Ú -• x( )h( t

t

t

)

- t e - j2

f

p t

dt

(5)

where f is the frequency. Then the power spectrum (also called the spectrogram) of the modified signal becomes

( ) ( )

G f ,t = S f ,t

2

2

=

1 2p

Fig. 4 — Power spectral density analyses for different wire feed rates (galvanized steel): A — 70 in./min; B — 90 in./min; C — 110 in./min; D — 130 i n./min; E — 150 in./min; and F — 170 in./min. Welding speed=0.25 m/min (10 in./min), voltage=15 V, and CTWD=13.97 mm (0.55 in.).


•

Ú -• x( )h( - t)e- j2 f d t

t

p t

t

.

(6)

The short-time Fourier transformation is the prototype of a time-frequency distribution and an extremely powerful tool in many areas. The advantage of the shorttime Fourier transformation is that it has an easily understandable interpretation, as described above, and gives a good timefrequency representation for many signals.

WELDING RESEARCH

Fig. 6 — Relationship between short-c ircuiting frequency and weldin g voltage.

Fig. 5 — Relati onshi p betwe en the short- circu iting frequ ency and wire feed rates: A — bare steel; and B — galva nized steel.

The commonly used windows include rectangular, triangular, Hanning, Hamming, and Blackman windows. In this study, a Hanning window was chosen and it worked well for the welding signal analysis. The mathematical formula defining the Hanning window (Ref. 11) is as follows:

(

h t

ÏÔÊ 1 - cos 2p t ˆ / 2, 0 £ t £ 1 , (7) = ) ÌÔË ( )¯ Ó0 , otherwise

For the sequence of a sampled signal, the discrete form of the short-time Fourier transformation is used. The signal processing and algorithm implementation were done with the signal processing toolbox of Matlab. Results and Discussion

Several sets of experiments with different welding parameters were conducted. Welding signals were collected and analyzed as described previously. A Powerwave 455 welding machine made by Lincoln Electric Co. was used as the welding power source, and an automatic trav-

Fig. 7 — Relationship between short-c ircuiting frequency and CTWD.

Table 1 — Welding Parameters and Consumables Used in the Study

Wire Type ER70S-6

Wire Diameter in. (mm) 0.035 (0.9)

Feed Voltage Welding Electrode Rate (volt) Speed CTWD in./min in./min in. (mm) (m/min) (m/min) 50–190 15 5~30 0.55 (1.27–4.83) (0.127~0.765) (13.97)

eling cart was employed to move the welding torch according to a preset welding speed. ER70S-6 was chosen as the welding filler metal. The contact tip-to-workpiece distance (CTWD) was 13.97 mm (0.55 in). Bare and galvanized steels with gauges of 0.063 in. (1.6 mm) were used in the welding trials. Bead-on-plate welds were made with GMAW usin g various welding parameters. Table 1 lists the welding parameters and welding consumables used in this study. The welding voltage and current signals were collected by the data acquisition system during the experiments. Photographs of the weld surfaces were taken and weld specimens were cut to measure

Gun Shielding Angle Gas 90 deg

75%Ar +25%CO2

Flow Rate (ft3 /h) 30

the weld bead geometry, and to check internal weld quality, porosity, and weld penetration. The weld surface quality was evaluated based on three criteria: uniformity of the weld bead width, smoothness of the weld surface, and amount of the spatter. Based on the evaluation result of the weld surface and the examination outcome of the weld cross section, a weld quality judgment was given to each weld. With the welding voltages and current signals, a low-pass filter is designed and applied to filter measurement noise and induced noise. In the discussion that follows, we describe the analysis of various welding signals using the methods described above.


