WJ 2012 12 PDF

December 2012 Cover_4/06 Cover 11/12/12 9:27 AM Page C1
December 2012
WELDING JOURNAL VOLUME 91 NUMBER 12 DECEMBER 2012
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
select arc_FP_TEMP 11/7/12 3:38 PM Page C2
For Info go to www.aws.org/ad-index

cpec_FP_TEMP 11/7/12 3:53 PM Page 1
WeldOffice
The Industry Standard
Software Solutions
www.cspec.com
AWS D1.1 and ASME IX Code Compliant
Procedures & Welders
WPS - Create and manage multi-code (ASME, AWS, ISO), welding procedure
WPS specifications. WPS and PQR creation is simple, fast and accurate with
WeldOffice is a registered trademark of ASMEIX Corporation dba C-SPEC

automatic code checking and links to code related software modules.
WPQ - Create and manage multi-code welder qualification records.

WPQ Simple, fast and accurate WPQ creation with automatic code checking and
welder continuity maintenance. Finds qualified welders for actual produc-
tion requirements and/or WPS requirements.
NDE - Simple, fast and accurate nondestructive examination and visual

NDE inspection test reports with pre-defined layouts plus editable technique
sketches for radiographic, ultrasonic, magnetic particle and liquid
penetrant examination.
Turbo-IX -The quickest and the easiest way to review WPSs and support-
TIX ing PQRs for code compliance. Identifies and displays the actual ASME
Section IX variables and code requirements. Provides justification for WPS
qualification acceptance and/or rejection.
Turbo-INT - Instantly resolves code disputes involving welding procedures,

INT welder qualifications and construction code issues. Includes over 10,000
ASME B&PV Code Interpretations, Sections I, II, III, IV, V, VI, VII, VIII, IX, X, XI,
B31.1, and B31.3.
1-877-977-7999
For Info go to www.aws.org/ad-index weldoffice.com
camfil farr_FP_TEMP 11/7/12 3:35 PM Page 2

December 2012_Layout 1 11/8/12 10:19 AM Page 3
CONTENTS December 2012 Volume 91 Number 12

AWS Web site www.aws.org
Features Departments
24 Reducing the Ecological Impact of Arc Welding
Some practical advice is offered for ways to reduce energy Editorial ............................4
consumption when welding
32 28
M. A. Purslow
Program Aids in Modeling Welding Thermodynamics

Washington Watchword ..........6
Press Time News ..................8
News of the Industry ............10
Examples are given how computational thermodynamics is Aluminum Q&A ..................14
used to help design welding alloys and improve process
efficiency Brazing Q&A ......................16
P. Mason Product & Print Spotlight ......18
Coming Events....................40
32 Green: A Way of Life for Weld Tooling Company Certification Schedule ..........44
A shop that specializes in manufacturing weld fixtures has
been recycling for so long, it has become second nature to its Society News ....................47
operation Tech Topics ......................48
B. Kratz Errata AWS D3.6M:2010 ......48
Underwater Welding Code
38 Moving from Paper to Pixels
Guide to AWS Services ........64
73 There is a way to save time and money with the use of welding
documentation software
D. Craig
Personnel ........................68
The American Welder
Learning Track ..................84
The American Welder Fact Sheet ......................88
73 Selecting Fume Collectors for Welding Applications Welding Journal Index ..........96
The seven most important things to take into consideration Classifieds ......................108
when searching for a cartridge fume-collection system are Advertiser Index ................110
addressed
G. Schreier
78 From the Lab to the Production Floor: Students Learn It All

Ferris State University welding students are benefiting from a
close working relationship with industry professionals
K. Packard et al.
Welding Research Supplement

319-s Development of an Oxyrutile Electrode for Wet Welding
An experimental electrode developed for underwater welding Welding Journal (ISSN 0043-2296) is published
78 showed improved weld metal properties

V. R. Santos et al.
monthly by the American Welding Society for
$120.00 per year in the United States and posses-
sions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
329-s Modeling of Human Welder Response to 3D Weld Pool
$14.00 single issue for international. American
Surface: Part II Results and Analysis Welding Society is located at 8669 Doral Blvd.,
An initiative was made to develop a model that simulates a human Doral, FL 33166; telephone (305) 443-9353. Peri-
welders response to a weld pool in an effort to improve intelligent odicals postage paid in Miami, Fla., and additional
robotic systems mailing offices. POSTMASTER: Send address
changes to Welding Journal, 8669 Doral Blvd.,
W. J. Zhang and Y. M. Zhang Suite 130, Doral, FL 33166. Canada Post: Publi-
cations Mail Agreement #40612608 Canada Re-
338-s Theoretical and Empirical Validation of a Mobile turns to be sent to Bleuchip International, P.O. Box
Robotic Welding Platform 25542,London, ON N6C 6B2
A mobile robot welding system was investigated to expand the use Readers of Welding Journal may make copies of
of robots for nontraditional fabrication of large products such as articles for personal, archival, educational or
ships research purposes, and which are not for sale or
J. Stacy and S. Canfield resale. Permission is granted to quote from arti-
cles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
346-s Double Stage Plasma Arc Pipe Welding Process excluded from copyright.
A plasma arc system that utilized both the keyhole and conduction
modes was used to produce a desirable root weld in pipe
X. R. Li et al.
WELDING JOURNAL 3
Editorial December 2012_Layout 1 11/9/12 1:21 PM Page 4
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Meeting the Welding Officers

President William A. Rice Jr.
Workforce Shortfall Head-on OKI Bering
Vice President Nancy C. Cole

My year as president of the American Welding Society (AWS) is rapidly winding NCC Engineering
down, but I have seen enough positive changes in the past 12 months to keep me invig- Vice President Dean R. Wilson
orated for a long time. Those of you who attended the AWS business meeting last Well-Dean Enterprises
month in Las Vegas heard me speak about recent successes with our American
Welding Online training programs, the move of AWS into a new World Headquarters, Vice President David J. Landon
the Welding Merit Badge introduced by the Boy Scouts of America, and some of the Vermeer Mfg. Co.
work we are doing in developing new business around the world. But, perhaps the
Treasurer Robert G. Pali
most important project AWS is involved in at the moment is the workforce develop-
J. P. Nissen Co.
ment program presently being managed through the AWS Foundation.
I am sure you are familiar with the scenario by now: 1) an aging workforce of skilled Executive Director Ray W. Shook
professionals is declining by approximately 10% per year, primarily through retire- American Welding Society
ment; 2) an insufficient number of young people are entering the field to replace
them; and 3) the country is facing a shortfall of qualified people in many welding fields
that could reach 238,000 by 2019. Directors
AWS is working diligently to address what we call the welder shortage, and many T. Anderson (At Large), ITW Global Welding Tech. Center
programs have been put into place to inform students, parents, career counselors, and
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
even mid-career professionals of the numerous opportunities in the field of welding.
This is being done by publishing career guides, exhibiting at various trade shows, seek- J. C. Bruskotter (Past President), Bruskotter Consulting Services
ing attention of print and broadcast media, and alerting public officials to the prob- G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
lem. However, the biggest and most visible step in workforce development may be the T. A. Ferri (Dist. 1), Victor Technologies
launch of the AWS/Lincoln Electric Careers Trailer.
D. A. Flood (Dist. 22), Tri Tool, Inc.
Lets take a look at how this latter initiative developed. A couple of years ago, I was
shown a welder training tractor-trailer that former AWS District Director Ken R. A. Harris (Dist. 10), Total Quality Testing
Stockton had built. I was impressed, and I brought the idea of doing something simi- D. C. Howard (Dist. 7), Concurrent Technologies Corp.
lar to the AWS Board this time with computer-based virtual welding equipment J. Jones (Dist. 17), Victor Technologies
that has special appeal to young people. The trailer was formally launched at the 2011
FABTECH Show in Chicago. It has since taught many thousands more people about W. A. Komlos (Dist. 20), ArcTech, LLC
job opportunities in welding as it has traveled across North America. This year, the R. C. Lanier (Dist. 4), Pitt C.C.
Welding Careers Trailer visited Ohios State of the State event, FABTECH Canada T. J. Lienert (At Large), Los Alamos National Laboratory
in Toronto, the Boy Scouts Camporee in Ohio, the Indy 500 automobile race, the
J. Livesay (Dist. 8), Tennessee Technology Center
Airventure Air Show in Wisconsin, several state fairs, the IMTS show in Chicago,
FABTECH 2012 in Las Vegas, and numerous other events. M. J. Lucas Jr. (At Large), Belcan Engineering
And, this is just the beginning. We have a great deal of work to do in informing the D. E. Lynnes (Dist. 15), Lynnes Welding Training
public about the importance of welding in our lives, the varied employment opportuni- C. Matricardi (Dist. 5), Welding Solutions, Inc.
ties in this field, and how to get the training needed to start on this exciting career path-
D. L. McQuaid (At Large), DL McQuaid & Associates
way. Judging by media attention to our efforts, and by fast-growing enrollment in welder
training programs, weve got the publics attention. We also have the attention of weld- J. L. Mendoza (Past President), Lone Star Welding
ing and manufacturing organizations in other countries, which are facing similar kinds S. P. Moran (At Large), Weir American Hydro
of difficulties filling positions in the skilled trades. We have seen enthusiastic response K. A. Phy (Dist. 6), KA Phy Services, Inc.
to our workforce development efforts from welding and trades organizations in Europe,
W. R. Polanin (Dist. 13), Illinois Central College
Asia, and Australia after all, its a worldwide problem demanding cooperative solu-
tions that serve to heighten the profile of welding technology everywhere. R. L. Richwine (Dist. 14), Ivy Tech State College
Its been a short year as AWS president, but we have been able to launch a career- D. J. Roland (Dist. 12), Marinette Marine Corp.
building effort that will serve our industry, and our N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
country, long-term. I can think of few things more
gratifying than to see this come to pass. N. S. Shannon (Dist. 19), Carlson Testing of Portland
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
William A. Rice
AWS President
4 DECEMBER 2012
esab_FP_TEMP 11/7/12 3:36 PM Page 5
TAKE A
WARRIOR

INTO
BATTLE.
Ordinary welders go to work. Warriors do battle. And youre a warrior youve got the experience to
prove it. Now theres an extraordinary machine thats as rugged and reliable as you are. Introducing Warrior
by ESAB. Designed with input from real-world welders like you and brought to life by ESABs leading-edge
engineering. Warrior is built with inverter technology and features a high-duty cycle, read-anywhere display,
and glove-friendly controls to give you the power to be your best, anywhere, anytime.
For more information, visit www.esabna.com/esab-warrior or scan this QR code.
ESAB Welding & Cutting Products / esabna.com / 1.800.ESAB.123

WW December_Layout 1 11/9/12 2:35 PM Page 6
WASHINGTON BY HUGH K. WEBSTER

WATCHWORD AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
Manufacturing Competitiveness Act Bill Introduced to Limit Reach of

Passed by House EPA Science Board
The House of Representatives, on a bipartisan vote, has ap- The Environmental Protection Agency (EPA) Science Advi-
proved the American Manufacturing Competitiveness Act of sory Board (SAB) Reform Act (H.R. 6564), seeks to lessen the
2012 (H.R. 5865). This legislation will create a bipartisan Manu- influence of the SAB, which in recent years has been criticized
facturing Competitiveness Board consisting of 15 members, five for being populated by persons who lack private sector experi-
from the public sector appointed by the president including ence and who receive grants from EPA, presenting possible con-
two governors from different parties and ten from the private flicts of interest. Concern has also been expressed regarding the
sector appointed by the House and Senate, with the majority ap- lack of opportunity for the public or other interested parties to
pointing three and the minority two in each chamber. The board offer comments on SAB recommendations. The SAB historically
will conduct a comprehensive analysis of the U.S. manufacturing has been quite influential in advising the EPA on regulations and
sector, covering everything from trade issues to taxation, regula- other initiatives. Defenders of the current SAB structure believe
tion, and new technologies. Based on this analysis, it will develop that the body offers guidance unfettered by considerations unre-
a strategy that includes specific goals and recommendations for lated to science.
achieving them. The first strategy will be due in 2014 and the sec- This legislation would, among other measures, allow for pub-
ond in 2018. The particular areas of focus include the following: lic participation and public comment opportunities, impose re-
Elimination or repeal of regulations that create disadvantages quirements for balance, establish a conflict of interest policy, and
for U.S. manufacturers compared to foreign competitors; limit any nonscientific policy advice or recommendations from
Improvement of government policies and coordination of pol- the SAB.
icy implementation;
Consolidation or elimination of government programs; and
Improvement of communication and interaction between gov- Effectiveness of Agency Performance Laws
ernment and the manufacturing community. Questioned
Public-Private Partnerships to Support A recent study by the Brookings Institution suggests that con-
gressional efforts over the past several years at improving the
Manufacturing overall management and performance of federal agencies have
Ten public-private partnerships have been awarded $20 mil- been ineffective. The centerpiece of the strategy to enhance man-
lion to support manufacturing in the United States. The partner- agement effectiveness has been the creation of a federal per-
ships were selected through the Advanced Manufacturing Jobs formance management system. This system consists of a set of
and Innovation Accelerator Challenge (AMJIAC), which is a routines to measure and disseminate performance data, with the
competitive multiagency grant process, to support initiatives that hope that such data will be used to improve programmatic out-
strengthen advanced manufacturing at the local level. These pub- comes. Importantly, federal law also requires agencies to develop
lic-private partnerships consist of small and large businesses, col- and publish performance plans and reports on a regular basis.
leges, nonprofits, and other local stakeholders that cluster in a However, according to the study, agency managers indicate
particular area. The funds will help the winning clusters support that these systems only improve the establishment of perform-
local efforts to spur job creation through a variety of projects, ance goals and measurements for those goals, but have little or
including initiatives that connect innovative small suppliers with no impact on the actual accomplishment of them.
large companies, link research with the start-ups that can com-
mercialize new ideas, and train workers with skills that firms need U.S.-Panama FTA Imminent
to capitalize on business opportunities.
The AMJIAC is a partnership between the Department of Final implementation of the U.S.-Panama Free Trade Agree-
Commerces Economic Development Administration, the Na- ment reportedly is imminent. The United States has taken all
tional Institute of Standards and Technology, the Department of steps necessary for finalization, and the FTA is now awaiting sig-
Energy, the Department of Labors Employment and Training nature by the president of Panama.
Administration, the Small Business Administration, and the Na- Over 86% of U.S. exports of consumer and industrial prod-
tional Science Foundation. ucts to Panama will become duty-free immediately, with remain-
ing tariffs phased out over ten years. The U.S. products that will
FTC Issues Revised Green Guides gain immediate duty-free access include information technology
equipment, agricultural and construction equipment, aircraft and
The Federal Trade Commission (FTC) has issued revised parts, medical and scientific equipment, environmental products,
Green Guides that regulate claims by companies about the en- pharmaceuticals, fertilizers, and agro-chemicals. United States
vironmental attributes of their products. Among other modifica- industrial goods currently face an average tariff of 7% in Panama,
tions, the guides caution companies not to make broad, unquali- with some tariffs as high as 81%.
fied claims that cannot be substantiated, such as a product being
environmentally friendly or promoting sustainability. The
guides also clarify guidance on compostable, ozone, recyclable,
recycled content, and source reduction claims. The FTC has
brought several actions in recent years related to allegedly de-
ceptive recyclability, biodegradable, and environmental certifi- Contact the AWS Washington Government Affairs Office at
cation claims as part of its overall effort to ensure that environ- 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
mental marketing is truthful and substantiated. hwebster@wc-b.com; FAX (202) 835-0243.
6 DECEMBER 2012
victor tech 1_FP_TEMP 11/7/12 3:39 PM Page 7
FROM SIMPLE SOFTWARE

TO HEAVY STEEL
The XT series of iCNCs from Victor Thermal Dynamics brings cutting

process intelligence to the table. The secrets of plasma cutting, and the
precise requirements necessary to provide consistent cut quality with
your table, are built in to every unit. And best of all, it combines
sophisticated control with ease of use, automatically.
We Bring Intelligence to the Table. TM

PTN DECEMBER 2012_Layout 1 11/9/12 1:32 PM Page 8
PRESS TIME
NEWS
Publisher Andrew Cullison
Apples New iMac Constructed with Friction Stir Welding
Editorial
The new Apple iMac has its front Editorial Director Andrew Cullison
and back panels joined by friction stir Editor Mary Ruth Johnsen
welding (FSW). Originally, engineers Associate Editor Howard M. Woodward
faced a challenge deciding what process Associate Editor Kristin Campbell
to use because the panels are too thin Editorial Asst./Peer Review Coordinator Melissa Gomez
to weld using traditional methods. They
searched for other ideas and found FSW Publisher Emeritus Jeff Weber
is commonly used on airplane wings,
rocket booster tanks, and other parts. Design and Production
The process uses a combination of in- Production Manager Zaida Chavez
Senior Production Coordinator Brenda Flores
tense friction-generated heat and pres-
Manager of International Periodicals and
sure to intermix the molecules of the two
Electronic Media Carlos Guzman
aluminum surfaces. It also creates a
Friction stir welding joins the new iMacs front seamless, precise, and superstrong joint. Advertising
and back panels. (Photo courtesy of Apple.) The new computer case design would National Sales Director Rob Saltzstein
not be possible without it. Advertising Sales Representative Lea Paneca
According to Apple, the case is 5-mm thin at its edge with up to 40% less volume Senior Advertising Production Manager Frank Wilson
than the previous generation. To do this required inventing new technologies, pioneer- Subscriptions
ing new manufacturing techniques, and devising all-new ways to do more in less space. Subscriptions Representative Sylvia Ferreira
sferreira@aws.org
United Stationers Signs Agreement to Acquire O.K.I.
American Welding Society
United Stationers, Inc., Deerfield, Ill., recently announced its wholly owned sub- 8669 Doral Blvd., Doral, FL 33166
sidiary, United Stationers Supply Co., has signed a stock purchase agreement to acquire (305) 443-9353 or (800) 443-9353
100% of the outstanding shares of O.K.I. Supply Co., Cincinnati, Ohio, the largest inde-
pendently owned welding, safety, and industrial products wholesaler in the country, for Publications, Expositions, Marketing Committee
D. L. Doench, Chair
an all-cash purchase price of $90 million. The transaction was expected to be completed
Hobart Brothers Co.
in November 2012, subject to customary closing conditions.
S. Bartholomew, Vice Chair
We are pleased to have the opportunity to join United Stationers and ORS Nasco, ESAB Welding & Cutting Prod.
and we see it as a perfect fit for our customers, suppliers, and company, said Bill Rice, J. D. Weber, Secretary
president/CEO of O.K.I. and AWS president. The scale and capabilities that this part- American Welding Society
nership represents uniquely positions us to bring additional value to our customers, en- D. Brown, Weiler Brush
abling them to succeed in an evolving market. T. Coco, Victor Technologies International
J. Deckrow, Hypertherm
GE, Manufacturing Institute, Alcoa, Boeing, and D. DeCorte, RoMan Mfg.
J. R. Franklin, Sellstrom Mfg. Co.
Lockheed Martin Launch Coalition to Train U.S. Veterans F. H. Kasnick, Praxair
D. Levin, Airgas
GE joined with business, digital, academic, and not-for-profit partners to launch a E. C. Lipphardt, Consultant
new coalition, Get Skills to Work, that aims to train military veterans for advanced man- R. Madden, Hypertherm
ufacturing jobs, bolster the talent pipeline, and enhance American competitiveness. D. Marquard, IBEDA Superflash
The coalition will focus on accelerating skills training for U.S. veterans; helping J. Mueller, Victor Technologies International
veterans and employers translate military skills to advanced manufacturing jobs; and J. F. Saenger Jr., Consultant
empowering employers with tools to recruit, get on board, and mentor veterans. It S. Smith, Weld-Aid Products
will be managed by the Manufacturing Institute and supported through financial and N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
in-kind commitments from GE, Alcoa Inc., Boeing, and Lockheed Martin. The initial
L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
investments will help 15,000 veterans translate military experience to corresponding S. P. Moran, Ex Off., Weir American Hydro
advanced manufacturing opportunities and gain technical skills needed to qualify for E. Norman, Ex Off., Southwest Area Career Center
these careers. R. G. Pali, Ex Off., J. P. Nissen Co.
The coalition is seeking additional partners to meet its goal of reaching 100,000 vet- R. Ranc, Ex Off., Superior Products
erans by 2015. To learn more, visit www.GetSkillstoWork.org. W. A. Rice, Ex Off., OKI Bering
R. W. Shook, Ex Off., American Welding Society
AWS Careers in Welding Trailer Earns Design Award D. Wilson, Ex Off., Well-Dean Enterprises
Copyright 2012 by American Welding Society in both printed and elec-

The AWS Careers in Welding Trailer recently won a silver 2012 Event Design Award tronic formats. The Society is not responsible for any statement made or
in the best mobile marketing vehicle category. The 53-ft, single expandable trailer opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not in-
designed by MRA Experiential Tours and built by Triune Specialty Trailers features tended for use without independent, substantiating investigation on the
650-sq-ft of exhibit space. It showcases five Lincoln Electric VRTEX 360 welding sim- part of potential users.
ulators along with interactive educational exhibits. Descriptions of each award-winning

project appeared in the November issue of Event Design magazine.
MEMBER
8 DECEMBER 2012
victor tech 2_FP_TEMP 11/7/12 3:44 PM Page 9
Engineered Solutions
for Wear
ear & Corrosion
s-INING
s-INING
ss#ONSTRUCTION
#ONSTRUCTION
ss!GRICULTURE
!GRICULTURE
ss0OWER'ENERATION
0OWER'ENERRATION
ss3TEEL0RODUCTION
3TEEL0RODUCCTION
Oil and Gas High Alloy Joining

s Oils Sands ss
3TAINLESS
3TAINLESS3TEEL
3TE
EEL
4O
4OOL*OINT2EPAIR
ss4OOL*OINT2EPAIR $UPLEXES
--$UPLEXES
(ARDBANDING
ss(ARDBANDING 3PECIAL#OM
MPOUNDS
--3PECIAL#OMPOUNDS
ss
.ICKEL
.ICKEL
34//$9)3!6)#4/24%#(./,/')%3
4
"2!.$ Stoody
Stoody.com
NI December 2012_Layout 1 11/8/12 1:38 PM Page 10
NEWS OF THE
INDUSTRY
Marking Time Sundial Earns AWS Extraordinary Welding Award
AWS District 8 Director Joe Livesay presented the Societys

Extraordinary Welding Award for Marking Time, a stainless steel
sundial sculpture at the I-40 Smith County Welcome Center,
Buffalo Valley, Tenn., to Knoxville Artist Preston Farabow on
October 9.
It is quite an honor to have been recognized for this award,
Farabow said.
The sundial incorporates markers representing all 95 coun-
ties in the state. It points true north with the angle of the main
structure precisely at 36.14 deg to correspond to the degrees of
latitude for the site.
We had a beautiful day for the dedication. I believe that it
was the first time I have been at the site when the solar time as
displayed by the sundial and local time (CST) were in agreement
with each other, Farabow added.
Approximately 35 people attended the ceremony, including
Don Sadler, director, Tennessee Technology Center at Crossville;
the mayor of Smithville; the Chamber of Commerce president;
DOT officials; Dave Porter, Red Boiling Springs School, a new
AWS SENSE school, and his class; and Josh Burgess, metallur-
gist, University of Tennessee, Knoxville. Following the event, a
BBQ lunch was served.
From concept to completion, it took more than three years
for Farabow to create the sculpture, which was dedicated on May
14, 2007. Welding techniques used were gas metal arc and gas
tungsten arc welding. Materials incorporated in the sculpture
include stainless steel, concrete, earth, and stone.
My intention with the sundial was simply to provide an op-
portunity to pause and watch time pass, Farabow explained.
The ceremony gave me yet another opportunity to pause, and
specifically to reflect on the role that iron workers and welders
have played in our history. Our country today exists in its promi-
nence in the larger world, in my opinion, largely due to the work
of welders. Shipbuilders, iron workers, blacksmiths, and fabrica-
tors all are responsible for what we regard as the structure of
America.
The AWS Extraordinary Welding Award, selected by the AWS
Past Presidents Committee, celebrates technical design for out-
standing development in welded fabrication, recognizing weld-
ing excellence in construction, fabrication, and manufacturing,
and designating those welded structures whose purpose has im-
portance in, or influence on, history.
This public art project was also created in partnership with
former First Lady of Tennessee Andrea Conte, the wife of Gov-
ernor Phil Bredesen (20032011), the Tennessee Arts Commis-
sion, Tennessee Department of Transportation, and the Ten-
nessee Department of Tourist Development.
(Top) The Marking Time stainless steel sundial sculpture at the I-40
Smith County Welcome Center, Buffalo Valley, Tenn., incorporates
markers representing the states 95 counties.
(Bottom) At a ceremony on October 9, AWS District 8 Director Joe

Livesay (left) and Knoxville Artist Preston Farabow pose with the
AWS Extraordinary Welding Award presented to the Marking Time
sundial.
10 DECEMBER 2012
Mechanic on a Mission Honored as a

PEOPLE Teacher of the Year
Brian Copes, an AWS member and pre-engineering teacher
at Calera High School, Calera, Ala., has recently been selected
by PEOPLE magazine as one of five winners in its first Teacher
of the Year Awards.
Last summer, Copes took ten of his students to Honduras,
where they fit 14 amputees with artificial legs fashioned from old
Toyota Corolla parts. The class assembled basic utility vehicles
as well to provide ambulance services to remote locations there.
He believes it is important not only to teach his students a skill
or trade, but also the soft skills required for todays job market.
My students eyes were opened to the importance of helping
others. This is practical education that uses real-world problem-
solving techniques...my students, and myself, perhaps will never
know how great of an impact they have had on the lives of these
Hondurans, Copes said.
To create the artificial legs, they designed parts using Solid-
Works software. Then, the drawings were used to cut the parts
on a CNC plasma cutting machine. The parts were bent and gas
metal arc welded. Students also experimented with gas tungsten
arc welding. Both steel and aluminum were explored for mate-
rial selection. A micrometer was used for measuring. Once the
parts were fabricated, they conducted a small assembly line to
put the legs together. Final tweaking took place at the end of this
process.
Fitting a person onsite took less than an hour. We invented
a universal socket that allowed us to fit the amputees in a short
time period, Copes explained.
On this project and others, the high schoolers put in more AWS Member Brian Copes and his students used old car parts to
than 2000 after school, community service hours. fabricate artificial legs for amputees in Honduras.
/ Battery Charging Systems / Welding Technology / Solar Electronics
/ The relatively simple principle behind DeltaSpot is the indexing process tape which runs between
the electrode and the work piece. With each spot, the process tape indexes one step forward; its like
welding every spot with a brand new electrode, making the quality 100% predictable. Join aluminum
to aluminum or steel to steel, even dissimilar metals.
Want to know more? Check out: www.fronius-usa.com
For info go to www.aws.org/ad-index
WELDING JOURNAL 11
NI December 2012_Layout 1 11/9/12 11:02 AM Page 12
In addition, Children Changing the World, a documentary about

these students, is being produced. This film will be used as an
inspirational tool to inspire both students and teachers around
07 10 January 2013 the globe to dream big and change the world, Copes said.
Dubai, UAE The educators, nominated by readers and selected by PEO-
PLEs editors with guidance from an advisory board of educa-
tion professionals, were featured in the magazines October 22
issue and celebrated in New York at a luncheon. Each will re-
ceive $5000 ($4000 for their school and $1000 for themselves).
Advanced Resistance and Automotive

WELDING Technologies Abound at Sheet Metal
CUTTING Welding Conference XV
Arabia Essen 2013

Welding & Cutting
International Trade Fair
Joining, Cutting, Surfacing Shown at the AWS Detroit Sections booth during the vendor dis-
play portion of Sheet Metal Welding Conference XV are (from left)
In conjunction with: John Bohr, Mark D. Gugel, and Tom Natale.
Tekno Arabia 2013
Tube Arabia 2013 Top engineering minds from across the globe attended Sheet
Metal Welding Conference (SMWC) XV, hosted by the Ameri-
can Welding Societys (AWS) Detroit Section and cosponsored
by EWI, to hear the latest developments on this years theme of
welding and joining materials for lightweight structures.
MESSE ESSEN GmbH The successful hands-on workshop held October 2 at RoMan
Telephone +49(0)201-72 44-649 Engineering Services, Inc., Livonia, Mich., focused on welding
julia.wermter@messe-essen.de
www.arabia-essen-welding-cutting.com advanced high-strength steel vs. cold rolled steel. Tutorial Chair
Jeff Hill wanted to try an interactive approach this time. Resist-
ance spot, projection, and gas metal arc welding demonstrations
allowed attendees to translate what they learned in lectures into
PLEASE VISIT US AT BOOTH C264 actual welds.
AT DVS/MESSE ESSEN The technical portion October 35 at Schoolcraft Colleges
VisTaTech Center, Livonia, Mich., attracted nearly 150 partici-
pants. Students to leaders of major automotive companies and
tier-one/weld equipment suppliers heard 30 papers.
The conferences five sessions along with their leaders were
as follows: Resistance Welding and High-Strength Steel, Dr. Jerry
Gould of EWI; Modeling and Control, Dr. Murali Tumuluru of
United States Steel Corp.; Lasers and Friction Stir, Wes Doneth
of Fronius; Aluminum Resistance Welding, Dr. Michael
Karagoulis of General Motors; and Other Processes, Mike Palko
of Ford.
Dr. Mark D. Gugel, senior manufacturing project engineer,
global welding standards, General Motors, served as SMWC XV
chairman. He noted that this year the conference drew close to
100 authors; 25 staff members worked behind the scenes to make
it come together; and networking was valuable as individuals trav-
eled from overseas, including Europe and China, that could be
tied in with the automotive customer connection.
With the people who come here, this is the only venue for
the automotive joining industry doing thinner sheet metal, Gugel
12 DECEMBER 2012
said, pointing out its impact.

QUALITY TOOLS THAT GO TO WORK WITH YOU
Joe Beckham of Chrysler Group LLC served as SMWC XV
vice chairman while Menachem Kimchi of Welding Engineering
Consulting & Services, LLC, was the technical chairman.
Also, the evening of October 4, a vendor display open to the
public took place organized by Susann Morfino, sales represen-
tative, MJM Sales, Inc. Participants enjoyed visiting its 35 booths
exhibiting many company offerings, meeting with guests, and
dining on hors doeuvres made by the colleges culinary arts U.S.REGULATORS
UU.
.S.R
.REG
EGU
GUUL
ULAAT
ATO
TORS
RS
students.
The next SMWC, a biennial event, is expected to be held in
Uniweld. Still building the
Regulators you want
FFOR
OR U.S.
U.S. JJOBS
OBS
2014. For details on obtaining conference proceedings, visit right here in the U.S.A.
www.awsdetroit.org.
ASTM Launches New Initiative to Address

Environmental Impacts of Products
RV8010 Heavy Duty
ASTM Internationals new initiative is to be a program oper- Single Stage
ator for Product Category Rules (PCR) and Environmental Prod-
uct Declarations (EPD), which will provide the venue for devel-
oping PCRs and verifying EPDs.
According to Timothy Brooke, vice president of certification,
training, and proficiency testing at ASTM International, the or-
ganizations program will provide scientifically based, quantifi-
able information about product parameters such as resource con-
sumption and ozone depletion, which will give businesses and
consumers an understanding of a products real impact on the
environment. Also, through its certification program, technical Uniweld can build any
regulator you need: Heavy Duty, UNIWELD PRODUCTS, INC.
advisory committees will oversee the development process for Medium Duty, Single Stage, Two 2850 RAVENSWOOD ROAD
the PCR. Stage, Oxygen, all Fuels and every FORT LAUDERDALE, FL 33312 U.S.A.
gauge youll need to go with em 800.323.2111
all 100% tested. Call or email for catalog.
continued on page 107
LEADERS & INNOVATORS

In Narrow Groove Welding
The Preferred Choice for Automated Heavy
Wall, Pipe, Vessel, and Valve Welding
For 20 years AMI has led the way in developing the most advanced, reliable
and flexible systems for NGT welding. AMIs Oscillating Electrode Technology
offers significant advantages in Quality and Productivity:
t%FDSFBTFESFTJEVBMTUSFTTJO)";EVFUPMPXFSIFBUJOQVU

t$POTJTUFOUTJEFXBMMGVTJPOXJUINJOJNBMQPSPTJUZBOEJODMVTJPOT

t3FEVDFEOVNCFSPGXFMEQBTTFT

t)JHIEFQPTJUJPOSBUFXJUIIPUXJSFPQUJPO

0QUJPOTJODMVEF)PUPSDPMEXJSFUPSDIDPOHVSBUJPOTVQUPw NN
BOE

"DUJWF'JMUFS7JTJPO4ZTUFNT TUBOEBSEPO".*/(5UPSDIFT

Advanced Products, Systems & Solutions
Over 250 NGT Systems Installed Worldwide
1BDPJNB $"64"]UFM

]GBY
]TBMFT!BSDNBDIJOFTDPN]XXXBSDNBDIJOFTDPN

WELDING JOURNAL 13
Aluminum Q and A December 2012_Layout 1 11/9/12 1:23 PM Page 14
ALUMINUM
BY TONY ANDERSON
Q&A
Q: I have been informed of an Interna-
tional Standard, ISO 18273, Welding con-
sumables Wire electrodes, wires and rods
for welding aluminum and aluminum alloys
Classification. I have also been informed
that there is a new AWS A5.10, Specifica-
tion for Bare Aluminum and Aluminum-Alloy
Welding Electrodes and Rods, available. How
does this ISO standard compare to the
AWS standard, and does classification to
this ISO standard provide classification to
AWS A5.10? What are the changes to the
new A5.10 standard?
A: This is an interesting question, particu-

larly in light of some current developments
with the recently published new edition of
AWS A5.10. For the benefit of any readers
who are not familiar with AWS A5.10, this
specification prescribes requirements for
the classification of aluminum-alloy weld-
ing electrodes and rods for use with the gas
metal arc, gas tungsten arc, oxyfuel, and
plasma arc welding processes.
Before responding to your question, I Fig. 1 High-speed trains, many of which are being manufactured in China, often
will provide some relevant information on make use of the ER5087 filler metal. The ER5087 is one of the many new aluminum
the latest edition of AWS A5.10, some filler metal classifications listed in the new edition of AWS A5.10/A5.10M:2012 (ISO
changes/additions to this document, and 18273:2004 MOD).
how the new AWS document has been in-
fluenced by the ISO 18273 standard. A5.10 publication. Q: How does this ISO standard compare
As the chairman of the AWS A5C Sub- To quote directly from the foreword of to the AWS standard, and does classifi-
committee on Aluminum-Alloy Filler the new AWS A5.10 publication, This cation to this ISO standard provide clas-
Metals, which is responsible for the A5.10 standard is the U.S. national adoption of sification to AWS A5.10, Specification for
standard, I have been working with the ISO 18273:2004, Welding consumables Bare Aluminum and Aluminum-Alloy
subcommittee for the last two years to Wire electrodes, wires and rods for welding Welding Electrodes and Rods?
prepare a revised A5.10. The previous aluminum and aluminum alloys
AWS A5.10/A5.10M:1999, Specification Classification.
for Bare Aluminum and Aluminum-Alloy Adoption of the ISO 18273 standard
A: Again, to quote directly from the fore-
word of the new AWS A5.10 publication,
Welding Electrodes and Rods, was totally by the AWS A5 Committee on Filler Met-
Classification in accordance with ISO
independent of the ISO 18273 document. als and Allied Materials is part of the gen-
18273:2004 does not provide classification
However, the new AWS standard, AWS eral policy adopted by the committee to
in accordance with this document. The
A5.10/A5.10M:2012 (ISO 18273:2004 incorporate international filler metal stan-
primary reason for this nonclassification
MOD), has integrated the International dards within the relevant AWS A5 stan-
is the ISO standard does not provide for
Standard ISO 18273 within the new AWS dards wherever practicable.
any other testing other than chemical
analysis of the filler metal material.
The AWS A5.10 requirements for clas-
sification include chemical analysis of
filler metal (similar in nature to ISO
18273) with additional weld testing re-
quirements to verify the soundness of weld
metal produced by gas metal arc welding
electrodes and the deposition character-
istics of the welding rod. As a result, the
AWS A5.10 standard specifies additional
required information such as the base
metal types required for weld test assem-
blies, welding and testing procedures to
be employed for weld testing, and results
required for passing the stipulated test in
order to meet classification requirements.
Many of the testing requirements in the
AWS A5.10 standard are associated with
radiographic testing used to demonstrate
For info go to www.aws.org/ad-index the integrity of deposited weld metal.
14 DECEMBER 2012
Aluminum Q and A December 2012_Layout 1 11/9/12 1:23 PM Page 15
Therefore, a filler metal classified to AWS requirement to not exceed 0.0003% (from Summary
A5.10 should meet the classification re- the previous 0.0008% limit). The range of
quirements of ISO 18273. However, a filler base metals for test assemblies has also been The recently released AWS A5.10
metal classified to ISO 18273 does not pro- expanded to include the use of more 6xxx standard is an adoption of ISO 18273.
vide classification in accordance with the series materials, which will more easily sup- This new standard has many new, pre-
requirements of AWS A5.10. port the use of extruded test assemblies dominantly European, filler metals in-
commonly used to assist with testing pro- cluded within it. One new filler metal
Q: What are the changes to the new A5.10 cedures. There has also been the addition classification that was developed in the
standard? of one new filler metal that was not carried United States (ER4943) is also included
over from the ISO standard. in the new edition. Filler metals that are
One of the new filler metal classifica- classified to ISO 18273 would not pro-
A: The principal changes to A5.10 have tions added from the ISO Standard is vide classification in accordance with
been the inclusion of 38 new, predomi- ER5087. ER5087 is a filler metal increas- AWS A5.10 because the requirements for
nantly European, aluminum filler metal ingly used in the relatively new, rapidly classification within A5.10 stipulate test-
classifications. With the adoption of ISO developing industry of fast trains Fig. ing procedures that are not specified by
18273, the A5.10 standard now includes 1. Through modifications to the magne- ISO 18273.
the following additional classifications: sium and manganese content of this 5xxx
ER1070, R1070, ER1080A, R1080A, series filler alloy, we see a high-perform-
ER1200, R1200, ER1450, R1450, ance filler metal that is often chosen for TONY ANDERSON is director of aluminum
ER3103, R3103, ER4018, R4018, this high-performance industry sector. technology, ITW Welding North America. He is
ER4043A, R4043A, ER4046, R4046, The new filler metal ER4943 has also a Fellow of the British Welding Institute (TWI),
ER4047A, R4047A, ER5087, R5087, been added to the A5.10 standard. a Registered Chartered Engineer with the British
ER5183A, R5183A, ER5187, R5187, ER4943 was not obtained from the ISO Engineering Council, and holds numerous posi-
ER5249, R5249, ER5356A,R5356A, tions on AWS technical committees. He is chair-
standard, but added as a newly developed man of the Aluminum Association Technical
ER5556A, R5556A, ER5556B, R5556B, filler metal that originated here in the Advisory Committee for Welding and author of
ER5556C, R5556C, ER5654A, R5654A, United States. As its number suggests, this the book Welding Aluminum Questions and
ER5754, and R5754. new filler metal is a modification to filler Answers currently available from the AWS.
Other changes include modified beryl- alloy ER4043. ER4943, although heat Questions may be sent to Mr. Anderson c/o Weld-
lium limits, which have been amended for treatable, was developed primarily for its ing Journal, 8669 Doral Blvd., Doral, FL 33166, or
many of the filler metal classifications to improved as-welded strength over that of via e-mail at tony.anderson@millerwelds.com.
fall in line with the Aluminum Associations the commonly used ER4043 filler metal.

WELDING JOURNAL 15
Brazing Q+A December_Layout 1 11/8/12 10:06 AM Page 16
BRAZING
BY TIM P. HIRTHE
Q&A
Q: We are manufacturing refrigeration
lines consisting of a variety of copper tub-
ing joints. The joints are primarily copper
to copper but we do have some brass
valves and steel connections. We employ
dozens of hand brazers over several shifts
and have a tremendous variation in qual-
ity. We are using oxyacetylene torches. It
seems that everyone makes the joints
their own way. One of the most aggravat-
ing issues is that we have a great deal of
braze alloy teardrops and spatter. I am
sure we are using more braze alloy than is
necessary. I have included a photo for your
reference Fig. 1. My preference is to
find some other method of making these
joints. We are continually told that we
need to improve our training but it seems
Fig. 1 Examples of braze alloy drippings.
to me to be a training nightmare. There
must be equipment we can use to mini-
mize our brazer variation. What can we do
to take the manual aspects out of the op-
eration to try to get some consistency? teardrops that fell off instead of solidify- these subjects but you have a more acute
ing on the parts. I have seen this before. It need. Your brazers cannot do anything
A: In my experience, manual torch braz- typically comes from the brazer applying about joint designs, selection of base met-
ing is the most difficult brazing process to the heat to the braze filler metal rather als, selection of filler metals, and the like.
get under control. Generally, the process than the metals being joined. Either that You certainly should listen to their input
and resultant quality are in the hands of or the brazers just blasted away at it and about these matters, but what they really
the operator. It has a tremendous number kept adding filler until they were sure they need is training in how to properly heat
of variables associated with it but the indi- completed the joint, adding filler metal parts and how to add filler metal.
vidual brazer level of training, their dex- until it fell off. The flame needs to be ap- When talking to line brazers, you need
terity, and willingness to listen are proba- plied to the base metals. The braze filler to focus on the basics. There is general
bly the most important. metal is then melted by touching it to the agreement on what the fundamentals are.
As you mention, the first reaction is to heated joint. The molten braze filer metal There is some variation depending on who
institute more training. Companies are will not bond to the parts to be joined un- you talk to but basically it comes down to
hesitant because they assume it will take a less they are hot enough. That is a fairly these:
great deal of time and when the operators basic, but profound, concept. Focus your 1. Joint clearances and joint design
get back on the shop floor they will revert training effort on that. 2. Prebraze cleaning
to their bad habits anyway. That then re- If you are going to revise your braze 3. Assembly and fixturing of compo-
quires lots of management intervention to training program, the first thing is to make nents
keep things on track. Everyone is trying to sure safety is addressed. I recommend 4. Fluxing
eliminate headaches, and Im sure the starting by consulting ANSI Z49.1, Safety 5. Heating the parts and adding filler
continuation of manual torch brazing in Welding, Cutting and Allied Processes. It metal
seems to be a prescription for a long, ex- does a great job of covering the things to 6. Postbraze cleaning
tended headache. You are asking about be concerned about in oxyfuel processes. Your focus with your line brazers
the alternative, which is to take the brazer After safety, you should instruct the braz- should be on items 4 and 5.
out of the decision-making process. That ers in the expected conduct of their jobs, In summary, I suggest you do the
requires standardizing the process and, getting familiarized with their work areas, following:
perhaps, adding equipment. process paperwork, components to braze, 1. Provide training with an emphasis
Your photo appears to show something and the like. This is quite a bit of informa- on proper heating and adding of filler
more like drippings than spatter. I realize tion and it doesnt leave a lot of time for metal. Even without seeing them in action,
you want to find a magic bullet in the way braze training. Dont try to make them ex- I would guess that the torches are set too
of equipment that will eliminate the perts, at least not right away. Focus on the hot. People like to hear the torches hiss. It
brazer problem, and, while there are fundamentals. Regarding the drippings is assumed that a hotter flame means a
some things you can do in that regard, and general overuse of braze filler metal, faster production rate. To achieve a hotter
dont abandon the idea of improving train- showing them proper heating will go a flame you crank up the oxygen. Increasing
ing. The photo would seem to indicate a long way toward solving these problems. the oxygen results in an oxidizing flame.
basic misunderstanding of the brazing There is a great deal of brazing training The best results in brazing, however, are
process. There are a few simple things you available in the industry and I would rec- achieved with a reducing flame. It also re-
can do to make improvements. The key ommend you tap into it. Much of it, how- sults in a less oxidized part, improving the
word is simple. If you try to overdo it with ever, deals with things like the metallurgy aesthetics of the assembly and assisting
training, the brazers may become over- of brazing, the design of braze joints, etc. the braze alloy flow. Refer to Fig. 2.
loaded with information and tune out. There is absolutely nothing wrong with The following is taken from AWS
The drippings in the photo are actually teaching the brazers on your line about Guidelines for Hand Soldering Practices:
16 DECEMBER 2012
Brazing Q+A December_Layout 1 11/8/12 10:06 AM Page 17
selected for each joint design and clear-

ance and that it is used consistently in all
brazing areas.
Ensure that the form of filler metal
(rod cross section and length) is consistent
among operators and departments.
3. Introduce equipment as it makes
sense.
Infrared sensors can be used to let the
brazer know when the proper brazing tem- Manufacturin
Manufacturing
uring
perature has been reached. Some devices
are available that feed the filler metal once
a predetermined brazing temperature is
reached.
Flux Cored
You can cut your braze filler metal con-
sumption by making sure the brazers do
not overfeed a joint. Wire feeders that dis-
Welding
elding Wire
W
pense consistent amounts of braze filler
metal can be used to remove the decision
regarding how much braze alloy to add
COBALT
LT
from the brazer.
Units to control the flow rates of the
fuel gas and the oxygen can be used. These
can be locked out to prevent the operator
NICKEL
from changing the settings.
HARDFACE
E
Or you can change from an oxyfuel
process to an alternative method. Hand-
held induction units are available. Induc-
tion can be controlled very precisely to
take the heating variable out of the control
of the brazer. STAINLESS
TAINLESS
There is no simple answer to how to
make a manual torch brazing process
more consistent. The ideas listed here may
apply to some joint designs but not to oth-
ALLOY
Y STEEL
EEL
ers. There are, however, a number of
things you can introduce to the operation
and plenty of resources available in the in-
dustry to help.
TOOL STEEL
STEE
EEL
Fig. 2 Acetylene flame color guide.
From the AWS Guidelines for Hand Sol-
MAINTENANCE
MAINTENAN CE
dering Practices.
FORGE ALLO
ALLOYS
OYS
Heat the parts, not the filler metal. This column is written sequentially by
CUSTOM ALLOYS
OYS
Train the brazers to recognize what the TIM P. HIRTHE, ALEXANDER E.
proper amount of heat is. Overheating or SHAPIRO, and DAN KAY. Hirthe and
underheating most likely will result in an Shapiro are members of and Kay is an ad-
unsatisfactory joint. visor to the C3 Committee on Brazing and
Touch the filler metal to the heated Soldering. All three have contributed to the
5th edition of AWS Brazing Handbook.
COR-MET,, INC.
COR-MET,
parts to flow the filler metal.
12500 Grand
and River Rd.
Only add sufficient filler metal to fill Hirthe (timhirthe@aol.com) currently
the joint. Any filler metal outside the mat- serves as a BSMC vice chair and owns his
ing surfaces of the joint is an unnecessary own consulting business.
expense and serves no purpose. Signifi- Shapiro (ashapiro@titanium-braz-
ing.com) is brazing products manager at Ti-
Brighton, MI 481
48116
116
cant cost savings can be achieved by re-
ducing the amount of filler metal used.
2. Standardize brazing variables
tanium Brazing, Inc., Columbus, Ohio.
Kay (Dan@kaybrazing.com), with 40 800-848-2719
PH: 800 -848-27 719
throughout your plant. years of experience in the industry, operates
Set all torches to the same fuel gas and his own brazing training and consulting
business.
FAX: 810
FA 810-227-9266
-227-9266
oxygen flow rates.
Utilize the same torch tip style for
each brazer. Different joints may require
Readers are requested to post their ques-
tions for use in this column on the Brazing www.cor-met.com
www.cor
ww -met.com
t.com
different torch styles and tips. Forum section of the BSMC Web site
Ensure that the proper braze alloy is www.brazingandsoldering.com. sales@cor-met.com
sales@cor -met.co
t.com
WELDING JOURNAL 17
P and P December 2012_Layout 1 11/8/12 1:35 PM Page 18
PRODUCT & PRINT

SPOTLIGHT
Software Platform Features New Baseline Cost Models

The aPriori 2012r1 offers enhancements that expand
the platforms cost optimization functionality with base-
line processes for manufacturers in automotive, con-
sumer products, and industrial equipment. The prod-
uct cost management software platform determines the
cost of a part or product by automatically pulling geo-
metric and feature information from a CAD model,
plus leveraging its cost models to determine reasonable
default inputs once the user has selected the manufac-
turing process, materials, and factory or region where
it will be produced. As a product evolves through the
development life cycle, users have the ability to refine
the cost by providing detailed inputs and overriding de-
faults to create a should-cost for negotiation or a man-
ufacturing estimate. As design changes are made, or
new product specs introduced, it automatically re-
assesses and provides an updated product cost. In ad-
dition, abilities are expanded to cost plastics compo-
nents, including piece parts and tooling costs. New base-
line cost models consist of the following: thermoform-
ing, structural foam and reaction injection molding,
cross-system cost integration, an internationalization
infrastructure, and automated bulk analysis for in-
creased throughput.
aPriori
www.apriori.com
(978) 371-2006
Environmentally Safe it is safer for workers and the environment

because it does not use corrosive and toxic
Cleaner Eradicates Rust acids. As part of the companys Bio-Cir-
cle Environmental Solutions, the product
is free of volatile organic compounds, sol-
vents, and phosphates. To use, the worker
immerses parts in the liquid at room tem-
perature. It has a high workload and can
remove 1.0 kg of iron oxide per 20 L of its
liquid. Once rust is removed, the worker
rinses parts with water, then immediately
applies a corrosion protection product or
long-term corrosion inhibitor.
Walter Surface Technologies

www.walter.com
(800) 522-0321
machinery engineering. Users can search
GoTo Products Program by product category, by selecting from a
master product directory, or through the
Introduces iPhone App applications built-in search tools. GPS lo-
cation services and autodial features make
The company has released a new it simple to order from the nearest distrib-
iPhone app combining more than 3500 utor. The application can be downloaded
Bio-Rust is a noncorrosive solution products into a single digital catalog, al- free through iTunes. For further informa-
that eradicates rust on iron and mild steel. lowing on-the-go access to product infor- tion, visit the Web site shown.
Fabrication shops can use the product to mation and specifications. Graphic menus
clean steel prior to painting or coating. and easy to use touchscreen control make Rexroth Bosch Group
Comprised of selective chelating agents it simple to access specific details on prod- www.boschrexroth-us.com/gotoapp
that work to detach iron oxide from steel, ucts for manufacturing, automation, and (800) 739-7684
18 DECEMBER 2012
Laser Processing Cell on the shop floor that have similar oper- and can be used for inside and tunnel/un-
ations. With the integration, work orders derground applications. The generator
Offers Large Field of View that are part of a nest can be sent to Meta- can be operated for up to 26 h at full load
cams nesting module to be dynamically with a low noise level of 44 decibels at 23
nested. Its nesting module automatically ft. It requires minimal maintenance be-
separates nest patterns by material and cause there are virtually no moving parts
thickness. and no fuel to spill. According to Torsten
Erbel, vice president product manage-
MIE Solutions ment, engineering and customer support
www.mie-solutions.com for the company, with one unit it is able
(714) 786-6230 to displace 900 gal of diesel fuel per year
and eliminate 9.1 metric tons of CO2 per
Eco-Friendly Generator year.
Runs with Zero Emissions
Multiquip, Inc.
www.multiquip.com
(800) 421-1244
Manufacturer Launches
Upgraded Web Site
The Flex Lase Pro, a 3-axis scanner-
based laser processing cell, is equipped The manufacturing company has
with an IPG 2-kW single mode fiber laser launched an upgraded Web site featuring
and Cambridge Technologies 3D high- its line of portable welding end prep tools,
speed scanner head. Typical spot size at pneumatic saws, and accessories for ma-
mid-range field of view is approximately chining and cutting tube, pipe, pipelines,
20 microns. It is suited for prototyping, boiler tube panels, and other metalwork-
process development, and production. Of- The MQ H2G EarthSmart hydrogen ing applications. Highlighted is an ex-
fering a large field of view working area fuel-cell powered generator is environ- panded search capability, which allows
(up to 1000 1000 mm) and Z axis, it can mentally friendly and pollution free. The users to select tools based on product type,
laser weld, cut, or mark a nearly unlim- machine does not use fossil fuel sources. tool model, and tube size or application
ited range of parts and shapes. Laser, It also operates clean with zero emissions of the tool. The search then offers a choice
chiller, fume exhaust, gas management,
and controls are on board. Within the class
1 enclosed laser workspace area, connec-
tions are provided for gas management,
pneumatics, and 110-V power.
Wayne Trail
www.waynetrail.com
(937) 295-2120
Software Integration Allows

Comparing Run Time Data
The company and Metamation have

released MetaQuote and MetaCAM. At-
tributes to the integration include the ca-
pability for information to be transferred
from the CAM system to MIETrak for cre-
ating quotes; tooling is assigned based on
Metacam settings; all information is trans-
ferred and stored within MIE Trak; data
is used in estimating formulas; and com-
paring run time data from any laser,
plasma, CNC turret, or water jet machine.
Additionally, the work order nesting fea-
ture allows users to group together jobs
WELDING JOURNAL 19
Weld Simulator Combines

Software, Curriculum
of tools to select from, provides photos of

each, a description, key features, specifi-
cations, application photos, a parts list,
options, ordering information, and a RFQ
capability. The Web sites major cate-
gories include products, rentals, applica- Scrape-N-Burr line. The dual working
tions, news and events, about the com- edges of the easily replaceable blade are
pany, and a user login to view order formulated to hold up to repeated pound-
history. ing of steel on steel without shattering and
are long lasting. The blade can also be re- The teachWELD welding simulator
freshed to factory edge specification by for practicing welding and teaching vari-
ESCO Tool ous welding techniques incorporates
www.escotool.com following the included instructions. Tools
(800) 343-6926 with this blade factory installed are avail- hardware, software, and curriculum. Its
able in 1- and 3-in. models. Replace- online, game-like interface gives students
ment blades are offered in 4- and 6-in. a hands-on learning experience in basic
Replacement Blades welding form and proper technique within
sizes.
Available for Scraper a virtual environment. Learning is evalu-
Innovative Product Ideas, LLC ated through diagnostic and welding in-
The DuaLast edge technology www.scrapenburr.com tegrity assessments for each welding ex-
scraper blades are an addition to the (920) 486-5351 ercise. The simulation gives students a
20 DECEMBER 2012
chance to explore this career path and also

reduce the use of welding materials.
Realityworks, Inc.
www.realityworks.com
(800) 830-1416
Software Helps Improve

Robotic Efficiency
RobotExpert software, a robotic sim-

ulation and programming system for
small- and medium-size manufacturers,
helps minimize downtime and increase
throughput for shop floor robots. It sup-
ports industry applications such as arc
welding, pick-and-place, and polishing. In
addition, the software enables the design,
simulation, optimization, and offline pro-
gramming of robotic applications. Featur-
ing a 3D environment, it combines the
simplicity to optimize robotic paths and
WELDING JOURNAL 21
improve cycle times with power to simu- special GTA mode with uphill and down-
late virtual mockups of complete manu- hill control; and eight unique memory set-
facturing cells and systems. It can be used tings allow customizing each helmet. The
to generate the most suitable combination filter is available in the modern Vision
of equipment to meet manufacturing helmet or the racing-inspired Python in
needs. It also provides an offline pro- viewing areas large and Xtreme.
gramming and simulation tool.
ArcOne
Siemens PLM Software www.arc1weldsafe.com
www.siemens.com/plm/robotexpert (800) 223-4685
(972) 987-3000
Biodegradable Aluminum
Filter Contains GTA Mode
Brightener Removes Stains
with Uphill Control
Safe-Bright, a replacement for hydro-
fluoric acid and other acids used to
brighten aluminum, uses a new material
that received the EPA P2 Pollution Preven-
tion Award. It deoxidizes and brightens
aluminum surfaces, plus will not attack or
etch glass and is safe to use on painted sur-
faces, chrome-plated hydraulic rams, plas-
tic, and rubber seals. The product contains
no hydrochloric acid, does not produce cor-
rosive fumes or vapors, and has a low odor.
It will not dull or etch aluminum and is pro-
ductive for removing hard water/acid rain
stains from painted surfaces.
The iDF Intelligent-Darkening-Filter
was developed with feedback from welders. Fortrans, Inc.
It offers a standard shade adjustment 3/5- www.fortransinc.com
14; autovariable shade adjustment 3/5-14; (866) 958-7267
For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index
22 DECEMBER 2012
Metal Fabricator Publishes

New Brochure
The metal fabrication and machine

shop has published a new brochure high-
lighting its precision metal fabricating ca-
pabilities. Featured are the companys
services, including fabrication, machining,
vertical turning, welding, sawing, flame
cutting, punching, sandblasting, painting,
and assembly. The brochure may be re-
quested from the contact information For info go to www.aws.org/ad-index
below.
TC/American Manufacturing
www.tcamerican.com
(320) 251-8616
$6450.
$ 6450.
Publication Designed for
Welding Engineers 3&13*/54
3 &13*/54
0QFO:PVS
Applied Welding Engineering: Processes,
Codes and Standards provides instruction
for the selection of the materials incorpo-
&EJUPSJBM&YQPTVSF
rated in the joint, joint inspection, and
quality control for the final product. The
books featured topics include an exposi-
tion of the science of metallurgy, welding
metallurgy and welding processes, nonde-
structive examination, and codes and stan-

dards. Other subjects include mechanical
properties and testing of metals, heat
treatment of steels, effect of heat on ma-
terial during welding, stresses, shrinkage
and distortion in welding, welding, corro-
sion-resistant alloys-stainless steel, weld-
ing defects and inspection, codes, specifi-
cations, and standards. The publication,
list price about $90, may be ordered from
the contact details listed.