WELDING RESEARCH

Fig. 8 — Time-frequency spectrum analyses for various wire feed rates under a welding speed of 30 in./min (for bare steel): A — 50 in./min; B — 70 in./min; C — 90 in./min; D — 110 in./min; E — 130 in./min; and F — 150 in./min.

short-circuiting frequency (Hz); the y-axis is the power (or energy) density magnitude. As can be seen in Fig. 3, the maximal spectral peak varies when the wire feed rate changes from 50 to 150 in./min (1.27 to 4.83 m/min). The corresponding dominant frequency increases when the wire feed rate increases from 50 to 130 in./min (1.27 to 3.30 m/min). However, while the wire feed rate continues to increase, the dominant frequency decreases. This im Fig. 9 — Frequency- wire feed rate spectral graph of the welding plies that there exists a wire process for a welding speed of 20 in. /min (for bare steel). feed rate at which the shortcircuiting frequency reaches the maximum. At 130 Power Spectral Density Analysis in./min (3.30 m/min) wire feed rate in this set of experiments, the weld bead is obBy computing the power spectral denserved to be the most uniform and exhibits sity of welding currents (Equations 1 or 3), the best surface quality. The different an analysis of welding experiments was magnitudes in the power spectral density carried out. Figures 3 and 4 show the mean that the signals consist of different power spectral density analysis results of frequency components with comparable the welding current at different wire feed energy. The multifrequencies, as shown in rates for bare steel and galvanized steel, Figs. 3A, 3B, 3C, and 3F, correspond to respectively. In the figures, the x-axis is the nonuniform welds and significant spatter.

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The welding process with a unique frequency (Figs. 3D and 3E) corresponds to uniform welds and good weld surface quality. A systematic analysis based on experimental data shows that the short-circuiting frequency is a determining factor on the stability of welding processes. A series of experiments for galvanized steel was also conducted. The analysis results show that when the wire feed rate is 110 in./min (2.79 m/min), the dominant short-circuiting frequency of the process stays constant during the whole welding process and reaches the maximum, as shown in Fig. 4C. Similarly, as the wire feed rate increases from 70 to 170 in./min (1.78 to 4.32 m/min), the weld quality changes from poor to good, then to poor again. The best weld quality is obtained at a wire feed rate of around 110 in./min (2.79 m/min). A very interesting phenomenon is that there is a low-frequency component with very high energy when the wire feed rate is larger than 130 in./min (3.3 m/min) for galvanized steel. This can be explained by the fact that there is al ways a periodic long arc period after several normal short-circuiting periods. Once this phenomenon had occurred, there was much spatter during welding, which can be observed from the welds pictured in Fig. 4. A further study will be conducted for detailed explanation and analysis. Figures 5A and B illustrate the relationship between the dominant short-circuiting frequency and the wire feed rate at different welding speeds for bare and gal vanized steel, respectively. As can be seen, there is the maximal frequency around 105 Hz corresponding to different welding speeds for the bare steel. The maximal frequency has a slight right shift, but not much change when the welding speed increases. There is no significant change of the short-circuiting frequency for the gal vanized steel and bare steel welding. The above analysis results show that most uniform welds can be obtained under a unique short-circuiting frequency reaching maximum value. Furthermore, keeping a constant short-circuiting frequency is a necessary condition to obtain a stable welding process and good weld quality. With this method, it is easy to test the various welding conditions and identify whether a welding process is stable or not. Based on the stability analysis, an operational range resulting in stable welding processes can be suggested. Figure 6 shows the relationship between the short-circuiting frequencies and the welding voltages while other welding parameters are kept constant at a wire feed rate of 110 in./min (2.79 m/min), welding speed of 20 in./min (0.51 m/min), and CTWD of 0.55 in. (13.97 mm). From the figures, it can be seen that the short-