Research and Markets Ltd.

www.researchandmarkets.com
(800) 526-8630
$BMMPSTBMFT!GPTUFSQSJOUJOHDPN
WELDING JOURNAL 23
Purslow Feature December 2012_Layout 1 11/8/12 3:11 PM Page 24
Reducing the Ecological

Impact of Arc Welding
Practical strategies are offered for BY MARC ALAN PURSLOW
MARC ALAN PURSLOW (mpurslow@ewi.org)
reducing energy consumption when is an applications engineer, Arc Welding, EWI,
using various arc welding processes Columbus, Ohio.
rc welding processes consume a
A great deal of energy and are widely

used in manufacturing. Practical
strategies for reducing energy consump-
tion are particularly important consider-
ing the need to create more eco-friendly
manufacturing environments. This arti-
cle explores practical strategies relating
to arc welding power source efficiency,
equipment setup, and welding technique
to reduce the ecological impact of widely
employed arc welding processes.
Improved Power Source

Efficiency Fig. 1 Idling power consumption for different welding power supply types (Ref. 1).
Power source technology has matured

significantly in recent decades. Modern
power supplies use significantly less en-
ergy when welding as well as when sitting
idle with the power on. Older trans-
former/rectifier power supplies have
poor energy conversion rates during
welding and have high idle power. In-
verter power supplies require less energy
when welding and have significantly
lower idle power. Inverter power supplies
with transistor technology are the most
efficient when welding and when idling,
and provide faster response times and
higher pulse frequencies. Figure 1 shows
power consumption while idling for three
different power supply types (Ref. 1).
Typical utilization for manual or semi-
automatic arc welding processes is 25%,
meaning the power supply is idling 75%
of the time. For a facility running three
shifts per day, five days a week, and 52
weeks per year at this utilization, a trans- Fig. 2 Power source efficiency vs. percent of rated load (Ref. 2).
24 DECEMBER 2012
Purslow Feature December 2012_Layout 1 11/9/12 9:12 AM Page 25
Fig. 3 Pounds of filler metal consumed

per kWh of welding power.
Fig. 4 Pounds of filler metal consumed

per kWh of welding power at different
power-supply efficiencies.
ever, the opposite is true. Operating a

power supply at a load below its rating
can significantly reduce its efficiency. As
indicated in Fig. 2, operating an 81% ef-
ficient power supply at only 25% of its
rated load decreases the operating effi-
ciency to approximately 65% (Ref. 2). By
using power supplies with a maximum
rated load closer to the expected operat-
ing parameters, manufacturers can take
better advantage of increased-efficiency
power sources and reduce energy
consumption.
Parameter Optimization
Parameters can be optimized to im-
prove the electrode melt-off efficiency,
allowing more material to be deposited
for a given amount of power consumed.
This can be accomplished by increasing
the welding current. While increasing the
Table 1 The Effect of Welding Current on Burn-Off Efficiency current alone may not be an option due
to heat-input limitations, material thick-
Current 250 A 425 A
ness, or an open-root joint preparation,
Voltage 25 V 25 V increasing the travel speed to maintain a
Cost of power $0.11/kWh $0.11/kWh consistent current/travel-speed ratio may
Deposition efficiency 99% 99% resolve these issues. Figure 3 illustrates
Power supply efficiency 80% 80% the increase in pounds of filler metal con-
Steel filler deposited/kWh 0.727 lb 0.883 lb sumed per kWh of welding power at
Utilization 50% 25%
three different current settings for sub-
Arc-on hours 3120 h 1560 h
Yearly power consumption 24,375 kWh 20,719 kWh merged arc welding in constant current
Yearly power cost $2,681.25 $2,279.09 mode with a 332-in.-diameter electrode.
Yearly deposition (steel) 17,720.63 18,294.88 Increasing the welding current from 250
to 425 A resulted in a 21.4% increase in
the amount of steel filler metal consumed
per kWh of welding power. This means
former-rectifier power supply will con- turning power supplies off when not in that for the same amount of power,
sume 6177 kWh of power while idling. At use is a simple method of reducing en- a greater amount of filler metal will be
a cost of $0.11 per kWh, this results in a ergy consumption. This can be accom- deposited.
yearly cost of $680 per power supply. An plished by equipping power supplies with Since no currently available welding
inverter/transistor power supply will con- an idle time-out feature. Newer power power supply is 100% efficient, typical
sume only 749 kWh, resulting in a yearly supplies reduce power use by turning the power supply efficiency ranges must be
cost of $82 per power supply. In this ex- cooling fans on only when they are used to convert the data provided in Fig.
ample, changing to a more efficient in- needed. 3 into something more meaningful. Fig-
verter/transistor power supply will result ure 4 provides pounds of steel filler metal
in a yearly savings of $598 per power sup- Power Supply Rating consumed per kWh of power for four dif-
ply during idle time. For a facility with ferent power supply efficiencies. These
25 power supplies, this savings is $14,925 It is commonly believed that operat- data can be used to estimate a cost per
per year. ing a power supply at or near its maxi- pound of filler metal deposited using the
In addition to using power supplies mum rated load will cause damage or appropriate deposition efficiency num-
that consume less power while idling, cause it to operate less efficiently; how- ber and power cost per kWh.
WELDING JOURNAL 25
Fig. 5 Output current of pulsed vs. CV

GMAW.
Table 1 provides a comparison be-

tween a submerged arc welding power
supply operated at 250 vs. 425 A for one
year in a facility running three shifts per
day, five days a week, and 52 weeks per
year. By increasing the welding current
to 425 A, power consumption would be
decreased by 3656 kWh, the cost of power
would be decreased by $402, and the uti-
lization required to deposit the same
amount of steel filler metal would be re-
duced from 50% to less than 25%. For a
Table 2 Deposition Efficiency Ranges for Consumable-Electrode Arc Welding
facility with 25 power supplies, this rep- Processes (Ref. 3)
resents a savings of $10,054 in power
costs and the required arc-on time to do Welding Process Deposition Efficiency (%)
the same amount of welding would be re-
duced by 39,000 hours. Shielded metal arc welding (SMAW) 5575
Flux cored arc welding (FCAW) 8090
Deposition Efficiency Gas metal arc welding (GMAW)
Submerged arc welding (SAW)
9097
9599
Table 2 provides typical deposition
efficiency ranges for four consumable-
electrode arc welding processes. Ranges
Table 3 CV vs. Pulsed GMAW
are provided as deposition efficiency is
dependent on spatter level and/or stub Pulsed vs. CV CV Pulsed
loss [shielded metal arc welding
(SMAW)]. Process parameters can have Average current 265 A 235 A
a significant effect on the former, and Voltage 27 V 27 V
welder technique can impact the latter. Cost of power $0.11/kWh $0.11/kWh
A straightforward method of decreas- Power supply efficiency 80% 80%
Utilization 80% 80%
ing energy consumption is to change to
Yearly power cost $6139 $5444
a process that has an inherently higher
deposition efficiency. There are, of
course, trade-offs for any such change
that must be considered. For instance,
Pulse vs. Constant ity running three shifts per day, five days
gas metal arc welding (GMAW) has a
a week, and 52 weeks per year. Due to
higher deposition efficiency than flux Voltage the reduction in average current, the cost
cored arc welding (FCAW); however, it
of power to operate one power supply
is generally less tolerant to contaminants, Pulsed GMAW waveforms are used
was decreased by $695. For a facility with
is more challenging to use out of posi- to achieve spray transfer at a lower aver-
25 power supplies, this represents a sav-
tion, and requires a higher level of welder age current than welding in constant volt-
ings of $13,900 in power costs.
skill. age (CV) mode by employing a peak cur-
Another method of decreasing energy rent and a background current. The peak
consumption is to increase the deposi- current promotes spray transfer while the Resistive Heating of the
tion efficiency of the arc welding process background current maintains the arc be- Electrode
currently being used. Since the deposi- tween pulses. Figure 5 illustrates the dif-
tion efficiency of a process determines ference in current/wire-feed-speed ratios For a given wire-feed speed, the cur-
the percentage of filler material that is for 0.045-in.-diameter wire for the rent output of the power supply is af-
actually deposited into the weld pool, in- GMAW process in pulsed and CV weld- fected by the contact tip-to-work distance
creasing it will increase productivity for ing modes. (CTWD). Due to the effect of resistive
the same level of power consumption. At a wire feed speed of 350 in./min, (I2R) heating, increasing the CTWD will
This can be accomplished by optimizing the welding current in CV mode was 265 decrease the current needed to melt the
parameters for improved arc stability and A, while the welding current in pulse electrode or increase the deposition rate
droplet transfer to reduce spatter gener- mode was 235 A. This represents an for a given current. The effect is greater
ation. A 5% increase in deposition effi- 11.3% reduction in arc power. for smaller-diameter wires since they
ciency will result in at least a 5% increase Table 3 provides a comparison be- have a higher electrical resistance.
in the amount of consumed filler mate- tween robotic welding using CV GMAW Figure 6 illustrates the effect of resis-
rial that is deposited into the weld joint. vs. pulsed GMAW for one year in a facil- tive heating on 0.063-in.-diameter solid
26 DECEMBER 2012
Fig. 6 Effect of CTWD on output current.
Fig. 7 Power loss vs. length of 4/0 cable.
wire using the GMAW process. In weld

trials conducted at EWI, at a CTWD of
0.75 in., the current output of the power
supply was 300 A. Increasing the CTWD
to 1.125 in. reduced the current output
by 23% to 230 A. Figure 6 also illustrates
that welding in CV mode with the ex-
tended CTWD still required 300 A, which
supports previous conclusions on the re-
duction in average current when using
pulsed GMAW.
Table 4 provides a comparison be-
tween a single robotic welding operation
with a 0.75-in. vs. 1.125-in. CTWD for
one year in a facility running three shifts
per day, five days a week, and 52 weeks
per year. Due to the reduction in aver-
age current, the cost of power was de-
creased by $1441. For a facility with 25
power supplies, this represents a savings
of $36,035 in power costs.
Power Loss Associated

with Cable Length and
Gauge Table 4 0.75-in. vs. 1.125-in. CTWD
CTWD 0.75 in. 1.125 in.

For the purpose of clarity, the previ-
ous examples have been calculated as- Average current 300 A 230 A
suming zero power loss through the weld- Voltage 30 V 30 V
ing cables; however, some amount of Cost of power $0.11/kWh $0.11/kWh
power loss is inevitable. Using an incor- Power supply efficiency 80% 80%
rect cable gauge can contribute signifi- Utilization 80% 80%
cantly to power loss, as can excessive Yearly power cost $6177.60 $4736.20
cable length. It can be calculated that at
a welding current of 300 A using 4/0
gauge cable, a set-up with 10-ft-long lead ity with 25 power supplies, this represents
and ground cables will result in approxi- a savings of $10,033 in additional power References
mately a 1.2% power loss. Increasing costs per year.
both cables to 50 ft will increase the
1. Bird, Terry. 1993. Inverter
power loss more than four times to ap-
proximately 6.1%. If the current-carry- Conclusions power sources: An efficient alterna-
ing capacity of the cable gauge is ex- tive. Welding Journal 72(1): 3740.
ceeded, this effect becomes more signif- This article provides a number of 2. Welding Handbook, Vol. 2, 9th
icant, as illustrated in Fig. 7. practical strategies for reducing energy Ed. 2001. Annette OBrien and Cyn-
Using the same parameters as the ex- consumption for arc welding processes. thia Jenney, eds. Doral, Fla.: Ameri-
ample above with a 0.75-in. CTWD, the In addition to using more energy-
can Welding Society. p. 43.
power loss associated with 10-ft-long efficient power supplies that use less
cable lengths will require an additional power during welding and while idling, 3. Welding Handbook, Vol. 1, 8th
682 kWh of power. The power loss asso- significant improvements can be made by Ed. Leonard P. Connor, ed. Doral,
ciated with 50-ft-long cable lengths will implementing changes in equipment Fla.: American Welding Society.
require an additional 3648 kWh of power. setup and welding technique to reduce p. 272.
This represents an additional $401 of the ecological impact of widely employed
power cost per power supply. For a facil- arc welding processes.
WELDING JOURNAL 27
Mason Feature December 2012_Layout 1 11/7/12 8:16 AM Page 28
Program Aids in Modeling

Welding Thermodynamics
Software related to the calculation BY PAUL MASON
PAUL MASON (paul@thermocalc.com)
of phase diagrams is being used to is with ThermoCalc Software Inc.,
McMurray, Pa.
aid in the design of new alloys and
optimize the welding processes to
join them
he National Academies report on ing to Babu (Ref. 3), Oak Ridge National examples of how CALPHAD-based tools
T Integrated Computational Materi-

als Engineering (ICME) published
in 2008 (Ref. 1) and President Obamas
Laboratory researchers developed nickel
aluminides (Ni3Al) that have exceptional
properties, but there was almost a 15-
are also being employed to welding-
related applications.
announcement of the Materials Genome year delay in fully deploying these alloys
Initiative (MGI) in June 2011 (Ref. 2) due to the lack of appropriate welding A Basis for Computational
highlights the interest in using computa- processes and welding wire technologies. Thermodynamics and
tional methods to aid materials design Reducing the time to identify and evalu- Kinetics
and process improvement that has been ate joining methods is also critical if
growing over the last twenty years. ICME and MGI are to reach their full By adopting the CALPHAD tech-
Integrated Computational Materials potentials. nique, all available thermochemical in-
Engineering is an approach to designing Computational thermodynamics and formation both thermodynamic and
components, the materials they are made kinetics are core components of ICME phase equilibria data is used to fit
of, and their associated materials pro- and MGI since they fundamentally link model parameters used to describe the
cessing methods by linking materials the phases that form, and hence the mi- Gibbs energy of individual crystallo-
models at multiple length scales. The crostructure, to the chemical composi- graphic phases. The objective is to ob-
focus of ICME is on materials; that is, tion of an alloy, and also the temperature tain a consistent set of model parameters
understanding how processes produce variations to which a material may be that can describe the thermodynamic
material structures, how those structures subjected. They are also essentially the properties of the system in a realistic way.
give rise to material properties, and how driving forces for many of the phase The Gibbs energy of each phase is de-
to select materials for a given applica- transformation reactions that take place scribed by an appropriate thermody-
tion. The Materials Genome Initiative is during materials processing. For more namic model dependent on its physical
a national initiative to double the speed than 25 years, researchers have success- and chemical properties, for example,
and reduce the cost of discovering, de- fully applied the CALPHAD (CALcula- crystallography, type of bonding, order-
veloping, and deploying new advanced tion of PHAse Diagrams) approach disorder transitions, and magnetic prop-
materials. (Refs. 4, 5) a field of computational erties. These Gibbs energy functions,
Aside from designing new alloys and thermodynamics to assist in alloy de- which take into consideration chemical
materials, understanding how to process sign and process optimization for many composition and temperature depend-
and join them are also critical factors to different alloy types including steels and ence, are obtained by the critical evalua-
consider before the new materials can be ferrous-based alloys, Ni superalloys, Al, tion of binary and ternary systems and
deployed. For example, in 1985, accord- Ti, Mg, etc. This article provides a few then, through the use of software such as
28 DECEMBER 2012
Fig. 1 Mole fraction of carbonitrides as a function of Fig. 2 Fraction solid as a function of temperature for IN939.
temperature.
Thermo-Calc (Ref. 6), calculations for (welding, brazing, soldering, and solid under both equilibrium and nonequilib-
multicomponent systems of industrial state), but with 323 references, it is not rium conditions. These data are impor-
importance can be made, based on the possible to summarize all of the differ- tant because carbides and nitrides are im-
constraints of composition and tempera- ent examples covered by the review here. portant in the microstructural develop-
ture and pressure for the system as a However, the review identified the fol- ment of weldments. Figure 1 shows a
whole. lowing general classifications: step diagram, where the amount (mole
Additionally, the CALPHAD method fraction) of carbonitrides predicted to
can be extended to model atomic mobil- form under equilibrium conditions at dif-
ities and diffusivities in a similar way. By Liquid-gas equilibrium ferent temperatures is plotted for the
combining the thermodynamic and mo- Liquid-slag equilibrium welding wire composition Fe-0.05C-
bility databases, kinetic reactions during Inclusion formation 0.2Si-1.84Mn-0.015P-0.002S-0.034Al-
solidification and subsequent heat treat- Liquid-solid interactions 0.066Nb-0.027V-0.01Cu-0.015Ti-0.13Cr-
ment processes can be simulated with the Phases formed during equilibrium 0.2Mo-0.01N (all amounts in wt-%).
use of other software such as DICTRA and nonequilibrium solidification Such calculations can be made to show
and TC-PRISMA, which are computer Microsegregation during the amounts and compositions of precip-
programs for simulating diffusion- solidification itates that may form and the temperature
controlled phase transformations range over which they are stable.
Calculation of solidification rate
and multiparticle precipitation kinetics
Prediction of heat-affected zone
in multicomponent alloy systems, Nonequilibrium Solidification
respectively. grain boundary liquation.
Through the use of such simulations, Thermodynamic calculations can be
it is possible to optimize alloy composi- made to predict properties such as liq-
tions and filler materials, and predict op- Additionally, postweld heat treatment uidus and solidus temperatures and also
timal solidification processes and solu- could be added. the phases to form from the liquid dur-
tion heat treatment temperature ranges, Four examples are described here. ing welding. According to Babu (Ref. 3),
thus reducing the number of time-con- weld researchers use this methodology
suming and costly experiments required Development of Welding to understand phase stability in the heat-
during a typical development cycle. Consumables affected zone for dissimilar materials and
dilution effects. However, equilibrium
Applications of CALPHAD Madeni et al. (Ref. 7) have used calculations assume that as the weld
Based Tools to Welding Thermo-Calc in the development of a metal cools thermodynamic equilibrium
filler metal for welding high-strength is achieved at every temperature, which
Babu (Ref. 3) has published an exten- steels using submerged arc welding. Cal- may not be realistic due to large differ-
sive review of the application of compu- culations were made using the software ences in the diffusivity of elements in the
tational thermodynamic and kinetic sim- to predict the amounts of carbides and solid and liquid phases. It is well known
ulations to joining of metals and alloys nitrides and the chemical composition, though that the diffusivity in liquid is
WELDING JOURNAL 29
established in the areas of alloy design

Software tools can reduce the time and costs and process optimization. While such
associated with trialanderror experiments tools are being increasingly used to de-
sign alloys for the optimization of mate-
rial properties, that these materials often
need to be joined to other materials for
many orders of magnitude greater than the stainless steel was predicted to car- use in service should not be ignored.
in the solid, and as a result, the solute burize with carbide precipitates forming While weld metallurgy is a complex, non-
distribution in the solid may be nonuni- in an austenite matrix. Comparison of the equilibrium problem, such tools can give
form leading to a depression of the experimental data to the simulations insight and direction into understanding
solidus temperature. This can be consid- shows the measured width of the ferritic the fundamental phenomena driving
ered using the Scheil-Gulliver approach layer for a diffusion couple produced in these processes and thus accelerate
that is incorporated into Thermo-Calc. this temperature range is 530 m com- development and reduce the time and
Figure 2 shows the calculated fraction pared with a predicted value of 560 m. costs associated with trial-and-error
solid curve for an IN-939 Ni-based su- In the stainless steel, the carburized layer experiments.
peralloy comparing the Scheil-Gulliver had a measured width of 100 m com-
prediction with the equilibrium calcula- pared with a calculated value of 70 m.
tion (dashed line). What is apparent from This discrepancy corresponds to an un- References
this figure is the larger freezing range cal- certainty in the carbon diffusivity of a fac-
culated for the Scheil-Gulliver predic- tor of two, which is within the accuracy 1. National Research Council. 2008.
tion compared with the equilibrium cal- reported by Jnsson (Ref. 9) in his as- Integrated Computational Materials Engi-
culation. Babu (Ref. 3) points out that sessment. The authors concluded the re- neering: A Transformational Discipline for
this enhanced solidification range is ex- sults of the simulations were in general Improved Competitiveness and National
pected to promote solidification crack- agreement with practical experience and Security. Washington, D.C.: The National
ing, and such calculations can be made noted that such simulations are used by Academies Press.
to indicate which alloys may be more sus- industry for optimizing the heat treat- 2. www.whitehouse.gov/sites/default/
ceptible to such cracking using such an ment of composite tubes. files/microsites/ostp/materials_genome_ini
approach. tiative-final.pdf
It should be stressed, however, that Design of a Weldable Alloy 3. Babu, S. S. 2009. Thermodynamic
equilibrium and Scheil-Gulliver calcula- and kinetic models for describing mi-
tions give two extreme conditions of weld Tancret (Ref. 10) has taken the use of crostructure evolution during joining of
solidification, but neither of these ap- these tools one step further, and has de- metals and alloys. Int. Mat. Rev., Vol. 54,
proaches actually consider cooling rates, scribed a semiautomated procedure for No. 6, pp. 333367.
or time. To consider these effects would the design of an affordable, weldable, 4. Kaufman, L., and Bernstein, H.
require a computational kinetics code, creep-resistant superalloy. The approach 1970. Computer Calculation of Phase Di-
such as DICTRA. consists of automatically calculating the agram. New York, N.Y.: Academic Press
equilibrium and Scheil out-of-equilib- Inc.
Postweld Heat Treatment rium thermodynamic properties for a 5. Saunders, N., and Miodownik, A.
large number of potential candidate alloy P. 1998. Calphad (calculations of phase
DICTRA is a software package for ac- compositions to determine their stability diagrams): A comprehensive guide. Perg-
curate simulations of one-dimensional at the expected service temperature, amon Materials Series, Vol. 1, Ed. R. W.
diffusion in multicomponent alloys. As their forging window and weldability Cahn (Oxford, UK: Elsevier Science
mentioned previously, it can be used to (through, for instance, the calculation of Ltd.).
investigate microsegregation effects dur- brittle temperature range and volume 6. Andersson, J. O., et al. 2002.
ing solidification taking into considera- fraction) and also combining these with Thermo-Calc and DICTRA, Computa-
tion cooling rates and time. Another ap- predictions of creep rupture resistance tional tools for materials science. CAL-
plication of the software is in regard to through the use of a neural network PHAD, Vol. 26, pp. 273312.
postweld heat treatment. model. By establishing criteria for poten- 7. Madeni, J. C., et al. 2006. Thermo-
Helander and gren (Ref. 8) simu- tial candidate alloys, such as the vol- dynamic modeling using Thermo-Calc in
lated the diffusion of a typical joint of a ume fraction being less than 0.25 at 750C the development of specialty welding
stainless steel and a low-alloy steel in a to minimize the potential for cracking consumables. Proc. American Welding So-
temperature range between 600 and and having a calculate creep rupture ciety. American Welding Society, Doral,
1200C and compared the calculated car- stress of approximately 100 MPa at 750C Fla.
bon concentration profiles with experi- after 100,000 h, Tancret was able to 8. Helander, T., and gren, J. 1997.
mental data at 650C. Diffusion simula- screen 7776 different compositions in a Computer simulation of multicomponent
tions were performed in the temperature nine-element system comprised of Ni, Cr, diffusion in joints of dissimilar steels.
range between 600 and 1200C for 10 h Fe, W, Al, Ti, C, Si, and B, and identify Met. Trans. A, Vol. 28A, pp. 303308.
for two alloys comprising 18Cr-10Ni- four potential candidate alloys for fur- 9. Jnsson, B. 1994. Z. Metallkd, Vol.
0.015C-Bal. Fe (stainless steel) and ther experimental testing. 85, pp. 502509.
0.1Cr-0.1Ni-0.2C-Bal. Fe (low-alloy 10. Tancret, F. 2009. Computational
steel). For the lower temperature range Conclusions tools for the design of weldable and
(600 to 850C), a ferritic layer was pre- creep-resistant superalloys. TMS, Supp.
dicted to form in the low-alloy steel at The use of computational thermody- Proc. Vol. 2, Mat. Characterization, Com-
the interface between the steels, while namics and kinetic simulations are well putation and Modeling.
30 DECEMBER 2012
greiner_FP_TEMP 11/7/12 3:36 PM Page 31
Greiner has some of the biggest equipment of its kind in the

Eastern United States and certications for handling just about
any large, heavy-duty steel fabrication job for you.
25-inch diameter steel node connectors

at JFK International Airport.
24-foot hammerhead columns and base

plates for the World Trade Centers new 133-ton transfer girder for a
Transportation Hub. New York City high-rise.
Capacity. Precision. Strength.
STRUCTURAL STEEL FABRICATION

We can roll a beam up to 40 inches the easy way and pipe up to 20
inches. Our press brake has 2,750 tons of power with a 40-foot bed. Our
CNC horizontal boring mill has a 12-foot high by 30-foot long machining
envelope. Our G&L bay boasts a 50-ton lifting capacity with 31-foot hook
height of overhead cranes. Our 30-foot by 50-foot, permanently installed,
leveling bed allows us to level to within fteen thousandths of an inch. Structural Steel Fabrication
Steel Plate & Sheet Metal Fabrication
INDUSTRIAL BLASTING & COATING Miscellaneous Metals
Our capabilities include 81,000 square feet of capacity, 34-foot by 34-foot Machining
doors and a 100-ton four-point pick-and-carry crane. Rolling & Forming Services
Cutting Services
You can count on Greiner! Industrial Coatings
Industrial & Electrical Contracting
Call us at 800-782-2110 for a free quote on your Crane Rental & Trucking Services
Heat-Bending Services
next project. (AISC Certied for Major Steel
www.greinerindustries.com Bridge Fabrication)
Rentapen Feature December 2012_Layout 1 11/7/12 3:40 PM Page 32
Green:
A Way of Life
for Weld Tooling
Company
F
or more than twenty years, This article not only details the com- Susan Straley and Vice President George
Rentapen, Inc., a machine tool de- panys long-standing efforts to be green Straley became part of a Household
sign company located in Waukesha, but also its implementation of key prac- EcoTeam program for people who
Wis., has been green. tices to remain there. wanted to reduce resource consumption
The firm specializes in weld fixtures. and save money. Their group consisted
Rentapen helps manufacturers when of about eight people who met periodi-
they are tooling their factories to pro-
Repeating the Three Rs cally for several months and worked
duce a new product by providing the fol- Reduce, Reuse, and Recycle through a manual along the way. Each
lowing: 3D CAD design services; build chapter focused on different areas
of small- to medium-sized weld fixtures; Rentapens owners were reducing, water consumption, paper, energy, trans-
and a line of weld-tooling components reusing, and recycling long before Wis- portation, packaging, and purchases.
called RAPid Tooling Components. consin took action to require recycling According to the Global Action Plan
The product line includes blocks, plates, with a state law. International, It has been demonstrated
clamp risers, and shims Fig. 1. In the early 1990s Rentapen President that, given effective leadership, engag-
32 DECEMBER 2012
By recycling all its

materials, Rentapen
operates as green as
possible in both its
factory and office
BY BETHANY KRATZ
BETHANY KRATZ (bethany@rentapen.com)
is the marketing assistant and duchess of
cost reductions at Rentapen, Inc.
(www.rentapen.com), Waukesha, Wis.
A few of the ways Rentapen has gone green

throughout the years includes setting up cut
files so any material left for recycling is minimal;
keeping minimal inventory, making for less
waste; and using cloth rags vs. paper towels. As
pictured, the companys 150-W Kern laser cuts
custom shims for a customer.
ernment agencies, and institutions about

recycling.
Rentapen has support from its waste
management companys recycling pro-
gram for its green efforts.
In Waukesha, Wis., Waste Manage-
ment, Inc., has a sorting facility. We can
put all our recyclables into one container,
and we do not have to spend time sort-
ing the cans from the paper, said Susan
Straley.
ing as few as 510% of the households in and Recycling Law to create new ways to The co-mingling of the recyclables
a housing estate in the EcoTeam program manage solid waste as well as encourage helps simplify the whole process of train-
will influence the behavior of the whole reduction, reuse, and recycling of solid ing new employees and takes less space,
community. waste. she added.
When the Straleys moved the business The Wisconsin recycling law requires It costs Rentapen $20 per month for
from their home to an office, the prac- local governments to develop and imple- the additional recycling dumpster. The
tices of reducing, reusing, recycling, and ment recycling programs for 14 materi- trash bin has a higher fee because of the
staying lean and green moved with it. In als now banned from municipal landfills dumping fee for the trash hauler.
2001, Rentapen started manufacturing, and incinerators, including corrugated
and green values influenced that division. cardboard, glass bottles and jars, alu- Good Shop Routines to Follow
Today, the company has grown to include minum cans, and plastic food and bever-
14 employees. age containers. The law also requires es- Rentapen recycles all recyclable ma-
In 1990, the state of Wisconsin passed tablishment of local ordinances and ed- terials in both its factory and the office.
the Solid Waste Reduction, Recovery, ucation of all residents, businesses, gov- The companys shop manufactures its
WELDING JOURNAL 33
weld fixture components, known as Fig. 1 Rentapen President Susan 1

RAPid Tooling Components. The line Straley holds a simple weld fixture
consists of blocks, plates, and clamp ris- that contains many of the companys
ers, which are created in a Haas Super RAPid Tooling Components.
Mini Mill CNC machine Fig. 2A, B.
The line also includes RAPid Shims cut
on a Kern industrial cutting laser. Fig. 2 Examples of the companys
When Rentapens shop team receives weld fixture components include the
an order for blocks or plates, the mate- following: A Customized RAPid
rials needed stainless steel, aluminum, Blocks; B RAPid Plates RP02 in
mild steel, and so on are selected first. bronze.
The shop associate then considers mak-
ing the selection from the boxes of dis-
carded material that may be reused
before going to the inventory of new
material.
Next, the material is processed on a
band saw and then the CNC. Sawing,
grinding, and putting the finished holes
in the blocks produces scrap metal, which
goes into a basket to be recycled Fig.
3. This is a common practice in the man-
ufacturing industry and a way to recap-
ture some of the costs of the metal and 2A
reduce waste. When bins get full, shop
associates call the scrap dealer, who picks
up the metal and pays the company for
it. In the first nine months of 2012,
Rentapen received more than $3500
from recycling its metal waste.
Making Weld Fixtures with

Left-over Scrap Metal
Last year, Rentapen sold a 4000-W

laser machine to focus more on its spe-
cialty, weld fixtures. Before completing
the sale, the company realized there was
a lot of left-over scrap metal still in the
factory inventory for cutting on the large
laser. So, before the equipment was
hauled away, the shop team came up with
a plan to use that metal. They cut it up
into smaller parts the mini-mill CNC
could handle or that could be easily cut 2B
on the band saw. The metal was set aside
for later use for building weld fixtures or
tooling components. The old steel was
made useful through the shop teams in-
novation, plus a culture of cost cutting
and waste reduction.
Laser Machine Equals a

Clean Cutting Process
In 2004, Rentapen purchased a 150-

W Kern laser to cut its custom and stan-
dard metal shims, shim packs, and die-
sharpening shims see lead photo and
Fig. 4A, B.
The cleanliness of the process greatly
influenced the companys decision to use
laser cutting rather than water jet cutting
for precision adjustment shims. Water
34 DECEMBER 2012
3 Fig. 3 Metal chips from a band saw go into a basket

to then get recycled.
Fig. 4 Following are two shapes cut from the

companys 150-W Kern laser: A Die sharpening shims;
B custom shims.
4A 4B
jets are messy and use a lot of water, ex- metal between shims Fig. 5A, B. A tomers, but it also saves resources.
plained George Straley. small amount of metal is kept between We learned early on that our prod-
the shims for efficiency in handling them uct line is so versatile that we actually
Minimizing Metal between Shims when unloading the laser. However, the have a billion versions of our products.
amount of metal left is minimal, and So for us to make them ahead of time to
Metal adjustment shims are com- every bit is recycled. Rentapens staff de- try to anticipate our customers needs
monly used to finely adjust the location veloped a system to pick up the small would be fruitless and wasteful. Just-in-
of how a weld fixture holds the product pieces that fall through the support grid time makes sense for us and our cus-
so that it is welded within dimension tol- and place them into the recycling bin. tomers, said Susan Straley.
erances. A pack of thin metal shims is
placed between two components in a Made-to-Order Production Process Reusing Paper as a Packing
weld fixture. The first component is fixed Saves Resources Material to Ship Orders
in place while the second is attached to
the first component with the pack of Rentapen follows a minimal-waste In addition, Rentapen uses recycled
shims in between. Removing one shim or and made-to-order production process, paper for packaging in its shipping/re-
adding one shim slightly adjusts the lo- reducing inventory, which keeps storage ceiving department Fig. 6. When pack-
cation of the second component. This is space to a minimum. This is beneficial ing products, the company uses new
important to manufacturers who want to considering storage space has to be boxes but old packing materials. With any
have the products parts assemble easily heated/cooled and paid for. By using a incoming packages, the peanuts and bub-
after being welded. made-to-order production process, the ble wrap are placed in a large box to be
The program to nest the shims into a company not only saves on inventory reused in shipping its tooling compo-
cutting file minimizes the amount of cost, which are passed on to its cus- nents. Each year, an old box of docu-
WELDING JOURNAL 35
5A 5B
Fig. 5 A and B Rentapens nesting program allows mini- 6

mal scrap when cutting its custom and standard shims.
Fig. 6 Recycled scrap paper is used as packaging material

for shipping orders.
ments is shredded, and the material is all the recyclables: paper and plastic bot- plates or plastic silverware either.
used for shipping. All the paper in the of- tles, plus aluminum and tin cans. Reusable plates, cups, and metal silver-
fices recycle bins is shredded and used ware are used instead.
as shipping material. Employees are en- Using Cloth Towels, Reusable In the summer, the air conditioning is
couraged to bring in old newspapers for Cups, and Much More kept at a more efficient temperature and
use as packing material, too. fans are used to keep the office and shop
Office paper has a planned journey The company does not purchase comfortable.
at Rentapen. It travels from the printer paper towels for the bathroom and In 2012, George and Susan Straley
to the desk or boardroom or file. If it is kitchen areas. Instead, it provides cloth purchased a water cooler for employees.
printed on only one side, then it moves towels and rags that are washed weekly. When selecting a supplier for drinking
to the scratch paper box, said Susan Instead of buying new towels and water, they chose a company that reuses
Straley. rags, we try to buy them from rummage the bottles over a less costly option where
The paper moves from the recycle bin sales and thrift shops. That saves money bottles are not reused.
to the shredder, then to the packing ma- and resources, said Straley. Most of the companys furniture was
terials box. At first, the Straleys were concerned purchased second-hand. When there is a
with washing the shop towels used in need to add a new desk or filing cabinet,
Rentapens factory considering the oil it starts checking out thrift stores.
Efficient Practices and metal shavings on them. However,
Carry over to the Office they consulted a water quality expert, Conclusion
who stated that since after the company
Rentapen practices green manufac- washes the towels, the water goes Through various ways, Rentapen has
turing not only in its factory, but also in through the city sewer system, it was practiced green manufacturing for quite
the office. Every room has a trash bin and okay. The quantity of towels is small and some time and keeps on making strides
a separate recycling bin. Because of the city has processes to clean up the oil toward being even more environmentally
Waukesha Countys sorting service, a and metals before they go into the river. friendly. Fortunately, it also has seen
simple blue waste basket serves to hold Rentapen does not provide paper growth straight through the recession.
36 DECEMBER 2012
astaras_FP_TEMP 11/7/12 3:45 PM Page 37
4 4 4 4
4 4 4
4 4 44
4 4 4 4
4 4 4
4 4 4 4
4 4 4
4 4 4 4 4
4
4 4 4 4
4 4 4
4
4 4 4 4 4
4 4 4 4 4
4 4 4 4
4 4 4
4 4 4 4
4 Field Testing
4 4 4 4
4 4 4 4 4
4 4 4 4 4 4
4 4 4 4 4 4 41+0,)1241,04%)4
4 4 4 4
4 4 4 20+,+-4,,('2
4
4 4 4

Craig Feature December 2012_Layout 1 11/8/12 8:02 AM Page 38
Moving from Paper to Pixels

How welding documentation BY DAVID CRAIG
software can save you time, DAVID CRAIG (dcraig@thinkcei.com)

is sales manager, CEI, Blue Springs, Mo.
money, and headaches
T
ake a moment to consider your cur- the control and convenience they offer the sheer bulk of paper can make stor-
rent document control system. Does you. age and organization burdensome and
it involve copious amounts of paper can represent a potential liability. Creat-
and time? Or perhaps you have devel- Electronic Documents ing a new document with paper and pen
oped home-brew documents within a is innately time consuming when com-
word-processing or spreadsheet program. Welding procedures, procedure qual- pared to software, especially when that
Given the power of the welding docu- ifications, and welder qualifications are software offers built-in document cre-
mentation products available today, you all of vital importance to code-based ation assistance.
would be doing yourself and your com- welding shops and fabricators. Sure these Once you have experienced document
pany a disservice by not taking a look at can be designed with paper and pen, but creation assistance, you will wonder why
Fig. 1 Todays software offers

advanced reporting features to
help reduce your workload.
38 DECEMBER 2012
Craig Feature December 2012_Layout 1 11/8/12 8:02 AM Page 39
you stuck with paper so long. This assis- a filing cabinet full of paper can be a plex reports that blur the lines of tradi-
tance ranges from simply copying over nightmare. Spreadsheets have their uses, tional functionality by adding the ability
data from like fields between document but keeping data relevant and up to date to apply code rules on the fly as a filter-
types to accessing built-in databases and can be a huge undertaking. Finding a spe- ing mechanism Fig. 1. It is even pos-
offering practical suggestions for filler cific Welding Procedure Specification sible to create and use completely cus-
metals, gases, travel speeds, voltage, am- (WPS) or Procedure Qualification tomized reports.
perage, and other variables, all the way Record (PQR) among thousands of doc- The added convenience of electronic
up to providing high-level guidance and uments is virtually impossible without documentation benefits your customers
qualified ranges based on code require- dedicated software. Welder documenta- as well. Job data can be gathered into a
ments, thereby practically generating the tion software provides the ability to single PDF that can then be emailed or
documents for you, such as with search based on document-specific cri- uploaded. Compare this to the time spent
ProWrite software. teria. This drastically reduces your time gathering, copying, faxing or mailing, and
In addition to being time consuming, spent looking for documents and can refiling paper documents.
paper documents are also difficult to help eliminate duplication. Search out a
store and organize. They are susceptible qualified welder based on his or her suit- Make the Change
to fire, flood, and even time. Many peo- ability for a particular application or,
ple are stunned when they find that their even better, match up welders with new The latest generation of welding doc-
photocopied duplicates have faded al- WPSs based on their previous qualifica- umentation software can lead you down
most completely in only a decade, but this tion ranges under the guidance of code the path toward better organization,
is an all too common scenario. You can rules and eliminate unnecessary testing. safer storage, and greatly improved us-
alleviate some concerns by keeping du- The reports available in todays weldability and accessibility of your informa-
plicates off-site, but now you have dou- ing documentation software range from tion. Add that to the time and money sav-
bled your storage space requirements simple listings of various documents cre- ings it offers and the question becomes
and made it difficult to process any doc- ated in the software, to welders and their less should you use software? and more
ument changes. When you instead cre- continuity/expiration to massively com- why arent you already?
ate and store your documents electroni-
cally, you can keep millions of documents
in a drive the size of a book, document
changes are accomplished with a few but-
ton clicks, and online storage gives you
access to your documents from any In-
ternet-enabled location.
Electronic documentation opens up
new possibilities. Where you would need
to copy and either fax or mail a paper
document, you can save an electronic
document as a PDF and send it by e-mail,
putting your documents in the recipients
hands in moments. Not only does this
make your life easier, it looks more pro-
fessional to your customers when you can
show clean, accurate documentation for
an upcoming or current job.
Welder Continuity
Tracking production welds over time
can be an issue even with just a handful
of welders. Keeping an eye on process
expiration can be difficult; should any-
one slip through the cracks, you have the
added expense of qualification tests that
could have been avoided. Welding docu-
mentation software makes managing
your welder continuity a very simple
process and may even take things a step
further by allowing you to track defect
and NDE information on your produc-
tion welds so you can stay on top of re-
jection rates.
Data and Reports

Trying to correlate usable data from
WELDING JOURNAL 39
Coming Events Layout_Layout 1 11/8/12 1:34 PM Page 40
COMING
NOTE: A DIAMOND ( ) DENOTES AN AWS-SPONSORED EVENT.
EVENTS
Intl Conf. on Nanojoining and Microjoining. Dec. 25. Jin Chun members receive discounted registration. www.lia.org/confer-
Yuan Hotel, Tsinghua University, Beijing, China. Cosponsored by ences/lam.
IIW, Medtronic, CMES, NSFC, and others. www.nmj2012.com.
Solar POWER-GEN Conf. and Expo. Feb. 1315. San Diego
Power-Gen Intl Show. Dec. 1113. Orange County Convention Convention Center, San Diego, Calif. www.solar-powergen.com.
Center, Orlando, Fla. www.power-gen.com.
AWS 8th Shipbuilding Conf. Feb. 26, 27. Wyndham Riverfront
Intl Conf. on Advanced Material and Manufacturing Science New Orleans, New Orleans, La. Sponsored by the American
(ICAMMS 2012). Dec. 20, 21. High-Tech Mansion BUPT, Beijing, Welding Society (800/305) 443-9353, ext. 264; www.aws.org/
China. www.icamms-conf.org. conferences.
Intl Conf. on Frontiers of Mechanical Engineering, Materials, Adhesion Society Annual Meeting & Expo. March 36. Hilton
and Energy (ICFMEME 2012). Dec. 20, 21. Beijing, China. Daytona Beach Oceanfront Resort, Daytona Beach, Fla. www.ad-
www.icfmeme.org. Conference general contact is Dr. Zheng, hesionsociety.org/Meeting/meeting.htm.
icfmeme@163.com.
ASNT 22nd Annual Research Symposium. March 1821. The
API 2013 Inspection Summit & Expo. Jan. 710. Galveston Is- Peabody Memphis, Memphis, Tenn. American Society for Non-
land Convention Center, Galveston, Tex. American Petroleum In- destructive Testing. www.asnt.org.
stitute. www.api.org/inspectionsummit. ILSC Intl Laser Safety Conf. March 1821. Doubletree by
Hilton, Orlando, Fla. Laser Institute of America. www.lia.org/ilsc.
Automate 2013 Show and Conf. Colocated with ProMat 2013.
Jan. 2124. McCormick Place, Chicago, Ill. Robotics Industries AeroDef Manufacturing and Composites Manufacturing 2013.
Assn., AIA Advancing Vision + Imaging, and Motion Control March 1921. Long Beach Convention Center, Long Beach, Calif.
Assn. www.automate2013.com. Society of Manufacturing Engineers. www.aerodefevent.com.
LAM 5th Annual Laser Additive Manufacturing Workshop. [MC]2 2013 MTConnect: Connecting Manufacturing Conf. April
Feb. 12, 13. Hilton Houston North Hotel, Houston, Tex. Ameri- 10, 11. Hyatt Regency, Cincinnati, Ohio. MTConnect Institute.
can Welding Society is a cooperating society in this event. AWS www.mtconnectconference.org.
SERIOUS AIR FOR SERIOUS PLACES
A powerhouse ventilator for the toughest jobs.
High quality industrial products: circulation fans, exhaust,

misting, evaporative cooling and infrared heat.

40 DECEMBER 2012
GAWDA 2013 Spring Management Conf. April 1316. Grand cal, Materials, and Mining Assn. www.abmbrasil.com.br.
Hyatt Hotel and Convention Center, River Walk, San Antonio,
Tex. Gases and Welding Distributors Assn. www.gawda.org. 12th Intl Conf. on Application of Contemporary Non-Destructive
Testing in Engineering. Sept. 46. Grand Hotel Metropol, Por-
Society of Vacuum Coaters SVC TechCon 2013. April 2025. toroz, Slovenia. Sponsored by The Slovenian Society for Non-De-
Rhode Island Convention Center, Providence, R.I. www.svc.org. structive Testing. www.fs.uni-lj.si/ndt.
JOM-17, Intl Conf. on Joining Materials. May 58. Konven- 66th IIW Annual Assembly and Intl Conf. on Automation in
tum Lo Skolen, Helsingr, Denmark. Institute for the Joining of Welding. Sept. 1117. Essen, Germany. Organized by DVS (Ger-
Materials (JOM) in association with the IIW. Cosponsored by man Welding Society). www.dvs-ev.de/IIW2013/.
AWS, TWI, Danish Welding Society, Welding Technology Insti-
tute of Australia, University of Liverpool, Cranfield University, ASM Heat Treating Society Conf. and Expo. Sept. 1618, 2013. In-
Force Technology, and ABS (Brazilian Welding Assn.). E-mail diana Convention Center, Indianapolis, Ind. www.asminterna-
Osama Al-Erhayem at jom_aws@post10.tele.dk; www.jominsti- tional.org/content/Events/heattreat/.
tute.com/side6.html.
18th Intl Schweissen & Schneiden Trade Fair. Sept. 1621. Messe
INTERTECH 2013, Superabrasive Materials, Principles, and Essen, Essen, Germany. Sponsored by DVS (German Welding
Applications for the Aerospace and Defense Industries. May 68. Society). www.messe-essen.de/en/messeessen/index.html.
Hyatt Regency Baltimore Harbor Hotel, Baltimore Md. Indus-
trial Diamond Assn. www.intertechconference.com. POWER-GEN Brasil 2013, HydroVision Brasil, and DistribuTech
Brasil. Sept. 2426. Transamerica Center, So Paulo, Brazil.
POWER-GEN India & Central Asia, Renewable Energy World www.power-gen.com.
Conf. & Expo, and HydroVision India. May 68. Bombay Exhi-
bition Centre, Goregaon, Mumbai, India. www.power-genindia. WESTEC. Oct. 1517, 2013. Los Angeles Convention Center, Los
com/index.html. Angeles, Calif. The Society of Manufacturing Engineers.
www.westeconline.com; (800) 733-4763.
IIE Annual Conf. and Expo. May 1822. Caribe Hilton, San Juan,
Puerto Rico. www.iienet2.org/annual2. Educational Opportunities
44th Steelmaking Seminar Intl. May 1922. Tau Grande Laser Welding and Equipment Fundamentals. Jan. 17. Edison
Hotel Termas & Convention Arax, Estncia Parque do Barreiro, Welding Institute, Columbus, Ohio. Call (614) 688-5049, e-mail
s/n Arax - Minas Gerais, Brazil. Held by Brazilian Metallurgi- education@ewi.org.
WELDING JOURNAL 41
Introduction to Ultrasonic Joining. Feb. 7. Edison Welding CWI/CWE Course and Exam. Troy, Ohio. A two-week prepara-
Institute, Columbus, Ohio. Call (614) 688-5049, e-mail education and exam program. Hobart Institute of Welding Technology;
tion@ewi.org. (800) 332-9448; www.welding.org.
ASM Intl Courses. Numerous classes on welding, corrosion, fail- CWI/CWE Prep Course and Exam and NDT Inspector Training
ure analysis, metallography, heat treating, etc., presented in Courses. An AWS Accredited Testing Facility. Courses held year-
Materials Park, Ohio, online, webinars, on-site, videos, and round in Allentown, Pa., and at customers facilities. Welder
DVDs; www.asminternational.org, search for courses. Training & Testing Institute; (800) 223-9884; info@wtti.edu;
www.wtti.edu.
Automotive Body in White Training for Skilled Trades and
Engineers. Orion, Mich. A five-day course covers operations, CWI Preparatory and Visual Weld Inspection Courses. Classes
troubleshooting, error recovery programs, and safety procedures presented in Pascagoula, Miss., Houston, Tex., and Houma and
for automotive lines and integrated cells. Applied Mfg. Sulphur, La. Real Educational Services, Inc. (800) 489-2890;
Technologies; (248) 409-2000; www.appliedmfg.com. info@realeducational.com.
Basic and Advanced Welding Courses. Cleveland, Ohio. The Consumables: Care and Optimization. Free online e-courses on
Lincoln Electric Co.; www.lincolnelectric.com. the basics of plasma consumables for plasma operators, sales,
and service personnel; www.hyperthermcuttinginstitute.com.
Basics of Nonferrous Surface Preparation. Online course, six
hours includes exam. Offered on the 15th of every month by The
Crane and Hoist Training for Operators. Konecranes Training
Society for Protective Coatings. Register at www.sspc.org/training.
Institute, Springfield, Ohio; www.konecranesamericas.com; (262)
Best Practices for High-Strength Steel Repairs. I-CAR courses 821-4001.
for vehicle repair and steel structural technicians. www.i-car.com.
Dust Collection Seminars. Free, full-day training on industrial
Boiler and Pressure Vessel Inspectors Training Courses and ventilation basics and OSHA, EPA, and NFPA regulations.
Seminars. Columbus, Ohio; www.nationalboard.org; (614) 888- Presented throughout the year at numerous locations nation-
8320. wide. Call Camfil Farr APC, (800) 479-6801.
Canadian Welding Bureau Courses. Welding inspection courses EPRI NDE Training Seminars. Training in visual and ultrasonic
and preparation courses for Canadian General Standards Board examination and ASME Section XI. Sherryl Stogner (704) 547-
and Canadian Nuclear Safety Commission certifications. The 6174; sstogner@epri.com.
CWB Group, www.cwbgroup.org.
42 DECEMBER 2012
weld engineering_FP_TEMP 11/7/12 3:40 PM Page 43

Cert Schedule 2013_Layout 1 11/8/12 10:16 AM Page 44
CERTIFICATION
SCHEDULE
Certification Seminars, Code Clinics, and Examinations
Certified Welding Inspector (CWI) Dallas, TX March 1015
LOCATION SEMINAR DATES EXAM DATE Doral, FL April 712
Charlotte, NC Jan. 611 Jan. 12 Sacramento, CA April 28May 3
Beaumont, TX Jan. 611 Jan. 12 Charlotte, NC May 510
Doral, FL Exam only Jan. 17
Long Beach, CA Jan. 27Feb. 1 Feb. 2 Certified Welding Supervisor (CWS)
Denver, CO Jan. 27Feb. 1 Feb. 2 LOCATION SEMINAR DATES EXAM DATE
Doral, FL Jan. 27Feb. 1 Feb. 2 Atlanta, GA Jan. 711 Jan. 12
Pittsburgh, PA Jan. 27Feb. 1 Feb. 2 New Orleans, LA April 1519 April 20
Corpus Christi, TX Exam only Feb. 9 CWS exams are also given at all CWI exam sites.
Seattle, WA Feb. 38 Feb. 9
New Orleans, LA Feb. 1015 Feb. 16
Certified Radiographic Interpreter (CRI)
Waco, TX Feb. 1015 Feb. 16
LOCATION SEMINAR DATES EXAM DATE
San Diego, CA Feb. 24March 1 March 2
Seattle, WA Feb. 25March 1 March 2
Atlanta, GA Feb. 24March 1 March 2
Houston, TX April 1519 April 20
Mobile, AL March 38 March 9
Las Vegas, NV May 610 May 11
Kansas City, MO March 38 March 9
The CRI certification can be a stand-alone credential or can
Houston, TX March 38 March 9
exempt you from your next 9-Year Recertification.
Norfolk, VA March 38 March 9
Milwaukee, WI March 38 March 9 Certified Welding Sales Representative (CWSR)
Birmingham, AL March 1015 March 16 CWSR exams will be given at CWI exam sites.
Indianapolis, IN March 1015 March 16
Portland, OR March 1015 March 16 Certified Welding Educator (CWE)
Doral, FL March 1722 March 23 Seminar and exam are given at all sites listed under Certified
Chicago, IL March 1722 March 23 Welding Inspector. Seminar attendees will not attend the Code
Boston, MA March 1722 March 23 Clinic portion of the seminar (usually the first two days).
Mobile, AL Exam only March 23 Certified Robotic Arc Welding (CRAW)
Rochester, NY Exam only March 23 The course dates are followed by the location and phone number
York, PA Exam only March 23
Corpus Christi, TX Exam only April 6 Feb. 26; June 1721, Dec. 913 at
Springfield, MO April 712 April 13 ABB, Inc., Auburn Hills, MI; (248) 3918421
Dallas, TX April 712 April 13
Doral, FL Exam only April 18 Feb. 25March 1; May 2024, Aug. 1923, Dec. 26 at
Minneapolis, MN April 1419 April 20 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Las Vegas, NV April 1419 April 20
Syracuse, NY April 1419 April 20 March 4, Oct. 14 at
San Francisco, CA April 2126 April 27 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
New Orleans, LA April 2126 April 27
Nashville, TN April 2126 April 27 Feb. 1115, April 2226, July 1519, Oct. 2125 at
Annapolis, MD April 28May 3 May 4 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Detroit, MI April 28May 3 May 4
St. Louis, MO Exam only May 4 Jan. 21, March 25, May 20, July 22, Sept. 23, Nov. 18 at
Fresno, CA May 510 May 11 Wolf Robotics, Fort Collins, CO; (970) 225-7736
Doral, FL May 510 May 11
Albuquerque, NM May 510 May 11 On request at:
Oklahoma City, OK May 510 May 11 MATC, Milwaukee, WI; (414) 297-6996
Corpus Christi, TX May 510 May 11
Knoxville, TN Exam only May 18
Certified Welding Engineer; Senior Certified Welding
9Year Recertification Seminar for CWI/SCWI (No exams Inspector
given) Exams can be taken at any site listed under Certified Welding
For current CWIs and SCWIs needing to meet education require- Inspector. No preparatory seminar is offered.
ments without taking the exam. The exam can be taken at any site
listed under Certified Welding Inspector.
LOCATION SEMINAR DATES International CWI Courses and Exams Schedules
New Orleans, LA Jan. 611 Please visit www.aws.org/certification/inter_contact.html.
Denver, CO Feb. 1015
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the seminar/exam or
exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our Web site
www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept. to confirm your course status before making travel
plans. For information on AWS seminars and certification programs, or to register online, visit www.aws.org/certification or call (800/305) 443-9353,
ext. 273, for Certification; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.
44 DECEMBER 2012
otc daihen_FP_TEMP 11/7/12 3:52 PM Page 45

edu shipbuilding conf_FP_TEMP 11/6/12 3:12 PM Page 46
AWS
AWS Conferences
Conferences & Exhibitions:
8th Shipbuilding Conference
Conference
February 26-27, 2013 / Wyndham
Wyndham River
Riverfront
front New Orleans
Join us in New Orleans for an exciting look into the world of shipbuilding!
Our featured
featured speakers will cover a multitude of topics including robotics
robotics
and mechanized welding for shipbuilding applications, aluminum
applications, advanced welding processes
processes and much more.
more.
Highlights
Learn progress of new and innovative

Learn about the progress
developments in shipbuilding.
Network with industry peers to discuss the best solutions for

Network
business growth.
growth.
Information
Information on new and emer ging technologies being
emerging
developed for shipbuilding applications.
AWS
AWS Conference
Conference attendees ar e awar
are ded 1 PDH
awarded
(Professional Development Hour) for each hour of
(Professional
confer ence attendance. These PDHs can be applied
conference
towar
towardd AWS
AWS recertifications
recertifications and renewals.
renewals.
FFor
or the latest conference information and registration visit our web site at
registration
w..aws.org/conferences or call 800-443-9353, ext. 264.
www
www.aws.org/conferences
Society News December_Layout 1 11/8/12 2:09 PM Page 47
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
Detroit Section Honors Welding Students
Forty-four students (above) received Detroit Section-sponsored scholarships totaling $36,800 at the Sept. 20 event.
Shown are (from left) AWS President Bill Rice, Detroit Section Chair Mike Palko, Secretary Andre Young, AWS Corporate Director Workforce
Development Monica Pfarr, and Scholarship Chair Wesley Doneth during the presentation of the Detroit Sections donation of $350,000 to the
AWS Foundation scholarship program.
Supporting educational programs nounced it would, for a limited time, velopment, Sept. 20 at the VistTaTech
and student scholarships are important match funds donated to new and exist- Center, Schoolcraft College, in Livonia,
to the Detroit Section members and its ing named scholarships, the Section Mich. The event included a welding shop
patrons, said Mike Palko, Detroit Sec- elected to donate $350,000 to the AWS open house in the afternoon, followed
tion chairman. He noted that the Sec- Foundation. by dinner, presentations by Bill Rice and
tion has been donating about $35,000 an- The funds were presented to AWS SkillsUSA competitor Alex Pazkowski,
nually to student scholarships, but when President Bill Rice and Monica Pfarr, and concluded with awarding $36,800 in
the American Welding Society an- AWS corporate director workforce de- scholarships to 44 students.
WELDING JOURNAL 47
Tech Topics
A2 Committee on Definitions and Symbols Meets in West Virginia
Shown are from left (front row) Chuck Ford, Pat Newhouse, and Stephen Borrero, (back row) Ted Hutton, Ben Grimmett, Dick Holdren,
Chris Lander, Larry Barley, J. P. Christein, and David Beneteau.
The A2 Committee on Definitions and Examination, and AWS A3.0M/A3.0, Stan- Grimmett, A2B Subcommittee Chair Dick
Symbols met October 35 at Oglebay Re- dard Welding Terms and Definitions includ- Holdren, A2C Subcommittee Chair J. P.
sort and Conference Center in Wheeling, ing Adhesive Bonding, Brazing, Soldering, Christein, Chris Lander, Larry Barley,
W.Va., to continue its work on the main- Thermal Cutting, and Thermal Spraying. David Beneteau, Chuck Ford, Pat New-
tenance of AWS A2.4, Standard Symbols Attending the meeting were G1 Com- house, and Stephen Borrero, AWS staff
for Welding, Brazing, and Nondestructive mittee Chair Ted Hutton, A2 Chair Ben secretary to the A2 Committee.
Standards for Public Review ing the approval process. The above re- G2.3M/G2.3:2012, Guide for the Join-
A5.16/A5.16M:20XX (ISO 24034: 2010 vised standards were submitted for pub- ing of Solid Solution Austenitic Stainless
MOD), Specification for Titanium and Ti- lic review. Draft copies may be obtained Steels. Revised. 10/16/12.
tanium-Alloy Welding Electrodes and Rods. from R. ONeill, roneill@aws.org, ext. 451.
$25. 12/3/12. Technical Committee Meetings
B5.16:20XX, Specification for the Qual- Standards Approved by ANSI All AWS technical committee meet-
ification of Welding Engineers. $25. 12/3/12. A5.4/A5.4M:2012, Specification for ings are open to the public. To attend a
F1.2:20XX, Laboratory Method for Stainless Steel Electrodes for Shielded Metal meeting, contact the committee secretary
Measuring Fume Generation Rates and Arc Welding. Revised. 10/5/12. as listed below. Call (800/305) 443-9353
Total Fume Emission of Welding and Al- A5.10/A5.10M:2012 (ISO 18273:2004 at the extention shown. Visit www.aws.
lied Processes. $25. 11/26/12. MOD), Welding Consumables Wire org/technical/jointechcomm.html to learn
AWS was approved as an accredited Electrodes, Wires and Rods for Welding of more about what technical committees
standards-preparing organization by the Aluminum and Aluminum-Alloys Classifi- do, membership requirements, and to
American National Standards Institute cation. Revised. 10/4/12. apply for membership online.
(ANSI) in 1979. AWS rules, as approved G2.1M/G2.1:2012, Guide for the Join- Dec. 5, 6, Safety and Health Commit-
by ANSI, require that all standards be ing of Wrought Nickel-Based Alloys. Re- tee. Doral, Fla. S. Hedrick, 305.
open to public review for comment dur- vised. 10/16/12.
Errata AWS D3.6M:2010 AWS Members Get Low Rate for Laser Workshop
Underwater Welding Code
The following errata, in addtion to previously announced American Welding Society members will receive a discounted
corrections (visit www.aws.org), have been identified and will fee to attend the Laser Institute of America (LIA) 5th Annual
be incorporated into the next reprinting of this document. Laser Additive Manufacturing Workshop to be held Feb. 12, 13,
Page 60, Figure 7.2, note 2b. Correct to . 2013, at Hilton Houston North Hotel in Houston, Tex. The two
Page 63, Figure 7.3, note a. Correct to . societies have signed a cooperating society agreement wherein
Page 63, Figure 7.3, note b. Correct to . AWS is listed as a Cooperating Society for the event and AWS
Page 75, Figure 8.2, note 3b. Correct to . members receive the LIA member discount. For complete infor-
Page 77, Figure 8.3, note b. Correct to . mation, visit www.lia.org/conferences/lam.
48 DECEMBER 2012
Opportunities to Contribute to AWS Welding Standards and Codes

NOTE: LEARN MORE ABOUT TECHNICAL COMMITTEES AND APPLY FOR MEMBERSHIP ONLINE AT www.aws.org/technical/jointechcomm.html.
D14 Committee on Machinery and Equip- Friction Stir Welding of Aluminum Alloys for cators to help review its documents. Contact
ment seeks professionals in the design, pro- Aerospace Applications. Contact A. Diaz, E. Abrams, eabrams@aws.org; ext. 307.
duction, engineering, testing, and safe opera- adiaz@aws.org; ext. 304. D14H Subcommittee on Surfacing and
tion of machinery and equipment to prepare J1 Committee on Resistance Welding Reconditioning of Industrial Mill Rolls to re-
and revise its documents. Contact E. Abrams, Equipment seeks educators, general interest, vise AWS D14.7, Recommended Practices for
eabrams@aws.org; ext. 307. and users to help develop its documents on Surfacing and Reconditioning of Industrial Mill
C2 Committee on Thermal Spraying seeks controls, installation and maintenance, cali- Rolls. Contact E. Abrams, eabrams@aws.org;
educators, general interest, and users to up- bration, and resistance welding fact sheets. ext. 307.
date its documents. Contact E. Abrams, Contact E. Abrams, eabrams@aws.org; ext. D8 Committee on Automotive Welding
eabrams@aws.org; ext. 307. 307. seeks members to help prepare standards on
D16 Committee on Robotic and Automatic A5L Subcommittee on Magnesium Alloy all aspects of welding in the automotive in-
Welding seeks general interest and educators Filler Metals to assist in updating its docu- dustry. Contact E. Abrams, eabrams
to help revise its documents. Contact B. Mc- ment. Contact R. Gupta, gupta@aws.org, ext. @aws.org; ext. 307.
Grath, bmcgrath@ aws.org; ext. 311. 301. D10P Subcommittee for Local Heat Treat-
D17J Subcommittee seeks members to C4 Committee on Oxyfuel Gas Welding ing of Pipe seeks members. Contact B. Mc-
help revise D17.3/D17.3M, Specification for and Cutting seeks general interest and edu- Grath, bmcgrath@aws.org; ext. 311.
Member-Get-A-Member Campaign
Listed are standings as of Oct. 16, 2012. See Presidents Roundtable Student Member Sponsors
page 65 of this Welding Journal for a complete M. Pelegrino, Chicago 16 W. England, West Michigan 33
list of rules and a prize list, or visit E. Ezell, Mobile 12 H. Hughes, Ozark 31
www.aws.org/mgm. Call the AWS Membership R. Fulmer, Twin Tiers 10 S. Siviski, Maine 24
Dept. at (800) 443-9353, ext. 480, with questions P. Strother, New Orleans 9 M. Arand, Louisville 22
about your member-proposer status. A. Tous, Costa Rica 9 G. Gammill, NE Mississippi 21
Presidents Club B. Scherer, Cincinati 19
Winners Circle W. Komlos, Utah 7 R. Munns, Utah 18
Listed below are the sponsors of 20 or more J. Smith, San Antonio 6 S. Lindsey, San Diego 17
Individual Members per year, since June 1, 1999. C. Becker, Northwest 5 E. Norman, Ozark 16
The superscript denotes the number of years the L. Webb, Lexington 4 D. Pickering, Central Arkansas 13
member has earned Winners Circle status if A. Bernard, Sabine 3 J. Daugherty, Louisville 12
more than once. P. Brown, New Orleans 3 S. Robeson, Cumberland Valley 12
E. Ezell, Mobile10 D. Buster, Eastern Iowa 3 D. Saunders, Lakeshore 11
J. Compton, San Fernando Valley7 C. Daon, Israel 3 A. Theriot, New Orleans 10
J. Merzthal, Peru2 G. Gammill, NE Mississippi 3 A. Duron, Cumberland Valley 10
G. Taylor, Pascagoula2 D. Jessops, Mahoning Valley 3 J. Boyer, Lancaster 9
L. Taylor, Pascagoula2 R. Wright, San Antonio 3 G. Seese, Johnstown-Altoona 8
B. Chin, Auburn Presidents Honor Roll C. Schiner, Wyoming 8
S. Esders, Detroit W. Larry, Southern Colorado 2 R. Zabel, SE Nebraska 7
M. Haggard, Inland Empire E. Norman, Ozark 2 R. Udy, Utah 7
M. Karagoulis, Detroit A. Sam, Trinidad 2 T. Buckley, Columbus 6
S. McGill, NE Tennessee D. Saunders, Lakeshore 2 R. Fuller, Green & White Mountains 6
B. Mikeska, Houston A. Vogt, New Jersey 2 R. Richwine, Indiana 5
W. Shreve, Fox Valley M. Wheeler, Cleveland 2 W. Wilson, New Orleans 5
T. Weaver, Johnstown/Altoona W. Wilson, New Orleans 2 J. Reed, Ozark 4
G. Woomer, Johnstown/Altoona D. Wright, Kansas City 2 G. Sieper, Kansas 4
R. Wray, Nebraska R. Zabel, SE Nebraska 2 P. Strother, New Orleans 4
District Meritorious and District Director Awards Announced

District Meritorious Award Joseph Nedorezov, Philadelphia Todd Morris, Tulsa Section
Mike Vincent, Kansas City Section, was Joe Kass, Long Island Debbie Rudichuk, Tulsa Section
nominated to receive the District Meritori- Thomas Colasanto, New York Paul Stanglin, North Texas Section
ous Award at the District 16 conference. Debra Stanglin, North Texas Section
Roy Lanier, District 4 director, nominated: Clayton Roszell, Lincoln College of Tech-
District Director Awards Tidewater Section, #121 nology, North Texas Section
The District Director Award provides a Charlotte Section, #140 Casey Cordell, North Texas Section
means for District Directors to recognize in- Northeastern Carolina Section, #137 Anita Holstien, Ozark Section
dividuals and corporations who have con- Carolina Section, #87 Brian Chatcherine, Ozark Section
tributed their time and effort to the affairs of Southwest Virginia Section, #179 Kenny McCoy, Ozark Section
their local Section and/or District. Central Piedmont Community College College of the Ozarks, Ozark Section
Tom Ferri, District 1 director, nominated: Student Chapter Oren Reich, Central Texas Section
Gil Trigo, Montreal Section Rowan Carbarrus Community College Texas State Technical College, Central
Michel Marier, Montreal Section Student Chapter Texas Section
Wake Tech Community College Student Kilgore Jr. College, East Texas
Harland Thompson, District 2 director, Chapter Cody Edward, East Texas
nominated: The Roberts Co., North State Steel Stu-
Herb Browne, New Jersey dent Chapter Dale Flood, District 22 director, nominated:
Alfred Fleury, New Jersey Aleda Vaughn, Sacramento Valley
Pat Grillon, New Jersey J. Jones, District 17 director, nominated: Brandon Beattie, Sacramento Valley
Mike Chomin, Philadelphia Ralph Johnson, Tulsa Section Nathan Flatt, Sierra Nevada
WELDING JOURNAL 49
Membership Committee Meets at Lincoln
Shown during the Membership Committees business meeting at The Lincoln Electric Co. are (from left) Lee Kvidahl, David Trees, Cassie
Burrell, Jim Appledorn, AWS Vice President David Landon, Rhenda Kenny, Bill Komlos, Harland Thompson, and Dale Flood.
The fall Membership Committee committee members toured the company rector Bill Komlos, District 22 Director
meeeting was held at The Lincoln Elec- facilities, including the Electrodes Div. Dale Flood, David Trees, Jim Appledorn,
tric Co. headquarters in Cleveland, Ohio. Participating in the business meeting were AWS Senior Associate Deputy Director
Committee member Jim Appledorn, U.S. AWS Vice President David Landon, past Cassie Burrell, and Rhenda Kenny, Di-
distributor sales manager for Lincoln, AWS President Lee Kvidahl, District 2 Di- rector, Member Services.
served as host. Following the meeting, the rector Harland Thompson, District 20 Di-
New AWS Supporters

Sustaining Company JNE Welding New River Community & Technical College
Cavagna North America, Inc. 3915 Thatcher Ave. Greenbrier Valley Campus
50 Napoleon Ct., Saskatoon, SK S7R1A3 101 Church St.
Somerset, NJ 08873 Canada Lewisburg, WV 24901
Representative: David S. Ellis
www.cavagnagroup.com K.E.M. Welding Northern Industrial Training
The Cavagna Group, founded in 1949, is a 11 Lindbergh Trail 1740 N. Terrilou Ct.
supplier of equipment and fittings for com- Rockaway, NJ 07866 Palmer, AK 99645
pressed gases, gas storage, and control. It re-
lies on eight vertically integrated production Saber Engineering & Fabrication, Inc. Pickens County Career and
units in Italy and seven additional units in other 3261 Armstrong Ln. Technology Center
countries. With its distribution network of an Hillsborough, OH 45133 990 Chastian Rd.
additional 15 commercial business units, it Liberty, SC 29657
services customers worldwide, including the Special Testing & Consulting, LLC
major oil companies and producers of com- 144 Toledo St. San Felipe Del Rio C.I.S.D.
pressed gases containers and the original Farmingdale, NY 11735 100 Memorial Dr.
equipment manufacturers of gas appliances. PO Box 420128
Star Metal Fabrication, Inc. Del Rio, TX 78840
Supporting Companies 707 Nelson Ln.
J. E. Johnson, Inc. Wharton, TX 77488 Starke County Initiative for
1550 E. Virginia Dr. Lifelong Learning Center
Midland, MI 48642 Titan Contracting Services 1300 Kloeckner Dr.
7463 Varna Ave. Knox, IN 46534
Southwest United Industries, Inc. North Hollywood, CA 91605
422 S. St. Louis Ave. AWS Member Counts
Tulsa, OK 74120 Wenatchee Quality Welding & Fabrication November 1, 2012
5830 Sunset Hwy.
Affiliate Companies Cashmere, WA 98815 Grades
Big R Bridge, LLC
Sustaining ......................................549
PO Box 1290, Greeley, CO 80632
Educational Institutions Supporting .....................................349
Borrelli Steel Fabricators, LLC College of Western Idaho Educational ...................................606
2800 Industrial Way 1464 University Dr. Affiliate..........................................479
Vineland, NJ 08360 Boise, ID 83706 Welding Distributor........................50
Total Corporate ..........................2,033
Eagle Crest Enterprises , LLC Echols Middle School Individual .................................58,346
403 B Quillens Point Ln. 2701 Echols Ave. Student + Transitional .................9,558
Smithfield, VA 23430 Northport, AL 35476 Total Members .........................67,904
50 DECEMBER 2012
SECTIONNEWS
Connecticut Section members (from left)

Steve Goodrow, Frank Gulluni, and Carole
del Vecchio taught middle school students Students are shown working on a welded wind chime assignment at summer classes con-
how to weld during the summer. ducted by Connecticut Section members.
Robert Petrino (left) is shown with Thomas

Ferri, District 1 director, at the Boston Sec- Shown at the Maine Section Sept. 18 program are (from left) Joel Stanley, Vice Chair Patrick
tion award-presentation event. Kein, Jon Ferreira, Alan Smith, and Scott Smith.
del Vecchio presented two-week-long
District 1
Thomas Ferri, director
welding training courses to local 7th and
8th grade students. On Oct. 19, the Sec-
(508) 527-1884 tion relocated its technical library to the
thomas_ferri@victortechnologies.com college in Enfield, Conn. These resources
are available to all AWS members and to
students in the colleges welding technolo-
BOSTON gies programs. For information, contact
SEPTEMBER 28 Goodrow or del Vecchio at (860) 253-3167.
Activity: Thomas Ferri, Dist. 1 director,
presented the District Educator of the
Year Award to Robert Petrino. Petrino is MAINE
the lead teacher in the Metal Fabrication SEPTEMBER 12
and Welding Department at South Shore Activity: Welding instructor David Hart-
Regional Technical School in Hanover, ley received the Section Educator of the
Mass. The presentation was made at the Year Award from Vice Chair Pat Kein. The
school. presentation was made at a gathering of
students and faculty at Northern Penob-
scot Technical High School in Lincoln, David Hartley (left) displays the Section Ed-
CONNECTICUT Maine. ucator Award certificate presented by Pat
Activities: During the summer months, As- Kein, Maine Section vice chair.
nuntuck Community College Welding De- SEPTEMBER 18
partment Head Steve Goodrow, Director Activity: The Maine Section members met Section Certified Welding Inspector
of Manufacturing Technologies Frank at the Fastco Corp. fabrication shop in Lin- (CWI) of the Year Award. Vice Chair Pat
Gulluni, and Welding Instructor Carole coln, Maine, to present Jon Ferreira the Kein presented the award.
WELDING JOURNAL 51
Philadelphia Section members are shown at the Miller Electric Mfg. Co. facility with Harland Thompson, District 2 director, assisting with
banner-support duties.
Shown at the Maine Section meeting are (from left) Chair Jim Kein, Mark Legel, Bob Bernier,
and Patrick Kein. Presenter Charlie Minnick (left) is shown
with Ken Temme, Philadelphia Section
chair.
Shown during the New Jersey Section tour of Sheet Metal Workers Local 22 Training Center
are (from left) Vice Chair Jim Dolan, presenters Frank Martino and Charles Beelitz, and
District 2 Director Harland Thompson.
SEPTEMBER 27 NEW JERSEY

Activity: The Maine Section executive OCTOBER 16
board met at Ocean Gardens Restaurant Activity: The Section members toured the Tim Stout discussed submerged arc welding
in Lincoln, Maine, to plan future Section Sheet Metal Workers Local 22 Training at the Philadelphia Section program.
events. Attending were Chair Jim Kein, Center in Cranford, N.J. Conducting the
Mark Legel, Bob Bernier, and Patrick program were Frank Martino and Charles Miller Electric Mfg. Co. facility in Swedes-
Kein. Beelitz, welding instructor and training co- boro, N.J. Charlie Minnick, Northeast
ordinator, respectively. training coordinator, presented demon-
District 2
Harland W. Thompson, director PHILADELPHIA
strations of gas tungsten arc and sub-
merged arc welding (SAW). District Man-
ager Tim Stout discussed the SAW process.
(631) 546-2903 OCTOBER 17 Harland Thompson, District 2 director, at-
harland.w.thompson@us.ul.com Activity: The meeting was held at the tended the event.
52 DECEMBER 2012
The Southwest Virginia Section members are shown during their tour of Altec Industries.
District 3
Michael Wiswesser, director
(610) 820-9551
mike@welderinstitute.com
District 4
Roy C. Lanier, director
(252) 321-4285
rlanier@email.pittcc.edu
SOUTHWEST VIRGINIA
OCTOBER 18
Activity: The Section members toured the
Altec Industries facility in Daleville, Va. Shown at the Atlanta Section program are (from left) District 5 Director Carl Matricardi,
The program was conducted by David Chair David Ennis, host John Sweigart, and presenter George Fairbanks, District 9 director.
Owens.
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
ATLANTA
SEPTEMBER 13
Speaker: George Fairbanks, District 9 di-
rector, owner
Affiliation: Fairbanks Inspection and Test
ing, LLC
Topic: Inspecting and repairing cracks in
large cast weldments at a paper mill Shown during the South Carolina Section tour are (from left) Eric Carlson, presenter Fred
Activity: David Ennis, Section chair, re- Carlson, Tom Wickel, Johnny Bargesser, and Chair Gale Mole.
ceived the District Educator Award from
Carl Matricardi, District 5 director. The tendees. Contact Chairman Charles
event was hosted by Southern Polytechnic Crumpton, charles@crumptonws.com,
State University in Marietta, Ga., and John about upcoming events.
Sweigart, director of the Engineering CALENDAR
Technology Dept. Jan. 9: Alex Klahm will discuss light-
house restoration
Feb. 13: Tour GMF Industries
FLORIDA WEST COAST March 2: Annual golf tournament
OCTOBER 10
Speaker: Heather Gilmer, QC manager
Affiliation: Tampa Tank, Inc. SOUTH CAROLINA
Topic: Phased array ultrasonic inspection SEPTEMBER 20
in the steel and bridge industries Activity: The Section members visited Atlanta Section Chair David Ennis (right)
Activity: The program was held at Fron- Streit USA Armoring, LLC, in North receives the District Educator Award from
tier Steakhouse in Tampa, Fla., for 22 at- Charleston, S.C., to study the fabrication Carl Matricardi, District 5 director.
WELDING JOURNAL 53
Local 7 Plumbers & Steamfitters Training

Center in Latham, N.Y., to tour the facil-
ity. Dan Bliven, high-purity tubing weld-
ing instructor, conducted the program.
Highlights included the clean room for
nano-tech welding, brazing hospital pip-
ing, and orbital welding of 18-in.-diameter
stainless steel tube.
District 7
Don Howard, director
(814) 269-2895
Shown at the Niagara Frontier Section program are (from left) Howard Johns, Mark Felschow, navigatorlost@hotmail.com
presenter Marty Sidall, and Fred Schmidt, Section chair.
DAYTON
AUGUST 14
Activity: Members of the Section joined
members of the AWS D16 Committee on
Robotic and Automatic Welding for a
demonstration of the first net shape
GTAW manufacturing process to be incor-
porated in the University of Dayton (UD)
Advanced Production Research Labora-
tory. The demonstration was conducted by
Larry Barley, a welding engineer at OTC
Robots, Tipp City, Ohio, and Darryl
Swann, OTC national sales manager and
a member of a D16 Subcommittee. Engi-
neering student Christian Stuck volun-
Presenter Larry Barley (right) demonstrates robot programming at the joint Dayton Section teered to serve as the first president of the
and D16 Committee program. new UD Student Chapter.
of armored vehicles. Fred Carlson, pro-

duction supervisor, presented the history Northern Westmoreland
of the company then conducted a tour of Student Chapter
the production lines for the South Carolina SEPTEMBER
Section members and guests. Activity: The Student Chapter held a meet-
ing at the technology center in New Kens-
ington, Pa. The presenters included Advi-
District 6
Kenneth Phy, director
sor Jeremy Dawson and Chair Michael
Shafer.
(315) 218-5297
kenneth.phy@gmail.com
PITTSBURGH
NIAGARA FRONTIER SEPTEMBER 11
OCTOBER 4 Activity: The Section toured the Bug-O
Welding student Miriah Gaudy is shown Speaker: Marty Sidall Systems International facility in Canons-
working with the virtual reality arc welding Affiliation: The Lincoln Electric Co. burg, Pa. The program was headed by Chip
trainer at the Niagara Frontier Section event. Topic: The VRTEX360 virtual reality arc Cable, president; Norm Sted, vice presi-
welding trainer dent, sales and marketing; and Mark
Activity: The event was held at the Inter- Binder, vice president, operations.
national Brotherhood of Boilermakers
Local Lodge 7 in Orchard Park, N.Y. Par- OCTOBER 9
ticipating in the demonstration were Speaker: Matt Bosley, applications engi-
Lodge Apprentice Coordinator Mark neer
Felschow, Section board member Howard Affiliation: Capture 3D
Johns, and Fred Schmidt, Section chair. Topic: Automated inspection using 3D dig-
Miriah Gaudy, a BOCES, Batavia, N.Y., ital scanning
welding student, demonstrated the equip- Activity: The talk included a demonstra-
ment. tion of the ATOS high-resolution 3D scan-
ning equipment for measuring both intri-
cate geometric parts and objects as large
Dan Bliven (left) receives a presenter gift NORTHERN NEW YORK as a military transport aircraft. This Pitts-
from Larry Hidde, chair, Northern New York OCTOBER 2 burgh Section program was held at Spring-
Section. Activity: The Section members met at field Grille in Mars, Pa.
54 DECEMBER 2012
Presenter Matt Bosley (left) is shown with

John Menhart, Pittsburgh Section chair, at The Northern Westmoreland Student Chapter members are shown at their recent meeting.
the October meeting.
Pittsburgh Section members are shown during their September tour of Bug-O Systems.
Tony Giggy discussed construction of the
Raccoon Mountain project for the Chat-
tanooga Section members.
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
CHATTANOOGA
SEPTEMBER 18
Activity: The Section members toured the Shown during the Pittsburgh Section September tour are (from left) Mark Binder, Chair John
Tennessee Valley Authority (TVA) Rac- Menhart, Chip Cable, and Norm Sted.
coon Mountain Pumped-Storage Power
Plant to study the operation of the hydro-
electric power station and the TVAs fos-
sil-fueled and nuclear power systems. The
tour guides at the Visitors Center were
Tony Giggy, Al Burzese, and Jim Sexton.
HOLSTON VALLEY
OCTOBER 16
Speaker: Zack Estes, territory sales man-
ager Pittsburgh Section members are shown during the October event.
Affiliation: ESAB Welding and Cutting
Topic: Safety with oxyfuel cutting and
welding equipment
Activity: The program was held at Mamas
House Restaurant in Kingsport, Tenn.
District 9
George Fairbanks Jr., director
(225) 473-6362
fits@bellsouth.net The Holston Valley Section members and guests are shown at the October program.
WELDING JOURNAL 55
Lawson State C. C.
Student Chapter
OCTOBER 9
Activity: Sixty-three attendees visited Oxy-
lance, Inc., in Birmingham, Ala., for
demonstrations of its exothermal process
used in underwater steel-cutting opera-
tions. The lecture included setting up the
oxyfuel gas cutting (OFC) equipment and
how it works, with emphasis on OFC safety
regulations. Greg Cain, vice president of
operations, conducted the program.
MOBILE
OCTOBER 11
Scholarship winner Cameran Kuperus (left) is shown with Marilyn and Amos Winsand, an Speaker: Jackie Morris, owner
AWS past treasurer, at the Detroit Section program. Affiliation: Morris Marine Consulting,
LLC
Topic: Hand-held inspection gauges
Activity: Morris demonstrated the correct
use of inspection gauges and discussed the
AWS CWI test tool kit. The program was
held at Original Oyster House in Spanish
Fort, Ala., for 51 attendees, including Dis-
trict 9 Director George Fairbanks and
welding students from Locklin Tech.
District 10
Richard A. Harris, director
Lawson State C. C. Student Chapter members are shown at their October meeting. (440) 338-5921
richaharris@windstream.net
CLEVELAND
OCTOBER 9
Speaker: Damian Kotecki, president
Affiliation: Damian Kotecki Welding Con-
sultants, Inc.
Topic: How to convert good stainless steel
filler metal into bad welds
Activity: The event was held at St. Paul Hel-
lenic Center in North Royalton, Ohio.
District 11
Robert P. Wilcox, director
Speaker Jackie Morris (right) is shown with Bill Rice (right), AWS president, is shown
Johnny Dedeaux, Mobile Section chair. with Mike Palko, Detroit Section chair. (313) 949-3676
rwilcox1@ford.com
DETROIT
SEPTEMBER 20
Speaker: Bill Rice, AWS president
Affiliation: OKI-Bering, CEO
Topic: Future of the welding community
Activity: The Section held its students
night program at VisTaTech Center,
Schoolcraft College, in Livonia, Mich. Alex
Pazkowski discussed his experiences com-
peting in the SkillsUSA welding competi-
tions. The Amos and Marilyn Winsand
Scholarship was awarded to Cameran Ku-
perus. Rice and Robert Wilcox, District 11
director, presented The Dalton E. Hamil-
ton Memorial CWI of the Year Award to
Viji Kuruvilla. The Section presented a
Speaker Damian Kotecki (right) is shown Speaker Alex Pazkowski is shown with Mike $350,000 donation to the AWS Founda-
with Mike Sherman, Cleveland Section chair. Palko, Detroit Section chair. tion. See photos and story on page 47.
56 DECEMBER 2012
NORTHWEST OHIO
JULY 6
Activity: The Section hosted its annual
Donald J. Leonhardt golf outing to raise
funds for scholarships for Owen Commu-
nity College students. The event co-chairs
were Mike Rogers, Tony Duris, and Mark
Scalise. Competing were 16 four-member
teams. District 11 Director Robert P.
Wilcox attended the outing, held in Toledo,
Ohio.
Madison-Beloit Section members are shown at the September program.

District 12
Daniel J. Roland, director
(715) 735-9341, ext. 6421
daniel.roland@us.fincantieri.com
LAKESHORE
SEPTEMBER 20
Activity: The Section members toured the
Fox Valley Tool & Die, Inc., facilities in
Kaukauna, Wis., to study operations in its
main plant. Heading the tour were Pete
Uvass, president; Brian Tetzlaff, vice pres-
ident; and Mark Dennis, manufacturing
manager, who discussed its precision ma-
chining, jig grinding, and EDM operations.
The business meeting was held at Hyland Racine-Kenosha Section members are shown during their tour of Racine Metal-Fab.
House Supper Club for 24 attendees.
MADISON-BELOIT
SEPTEMBER 26
Speaker: Anton Stute, Section chair
Affiliation: Madison Area Technical Col-
lege
Topic: Job opportunities in welding
Activity: The Section convened at the col-
lege to meet with the instructors and stu-
dents and tour the welding facilities. On
hand to demonstrate equipment and an-
swer questions were Rob Stinson with Lin-
coln Electric, James Maynard with Miller, Shown at the Madison-Beloit Section event
Dave Gilbertson with Encompass of Madi- Guides for the Lakeshore Section tour are are Madison Area Technical College stu-
son, Ben Newcomb with Badger Welding (from left) Fox Valley Tool & Die executives dents (from left) Drew Nafzger, Jake Olson,
Supplies, and Jim Chapman with Airgas. Pete Uvass, Mark Dennis, and Brian Tetzlaff. and Nick Neuburg.
Anton Stute was recognized for his serv-
ices as Section chair.
District 14
Robert L. Richwine, director
RACINE-KENOSHA (765) 378-5378
OCTOBER 2 bobrichwine@aol.com
Activity: The Section members visited
Racine Metal-Fab, Ltd., to study its light- INDIANA
gauge metal fabrication operations. The OCTOBER 4
presenters were Scott Lucas, president; Activity: Dick Alley, an AWS past presi-
and Ralph Fechhelm, director of opera- dent, served as MC for the Sections
tions. awards presentation program held at
Shapiros Deli in downtown Indianapolis.
Honored were its past Image of Welding
Award winners: District 14 Director
District 13
W. Richard Polanin, director
Robert Richwine, Chair Bennie Flynn, past
AWS President Richard Alley, Wally and
Jay Brant from Indiana Oxygen, Pat and Anton Stute (left) receives his chairmans
(309) 694-5404 Matt Garten from Sutton Garten, and appreciation award from Levi George at the
rpolanin@icc.edu Fritz Pring and Jack Laudig from West- Madison-Beloit Section program.
WELDING JOURNAL 57
Shown at the Indiana Section awards-presentation program are (from left) Chair Bennie Flynn, Dick Alley, Tony Brosio, Pat and Matt
Garten, Fritz Pring, Jack Laudig, Gary Dugger, District 14 Director Bob Richwine, and Jay and Wally Brant.
Dick Alley (far left), an AWS past president, is shown with Indiana Section Student Chapter members.
field Steel. Section CWI of the Year
Awards were presented to Bennie Flynn,
Tony Brosio, and Gary Dugger. Section
Meritorious Awardees were David Jack-
son, Josiah Miller, and Steve Gillig. Tony
Brosio received the Section Private Sector
Instructor Award, and Mike Anderson re-
ceived the Section Educator Award. The
District CWI of the Year Award was pre-
sented to Jack Laudig. Bennie Flynn re-
ceived the District Private Sector Award.
Eric Cooper and Rick Ferguson received
District 14 Director Awards from Direc-
Shown at the Lexington Section program are (from left) Shawn Gannon, Luke Williams, tor Robert Richwine. Attending were In-
Chair Frank McKinley, Frank Stringer, David Hoff, and Karl Watson. diana Section Student Chapter members.
LEXINGTON
SEPTEMBER 20
Speaker: Jim Nye, district manager
Affiliation: Miller Electric
Topic: Gas metal arc welding
Activity: Gordie Hall, Coy Hall, and Karl
Watson received District Director Awards
and Scott Stringer received the Section
Educator Award. Students Luke Williams,
Frank Stringer, and David Hoff received
$500 scholarships. Attending were weld-
ing instructors Shawn Gannon with Blue
Grass C. C. and Karl Watson with Somer-
Lexington Section awardees are (from left) Gordie Hall, Coy Hall, Scott Stringer, and Karl set C. C. About 70 members, students, and
Watson with Chair Frank McKinley. guests attended the event.
58 DECEMBER 2012
Shown at the St. Louis Section tour are (from left) Eric Spencer, Charlie Klapp, Steve Fults, Chair Tully Parker, Heath Wells, Vic Shorkey,
Rick Suria, Pat Cody, Mike Kamp, John Crowe, Chris Johnson, Susan Crowe, and Gale Mizner.
ST. LOUIS
SEPTEMBER 20
Activity: The Section members visited the
Missouri Equipment Co. facility to study
its operations. The tour was conducted by
Charlie Klapp, vice president. Attending
were Chair Tully Parker, Rick Suria, Pat
Cody, John Crowe, Eric Spencer, Steve
Fults, Heath Wells, Vic Shorkey, Mike
Kamp, Chris Johnson, Gale Mizner, and
Susan Crowe.
District 15
David Lynnes, director
(701) 365-0606
Shown at the Northwest Sections 75th anniversary banquet are Chair Jay Gerdin (kneel-
dave@learntoweld.com
ing) and (from left) Dean Hambleton, Bruce Danielson, Mace Harris, Randy Anderson,
Bob Sands, MC Mike Hanson, Dan Johnson, Dana Sorenson, and Don Peterson.
NORTHWEST
SEPTEMBER 20
Activity: Mike Hanson served as MC for
the Sections 75th anniversary open house
and banquet held at Sundance Golf and
Bowl in Dayton, Minn. The presenters in-
cluded Dave Lynnes, District 15 director;
Chair Jay Gerdin; Gold Member Don Pe-
terson; Life Members Mark Falconer,
Bruce Danielson, and Dean Hambleton;
Silver Member Bob Sands; Mace Harris,
Randy Anderson, Dan Johnson, Dana
Sorenson, and Laura Savin, representing
St. Paul College. Shown at the Saskatoon Section program are (from left) Huawei Guo, Chair Ike Oguocha,
Akindele Odeshi, and Paul Fraser.
SASKATOON KANSAS
SEPTEMBER 28 OCTOBER 11
Activity: The Section participated in the Speaker: Jack Minser, technical sales
Steel Day open house held at the Supreme manager
Steel Saskatoon facilities. The event in- Affiliation: Victor Technologies
cluded a factory tour and a presentation Topic: Oxyfuel safety
on software used by the company for ana- Activity: The Section held its second an-
lyzing steel structure designs. nual student night program at Hutchinson
Community College in Hutchinson, Kan.
District 16
Dennis Wright, director
KANSAS CITY
SEPTEMBER 13
(913) 782-0635 Speaker: Steve Donner Jack Minser discussed oxyfuel safety for stu-
awscwi1@att.net Affiliation: Kansas City Codes Adm. dents at the Kansas Section program.
WELDING JOURNAL 59
Kansas Section members and students are shown at the October event.
OCTOBER 17
Activity: Chair Mike Vincent and several
Kansas City Section members attended an
advanced process pipe welding seminar
presented by Lincoln Electric in Lenexa,
Kan. The topics included GTA orbital
welding and GMA and FCA welding using
the new surface tension transfer and wave-
form control technologies.
MID-PLAINS
SEPTEMBER 20
Activity: The Section members joined
Kansas City Section members and guests are shown at the October 11 program. members of the SME Southeast Nebraska
Chapter 222 for dinner and a tour of Hor-
nady Mfg. Co., Grand Island, Neb., a sup-
plier of ammunition products.
District 17
J. Jones, director
(940) 368-3130
jjones@victortechnologies.com
Kansas City Section members are shown at the Lincoln Electric seminar Oct. 17.
District 18
John Bray, director
(281) 997-7273
sales@affiliatedmachinery.com
HOUSTON
SEPTEMBER 19
Speaker: Dan Allford, president
Affiliation: ARC Specialties
Topic: Submerged arc welding and robots
Activity: Eugene Bickford and Cary Roth
Shown at the October Kansas City Section received Life Member certificates for 35
program are (from left) Chris Self, Chair years of service to the Society. Members
Mike Vincent, and speaker Randy Carrel. Speaker Dan Allford (right) is shown with recognized for serving at the Instruction
Grant Peltier, Houston Section secretary. Institute and Student Certification Day
events were Chair Justin Gordy, Justin
Topic: Qualification of fabricators and spe- Kirby, Scott Witkowski, Bryan Suarez,
cial inspectors Dan Jones, Tripp Fulmer, Albert Stredny,
Activity: Chair Mike Vincent received the and Andre Horn. The program was held
District Meritorious Award from Dennis at Bradys Landing in Houston, Tex.
Wright, District 16 director. The program
was held at Johnny Cs Restaurant in
Kansas City, Mo. RIO GRANDE VALLEY
SEPTEMBER 12
OCTOBER 11 Speaker: John Bray, District 18 director
Speaker: Randy Carrel Affiliation: Affiliated Machinery, Inc.
Affiliation: S1ngle Source, Inc. Topic: The District 18 and IIW conferences
Gene Bickford (right) receives the Life Mem- Topic: Prepping metal and welds for paint Activity: Ray Rivera addressed the 18 stu-
ber certificate from Grant Peltier, secretary, Activity: The program was held at Johnny dents attending the program about AWS
at the Houston Section program. Cs in Kansas City, Mo. Scholarships. Israel Garza, a welding in-
60 DECEMBER 2012
Shown at the Houston Section program are Chair Justin Gordy (front) and (standing from left) Justin Kirby, Scott Witkowski, Bryan Suarez,
Dan Jones, Tripp Fulmer, Albert Stredny, and Andre Horn.
Attendees at the Rio Grande Valley Section are shown at the September program.
structor at Joe Calvillo Technology Cam-
pus, discussed the schools three-year
welding program.
SAN ANTONIO
SEPTEMBER 11
Speaker: John Bray, District 18 director
Affiliation: Affiliated Machinery, Inc.
Topic: The District 18 and IIW conferences
Activity: Attending the program were 48
students from Alamo College and the Flo-
Shown at the British Columbia Section program are (from left) Rob Third, Richard Reyes, resville High School Student chapter ac-
and Brad Moe. companied by Advisor Clifton Rogers. The
event was held at Don Pedro Mexican
Restaurant in San Antonio, Tex.
District 19
Neil Shannon, director
(503) 201-5142
neilshnn@msn.com
BRITISH COLUMBIA
OCTOBER 16
Speaker: Rick Brown, metallurgist
Affiliation: Ifastgroupe
Phil Formento (left) receives an olympic-size Topic: Fasteners 101 Anatomy of the
Rick Brown receives a speaker gift from Pat speaker gift from Sjon Delmore, Olympic bolted joint
Newhouse at the British Columbia meeting. Section chair. Activity: Following the presentation,
WELDING JOURNAL 61
Olympic Section attendees are shown at the October program.
Utah Section and ASM International Utah Chapter members are shown during their tour of Shaw NAPTech, Inc., in September.
Shown during the Colorado School of Mines Student Chapter Trinity Industries tour are (from left) Advisor Stephen Liu, Sindhu Thomas,
Ali AlShawaf, speaker Steve Smith, Scott Nelson, speaker Blake Craft, Stephen Tate, Kin-Ling Sham, Erik Pfeif, Steven Klimowicz, and
Josue Mushidi.
Idaho/Montana Section members are from

left (standing) Tevan Boersma and Chair
Paul Tremblay, (seated) Dale Mortenson,
Colorado School of Mines Student Chapter members enjoyed a tour of Wolf Robotics. William McPherson, and Ofilia Tremblay.
62 DECEMBER 2012
Brown offered the attendees a hands-on Activity: The Student Chapter members
demonstration of various structural bolted hosted the program at Colorado School of
fasteners. Richard Reyes received a Bruce Mines in Golden, Colo.
Third Welding Scholarship and a one-year
AWS membership presented by Rob Third
and Brad Moe, British Columbia Section IDAHO/MONTANA
scholarship chairman. SEPTEMBER 11
Speaker: Jean-Francois Villard, head,
CEA laboratory
OLYMPIC Affiliation: French Alternative Energies
OCTOBER 16 and Atomic Energy Commission (CEA)
Speaker: Phil Formento Topic: Instrumentation development for
Affiliation: ESAB Welding & Cutting the future Jules Horowitz Reactor
Topic: History and advancements of the Activity: The Section members joined
subarc welding process members of the local IEEE Chapter and
Activity: The program, attended by about Idaho Section of the American Nuclear
60 members and guests, was held at Bates Society for this program, held at the Cen-
Technical College in Tacoma, Wash. ter for Advanced Energy Studies, Idaho
Falls, Idaho.
AWS Vice President Dean Wilson chats with
Sharon Jones, San Francisco Section co-
District 20
William A. Komlos, director
UTAH
SEPTEMBER 20
chair.
(801) 560-2353
bkoz@arctechllc.com
Activity: The Utah Section joined mem-
bers of the Utah Chapter of ASM Inter- District 22
Dale Flood, director
national to tour Shaw NAPTech, Inc., in
Colorado School of Mines Clearfield, Utah. Firdosh Kavarana, man- (916) 288-6100, ext. 172
Student Chapter ager, and senior metallurgist, Bending d.flood@tritool.com
SEPTEMBER 25 Div., conducted the tour and explained the
Activity: Advisor Stephen Liu took his companys methods for induction bending SAN FRANCISCO
Chapter members to Wolf Robotics in Fort of pipe and tube. OCTOBER 2
Collins, Colo., to study its operations. Speaker: Dean Wilson, AWS vice presi-
dent
OCTOBER 9
Speakers: Steve Smith, VP engineering, District 21
Nanette Samanich, director
Affiliation: Well-Dean Enterprises, presi-
dent
and Blake Craft, chief welding engineer Topic: Recent AWS major milestones
Affiliation: Trinity Industries (702) 429-5017 Activity: The program was held at
Topic: Trinity Industries operations nan07@aol.com Spengers Restaurant in Berkeley, Calif.
Candidates Sought for Welding-Related Awards