WELDING RESEARCH circuiting frequency varies as the welding voltage changes. Especially when the voltage increases to 15 V, the frequency starts decreasing. As the welding voltage increases beyond this, the short-circuiting frequency decreases and weld surface quality becomes poor. In other words, under these experimental conditions, the short-circuiting frequency reaches a maximum around a welding voltage of 15 V, where the welding process is most stable, and the best weld quality is obtained. Figure 7 illustrates the relationship between the short-circuiting frequency and CTWD when other welding parameters keep constant at a wire feed rate of 110 in./min (2.79 m/min), welding speed of 20 in./min (0.51 m/min), and welding voltage of 15 and 17 V, respectively. As shown in Figure 7, the short-circuiting frequency does not have much change; it becomes slightly smaller as CTWD increases. But the weld surface quality becomes poor. Similarly, there is a maximum shortcircuiting frequency at which the welding process is most stable. With the same CTWD, the short-circuiting frequency under a welding voltage of 15 V is higher than under a welding voltage of 17 V. Compared with the CTWD and the welding voltage, the CTWD has less influence on the short-circuiting frequency and weld surface quality. However, it does affect the weld bead geometry and ignition of welding arc. The higher the CTWDs are, the shallower the penetrations.

Fig. 10 — Time-frequency analyses of welding currents with oils on part of weld surfaces: A — bare steel; B — galvanized steel.

Time-Frequency Analysis

If a welding process is stable and with constant metal transfer frequency, then the power spectral density can be used for analysis by taking any piece of the signal from the long welding process. But if a welding process is not stable or there are surface disturbances, then the welding voltage or current may fluctuate and the short-circuiting frequencies of the signals cannot be kept constant. For these nonstationary signals we use the time-varying spectrogram analysis method described above to perform a time-frequency analysis for the welding current. In this section we apply time-frequency analysis to again study the effect of wire feed rate on process stability. In the following subsection, we apply the method to explore the effect of several types of surface disturbances on process stability. The experimental parameters were the same as used in the previous subsection. Figure 8 shows the time-frequency spectral graphs of the welding currents at six different wire feed rates at a constant welding voltage of 15 V, a constant CTWD of 0.55 in. (13.97 mm), and a welding speed of 30 in./min (0.76 m/min). In Fig. 8,

Fig. 11 — Time-frequency analyses with various disturbanc es: A — hole; B — no shielding gas; C — paint (bare steel); and D — pain t (galvanized steel).

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WELDING RESEARCH

Fig. 12 — Time-frequency analysis of welding current with the butt joint for two materials of bare and galvanized steels with different thicknesses: A — time-frequency spectra; B — dominant frequency at peak powers; and C — welded specimen.

the x-axis is time; y-axis is the shortcircuiting frequency (Hz); and z-axis is the magnitude of the time-varying power spectrum function. From these graphs, it can be seen how the short-circuiting frequencies vary during a welding process and under different welding parameters. As shown in Fig. 8, when the wire feed rate is 50 in./min (1.27 m/min), no periodic components and frequency components can be identified during certain time periods due to the irregular short-circuiting processes. No continuous weld was formed, only some weld spots. When the wire feed rate increases to 70 in./min (1.78 m/min), the frequency components distribution along the time axis is clearly shown in Fig. 8B. This figure shows that the spectrum of welding current contains a wide range of short-circuiting frequency components with comparable energy of signals. This means that the spectrum of welding current consists of different shortcircuiting frequencies and the welding process was not stable. Based on the observation from Figs. 3, 8, and 9, the nonuniform weld surface is consistent with the signal analysis results. When the wire feed rate increases to 110 in./min (2.79 m/min) (Fig. 8D), the short-circuiting frequency stays almost constant during the whole welding process. This is a stable welding process and thus results in a very uniform weld surface. The analysis results show that the wire feed rate from 100 to 120