November 1, 2013, is the deadline for submitting nomina- at least three letters of recommendation from fellow researchers.
tions for the 2014 Prof. Koichi Masubuchi Award. This award is sponsored by the Dept. of Ocean Engineering at
This award is presented each year to one person, 40 years Massachusetts Institute of Technology (M.I.T.), this award in-
old or younger, who has made significant contributions to the cludes a $5000 honorarium.
advancement of materials joining through research and devel- E-mail your nomination package to Todd A. Palmer, assis-
opment. Nominations should include a description of the candi- tant professor, The Pennsylvania State University,
dates experience, list of publications, honors, and awards, and tap103@psu.edu.
The deadline for nominating candidates for the following awards is December 31 prior to the year of the awards presentations.
Contact Wendy Sue Reeve, wreeve@aws.org; (800/305) 443-9353, ext. 293.
William Irrgang Memorial Award tions with industry and other organizations, and for contribu-
This award is given to the individual who has done the most tions of time and effort on behalf of the Society.
over the past five years to enhance the Societys goal of advanc-
ing the science and technology of welding. It includes a $2500 George E. Willis Award
honorarium and a certificate. This award is given to an individual who promoted the ad-
vancement of welding internationally by fostering cooperative
Honorary Membership Award participation in technology transfer, standards rationalization,
This award acknowledges eminence in the welding profes- and promotion of industrial goodwill. It includes a $2500 hono-
sion, or one who is credited with exceptional accomplishments rarium.
in the development of the welding art. Honorary Members have
full rights of membership. Intl Meritorious Certificate Award
This honor recognizes recipients significant contributions to
Nat. Meritorious Certificate Award the welding industry for service to the international welding com-
This award recognizes the recipients counsel, loyalty, and munity in the broadest terms. The award consists of a certificate
dedication to AWS affairs, assistance in promoting cordial rela- and a one-year AWS membership.
WELDING JOURNAL 63
Guide to AWS Services

American Welding Society
8669 Doral Blvd., Ste. 130, Doral, FL 33166
(800/305) 443-9353; FAX (305) 443-7559; www.aws.org
Staff phone extensions are shown in parentheses.
AWS PRESIDENT INTERNATIONAL SALES TECHNICAL SERVICES
William A. Rice Managing Director, Global Exposition Sales Department Information . . . . . . . . . . . . . . . . .(340)
brice@oki-bering.com Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . .(297) Managing Director
1411 Connell Rd. Andrew R. Davis.. adavis@aws.org . . . . . . .(466)
Charleston, WV 25314 Corporate Director, International Sales International Standards Activities, American Coun-
Jeff P. Kamentz..jkamentz@aws.org . . . . . . .(233) cil of the International Institute of Welding (IIW)
ADMINISTRATION Oversees international business activities involving
Executive Director certification, publication, and membership. Director, National Standards Activities
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210) Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Sr. Associate Executive Director PUBLICATION SERVICES Manager, Safety and Health
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253) Department Information . . . . . . . . . . . . . . . . .(275) Stephen P. Hedrick.. steveh@aws.org . . . . . .(305)
Managing Director Metric Practice, Safety and Health, Joining of Plas-
Sr. Associate Executive Director Andrew Cullison.. cullison@aws.org . . . . . .(249) tics and Composites, Welding Iron Castings, Per-
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246) sonnel and Facilities Qualification
Welding Journal
Chief Financial Officer Publisher Managing Engineer, Standards
Gesana Villegas.. gvillegas@aws.org . . . . . .(252) Andrew Cullison.. cullison@aws.org . . . . . .(249) Brian McGrath .... bmcgrath@aws.org . . . . .(311)
Structural Welding, Methods of Inspection, Me-
Executive Assistant for Board Services Editor chanical Testing of Welds, Welding in Marine Con-
Gricelda Manalich.. gricelda@aws.org . . . . .(294) Mary Ruth Johnsen.. mjohnsen@aws.org . .(238) struction, Piping and Tubing
Administrative Services National Sales Director Senior Staff Engineer
Managing Director Rob Saltzstein.. salty@aws.org . . . . . . . . . . .(243) Rakesh Gupta.. gupta@aws.org . . . . . . . . . .(301)
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214) Filler Metals and Allied Materials, International
Society and Section News Editor Filler Metals, UNS Numbers Assignment, Arc
IT Network Director Howard Woodward..woodward@aws.org . .(244) Welding and Cutting Processes
Armando Campana..acampana@aws.org . .(296)
Welding Handbook Standards Program Managers
Director Editor Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287) Annette OBrien.. aobrien@aws.org . . . . . . .(303) Thermal Spray, Automotive, Resistance Welding,
Machinery and Equipment
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245) MARKETING COMMUNICATIONS Stephen Borrero... sborrero@aws.org . . . . .(334)
Director Brazing and Soldering, Brazing Filler Metals and
Human Resources Ross Hancock.. rhancock@aws.org . . . . . . .(226) Fluxes, Brazing Handbook, Soldering Handbook,
Director, Compensation and Benefits Railroad Welding, Definitions and Symbols
Luisa Hernandez.. luisa@aws.org . . . . . . . . .(266) Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416) Alex Diaz.... adiaz@aws.org . . . . . . . . . . . . . .(304)
Director, Human Resources Welding Qualification, Sheet Metal Welding, Air-
Dora A. Shade.. dshade@aws.org . . . . . . . . .(235) Webmaster craft and Aerospace, Joining of Metals and Alloys
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
International Institute of Welding Patrick Henry.. phenry@aws.org . . . . . . . . . .(215)
Senior Coordinator Section Web Editor Friction Welding, Oxyfuel Gas Welding and Cut-
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319) Henry Chinea...hchinea@aws.org . . . . . . . . .(452) ting, High-Energy Beam Welding, Robotics Weld-
Liaison services with other national and international ing, Welding in Sanitary Applications
societies and standards organizations.
MEMBER SERVICES Senior Manager, Technical Publications
GOVERNMENT LIAISON SERVICES Department Information . . . . . . . . . . . . . . . . .(480) Rosalinda ONeill.. roneill@aws.org . . . . . . .(451)
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com Sr. Associate Executive Director AWS publishes about 200 documents widely used
Webster, Chamberlain & Bean, Washington, D.C., Cassie R. Burrell.. cburrell@aws.org . . . . . .(253) throughout the welding industry
(202) 785-9500; FAX (202) 835-0243. Monitors fed-
eral issues of importance to the industry. Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260) Note: Official interpretations of AWS standards
CONVENTION and EXPOSITIONS Serves as a liaison between Section members and AWS may be obtained only by sending a request in writ-
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246) headquarters. ing to Andrew R. Davis, managing director, Tech-
Director, Convention and Meeting Services nical Services, adavis@aws.org.
CERTIFICATION SERVICES Oral opinions on AWS standards may be ren-
Matthew Rubin.....mrubin@aws.org . . . . . . .(239) Department Information . . . . . . . . . . . . . . . . .(273)
Managing Director dered, however, oral opinions do not constitute of-
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472) ficial or unofficial opinions or interpretations of
ITSA International Thermal Oversees all certification activities including all inter- AWS. In addition, oral opinions are informal and
Spray Association national certification programs. should not be used as a substitute for an official
Senior Manager and Editor interpretation.
Kathy Dusa.kathydusa@thermalspray.org . . .(232) Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
RWMA Resistance Welding scoring. AWS FOUNDATION, INC.
Manufacturing Alliance www.aws.org/w/a/foundation
Management Specialist Director, Certification Programs General Information
Keila DeMoraes....kdemoraes@aws.org . . . .(444) Linda Henderson..lindah@aws.org . . . . . . .(298) (800/305) 443-9353, ext. 212, vpinsky@aws.org
Oversees the development of new certification pro-
grams, as well as AWS-Accredited Test Facilities, and Chairman, Board of Trustees
WEMCO Association of AWS Certified Welding Fabricators. Gerald D. Uttrachi
Welding Manufacturers
Management Specialist Executive Director, Foundation
Keila DeMoraes....kdemoraes@aws.org . . . .(444) EDUCATION SERVICES Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Director, Operations
Brazing and Soldering Martica Ventura.. mventura@aws.org . . . . . .(224) Corporate Director, Workforce Development
Manufacturers Committee Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246) Director, Education Development
David Hernandez.. dhernandez@aws.org . . .(219) The AWS Foundation is a not-for-profit corpora-
GAWDA Gases and Welding tion established to provide support for the educa-
Distributors Association tional and scientific endeavors of the American Weld-
Executive Director AWS AWARDS, FELLOWS, COUNSELORS ing Society.
John Ospina.. jospina@aws.org . . . . . . . . . .(462) Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293) Promote the Foundations work with your financial
Operations Manager Coordinates AWS awards, Fellow, Counselor nom- support. Call (800) 443-9353, ext. 212, for complete
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401) inees. information.
64 DECEMBER 2012
aws cert (9 yr. cert)_FP_TEMP 11/7/12 11:09 AM Page 67
Plan ahead.
Even if your nine-year recertification
deadline is years away, you can fulfill
it now with a CWI endorsement.
Expand your credentials with an endorsement that fulfills your recertification requirements.
Recertification every nine years requires either 80 hours of documented continuing
education, retaking the Part B Practical Exam, or an endorsement to your certification.
You can do this at any time, so why not do it now and secure the prestige and enhanced
career potential of a credential in an additional welding code or skill?
A CWI or SCWI
SC can take a Supplemental Inspection Exam anytime during the nine-year cycle.
Qualifying for and passing one of these exams meets the requirements for recertification.
Endorsements are listed on your endorsement card. Endorsements require passing a
two-hour exam on one of the following:
AWS
AW Welding
WS D1.1 Structural Welding
ASME Section IX, B31.1 &

AWS
AW
WS D1.2 Aluminum B31.3 Boiler
er & Pressure V Vessel
e
essel
A
AWS
W
WS D1.5 Bridge ASME Section VIII, Div
Div.. 1 &
A
AWS
W
WS D15.1 Railroad Section IX
X Boiler & Pressure V Vessel
ess
essel
e
API 1
1104
104 Pipeline Structural Drawing Reading
Seminars to prepare you for the two-hour exam on D1.1 or API 1104
1104 are available at numerous
country..
seminar sites across the country
One other stand-alone credential can serve as an endorsement credit and also fulfills your
recertification requirement. At any time during your nine-year cycle, if you meet the prerequisites,
you can apply to become certified as an A AWS
WS Certified Radiographic hic Interpreterr (CRI).
The five-day CRI seminar is designed to ensure that you have the knowledge to properly assess
indications produced on radiographic media. It will prepare you for the CRI certification exam, which
is given at the end of each seminar week. This is a valuable certification that fulfills your
nine-year requirement. Upcoming seminars and exams for CRI are:
Seattle
ttle Feb. 25 - Mar
Mar.
r. 2 Houston Apr.

Apr. 15-20
Las V
Vegas
e
egas May 6-1
6-11
1
If you dont want to take any exams at all, you can fulfill the 80-hour education requirement by
attending a six-day AAWS
WS 9-Y
9-Year
Year
e Recertification
Recert Course. Courses are scheduled for:
New Orleans Jan. 6-1
6-11
1
Denver Feb. 10-15
Dallas Mar
Mar.. 10-15
Miami Apr
Apr.. 7-12
One more option is to recertify by taking the Part B CWI Practical Exam. This exam and refresher
V
Visual
isual Inspection
ection W
Workshop
Wo
orkshop seminars
seminars, aare offered
offfered
f at convenient CW
CWI seminar/exam sites across
the country
country..
www.aws.org/certification
(800) 443-9353 ext 273
Personnel Dec._Layout 1 11/8/12 1:41 PM Page 68
PERSONNEL
Lincoln Names Two

Directors Member Milestone
Damian J. Kotecki, a past AWS president, AWS Fellow and Life Member, recently
received two prestigious awards for his contributions to the industry. The American
National Standards Institute (ANSI) presented Dr. Kotecki with the Finegan Stan-
dards Medal, which honors an individual who has shown extraordinary leadership in
the development and application of voluntary standards. The Welding Institute
(TWI) awarded him its most prestigious award, the Brooker Medal, in recognition of
his personal contribution to the science, technology, and industrial exploitation of
metal joining. It recognizes high industrial, research, or educational responsibility of
a character which has beneficially influenced the advancement of metal joining tech-
Frank Armao Bruce Chantry nology. Dr. Kotecki is president of Damian Kotecki Welding Consultants, Inc., and
writes Stainless Q & A, a bimonthly column in Welding Journal. Prior to his retire-
The Lincoln Electric Co., Cleveland, ment, he served The Lincoln Electric Co. as technical director for stainless and high
Ohio, has appointed Frank Armao direc-
alloy product development. He contributes his expertise to many AWS technical com-
tor of aluminum welding technology and
mittees including serving as chair of the A5 Committee on Filler Metals and Allied
promoted Bruce Chantry to director of
marketing, North America. Armao, who Materials. Kotecki has received numerous AWS awards, including Comfort A. Adams
is chairman of the AWS D1G Subcom- Memorial Lecture, James F. Lincoln Gold Medal, William Irrgang, R. D. Thomas Me-
mittee on Aluminum Structures, will col- morial, R. D. Thomas International Lecture, George E. Willis, Prof. Dr. Ren Wasser-
laborate with both the aluminum welding man Memorial, A. F. Davis Silver Medal, International Meritorious Certificate, and
technology teams at the Cleveland head- Warren F. Savage Memorial.
quarters and at Lincolns subsidiary In-
dalco Alloys, a producer of aluminum
wire products based in Ontario, Canada.
He previously served 13 years as director,
application engineering and country man-
ager, Korea, for Lincolns Asia-Pacific
business unit. With the company for 17
years, Chantry most recently served four
years as a portfolio manager for welding
equipment.
Taylor-Wharton Fills Key

Posts
James Pauley (left), chairman of the Dr. Kotecki (left) receives the TWI
ANSI board of directors, presents the Brooker Medal from TWI President
Finegan Standards Medal to Damian John Baxter.
Kotecki.
Claus Emmer David Barr

Taylor-Wharton LNG sales. Barr most recently worked for named Garrett
International, LLC, Lubrication Technologies, Inc., where he VanAtta to the newly
Mechanicsburg, Pa., developed a LNG distribution business in created position of
a supplier of pressure Minnesota. Emmer has extensive experi- vice president of in-
vessels and precision ence with MVE, Inc., working with su- novation engineer-
valves, has hired perinsulated cryogenic vessels. Cushman ing. Previously,
David Barr to head worked ten years selling capital equip- VanAtta managed
its newly created liq- ment and fluids to the cryogenic industry. textile operations and
uefied natural gas engineering at Po-
(LNG) business unit Auburn Mfg. Appoints VP lartecs Malden Mills
Garrett VanAtta facilities in Maine
as vice president and Bobby Cushman
general manager. Auburn Manufacturing, Mechanic and Massachusetts,
Claus Emmer was named director of ap- Falls, Maine, a provider of high-tempera- and most recently served as president of
plications development, and Bobby Cush- ture textiles for protective welding cloth- SPX Communications Technology.
man was appointed director of global ing and other industrial applications, has
continued on page 70
68 DECEMBER 2012
edu awo safety_FP_TEMP 11/6/12 3:10 PM Page 69
awo.aws.org
Online W
Welding
elding Safety
Safety Certificate Course
OSHA
OSH A estimates that
4 out of every 1,000
welders will
experience a fatal
injury or accident over
their working lifetime
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Three-hour self-paced course covers electric shock, vision and skin protection,
ventilation, fire protection, handling of gases, and much more.
Sample seminar at awo.aws.org/seminars/safety

Personnel Dec._Layout 1 11/8/12 1:41 PM Page 70
PERSONNEL
continued from page 68
Ervin Industries Appoints tions. Hensley, who counts in Missouri, Kansas, Iowa, and Ne-
has more than 20 braska. Luedtke will work in Minnesota,
General Sales Manager years of material- Wisconsin, upper peninsula of Michigan,
handling sales expe- and North and South Dakota. Bomba pre-
Ervin Industries,
rience, most recently viously worked as a senior civil specialist
Inc., Ann Arbor,
served as a contract at Hilti. Cash previously was a channel
Mich., has promoted
manager for Jackson- partner manager at ZOLL Medical Corp.
Joe McGreal to gen-
Madison County Luedtke previously served as a regional
eral sales manager,
General Hospital sales manager at DGI Supply.
responsible for the
and as director of
North American sales Paul Hensley global operations for
of AMASTEEL and
NCR.
AMACAST metal
abrasives. With the
Joe McGreal company for 13 years, Obituary
McGreal most re- Laboratory Testing Fills
cently served as a salesman and district New Post James F. Colosimo Sr.
sales manager for the Iowa region.
Laboratory Test-
James F. Colosimo Sr., 75, died Oct. 1
NAWIC Installs Officers ing, Inc., Hatfield,
in Harrison Township, Mich. A member
Pa., has promoted
The National Association of Women in Frank Peszka to the of the AWS Detroit Section for 45 years,
Construction, Fort Worth, Tex., has in- newly created posi- he achieved Gold Member status with 50
stalled Cindy Johnsen as its 58th national tion of director of years of AWS membership this year. He
president 20122013, succeeding Judy quality. Most re- graduated from the Eveleth High School
DeWeese, San Antonio, Tex., Chapter. cently, Peszka served and the University of Notre Dame where
Johnsen, an office administrator III for six years as quality as- he was a four-year football letterman. He
Granite Construction Co., has been a surance manager. started working in the welding industry in
member of the associations San 1962 at A. O. Smith Corp. where he
Frank Peszka served as a sales-
Bernardino-Riverside, Calif., Chapter
since 1997. Also installed were Yasmine A. man, district man-
Branden, Portland, Ore., Chapter, as ager, and automo-
IMS WaterJet Names tive account man-
president-elect; Sandy K. Field, Houston,
Tex., Chapter, as treasurer; and Connie M. Marketing Director ager in Detroit.
Leipard, Central Missouri Chapter, as While there, he was
secretary. IMS WaterJet, Inc., Waterbury, Conn., instrumental in de-
has hired Kevin Dokla as director of mar- veloping the first
keting. Prior to joining the company, CO 2 arc welded
Fronius Names Tennessee Dokla held marketing leadership posi- wheel system for the
Sales Manager tions at Eemax, Inc., Pyramid Technolo- Motor Wheel Corp.
gies, Office Depot Co., and Cendant, Inc. James Colosimo replacing its former
Fronius has ap- methods using re-
pointed Rick Whit- sistance welding or rivets. He also devel-
field to serve as area
Noble Gas Makes Staff
oped the first dual wire drive system for
sales manager work- Changes semiautomatic welding, integration and
ing out of the Chat- installation of the first production elec-
tanooga, Tenn., loca- Noble Gas Solutions, Albany, N.Y.,
tric robots for gas metal arc welding at
tion. Whitfield has has named Wayne Geraci plant and distri-
the Ford Frame Plant, and in conjunction
many years of experi- bution manager, and promoted Mark
with ASEA, installed the first laser track-
ence in the welding Stagliano to customer service manager.
ing system for gas metal arc welding in
automation field in Geraci previously worked at Vertis Com-
the auto industry. Colosimo also colabo-
Rick Whitfield sales management munications as engineering project man-
rated with Alloy Rods and Tri-Mark to
and marketing of ad- ager. Stagliano, with the company since
develop the 4409 series of stainless steel
vanced welding automation equipment. 2008, previously served as asset manager.
core wires. In 1970, he founded Michigan
Arc Products where he served as CEO
Intelligrated Appoints CGW-Camel Adds Three until his death. He was a member of the
Senior Sales Engineer Managers Notre Dame Club of Detroit, North
Channel Yacht Club, the Detroit Curling
Intelligrated, Cincinnati, Ohio, an CGW-Camel Grinding Wheels, Niles, Club, and a charter member of the Robot
automated material-handling solutions Ill., has appointed Rich Bomba, Dana Division of the Society of Mechanical
provider, has appointed Paul Hensley to Cash, and Brett Luedtke as new territory Engineers. He is survived by Carol, his
senior sales engineer for the companys managers. Bomba will service Illinois and wife of 50 years, a son, two daughters, a
Cincinnati-based central regional opera- northern Indiana. Cash is assigned to ac- brother, and ten grandchildren.
70 DECEMBER 2012
buyer's guide_FP_TEMP 11/6/12 1:37 PM Page 71
edu awo math_FP_TEMP 11/6/12 3:09 PM Page 95
awo.aws.org
Online Math for W

Welders
elders Course
Mathematics is a necessary part of a weldin

weldingg professionals
professionals activities. However,
However, math can be
complicated and confusing for beginners, and di fficult
f
difficult for adults who havent used math principles

awhile. This course provides a combination of cl ear step-by-step verbal and visual explanations that
clear
make each mathematical concept easy to unde rstand and remember.
understand remember. Topics
Topics
o include place
pla value,
simplification, estimation, measurement, and the addition, subtraction, multiplication and division of
whole numbers, fractions, decimals and mixed numbers. Practical exercises allow welders, welding
students, supervisors and inspectors to apply basic math skills to various aspects of the welding
through this course toward AWS
process. Eighteen PDHs are provided through AWS recertification.
SSample
ample seminar at
at aw
awo.aws.org/seminars/math-for-welders-level-1
wo.aw
aw
ws.orrg
g/seminars/math-forr-welders
e -leve
el-
el-1
Camfil Farr December_Layout 1 11/7/12 3:34 PM Page 73
THE AMERICAN WELDER
Selecting Fume Collectors for

Welding Applications
BY GREG SCHREIER
Choosing a cartridge fumecollection
GREG SCHREIER (filterman@farrapc.com) system that will protect welders
is metalworking market manager, Camfil Farr and operate efficiently involves
Air Pollution Control, Jonesboro, Ark.
study and attention to details
well-designed and maintained car- workers and achieve compliance, but will Pollutants Rule 6x changed all that. This
A tridge dust and fume collection

system can help to prevent respira-
tory and health problems and keep weld-
also run efficiently and reliably. The first
three points relate to the three agencies
that impact compliance: Environmental
standard encompasses all manufacturing
processes using materials that contain
0.1% of cadmium, lead, nickel, or
ing operations in compliance with regu- Protection Agency (EPA), Occupational chromium, and any material that con-
latory requirements. Such a system will Safety and Health Administration tains 1% manganese, which includes
properly filter welding fumes and other (OSHA), and National Fire Protection most welding rods and wires. Simply
hazardous contaminants, and the Association (NFPA). stated, in any 20-min test period, there
cleaned air can be recirculated back into can be no more than 3 min of visible
the facility or exhausted outside. These 1. Achieving EPA Rule 6x emissions (zero opacity) from these
systems use self-cleaning mechanisms types of processes. The standard spells
that pulse dust off the filters, allowing Compliance out the monitoring and test methods
the units to run for extended periods required for compliance and outlines
between filter change-outs. For years, many plants dealt with control techniques that may be used.
This article addresses the seven most welding fumes by simply exhausting Though this standard went into effect
important points to consider in selecting them outside. The latest EPA National July 2011, many companies remain
a collector that will not only protect Emission Standard for Hazardous Air unaware of it, apart from some larger
facilities that have launched proactive
programs to achieve compliance. Rule 6x
is directly applicable to most welding
shops. It is in force now, and everyone
engaged in welding must be knowledge-
able about what actions are required.
Fig. 1 Shown is an example of an ambi

ent fume and dustcollection system that
recirculates filtered air back into the plant
downstream of the collector. A recirculat
ing system is the best way to maximize
return on investment by conserving the
shops heated or cooled air.
WELDING JOURNAL 73
THE AMERICAN WELDER

Fig. 2 This dust collector features an
explosion vent that opens when a prede
termined pressure is reached inside the
collector. During a combustible dust explo
sive event, the excess pressure and flame
front are vented to a safe area.
One corrective strategy is to use a

dust and fume collector with high-
efficiency cartridge filtration. Cartridge
filtration is identified in the regulation
as an acceptable control device to elimi-
nate visible emissions and will, in many
cases, be the solution of choice.
2. Meeting OSHA PEL

Requirements
When air is exhausted outdoors, the
EPA Rule 6x applies as above. Should
you opt instead to recirculate the filtered
air downstream of the dust collector
rather than exhausting it outside (Fig. 1),
the indoor air must still comply with
OSHAs permissible exposure limits
(PELs). OSHA has established PELs for
hundreds of dusts based on an 8-h time-
weighted average (TWA) exposure. The
OSHA PEL for welding fume is 5
mg/m3, which is three times stricter than
the PEL for nuisance dust. lection equipment supplier to determine
To verify a dust collector complies
3. Complying with NFPA
the best methods for compliance.
with emission thresholds, require your Standards
equipment supplier to provide a written
guarantee stating the maximum emis- It is also necessary to stay up to date 4. Safeguarding against
sions rate for the equipment over an 8-h on the relevant NFPA standards. A good Fire/Explosion Hazards
TWA. Filter efficiency stated as a per- starting point is NFPA 654, Standard for
centage is not an acceptable substitute, the Prevention of Fire and Dust The NFPA states that a hazard analy-
even if the supplier promises 99.9% effi- Explosions from the Manufacturing, sis, conducted either internally or by an
ciency. OSHAs concern is to protect the Processing and Handling of Combustible independent consultant, is needed to
breathing zone of workers by ensuring Particulate Solids. This is an all-encom- assess risk and determine the required
that the contaminants in the air are passing standard on how to design a safe level of fire and explosion protection.
below established limits. dust-collection system. It also references When it comes to explosion protection,
Regulatory compliance is not the other relevant explosion-prevention the first step is to determine the explo-
only reason for keeping indoor emission standards including NFPA 68, Standard sive index (Kst) and maximum pressure
levels as low as possible. Workers are on Explosion Protection by Deflagration (Pmax) characteristics of your dust. Any
healthier and more productive when the Venting; NFPA 69, Standard on Explosion dust above 0 Kst is considered to be
indoor air is clean. They experience Prevention Systems; and NFPA 484, explosive, and the majority of dusts fall
fewer headaches and sinus congestion Standard for Combustible Metals. into this category. If there is no explosion
and a reduction in more serious upper- Its important to note that grinding protection in place, even a very low Kst
respiratory ailments. Clean shop air also and other finishing operations that are dust could result in an OSHA citation.
prevents the buildup of nuisance dust on often performed in the welding area can Spark generation is another concern.
electrical control panels, circuit boards, generate explosive dust. These processes Raw carbon steels are often coated with
inspection equipment, and paperwork need to be taken into account, along with oil before welding. When oil is exposed
that can interfere with everyday the welding operations, when reviewing to heat, some of it burns and turns to
operations. the NFPA standards with your dust col- ash. The oil that doesnt get hot enough
74 DECEMBER 2012
THE AMERICAN WELDER
Fig. 3 Horizontally mounted cartridges, shown above, allow dust Fig. 4 The integrated safety monitoring filter shown here pre
to become trapped in the pleats in the upperthird of the filters, cre vents collected dust from reentering the workspace should a leak
ating a potential fire hazard. Vertically mounted systems reduce occur in the dust collectors primary filtering system.
the dust load on the filters and help minimize this hazard.
to combust transforms into an airborne from an outside wall, or outside with no infrared sensors that release water to
mist that can enter the collector and practical safe zone around them, partic- extinguish the sparks before they can
accumulate on the air ducts and filters. If ulate retention and flame-arresting enter the collector. Mechanical spark-
a spark enters the system, a fire can devices are commonly utilized. These arresting devices include drop-out boxes,
result. devices are usually bolted over the perforated screens, and other devices
The best way to safeguard against explosion vents to reduce particulates that create torturous paths for the sparks
these hazards is to work with an experi- from escaping in quantities that could and embers so they have more time to
enced equipment supplier who can help further support combustion, while burn out and lose their heat. Well-
with testing to determine the dusts haz- reducing the heat of an explosion to safe designed arrestors direct the sparks away
ardous properties; make engineered rec- levels. from the filter media while adding very
ommendations based on experience with Active systems commonly employ little static pressure losses to the system.
similar workplaces; and provide the fire- electronic monitoring devices to control Adding flame-retardant filter media can
and explosion-prevention technologies other devices actions during an explo- provide an extra measure of protection.
that will work best for your specific sive event. Chemical isolation and chem- Dust collectors with vertically mount-
applications. ical suppression are examples of active ed filter cartridges offer reduced fire and
Passive and active explosion protec- systems. When these devices are used in explosion risks. Vertically mounted sys-
tion. Explosion protection systems may the ductwork, they are commonly tems also reduce the dust load on the fil-
be either passive or active. Passive sys- referred to as chemical isolation as ters to help minimize this hazard.
tems usually incorporate mechanical they create a chemical barrier inside the With horizontally mounted car-
devices on both the dust collector and ducting that isolates the explosion inside tridges, dust can become trapped in the
connected ducting systems. An example the dust collector from processes up pleats in the upper-third of the filters
is an explosion vent on the dust collector and/or downstream of the system. When Fig. 3. This trapped dust can burn even if
that opens at a preset pressure to direct they are used on the dust collector itself, the filter media is fire retardant.
the pressure and flame fronts from an they are referred to as chemical sup-
explosion to a designated safe area
Fig. 2. Mechanical dampers are typically
pression as they work at suppressing
the explosion inside the dust collector to
5. System Configurations
used in the inlet and outlet ducting sys- a minimal event. Both of these systems
tems to create mechanical barriers to commonly utilize sensors to monitor the There are three general types of car-
block these fronts. The valves commonly pressure inside the dust collector and tridge dust- and fume-collection systems
incorporate flaps or some other device within milliseconds can trigger the suitable for use with welding processes:
that moves to block the open passage of release of the chemical agent inside the Source capture systems are popular
the ducting. dust collector and/or ducting. for applications involving small parts
The NFPA defines safe zones as being Other fire-protection technologies and fixture welding. They typically uti-
located outside. When dust collectors include conventional sprinkler systems lize a flexible source-capture arm or a
are located inside a building and too far and systems that can detect sparks using complete enclosure around the opera-
WELDING JOURNAL 75
THE AMERICAN WELDER

tion, such as a glass enclosure around a 6. Optimizing the Safety Finally, a safety monitoring filter is a
robotic weld cell. This approach is usual- required component in a recirculating
ly limited to smaller work areas. Features dust collection system and can help to
Hoods are often utilized for medium- meet todays more stringent emission
size areas with a footprint of 12 20 ft The ease of maintenance should be requirements. Where feasible, the best
or less. Curtains or hard walls may be considered. The filters, drums, or barrels way to maximize return on investment is
added to create a booth or enclosure should be positioned for easy access and through use of a recirculating system. By
when workplace conditions permit. servicing, and the filters should slide in recycling heated or cooled air back
Ambient systems use a central collec- and out of the housing readily. Avoid through the plant, the cost to replace
tor or a number of smaller collectors to equipment using threaded connections that conditioned air is eliminated. Many
filter all the air in the shop. An ambient on the filter access doors or hoppers plants report annual energy savings with
system is more practical to control fumes because dust leakage is possible when a payback ranging from one to three
in a facility with multiple operations. the threads are not tightened properly. years. Also, dust collectors in welding
Various welding processes, large parts, OSHA-compliant platforms and shops with high ceilings can often
and stitch welding are examples of oper- caged ladders should be used to prevent improve the efficiency of a heating sys-
ations that are well suited to ambient accidents when workers access the col- tem by taking hot air off the ceiling and
collection. lector for service. delivering it at ground level.
The best fume-collection system for a A safety monitoring filter (Fig. 4),
given operation is not always obvious sometimes called a secondary or afterfil-
and should not be selected by simply ter, is a good investment and is a Supplementary Reading
searching the Internet. It is wiser to con- required component in a recirculating
sult a sales engineer who specializes in dust-collection system that filters air EPA National Emission Standard for
industrial dust- and fume-collection from a list of specific hazardous materi- Hazardous Air Pollutants Rule 6x.
equipment who can evaluate your opera- als. It contains a bank of high-efficiency www.epa.gov/ttn/atw/6x/6xpg.html.
tion and conduct a site survey. The selec- air filters to prevent collected dust from OSHA Permitted Exposure Limits
tion process is multifaceted and must reentering the workspace should a leak (PELs), www.osha.gov/SLTC/pel.
take a number of factors into account. occur in the dust collectors primary fil- NFPA Standards. www.nfpa.org.
Analyzing the situation begins by tering system. Ductwork and a transition National Fire Protection Association
addressing the current problems the new section are usually required to connect (NFPA), 1 Batterymarch Park, Quincy,
dust collector must resolve. Is the cur- this secondary filter module to the dust- MA 02169; www.nfpa.org.
rent equipment plugging? Are fires collection system, but new integrated NFPA 68: Standard on Explosion
occurring? Are health and/or OSHA designs are available in which the safety Protection by Deflagration Venting (2007).
concerns driving the need for cleaner filter is mounted on top of the collector NFPA 69: Standard on Explosion
indoor air? Is excessive noise a concern? so that additional floor space is not Prevention Systems (2008).
Where will the collector be located? Will required. NFPA 484: Standard for Combustible
it be outdoors or inside? If indoors, will Fan noise can be an important safety Metals (2012).
the equipment be installed at ground concern. Noise can cause worker fatigue, NFPA 654: Standard for the
level or on a mezzanine? What is the hearing loss, and other health problems. Prevention of Fire and Dust Explosions
ceiling height? A collector that offers a Consider using silencers or customized from the Manufacturing, Processing and
small footprint and low-profile design noise reducers in the design of your dust Handling of Combustible Particulate
options can offer the greatest flexibility. collector. Solids (2006).
Consider the process factors as well. Occupational Safety & Health
What are the processes, the contami-
nants to be collected, hours of operation,
7. Determining the Total Administration (OSHA),
Constitution Avenue, Washington, DC
200
work conditions, electrical requirements, Cost of Ownership 20210; www.osha.gov.

airflow, pressure ratings, etc.? How do OSHA Combustible Dust National
the fixtures operate? How do positioners It is not just the initial purchase price Emphasis Program (Reissued)
hold the metal parts during welding? but total cost of ownership that counts. Directive Number: CPL 03-00-008;
How large are the parts? What second- Consider the operating and maintenance effective date March 11, 2008.
ary operations are being performed? costs and compressed-air requirements. OSHA Permissible Exposure Limits
Considering all of these factors will Consider designs that incorporate green (last updated 10-30-2006).
help determine whether a source- features such as variable-frequency U.S. Environmental Protection
capture arm, a hood, or an ambient sys- drives and premium efficiency fan Agency (EPA), 1200 Pennsylvania Ave.,
tem is best for a particular application. motors to reduce your energy costs. A NW, Washington, DC 20460;
Dust testing, too, is an essential part of reputable equipment supplier can proj- www.epa.org.
the selection process. The tests should ect these costs to recommend the best Rule and Implementation Information
determine both the physical characteris- ways to reduce the total cost of owner- for Nine Metal Fabrication and Finishing
tics of the dust as well as the fire and ship and get the most out of the dust col- Area Source Categories 40 CFR Part 63
explosion risks involved. lector performance. Subpart 6X; July 23, 2008.
76 DECEMBER 2012
aws cert (robotic arc wldg)_FP_TEMP 11/6/12 3:08 PM Page 77
B ecome Certified in Robotic Arc Welding

and Join the Ranks of the Elite
in the R Industry
Robotics Indu
ustry
AWS under
understands the need for certified individuals within the robotic arc welding industry. In response to this need, a program
ram based on
AWS
the AW S QC
QC19 and D16.4 specifications, has been developed.
Depending on the level of experience, individuals who pass a written exam and performance test can be certified as either
Robotic
R Operators.
obotic Arc Welding Technicians or Operato rs.
For information
For more information regarding this program, including how to become an AWS Approved Testing Center, visit our website today
AWS
at www.aws.org/certif
www.aws.org/certification/CRAW
ication/CRAW or call ((800) linda@aws.org).
800) 443-9353 ext. 298 (email linda@aws.org).
these
To schedule training and testing to become certified in robotic arc welding, contact one of these AWS Approved Testing Centers.
Colorado
Co //Wolf
lorado / Robotics
/Wolf R //(970)
obotics //4600 Innovation Drive //Fort Collins, CO 80525 // 225-7736//
(970) 225-7736
6/
// Darren
Darren Pape
Pape
Iowa
Iowa //Genesis
//Genesis Systems Group
Group //8900 Harrison
Harrison Street
Street //Davenport, IA
IA 52806 //(563)
//(563) 445-5688
445-5688//
8/
// Jane Eagle
Michigan //ABB,
//ABB, Inc. //1250 Brown Road //Auburn H
Hills, //(248)
ills, MI 48326 // 391-8421//
(248) 391-8421 // Keith Lloyd
Ohio //The St.
//The Lincoln Electric Co. //22221 S 44117//(216)
t. Clair Ave. //Cleveland, OH 44117// (216) 383-8542
383-8542//
2/
// Patricia
Patricia DeDonno
Ohio //OTC
//OTC Daihen, Inc. //1400 Blauser Drive //Tipp City, OH 45371 //
//(973)
(973) 667-0800
667-0800//
0/// Todd Gri
Griffieth
ffieth
Wisconsin //Milwaukee
//Milwaukee Area Technical College //
//1200
1200
00 South 71st Streett //
//West
West Allis, WI
WI 53214 //
//(414)
(414) 297-6996
297-6996//
6/// Lawre
Lawrence
nce Gross
2013 SEMINAR / EXAM SCHEDULE

SEMINAR/EXAM
AWS Appro
Approved
ved Testing Centers
ABB, Inc. Genesis Systems Group OTC Daihen, Inc. The Linco
Lincoln
ln Electric Co. Wolf Ro
Robotics
botics
2/2 2/5 2/25 2/28 2/11 2/15 3/4 1/21

6/17 6/20 5/20
5/20 5/23
5/23 4/22 4/26 10/14 3/25
12/2 12/5 8/19 8/22 7/15 7/19 5/20
12/2 12/5 10/21 10/25 7/22
9/23
11/18
Packard and Farkas AW Feature December 2012_Layout 1 11/8/12 8:08 AM Page 78
THE AMERICAN WELDER
From the Lab to the

Production Floor:
Students Learn It All
Thanks to recent industry donations BY KEITH PACKARD,
DERICK RAILLING, AND
and hands-on training, welding BRIAN FARKAS
engineering technology students at KEITH PACKARD is segment manager,

power generation, and DERICK RAILLING is
Ferris State University experience product manager, global onshore pipeline,
for Hobart Brothers Co. (hobart@hobart-
real-world career preparation brothers.com,
www.hobartbrothers.com), Troy, Ohio.
BRIAN FARKAS is a national account man-
ager for MAXAL International, Inc.
(www.maxal.com), Traverse City, Mich.
For more information on Ferris State Uni-

versitys welding engineering technology
department, contact Jeff Carney, associate
professor and program coordinator, at
carneyj@ferris.edu.
erris State University (FSU) is in certificate skill training program to a ties available in the marketplace.
F the business of producing welding

engineering technology graduates
and not just any ordinary ones. They
bachelor of science degree that teaches
process selection, nondestructive exami-
nation, welding procedure development,
Recently, Hobart Brothers and MAXAL
representatives had the chance to talk
about opportunities with their compa-
are training students to enter emerging and equipment specification. Students nies and the markets they serve, and to
markets and use their knowledge to also study automation, weldment design, provide students with insight into devel-
oversee the many welding technologies welding metallurgy, and project manage- opments in filler metal technology.
theyll find there. ment. They learn how to weld using gas Hobart Brothers has employed many
Trends in the automotive, energy, tungsten arc (GTA), gas metal arc FSU graduates over the years and, as
heavy equipment manufacturing, and (GMA), shielded metal arc (SMA), and with many other companies, continues to
welding equipment industries are no other processes. maintain strong bonds with the program
mystery to these students. Thats just and also provide instructors for technical
one of the reasons the school has such a support.
high demand for graduates and also why Securing Insight and Hobart Brothers and MAXAL are
they boast a more than 95% job place- Support from Industry also among several companies that pro-
ment for those leaving with a bachelors vide filler metal and equipment dona-
degree from FSUs welding engineering In addition to the guidance of their tions that help support the program.
technology program. professors, students have the opportuni- They recently gave FSU a large donation
The Big Rapids, Mich.-based welding ty to meet regularly with industry profes- of SMAW electrodes and tubular wires,
program has been around since 1955 and sionals to help keep them apprised of the including metal-cored and flux-cored
in that time has evolved from a one-year welding technologies and job opportuni- wires, along with aluminum GMAW and
78 DECEMBER 2012
THE AMERICAN WELDER

Jeff Carney, an associate professor and
program coordinator at Ferris State
Universitys welding engineering
technology department, demonstrates
and discusses welding technique with
student Jeremy Brewster.
program and has served as the patriarch

of it since, teaching all of the Hobart
Brothers welding engineers who have
graduated with the four-year degree, as
well as fellow instructors England and
Jeff Carney (see lead photos), associate
professor and program coordinator, who
has been with the department since
1996.
Earning Associate and

Bachelor Degrees
Today, the university has what
England calls a true two plus two
welding program, which is also accredit-
ed by the Engineering Technology
Accreditation Commission (ETAC/
ABET). The resulting degrees are an
associate in applied science in welding
technology and a bachelor of science in
welding engineering technology.
Whereas an associate degree at a
community college is often focused on
GTAW wire, and to help guide the stu- The Program meeting the needs of that region and
dents in their proper usage. A day was
spent working in the labs with students Yesterday and Today preparing students to go right in the
workforce, ours is designed to build into
and conducting a seminar on metal-
The welding department at FSU the bachelors degree, he explained.
cored wires and aluminum filler metals
offered a certificate program to its stu- Our students can leave the program
Figs. 13.
dents from its inception until the 1970s after two years and find gainful employ-
We appreciate and encourage the
when it established an associate degree ment or they can build on that founda-
support that all the welding equipment
program. It then expanded the curricu- tion for another two years and become a
and filler metal manufacturers provide
lum by graduating its first four-year welding engineer.
us, said William England, technical
bachelors degree recipients in 1986. England estimates that approximate-
instructor Fig. 4. Our students really
Professor Kenneth Kuk joined the staff ly 60% of students continue on for their
benefit from it, and thats whats
in 1985 to start the bachelor of science bachelors degree.
important.
WELDING JOURNAL 79
THE AMERICAN WELDER

1 2
Fig. 1 Brian Farkas of MAXAL International

3 demonstrates aluminum welding to students
during a visit to the welding technology lab.
Fig. 2 Keith Packard, segment manager,

Hobart Brothers, assesses a completed weld
and provides feedback to student Keith
Zebell.
Fig. 3 Derick Railling, product manager,

Hobart Brothers, demonstrates uphill weld-
ing with metal-cored wire.
Training Details
For the first two years, students learn
to master oxyacetylene, SMAW, GTAW,
and GMAW processes, as well as solder-
ing, brazing, and plasma cutting, com-
pleting coursework that consists of both
lectures and hands-on labs. Labs are
three hours a day, four days a week.
To show the competency of their skills
during the second semester of their
sophomore year, students are required
to complete a capstone project. They
design and fabricate projects ranging
from dog carriers and syrup cookers to
wood stoves, boiler systems, and log
splitters the choice is theirs. Or they
can opt to complete a project needed by
someone in the community.
80 DECEMBER 2012
THE AMERICAN WELDER

4 Fig. 4 William England (far right), techni-
cal instructor at FSU, assesses students
welding wire selection during a lab. Others
shown from left are Matt Brandt, Brad
Williamson, and John Delboy.
Fig. 5 Welding engineering students

gather in the departments nondestructive
examination lab to complete coursework.
ing equipment to gauge their progress

5 Fig. 5. The labs contain tensile and weld
bend-testing equipment, and there is
also a nondestructive examination lab
where the students can make assess-
ments. The space, which the school ren-
ovated in recent years, also serves as a
study and gathering area for students.
Benefits of the
FSU Approach
One of the first things thats immedi-
ately noticeable when visiting the weld-
ing laboratories at FSU isnt just the
noise or busyness of them (although
there is plenty of both), but rather its
the focus and independence of the stu-
dents during their labs Fig. 6.
According to Carney, that autonomy
is essential for the students to grow their
skills.
Theres a lot of trial and error to
what theyre doing, he explained. Its
Those students who are accepted into management of a project from the all about cause and effect. The students
the competitive bachelor of science pro- ground up, using all the knowledge they refine their skills by learning how to look
gram spend their junior and senior years have amassed from their studies. at a weld, determine what might be
studying and applying themselves to the wrong with it and how to fix it. We help
engineering technology side of welding,
including weldment design and automa-
Operating Testing them along the way, of course, but the
process of learning how welding works is
tion. They culminate their knowledge, as Equipment absolutely necessary for them to become
in their sophomore year, with a capstone proficient welding engineers.
project that incorporates a cradle to In addition to the design and welding England expands on that philosophy,
grave concept, including the design, instruction, students also have the adding, FSU is focused on producing
engineering, fabrication, testing, and opportunity to use the departments test- plant-level welding engineers. Here stu-
WELDING JOURNAL 81
THE AMERICAN WELDER

Fig. 6 Student Greg Jonker practices
making welds. Lab work in FSUs welding
technology program consists of multiple
projects that students must complete each
semester and test for quality.
dents develop the ability to think criti- of them. Such training becomes especial- turers throughout the heavy equipment,
cally and troubleshoot, and they have the ly important for third- and fourth-year automotive, and energy sectors. About
hands-on experience to back up the the- students, said Jeff Hardesty, assistant half of those internships, according to
ories they learn. professor, when they begin to focus on Hardesty, lead to full-time employment
welding automation. with the company after graduation.
Learning Valuable Skills Our goal isnt just to teach students Hobart Brothers is an active partici-
to be proficient programmers, he pant in the internship program with FSU
from Project Work explained, but more importantly, we and continues to hire interns for full-
teach them how to spec out and design time employment, including two recent
In the first two years of study, stu-
the robotic cells and fixtures, trou- graduates, Robert Fox and Blain Guy.
dents are given a set amount of small
bleshoot, and be able to put automation The school has a career placement
projects, typically 18, to complete during
into production in the real world. They center that assists in locating these
a semester. The projects involve weld
need to be able to produce good welds, internships, as well as placing graduates
preparation and completing various
and that might involve knowing when in companies in emerging markets.
types of welds for which each student
and how to seam track or creating a cer- Counselors keep in close contact with
must determine and refine the welding
tain fixture for the application. companies, and members of the depart-
parameters. Welding instructors, like
Hardesty adds that learning how to ment say they receive calls daily, if not
Dave Murray, associate professor, are
deal with different materials and filler multiple times a day, from companies
always on hand to help. Murray has been
metals is also essential for students to looking to recruit welding engineers.
with the program since 1981 and moves
apply their knowledge in the real world.
throughout the lab, working side by side
They learn about metal-cored wires and
with students to consult with them on
flux-cored wires, for example, including Staying Ahead of the
everything from the placement of welds
on their capstone projects to testing
the best applications for each and how to Curve
set the proper welding parameters for
welds and prepping materials.
them. Because industry demands change,
instructors in the welding engineering
The Importance of Where to Next? technology program at FSU know that
Real-Life Relevance their curriculum and focus will also have
All students enrolled in the bache- to change if they are to keep their grad-
Another part of refining student skills lors degree program are required to uates at the leading edge.
is to incorporate real-world applications complete an internship between their This program is an evolving con-
in the curriculum, including designing junior and senior year. The internships cept, said England. We are still devel-
weldments for various industries and take place at welding equipment or filler oping, and we always will be. Its what
determining the financial ramifications metal manufacturers, and also manufac- sets this program apart from the rest.
82 DECEMBER 2012
foundation_FP_TEMP 11/6/12 3:22 PM Page 83
Uttrachi Learning Track_Layout 1 11/7/12 1:22 PM Page 84
THE AMERICAN WELDER

LEARNING TRACK
Fig. 1 The Florence Darlington Technology Centers welding

training facility is an AWS Accredited Test Facility.
How Florence Darlington Technical

College Grew Its Welding Program
Committed instructors coupled with an active BY GERALD D. UTTRACHI
advisory board and responsive college manage GERALD D. UTTRACHI (guttrachi@aol.com) is

a past AWS president, president of WA
ment proves to be a winwin relationship for Technology, chair of the AWS Foundation
both the college and local industry Board of Trustees, and an active member of
the Welding Advisory Board at Florence
Darlington Technical College in Florence, S.C.
uring the past 25 years, many from the colleges Welding Advisory contends the industries hiring his weld-
D improvements have been imple-

mented at Florence Darlington
Technical College (FDTC) in Florence,
Board members and to the efforts of
Ross Gandy (Fig. 2), director of the
Advanced Welding and Cutting Center,
ing graduates are also his customers, as
well as all of the sources that help to sup-
port the colleges welding education
S.C., but one of the most significant is as most of this growth occurred during programs.
the increase in enrollments in the weld- his 13-year tenure. Since Gandy plans to Gandy wears a number of hats. He
ing department growing from 12 to retire at the end of this year, it is appro- serves as the director for the center,
188 students. The college has also priate to publish some of his ideas that business manager responsible for seeing
become an American Welding Society helped to turn the welding program students meet the needs of fabricators
Accredited Test Facility, authorized to around. and increasing enrollments to meet
test and certify welders Fig. 1. When Gandy accepted the position as demands, department head for the weld-
director of the training facility, the col- ing curriculum program responsible for
Reasons for the Growth lege president advised him to treat it course content, personnel, etc., and pro-
like a business. Gandy has done that gram manager for the continuing educa-
While there are a number of reasons very well by focusing on the customer. tion segment of the center. In that later
for this growth in welder training, much While many educators may consider duty, FDTC works with local industry to
of the credit goes to recommendations the student their only customer, Gandy develop and teach programs specifically
84 DECEMBER 2012
THE AMERICAN WELDER

LEARNING TRACK
Fig. 2 Ross Gandy, director of welding at designed to fit their special needs. For
the college, worked 13 years to customize example, Honda needed some of the
his training to fit the needs of local companys welders trained to use gas
industries. metal arc welding to join thin-wall tubing
in the all-terrain vehicle (ATV) produc-
Fig. 3 A student is shown during the tion area. Gandy developed the course
intensive 12week, 40h/week pipe welding to Hondas specific requirements. He
course. also arranged for Honda to donate sam-
ples of the thin-wall tubing for the class-
es so their welders could practice weld-
ing on actual production parts. This
enhanced their training experience and
spared the college the expense of pur-
chasing these materials.
Custom Training Courses

Since companies typically request
these custom training courses be held in
the evening, Gandy provides either a
daytime welding instructor, if one is
available, or he hires a part-time instruc-
tor to conduct the training.
At FDTC, the regular welding cur-
riculum programs require all instructors
have a college degree and education
training; the continuing education class-
es require only that trainers possess
good welding and teaching skills. These
special classes can be conducted as need-
ed since they are not tied to the regular
semester dates.
The Welding Advisory Board

The colleges Welding Advisory
Board has been very supportive and is
responsible for helping to improve the
effectiveness of the colleges welding
programs. The board meetings, held sev-
eral times a year at the college, are
attended by about 20 industry represen-
tatives. Following a barbecue dinner pre-
pared by the college staff, they discuss
the skills most needed by the local indus-
tries to provide excellent feedback to the
college staff on how to adjust their cur-
riculums to better train their students to
fill these jobs. The board members also
help in other ways.
In the past, when Gandy expressed a
need for tools and equipment for a new
shop project, a board member would
often donate just what he needed. One
company offered a press brake for a
sheet metal forming project and another
company volunteered to transport the
machine to the college facility. In addi-
tion to working with the advisory board
members, Gandy stays in contact with
the welding fabricators in the area. He
visits the shops to learn first-hand what
welder skills are in demand.
WELDING JOURNAL 85
THE AMERICAN WELDER

LEARNING TRACK
What the Employers Want Fig. 4 Pipe fitting instructor Rick Butler
developed the college pipe fitter training
Gandy noted that in addition to hir- programs.
ing workers with good welding skills, the
employers want workers with good work
ethics. Gandy stresses this in his classes Fig. 5 The students assembled this com
to make reliability and punctuality plex assembly of pipes and fittings near the
important parts of his training programs. shop ceiling while standing on scaffolding
He requires his students to be on time to simulate the conditions they will incur on
for classes, and punishes excessive late- the job in power plants.
ness with a lower grade or remedial
action. He also insists that his students
dress appropriately for their classes.
Gandy impresses upon his students that
a good work ethic and proper dress can
go a long way toward improving their
chances for getting a good-paying job.
As an example, Gandy cited a request
from a local fabricator to provide 15
welders to help build cabs for tractors.
The college trained 20 students to the
fabricators requirements. After com-
pleting the course, 15 students passed
the welding qualification tests. The com-
pany representatives then interviewed
the students and opted to hire all 15
qualified welders and, in addition, hired
the remaining five students to work in
other construction areas since they were
impressed by the students demeanor.
Pipe Welder and Fitter

Programs
Recently, the college seized another
opportunity to serve the community and
grow its welding program when two
South Carolina power companies
expressed the need to hire qualified
welders to help build nuclear power
plants. Both companies agreed to finan-
cially support a pipe-welding program to
their specifications. They also volun-
teered an instructor to assist with the
training to get the program started. The
program the college developed is now a
continuing education program presented
at its Pipe Welding Academy. The course
is a 40-h/week, 12-week-long certificate
program. The facility has grown to
include 30 welding booths dedicated to
pipe-welder training Fig. 3. power companies attended the qualifica- Although the college has offered this
To be accepted into this advanced tion testing to witness the students pipe-welding course for less than three
program, a student must first pass flat results, and they hired the successful years, it has qualified 150 students.
plate welding tests in two positions with graduates for their projects. The success of the pipe-welding pro-
a GTAW (gas tungsten arc welded) root The weld test the power companies gram prompted the participating power
and SMAW (shielded metal arc welded) require is a difficult 6G position butt companies to ask the college to develop
fill passes. The students train by making joint weld in heavy-wall, 16-mm (58-in.) a pipe-fitter program. In response,
pipe welds in various materials and sizes, pipe with a 70-mm (234-in.) OD with a FDTC hired Rick Butler (Fig. 4), an
including welds made under restricted- 75-deg, single-bevel joint preparation. experienced pipe fitter and construction
access conditions. After passing the final The root weld is made with GTAW supervisor, to write the course. Butler
test, the students are qualified as pipe and fill and cap passes with SMAW. The developed a 16-week program that fea-
welders. Representatives from both weld has to pass visual and bend tests. tures math instruction designed for pipe
86 DECEMBER 2012
THE AMERICAN WELDER

LEARNING TRACK
fitters and layout students. In his classes, power plant has about 60 miles of piping three local high schools and has
Butler stresses the proper use of tools and many thousands of valves. Some approved students from one of the
including industrial pipe-preparation valves are welded in place and can be schools to earn college credits toward a
equipment donated to the school by E. rebuilt on site. Many of these valves have FDTC welding program. High school
H. Wachs. pneumatic or motor-driven actuators. welding students who take the required
To simulate actual working conditions The college hired Mike Ward to develop tests in their junior and senior years, can
the students may encounter on the job, a course of study to cover all of these get credit for one-third of the college
the course requires students to interpret skills. The course is currently offered as requirements. A skilled high school stu-
engineering plans then, working on scaf- a five-week certificate program. Its grad- dent can then attend FDTC for one year,
folding, fabricate and tack weld a com- uates are also in demand from other and after passing the qualification tests,
plex pipe layout mounted near the lab companies specializing in valve mainte- can take the 12-week pipe-welding pro-
ceiling Fig. 5. nance contracting. gram. Students who successfully com-
One thing Butler laments is that plete this program often are offered jobs
many companies have eliminated the paying $20/h or more at a power plant.
position of fitters helper, a job category
Working with a Shipyard and An important point to growing a
that was common when he started in the Local High Schools welder training program is to heed the
business. Fitter helpers were apprentices customers needs then develop the pro-
who learned the trade from working with Recently, a large shipyard contacted grams to fill their needs. Florence
the skilled fitters. Today, welder fitter the school in search of graduate welders Darlington Technical College has suc-
skills are only taught in schools. who would consider working in the Gulf ceeded in growing its welding programs
The power companies were so satis- Coast area. Twelve students accepted the by working with its Welding Advisory
fied with the graduates from these two offer, and took the written and practical Board members, local businesses, and
pipe programs that they asked FDTC to tests administered by the shipyard. All high schools, and providing custom-
develop another course to train pipe passed. Several graduates took the ship- designed courses taught by experts in the
valve technicians. Pipe valve technicians yards test for welding in restricted field to train students for the skills in
were needed for their repair, rebuild, spaces, and they passed as well. current demand.
and test operations. A typical nuclear The college also works closely with
See what a large fabricator says ALM Positioners save us 30% on our
production time on a typical trailer.
about their ALM Positioners. We were looking for a piece of equipment

that would position our large weldments
versus having to get a crane to change the
welding position of our product.
The time saving. It goes right to the bottom
line of what we are doing. We dont have to
wait on a crane to change its position. We just
go over and hit a button and it moves.
Its a 100% safer than having to sling chains,
rig equipment and move it. You know you
have to deal with humans and you have a
risk there.
The workers get it in a better position for flat
welding...where they are more comfortable
working and they dont have to be up on a
ladder. Its that much safer for us all the
Mertzs products include well way around.
Paul Zimmerman
servicing equipment and specialty Mertzs Weld Shop Manager.
trailers used in oil and gas
production, parts for large construction equipment,
compact utility loaders, and mini-excavators.
We couldnt say it better ourselves.

Let us show you how to increase throughput and safety
Call 800-544-5438 or visit www.almmh.com
WELDING JOURNAL 87
Fact Sheet_Layout 1 11/9/12 1:25 PM Page 88
THE AMERICAN WELDER

FACT SHEET
Terms Related to Bevels
Bevel, V-groove, and U-groove joint Although single-torch beveling can be bevel edge shape (see Fig. 1G and H).
designs may be specified for the welding accomplished manually, beveling is best Depth of Bevel. The perpendicular
of steel components. Among the done by machine for accurate control of distance from the base metal surface to
processes that can be used to create the cutting variables. When cutting the root edge or the beginning of the
bevels angular edge shapes is oxy- bevels with two or three torches, plate- root face.
gen cutting or gouging. The beveling of riding devices should be used to ensure a Groove Angle. The included angle
plate edges in preparation for welding is constant tip position above the plate. between the groove faces of a weld
necessary in many applications to ensure Following are definitions of some of groove.
the proper dimensions and fit and to the terms related to bevels: Bevel Radius. The radius used to
accommodate standard welding tech- Bevel Angle. The angle between the form a J-edge shape (see Fig. 1B and E).
niques. Plate edges can be beveled with bevel of a joint member and a plane per- Root Opening. A separation at the
the use of a single torch or multiple pendicular to the surface of the member. joint root between the workpieces (see
torches operating simultaneously. Bevel Face. The prepared surface of a Fig. 1A, E, and D).
Fig. 1 Bevel angle, bevel face, depth of bevel, groove angle, bevel radius, and root opening.
Excerpted from Welding Handbook, Vol. 2, 9th Edition, and AWS A3.0M/A3.0:2010, Standard Welding Terms and Definitions, Including
Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying.
88 DECEMBER 2012
edu cracking conf_FP_TEMP 11/6/12 3:11 PM Page 89
AWS Conferences & Exhibitions:
Weld Cracking Conference

March 26-27, 2013 / Las Vegas
AWS
A W
WS invites
invite you to join us in Las V
Vegas
eegas to expand
expan your weld cracking
knowledge! Our featured presenters will explore the many causes of weld
cracking as well as provide information on preventive measures.
Gain practical knowledge on the types and causes of weld cracking.

Network with industry peers to discuss the best solutions for business growth.
AWS
AWWS Conference
Conf attendees are awarded 1 PDH (Professional Development Hour)
for each hour of conference attendance. These PDHs can be applied toward AWS
AW
WS
recertifications and renewals.
For the latest conference information and registr

For registration
ation visit our web site
www.aws.org/conferences
at wwww..aws.org/conferences or call 800-443-9353, ext. 264264..
Page 90&91_FP_TEMP 11/8/12 2:53 PM Page 90
PROFESSIONAL
PROFESSIONAL PR
PROGRAM
OGRAM A ABSTRACT
BSTRACT SUBMITTAL
SUBMITTAL
ANNUAL
ANNUAL FABTECH
FABTECH SHOW
SHOW
Chicago, IL - Nov
November 21, 2013
ember 18-21,
Submission
Submission Deadline:
Deadline: March
March 15,
15, 2013
2013
0
(Complete
(Complete a separate
e submittal
separate al for
submitta each
fo r e ach paper
paper to
o be
be presented.)
presented..)
Primary
Primary A Author (Full
uthor (F Name):
u ll N a m e ):
Affiliation:
Affiliation:
Mailing
Mailing Address:
Address:
City:
City: State/Province
State/Province Zip/Mail Code
Zip/Mail Code Country:
Country:
Email:
Email:
Co-Author(s):
Co-Author(s):
Name (Full
Name (Full Name):
N a m e ): Name
Name (Full Name):
(Full Na m e ):
ffilia tio n
Affiliation
Af Affiliation:
ffilia tio n :
Af
Address:
Address: Address:
Address:
City:
City:
State/Province
State/Province City:
City:
Zip/Mail
Zip/Mail C Code
ode State/Province:
State/Province:
Country:
Country: E-Mail:
E-Mail: Zip/Mail
Zip/Mail C Code:
ode:
Country:
Country: E-Mail:
E-Mail:
Name (Full
Name (Full Na m e ):
Name): Name
Name (Full Name):
(Full Na m e ):
Affiliation:
ffilia tio n :
Af Affiliation:
ffilia tio n :
Af
Address:
Address: Address:
Address:
City:
City: City:
City:
State/Province:
State/Province: State/Province:
State/Province:
Zip/Mail
Zip/Mail C Code:
ode: Zip/Mail
Zip/Mail C Code:
ode:
Country:
Country: E-Mail:
E-Mail: Country:
Country: E-Mail:
E-Mail:
Answer the
Answer the following
fo llo w in g a about
bout tthis paper
h is p aper
Original ssubmittal?
Original u b m it t a l? Y es
Yes No Progress report? Yes
Progress report? Yes No Review paper? Yes
Review paper? Yes No Tutorial? Y
Tutorial? es
Yes No
What ar
What are e tthe
he we lding/Joining pr
welding/Joining ocesses us
processes used?ed?
What
What ar are e tthe
he mamaterials used?
te r ia ls u sed?
What iis
What s tthe
he m ain emphasis
main emphasis of of this
this paper?
paper? Process
Process Oriented
O r ie n te d Materials O
Materials rie n te d
Oriented Modeling
Modeling
what industry
To what industry segments
segments is is this
th is p aper most
paper most applicable?
a p p lic a b le ?
Has material
Has material in in this
this paper
paper ever
ever beenbeen p u b lis h e d o
published orr p r e s e n te d p
presented r e v io u s ly ? Y
previously? Yes
es No
If Yes,
Yes, w hen and
when and where?
w h e re ?
Is th is a g
this raduate study
graduate study related esearch? Yes
related rresearch? Yes No
If a ccepted, w
accepted, ill the
will the author(s)
author(s) p present
resent this
this p paper
aper inin person?
person? Yes Yes Maybe
Maybe No
Ke ywords: Please
Keywords: Please indicateindicate the the top
top four keywords associated
four keywords associated with with youryour research
research below
below
Guidelines for
Guidelines for abstract
abstract submittal
s u b m itta l a nd selection
and selection criteria:
c r ite r ia :
Only those
Only those abstracts
abstracts submitted
submitted on on this
this form
form will
will be
be considered.
considered. Follow
Follow the
the guidelines
guidelines and
and word
word limits
limits indicated.
indicated.
Complete this
Complete this fform
orm using
using MSWord.
MSWord. SubmitSubmit electronically
electronically vvia ia e mail to
email to mventura@aws.org
mventura@aws.org
Technical/Research Oriented
Technical/Research O r ie n te d Applied
Ap p lie d T
Technology
e c h n o lo g y Education
Education
Ne
New w science
science or or research.
re s e a rc h . Ne
New w or
or unique
unique applications.
a p p lic a t io n s . Innovation in w
Innovation elding education
welding education atat all
all
Se
Selection
le c t io n b
based
ased on on technical
technical merit.
m e r it . Se lection based
Selection based on on technical
technical merit.merit. levels.
levels.
Em
Emphasis
phasis is on on previously
previously unpublished
unpublished Em phasis is
Emphasis is on
on previously
p r e v io u s ly Emphasis is
Emphasis is on education/ttraining
on education/training
wo
workrk in
in science
science or or engineering
engineering relevant
relevant to to unpubl ished work
unpublished work that that appl
applies known
ies known methods and
methods and their successes.
their successes.
we
welding,
lding, jjoining
o in in g aandnd aallied
llie d p
processes.
ro c e s s e s . pr inciples of jjoining
principles oining sscience
cience or Pa pers should
Papers address overall
should address o v e r a ll
Pr
Preference
e fe re n c e wwill
ill b
be eggiven
iven to to submittals
submittals with w it h engineering iin
engineering n uni que w
unique ays.
ways. relevance to
relevance to the welding industry.
the welding industry.
clearly co
clearly mmunicated benefit
communicated benefit to to the
th e Pr eference will
Preference w ill b
bee given
given to s u b m it t a ls
to submittals
we lding industry.
welding in d u s tr y . wi th clearly
with clearly ccommunicated
ommunicated benefit benefit to to
the welding
the welding industry.
industry.
Check
Check the
the category
category tthat
hat b
best
est a
applies:
p p lie s :
Technical/Research
Technical/Research O r ie n te d
Oriented Applied
Applied T
Technology
e c h n o lo g y Ed
Education
u c a tio n
Proposed Title (max. 50 characters):

Proposed Subtitle (max. 50 characters):
Abstract:
Introduction (100 words max.) Describe the subject of the presentation, problem/issue being addressed and its
practical implications for the welding industry. Describe the basic value to the welding community with reference to
specific communities or industry sectors.
Technical Approach, for technical papers only (100 words max.) Explain the technical approach, experimental methods
and the reasons why this approach was taken.
Results/Discussion (300 words max.) For technical papers, summarize the results with emphasis on why the results
are new or original, why the results are of value to further advance the welding science, engineering and applications.
For applied technology and education papers, elaborate on why this paper is of value to the welding community,
describe key aspects of the work developed and how this work benefits the welding industry and education.
.Conclusions (100 words max.) Summarize the conclusions and how they could be put to use how and by whom.
NOTE: Abstract must not exceed one page and must not exceed the recommended word limit given above
Note: The Technical Program is not the venue for commercial promotions of a company or a product. All presentations should avoid
the use of product trade names. The Welding Show provides ample opportunities for companies to showcase and advertise their
processes and products.
Return this form, completed on both sides, via email to mventura@aws.org
MUST BE RECEIVED NO LATER THAN MARCH 15, 2013

general corporate_FP_TEMP 11/6/12 1:37 PM Page 92
POSTER ABSTRACT SUBMITTAL

ANNUAL FABTECH SHOW
Chicago, IL November 18-21, 2013
Submission Deadline: April 19, 2013

(Complete a separate submittal for each poster.)
Primary Author (Full Name):
School/Company:
Mailing Address:
City: State/Province: Zip/Mail Code: Country:

Email:
Poster Title (max. 50 characters):
Poster Subtitle (max. 50 characters):
Co-Author(s):
Name (Full Name): Name (Full Name):
Affiliation: Affiliation:
Address: Address:
City: City:
State/Province: State/Province:
Zip/Mail Code: Zip/Mail Code:
Country: Email: Country: Email:
Poster Requirements and Selection Criteria:
Only those abstracts submitted on this form will be considered. Follow the guidelines and word limits indicated.
Complete this form using MSWord. Submit electronically via email to mventura@aws.org or print and mail.
Any technical topic relevant to the welding industry is acceptable (e.g. welding processes & controls, welding procedures, welding design,
structural integrity related to welding, weld inspection, welding metallurgy, etc.).
Submittals that are incomplete and that do not satisfy these basic guidelines will not be considered for competition.
Posters accepted for competition will be judged based on technical content, clarity of communication, novelty/relevance of the subject & ideas
conveyed and overall aesthetic impression.
Criteria by category as follows:
(A) Student (B) Student (C) Student (D) Professional
Students enrolled in 2 yr. college For students enrolled in For students enrolled in graduate For anyone working in the welding
and/or certificate programs at time baccalaureate engineering or degree programs in engineering or industry or related field.
of submittal. engineering technology programs engineering technology at time of Poster must demonstrate technical
Presentation need not represent at the time of submittal. submittal. or scientific concepts. Emphasis is
actual experimental work. Rather, Poster should represent the Poster should represent the placed on original contributions
emphasis is placed on students own experimental work. students own experimental work. and the novelty of the presentation.
demonstrating a clear Emphasis is place on Poster must demonstrate technical Potential relevance to the welding
understanding of technical demonstrating a clear or scientific concepts. Emphasis is industry is important and should be
concepts and subject matter. understanding of technical placed on originality and novelty of demonstrated.
Practical application is important concepts and subject matter. ideas presented. (E) High School
and should be demonstrated. Practical application and/or Potential relevance to the welding Junior or Senior high school
potential relevance to the welding industry is important and should be students enrolled in a welding
industry is important and should demonstrated. concentration at the time of
be demonstrated. submittal.
Presentation should represent
technical concepts and application
to the welding industry.
Practical application and creativity
are important and should be
demonstrated.
Check
Check the
the category
category that
that applies:
a p p lie s :
(A)
(A) Student
Student 2-yr.
2-yr. or
or (B)
(B) Student
Student 4-yr.
4-yr. (C) Graduate
(C) G raduate (D)) Professional
(D Professional (E) High
(E) H igh School
School
Certificate Program
Certificate P ro g ra m Undergraduate
Undergraduate Student
Student
Poster
Poster TitleTitle ((max.
max. 5050 characters):
c h a ra c te rs ):
Poster
Poster Subtitle
Subtitle (max.
(max. 5050 characters):
characters):
Abstract:
Abstract:
Introduction (1
Introduction (10000 w ords) Describe
words) Describe the the subject
subject ooff tthe
he pposter,
oster, pproblem/issue
roblem/issue being
being addressed
addressed and
and its
its practical
practical implications
implications for
for tthe welding
he we ld in g
in d u s try .
industry.
Te
Technical
c h n ic a l A pproach & Results
Approach Results (200
(200 words)
words) Explain
Explain the
the technical
technical appr oach. S
approach. ummarize the
Summarize the work
work that
that was
was done as itit relates
relates to
to the
the ssubject
ubject of
th
thee poster.
poster.
.
Co nclusions (1
Conclusions 00 w
(100 ords) Su
words) mmarize the
Summarize the conclusions
conclusions aand
nd how
how they
they could
could be
be used
used in
in a welding
welding application.
application.
Return
Return this
this form,
form, co
completed
mpleted oonn both
both sides,
sides, via
via email
email to mventura@aws.org
mventura@aws.org
MUST BE
MUST BE RECEIVED
RECEIVED NO NO LATER
LATER THAN April
E THAN April 19, 2013
edu awo fundamentals_FP_TEMP 11/6/12 3:24 PM Page 95
Welding Fundamentals
AWSs American Welding Online is introducing a self-paced online seminar designed to
provide technical knowledge and insight to non-welders who work in the welding and
fabricating industry.
Welding Fundamentals is an approximately 14-hour course that can be taken at your own
speed and convenience. The course provides a fundamental overview of welding, focusing
on the most widely used welding processes. Fundamental instruction is presented on
welding theory, equipment, safety, weld design, metallurgy, welding inspection, and quality
control.
Professional Development Hours and a certificate of completion will be provided upon

completion.
For more information, visit American Welding Online at

.aws.org
WJ Index 2012_WJ Index 2006 11/8/12 10:42 AM Page 96
WELDING JOURNAL
INDEX
Part 1 WELDING JOURNAL
SUBJECT INDEX
VOLUME 91
A Composite Solder Alloy Preform for High-Temperature Glynn, (Sept) 32
Lead-Free Soldering Applications W. Liu, P. Bachorik, College Welding Program Update, Community D. Postleth-
and N.-C. Lee, (July) 50 waite, (April) 33
A Holistic Study of Automated Plasma System Costs J. P. Community College Welding Program Update D. Postleth-
Kinos and D. Ott, (Nov) 28 waite, (April) 33
Aluminum in the Auto Industry, Whats New for Welding Corrosion Resistance when Welding Stainless Tube and Pipe,
N. Scotchmer and K. Chan, (Jan) 34 Maintaining J. Cuhel and D. Benson, (Nov) 46
Aluminum on Ships An Overview, Welded G. A. Mir- Cost Benefits of Preformed and Premixed Brazing Materials
gain, (March) 43 J. Kapur, (Feb) 51
Aluminum, Recent Advances in Solid-State Joining of . Cutting, and Welding, Automating On-Site Beveling, N.
Grong, (Jan) 26 Drake and B. Malkani, (Aug) 38
Aluminum, Selecting Equipment for Welding T. Burns, Cutting for Medical Devices, Fiber Lasers Perform Precision
(Jan) 52 (April) 52
An IIW Primer D. J. Kotecki and T. M. Mustaleski, (Feb) Cutting Process is Best for Your Application?, Which Metal
28 M. Avila, (Oct) 32
Answers to FAQs about Welding Automation D. Imus, Defect Assessment of Brazed Steel Components C. Leinen-
(Nov) 38 bach, M. Koster, A. Lis, and H. J. Schindler, (July) 42
Arc Welding Potential, Unlocking Your Gas Metal P. A. Digitized and Ready to Travel, The Welding Journal: C. Guz-
Blomquist, (April) 28 man, (Sept) 46
Auto Industry, Whats New for Welding Aluminum in the Ecological Impact of Arc Welding, Reducing the M. A.
N. Scotchmer and K. Chan, (Jan) 34 Purslow, (Dec) 24
Automating On-Site Beveling, Cutting, and Welding N. Electroslag Is Process of Choice for Welding San Francisco-
Drake and B. Malkani, (Aug) 38 Oakland Bay Bridge, Narrow Gap B. Turpin, D. Danks,
Automation, Answers to FAQs about Welding D. Imus, J. Callaghan, and W. Wood, (May) 24
(Nov) 38 Engine-Driven Welding Machine?, What Do You Need in an
AWS Enters New Era with World Headquarters H. M. J. Leisner and J. Gitter, (May) 38
Woodward, (Nov) 42 Equipment for Welding Aluminum, Selecting T. Burns,
Benches for Fun and Fund-Raising, Welded H. Woodward, (Jan) 52
(March) 93 Equipping Welding Cells to Fabricate Wind Towers B.
Beveling, Cutting, and Welding, Automating On-Site N. Williams and M. Vandenberg, (Jan) 48
Drake and B. Malkani, (Aug) 38 Evaluating Low-Temperature Brazing Filler Metals for Join-
Brazed Steel Components, Defect Assessment of C. ing Titanium T. Eckardt, B. Hanhold, D. Petrasek, S. Sat-
Leinenbach, M. Koster, A. Lis, and H. J. Schindler, (July) tler, A. Benatar, and A. Shapiro, (Feb) 45
42 Exchange Drives the 65th IIW Assembly, Technology A.
Brazing Alloys, Managing Precious Metal Volatility in G. Cullison, (Oct) 48
Alexy, (July) 60 Fabrication Support Is Vital to Weld Quality, On-Site W. C.
Brazing Filler Metals for Joining Titanium, Evaluating Low- LaPlante, (Oct) 54
Temperature T. Eckardt, B. Hanhold, D. Petrasek, S. Sat- FABTECH (Oct) 60
tler, A. Benatar, and A. Shapiro, (Feb) 45 FABTECH 2011 A. Cullison, M. R. Johnsen, K. Campbell,
Brazing Materials, Cost Benefits of Preformed and Premixed and C. Guzman, (Jan) 38
J. Kapur, (Feb) 51 FABTECH Comes to Canada (March) 40
Brazing, The Effects of Rework on D. G. Stroppa, T. Factors that Affect Hexavalent Chromium Emissions S.
Hermenegildo, J. Unfried S., N. Oliveira, and A. J. Ferree and F. Lake, (Aug) 29
Ramirez, (Feb) 41 Failures, Six Ways to Prevent Weld J. Bundy, (Feb) 30
Bridge, Narrow Gap Electroslag Is Process of Choice for Fiber Lasers Perform Precision Cutting for Medical Devices
Welding San Francisco-Oakland Bay B. Turpin, D. (April) 52
Danks, J. Callaghan, and W. Wood, (May) 24 Finishing Stainless Steel Welds for Food Processing Equip-
Build Your Own Campfire Grill B. Pelky, (March) 48 ment D. Long, (July) 30
Building a Welding Career from the Ground Up (April) 45 Flux Cored and Metal Cored Electrodes, New AWS Spec De-
Building Demand for Tradeswomen (Sept) 81 tails D. Crockett, (March) 51
Cable, How to Pick the Right-Sized Welding A. F. Manz Food Processing Equipment, Finishing Stainless Steel Welds
(March) 91 for D. Long, (July) 30
Campground to the Welding Lab, Scouts Move from the Forward on the Job, Putting Your Best Foot M. Reilly,
(June) 121 (Aug) 54
Career from the Ground Up, Building a Welding (April) 45 From the Lab to the Production Floor: Students Learn It All
Cells to Fabricate Wind Towers, Equipping Welding B. K. Packard, D. Railling, and B. Farkas, (Dec) 78
Williams and M. Vandenberg, (Jan) 48 Fume Collectors for Welding Applications, Selecting G.
Choosing a Surface Coating Technology T. Peters and T. Schreier, (Dec) 73
96 DECEMBER 2012
Good Design Plus Early Inspection Equals High Productivity Fletcher, (July) 36
J. Noruk and J.P. Boillot, (Sept) 26 New AWS Spec Details Flux Cored and Metal Cored Elec-
Green: A Way of Life for Weld Tooling Company B. Kratz, trodes D. Crockett, (March) 51
(Dec) 32 New Face in Welding?, Is Small Town America the B.
Green Technology, Thermal Spray Wins as a R. S. Brun- Wehrman, (May) 44
house, P. Foy, and D. R. Moody, (Sept) 41 New Processes and Metal Cored Wire Combine to Improve
Headquarters, AWS Enters New Era with World H. M. Pipe Fabrication J. Cuhel and K. Packard, (June) 68
Woodward, (Nov) 42 Oilfield Operations, Welding Supports Prudhoe Bay W. C.
Hexavalent Chromium Emissions, Factors that Affect S. LaPlante, (June) 62
Ferree and F. Lake, (Aug) 29 On-Site Fabrication Support Is Vital to Weld Quality W. C.
High-Frequency Welding of Stainless Steel, What to Consider LaPlante, (Oct) 54
before L. D. Frame, (Nov) 34 Orbital Welding for Power Plant Construction, Using On-Site
How Multiple Weld Repairs Impact Maraging Steel B. T. E. Gittens, G. R. Lacey, and M. Kent, (June) 51
Ahmed, F. Tariq, N. Naz, and R. A. Baloch, (Oct) 38 Oxyfuel Safety: Its Everyones Responsibility J. Hender-
How Often Can Joints Be Cut and Rewelded in Low-Carbon son, (Aug) 48
Steel? A. Gonalves de Mello Jr., G. S. Crisi, E. Vitor, Phased Array Testing of Resistance Spot Welds J. K. Na,
and R. A. Lopes Da Silva, (Feb) 25 (Sept) 36
How Todays Power Sources Aid Pulsed GMAW L. Barley, Pipe Fabrication, New Processes and Metal Cored Wire Com-
(April) 48 bine to Improve J. Cuhel and K. Packard, (June) 68
How to Pick the Right-Sized Welding Cable A. F. Manz, Pixels, Moving from Paper to D. Craig, (Dec) 38
(March) 91 Plasma System Costs, A Holistic Study of Automated J. P.
How Would Lower Limits for Manganese Affect Welding? Kinos and D. Ott, (Nov) 28
P. Blomquist and D. Chute, (Aug) 42 Power Plant Construction, Using On-Site Orbital Welding for
Hybrid Process Welds Thick-Walled Tubes M. O. Gebhardt, T. E. Gittens, G. R. Lacey, and M. Kent, (June) 51
A. Gumenyuk, and M. Rethmeier, (June) 55 Power Source Technology Drives Process Improvement, Mod-
IBSC 2012 Attracts Worldwide Audience K. Campbell, ern T. McEllis, (April) 38
(July) 38 Precious Metal Volatility in Brazing Alloys, Managing G.
Industrial Arts, Unleash Your Inner Creativity: Explore K. Alexy, (July) 60
Campbell, (June) 115 Program Aids in Modeling Welding Thermodynamics P.
Inspection Equals High Productivity, Good Design Plus Early Mason, (Dec) 28
J. Noruk and J.P. Boillot, (Sept) 26 Projection Welding Basics, Spot and L. H. McDevitt, (Sept)
Is Small Town America the New Face in Welding? B. 81
Wehrman, (May) 44 Pulsed GMAW, How Todays Power Sources Aid L. Barley,
Lab to the Production Floor: Students Learn It All, From the (April) 48
K. Packard, D. Railling, and B. Farkas, (Dec) 78 Purging Methods, Need for Weld Purity Drives M. J.
Lasers Perform Precision Cutting for Medical Devices, Fiber Fletcher, (July) 36
(April) 52 Putting Your Best Foot Forward on the Job M. Reilly, (Aug)
Lead-Free Soldering Applications, A Composite Solder Alloy 54
Preform for High-Temperature W. Liu, P. Bachorik, and Recent Advances in Solid-State Joining of Aluminum O.
N.-C. Lee, (July) 50 Grong, (Jan) 26
Low-Carbon Steel?, How Often Can Joints Be Cut and Reducing the Ecological Impact of Arc Welding M. A.
Rewelded in A. Gonalves de Mello Jr., G. S. Crisi, E. Purslow, (Dec) 24
Vitor, R. A. Lopes Da Silva, (Feb) 25 Repairs Impact Maraging Steel, How Multiple Weld B.
Maintaining Corrosion Resistance when Welding Stainless Ahmed, F. Tariq, N. Naz, and R. A. Baloch, (Oct) 38
Tube and Pipe J. Cuhel and D. Benson, (Nov) 46 Research from the Lab to Industry, Moving Laser F. Sci-
Managing Precious Metal Volatility in Brazing Alloys G. ammarella, (May) 50
Alexy, (July) 60 Resistance Spot Welds, Phased Array Testing of J. K. Na,
Manganese Affect Welding?, How Would Lower Limits for (Sept) 36
P. Blomquist and D. Chute, (August) 42 Retrofit, Ten Signs Youre Ready for an Automated Plasma
Maraging Steel, How Multiple Weld Repairs Impact B. T. Rice and D. Ott, (Feb) 34
Ahmed, F. Tariq, N. Naz, and R. A. Baloch, (Oct) 38 Rewelded in Low-Carbon Steel?, How Often Can Joints Be
Medical Devices, Fiber Lasers Perform Precision Cutting for Cut and A. Gonalves de Mello Jr., G. S. Crisi, E. Vitor,
(April) 52 R. A. Lopes Da Silva, (Feb) 25
Metal Cored Electrodes, New AWS Spec Details Flux Cored Robots in the Weld Shop: More than Just Welding V. Man-
and D. Crockett, (March) 51 gold, (Nov) 52
Modeling Welding Thermodynamics, Program Aids in P. Safeguarding Your Vision J. Bulan, E. Cull, and F. Stupczy,
Mason, (Dec) 28 (Aug) 54
Modern Power Source Technology Drives Process Improve- Safety: Its Everyones Responsibility, Oxyfuel J. Hender-
ment T. McEllis, (April) 38 son, (Aug) 48
Moving from Paper to Pixels D. Craig, (Dec) 38 Scouts Move from the Campground to the Welding Lab
Moving Laser Research from the Lab to Industry F. Sci- (June) 121
ammarella, (May) 50 Selecting Equipment for Welding Aluminum T. Burns,
Narrow Gap Electroslag Is Process of Choice for Welding San (Jan) 52
Francisco-Oakland Bay Bridge B. Turpin, D. Danks, J. Selecting Fume Collectors for Welding Applications G.
Callaghan, and W. Wood, (May) 24 Schreier, (Dec) 73
Need for Weld Purity Drives Purging Methods M. J. Shop: More than Just Welding, Robots in the Weld V. Man-
WELDING JOURNAL 97
gold, (Nov) 52 Tooling Company, Green: A Way of Life for Weld B. Kratz,
Six Ways to Prevent Weld Failures J. Bundy, (Feb) 30 (Dec) 32
Solder Alloy Preform for High-Temperature Lead-Free Sol- Tubes, Hybrid Process Welds Thick-Walled M. O. Geb-
dering Applications, A Composite W. Liu, P. Bachorik, hardt, A. Gumenyuk, and M. Rethmeier, (June) 55
and N.-C. Lee, (July) 50 Tungsten Electrodes, Tips for Preparing and Selecting J.
Solid-State Joining of Aluminum, Recent Advances in O. Sprinkle, (June) 111
Grong, (Jan) 26 Undertaking a Complex Underwater Repair D. Phillips,
Spot and Projection Welding Basics L. H. McDevitt, (Sept) (March) 32
81 Underwater Repair, Undertaking a Complex D. Phillips,
Stainless Steel Welds for Food Processing Equipment, Finish- (March) 32
ing D. Long, (July) 30 Unleash Your Inner Creativity: Explore Industrial Arts K.
Stainless Steel, What to Consider before High-Frequency Campbell, (June) 115
Welding of L. D. Frame, (Nov) 34 Unlocking Your Gas Metal Arc Welding Potential P. A.
Stainless Tube and Pipe, Maintaining Corrosion Resistance Blomquist, (April) 28
when Welding J. Cuhel and D. Benson, (Nov) 46 Using On-Site Orbital Welding for Power Plant Construction
Students Learn It All, From the Lab to the Production Floor: T. E. Gittens, G. R. Lacey, and M. Kent, (June) 51
K. Packard, D. Railling, and B. Farkas, (Dec) 78 Welded Aluminum on Ships An Overview G. A. Mir-
Surface Coating Technology, Choosing a T. Peters and T. gain, (March) 43
Glynn, (Sept) 32 Welded Benches for Fun and Fund-Raising H. Woodward,
Talent Pool, Welding Researchs New A. Cullison, M. R. (March) 93
Johnsen, H. Woodward, and K. Campbell, (May) 33 Welding Researchs New Talent Pool A. Cullison, M. R.
Technology Exchange Drives the 65th IIW Assembly A. Johnsen, H. Woodward, and K. Campbell, (May) 33
Cullison, (Oct) 48 Welding Supports Prudhoe Bay Oilfield Operations W. C.
Ten Signs Youre Ready for an Automated Plasma Retrofit LaPlante, (June) 62
T. Rice and D. Ott, (Feb) 34 What Do You Need in an Engine-Driven Welding Machine?
The Effects of Rework on Brazing D. G. Stroppa, T. J. Leisner and J. Gitter, (May) 38
Hermenegildo, J. Unfried S., N. Oliveira, and A. J. What to Consider before High-Frequency Welding of Stain-
Ramirez, (Feb) 41 less Steel L. D. Frame, (Nov) 34
The Welding Journal: Digitized and Ready to Travel C. Guz- Whats New for Welding Aluminum in the Auto Industry
man, (Sept) 46 N. Scotchmer and K. Chan, (Jan) 34
Thermal Spray Wins as a Green Technology R. S. Brun- Which Metal-Cutting Process is Best for Your Application?
house, P. Foy, and D. R. Moody, (Sept) 41 M. Avila, (Oct) 32
Tips for Preparing and Selecting Tungsten Electrodes J. Wind Towers, Equipping Welding Cells to Fabricate B.
Sprinkle, (June) 111 Williams and M. Vandenberg, (Jan) 48
Titanium, Evaluating Low-Temperature Brazing Filler Metals Worldwide Audience, IBSC 2012 Attracts K. Campbell,
for Joining T. Eckardt, B. Hanhold, D. Petrasek, S. Sat- (July) 38
tler, A. Benatar, and A. Shapiro, (Feb) 45
AUTHORS FOR FEATURE ARTICLES

Ahmed, B., Tariq, F., Naz, N., and Baloch, R. A. How Mul- spection Equals High Productivity, (Sept) 26
tiple Weld Repairs Impact Maraging Steel, (Oct) 38 Brunhouse, R. S., Foy, P., and Moody, D. R. Thermal Spray
Alexy, G. Managing Precious Metal Volatility in Brazing Wins as a Green Technology, (Sept) 41
Alloys, (July) 60 Bulan, J., Cull, E., and Stupczy, F. Safeguarding Your Vi-
Avila, M. Which Metal-Cutting Process is Best for Your sion, (Aug) 58
Application?, (Oct) 32 Bundy, J. Six Ways to Prevent Weld Failures, (Feb) 30
Bachorik, P., Lee, N.-C., and Liu, W. A Composite Solder Burns, T. Selecting Equipment for Welding Aluminum,
Alloy Preform for High-Temperature Lead-Free Soldering (Jan) 52
Applications, (July) 50 Callaghan, J., Wood, W., Turpin, B., and Danks, D. Narrow
Baloch, R. A., Ahmed, B., Tariq, F., and Naz, N. How Mul- Gap Electroslag Is Process of Choice for Welding San Fran-
tiple Weld Repairs Impact Maraging Steel, (Oct) 38 cisco-Oakland Bay Bridge, (May) 24
Barley, L. How Todays Power Sources Aid Pulsed GMAW, Campbell, K., Cullison, A., Johnsen, M. R., Woodward, H.
(April) 48 Welding Researchs New Talent Pool, (May) 33
Benatar, A., Shapiro, A., Eckardt, T., Hanhold, B., Petrasek, Campbell, K., Guzman, C., Cullison, A., and Johnsen, M. R.
D., and Sattler, S. Evaluating Low-Temperature Brazing FABTECH 2011, (Jan) 38
Filler Metals for Joining Titanium, (Feb) 45 Campbell, K. IBSC 2012 Attracts Worldwide Audience,
Benson, D., and Cuhel, J. Maintaining Corrosion Resist- (July) 38
ance when Welding Stainless Tube and Pipe, (Nov) 46 Campbell, K. Unleash Your Inner Creativity: Explore In-
Blomquist, P. A. Unlocking Your Gas Metal Arc Welding dustrial Arts, (June) 115
Potential, (April) 28 Chan, K., and Scotchmer, N. Whats New for Welding Alu-
Blomquist, P., and Chute, D. How Would Lower Limits for minum in the Auto Industry, (Jan) 34
Manganese Affect Welding?, (Aug) 42 Chute, D., and Blomquist, P. How Would Lower Limits for
Boillot, J.P., and Noruk, J. Good Design Plus Early In- Manganese Affect Welding?, (Aug) 42
98 DECEMBER 2012
Craig, D. Moving from Paper to Pixels, (Dec) 38 FABTECH 2011, (Jan) 38

Crisi, G. S., Vitor, E., Lopes Da Silva, R. A., and Gonalves Johnsen, M. R., Woodward, H., Campbell, K., and Cullison,
de Mello Jr., A. How Often Can Joints Be Cut and A. Welding Researchs New Talent Pool, (May) 33
Rewelded in Low-Carbon Steel?, (Feb) 25 Kapur, J. Cost Benefits of Preformed and Premixed Braz-
Crockett, D. New AWS Spec Details Flux Cored and Metal ing Materials, (Feb) 51
Cored Electrodes, (March) 51 Kent, M., Gittens, T. E., and Lacey, G. R. Using On-Site
Cuhel, J., and Benson, D. Maintaining Corrosion Resist- Orbital Welding for Power Plant Construction, (June) 51
ance when Welding Stainless Tube and Pipe, (Nov) 46 Kinos, J. P., and Ott, D. A Holistic Study of Automated
Cuhel, J., and Packard, K. New Processes and Metal Cored Plasma System Costs, (Nov) 28
Wire Combine to Improve Pipe Fabrication, (June) 68 Koster, M., Lis, A., Schindler, H. J., and Leinenbach, C. De-
Cull, E., Stupczy, F., and Bulan, J. Safeguarding Your Vi- fect Assessment of Brazed Steel Components, (July) 42
sion, (Aug) 58 Kotecki, D. J., and Mustaleski, T. M. An IIW Primer, (Feb)
Cullison, A. Technology Exchange Drives the 65th IIW As- 28
sembly, (Oct) 48 Kratz, B. Green: A Way of Life for Weld Tool Company,
Cullison, A., Johnsen, M. R., Campbell, K., and Guzman, C. (Dec) 32
FABTECH 2011, (Jan) 38 Lacey, G. R., Kent, M., and Gittens, T. E. Using On-Site
Cullison, A., Johnsen, M. R., Woodward, H., and Campbell, Orbital Welding for Power Plant Construction, (June) 51
K. Welding Researchs New Talent Pool, (May) 33 Lake, F., and Ferree, S. Factors that Affect Hexavalent
Danks, D., Callaghan, J., Wood, W., and Turpin, B. Narrow Chromium Emissions, (Aug) 29
Gap Electroslag Is Process of Choice for Welding San Fran- LaPlante, W. C. On-Site Fabrication Support Is Vital to
cisco-Oakland Bay Bridge, (May) 24 Weld Quality, (Oct) 54
Drake, N., and Malkani, B. Automating On-Site Beveling, LaPlante, W. C. Welding Supports Prudhoe Bay Oilfield
Cutting, and Welding, (Aug) 38 Operations, (June) 62
Eckardt, T., Hanhold, B., Petrasek, D., Sattler, S., Benatar, A., Lee, N.-C., Liu, W., and Bachorik, P. A Composite Solder
and Shapiro, A. Evaluating Low-Temperature Brazing Alloy Preform for High-Temperature Lead-Free Soldering
Filler Metals for Joining Titanium, (Feb) 45 Applications, (July) 50
Farkas, B., Packard, K., and Railling, D. From the Lab to Leinenbach, C., Koster, M., Lis, A., and Schindler, H. J. De-
the Production Floor: Students Learn It All, (Dec) 78 fect Assessment of Brazed Steel Components, (July) 42
Ferree, S., and Lake, F. Factors that Affect Hexavalent Leisner, J., and Gitter, J. What Do You Need in an Engine-
Chromium Emissions, (Aug) 29 Driven Welding Machine?, (May) 38
Fletcher, M. J. Need for Weld Purity Drives Purging Meth- Lis, A., Schindler, H. J., Leinenbach, C., and Koster, M. De-
ods, (July) 36 fect Assessment of Brazed Steel Components, (July) 42
Foy, P., Moody, D. R., and Brunhouse, R. S. Thermal Spray Liu, W., Bachorik, P., and Lee, N.-C. A Composite Solder
Wins as a Green Technology, (Sept) 41 Alloy Preform for High-Temperature Lead-Free Soldering
Frame, L. D. What to Consider before High-Frequency Applications, (July) 50
Welding of Stainless Steel, (Nov) 34 Long, D. Finishing Stainless Steel Welds for Food Process-
Gebhardt, M. O., Gumenyuk, A., and Rethmeier, M. Hy- ing Equipment, (July) 30
brid Process Welds Thick-Walled Tubes, (June) 55 Lopes Da Silva, R. A., Gonalves de Mello Jr., A., Crisi, G. S.,
Gittens, T. E., Lacey, G. R., and Kent, M. Using On-Site and Vitor, E. How Often Can Joints Be Cut and
Orbital Welding for Power Plant Construction, (June) 51 Rewelded in Low-Carbon Steel?, (Feb) 25
Gitter, J., and Leisner, J. What Do You Need in an Engine- Malkani, B., and Drake, N. Automating On-Site Beveling,
Driven Welding Machine?, (May) 38 Cutting, and Welding, (Aug) 38
Glynn, T., and Peters, T. Choosing a Surface Coating Tech- Mangold, V. Robots in the Weld Shop: More than Just
nology, (Sept) 32 Welding, (Nov) 52
Gonalves de Mello Jr., A., Crisi, G. S., Vitor, E., and Lopes Manz, A. F. How to Pick the Right-Sized Welding Cable,
Da Silva, R. A. How Often Can Joints Be Cut and (March) 91
Rewelded in Low-Carbon Steel?, (Feb) 25 Mason, P. Program Aids in Modeling Welding Thermody-
Grong, . Recent Advances in Solid-State Joining of Alu- namics, (Dec) 28
minum, (Jan) 26 McDevitt, L. H. Spot and Projection Welding Basics, (Sept)
Gumenyuk, A., Rethmeier, M., and Gebhardt, M. O. Hy- 81
brid Process Welds Thick-Walled Tubes, (June) 55 McEllis, T. Modern Power Source Technology Drives
Guzman, C., Cullison, A., Johnsen, M. R., and Campbell, K. Process Improvement, (April) 38
FABTECH 2011, (Jan) 38 Mirgain, G. A. Welded Aluminum on Ships An
Guzman, C. The Welding Journal: Digitized and Ready to Overview, (March) 43
Travel, (Sept) 46 Moody, D. R., Brunhouse, R. S., and Foy, P. Thermal Spray
Hanhold, B., Petrasek, D., Sattler, S., Benatar, A., Shapiro, A., Wins as a Green Technology, (Sept) 41
and Eckardt, T. Evaluating Low-Temperature Brazing Mustaleski, T. M., and Kotecki, D. J. An IIW Primer, (Feb)
Filler Metals for Joining Titanium, (Feb) 45 28
Henderson, J. Oxyfuel Safety: Its Everyones Responsibil- Na, J. K. Phased Array Testing of Resistance Spot Welds,
ity, (Aug) 48 (Sept) 36
Hermenegildo, T., Unfried S., J., Oliveira, N., Ramirez, A. J., Naz, N., Baloch, R. A., Ahmed, B., and Tariq, F. How Mul-
and Stroppa, D. G. The Effects of Rework on Brazing, tiple Weld Repairs Impact Maraging Steel, (Oct) 38
(Feb) 41 Noruk, J., and J.P. Boillot Good Design Plus Early In-
Imus, D. Answers to FAQs about Welding Automation, spection Equals High Productivity, (Sept) 26
(Nov) 38 Oliveira, N., Ramirez, A. J., Stroppa, D. G., Hermenegildo, T.,
Johnsen, M. R., Campbell, K., Guzman, C., and Cullison, A. and Unfried S., J. The Effects of Rework on Brazing,
WELDING JOURNAL 99
(Feb) 41 Scotchmer, N., and Chan, K. Whats New for Welding Alu-
Ott, D., and Kinos, J. P. A Holistic Study of Automated minum in the Auto Industry, (Jan) 34
Plasma System Costs, (Nov) 28 Shapiro, A., Eckardt, T., Hanhold, B., Petrasek, D., Sattler, S.,
Ott, D., and Rice, T. Ten Signs Youre Ready for an Auto- and Benatar, A. Evaluating Low-Temperature Brazing
mated Plasma Retrofit, (Feb) 34 Filler Metals for Joining Titanium, (Feb) 45
Packard, K., and Cuhel, J. New Processes and Metal Cored Sprinkle, J. Tips for Preparing and Selecting Tungsten Elec-
Wire Combine to Improve Pipe Fabrication, (June) 68 trodes, (June) 111
Packard, K., Railling, D., and Farkas, B. From the Lab to Stroppa, D. G., Hermenegildo, T., Unfried S., J., Oliveira, N.,
the Production Floor: Students Learn It All, (Dec) 78 and Ramirez, A. J. The Effects of Rework on Brazing,
Pelky, B. Build Your Own Campfire Grill, (March) 48 (Feb) 41
Peters, T., and Glynn, T. Choosing a Surface Coating Tech- Stupczy, F., Bulan, J., and Cull, E. Safeguarding Your Vi-
nology, (Sept) 32 sion, (Aug) 58
Petrasek, D., Sattler, S., Benatar, A., Shapiro, A., Eckardt, T., Tariq, F., Naz, N., Baloch, R. A., and Ahmed, B. How Mul-
and Hanhold, B. Evaluating Low-Temperature Brazing tiple Weld Repairs Impact Maraging Steel, (Oct) 38
Filler Metals for Joining Titanium, (Feb) 45 Turpin, B., Danks, D., Callaghan, J., and Wood, W. Narrow
Phillips, D. Undertaking a Complex Underwater Repair, Gap Electroslag Is Process of Choice for Welding San Fran-
(March) 32 cisco-Oakland Bay Bridge, (May) 24
Postlethwaite, D. Community College Welding Program Unfried S., J., Oliveira, N., Ramirez, A. J., Stroppa, D. G., and
Update, (April) 33 Hermenegildo, T. The Effects of Rework on Brazing,
Purslow, M. A. Reducing the Ecological Impact of Arc (Feb) 41
Welding, (Dec) 24 Vandenberg, M., and Williams, B. Equipping Welding Cells
Railling, D., Farkas, B., and Packard, K. From the Lab to to Fabricate Wind Towers, (Jan) 48
the Production Floor: Students Learn It All, (Dec) 78 Vitor, E., Lopes Da Silva, R. A., Gonalves de Mello Jr., A.,
Ramirez, A. J., Stroppa, D. G., Hermenegildo, T., Unfried S., and Crisi, G. S. How Often Can Joints Be Cut and
J., Oliveira, N. The Effects of Rework on Brazing, (Feb) Rewelded in Low-Carbon Steel?, (Feb) 25
41 Wehrman, B. Is Small Town America the New Face in Weld-
Reilly, M. Putting Your Best Foot Forward on the Job, (Au- ing?, (May) 44
gust) 54 Williams, B., and Vandenberg, M. Equipping Welding Cells
Rethmeier, M., Gebhardt, M. O., and Gumenyuk, A. Hy- to Fabricate Wind Towers, (Jan) 48
brid Process Welds Thick-Walled Tubes, (June) 55 Wood, W., Turpin, B., Danks, D., and Callaghan, J. Narrow
Rice, T., and Ott, D. Ten Signs Youre Ready for an Auto- Gap Electroslag Is Process of Choice for Welding San Fran-
mated Plasma Retrofit, (Feb) 34 cisco-Oakland Bay Bridge, (May) 24
Sattler, S., Benatar, A., Shapiro, A., Eckardt, T., Hanhold, B., Woodward, H., Campbell, K., Cullison, A., and Johnsen, M.
and Petrasek, D. Evaluating Low-Temperature Brazing R. Welding Researchs New Talent Pool, (May) 33
Filler Metals for Joining Titanium, (Feb) 45 Woodward, H. M. AWS Enters New Era with World Head-
Schindler, H. J., Leinenbach, C., Koster, M., and Lis, A. De- quarters, (Nov) 42
fect Assessment of Brazed Steel Components, (July) 42 Woodward, H. Welded Benches for Fun and Fund-Raising,
Schreier, G. Selecting Fume Collectors for Welding Appli- (March) 93
cations, (Dec) 73
Sciammarella, F. Moving Laser Research from the Lab to
Industry, (May) 50
100 DECEMBER 2012