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in./min (2.54 to 3.05 m/min) is a good range for obtaining stable welding processes for bare steel with a thickness of 0.06 in. (1.52 mm) under the welding voltage of 15 V, the CTWD of 0.55 in. (13.97 mm), and welding speeds from 5 to 30 in./min (0.127 to 0.762 m/min). Therefore, with the time-frequency analysis, it is easy to identify which welding process is stable, whether a process remains stable during a long welding process, and the variation of the short-circuiting frequency. In Fig. 9, seven normalized timefrequency spectral results are combined together to intuitively compare the frequency components of signals under different wire feed rates (WFR), in the x-axis corresponding to 50, 70, 90, 110, 130, 150, and 170 in./min (1.27, 1.78, 2.29, 2.79, 3.30, 3.81, and 4.31 m/min), respectively. As can be seen in the figure, while the wire feed rate varies from 50 to 150 in./min (1.27 to 3.81 m/min), the obvious change of the dominant frequency can be observed. The figure demonstrates the stable regions [110–130 in./min (2.79~3.30 m/min)] of the welding processes at the designed welding conditions. Time-Frequency Analysis for Welding with Disturbances

Various welding conditions were created for bead-on-plate welds by setting some disturbances on the plate surfaces.

We examined the effect of oily surfaces, small holes, lack of shielding gas, and paint on the weld plate surface. With these disturbance conditions, two sets of experiments were conducted; one set for bare steel, the other for galvanized steel. The welding parameters kept constant were wire feed rate [110 in./min (2.79 m/min)], welding voltage (15 V), CTWD [0.55 in. (13.97 mm)], and arc welding speed [20 in./min (0.51 m/min)]. Also, a butt joint weld was carried out with two different materials, joining a bare steel sheet to a galvanized steel sheet. Figures 10A and B show the timefrequency analysis results of the welding current with dirty oil on the plate surfaces for bare steel and galvanized steel, respectively. As observed from the appearance of the weld bead, this influenced the weld surface quality. The bead width and reinforcement become smaller than normal on the oily parts. As shown in Fig. 10A, at the first part, the welding process was operated under the normal condition; the dominant frequency is at mean 106.4 Hz, standard deviation (STD) 5.87 Hz. When going to the part with oil, the shortcircuiting process was abnormal and the dominant frequencies at the peak powers vary dramatically with mean 60.2 Hz and STD 38.1 Hz. Thus, this results in the nonuniform weld. Figure 10B shows similar analysis results for galvanized steel, except that the mean value of the short-circuiting frequency was 60 Hz for galvanized steel, instead of 105 Hz for bare steel. Figures 11A–D show the timefrequency analysis results for four kinds of disturbances: a small hole on the weld plate, lack of shielding gas, and some paints on plate surfaces, respectively. As shown in Fig. 11A, when the welding path passes a small hole, the welding current drops sharply and the short-circuiting frequency at that time decreases signifiantly. Shielding gas is used to prevent oxidation and contamination of weld joints. The weld surface quality is sensitive to the lack of shielding gas. The weld surfaces of both the bare steel and the galvanized steel exhibit significant porosity when the shielding gas was insufficient or lost. The reinforcement and bead width are smaller than normal welds. The short-circuiting process during that period is not dominated by one frequency, but multifrequency components, as seen in Fig. 11B. This implies an unstable process. When some paint was put on the surfaces of both bare and galvanized sheet steels, the experimental results show that the weld bead geometries and surface quality changed at the painted area, which reflects the change of the welding voltage and current. The bead width and weld penetration

WELDING RESEARCH at the painted area are narrower and shallower than those made at nominal conditions. As shown in the time-frequency analysis result of Fig. 11C, the mean of the short-circuiting frequency has changed, decreasing to 57.8 Hz on the painted surface from 97.5 Hz under the normal condition. For the galvanized steel, the welding current suddenly jumps from its normal value at the first boundary between the painted area and the unpainted area, and then returns to normal on the painted surface. But at the secondary boundary end edge between the painted area and the unpainted area, the welding current has a second jump. At these two boundaries, the weld beads have serious defects, very nonuniform, almost no reinforcement. The time-frequency analysis also shows the frequency change at the two boundaries in Figs. 11C and D. Finally, we examined the joining of two sheets with different coatings. Bare steel and galvanized steel were welded together using a butt joint method. Figure 12C shows the picture of the weld. The first part of the weld is uniform and of good quality, but the second part of the weld shows defects due to the deviation of the root opening between the two parts caused by heat deformation after welding of the first part. The short-circuiting frequency at the first part is about 40 Hz, but at the second part, the short-circuiting frequency dropped and varied dramatically. The change of the frequency represents the weld surface quality change.