Part 2 RESEARCH
SUPPLEMENT SUBJECT INDEX
VOLUME 91
Adhesive Placement in Weld-Bonding Multiple Stacks of Steel Design Considerations of Graded Transition Joints for Welding
Sheets J. Shen, Y. S. Zhang, X. M. Lai, and P. C. Wang, Dissimilar Alloys G. J. Brentrup, B. S. Snowden, J. N.
(Feb) 59-s DuPont, and J. L. Grenestedt, (Sept) 252-s
Aluminum 2024, Ultrasonic Soldering of Shape Memory NiTi Design of Experiment and Goal Programming Application for
to R. Hahnlen, G. Fox, and M. Dapino, (Jan) 1-s the GMAW Process Y. T. I, F. Elaldi, F. Pakdil, and N. E.
Aluminum Alloys with High-Power Diode Laser, Weldability of I. Pek, (April) 106-s
J. M. Snchez-Amaya, Z. Boukha, M. R. Amaya-Vzquez, Developing an Alternative Heat Indexing Equation for FSW
and F. J. Botana J. A. Querin and J. A. Schneider, (March) 76-s
Aluminum Sheet in the Automotive Industry A 30 Year His- Development of an Oxyrutile Electrode for Wet Welding V.
tory, Joining J. E. Gould, (Jan) 23-s R. Santos, M. J. Monteiro, F. C. Rizzo, A. Q. Bracarense, E.
An Evaluation of the Cross-Tension Test of Resistance Spot C. P. Pessoa, R. R. Marinho, and L. A. Vieira, (Dec) 319-s
Welds in High-Strength Dual-Phase Steels D. J. Radakovic Dissimilar Alloys, Design Considerations of Graded Transition
and M. Tumuluru, (Jan) 8-s Joints for Welding G. J. Brentrup, B. S. Snowden, J. N.
Analysis of Thermal Cycle during Multipass Arc Welding C. DuPont, and J. L. Grenestedt, (Sept) 252-s
S. Pathak, L. G. Navale, A. D. Sahasrabudhe, and M. J. Dissimilar Metal Joints, Fatigue Behavior of Electron Beam
Rathod, (May) 149-s Welded A. alik, M. S. Karaka, and R. Varol, (Feb) 50-s
Arc Characteristics in Pulsed-GMA Welding with Acute Groove Double Stage Plasma Arc Pipe Welding Process X. R. Li, Z.
Angles R-H. Kim, G-D. Choi, C-H. Kim, D-W. Cho, and Shao, and Y. M. Zhang, (Dec) 346-s
S-J. Na, (April) 101-s Dual-Phase Steels, An Evaluation of the Cross-Tension Test of
Artificial Neural Network Prediction of Weld Geometry Per- Resistance Spot Welds in High-Strength D. J. Radakovic
formed Using GMAW with Alternating Shielding Gases and M. Tumuluru, (Jan) 8-s
S. W. Campbell, A. M. Galloway, and N. A. McPherson, Ductility-Dip Cracking, Susceptibility of IN740 to HAZ Liqua-
(June) 174-s tion Cracking and J. E. Ramirez, (April) 122-s
Austenitic Stainless Steel Solidification Modes Characteriza- Effect of the Consumable on the Properties of Gas Metal Arc
tion, Reagent Selection in M. A. Valiente Bermejo, (May) Welded EN 1.4003-Type Stainless Steel E. Taban, A.
133-s Dhooge, E. Kaluc, and E. Deleu, (Aug) 213-s
Automotive Industry A 30 Year History, Joining Aluminum Effect of Titanium Content on Microstructure and Wear Re-
Sheet in the J. E. Gould, (Jan) 23-s sistance of Fe-Cr-C Hardfacing Layers Y. F. Zhou, Y. L.
Beam Diagnostic Tools, Identifying Performance Differences in Yang, D. Li, J. Yang, Y. W. Jiang, X. J. Ren, and Q. X. Yang,
Transmissive and Reflective Laser Optics Using J. Blecher, (Aug) 229-s
T. A. Palmer, S. M. Kelly, and R. P. Martukanitz, (July) 204-s Effects of FSW Parameters on Joint Properties of AlMg3 Alloy
Brazing of Copper-Beryllium Alloy (C17200) Using Silver- Z. Barlas and U. Ozsarac, (Jan) 16-s
Based Interlayer, Partial Transient Liquid Phase Diffusion Effects of Welding Direction and Position on Susceptibility to
M. M. Atabaki, (Feb) 35-s Weld Transverse Cracking in Welding High-Strength Pipeline
Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P, Study on Steel with Cellulosic Electrodes S. Sarafan, F. M. Alek
Vacuum Z. Zhong, J. Zhou, X. Shen, and X. Ling, (Sept) Ghaini, and E. Rahimi, (June) 182-s
237-s Electrode for Wet Welding, Development of an Oxyrutile V.
Characterization of Three-Dimensional Weld Pool Surface in R. Santos, M. J. Monteiro, F. C. Rizzo, A. Q. Bracarense, E.
GTAW W. Zhang, Y. Liu, X. Wang, and Y. M. Zhang, C. P. Pessoa, R. R. Marinho, and L. A. Vieira, (Dec) 319-s
(July) 195-s Electron Beam Welded Dissimilar Metal Joints, Fatigue Behav-
Composite and AISI 1030, Continuous Drive Friction Welding ior of A. alik, M. S. Karaka, and R. Varol, (Feb) 50-s
of Al/SiC S. elik and D. Gne, (Aug) 222-s Estimating the Cooling Rates of a Spot Welding Nugget in
Consumable on the Properties of Gas Metal Arc Welded EN Stainless Steel Y. Zhang, T.-J. Ma, H.-X. Xie, Y.-M. Tan,
1.4003-Type Stainless Steel, Effect of the E. Taban, A. and P.-Y. Li, (Sept) 247-s
Dhooge, E. Kaluc, and E. Deleu, (Aug) 213-s Failure Mode Transition in AISI 304 Resistance Spot Welds
Continuous Cooling Transformation Behavior in the CGHAZ M. Pouranvari and S. P. H. Marashi, (Nov) 303-s
of Naval Steels X. Yue, J. C. Lippold, B. T. Alexandrov, and Fatigue Behavior of Electron Beam Welded Dissimilar Metal
S. S. Babu, (March) 67-s Joints A. alik, M. S. Karaka, and R. Varol, (Feb) 50-s
Continuous Drive Friction Welding of Al/SiC Composite and Ferrite Determination in Stainless Steels, Predictive and Meas-
AISI 1030 S. elik and D. Gne, (Aug) 222-s urement Methods for Delta M. A. Valiente Bermejo,
Copper-Beryllium Alloy (C17200) Using Silver-Based Inter- (April) 113-s
layer, Partial Transient Liquid Phase Diffusion Brazing of Fluid Flow and Solidification in Welding: Three Decades of Fun-
M. M. Atabaki, (Feb) 35-s damental Research at the University of Wisconsin S. Kou,
Cracking and Ductility-Dip Cracking, Susceptibility of IN740 to (Nov) 287-s
HAZ Liquation J. E. Ramirez, (April) 122-s Fracture Toughness of Simulated Heat-Affected Zones in
Cracking in Welding High-Strength Pipeline Steel with Cellu- NUCu-140 Steel B. M. Leister and J. N. DuPont, (Feb)
losic Electrodes, Effects of Welding Direction and Position on 53-s
Susceptibility to Weld Transverse S. Sarafan, F. M. Alek Friction Stir Welded Joints, Improvement of Formation Quality
Ghaini, and E. Rahimi, (June) 182-s for R.-D. Fu, R.-C. Sun, F.-C. Zhang, and H.-J. Liu, (June)
Cracking Susceptibility of Ni-Based Superalloys as a Function of 169-s
Strain Rate, Temperature, and Alloy Composition, Strain- Friction Welding of Al/SiC Composite and AISI 1030, Continu-
Age D. A. Metzler, (June) 163-s ous Drive S. elik and D. Gne, (Aug) 222-s
WELDING JOURNAL 101

FSW Parameters on Joint Properties of AlMg3 Alloy, Effects of Naval Steels, Continuous Cooling Transformation Behavior in
Z. Barlas and U. Ozsarac, (Jan) 16-s the CGHAZ of X. Yue, J. C. Lippold, B. T. Alexandrov,
Fundamental Research at the University of Wisconsin, Fluid and S. S. Babu, (March) 67-s
Flow and Solidification in Welding: Three Decades of S. Neural Network Prediction of Weld Geometry Performed
Kou, (Nov) 287-s Using GMAW with Alternating Shielding Gases, Artificial
Gas Tungsten Arc Welding Using an Arcing Wire J. S. Chen, S. W. Campbell, A. M. Galloway, and N. A. McPherson,
Y. Lu, X. R. Li, and Y. M. Zhang, (Oct) 261-s (June) 174-s
Gases, Artificial Neural Network Prediction of Weld Geometry Nonlinear Modeling of Dynamic Metal Transfer in Laser-
Performed Using GMAW with Alternating Shielding S. Enhanced GMAW Y. Huang, Y. Shao, and Y. M. Zhang,
W. Campbell, A. M. Galloway, and N. A. McPherson, (June) (May) 140-s
174-s Numerical Analysis of a High-Frequency Induction Welded Pipe
Glass to Kovar Alloy with Cu-Ni-Sn-P, Study on Vacuum Y. Han and E. L. Yu, (Oct) 270-s
Brazing of Z. Zhong, J. Zhou, X. Shen, and X. Ling, Partial Transient Liquid Phase Diffusion Brazing of Copper-
(Sept) 237-s Beryllium Alloy (C17200) Using Silver-Based Interlayer
GMAW, Ultrasonic Wave Assisted Y. Y. Fan, C. L. Yang, S. M. M. Atabaki, (Feb) 35-s
B. Lin, C. L. Fan, and W. G. Liu, (March) 91-s Pipe, Numerical Analysis of a High-Frequency Induction
GTAW, Characterization of Three-Dimensional Weld Pool Sur- Welded Y. Han and E. L. Yu, (Oct) 270-s
face in W. Zhang, Y. Liu, X. Wang, and Y. M. Zhang, (July) Pipe Welding Process, Double Stage Plasma Arc X. R. Li, Z.
195-s Shao, and Y. M. Zhang, (Dec) 346-s
Hardfacing Layers, Effect of Titanium Content on Microstruc- Pipeline Steel with Cellulosic Electrodes, Effects of Welding Di-
ture and Wear Resistance of Fe-Cr-C Y. F. Zhou, Y. L. rection and Position on Susceptibility to Weld Transverse
Yang, D. Li, J. Yang, Y. W. Jiang, X. J. Ren, and Q. X. Yang, Cracking in Welding High-Strength S. Sarafan, F. M. Alek
(Aug) 229-s Ghaini, and E. Rahimi, (June) 182-s
Heat-Affected Zones in NUCu-140 Steel, Fracture Toughness Plasma Arc Pipe Welding Process, Double Stage X. R. Li, Z.
of Simulated B. M. Leister and J. N. DuPont, (Feb) 53-s Shao, and Y. M. Zhang, (Dec) 346-s
Heat Indexing Equation for FSW, Developing an Alternative Predictive and Measurement Methods for Delta Ferrite Deter-
J. A. Querin and J. A. Schneider, (March) 76-s mination in Stainless Steels M. A. Valiente Bermejo,
Hexavalent Chromium from Stainless Steel Welding, Selecting (April) 113-s
Processes to Minimize M. Keane, A. Siert, S. Stone, B. Programming Application for the GMAW Process, Design of
Chen, J. Slaven, A. Cumpston, and J. Antonini, (Sept) 241-s Experiment and Goal Y. T. I, F. Elaldi, F. Pakdil, and N.
High-Frequency Induction Welded Pipe, Numerical Analysis of E. I. Pek, (April) 106-s
a Y. Han and E. L. Yu, (Oct) 270-s Properties of AlMg3 Alloy, Effects of FSW Parameters on Joint
Human Welder Response to 3D Weld Pool Surface: Part 1 Z. Barlas and U. Ozsarac, (Jan) 16-s
Principles, Modeling of W. J. Zhang and Y. M. Zhang, Pulsed-GMA Welding with Acute Groove Angles, Arc Charac-
(Nov) 310-s teristics in R-H. Kim, G-D. Choi, C-H. Kim, D-W. Cho, and
Human Welder Response to 3D Weld Pool Surface: Part II S-J. Na, (April) 101-s
Results and Analysis, Modeling of W. J. Zhang and Y. M. Reagent Selection in Austenitic Stainless Steel Solidification
Zhang, (Dec) 329-s Modes Characterization M. A. Valiente Bermejo, (May)
Identifying Performance Differences in Transmissive and Re- 133-s
flective Laser Optics Using Beam Diagnostic Tools J. Resistance Spot Welded TRIP Steel, Second Pulse Current in
Blecher, T. A. Palmer, S. M. Kelly, and R. P. Martukanitz, Effects on the Microstructure and Mechanical Behavior V.
(July) 204-s H. Baltazar Hernandez, Y. Okita, and Y. Zhou, (Oct) 278-s
Improvement of Formation Quality for Friction Stir Welded Resistance Spot Welds, Failure Mode Transition in AISI 304
Joints R.-D. Fu, R.-C. Sun, F.-C. Zhang, and H.-J. Liu, M. Pouranvari and S. P. H. Marashi, (Nov) 303-s
(June) 169-s Resistance Spot Welds in High-Strength Dual-Phase Steels, An
Improving Supermartensitic Stainless Steel Weld Metal Tough- Evaluation of the Cross-Tension Test of D. J. Radakovic
ness S. Zappa, H. G. Svoboda, N. M. Ramini de Rissone, and M. Tumuluru, (Jan) 8-s
E. S. Surian, and L. A. de Vedia, (March) 83-s Robotic Welding Platform, Theoretical and Empirical Valida-
Joining Aluminum Sheet in the Automotive Industry A 30 tion of a Mobile J. Stacy and S. Canfield, (Dec) 338-s
Year History J. E. Gould, (Jan) 23-s Scaling Themocapillary Weld Pool Shape and Transport Vari-
Laser-Enhanced GMAW, Nonlinear Modeling of Dynamic ables in Metals P. S. Wei and H. J. Liu, (July) 187-s
Metal Transfer in Y. Huang, Y. Shao, and Y. M. Zhang, Second Pulse Current in Resistance Spot Welded TRIP Steel
(May) 140-s Effects on the Microstructure and Mechanical Behavior V.
Laser Optics Using Beam Diagnostic Tools, Identifying Per- H. Baltazar Hernandez, Y. Okita, and Y. Zhou, (Oct) 278-s
formance Differences in Transmissive and Reflective J. Selecting Processes to Minimize Hexavalent Chromium from
Blecher, T. A. Palmer, S. M. Kelly, and R. P. Martukanitz, Stainless Steel Welding M. Keane, A. Siert, S. Stone, B.
(July) 204-s Chen, J. Slaven, A. Cumpston, and J. Antonini, (Sept) 241-s
Laser, Weldability of Aluminum Alloys with High-Power Diode Soldering of Shape Memory NiTi to Aluminum 2024, Ultrasonic
J. M. Snchez-Amaya, Z. Boukha, M. R. Amaya-Vzquez, R. Hahnlen, G. Fox, and M. Dapino, (Jan) 1-s
and F. J. Botana Solidification in Welding: Three Decades of Fundamental Re-
Modeling of Human Welder Response to 3D Weld Pool Surface: search at the University of Wisconsin, Fluid Flow and S.
Part 1 Principles W. J. Zhang and Y. M. Zhang, (Nov) Kou, (Nov) 287-s
310-s Spot Welding Nugget in Stainless Steel, Estimating the Cooling
Modeling of Human Welder Response to 3D Weld Pool Surface: Rates of a Y. Zhang, T.-J. Ma, H.-X. Xie, Y.-M. Tan, and
Part II Results and Analysis W. J. Zhang and Y. M. P.-Y. Li, (Sept) 247-s
Zhang, (Dec) 329-s Spot Welds in High-Strength Dual-Phase Steels, An Evaluation
102 DECEMBER 2012

of the Cross-Tension Test of Resistance D. J. Radakovic Yang, D. Li, J. Yang, Y. W. Jiang, X. J. Ren, and Q. X. Yang,
and M. Tumuluru, (Jan) 8-s (Aug) 229-s
Stainless Steel, Effect of the Consumable on the Properties of Toughness of Simulated Heat-Affected Zones in NUCu-140
Gas Metal Arc Welded EN 1.4003-Type E. Taban, A. Steel, Fracture B. M. Leister and J. N. DuPont, (Feb) 53-
Dhooge, E. Kaluc, and E. Deleu, (Aug) 213-s s
Stainless Steel, Estimating the Cooling Rates of a Spot Welding Toughness, Improving Supermartensitic Stainless Steel Weld
Nugget in Y. Zhang, T.-J. Ma, H.-X. Xie, Y.-M. Tan, and Metal S. Zappa, H. G. Svoboda, N. M. Ramini de Rissone,
P.-Y. Li, (Sept) 247-s E. S. Surian, and L. A. de Vedia, (March) 83-s
Stainless Steel Welding, Selecting Processes to Minimize Hexa- Transfer in Laser-Enhanced GMAW, Nonlinear Modeling of
valent Chromium from M. Keane, A. Siert, S. Stone, B. Dynamic Metal Y. Huang, Y. Shao, and Y. M. Zhang,
Chen, J. Slaven, A. Cumpston, and J. Antonini, (Sept) 241-s (May) 140-s
Stainless Steels, Predictive and Measurement Methods for Delta Transformation Behavior in the CGHAZ of Naval Steels, Con-
Ferrite Determination in M. A. Valiente Bermejo, (April) tinuous Cooling X. Yue, J. C. Lippold, B. T. Alexandrov,
113-s and S. S. Babu, (March) 67-s
Strain-Age Cracking Susceptibility of Ni-Based Superalloys as a Transition in AISI 304 Resistance Spot Welds, Failure Mode
Function of Strain Rate, Temperature, and Alloy Composi- M. Pouranvari and S. P. H. Marashi, (Nov) 303-s
tion D. A. Metzler, (June) 163-s Transition Joints for Welding Dissimilar Alloys, Design Consid-
Study on Vacuum Brazing of Glass to Kovar Alloy with Cu-Ni- erations of Graded G. J. Brentrup, B. S. Snowden, J. N.
Sn-P Z. Zhong, J. Zhou, X. Shen, and X. Ling, (Sept) 237- DuPont, and J. L. Grenestedt, (Sept) 252-s
s TRIP Steel, Second Pulse Current in Resistance Spot Welded
Superalloys as a Function of Strain Rate, Temperature, and Effects on the Microstructure and Mechanical Behavior V.
Alloy Composition, Strain-Age Cracking Susceptibility of Ni- H. Baltazar Hernandez, Y. Okita, and Y. Zhou, (Oct) 278-s
Based D. A. Metzler, (June) 163-s Tungsten Arc Welding Using an Arcing Wire, Gas J. S. Chen,
Supermartensitic Stainless Steel Weld Metal Toughness, Im- Y. Lu, X. R. Li, and Y. M. Zhang, (Oct) 261-s
proving S. Zappa, H. G. Svoboda, N. M. Ramini de Ris- Ultrasonic Soldering of Shape Memory NiTi to Aluminum 2024
sone, E. S. Surian, and L. A. de Vedia, (March) 83-s R. Hahnlen, G. Fox, and M. Dapino, (Jan) 1-s
Surface: Part 1 Principles, Modeling of Human Welder Re- Ultrasonic Wave Assisted GMAW Y. Y. Fan, C. L. Yang, S.
sponse to 3D Weld Pool W. J. Zhang and Y. M. Zhang, B. Lin, C. L. Fan, and W. G. Liu, (March) 91-s
(Nov) 310-s Validation of a Mobile Robotic Welding Program, Theoretical
Surface: Part II Results and Analysis, Modeling of Human and Empirical J. Stacy and S. Canfield, (Dec) 338-s
Welder Response to 3D Weld Pool W. J. Zhang and Y. M. Weldability of Aluminum Alloys with High-Power Diode Laser
Zhang, (Dec) 329-s J. M. Snchez-Amaya, Z. Boukha, M. R. Amaya-Vzquez,
Susceptibility of IN740 to HAZ Liquation Cracking and Ductil- and F. J. Botana, (May) 155-s
ity-Dip Cracking J. E. Ramirez, (April) 122-s Weld-Bonding Multiple Stacks of Steel Sheets, Adhesive Place-
Theoretical and Empirical Validation of a Mobile Robotic Weld- ment in J. Shen, Y. S. Zhang, X. M. Lai, and P. C. Wang,
ing Platform J. Stacy and S. Canfield, (Dec) 338-s (Feb) 59-s
Thermal Cycle during Multipass Arc Welding, Analysis of C. Wet Welding, Development of an Oxyrutile Electrode for V.
S. Pathak, L. G. Navale, A. D. Sahasrabudhe, and M. J. R. Santos, M. J. Monteiro, F. C. Rizzo, A. Q. Bracarense, E.
Rathod, (May) 149-s C. P. Pessoa, R. R. Marinho, and L. A. Vieira, (Dec) 319-s
Thermocapillary Weld Pool Shape and Transport Variables in
Metals, Scaling P. S. Wei and H. J. Liu, (July) 187-s
Titanium Content on Microstructure and Wear Resistance of
Fe-Cr-C Hardfacing Layers, Effect of Y. F. Zhou, Y. L.
AUTHORS FOR RESEARCH SUPPLEMENTS
Alek Ghaini, F. M., Rahimi, E., and Sarafan, S. Effects of Babu, S. S., Yue, X., Lippold, J. C., and Alexandrov, B. T.
Welding Direction and Position on Susceptibility to Weld Continuous Cooling Transformation Behavior in the
Transverse Cracking in Welding High-Strength Pipeline CGHAZ of Naval Steels, (March) 67-s
Steel with Cellulosic Electrodes, (June) 182-s Baltazar Hernandez, V. H., Okita, Y., and Zhou, Y. Second
Alexandrov, B. T., Babu, S. S., Yue, X., and Lippold, J. C. Pulse Current in Resistance Spot Welded TRIP Steel Ef-
Continuous Cooling Transformation Behavior in the fects on the Microstructure and Mechanical Behavior,
CGHAZ of Naval Steels, (March) 67-s (Oct) 278-s
Amaya-Vzquez, M. R., Botana, F. J., Snchez-Amaya, J. M., Barlas, Z., and Ozsarac, U. Effects of FSW Parameters on
and Boukha, Z. Weldability of Aluminum Alloys with Joint Properties of AlMg3 Alloy, (Jan) 16-s
High-Power Diode Laser, (May) 155-s Blecher, J., Palmer, T. A., Kelly, S. M., and Martukanitz, R. P.
Antonini, J., Keane, M., Siert, A., Stone, S., Chen, B., Slaven, Identifying Performance Differences in Transmissive
J., and Cumpston, A. Selecting Processes to Minimize and Reflective Laser Optics Using Beam Diagnostic Tools,
Hexavalent Chromium from Stainless Steel Welding, (July) 204-s
(Sept) 241-s Botana, F. J., Snchez-Amaya, J. M., Boukha, Z., and Amaya-
Atabaki, M. M. Partial Transient Liquid Phase Diffusion Vzquez, M. R. Weldability of Aluminum Alloys with
Brazing of Copper-Beryllium Alloy (C17200) Using Silver- High-Power Diode Laser, (May) 155-s
Based Interlayer, (Feb) 35-s Boukha, Z., Amaya-Vzquez, M. R., Botana, F. J., and
WELDING JOURNAL 103

Snchez-Amaya, J. M. Weldability of Aluminum Alloys Artificial Neural Network Prediction of Weld Geometry
with High-Power Diode Laser, (May) 155-s Performed Using GMAW with Alternating Shielding
Bracarense, A. Q., Pessoa, E. C. P., Marinho, R. R., Vieira, L. Gases, (June) 174-s
A., Santos, V. R., Monteiro, M. J., and Rizzo, F. C. De- Gould, J. E. Joining Aluminum Sheet in the Automotive
velopment of an Oxyrutile Electrode for Wet Welding, Industry A 30 Year History, (Jan) 23-s
(Dec) 319-s Grenestedt, J. L., Brentrup, G. J., Snowden, B. S., and
Brentrup, G. J., Snowden, B. S., DuPont, J. N., and Grenest- DuPont, J. N. Design Considerations of Graded Transi-
edt, J. L. Design Considerations of Graded Transition tion Joints for Welding Dissimilar Alloys, (Sept) 252-s
Joints for Welding Dissimilar Alloys, (Sept) 252-s Gne, D., and elik, S. Continuous Drive Friction Weld-
alik, A., Karaka, M. S., and Varol, R. Fatigue Behavior ing of AI/SiC Composite and AISI 1030, (Aug) 222-s
of Electron Beam Welded Dissimilar Metal Joints, (Feb) Hahnlen, R., Fox, G., and Dapino, M. Ultrasonic Solder-
50-s ing of Shape Memory NiTi to Aluminum 2024, (Jan) 1-s
Campbell, S. W., Galloway, A. M., and McPherson, N. A. Han, Y., and Yu, E. L. Numerical Analysis of a High-Fre-
Artificial Neural Network Prediction of Weld Geometry quency Induction Welded Pipe, (Oct) 270-s
Performed Using GMAW with Alternating Shielding Huang, Y., Shao, Y., and Zhang, Y. M. Nonlinear Model-
Gases, (June) 174-s ing of Dynamic Metal Transfer in Laser-Enhanced GMAW,
Canfield, S., and Stacy, J. Theoretical and Empirical Vali- (May) 140-s
dation of a Mobile Robotic Welding Platform, (Dec) 338-s I, Y. T., Elaldi, F., Pakdil, F., and Pek, N. E. I. Design of
elik, S., and Gne, D. Continuous Drive Friction Weld- Experiment and Goal Programming Application for the
ing of Al/SiC Composite and AISI 1030, (Aug) 222-s GMAW Process, (April) 106-s
Chen, B., Slaven, J., Cumpston, A., Antonini, J., Keane, M., Jiang, Y. W., Ren, X. J., Yang, Q. X., Zhou, Y. F., Yang, Y. L.,
Siert, A., and Stone, S. Selecting Processes to Minimize Li, D., and Yang, J. Effect of Titanium Content on Mi-
Hexavalent Chromium from Stainless Steel Welding, crostructure and Wear Resistance of Fe-Cr-C Hardfacing
(Sept) 241-s Layers, (Aug) 229-s
Chen, J. S., Lu, Y., Li, X. R., and Zhang, Y. M. Gas Tung- Kaluc, E., Deleu, E., Taban, E., and Dhooge, A. Effect of
sten Arc Welding Using an Arcing Wire, (Oct) 261-s the Consumable on the Properties of Gas Metal Arc
Cho, D-W., Na, S-J., Kim, R-H., Choi, G-D., and Kim, C-H. Welded EN 1.4003-Type Stainless Steel, (Aug) 213-s
Arc Characteristics in Pulsed-GMA Welding with Acute Karaka, M. S., Varol, R., and alik, A. Fatigue Behavior
Groove Angles, (April) 101-s of Electron Beam Welded Dissimilar Metal Joints, (Feb)
Choi, G-D., Kim, C-H., Cho, D-W., Na, S-J., and Kim, R-H. 50-s
Arc Characteristics in Pulsed-GMA Welding with Acute Keane, M., Siert, A., Stone, S., Chen, B., Slaven, J., Cumpston,
Groove Angles, (April) 101-s A., and Antonini, J. Selecting Processes to Minimize
Cumpston, A., Antonini, J., Keane, M., Siert, A., Stone, S., Hexavalent Chromium from Stainless Steel Welding,
Chen, B., and Slaven, J. Selecting Processes to Minimize (Sept) 241-s
Hexavalent Chromium from Stainless Steel Welding, Kelly, S. M., Martukanitz, R. P., Blecher, J., and Palmer, T. A.
(Sept) 241-s Identifying Performance Differences in Transmissive
Dapino, M., Hahnlen, R., and Fox, G. Ultrasonic Solder- and Reflective Laser Optics Using Beam Diagnostic Tools,
ing of Shape Memory NiTi to Aluminum 2024, (Jan) 1-s (July) 204-s
De Vedia, L. A., Zappa, S., Svoboda, H. G., Ramini de Ris- Kim, C-H., Cho, D-W., Na, S-J., Kim, R-H., and Choi, G-D.
sone, N. M., and Surian, E., S. Improving Supermarten- Arc Characteristics in Pulsed-GMA Welding with Acute
sitic Stainless Steel Weld Metal Toughness, (March) 83-s Groove Angles, (April) 101-s
Deleu, E., Taban, E., Dhooge, A., and Kaluc, E. Effect of Kim, R-H., Choi, G-D., Kim, C-H., Cho, D-W., and Na, S-J.
the Consumable on the Properties of Gas Metal Arc Arc Characteristics in Pulsed-GMA Welding with Acute
Welded EN 1.4003-Type Stainless Steel, (Aug) 213-s Groove Angles, (April) 101-s
Dhooge, A., Kaluc, E., Deleu, E., and Taban, E. Effect of Kou, S. Fluid Flow and Solidification in Welding: Three
the Consumable on the Properties of Gas Metal Arc Decades of Fundamental Research at the University of
Welded EN 1.4003-Type Stainless Steel, (Aug) 213-s Wisconsin, (Nov) 287-s
DuPont, J. N., and Leister, B. M. Fracture Toughness of Lai, X. M., Wang, P. C., Shen, J., and Zhang, Y. S. Adhe-
Simulated Heat-Affected Zones in NUCu-140 Steel, (Feb) sive Placement in Weld-Bonding Multiple Stacks of Steel
53-s Sheets, (Feb) 59-s
DuPont, J. N., Grenestedt, J. L., Brentrup, G. J., and Snow- Leister, B. M., and DuPont, J. N. Fracture Toughness of
den, B. S. Design Considerations of Graded Transition Simulated Heat-Affected Zones in NUCu-140 Steel, (Feb)
Joints for Welding Dissimilar Alloys, (Sept) 252-s 53-s
Elaldi, F., Pakdil, F., Pek, N. E. I., and I, Y. T. Design of Li, D., Yang, J., Jiang, Y. W., Ren, X. J., Yang, Q. X., Zhou, Y.
Experiment and Goal Programming Application for the F., and Yang, Y. L. Effect of Titanium Content on Mi-
GMAW Process, (April) 106-s crostructure and Wear Resistance of Fe-Cr-C Hardfacing
Fan, C. L., Liu, W. G., Fan, Y. Y., Yang, C. L., and Lin, S. B. Layers, (Aug) 229-s
Ultrasonic Wave Assisted GMAW, (March) 91-s Li, P.-Y., Zhang, Y., Ma, T.-J., Xie, H.-X., and Tan, Y.-M.
Fan, Y. Y., Yang, C. L., Lin, S. B., Fan, C. L., and Liu, W. G. Estimating the Cooling Rates of a Spot Welding Nugget in
Ultrasonic Wave Assisted GMAW, (March) 91-s Stainless Steel, (Sept) 247-s
Fox, G., Dapino, M., and Hahnlen, R. Ultrasonic Solder- Li, X. R., Shao, Z., and Zhang, Y. M. Double Stage Plasma
ing of Shape Memory NiTi to Aluminum 2024, (Jan) 1-s Arc Pipe Welding Process, (Dec) 346-s
Fu, R.-D., Sun, R.-C., Zhang, F.-C., and Liu, H.-J. Im- Li, X. R., Zhang, Y. M., Chen, J. S., and Lu, Y. Gas Tung-
provement of Formation Quality for Friction Stir Welded sten Arc Welding Using an Arcing Wire, (Oct) 261-s
Joints, (June) 169-s Lin, S. B., Fan, C. L., Liu, W. G., Fan, Y. Y., and Yang, C. L.
Galloway, A. M., McPherson, N. A., and Campbell, S. W Ultrasonic Wave Assisted GMAW, (March) 91-s
104 DECEMBER 2012

Ling, X., Zhong, Z., Zhou, J., and Shen, X. Study on Vac- GMAW Process, (April) 106-s
uum Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P, Pessoa, E. C. P., Marinho, R. R., Vieira, L. A., Santos, V. R.,
(Sept) 237-s Monteiro, M. J., Rizzo, F. C., and Bracarense, A. Q. De-
Lippold, J. C., Alexandrov, B. T., Babu, S. S., and Yue, X. velopment of an Oxyrutile Electrode for Wet Welding,
Continuous Cooling Transformation Behavior in the (Dec) 319-s
CGHAZ of Naval Steels, (March) 67-s Pouranvari, M., and Marashi, S. P. H. Failure Mode Transi-
Liu, H. J., and Wei, P. S. Scaling Themocapillary Weld Pool tion in AISI 304 Resistance Spot Welds, (Nov) 303-s
Shape and Transport Variables in Metals, (July) 187-s Querin, J. A., and Schneider, J. A. Developing an Alterna-
Liu, H.-J., Fu, R.-D., Sun, R.-C., and Zhang, F.-C. Im- tive Heat Indexing Equation for FSW, (March) 76-s
provement of Formation Quality for Friction Stir Welded Radakovic, D. J., and Tumuluru, M. An Evaluation of the
Joints, (June) 169-s Cross-Tension Test of Resistance Spot Welds in High-
Liu, W. G., Fan, Y. Y., Yang, C. L., Lin, S. B., and Fan, C. L. Strength Dual-Phase Steels, (Jan) 8-s
Ultrasonic Wave Assisted GMAW, (March) 91-s Rahimi, E., Sarafan, S., and Alek Ghaini, F. M. Effects of
Liu, Y., Wang, X., Zhang, Y. M., and Zhang, W. Charac- Welding Direction and Position on Susceptibility to Weld
terization of Three-Dimensional Weld Pool Surface in Transverse Cracking in Welding High-Strength Pipeline
GTAW, (July) 195-s Steel with Cellulosic Electrodes, (June) 182-s
Lu, Y., Li, X. R., Zhang, Y. M., and Chen, J. S. Gas Tung- Ramini de Rissone, N. M., Surian, E. S., De Vedia, L. A.,
sten Arc Welding Using an Arcing Wire, (Oct) 261-s Zappa, S., and Svoboda, H. G. Improving Supermarten-
Ma, T.-J., Xie, H.-X., Tan, Y.-M., Li, P.-Y., and Zhang, Y. sitic Stainless Steel Weld Metal Toughness, (March) 83-s
Estimating the Cooling Rates of a Spot Welding Nugget in Ramirez, J. E. Susceptibility of IN740 to HAZ Liquation
Stainless Steel, (Sept) 247-s Cracking and Ductility-Dip Cracking, (April) 122-s
Marashi, S. P. H., and Pouranvari, M. Failure Mode Transi- Rathod, M. J., Pathak, C. S., Navale, L. G., and Sahasrabudhe,
tion in AISI 304 Resistance Spot Welds, (Nov) 303-s A. D. Analysis of Thermal Cycle during Multipass Arc
Marinho, R. R., Vieira, L. A., Santos, V. R., Monteiro, M. J., Welding, (May) 149-s
Rizzo, F. C., Bracarense, A. Q., and Pessoa, E. C. P. De- Ren, X. J., Yang, Q. X., Zhou, Y. F., Yang, Y. L., Li, D., Yang,
velopment of an Oxyrutile Electrode for Wet Welding, J., and Jiang, Y. W. Effect of Titanium Content on Mi-
(Dec) 319-s crostructure and Wear Resistance of Fe-Cr-C Hardfacing
Martukanitz, R. P., Blecher, J., Palmer, T. A., and Kelly, S. M. Layers, (Aug) 229-s
Identifying Performance Differences in Transmissive Rizzo, F. C., Bracarense, A. Q., Pessoa, E. C. P., Marinho, R.
and Reflective Laser Optics Using Beam Diagnostic Tools, R., Vieira, L. A., Santos, V. R., and Monteiro, M. J. De-
(July) 204-s velopment of an Oxyrutile Electrode for Wet Welding,
McPherson, N. A., Campbell, S. W., and Galloway, A. M. (Dec) 319-s
Artificial Neural Network Prediction of Weld Geometry Sahasrabudhe, A. D., Rathod, M. J., Pathak, C. S., and Navale,
Performed Using GMAW with Alternating Shielding L. G. Analysis of Thermal Cycle during Multipass Arc
Gases, (June) 174-s Welding, (May) 149-s
Metzler, D. A. Strain-Age Cracking Susceptibility of Ni- Snchez-Amaya, J. M., Boukha, Z., Amaya-Vzquez, M. R.,
Based Superalloys as a Function of Strain Rate, Tempera- and Botana, F. J. Weldability of Aluminum Alloys with
ture, and Alloy Composition, (June) 163-s High-Power Diode Laser, (May) 155-s
Monteiro, M. J., Rizzo, F. C., Bracarense, A. Q., Pessoa, E. C. Santos, V. R., Monteiro, M. J., Rizzo, F. C., Bracarense, A. Q.,
P., Marinho, R. R., Vieira, L. A., and Santos, V. R. De- Pessoa, E. C. P., Marinho, R. R., and Vieira, L. A. De-
velopment of an Oxyrutile Electrode for Wet Welding, velopment of an Oxyrutile Electrode for Wet Welding,
(Dec) 319-s (Dec) 319-s
Na, S-J., Kim, R-H., Choi, G-D., Kim, C-H., and Cho, D-W. Sarafan, S., Alek Ghaini, F. M., and Rahimi, E. Effects of
Arc Characteristics in Pulsed-GMA Welding with Acute Welding Direction and Position on Susceptibility to Weld
Groove Angles, (April) 101-s Transverse Cracking in Welding High-Strength Pipeline
Navale, L. G., Sahasrabudhe, A. D., Rathod, M. J., and Steel with Cellulosic Electrodes, (June) 182-s
Pathak, C. S. Analysis of Thermal Cycle during Multi- Schneider, J. A., and Querin, J. A. Developing an Alterna-
pass Arc Welding, (May) 149-s tive Heat Indexing Equation for FSW, (March) 76-s
Okita, Y., Zhou, Y., and Baltazar Hernandez, V. H. Second Shao, Y., Zhang, Y. M., and Huang, Y. Nonlinear Model-
Pulse Current in Resistance Spot Welded TRIP Steel Ef- ing of Dynamic Metal Transfer in Laser-Enhanced GMAW,
fects on the Microstructure and Mechanical Behavior, (May) 140-s
(Oct) 278-s Shao, Z., Zhang, Y. M., and Li, X. R. Double Stage Plasma
Ozsarac, U., and Barlas, Z. Effects of FSW Parameters on Arc Pipe Welding Process, (Dec) 346-s
Joint Properties of AlMg3 Alloy, (Jan) 16-s Shen, J., Zhang, Y. S., Lai, X. M., and Wang, P. C. Adhe-
Pakdil, F., Pek, N. E. I., I, Y. T., and Elaldi, F. Design of sive Placement in Weld-Bonding Multiple Stacks of Steel
Experiment and Goal Programming Application for the Sheets, (Feb) 59-s
GMAW Process, (April) 106-s Shen, X., Ling, X., Zhong, Z., and Zhou, J. Study on Vac-
Palmer, T. A., Kelly, S. M., Martukanitz, R. P., and Blecher, J. uum Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P,
Identifying Performance Differences in Transmissive (Sept) 237-s
and Reflective Laser Optics Using Beam Diagnostic Tools, Siert, A., Stone, S., Chen, B., Slaven, J., Cumpston, A., An-
(July) 204-s tonini, J., and Keane, M. Selecting Processes to Mini-
Pathak, C. S., Navale, L. G., Sahasrabudge, A. D., and Rathod, mize Hexavalent Chromium from Stainless Steel Welding,
M. J. Analysis of Thermal Cycle during Multipass Arc (Sept) 241-s
Welding, (May) 149-s Slaven, J., Cumpston, A., Antonini, J., Keane, M., Siert, A.,
Pek, N. E. I., I, Y. T., Elaldi, F., and Pakdil, F. Design of Stone, S., and Chen, B. Selecting Processes to Minimize
Experiment and Goal Programming Application for the Hexavalent Chromium from Stainless Steel Welding,
WELDING JOURNAL 105

(Sept) 241-s Yang, Y. L., Li, D., Yang, J., Jiang, Y. W., Ren, X. J., Yang, Q.
Snowden, B. S., DuPont, J. N., Grenestedt, J. L., and Bren- X., and Zhou, Y. F. Effect of Titanium Content on Mi-
trup, G. J. Design Considerations of Graded Transition crostructure and Wear Resistance of Fe-Cr-C Hardfacing
Joints for Welding Dissimilar Alloys, (Sept) 252-s Layers, (Aug) 229-s
Stacy, J., and Canfield, S. Theoretical and Empirical Vali- Yu, E. L., and Han, Y. Numerical Analysis of a High-Fre-
dation of a Mobile Robotic Welding Platform, (Dec) 338-s quency Induction Welded Pipe, (Oct) 270-s
Stone, S., Chen, B., Slaven, J., Cumpston, A., Antonini, J., Yue, X., Lippold, J. C., Alexandrov, B. T., and Babu, S. S.
Keane, M., and Siert, A. Selecting Processes to Minimize Continuous Cooling Transformation Behavior in the
Hexavalent Chromium from Stainless Steel Welding, CGHAZ of Naval Steels, (March) 67-s
(Sept) 241-s Zappa, S., Svoboda, H. G., Ramini de Rissone, N. M., Surian,
Sun, R.-C., Zhang, F.-C., Liu, H.-J., and Fu, R.-D. Im- E. S., and De Vedia, L. A. Improving Supermartensitic
provement of Formation Quality for Friction Stir Welded Stainless Steel Weld Metal Toughness, (March) 83-s
Joints, (June) 169-s Zhang, W., Liu, Y., Wang, X., and Zhang, Y. M. Charac-
Surian, E. S., De Vedia, L. A., Zappa, S., Svoboda, H. G., and terization of Three-Dimensional Weld Pool Surface in
Ramini de Rissone, N. M. Improving Supermartensitic GTAW, (July) 195-s
Stainless Steel Weld Metal Toughness, (March) 83-s Zhang, F.-C., Liu, H.-J., Fu, R.-D., and Sun, R.-C. Im-
Svoboda, H. G., Ramini de Rissone, N. M., Surian, E. S., De provement of Formation Quality for Friction Stir Welded
Vedia, A., and Zappa, S. Improving Supermartensitic Joints, (June) 169-s
Stainless Steel Weld Metal Toughness, (March) 83-s Zhang, W. J., and Zhang, Y. M. Modeling of Human
Taban, E., Dhooge, A., Kaluc, E, and Deleu, E. Effect of Welder Response to 3D Weld Pool Surface: Part 1 Prin-
the Consumable on the Properties of Gas Metal Arc ciples, (Nov) 310-s
Welded EN 1.4003-Type Stainless Steel, (Aug) 213-s Zhang, W. J., and Zhang, Y. M. Modeling of Human
Tan, Y.-M., Li, P.-Y., Zhang, Y., Ma, T.-J., and Xie, H.-X. Welder Response to 3D Weld Pool Surface: Part II Re-
Estimating the Cooling Rates of a Spot Welding Nugget in sults and Analysis, (Dec) 329-s
Stainless Steel, (Sept) 247-s Zhang, Y. M., and Zhang, W. J. Modeling of Human
Tumuluru, M., and Radakovic, D. J. An Evaluation of the Welder Response to 3D Weld Pool Surface: Part 1 Prin-
Cross-Tension Test of Resistance Spot Welds in High- ciples, (Nov) 310-s
Strength Dual-Phase Steels, (Jan) 8-s Zhang, Y. M., and Zhang, W. J. Modeling of Human
Valiente Bermejo, M. A. Predictive and Measurement Welder Response to 3D Weld Pool Surface: Part II Re-
Methods for Delta Ferrite Determination in Stainless sults and Analysis, (Dec) 329-s
Steels, (April) 113-s Zhang, Y. M., Chen, J. S., Lu, Y., and Li, X. R. Gas Tung-
Valiente Bermejo, M. A. Reagent Selection in Austenitic sten Arc Welding Using an Arcing Wire, (Oct) 261-s
Stainless Steel Solidification Modes Characterization, Zhang, Y. M., Huang, Y., and Shao, Y. Nonlinear Model-
(May) 133-s ing of Dynamic Metal Transfer in Laser-Enhanced GMAW,
Varol, R., alik, A., and Karakas, M. S. Fatigue Behavior (May) 140-s
of Electron Beam Welded Dissimilar Metal Joints, (Feb) Zhang, Y. M., Li, X. R., and Shao, Z. Double Stage Plasma
50-s Arc Pipe Welding Process, (Dec) 346-s
Vieira, L. A., Santos, V. R., Monteiro, M. J., Rizzo, F. C., Zhang, Y. M., Zhang, W., Liu, Y., and Wang, X. Charac-
Bracarense, A. Q., Pessoa, E. C. P., and Marinho, R. R. terization of Three-Dimensional Weld Pool Surface in
Development of an Oxyrutile Electrode for Wet Welding, GTAW, (July) 195-s
(Dec) 319-s Zhang, Y., Ma, T.-J., Xie, H.-X., Tan, Y.-M., and Li, P.-Y.
Wang, P. C., Shen, J., Zhang, Y. S., and Lai, X. M. Adhe- Estimating the Cooling Rates of a Spot Welding Nugget in
sive Placement in Weld-Bonding Multiple Stacks of Steel Stainless Steel, (Sept) 247-s
Sheets, (Feb) 59-s Zhang, Y. S., Lai, X. M., Wang, P. C., and Shen, J. Adhe-
Wang, X., Zhang, Y. M., Zhang, W., and Liu, Y. Charac- sive Placement in Weld-Bonding Multiple Stacks of Steel
terization of Three-Dimensional Weld Pool Surface in Sheets, (Feb) 59-s
GTAW, (July) 195-s Zhong, Z., Zhou, J., Shen, X., and Ling, X. Study on Vac-
Wei, P. S., and Liu, H. J. Scaling Themocapillary Weld Pool uum Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P,
Shape and Transport Variables in Metals, (July) 187-s (Sept) 237-s
Xie, H.-X., Tan, Y.-M., Li, P.-Y., Zhang, Y., and Ma, T.-J.
Estimating the Cooling Rates of a Spot Welding Nugget in Zhou, J., Shen, X., Ling, X., and Zhong, Z. Study on Vac-
Stainless Steel, (Sept) 247-s uum Brazing of Glass to Kovar Alloy with Cu-Ni-Sn-P,
Yang, C. L., Lin, S. B., Fan, C. L., Liu, W. G., and Fan, Y. Y. (Sept) 237-s
Ultrasonic Wave Assisted GMAW, (March) 91-s Zhou, Y., Baltazar Hernandez, V. H., and Okita, Y. Second
Yang, J., Jiang, Y. W., Ren, X. J., Yang, Q. X., Zhou, Y. F., Pulse Current in Resistance Spot Welded TRIP Steel Ef-
Yang, Y. L., and Li, D. Effect of Titanium Content on fects on the Microstructure and Mechanical Behavior,
Microstructure and Wear Resistance of Fe-Cr-C Hardfac- (Oct) 278-s
ing Layers, (Aug) 229-s Zhou, Y. F., Yang, Y. L., Li, D., Yang, J., Jiang, Y. W., Ren, X.
Yang, Q. X., Zhou, Y. F., Yang, Y. L., Li, D., Yang, J., Jiang, J., and Yang, Q. X. Effect of Titanium Content on Mi-
Y. W., and Ren, X. J. Effect of Titanium Content on Mi- crostructure and Wear Resistance of Fe-Cr-C Hardfacing
crostructure and Wear Resistance of Fe-Cr-C Hardfacing Layers, (Aug) 229-s
Layers, (Aug) 229-s
106 DECEMBER 2012

NEWS OF THE INDUSTRY cation; developing faculty who deliver a world-class manufactur-
ing education; and deploying resources to accomplish these goals.
continued from page 13
To download a copy, visit sme.org/WorkforceImperative.
Bug-O Donates Modular Drive Equipment Bellman-Melcor Celebrates 50 Years

to Hobart Institute of Welding Technology
Guests at the Tinley Park Convention Center pose with Bellman-

Melcor Founder/CEO Richard Campbell and his wife, June (cen-
ter), in honor of the companys 50th anniversary.
On August 19, Bellman-Melcor, LLC, Tinley Park, Ill., cele-

A modular drive system that will benefit students at the Hobart In- brated its 50th anniversary. The event was commemorated with
stitute of Welding Technology has been donated by Bug-O. Shown a reception held at the Tinley Park Convention Center to honor
(from left) are Elmer Swank, Russ Shurtz, Mark Campbell, Tom current and former employees as well as industry professionals
Sumerix, Dave Campbell, Nelson Morales, and Chuck Ford. who helped make the company a leader in the brazing and sol-
dering consumables industry. Guests enjoyed a casino-night
theme during which cash and prizes were awarded.
A new piece of automated welding equipment that will en- Bellman-Melcor was founded in 1962 by Richard Campbell
hance training demonstrations at the Hobart Institute of Weld- and Carl Osterman Sr., who worked together at a manufacturer
ing Technology (HIWT) was recently donated by Bug-O Sys- of brazed contact materials owned by Campbells cousin. Today,
tems, Inc., Canonsburg, Pa. Jeff Nelson, a welding engineer at the company has more than 35 full-time employees, all of whom
the company, coordinated the contribution. work to produce more than 600 million quality fabricated parts
The modular drive system allows custom configuring of one sold to more than 300 companies in 18 countries. Employees and
machine for various applications and runs on a standard Bug-O representatives are also active in the AWS C3 Committee on
Systems Rail. The modular design allows reconfiguring the unit Brazing and Soldering, and the Brazing and Soldering Manufac-
for straight line cutting or welding. At its center is the master turers Committee.
drive unit that houses the motor, speed control board, power sup-
ply, and clutch. Among the control module features are a digital
readout and control knob for longitudinal travel speed, plus a
Olympic Steel to Expand Operations
weave speed control of up to 100 in./min.
Pennsylvania Governor Tom Corbett recently announced
Mark Campbell and Dave Campbell, representatives for Bug-
Olympic Steel, Inc., will expand its steel processing facility in
O Systems Weld Tooling Corp., explained the operation to Ho-
Franklin County, creating at least 90 new manufacturing jobs.
bart Institutes technical instructor staff, including Elmer Swank,
The company ultimately elected to expand its Chambersburg
Chuck Ford, Tom Sumerix, Russ Shurtz, and Nelson Morales.
plant to better serve East Coast customers. It will create these
In related news, HIWT has also been named a Military
new jobs within three years, plus invest $11 million to purchase
Friendly School for 2013 by Victory Media, Inc., ranking the
new equipment and provide training to new employees. In addi-
institute in the top 15% of all colleges, universities, and trade
tion, it received a $400,500 funding offer from the Department
schools nationwide doing the most to embrace Americas mili-
of Community and Economic Development.
tary service members, veterans, and spouses as students and to
ensure their success on campus.
Industry Notes
SME Releases Manufacturing Education
Strategy to Solve Job Skills Gap Intelligrated, an automated material handling solutions
provider, relocated its Midwest operations to expanded fa-
The Society of Manufacturing Engineers (SME), Dearborn, cilities in Woodridge, Ill., that provides more space for engi-
Mich., recently revealed a national action plan, Workforce Imper- neering, project management, and sales personnel.
ative: A Manufacturing Education Strategy. New West Energy Services, Inc., Calgary, Alb., Canada, com-
The white paper calls for manufacturers, educators, profes-
pleted its previously announced transaction with Porterco
sional organizations, and government to coordinate and stan-
Welding Ltd., acquiring its operating assets.
dardize efforts at reversing the skills gap crisis and preparing a
skilled workforce for high-tech manufacturing jobs. The American Society of Safety Engineers is joining with the
In addition, the report calls on all stakeholders to work to- Occupational Safety and Health Administration and National
gether to close this gap through the following efforts: attracting Institute of Occupational Safety and Health to support a new
more students into manufacturing; articulating a standard core Fall Prevention Campaign (http://stopconstructionfalls.com/).
of manufacturing knowledge; improving the consistency and qual- NLB Corp. opened a regional branch facility in Crown Point,
ity of manufacturing education; integrating manufacturing top- Ind., to provide users in the Chicago area and upper midwest
ics into science, technology, engineering, and mathematics edu- with water jet pump units, accessories, training, and service.
WELDING JOURNAL 107

DEC 2012 WJ CLASSIFIEDS_Classified Template 11/9/12 8:36 AM Page 108
CLASSIFIEDS
CAREER CERTIFICATION
OPPORTUNITIES & TRAINING
Part Time Employment Place Your

Classified Ad Here! 2013
Accounts Bookkeeper
and Representatives
Payable/Receivable. Contact Frank Wilson, CWI PREPARATORY
Good communication and Senior Advertising Guarantee Pass or Repeat FREE!
80+ HOUR COURSE
organization skills. Production Manager MORE HANDSON/PRACTICAL APPLICATIONS
Send rsum to: (800) 443-9353, Pascagoula, MS Jan. 28Feb. 8

Houston, TX Jan. 1425
turbine1820@gmail.com ext. 465 Houma, LA Feb. 18Mar. 1
Ellijay, GA Mar. 1122
fwilson@aws.org 56+ HOUR COURSE
EXTRA INSTRUCTION TO GET A HEAD START
Pascagoula, MS Jan. 31 Feb. 8

Houma, LA Feb. 21Mar. 1
Put Your Products and 40 HOUR COURSE

Services to Work in the GET READY FAST PACED COURSE!
January 2013
Welding Marketplace Pascagoula, MS Feb. 48
Spread the word on your company around the world by promoting a Houma, LA Feb. 25Mar. 1
full-color photo of your newest and hottest welding product or services
to more than 80,000 AWS members and customers in the famous Test follows on Saturday at same facility &
includes additional self study for weekend
welding product photo guide, WELDING MARKETPLACE. As an extra
bonus your ad will be posted on the AWS Web site with an active link FOR DETAILS CALL OR E-MAIL:
to your Web site. Also a digital link of Welding Marketplace will be sent (800) 489-2890
info@realeducational.com
to more than 69,000 AWS members. Make AWS members your
customers! Closing date is November 15, 2012 Also offering: 9Year CWI Recertification,
RT Film Interpretation, MT/PT/UT Thickness,
Call the AWS sales team at: (800) 443-9353, Rob Saltzstein at ext. 243, Welding Procedure Fundamentals,
salty@aws.org or Lea Paneca at ext. 220, lea@aws.org CWS, SCWI, Advanced Inspection Courses
$ 6450.
$6450.
3 &13*/54
3&13*/54
0QFO:PVS&EJUPSJBM&YQPTVSF The world's first and only completely

online NDT & CWI training program!

NDT Training to meet global standards

including SNT-TC-1A, ISO 9712, etc.

Visit www.worldspec.org today and save
$100 instantly by entering the discount
code: aws59c2
Call toll free: 1-877-506-7773

$BMMPSTBMFT!GPTUFSQSJOUJOHDPN
108 DECEMBER 2012

EQUIPMENT FOR SALE OR RENT
JOE FULLER LLC MITROWSKI RENTS

We manufacture tank turning rolls Made in U.S.A.
3ton through 120ton rolls Welding Positioners
www.joefuller.com The worlds very 1-Ton thru 60-Ton
best portable end
prep tools and
abrasive saws
For sale or rent
800-343-6926
www.escotool.com
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184 Tank Turning Rolls
Our products are made in the USA Used Equipment for Sale
www.mitrowskiwelding.com
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
Place Your
Classified Ad Here! SERVICES
Contact Frank Wilson,
Senior Advertising
Production Manager
(800) 443-9353,
ext. 465
fwilson@aws.org
WELDING JOURNAL 109

ADVERTISER
INDEX
ALM Materials Handling Positioners . . . . . . . . . . . . . . . . . . . .87 Fronius Perfect Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
www.almmh.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 544-5438 www.fronius-usa.com . . . . . . . . . . . . . . . . . . . . . . .(810) 220-4414
Arc Machines, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Gedik Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

www.arcmachines.com . . . . . . . . . . . . . . . . . . . . . .(818) 896-9556 www.gedikwelding.com . . . . . . . . . . . . . . . . . . .+90 216 378 50 00
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460 www.greinerindustries.com . . . . . . . . . . . . . . . . . .(800) 782-2110
Astaras, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Hobart Institute of Welding Technology . . . . . . . . . . . . . . . . . .41

www.e3tungsten.com . . . . . . . . . . . . . . . . . . . . . .web contact only www.welding.org . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 332-9448
Atlas Welding Accessories, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .22 Industrial Maid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

www.atlaswelding.com . . . . . . . . . . . . . . . . . . . . . .(800) 962-9353 www.industrial-maid.com . . . . . . . . . . . . . . . . . . . .(877) 624-3247
AWS Certification Services . . . . . . . . . . . . . . . . . . . . . . .67, 72, 77 Intercon Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 443-9353 www.intercononline.com . . . . . . . . . . . . . . . . . . . . .(800) 665-6655
AWS Education Services . . . . . . . . . . . . . . . . . . . . . .46, 69, 89, 95 KMT Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

www.aws.org/education/ . . . . . . . . . . . . . . . . . . . . .(800) 443-9353 www.kmtsaw.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(269) 321-8860
AWS Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Lincoln Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC

www.aws.org/foundation/ . . . . . . . . . . . . . . . . . . . .(800) 443-9353 www.lincolnelectric.com . . . . . . . . . . . . . . . . . . . . .(216) 481-8100
AWS Membership Services . . . . . . . . . . . . . . . . . . . . . . . . . .71, 92 OTC Daihen, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

www.aws.org/membership/ . . . . . . . . . . . . . . . . . . .(800) 443-9353 www.daihen-usa.com . . . . . . . . . . . . . . . . . . . . . . . .(888) 682-7626
C-spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Schaefer Ventilation Equipment . . . . . . . . . . . . . . . . . . . . . . . . .40

www.weldoffice.com . . . . . . . . . . . . . . . . . . . . . . . . .(877) 977-7999 www.schaeferfan.com . . . . . . . . . . . . . . . . . . . . . . .(800) 779-3267
Camfil Farr Air Polution Control . . . . . . . . . . . . . . . . . . . . . . . . .2 Select Arc, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC

www.camfilfarrapc.com . . . . . . . . . . . . . . . . . . . . .(800) 479-6801 www.select-arc.com . . . . . . . . . . . . . . . . . . . . . . . . .(937) 295-5215
Champion Welding Alloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Stoody/Victor Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

www.championwelding.com . . . . . . . . . . . . . . . . . .(800) 321-9353 www.stoody.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(866) 279-2628
Commercial Diving Academy . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Thermal Dynamics/Victor Technologies . . . . . . . . . . . . . . . . . . .7

www.commercialdivingacademy.com . . . . . . . . . . .(888) 974-2232 www.thermaldynamicsautomation.com . . . . . . . .(866) 279-2628
Computer Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Triangle Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

www.thinkCEI.com/wj . . . . . . . . . . . . . . . . . . . . . . .(800) 473-1976 www.trieng.com . . . . . . . . . . . . . . . . . . . . . . . . . . . .(781) 878-1500
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Uniweld Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

www.cor-met.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 848-2719 www.uniweld.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 323-2111
Diamond Ground Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . .21 Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

www.diamondground.com . . . . . . . . . . . . . . . . . . .(805) 498-3837 www.weldengineering.com . . . . . . . . . . . . . . . . . . .(508) 842-2224
Divers Academy International . . . . . . . . . . . . . . . . . . . . . . . . . .19 Weld Hugger, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

www.diversacademy.com . . . . . . . . . . . . . . . . . . . . .(800) 238-3483 www.weldhugger.com . . . . . . . . . . . . . . . . . . . . . . . .(877) 935-3447
ESAB Welding & Cutting Products . . . . . . . . . . . . . . . . . . . . . . .5

www.esabna.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 372-2123
ESSEN Dubai, UAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 IFC = Inside Front Cover

www.arabia-essen-welding-cutting.com . . .+49(0)201-72 44-649 IBC = Inside Back Cover
OBC = Outside Back Cover
ESSEN Germany . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354-s
www.schweissen-schneiden.com . . . . . . . . . . .+1.9 14.9 62-13 20
Flex-Cable, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

www.flexcable.com . . . . . . . . . . . . . . . . . .(800) 245-3539, ext. 114 Visit the AWS Interactive Ad Index: www.aws.org/ad-index
110 DECEMBER 2012

Santos 12-12_Layout 1 11/9/12 1:34 PM Page 319
SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 2012

Sponsored by the American Welding Society and the Welding Research Council
Development of an Oxyrutile Electrode

for Wet Welding
An experimental electrode improved weld metal properties such as
diffusible hydrogen, porosity, and ductility when wet welding
in shallow waters on structural ship steels
BY V. R. SANTOS, M. J. MONTEIRO, F. C. RIZZO, A. Q. BRACARENSE,

E. C. P. PESSOA, R. R. MARINHO, AND L. A. VIEIRA
ABSTRACT weldability and operability underwater.

Rutile-based electrodes are generally pre-
The present paper describes the experimental development of an oxyrutile electrode. ferred due to their good operability. Com-
The aim of this experimental work was to improve the weld metal mechanical proper- mercial electrode evaluations as well as
ties and minimize the diffusible hydrogen content compared to existing commercial new coating compositions were made by
WELDING RESEARCH
electrodes. Eighteen batches of electrodes were produced in industrial facilities. Nickel Stalker (Ref. 3), Nbrega (Ref. 4), Gooch
and molybdenum were added to strengthen the weld metal. Most welding trials were (Refs. 5, 6), West (Ref. 7), Liu (Ref. 8),
carried out using laboratory simulations and also by divers in the sea at 10 m depth, Ibarra (Ref. 9), and Sanchez-Osio (Ref.
thereby aiming for qualification up to 20 m according to AWS D3.6M:2010. The me- 10). The general conclusions of these
chanical properties, chemical composition, porosity, and microstructures of the weld works can be summarized as follows:
metal among other features are presented. For comparison, three commercial elec- Austenitic electrodes are susceptible to so-
trodes were also tested. The results and the progress toward achievement of structural lidification cracking and formation of
Class A welds are discussed. Most of the experimental electrodes had low porosity and bands of hard martensite along the fusion
very few weld metal microcracks. The diffusible hydrogen content in this work was boundaries; ferritic electrodes have the
equivalent to that of typical oxidizing electrodes. Generally, in comparison to the results best performance and are divided into two
reported in the literature, the oxyrutile electrodes developed here showed lower poros- groups: rutile-based electrodes and iron
ity and had superior performance in terms of toughness and ductility. Overall, the re- oxide-based (oxidizing) electrodes. The
sults represent a significant improvement in the quality of wet welds, and most of them former have good arc stability and other
consistently exceeded the requirements for Class A. running characteristics as well as tensile
strength and toughness. The oxidizing
ductility, hardness, and bending are simi- electrodes have low diffusible hydrogen
lar to those required by the main engi- content (Hdif) and poor operability. In
Introduction general, oxidizing electrodes have a rough
neering codes for atmospheric welding.
There are very few reports in the literature bead surface, and the slag is difficult to re-
Considering the growing number of about achieving Class A in wet welding. move. The main properties of weldments
offshore floating production platforms in Class B welds are considered welds with made by rutile- and oxidizing-type elec-
operation, as well as the economic limita- limited structural quality, where both the trodes in terms of weld metal properties
tions for dry docking these structures, wet tests applied for procedure qualification and weldability are summarized in Table 1.
welding by shielded metal arc welding and the acceptance criteria are less strict. In the 1970s, Nobrega (Ref. 4) carried
(SMAW) is a very attractive technique for The improvement of wet weld quality has out work to develop an electrode with the
maintenance and structural repairs (Ref. been based on the improvement of the combined properties of the rutile- and ox-
1). Wet welds are classed as A and B ac- commercially available atmospheric weld- idizing-type electrodes. In spite of the
cording to AWS D3.6M:2010, Underwater ing electrodes that presented the best good results achieved, no commercial
Welding Code (Ref. 2). For Class A welds, electrode based on this development can
the requirements of toughness, strength, be found on the market today.
Due to expectations that the need for
V. R. SANTOS, M. J. MONTEIRO, and F. C.
KEYWORDS underwater structural maintenance on off-
RIZZO are with the Materials Engineering Depart- shore production platforms will grow, the
ment, Pontifcia Universidade Catlica do Rio de Underwater Welding
wet welding consumables (WWC) project
Janeiro, Rio de Janeiro, Brazil. A. Q. Wet Welding
was launched to develop an oxyrutile elec-
BRACARENSE is with the Mechanical Engineer- SMAW
ing Department, Universidade Federal de Minas
trode for wet welding. The participants in
Covered Electrodes
Gerais, Belo Horizonte, Brazil. E. C. P. PESSOA is this project are two universities, an oil
Diffusible Hydrogen
with the Instituto Federal de Educao, Cincia e company, and an electrode manufacturer.
Electrode Development
Tecnologia de Minas Gerais, Betim, Brazil. R. R. The main aim was to develop an electrode
MARINHO is with the PETROBRAS Research Oxidizing Electrode
based on iron oxide and titanium oxide
Center, Rio de Janeiro, Brazil. L. A. VIEIRA is with Oxygen
with improved mechanical properties min-
ESAB Indstria e Comrcio Ltda., Contagem, imizing the Hdif. Also, operability should
Minas Gerais, Brazil.
WELDING JOURNAL 319-s

A B
Fig. 1 Influence of TiO2/(Fe2O3 + SiO2) in the

coating on the diffusible hydrogen (tests at 0.5 m
welding depth).
be improved in relation to the typical oxi- scribe the development of the WWC project
dizing types. Welding trials were carried and present selected results emphasizing C
out in simulated depths of 10 m in the lab- weld metal mechanical properties and dif-
oratory and in the open sea, aiming pro- fusible hydrogen. Other features of the weld
cedures qualification for up to 20 m metal such as porosity and microstructure
according to AWS D3.6M:2010. The open are also presented. Comparisons with the
sea tests aimed a prequalification of two state-of-the-art electrodes are made, and
wet welding procedures, applicable up to the progress toward achievement of struc-
20 m in order to enlarge the options for tural Class A welds is discussed.
WELDING RESEARCH
the repair designer concerning the elec-

trode selection. Experimental Methods
The first phase of the WWC project was
to select an optimized coating composition Welding tests in Phase 1 of the WWC
as a base line for further developments. The project were carried out in the laboratory
main criteria were to achieve the lowest pos- by a mechanized gravity system at 0.5 m
sible Hdif, improve weldability, and maxi- water depth. This low depth was chosen in
mize the rutile content. The second phase order to guarantee that the experiments Fig. 2 Microstructures. A CR; B CGR; C
targeted the improvement of weld metal could maximize the influences of the base FGR. Representative of experimental electrode
properties with the addition of alloying ele- electrode coating composition and mini- (1E to 8E) weld metal microstructures. Nital 2%.
ments. The improvement of operability was mize the influences of other variables that Welding depth: 0.5 m.
again included in the second phase, but this could be affected by pressure, like pres-
development step is not presented in this ence of pores and weld metal chemical coating formulations were based on the
paper. Commercial electrodes were also composition. Eight experimental electrode combination of hematite (Fe2O3) ranging
tested. Results have already been published batches were produced for Phase 1. These from 40 to 60 wt-%, rutile (TiO2) ranging
(Refs. 12, 13). electrodes were named 1E to 8E accord- from 5 to 25 wt-%, and silica (SiO2) rang-
The aim of the present paper is to de- ing to the increasing rutile content. The ing from 10 to 40 wt-%, which totaled 85
Table 1 Comparative Properties of Rutile and Oxidizing Type Electrodes Based on Literature Data
Rutile Electrodes Oxidizing Electrodes

Weld metal chemical composition (Refs. 1113) Increasing depth decreases manganese Low sensitivity to depth. High oxygen and
and silicon and increases oxygen. low manganese and silicon at all depths.
Diffusible hydrogen (Refs. 1417) High (< 90 mL/100 g). Decreases Medium (< 20 mL/100 g). As low as 13 mL/100 g
with increasing pressure. has been reported.
Porosity (Refs. 1823) Increases considerably with depth Increases moderately with
depth in shallow waters. (<30 m)
Mechanical strength (Refs. 11, 2428) Class E 70XX is commonly achieved. Low-strength deposits. Class E 60XX
is commonly achieved.
Ductility (Refs. 12, 26, 28) Low elongation (< 15%) in the tensile test. Possible to achieve elongation
Decreases with depth. around 20% up to 20 m.
Toughness (Refs. 29, 30) Commonly meets the requirements Commonly meets requirements of the
of the main standards or codes. main standards or codes.
HAZ hydrogen cracking (Refs. 31, 32) High cracking susceptibility for C Low cracking susceptibility for
> 0.15% and C.E. > 0.38%. structural steels in general.
WM hydrogen cracking (Refs. 12, 13) High cracking susceptibility in general. Low cracking susceptibility in general.
320-s DECEMBER 2012, VOL. 91

A B
C D
Fig. 3 Groove joints welded at 10 m equivalent depth. A Elec-

trode 8A surface aspect; B electrode 2C surface aspect; C elec-
trode 8A transversal section; D electrode 2C transversal section.
WELDING RESEARCH
wt-%. The remaining 15 wt-% had invari- minor additions of exothermic substances. dition of arc stabilizer compounds. The re-
ant amounts of binding agents, gases and The electrodes named 1A, 2A, and 3A had maining experimental electrodes were
slag formers, and arc stabilizers. The coat- increasing additions of Ni. The electrodes those designed to improve operability, and
ing composition of the best electrode in 5A to 10A had increasing additions of Ni their results do not belong in the scope of
this phase was applied as the base compo- plus Mo. The alloying additions, made by this paper. The commercial electrodes
sition for further improvements in Phase Ni powder and Fe-Mo, never exceeded tested were named 1C (oxidizing type),
2. In this second phase, Ni and FeMo were 3% and the reduction of the other ingre- and 2C and 3C (rutile type) electrodes.
added to improve mechanical properties dients of the base formulation were pro- Most of tests in Phase 2 were performed
by alloying the weld metal. portionally distributed. Therefore, it is in the laboratory by a mechanized gravity
In Phase 2, 25 experimental electrode assumed that no relevant differences system at pressure equivalent to 10 m
batches were produced. In this phase, the would occur between either the oxiding water depth. Some manual welding trials
aim was to improve the weld metal prop- potential and operational behavior of the were made in the open sea down to 10 m
erties by adding Ni and Mo and also to im- electrodes 1A10A, with the exception for with electrodes 9A and 2C. A few labora-
prove operability by arc stabilizers and electrode 9A, which received an extra ad- tory tests with selected electrodes were
Table 2 Summary of Welding Conditions According to Depth
Phase Electrode Code Laboratory 0.5 m Laboratory 10 m Laboratory 20 m Open sea 10 m

1 1E to 8E X
2 1A and 2A X X X
2 3A, 5A to 8A X
2 4A X X
2 9A X X
2 10A X
Commercial 1C and 3C X X X
Commercial 2C X X X X
Table 3 Electrodes Steel Rod and Base Metal Compositions (wt-%)
C Si Mn P S Cr Ni Mo Cu
Electrodes steel rod Min spec. 0.04 0.40
Max spec. 0.08 0.02 0.60 0.01 0.015 0.05 0.1 0.05 0.05
Typical 0.06 0.01 0.47 0.0065 0.011 0.025 0.04 0.004 0.028
Base metal ASTM A36 0.15 0.20 0.85 0.022 0.007 0.023 0.012 0.008
Base metal ASTM AH 36 0.16 0.23 1.41 0.016 0.006 0.01 0.01 0.001 0.01

Fig. 4 Porosity as a function of depth for selected experimental and com- Fig. 5 Quantitative weld metal transverse crack evaluation in longitudinal
mercial electrodes. sections of groove welds as a function of pressure
A B
WELDING RESEARCH
Fig. 6 Macrographs of groove joints welded at 10 m in open sea. A

Electrode 9A; B electrode 2C.
performed at 0.5 m water depth and at of 1000 Hz. The weld beads were de- grain reheated region (FGR) were meas-
pressure equivalent to 20 m to evaluate posited in V grooves with an opening ured under 50 magnification in the cross
the influence of pressure. The test matrix angle of 45 deg, root opening of 3.25 mm, section, along a 10-mm line, perpendicu-
for the whole project according to the and 13.0 mm depth, machined on ASTM lar to the plate surface, located in the cen-
welding depth is presented in Table 2. A36, 16 280 150 mm plates. ter of the weld. The relative quantities of
All electrodes had 3.25-mm diameters Qualified AWS D3.6 Class B welders microconstituents were determined by
and were 350 mm long. Commercial elec- carried out the open sea welding tests. The counting points, applying a grid of 100
trodes 2C and 3C were provided with a power source was an electronic constant points over images with 500 magnifica-
waterproof coating; however, the manu- current characteristic, specially built for tion. The grain size in the FGR was deter-
facturers did not disclose the composition wet welding, operating on DCEN at a mined by the intersection method with
and application techniques. The electrode nominal 160 A. The weld beads were de- 500 magnification.
1C and the experimental electrodes were posited in V grooves with backing, an Energy X-ray dispersive spectroscopy
coated by dipping in a vinyl varnish. Elec- opening angle of 45 deg, a root opening of (EDS) was used to determine the chemi-
trodes steel rods and base metal composi- 10 mm, and a root face of 3 mm. Base ma- cal composition of at least 6 inclusions
tions are presented in Table 3. terials were ASTM AH36 16 280 150 with diameters between 4 and 8 m.
In the laboratory, welding tests were mm plates. Vickers hardness loads of 1 and 10 kgf
carried out with a welding power source A gas chromatography analyzer carried were used to measure the weld metal
operating on direct current electrode neg- out the diffusible hydrogen measurements hardness. The all-weld tensile tests were
ative (DCEN) at a nominal 160 A. A tank according to AWS A4.3, ASTM E260, and prepared in accordance with AWS
with capacity of 200 L was used for the E355. All samples were welded at 0.5 m. D3.6M:1999. The samples were 5 mm in
welds at 0.5 m water depth. A hyperbaric The chemical composition (except oxy- diameter and had a 25-mm gauge length,
welding simulator was used for the welds gen) was defined using optical emission or dimensions that are indicated in the
of 10 m and 20 m equivalent depth. All the spectrometry. A gas analyzer (LECO) was table footnotes.
welds were carried out in fresh water with used for the oxygen content. In the laboratory welding tests, 5000
a mechanized gravity system and using the Metallographic preparation was car- voltage and current readings were ac-
drag technique in the flat position and ried out by conventional polishing and quired between the 10th and 15th second.
with an electrode angle of 60 deg. The etching techniques. The quantities of the The following parameters were calculated:
welding voltage and current were moni- weld metal columnar region (CR), coarse average current (Iave), average voltage
tored by an acquisition system with a rate grain reheated region (CGR), and fine (Vave), current arc stability index (Si), volt-

age arc stability index (Sv), and indicative electrodes. Despite the variations of rutile Microstructural Aspects
number of short circuits (Nsc). The pa- and iron oxide contents, there was not a sig-
rameter Si is defined as the ratio of maxi- nificant change in the weld metal chemical The quantitative results of microstruc-
mum to minimum values of current. composition for the experimental elec- tural characterization for the experimental
Similarly, for voltage, the values of Sv are trodes. The low contents of Mn and Si, electrodes (1E to 8E) are listed in Table 6.
defined as the ratio of maximum to mini- which are deoxidizer elements, are charac- The columnar region is formed predomi-
mum values of voltage. The following ap- teristic of oxidizing-type electrodes (Refs. nantly by proeutectoid ferrite for all elec-
proach was used to calculate the values of 36, 12, 13). Rutile electrodes 2C and 3C trodes. Some regions of polygonal ferrite
S: for each 10 points (0.01 second), values had higher Si and Mn contents compared to and side plate ferrite can also be observed.
of current were taken and the maximum the high oxygen potential electrode 1C and This fact is a consequence of the low carbon,
current (Imax) was divided by the mini- the experimental electrodes. Electrodes 2C manganese, and silicon contents, which are
mum current (Imin) obtaining 500 values and 3C had consistently lower oxygen con- characteristic of oxidizing-type electrodes.
of S for each weld. With these values, the tents in the weld metal. No significant microstructural differences
average S was calculated. A short circuit were observed between the experimental
was assumed when any voltage value was
numerically lower than 5 V.
Geometrical bead reinforcement Table 4 Diffusible Hydrogen Measured from Samples Welded at 0.5 m Water Depth
(R/W) and penetration (P/W) aspect ra- (mL/100 g)
tios related to the bead width (W) were
measured on transverse sections of the Electrode Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Average
bead on plate trials. 1E 21.0 24.7 19.2 21.6
2E 13.3 15.7 11.3 13.4
Results 3E 25.6 34.3 33.1 23.3 22.7 27.8
4E 26.8 13.6 17.3 17.6 18.8
Phase 1 Electrodes 1E to 8E 5E 17.4 19.4 20.3 19.0
(Tests at 0.5 m) 6E 16.6 13.4 16.2 23.9 17.5
WELDING RESEARCH
7E 15.4 21.4 28.1 16.3 30.3 22.3
Diffusible Hydrogen. The results of dif- 8E 40.4 56.2 20.9 25.2 32.7 35.1
fusible hydrogen measurements at 0.5 m 1C 18.7 24.5 18.1 20.4
for the experimental electrodes (1E to 8E) 2C 85.1 105.2 78.9 72.3 85.4
are listed in Table 4. For comparison, re- 3C 98.8 101.4 91.4 97.2
sults for commercial electrodes are pre-
sented in the same table: typical rutile (2C
and 3C) and oxidizing (1C) electrodes. Table 5 Weld Metal Chemical Composition (wt-%)
Diffusible hydrogen values from the ex-
perimental electrodes are much lower
Electrode Mn Si P S C O Ni
than the rutile electrodes and near to the
oxidizing electrode values. The influence 1E 0.041 0.013 0.016 0.010 0.012 0.270 0.019
of the coating rutile content on the dif- 2E 0.041 0.012 0.015 0.008 0.022 0.242 0.021
fusible hydrogen for the experimental 3E 0.046 0.014 0.016 0.008 0.015 0.310 0.112
electrodes is shown in Fig. 1. As the 4E 0.072 0.070 0.019 0.009 0.016 0.320 0.029
TiO2/(Fe2O3 + SiO2) ratio increases, 5E 0.047 0.008 0.023 0.008 0.019 0.267 0.019
there is a tendency for the diffusible hy- 6E 0.049 0.015 0.021 0.031 0.011 0.255 0.024
7E 0.064 0.034 0.036 0.014 0.013 0.264 0.025
drogen to increase.
8E 0.044 0.009 0.025 0.007 0.014 0.276 0.019
1C 0.033 0.010 0.015 0.007 0.055 0.261 2.020
Weld Metal Chemical Composition
2C 0.513 0.384 0.014 0.009 0.070 0.092 0.069
3C 0.343 0.199 0.026 0.007 0.090 0.11 0.026
Table 5 lists the results of the weld metal
chemical composition for experimental (a) Welding depth: 0.5 m.
electrodes and, for comparison, commercial
Table 6 Quantitative Microstructural Characterization
Electrode PEF + PF + SPF

in the CR (%) CR (%)b CGR (%)b FGR (%)b FGS (m)
Average St. Dev
1E 100 25 13 62 8.0 1.8
2E 100 37 10 53 8.8 1.9
3E 100 27 9 64 7.3 1.5
4E 100 31 10 59 8.3 1.7
5E 100 26 9 65 6.9 1.4
6E 100 27 16 57 10.2 2.2
7E 100 38 10 52 7.3 1.1
8E 100 37 15 48 5.6 1.1
CR: columnar region. CGR: coarse-grain region in reheated zone. FGR: fine-grain region in reheated zone. PEF: pro-eutectoid ferrite. PF: polygonal ferrite. SPF: side plate ferrite. FGS: grain diame-
ter in FGR.
(a) Welding depth: 0.5 m.
(b) Average for 3 transversal sections.

Fig. 7 Charpy results of oxyrutile electrodes compared with the ones avail- Fig. 8 Elongation results of oxyrutile electrodes compared with the ones
able in the technical literature (Refs. 1, 3, 4, 6, 7, 12, 27, 28, 33, 36, 3841, available in the technical literature (Refs. 1, 3, 4, 7, 12, 27, 28, 33, 36, 3843).
43). Oxyrutile data for 10 and 20 m are from WWC project. Oxyrutile data for 10 and 20 m are from WWC project. Minimum requirements
for high-strength steels (HSS) and low-strength steels (LSS) are represented by
dashed lines.
electrodes. The exception is the variation of Analysis of Nonmetallic Inclusions potential of these electrodes. The group
the grain size in the fine-grain region, which represented by the experimental and com-
may be attributed to variations in welding The results of EDS analysis are sum- mercial 1C electrodes has high Fe and al-
parameters and conditions. Representative marized in Table 8. For comparison, the most no Ti, indicating high oxidizing
WELDING RESEARCH
images of the microstructures are shown in results of the commercial electrodes are potential during welding. The additions of
Fig. 2. A large amount of nonmetallic inclu- also tabulated. Two groups of electrodes rutile did not induce a measurable effect
sions can be observed. The fine-grain region can be identified. The group represented on the composition of the inclusions, since
corresponds to the major part of the weld by the commercial rutile electrodes 2C it was not possible to identify significant
metal for all experimental electrodes. and 3C has high Mn, Si, and Ti and low Fe differences between the results of elec-
contents according to the lower oxidizing trodes 1E to 8E.
Mechanical Properties
The average hardness and Charpy val-

Table 7 Weld Metal Hardness and Toughness
ues are listed in Table 7. The low hardness
and toughness values are typical of oxidiz-
ing-type electrodes. No consistent influ- Hardness (HV1) Charpy V 0C (J)
ence of rutile contents on hardness could Electrode Average St. Dev. Average St. Dev.
be noticed. Toughness seems to be slightly 1E 174 5 22.6 3.3
increased with increasing rutile content. 2E 152 2 15.0 1.5
These results are in agreement with mi- 3E 180 10 30.4 7.7
crostructural analysis, which shows a non- 4E 153 2 21.3 6.3
significant influence of rutile content in 5E 162 6 27.1 10.0
the microstructure. The small variation of 6E 148 4 22.6 5.1
toughness may be attributed to a small de- 7E 152 1 25.5 4.3
crease of the grain size in the FGR with 8E 179 7 37.3 6.8
increasing rutile content.
Table 8 Chemical Composition of Inclusions in the Weld Metal for Experimental and Commercial Electrodes(a) (wt-%)
Fe Mn Si Ti O
St. St. St. St. St.
Electrode Average Dev. Average Dev. Average Dev. Average Dev. Average Dev.
1E 66.3 4.2 3.5 0.9 4.8 2.2 0.0 25.5 1.4
2E 65.7 6.6 3.3 1.5 6.3 3.0 0.0 25.8 2.0
3E 66.6 3.9 4.6 1.1 3.9 1.9 0.0 24.9 1.2
4E 59.9 7.0 6.3 3.3 6.8 2.7 0.0 26.9 1.8
5E 54.7 10.0 6.7 1.9 9.7 5.1 0.0 28.8 3.3
6E 65.5 6.7 4.6 1.3 4.6 3.3 0.0 25.3 2.2
7E 64.7 4.0 5.9 1.9 4.0 1.3 0.0 25.0 0.9
8E 59.2 11.1 6.4 3.3 7.3 4.8 0.0 27.1 3.2
1C 55.8 7.6 7.3 2.7 8.5 3.1 0.0 28.3 2.0
2C 11.8 5.6 24.1 1.5 15.7 4.2 11.9 5.5 36.4 2.3
3C 12.5 5.5 20.7 2.9 20.7 5.5 7.3 2.5 38.3 3.1

The main requirement for selecting the 9. Although the electrode 2E (Table 4)
best performance electrode in Phase 1 was had the lowest diffusible hydrogen result
the diffusible hydrogen content. There- (13.4 mL/100 g), the electrode 6E (17.5
fore, to compare operational features mL/100 g) was selected as the basis for
only, the four lowest Hdif electrodes were Phase 2 based on its better operational
considered. The results are listed in Table performance, as indicated by lower Nsc
and higher Vave and P/W. The higher ru-
tile content in the coating was also consid-
Table 9 Operability Parameters for the ered an important feature of the electrode
Lowest Diffusible Hydrogen Electrodes 6E. The other weld metal properties (Ta-
bles 4 to 8) in general did not show suffi-
cient differences between the
2E 4E 5E 6E
experimental electrodes to influence the
final choice.
Vave 22 25 20 27
Iave 161 162 166 160 Fig. 9 Porosity results of oxyrutile electrodes
Phase 2 Electrodes 1A to 10A compared with the ones available in the technical
Sv 2.0 1.6 2.2 1.6
(Tests at 10 m) literature (Refs. 12, 18, 33, 27, 43). Oxyrutile data
Si 1.5 1.7 1.4 1.5
Nsc/5s 95 36 215 10 are from WWC project.
R/W 0.18 0.17 0.23 0.16 The typical weld metal surface and
P/W 0.15 0.18 0.18 0.24 transverse aspects for experimental oxyru-
tile electrodes (8A) and for commercial
Table 10 Weld Metal Properties of V-Grooved Joints Welded in the Laboratory at 10-m Simulated Depth Except for Diffusible Hydrogen Tests,
which Samples Were Welded at 0.5 m
WELDING RESEARCH
Electr. Y.S. U.T.S. Elong. Hardness (HV10)(b) Charpy V 0C (J)(c) Side Bend Porosity Hdif (mL/100 g)(c)
(MPa)(a) (MPa)(a) (%)(a) (%)
Aver. Min/Max Aver. Min/Max 2T(d) Aver. Min/Max
1A 398 462 19.0 172 158/180 50 48/51 4/5 0.14 20.9 14.6/30.6
2A 399 464 13.8 155 151/157 58 56/61 4/7 0.13 18.8 15.6/24.0
399 461 18.4
3A 407 482 20.0 190 174/220 52 48/54 4/4 0.021
417 479 18.8
4A 421 486 16.4 180 172/190 5/6 0.15 21.4 14.5/28.7
427 493 20.00
5A 410 483 27.2 187 172/206 50 48/52 0.09
6A 437 505 16.4 181 173/186 1/4 0.03 20.7 16.0/27.7
7A 423 493 15.6 193 172/226 54 52/56 0.06
441 504 23.4
8A 412 534 18.8 184 177/190 46 46/46 0/4 0.28 50.0 27.1/71.1
464 487 8.6
9A 441 515 16.0 174 171/177 2/5 0.26 30.8 20.2/53.8
463 533 21.6
440 513 23.0
10A 434 496 10.2 194 184/218 51 50/54 0.014
(a) All-weld-metal tension tests for each specimen. Lowest elongation values correspond to a higher incidence of weld defects in the tensile specimen.
(b) Average of five indentations minimum.
(c) Average for three specimens minimum. Samples welded at 0.5 m.
(d) Number of approvals/number of tests.
Table 11 Chemical Composition (wt-%),Amount of Fine Grain Region (area %) and Minimum Grain Size (m) in the Weld Metal
Electrode
1A 2A 3A 4A 5A 6A 7A 8A 9A 10A
C 0.052 0.024 0.031 0.054 0.034 0.048 0.027 0.037 0.053 0.040
Si 0.009 0.018 0.010 0.014 0.011 0.015 0.022 0.016 0.016 0.019
Mn 0.048 0.048 0.048 0.046 0.047 0.046 0.058 0.049 0.047 0.057
Ni 2.01 1.82 2.70 2.55 1.98 2.55 2.17 2.56 2.37 2.52
Mo 0.00 0.00 0.00 0.05 0.09 0.10 0.125 0.11 0.18 0.20
FGR (area %) 76 87 69 81 74 75 56 79
FGS (m) Average 3.9 3.7 3.7 2.9 3.1 2.8 3.0 3.1 3.1
Std. Dev. 0.7 0.4 0.3 0.3 0.4 0.3 0.3 0.4 0.4
P content range: 0.016 to 0.044 wt-%

S content range: 0.008 to 0.015 wt-%
(a) Multipass V-grooved joints welded in laboratory at 10 m simulated depth.

Table 12 Weld Metal Mechanical Properties of Multipass V Butt Jointsf
Electrode Y.S. U.T.S. Elong Rupture Stress Hardness Charpy V Side Bend Side Bend
(MPa)(a) (MPa)(a) (%)(a) (MPa)(b) (HV10)(c) 0C (J)(d) 22/3T(e) 6T(e)
9A 488 547 14.4 527/515 221 42.3 2/4 4/4
Min Max Min Max
201 229 38 46
2C 488 506 6.4 527/494 223 44.0 0/4 4/4
Min Max Min Max
194 250 42 47
(a) All-weld-metal tension tests for each specimen.

(b) Transversal tensile test.
(c) Average of five indentations minimum.
(d) Average for three specimens minimum.
(e) Number of approvals/number of tests.
(f) Welding at open sea down to 10 m.
Table 13 Weld Metal Microstructural Characterization on Multipass V Butt Joints(d)
Electr. Cracks Porosity Weld metal regions Weld metal micro-constituents FGS (m)
(number per cm2) (%) (%) (%)
CR CGR FGR AF PEF FSP PF AFC Aver. Std. Dev.
9A 0.0 0.09 2 30 68 3.4 2.8 1.0 89.0 3.8 2.3 0.3
2C 62.0 0.32 30 27 43 21.3 22.3 2.8 51.8 1.7 3.0 0.4
WELDING RESEARCH
CR: Columnar region; CGR: Coarse-grain region; FGR: Fine-grain region; AF: Acicular ferrite;
PEF: Pro-eutectoid ferrite; FSP: Ferrite with second phase; PF: Polygonal ferrite. FGS: Ferritic grain size in the FGR
(a) Welding at open sea down to 10 m.
rutile-type electrodes (2C) are shown in pressure in the range studied. UTS requirement for E70XX class, as
Fig. 3. The weld made with electrode 2C An evaluation of the incidences of hy- shown in Table 10. Tables 12 and 13 list the
exhibited a superior bead surface and a drogen cracks in the weld metal as a func- mechanical properties and microstructural
higher porosity level. tion of pressure was carried out by manual characterization related to the joints
Table 10 lists some selected weld metal counting on transversal sections micro- welded by divers down to 10 m, respec-
properties emphasizing mechanical proper- scopic images. The results are shown in tively. Both electrodes had tensile strength
ties related to the project phases in which Fig. 5. It is interesting to note the sharp higher than 490 MPa compatible with
the main target was the improvement of decrease of crack incidences with depth E70XX class. The commercial electrode
strength, ductility, and toughness by adding for rutile type electrodes particularly for 2C had low ductility. The bending test re-
alloying elements and keeping diffusible hy- electrode 3C. The lower crack incidence sults for both electrodes satisfied the AWS
drogen and porosity at low levels. The ulti- for electrode 3C compared to electrode D3.6M:2010 Class B requirements but not
mate tensile strength (UTS) and elongation 2C in the welding at 10 m was consistent the Class A requirements. The fine-grain
results are mostly higher than 490 MPa and with its lower weld metal hardness (~164 region was the predominant region for the
14%, respectively, which are the minimum HV10). The value obtained for electrode electrode 9A in both field and laboratory
levels required for AWS D3.6 Class A 2C was ~209 HV10. Moreover, diffusible tests. Figure 6 shows macrographs for both
welds. Hardness and Charpy tests data con- hydrogen for rutile electrodes is consid- electrodes in which lower porosity and
formed to the same criteria. The rather un- ered to decrease with increasing pressure smaller amount of columnar regions are
usually low porosity and diffusible hydrogen (Ref. 34). Diffusible hydrogen and hard- related to electrode 9A.
levels responsible for obtaining elongation ness are assumed to be the main control-
values in the order of 20% should be noted. ling factors of weld metal cracking in wet Discussion
Approval in the bend tests according to the welding. As a general tendency in this
AWS D3.6 Class A criteria were not consis- work, it is pointed out that oxidizing and Regarding the development of an opti-
tently achieved. Failures occurred from oxyrutile electrodes showed lower inci- mized base composition of an oxyrutile
small defects such as pores despite the good dence of weld metal microcracks. A survey electrode (objective of Phase 1), the tests
weld metal ductility. for weld metal microcracks in all the Phase performed at 0.5-m water depth indicated
The weld metal chemical compositions 2 samples welded at 10 m with oxyrutile a composition in which the rutile oxide
as well as the main microstructural fea- electrodes revealed practically no cracks. content was maximized without changing
tures responsible for promoting strength, significantly the Hdif comparing to a typi-
toughness, and ductility are presented in Results of Open Sea Tests cal oxidizing commercial electrode (both
Table 11. High amounts of the fine-grain are in the order of 20 mL/100 g). These re-
region can be observed. Small grain size in Electrodes 2C and 9A were selected sults are in accordance with results ob-
the reheated zone indicates the beneficial for the open sea tests aiming for prequal- tained by other authors (Refs. 36, 1317)
effects of Ni and Mo alloying made in the ification of procedures with both types of and accredit oxyrutile electrodes for weld-
Phase 2 of the project. electrodes for welding high-strength struc- ing higher carbon equivalent and carbon
Figure 4 shows the influence of equiv- tural ship steels. The electrode 9A was content steels without hydrogen cracking
alent water depth on porosity for selected chosen because it produced welds in labo- compared to rutile electrodes. Regardless
electrodes. The experimental electrodes ratory with UTS above 513 MPa and good of the different rutile contents in the coat-
show very little sensitivity to increasing elongation results, reaching reliably the ings of electrodes 1E to 8E, no significant

changes in the weld metal and nonmetallic under real conditions of the oxyrutile elec- known that good elongation results con-
inclusions in the chemical composition trodes developed in this project. For this stitute the strongest barrier to produce
were observed, as well as no observable purpose, more welding trials with divers structural quality welds at any depth. In
changes in the microstructural features. will soon be performed. this literature survey, the 14% minimum
Hardness and toughness seemed to show a The ductility of the experimental elec- elongation established by D3.6M:2010 for
small increase with rutile content, but the trode 9A measured by elongation and high-strength steels has not been consis-
data were limited in extent and may not be bending results indicates an enhancement tently reported until now Fig. 8. Also
statistically significant. However, this was in the achievable quality of wet welding depicted in Fig. 8, three events for rutile
not considered to be an important factor compared to the state of the art. At this electrodes and ten for oxidizing electrodes
for electrode selection in this phase of the stage of the project, the bending test is can be observed above the 14% border-
work. As the only powerful strengthening considered the main barrier to butt joint line. Nevertheless, despite the high scat-
mechanisms for high-oxygen weld metals weld procedure qualifications in AWS tering caused by the presence of defects in
in wet welding are grain refinement and D3.6 Class A. some tensile specimens, most of the oxi-
solid solution, electrode selection criteria The low ductility, typical of rutile wet rutile results reported (~80%) exceeded
were restricted to diffusible hydrogen and weld metal deposits in shallow waters, re- the 14% borderline, demonstrating an in-
operability. In view of these two proper- ported by several authors (Refs. 7, 9, 28, creased feasibility of obtaining qualifica-
ties, the electrode 6E was selected as the 33) and confirmed in this project, is at- tion in Class A. Regarding porosity, the
basis for the composition development in tributed mainly to the presence of trans- very low values for oxyrutile electrodes
Phase 2. verse microcracks in the weld metal (Refs. seem to be strongly associated to their low
In terms of improving the mechanical 12, 13). The cracking phenomenon tends diffusible hydrogen content. Regardless of
properties, the addition of the alloying el- to diminish with increasing pressure ac- the method used by other authors to meas-
ements Ni and Mo to the weld metal was cording to Fig. 5. Two factors may explain ure the porosity, it can be assumed that the
successful for most electrode batches as this feature: 1) the reduction of the dif- results presented in Fig. 9 distinguish the
shown in Table 10. The toughness meas- fusible hydrogen, and 2) the reduction of oxyrutile electrodes from the others. It is
ured by Charpy energy exceeds the limits the weld metal hardness and yield strength also important to note the repeatability in
required by the AWS D3.6M:2010, Under- caused by the Mn and Si losses. Ando and the porosity results obtained for oxyrutile
WELDING RESEARCH
water Welding Code. The tensile strength Asahina (Ref. 34) reported that diffusible electrodes and the high agreement with
results show that it is possible to overcome hydrogen decreases and porosity increases the results obtained in the open sea tests
the lower boundary value of 490 MPa re- with increasing pressure and a pore gas (Table 13). In summary, toughness, elon-
quired for class E70XX. Considering the composition of almost 100% hydrogen was gation, and porosity results related to
achievement of Class A welds, the ductil- observed. Consistently, Santos et al. (Ref. oxyrutile electrodes are consistently better
ity results, expressed by elongation and 12) reported a decrease in the incidence of compared to the rutile-type electrodes.
bending, are promising. For the base metal HAZ hydrogen cracks with increasing The most significant progress achieved in
yield strength higher than 350 MPa, the pressure. So, the occurrence of cold crack- this work is the consistent set of elonga-
minimum limits for the values of elonga- ing both in the weld metal and HAZ tion results opening up new possibilities
tion (14%) and bending (180 deg) were seems to be dependent on the porosity. for qualification in Class A. Low porosity
mostly achieved. These good results of The present results (Figs. 4, 5) suggest that and absence of microcracks are under-
ductility are associated not only to the high the hydrogen trapping in the pores is the stood here to be the main features re-
portion of the reheated region and small main mechanism responsible for this. The sponsible for this breakthrough.
grain size (Table 11), but also to the low pores can operate as sinks for the hydro-
porosity and absence of cracks in the weld gen atoms during their movement to the Conclusions
metal as shown in Table 10 and Figs. 35. metal surface and HAZ, thereby reducing
The open sea results shown in Table 13 the amount of available hydrogen for the The diffusible hydrogen content of
are useful to point out significant differ- cold cracking process. about 20 mL/100 g achieved in the develop-
ences between microstructural features for In order to demonstrate the signifi- ment of oxyrutile electrodes is approxi-
rutile and oxyrutile electrodes tested in cance of the present results to the state of mately equivalent to the content of typical
this project. In the oxyrutile type, the very art in wet welding, plots of some critical oxidizing electrodes and considerably lower
low content of acicular ferrite is counter- properties (toughness, ductility, and than the typical contents of the rutile-type
balanced by the higher proportion of the porosity, Figs. 7 to 9, respectively) were electrodes. Low porosity and the absence of
fine-grain region and polygonal ferrite. made. In these figures, results for the ex- weld metal microcracks were consequently
According to Table 12, both electrodes perimental electrodes 1A to 10A are com- achieved as well as enhanced operability re-
tested in the open sea had tensile strength, pared to data collected from the literature. lated to the commercial oxidizing electrode.
hardness, and toughness results compati- Regarding Charpy results, it is well known In Phase 1, all-weld-metal-compositions
ble to electrodes class E70XX and the re- that toughness has not been a significant had low Mn and Si and high oxygen con-
quirements of AWSD3.6M:2010 Class A. problem in wet welding in shallow waters, tents as well as iron-rich inclusions. These
It is well known that especially in wet as confirmed in Fig. 7. In this present lit- features are typical of high oxidizing poten-
welding, the properties of the weldments erature survey, the commonly adopted tial electrodes and similar to those observed
depend strongly on several operational minimum of 27 J is exceeded for all rutile for the commercial oxidizing electrode
factors, such as welders skills, sea condi- and oxyrutile electrodes. Oxidizing and tested. The additions of Ni and/or Mo were
tions, visibility, and other factors. The acid electrodes sometimes failed. The re- effective in strengthening the weld metal.
open sea test results were similar to the sults for oxyrutile electrodes were in gen- Based on the present results, class E70XX
laboratory test results, suggesting that the eral the highest and, despite the scattering electrodes for wet welding can be manufac-
properties of the oxyrutile electrodes de- presented in the results at 10 m, are con- tured. In general, compared to the results
veloped are reproducible and consistent sistent regarding the possibility of obtain- obtained in the literature, the electrodes de-
with laboratory results at depths up to 10 ing Class A welds. The lowest result (46 J) veloped here showed lower porosity and
m. Nevertheless, considering their limited is probably related to higher porosity and presented superior performance in terms of
number, other welding trials at sea are diffusible hydrogen contents, according to toughness (Charpy energy) and ductility
necessary to assure the performance Table 10. Regarding ductility, it is well (elongation).