Summary This paper focuses on the signature analysis of the short-circuiting frequency of GMAW processes for weld surface quality by using power spectral density

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and time-frequency analysis methods. The relationship between the short-circuiting frequency, welding stability, weld quality, and other welding parameters, such as the travel speed, the wire feed rate, and the welding voltage, was investigated based on experimental data analysis. A systematic analysis shows that the short-circuiting frequency is a determining factor on the stability of welding processes. A series of experiments was carried out for validation of the analysis results. The characteristic difference between welding processes for bare steel and galvanized steel were studied and compared. Based on the frequency signature analysis, a stable welding process and uniform weld beads can be obtained when the short-circuiting frequency remains stable and reaches its maximum. The analyses show that the time-frequency analysis method for welding signals is an effective approach for identifying the stability of processes and weld surface quality. This method is also very useful in tuning or refining a welding procedure to obtain the greatest level of stability. The study on the short-circuiting frequency of the metal transfer process is important in understanding the effect of weldi ng parameters on short-cir cuiting processes and weld stability in GMAW. Acknowledgments

This research was sponsored by the General Motors Collaborative Research Laboratory at the University of Michigan. The Lincoln Electric Co. is also acknowledged for providing welding machines. References

1. Hermans M. J. M., and Den Ouden, G. 1999. Process behavior and stability in short cir-

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cuit gas metal arc welding. Welding Journal 78(4): 137-s to 141-s. 2. Adolfsson, S., Bahrami, G., Bolmsio, G., and Claesson, I. 1999. On-line quality monitoring in short-circuit gas metal arc welding, Welding Journal 78(2): 59-s to 73-s. 3. Quinn T. P. M., Smith, C., McCowan, C. N., Blachowiak, E., and Madjgan, R. B. 1999. Arc sensing for defects in constant-voltage gas metal arc welding. Welding Journal 78(9): 322-s to 328-s. 4. Subramaniam, S., White, D. R., Jones, J. E., and Lyons, D. W. 1999. Experimental approach to selection of pulsing parameters in pulsed GMAW. Welding Journal 78(5): 166-s to 172-s. 5. Blumschein-E. 1997. Fast detection of essential changes in GMAW processes. Seventh International Conference on Computer Technology in Welding (NIST SP 923). Washington, D.C.: NIST, pp. 474–485. 6. Norrish, J. 1994. Process stability assessment and metal transfer control for robotic gas metal arc welding, 10th ISPE/IFAC International Conference on CAD/CAM, Robotics and Factories of the Future CARs & FOF’94. Information Technology for Modern Manufacturing. Conference Proceedings, pp. 336–41. 7. Cook, G. E., Maxwell, J. E., Barnett, R. J., and Thompson F. M. 1994. Statistical weld process monitoring and interpretation. Proc. of 1994 IEEE Industry Applications Society Annual Meeting , Vol. 3, Denver, Colo., pp. 1828–35. 8. Sanders, L., West, M., and Norrish, J. 1998. Real-time irregularity detection in gas metal arc welding. Proceedings of the 8th Inter national Conference on Compute r Technology in Welding, pp. 62–76. 9. Wezenbeek, H. C. 1992. A system for measurement and control of weld pool geometry in automatic arc welding. Ph.D. dissertation, Technische University, Eindhoven, Netherlands. 10. Hayes, M. H. 1996. Statistical Digital Sig nal Processing and Modeling. New York, N.Y.: John Wiley & Sons. 11. Carmona, R., Hwang, W.-L., and Torresani, B. 1998. Practical Time-Frequency Analysis. Academic Press.

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