The elongation results represent the R., Domingues, J. R., and Vieira, L. A. 2010. 26. Pope, A. M., Liu, S., Teixeira, J. C. G.,
most significant contribution of the pres- Recent evaluation and development of elec- Santos, V. R., and Paes, M. T. P. 1995. Use of
ent work in the search for upgraded weld trodes for wet welding of structural ship steels. nickel to improve the mechanical properties of
Proceedings of the 29th International Conference high oxygen underwater wet welds, OMAE,
metal mechanical properties, focusing on
on Ocean, Offshore and Arctic Engineering. Materials Engineering 3: 102117.
wet welding of structural ship steels in Shanghai, China. 27. Santos, V. R., Teixeira, J. C., Piza, M. T.
shallow waters. 13. Bracarense, A. Q., Pessoa, E. C. P., San- P., and Szelagowski, P. 1992. Final report on
tos, V. R., Monteiro, M. J., Rizzo, F. C., Pa- project UWT 8, wet welding. German/Brazilian
Acknowledgments ciornik, S., Reppold, R., Domingues, J. R., and Cooperation in Scientific Research and Tech-
Vieira, L. A. 2008. Comparative study of com- nological Development, Rio de Janeiro, Brazil
The authors wish to express their grat- mercial electrodes for underwater wet welding, 28. SSC-370. Underwater Repair Procedures for
IIW International Congress 2nd Latin Ameri- Ship Hulls. 1993. Fatigue and Ductility of Under-
itude to professors Sidnei Paciornick and
can Welding Congress XXXIV CONSOLDA, water Wet Welds Ship Structure Committee.
Marcos Henrique de Pinho Maurcio from Congresso Nacional de Soldagem, So Paulo, 29. Perez, F., Liu, S., Smith, C., and Ro-
PUC-Rio for images acquisition and pro- Brazil. drigues, E. 2003. Effect of nickel on toughness
cessing; Continental Servios Martimos 14. Pope, A. M., and Liu, S. 1996. Hydrogen of underwater wet welds. Proceeding of OMAE
Ltd. for the diving resources in the open content of underwater wet welds deposited by 2003-37291, 22nd International Conference on
sea tests; and the Brazilian Council for Sci- rutile and oxidizing electrodes. Proc. Conf. Offshore Mechanics and Arctic Engineering,
entific and Technological Development OMAE 96, American Society of Mechanical En- American Society of Mechanical Engineers.
CNPq for graduate scholarships. gineers 3: 8592. 30. Murzin, V., and Russo, V. L. 1994. Man-
15. Medeiros, R.C., and Liu, S. 1998. A pre- ual underwater welding structures of steel with
dictive electrochemical model for weld metal higher strength. Welding International 8(1).
References hydrogen pickup in underwater wet welds. 31. Ozaki, H., Naiman, J., and Masubuchi,
ASME Journal of Offshore Mechanics and Arctic K. 1977. A study of hydrogen cracking in un-
Engineering 120(4): 243248. derwater steel welds. Welding Journal 56(8):
1. Marinho, M. G., Pope, A. M., Meniconi, 16. Pope, A. M., Medeiros, R. C., and Liu, S. 231-s to 237-s.
L. C., Alves, L. H. M., and Delvechio, C. 2005. 1995. Solidification of underwater wet welds. 32. Kinugawa, J., Fukushima, S., and
Integrity assessment and on-site repair of a Proceeding Offshore Mechanics and Arctic Engi- Fukushima, T. 1982. Influence of equivalent car-
floating production platform. 24th International neering Conference. Copenhagen, Denmark. bon content of steels on proportions of marten-
WELDING RESEARCH
Conference on Offshore Mechanics and Arctic 17. Pope, A. M. 1995. Oxygen and hydrogen site, hardness and susceptibility to cold cracking
Engineering OMAE, paper 67504, Halkidiki, control in shielded metal underwater wet weld- at coarse-grained regions in underwater wet
Greece. ing, PhD dissertation, Metallurgical and Mate- welding. Transaction of National Research Insti-
2. Underwater Welding Code, ANSI/AWS rials Engineering Department, Colorado tute of Metals 24(3): 125133.
D3.6M:2010, American Welding Society, Doral, School of Mines, Golden, Colo. 33. Rowe, M. D., and Liu, S. 2001. Recent
Fla. 18. Suga, Y., and Hasui, A. 1986. On the for- developments in underwater wet welding. Sci-
3. Stalker, A. W. 1977. Underwater Welding mation of porosity in underwater weld metal. ence and Technology of Welding and Joining 6(6):
for Offshore Installations. Welding Institute Re- IIW Doc. IX 1388, 86. 387396.
search on Underwater Welding. The Welding 19. Pessoa, E. C. P., Bracarense, A. Q., Liu, 34. Ando, S. E., and Asahina, T. 1983. A
Institute: 6374. S., Guerrero, F. P., and Zica, E. M. 2006. Poros- study on the metallurgical properties of steel
4. Nbrega, A. F. 1981. Study of underwater ity variation along multipass underwater wet welds with underwater gravity welding, Under-
welding with covered electrodes. MSc disserta- welds and its influence on mechanical proper- water Welding, IIW Conference. Trondheim.
tion. Federal University of Rio de Janeiro, ties. Journal of Materials Processing Technology, Pergamun Press, pp. 255261.
Brazil (in Portuguese). Elsevier, 179: 239243. 35. Rowe, M. D., Liu, S., and Reynolds, T. J.
5. Gooch, T. G. 1983. Properties of under- 20. Perez, F. 2007. The mechanism of poros- 2002. The effect of ferro-alloy additions and
water welds. Part 1: Procedural trials. Metal ity formation in underwater wet welds using depth on the quality of underwater wet welds.
Construction (3): 164167. SMAW process. PhD dissertation, Colorado Welding Journal 81(8): 156-s to 166-s.
6. Gooch, T. G. 1983. Properties of under- School of Mines, Golden, Colo. 36. SSC335, Ship Structure Committee, Per-
water welds. Part 2: Mechanical properties. 21. Pessoa, E. C. P., Bracarense, A. Q., and formance of Underwater Weldments, 1990.
Metal Construction (4): 206216. Liu, S. 2007. Exothermic additions in a tubular 37. Szelagowski, P., Pachniuk, I., and Stuhff,
7. West, T. C., Mitchell, G., and Lindberg, E. covered electrode and oxidizing reactions influ- H. 1992. Wet welding for platform repair. Pro-
1990. Wet welding electrode evaluation for ship ence on underwater wet welding. 26th Interna- ceedings Second International Offshore and Polar
repair. Welding Journal 69(8): 48. tional Conference on Offshore Mechanics and Engineering Conference. San Francisco, Calif.
8. Liu, S., Olson, D. L., and Ibarra, S. 1994. Arctic Engineering, OMAE. International Society of Offshore and Polar En-
Electrode formulation to reduce weld metal hy- 22. Pessoa, E. C. P., Bracarense, A. Q., and gineers (ISOPE), Golden, Colo., pp. 208215.
drogen and porosity. Proceedings 13th Offshore Liu, S. 2008. Estudo do comportamento da 38. Grubbs, C., and Reynolds, T. 1998. State-
Mechanics and Arctic Engineering Conference porosidade ao longo de soldas subaquticas of-the-art underwater welding. World Oil (7):
OMAE. Copenhagen, Denmark, pp. 291298. molhadas multipasses. Metalurgia e Materiais 7983.
9. Ibarra, S., Reed, R. L., Smith, J. K., Pach- 64: 150152. 39. Grubbs, C., and Reynolds, T. 1999. Un-
niuk, I., and Grubbs, C. 1991. Underwater wet 23. Andrade, L. G. D., Silva, W. C. D., derwater wet welding. Underwater, Winter, pp.
welding repair of an offshore platform in the Ribeiro, L. F., Pessoa, E. C. P., Bracarense, A. 5255.
North Sea. Proceedings of the First International Q., and Liu, S. 2010. The effect of base metal 40. Nbrega, A. F. 1977. Soldagem subma-
Offshore and Polar Engineering Conference. Edin- and core rod carbon content on underwater wet rina. Boletim Tcnico da Petrobras 20(3):
burgh, UK, pp. 339346. weld porosity. Proceedings of the 29th Interna- 205219 (in Portuguese).
10. Sanchez-Osio, A., Liu, S., Ibarra, S., and tional Conference on Ocean, Offshore and Arctic 41. Kim, Min-Nam. 2003. A study on the de-
Olson, D. L. 1995. Designing shielded metal arc Engineering. velopment of underwater wet welding elec-
consumables for underwater wet welding in off- 24. Ibarra, S., Olson, D. L., and Grubbs, C. trodes. Journal of Ocean Engineering and
shore applications. J. Offshore Mech. Arctic Eng, E. 1989. Underwater wet welding of higher Technology 17(4): 5258.
117(3): 212220. strength offshore steels. 21st Annual Offshore 42. Silva, E. A., and Hazlett, T. H. 1971.
11. Liu, S., Pope, A. M., and Daemen, R. Technology Conference, Paper OTC 5898, Hous- Shielded metal arc welding underwater with iron
1994. Welding consumables and weldability. In- ton, Tex. powder electrodes. Welding Journal 50(6): 406.
ternational Workshop on Underwater Welding of 25. Kim, M. A. 2003. Study on the develop- 43. Working Group. 2010. Underwater Weld-
Marine Structures, La., pp. 321350. ment of underwater wet welding electrodes. ing Consumables Development, State of the Art,
12. Santos, V. R., Monteiro, M. J., Rizzo, F. Journal of Ocean Engineering and Technology Science, and Reliability of Underwater Welding
C., Bracarense, A. Q., Pessoa, E. C. P., Reppold, 17(4): 5258. and Inspection Technology. Houston, Tex.

Zhang Supplement Part 2 December 2012_Layout 1 11/9/12 1:26 PM Page 329
Modeling of Human Welder Response to

3D Weld Pool Surface: Part II
Results and Analysis
This paper is devoted to the design of dynamic experiments as well as

use of the resultant data to model and analyze a welders dynamic responses
BY W. J. ZHANG AND Y. M. ZHANG
identify and model the welders responses

ABSTRACT to the dynamic weld pool surface. To this
end, as the second part of the study, this
Understanding and modeling a human welders responses to a 3D weld pool sur- paper is devoted to the design of dynamic
face may help develop intelligent welding robotic systems and train welders faster. experiments as well as use of the resultant
In this first effort on modeling a human welders behavior, a novice welders ad- data to model and analyze a welders dy-
WELDING RESEARCH
justment on the welding current as a response to the 3D weld pool surface as char- namic responses.
acterized by its width, length, and convexity is studied. The first part of the paper The design of the dynamic experiments
used an innovative machine vision system to measure/record in real time the spec- is presented in the experimental method
ular 3D weld pool surface from experiments and conducted preparation experi- section. In the identification method sec-
ments to reduce the inconsistencies in the welders responses as well as determine tion, these methods are briefly introduced.
the welders delay and time intervals of the process response. In this part of the The modeling of the welders responses
paper, experiments are designed to produce random changes in the weld pool using and the analysis of resultant models are
random welding speeds in order to model the response of the welder to a dynamic detailed in the modeling and static re-
weld pool surface. The fluctuating weld pool surface and welders adjustments on sponse analysis parts of the modeling of
the welding current are recorded. Through the least squares algorithm, various response to weld pool surface section, re-
models with different structures are identified to correlate the current adjustment spectively. In the improved modeling and
to the 3D weld pool surface. It is found that the human welders responses are not understanding of human welder response
only related to the 3D weld pool surface but also rely on the welders previous ad- section, based on the analysis for the mod-
justments. The resultant model has been verified by further experiments for its ef- eling of response to weld pool surface sec-
fectiveness in predicting the welders responses. tion, the welders previous responses are
included to improve the response model.
Introduction signed and conducted to improve the To verify the resultant model, further ex-
welders response consistency and deter- periments were conducted, and the verifi-
The goal of this study on human welder mine the welders response time interval cation of the model using the data from
behaviors is to establish a dynamic model as determined by the transition time and those experiments is detailed in the verifi-
for a novice welders adjustment on the response delay. cation and discussion section. The conclu-
welding current in response to the ob- With the improved consistency and sion is drawn in the final section.
served 3D weld pool surface during a com- knowledge about the transition time and
plete-joint-penetration process. That is to welder response delay, the foundation to Experimental Method
establish a model that correlates the model the welders responses were estab-
welders responses (model output) to the lished in Part 1 of the paper. However, dy- In order to identify the model of the
characteristic parameters (inputs) of the namic variations in the welding speed welders dynamic responses to the 3D
3D weld pool surface. In Part 1 of this need to be applied to generate more dy- weld pool surface, dynamic experiments
paper (Ref. 1), the principle of a human namic weld pools in order to accurately with random welding speed variations will
welders behavior was analyzed. A vision- be conducted. These dynamic experi-
based sensing system was used to record in ments should be similar to those con-
real time the human welders responses ducted in the adaptation process. To this
KEYWORDS end, there are five welding speeds to be
and the 3D weld pool geometry character-
ized by three parameters the length, used in the dynamic experiments, as fol-
Human Welders Behavior lows: 1, 1.25, 1.5, 1.75, and 2.0 mm/s.
width, and surface convexity of the weld
Modeling Hence, for each experiment, the welding
pool. Preparation experiments were de-
3D Weld Pool Surface speed is randomly changed among the five
Gas Tungsten Arc Welding welding speeds. To determine how fre-
W. J. ZHANG and Y. M. ZHANG (GTAW)
(ymzhang@engr.uky.edu) are with the Institute quently the speed change should be made,
for Sustainable Manufacturing and Department the average transition time of the welding
of Electrical and Computer Engineering, Univer- process can be used as a reference. From
sity of Kentucky, Lexington, Ky. Part I, the average transition time is 8.7 s,

A B
C D
WELDING RESEARCH
Fig. 1 Identification experiment. A Current and speed; B length, current, and speed; C width, current, and speed; D convexity, current, and speed.
All variables are plotted using the normalized scale. The range for each variable is given in each plot and corresponds to [0, 1] in the normalized scale.
Each experiment speed period is 120 s. The arc length is set

has two periods. The at the same constant in each experiment in
constant speed period [2, 5 mm], i.e., 2, 3, 4, and 5 mm. Other ex-
and random speed pe- perimental settings are shown in Table 1 in
riod use a constant Part I of this paper.
welding speed and a The data from one experiment will be
Fig. 2 Backside weld bead from the identification experiment. randomly changing used to identify the model. This will then
welding speed, respec- be verified using data from all other ex-
tively. The purpose of periments. The arc length used in the
the constant speed pe- identification experiment that produces
including the time delay of the welder, the riod is to allow the human welder to bring the data to identify the model is 3 mm. The
welders response time, and the settling the welding process to the desired com- results of the identification experiment
time of the weld pool. In this sense, the plete-joint-penetration state, and the ran- are shown in Fig. 1. It is found in Fig. 1A
speed change interval should be shorter dom speed period is to produce the dy- that the current controlled by the human
than the transition time, since it is not nec- namic weld pool for the human welder to welder basically follows the tendency of
essary for each speed to last till the weld respond. The duration of the constant the welding speed changes. Since the weld
pool fully resumes its steady state. There- speed period is set at 18 s, long enough to pool dimension varies significantly as the
fore, in this study, the time interval for establish a steady state for the welding welding speed fluctuates, the human
each change is set to be 6 s. process. The duration for the random welder adjusts the current afterward. Fig-
ure 1B and C show that the tendency of the
current adjustment is appropriately oppo-
Table 1 Resultant Models of the Human Welder Response with One Input site to the length and width fluctuation.
The waveform of convexity as shown in
Inputs r Models Fig. 1D basically coincides with the cur-
rent variation. The variations in the weld
Length 1.9023 0.132 ik = 0.070llk4 + 0.20371k5 + 0.2968lk6 1.9215 pool surface geometry and the current in-
Width 1.9068 0.1 ik = 0.2287wk 3 + 0.1376wk4+ 0.2819wk5 0.7828 dicate that the human welder reduces the
current as the weld pool length or width
Convexity 1.8222 0.32 ik = 39.3114hk 3 + 3.2639 hk4 38.3469hk5 0.4715 raises, and increases it as the weld pool

A B
convexity rises. eters selected to de-

Figure 2 shows the backside weld bead scribe the front-side C
obtained from the identification experi- weld pool geometry are
ment. The weld bead width varies approx- the width (w), length
imately periodically. That indicates the (l), and convexity (h).
human welder did not adjust the current That is,
fast and accurately enough to compensate
WELDING RESEARCH
for the effect of the welding speed change = [w l h] (1)
on the weld pool geometry. It needs to
point out that this is, of course, not re- According to the
quired because not every skilled welder principle of a human
could even control the weld bead constant welders behavior de-
under frequent and substantial changes in tailed in Part 1 of this
the welding speed. In this study, this type study, it is reasonable
of variation is produced on purpose in to assume that a welder
order to identify how the welder responds would control the weld-
to the dynamic weld pool surface. ing process such that
the geometric parame-
Identification Method ter set approaches to Fig. 3 Estimation of the welders response using the models with the sin-
the desired dimension gle input. A Estimation using the length; B estimation using the
In the last section, the design of the dy- *: width; C estimation using the convexity.
namic experiments is detailed, and exper-
iments are conducted. Before the welder * = [w* l* h*] (2)
response is modeled using data from these
experiments, the methods for model es- where w*, l*, and h* are his newest observation (k d 1) (the
tablishment used in the field of system the desired parameters for the width, delay is included) from *:
identification (Refs. 2, 3) from experi- length, and convexity, respectively. In this
mental data are introduced in this section. sense, the adjustment on the current (i.e., i(k) = g(1)((k d 1) *)
System identification has been studied the current adjustment, i) made by the + e(k) (3)
for many years and is now a standard welder at the present instant k is to bring where g(1) = [g1w, g1l, g1h] is the gain vec-
method to extract dynamic models (Refs. 2, close to * intuitively, the welder makes tor, and e(k) is the error. More generally,
3). It can be classified into two categories, the adjustment based on the difference of a welder with a minimal skill should not
i.e., continuous time and discrete time.
Human welders always scan the weld pool
with a certain frequency during the welding
process, and the more skilled the human Table 2 Resultant Models of the Human Welder Response with Two Inputs
welder is, the slower frequency of scan is
needed. Therefore, it is reasonable to apply Inputs r Models
discrete identification methods in this study Length + Width 1.8994 0.14 ik = 0.0181lk4 0.4124lk5 + 0.8868lk6
to identify the model of the human welders +0.0316wk4+0.6415wk5 0.6716wk6 2.041
behavior. To determine the data acquisition
frequency, the scan frequency of a human Width + Convexity 1.7406 0.418 ik = 0.7345wk2 + 0.71wk3 0.9675wk4
welder can be considered as a reference. In + 0.9814wk5 + 43.7353hk2 35.8699hk3
this study, the data acquisition frequency se- + 51.3075hk4 54.2302hk5 0.5067
lected is 2 Hz.
Length + Convexity 1.7239 0.436 ik = 1.1.902lk2 + 1.6078lk3 2.0024lk4
Model Structure +1.4957lk5 +55.3252hk2 66.1454hk3 + 79.8977hk4
66.0899hk5 + 0.1113
In this study, the characteristic param-

A B
Identification Method rors, and then select the one with the min-
C imal sum of the squared model errors as
To estimate gains from the model for this number of parameters;
experimental data, Model 5 2) increase the number of parameters and
can be rewritten as use the F test (Ref. 7) to determine if the
i(k) = M, d M, d (k) resultant reduction in the sum of the
WELDING RESEARCH
+ e(k) (7) squared errors due to this increase is sig-

nificant; 3) if significant, increase the
where number of parameters again; otherwise,
the model before the increase gives the
M, d = (, g(1), g(2),..., identified model. Once the model is finally
g(M)) (8) selected/identified, its accuracy is meas-
ured by the standard deviation
M, d (k) = (1, (k d 1),
(k d 2),...,(k d
M)) (9)

(
= J M, d / N d M ) (11)
Identification of the
Fig. 4 Estimation of the welders response using the models with
two inputs. A Estimation using the length and width; B esti- human welders response A time delay has been proposed because
mation using the length and convexity; C estimation using the model is to estimate M, d of the neuromuscular and central nervous
width and convexity. from the experimental data latencies. The existence of this time delay
{i(k), M, d (k)}s (k = d + has been verified and estimated in the first
M + 1, d + M + 2, ..., N). part of the paper. It should be noted that
The most popular parame- this time delay varies according to the phys-
make the adjustment i(k) only based on ter estimation method is the ical health/mental conditions, skill level of
the newest difference (delay is included least squares algorithm (Refs. 46) that the human welder, and other human-
again) but also based on additional minimizes the sum of the squared model dependent and environmental factors. It
previous differences as follows: errors as follows: might vary from time to time during the
N

M J ( ) = min same welding process. Further, the delays
i (k ) = g ( j )( (k d j ) *) M,d

M,d k =d + M +1
for the three weld pool surface characteris-
tic parameters might not be exactly the
j =1
2 same. Also, it might not be an integer in the
+ e (k ) (4) i (k ) M,d M,d (k ) (10) discrete-time model (Ref. 8). However, it
^
w l h
where g(j) = [gj , gj , gj ]s, j = 1, 2, ...M are can be approximated to an integer, which
the gain vectors, and M is the order of the to produce the least square estimate M, d. can be determined through the model iden-
response model. Because * is a constant The standard least squares algorithm can tification process as aforementioned in the
vector, model (4) gives be used to analytically compute ^ M, d and proposed identification method.
the corresponding J( ^
M M, d) from the data
i (k ) = g ( j )(k d j ) {i(k), M, d (k)}s (k = d + M+ 1, d + M Modeling of Response to
j =1
+ 2, ..., N). For a given model order M and Weld Pool Surface
response delay d, its number of parame-
+ + e (k ) (5) ters in ^M, d is known. Modeling
where is a constant Identification of the human welders
M response model is as follows: 1) for a given With the introduction of model structure
= g ( j ) * (6) number of parameters, use the least and identification method in the last sec-
j =1
squares algorithms to calculate all possible tion, the modeling of a human welders re-
models (with different M and d) and cor- sponse from the experimental data is con-
responding sums of the squared model er- ducted in this section.

A B
Fig. 5 Estimation of the welders response using the models with three inputs. A Estimation of current adjustment; B estimation of current.
A subset of the three characteristic pa- front surface of the weld pool. length-to-width ratio does not vary signifi-
rameters may be used to model a human As can be seen from Fig. 3 and Table 1, cantly. That means the width and length
welders response first to see if all of the none of the three models in Table 1 matches fluctuate approximately proportional dur-
three parameters are needed. Using the the estimated current adjustments well ing our experiment that changes the weld-
WELDING RESEARCH
data shown in Fig. 1 and the identification with the measured ones. This indicates that ing speed to change the weld pool.
method given in the previous section, three the human welders response might depend The resultant model with all three geo-
models in Table 1 that only use one of the on more than one characteristic parameter metric parameters is shown in Equation 12.
three characteristic parameters are first of the weld pool surface. Hence, models The standard deviation of model in estimat-
identified. The current adjustments esti- with more inputs are identified. ing the current adjustment is 1.713, which is
mated using the resultant models are The resultant models with two input pa- smaller than those of the three models with
shown in Fig. 3. Correlation coefficient r in rameters are presented in Table 2. The cur- two inputs shown in Table 2, and the correla-
Table 1 measures the strength and direction rent adjustments estimated using the re- tion coefficient is 0.448. The current adjust-
of a linear relationship between measured sultant models are shown in Fig. 4. ments estimated using the resultant models
and estimated output (i) in this study According to the models in Table 2, the are shown in Fig. 5A. Figure 5B is the com-
(Ref. 9). The model with a higher accuracy human welder adjusts the current based on parison between the measured current and
is expected to obtain a higher correlation the weld pool surface 1 to 3 s ago. Also, the estimated current obtained by the model.
coefficient. Figure 3 and Table 1 show that two models using the convexity as one of
the model using the convexity as its input their inputs better modeled the welders re- ik = 1.3066lk2 + 2.4704lk3
obtains the smallest standard deviation and sponse. However, the two models that used 3.1688lk4 + 1.8859lk5 0.8893wk3
the highest correlation coefficient. It is be- the convexity show no significant differ- + 0.9658wk4 + 0.5371wk5 0.6277wk6
cause the convexity of the weld pool, when ences in terms of the standard deviation or + 55.2372hk2 63.4404hk3
the arc pressure is given, reduces as the correlation coefficient. It is probably be- + 90.8986hk4 96.1477hk5
backside weld pool width increases because cause the welding speed has a significant ef- + 17.5644hk6 + 0.2077 (12)
a greater backside weld pool width allows fect on the weld pool size, but a slight im-
more liquid metal to be pushed from the pact on the weld pool appearance, i.e., the
Table 3 ARX Models of the Human Welder Response
Inputs r Models
Length + Width 1.5722 0.571 ik 0.4725ikl + 0.1366ik2 =0.6097lk3 2.2283lk4

+ Convexity +1.6137lk5 1.2675wk3 + 1.7667wk4 + 0.0930wk5 0.6088wk6
+ 30.3658hk3 + 19.6357hk4 67.6373hk5 + 18.7761hk6
Table 4 Z-Transfer Functions of the ARX Model
Model z-transfer function
A'lwh (z) = z3 (z2 0.4725z + 0.1366)

Length + Width + Convexity A"lwh (z) = z4 (z2 0.4725z + 0.1366)
Bl lwh(z) = 0.6097z2 2.2283z +1.6137
Bwlwh(z) = 1.2675z3 + 1.7667z2 + 0.0930z 0.6088
Bhlwh(z) = 30.3658z3 +19.6357z2 67.6373z + 18.7761

Fig. 6 Estimation of the welders response using the ARX model that uses Fig. 7 Comparison of the ARX model estimated welding current with the
all three characteristic parameters. measured current. The ARX model makes use of the width, length, and con-
vexity calculated from the 3D weld pool surface as the weld pool characteris-
tic parameters, and the previous adjustments on the welding current to predict
the welders adjustment on the welding current.
A B
WELDING RESEARCH
Fig. 8 Step responses of the ARX model. A Length step response; B width
step response; C convexity step response. Because the output is i, all the step C
responses settle down back to approximately zero. The integration of the step re-
sponse gives the net change in the welding current due to the step change in one
of the characteristic parameters. In A, the integration is negative. This implies that
the welder reduces the current as a response to an increased weld pool length. In
B, the integration is negative. The welder again reduces the current as a response
to an increased weld pool width. In C, the integration is positive. The welder in-
creases the current as a response to an increased convexity.
Static Response Analysis
A human welder always tries to control the state of the welding

process approaching the desired state, and the desired state of the
weld pool geometry is contained in the constant of the model in
Equation 5. The desired state * can be obtained by solving the
static state equations of the models in Tables 1 and 2. The static
state equation of the model using the convexity as the input is
shown in Equation 13. The static state equations of the last two
models in Table 2 are shown, respectively, in Equations 14 and 15.
I = 4.2284H 0.4715 (13)

A B
C D
WELDING RESEARCH
Fig. 9 The prediction of the human welders response using model Hlwh (z). A Estimation of current adjustment with arc length 4.0 mm; B estimation
of current with arc length 4.0 mm; C estimation of current adjustment with arc length 5.0 mm; D estimation of current with arc length 5.0 mm.
I = 0.0106W + 4.9427H 0.5067 (14) It is reasonable for the human welder to I = 0.1191L 0.0141W + 3.8121H
I = 0.0891L + 2.9876H + 0.1113 (15) choose the set of the geometric parameters + 0.2077 (17)
as the desired state given the specific set-
where I is the current adjustment at static tings for the experiment detailed in the pre- Substituting Equation 16 into 17, and
state; W, L, and H are the width, length, vious experimental method section. It can letting I = 0, the estimated constant in
and convexity of the weld pool at static be seen in Fig. 2, the backside weld bead Equation 14 is obtained as the following:
state. As the welding process approaches width varies greatly during the process since
the desired state assessed by the human the welder does not perform well enough to = 0.2287 (18)
welder, the welder stops changing the cur- keep the width consistent. However, it is an
rent. The current adjustment equals zero. indication of the welders skill in execution The estimated value matches the value
In this sense, the W, L, and H are the de- of the current output, and irrelevant to the in the model with a 0.021 difference, which
sired state of the weld pool geometry, i.e., desired state the human welder wants to may be caused by the accuracy of the
W = w*, L = l*, and H = h*. Solving maintain. Also, the desired state of weld model in predicting the human welders
Equations 13 to 15, the resultant desired pool geometry can be verified by estimating response. Also, the disturbance/noise dur-
state * is as follows: the constant in the model with the three ining the data-acquisition process might
puts shown in Equation 12. The static state contribute some of the difference. Fur-
* = [4.1934 4.9933 0.1115] (16) equation of the model can be written in the ther, it is found that the estimated con-
following equation: stants coincide with constants in the mod-
Table 5 Poles and Zeros of the ARX Model
Inputs Poles and zeros
Alwh (z): [0.23630.2842i, 0,0,0], A"lwh (z): [0.23630.2842i, 0,0,0,0]

Length + Width+ Convexity Bl lwh(z): [0.9952, 2.6596], Bw lwh(z): [0.52, 0.95710.0823i]
Bh lwh(z): [1.9509, 0.9812, 0.323]

A B
Fig. 10 Standard deviations and correlation coefficients of the model using data from the verification experiments at different arc lengths. A Standard de-
viation of the model; B correlation coefficients of the model.
els listed in Tables 1 and 2. is one of its simplified structure. It may ad- the ARX models with all three character-
Furthermore, according to the static equately describe certain discrete-time dy- istic parameters are identified. The result-
WELDING RESEARCH
state equation of the model shown in namic processes but not all discrete-time ant model is listed in Table 3, and the
Equation 17, the human welder tends to dynamic processes. The model in Equa- model results are shown in Figs. 6 and 7.
reduce the current as the length or width tion 5, intuitively proposed based on our As can be seen from Table 3, the present
grows, and increases the current as the analysis and understanding of a human adjustment at instant k on the current ik
convexity of the weld pool rises. The coef- welders response, is apparently an MA depends on the characteristic parameters
ficient of the width in the model is smaller model with as the inputs and i as the 3 through 6 periods previously, i.e., k 3
than other coefficients in the model, while output. Its less than ideal accuracy may to k 6. Hence, the welder makes an ad-
the convexity has the largest coefficient in have been caused by its inadequacy in de- justment on the current based on the weld
the model. That indicates the welder is scribing the human welders dynamic re- pool he observed approximately 1.5 to 3 s
more sensitive to the convexity and length, sponse process. If this is the case, use of previously. There is a difference from 1 to
and less sensitive to the width of the weld the more general ARX model structure 3 s given by the less accurate intermediate
pool during the welding process. may improve the model accuracy signifi- model in Table 2, but this difference is con-
cantly and help us better understand the sidered insignificant.
Improved Modeling and behavior of the human welder. As can be seen, in general, the ARX
Understanding of Human Based on the above analysis, the fol- model well matches the estimated current
Welder Response lowing ARX model structure is proposed adjustments to the measured current ad-
to improve the modeling accuracy for the justments except a few current peaks
Although the model with all three human welders response: Fig. 6. The ARX model is much better
characteristic parameters is more accurate M than the MA models in Table 2 for pre-
1
dicting the human welders response. That
than those with less characteristic param- i (k ) = a(l )i (k l ) indicates the human welders adjustment
eters in predicting the welders responses,
the estimated current adjustment still l =1 on the current does also depend on his
M previous responses/actions. Figure 7
does not quite well fit the measured one. 2
To better understand and predict the + b ( j ) (k d j ) + e (k ) (21) shows the comparison between the meas-
welders behavior, lets analyze below. j =1
ured current and estimated current using
The following model, referred to as the the ARX model. Since the experiment is
auto-regressive with exogenous terms The inclusion of i(k 1), ..., i(k M1) conducted by a newly trained welder for
(ARX) model, is the general structure to into the model basically introduces the this study who may frequently overre-
describe discrete-time linear systems: welders previous actions. If this inclusion act/underreact during the operation, it is
can better predict the welders adjust- understandable that the steep current ad-
y(k) = a(1)y(k 1) + ... + a(M1)y(k M1) ments on the welding current, it would justments cannot, and should not, be fit
+ b(1)u(k d 1) + ... suggest that the welder not only depends well using the model. A model can possi-
+ b(M2)u(k d M2) + e(k) (19) on the weld pool surface but also on his bly better estimate the skilled human
previous actions to adjust the welding cur- welders response with fewer sudden cur-
where u is the input, y is the output, d is rent. Our understanding of the human rent changes and randomness in the weld-
the delay, e is the disturbance, and a(l), (l welders behavior would be improved. ing process.
= 1, ..., M1), b(j), (j = 1, ..., M2) are the The parameter estimation and model In order to analyze the models prop-
model parameters of the system. The MA structure identification for ARX models erties, the ARX model is written in z-
(moving-average) model are similar as those for MA models and transfer functions (Ref. 13), shown in
standard in the system identification liter- Table 4. The poles and zeros of the z-trans-
y(k) = b(1)u(k d 1) + ... ature (Refs. 1012). Since all three char- fer function are listed in Table 5.
+ b(M2)u(k d M2) + e(k) (20) acteristic parameters are found necessary, It can be seen that all the poles of the

model are inside the unit circle in Z-plane, coefficient are the criteria to evaluate the tion/concentration. The modeling errors
which means that the model as the con- performance of the model when applied to are a reflection of the human welders skill
troller in Table 4 is asymptotically stable different verification experiments. All the level and concentration.
(Ref. 14), which is easily understood. In standard deviations and correlation coeffi-
fact, the human welder makes the adjust- cients obtained for the model to estimate Acknowledgments
ment on the welding current as an intelli- the current adjustments in the verification
gent controller. This controller can and experiments are shown in Fig. 10A and B, This work is funded by the National Sci-
should be able to deliver a stable welding respectively. The square and error bar for ence Foundation under grant CMMI-
process despite his limited experience the experiments at each arc length in the fig- 0927707. We wish to thank Yi Lu and
Yukang Liu for their assistance on experi-
training. Hence, the model for the ures are the mean value and the range of the ments and graphics, and Lee Kvidahl for his
welders response should be stable. Fur- two values is from the verification experi- technical guidance on manual pipe welding.
ther, there is only one pair of conjugate ments conducted at this particular arc
poles. The oscillation frequency of the length. The average standard deviation is References
transition responses is about 1.6 A. The correlation coefficients at
the different arc lengths in Fig. 9 vary almost 1. Zhang, W. J., and Zhang, Y. M. 2012.
lwh = 1.7543 rad/s (22) within the same range around their mean Modeling of human welder response to 3D
values. The average correlation coefficient weld pool surface: Part I Principles. Welding
The settling time for the unit step re- of all the verification experiments is about Journal 91(11): 310-s to 318-s.
2. Wickens, C. D., and Carswell, C. M. 1997.
sponse is approximately 4 s, as can be seen 0.56. However, the mean correlation coeffi-
Information processing. Handbook of Human
in Fig. 8. Because the welding process is cient at arc length 5 mm is smaller than that Factors and Ergonomics. Ed. Salvendy, G. New
dynamic, the transition time discussed in in the other three arc lengths. It is possibly York: Wiley.
the first part of the paper is approximately because as the arc length increases, the cur- 3. Kerschen, G., Worden, K., Vakakis, A. F.,
the sum of the settling times for the con- rent required for the same penetration state and Golinval, J. C. 2006. Past, present, and fu-
troller and welding process. It is much is higher. Then, during the experiments, the ture of nonlinear system identification in struc-
longer than that of the controller, which is human welder needs to adjust the current in tural dynamics. Mechanical Systems and Signal
approximately 4 s as discussed above. a large range. That might have increased in- Processing 20: 505592.
WELDING RESEARCH
Another characteristic of the model is accuracy in predicting the current adjust- 4. Scharf, L. 1991. Statistical Signal Process-
that it is a nonminimum phase system ments using the model. Other than that, the ing. Reading, Mass.: Addison-Wesley.
5. Haykin, S. 1996. Adaptive Filter Theory,
(Ref. 15), since there are zeros outside the model shows a consistent performance in
Third Edition. Englewood Cliffs, N.J.: Pren-
unit circle in Z-plane as shown in Table 5. predicting the human welders response on tice-Hall.
Per literature (Refs. 16, 17), this often the adjustment of the current during the 6. Kailath, T., Sayed, A., and Hassibi, B.
leads to relatively large overshoot/under- verification experiments. 2000. Linear Estimation. Englewood Cliffs,
shoot. Such oscillations can be observed N.J.: Prentice-Hall.
from the simulated step responses shown Conclusion 7. Richard, G. L. 2007. Statistical Concepts:
in Fig. 8. It is suspected that the model for A Second Course, Third Edition. Routledge
a skilled/experienced welder would exhibit This paper modeled adjustments on Academic.
much less significant oscillations. 8. Boer, E. R., and Kenyon, R. V. 1998. Es-
the welding current made by a human
timation of time-varying delay time in non-sta-
welder in response to the 3D weld pool tionary linear systems: An approach to monitor
Verification and Discussion surface, as characterized by its length, human operator adaptation in manual tracking
width, and convexity, to maintain a consis- tasks. IEEE Transactions on Systems Man and
Due to the consistency of the human tent complete joint penetration in gas Cybernetics Part A-Systems and Humans 28(1):
welders performance, the obtained model tungsten arc welding (GTAW). The dy- 8999.
should have a similar performance to pre- namic changes in the weld pool surface 9. Edwards, A. L. 1976. An Introduction to
dict the current in other experiments. To were produced by conducting experiments Linear Regression and Correlation. San Fran-
further verify the model, the verification using randomly changed welding speeds cisco, Calif.: W. H. Freeman.
experiments are designed and conducted from 1.00 to 2.00 mm/s. Under the exper- 10. Ljung, L. 1999. System Identification
Theory for the User, 2nd edition. Upper Saddle
as discussed in the experimental method imental conditions used, the following River, N.J.: PTR Prentice Hall.
section. To produce an acceptable distri- were found: 11. Juang, J. 1994. Applied System Identifi-
bution of the welding parameters to en- The human welder makes the adjust- cation. Upper Saddle River, N.J.: Prentice Hall.
sure the validity of the resultant model, ment on the welding current based on the 12. Soderstrom, T., and Stoica, P. 1989. Sys-
each experiment is conducted at a concurrent and previous weld pool surfaces. tem Identification. Upper Saddle River, N.J.:
stant arc length in [2, 5 mm], i.e., 2, 3, 4, The adjustment on the welding cur- Prentice Hall.
and 5 mm. For each arc length setting, rent by the human welder requires the 13. Cornelius, T. L. 1996. Digital control sys-
there are five experiments conducted with length, width, and convexity of the weld tems implementation and computational tech-
the random welding speed signal. pool surface to model adequately. From niques. Academic Press.
14. Chen, C. T. 1999. Linear System Theory
Figure 9 shows the estimated cur- the established model, the human welder
and Design, 3rd Edition. Oxford University
rent/current adjustment obtained by the responds to the weld pool surface he ob- Press.
model using the data from two of the ver- served approximately 1.5 to 3 s previously. 15. Hassibi, B., Kailath, T., and Sayed, A. H.
ification experiments under different arc The human welder makes the adjust- 2000. Linear estimation. Englewood Cliffs,
lengths. It can be seen that the estimated ment on the welding current also based on N.J.: Prentice Hall.
current adjustments predict all the ten- the previous adjustments he has made 1 s 16. Hoagg, J. B., and Bernstein, D. S. 2007.
dencies of the measured current adjust- prior. Non-minimum phase zeros Much to do
ments, although there are some high and It is noted from the identification and about nothing. IEEE Control System Magazine
steep measured values at which the esti- verification results that the adjustments 27(3): 4557.
17. Lau, K., Middleton, R. H., and
mation cannot follow in magnitude. More- on the welding current cannot be fully pre-
Braslavsky, J. H. 2003. Undershoot and settling
over, the curves of the estimated and dicted. This is expected because of the rel- time tradeoffs for non-minimum phase systems.
measured current coincided well. atively limited skills of the novice human IEEE Transactions on Automatic Control 48(8):
The standard deviation and correlation welder and the inconsistency of his opera- 13891393.

Stacy Supplement December 2012_Layout 1 11/9/12 1:37 PM Page 338
Theoretical and Empirical Verification of a

Mobile Robotic Welding Platform
A mobile robotic welding robot will be verified both theoretically and empirically
using AWS and ASTM standards
BY J. STACY AND S. CANFIELD
ticular, steam plants and wind-energy

ABSTRACT production.
A number of researchers are investi-
Traditional robotic welding, common in industries such as automotive production, gating nontraditional robotic manufactur-
becomes impractical in industries that use unstructured manufacturing techniques, ing techniques based on nonserial
such as shipbuilding. This is due in part to the scale of the manufactured systems and architecture, movable-base robotic ma-
the size and locations of the weld. In these unstructured manufacturing environments, nipulators in the shipbuilding and similar
the state of the art for mechanized welding has historically consisted of a fixed-track industries. These efforts have resulted in
system with a mechanical welding carriage that operates along the track. However, al- several alternative approaches for au-
ternative mechanized welding approaches that make use of developments from the tomating manufacturing processes in un-
field of mobile robotics are being pursued. One such example is the semiautonomous structured environments. One approach
WELDING RESEARCH
Mobile Robotic Welding System (MRWS). The MRWS is a lightweight mobile ma- employs mobile, legged robotic platforms.
nipulator consisting of a two-degrees-of-freedom mobile platform and a three- Some examples of this approach are the
degrees-of-freedom torch manipulator. The MRWS is capable of climbing ferrous sur- ROWER project (Ref. 2), demonstrating
faces by the use of permanent magnet tracks and positioning the welding torch along a large-legged robot designed to travel
a weld joint. This system is designed to mechanize the welding process for a variety of through the hull of a ship while perform-
weld joints with minimal setup time. Setup consists of placing the MRWS on the sur- ing welding tasks and Robug (Ref. 3), a
face to be welded and driving to the intended weld joint. In order to be utilized in a smaller-legged platform used for inspec-
manufacturing environment, such a system must be verified for the welding process it tion and potential manufacturing pur-
is performing. This paper demonstrates and verifies the MRWS as a valid alternative poses. Another approach is based on a
for mechanized welding in unstructured environments. The verification process con- cable-driven system with a multi-degree-
sists of two components: design validation based on theoretical analysis of the MRWS of-freedom end effector. RoboCrane
system models to prove the weld process requirements can be met, followed by an em- (Ref. 4) developed by NIST provides an
pirical verification based on AWS weld test specifications for a specific, commonly example of this system. A third approach
used welding process. The design validation focuses on the two primary differences uses large-wheeled mobile robots to tra-
between the MRWS and proven fixed-track mechanized welding systems, torch mo- verse the welding site. A large, wheeled
tion control on a mobile platform, and impact of the MRWS magnetic feet on the weld platform that carries a six-axis robot called
process. The empirical verification was performed on a vertical groove weld on mild NOMAD (Ref. 5) is intended for welding
steel with uphill progression, 3G-PF. large-scale structures such as those found
in earth-moving equipment and bridge-
fabrication industries. Several groups
have been pursuing smaller, mobile climb-
Introduction used; however, due to the part/component ing robots for welding. One such approach
differences, the assembly process is con- uses wheeled robotic systems, for exam-
Expanding the use of robotics in indus- stantly changing from part to part. There ple, the two-wheeled mobile robot de-
tries that manufacture large products, are, however, significant benefits that can signed specifically for fillet welds in lattice
such as shipbuilding, is a relatively new en- be achieved through increasing the level (Ref. 6). Another approach utilizes con-
terprise. In general, every ship is unique. of automation within the shipbuilding tinuous-track robotic systems, which gen-
Further, the size and scale of a typical ship process in the United States (Ref. 1). The erally use attractive elements, such as suc-
combined with the high costs associated same discussion applies to the Electric tion cups, magnets, and gripping feet, that
with dry docks or real estate immediately Power Generation Industry (EPI), in par- allow these systems to climb (Refs. 710).
adjacent to the launch location has led to- This research is driven by the need for im-
ward a common manufacturing technique proved tools for manufacturing tasks such
in which the structural components of the KEYWORDS as welding in large-scale manufacturing
ship are assembled in multiple locations systems such as shipbuilding.
with only the final assembly occurring in Robotics While this research has resulted in a
the most expensive location. Some aspects Gas Metal Arc Welding large number of conceptual designs and
of a common assembly line technique are Automation prototypes for mechanized or robotic
Shipbuilding welding, there is a continued need to vali-
date these designs and bring them into
commercial practice. An important step
J. STACY is a graduate student, and S. CAN- includes documented weld verification
FIELD (scanfield@tntech.edu) is professor, Ten-
nessee Technological University, Cookeville, Tenn.
process, but this procedure has not been

Fig. 1 MRWS overall system. Fig. 2 MRWS overall control block diagram.
WELDING RESEARCH
Fig. 4 MRWS frame orientation and degrees of freedom.
the process of confir- years, there is evidence that these meet

mation by examination validation standards, although a lack of
of objective evidence validation examples are present in the lit-
that the requirements erature (Ref. 14). This paper demon-
for a specific intended strates and verifies a method for mecha-
use can be consistently nized welding in shipbuilding and related
fulfilled (Ref. 13). Vali- industries that offers an alternative to the
dation of the weld fixed-track systems. The method is based
process is a general re- on the mobile, climbing skid-steer plat-
quirement for most form with welding gun manipulator called
shipyard joining the Mobile Robotic Welding System
processes, and in many (MRWS) as described in Ref. 8. The
cases is demanded by MRWS is able to weld in various locations
Fig. 3 Control pendant. the customer (e.g., U.S. and orientations, including flat, vertical,
Navy). The validation horizontal, and overhead. The MRWS is
process must encom- designed to be a weld mechanization tool
reported in the literature for any mobile pass both the operator as well as the that requires very little setup time when
robotic systems. For the purposes of this equipment used to perform the weld. The compared to a fixed-track system. The
paper, weld verification is defined as the validation process generally consists of a fixed-track system requires a track to be
process of confirmation by examination of combination of training and weld verifica- accurately positioned and attached along
objective evidence that the specified re- tion (based on AWS weld process qualifi- the weld joint prior to the welding process.
quirements have been fulfilled, where the cation), leading to certification of weld op- The time for track setup must be added to
specified requirements are those given in erators. Traditional welding equipment, the weld time to get an overall process
AWS B2.1:2005 and D1.1/1.1M:2002 such as power supplies, are inherently a time. The use of a mobile robotic welding
(Refs. 11, 12). This is based on the defini- part of the weld verification testing. Since system eliminates the vast majority of the
tions and processes presented in Ref. 13. the fixed-track mechanized welding sys- setup and take-down time, which im-
Furthermore, weld validation is defined as tems have been in service for a number of proves the overall productivity of weld

Fig. 5 Fixed track frame orientation and degrees of freedom. Fig. 6 Manipulability ellipses surrounding the MRWS platform.
Shaded and hatched regions are the MRWS platform.
mechanization. The robot can climb ferrous (steel) struc- any motion disturbances, as well as keep the
In addition, this paper presents a tures in any orientation. The robot weighs gun adjustments relative to the surface local
method to demonstrate a level of weld val- approximately 60 lb and has a payload ca- to the weld.
idation for new, robotic welding systems. pacity of 100 lb that consists primarily of a The weld operator interacts with the
This is performed based on theoretical commercial wire feeder, welding gun, gun robot through a robot-control pendant,
WELDING RESEARCH
validation of the robotic welding machine manipulator, and sensor package. The shown in Fig. 3. The control pendant al-
at the time of design; therefore, it may be robot has onboard sensors, processing, lows the operator to drive the robot man-
termed design validation (Ref. 13). The and a control algorithm that allows it to ually or to supervise its semiautonomous
theoretical analysis focuses on the portion operate in a semiautonomous fashion. operation, and to define the weld motion
of the MRWS that deviates from the fixed- The robot platform consists of two sym- characteristics such as forward and trans-
track system design. In particular, the metric endless chain track units with at- verse speeds, dwell times, weld patterns,
MRWS is based on a kinematic arrange- tached magnetic feet. The magnetic track etc., remotely.
ment that is significantly different from units provide propulsion to the robot
that of the fixed-track system to achieve while adhering to ferrous surfaces, allow- Theoretical Validation of the
similar gun motions. Further, the MRWS ing for welding in all positions. Also con- MRWS for Welding Processes
relies on a high magnetic flux density in tained in each track unit is a suspension
the local vicinity of the weld joint while the that aids in adhering to an uneven welding Theoretical Validation Overview
fixed-track systems use a much lower mag- surface. Drive power is provided by DC
netic flux to attach the track to the struc- brushless motors, and the control is a com- This section presents a theoretical
ture (and often other forms of mechanical bined system of drivers and microcon- basis for validating the MRWS for welding
attachment of the track to the welding sur- troller to provide a closed-loop system. processes. When comparing the MRWS
face are used). The theoretical analysis Figure 1 shows the MRWS as a field-ready system with existing fixed-track welding
builds a justification for validation by com- system. systems, two fundamental differences
paring with existing mechanized weld sys- Robot navigation is defined globally by arise in their design and operation that
tems. The empirical verification applies to the operator through remote control, have the potential to impact the welding
the complete MRWS system through the while the robot locally uses operator in- processes: 1) kinematic differences in
AWS B2.1:2005 and D1.1/1.1M:2002 puts to close the loop on gun trajectory achieving desired motions of the gun, and
method for a specific weld type and orien- control. During operation, the welder ob- 2) variation in how tractive forces are gen-
tation (Refs. 11, 12). serves the weld in situ and makes gun tip erated between the welding platform and
The remainder of this paper proceeds position input and speed corrections as the surface on which the weld is per-
in the following order. First, a brief needed. An overview of the robot control formed. These are addressed in order in
overview of the MRWS system is provided diagram is shown in Fig. 2. the following sections.
followed by a theoretical analysis and de- The robot platform supports a five-
sign validation approach of the MRWS for degree-of-freedom gun manipulator to pro- Theoretical Validation Based on Motion
the welding process. Then, an empirical vide local control of the gun. The gun travel Control
weld verification of a gas metal arc weld- angle is adjusted manually, while the gun
ing (GMAW) vertical groove weld on mild translation, perpendicular to the weld joint, The ability of the MRWS to provide
steel with uphill progression, 3G-PF, that is actuated with a brushless DC motor, the necessary motion control is directly influ-
was welded using the MRWS platform, is work angle is adjusted by a geared servo enced by its kinematic arrangement. The
performed. The paper is completed with motor, and the height of the contact tip is gun motion is described by its position and
concluding remarks on the validation of controlled by a linear actuator. Coordinated time derivatives: gun velocity, accelera-
the overall system. control of the robot platform motion and tion, and so forth. To perform a desired
gun manipulator is provided by the onboard weld, the gun must follow a specified weld
MRWS Overview processor, allowing the gun motion to pro- trajectory in a smooth manner. This tra-
duce a variety of desired weld patterns. The jectory consists of both the geometric de-
The MRWS is a mobile robot based on gun manipulator is independently sus- scription of the gun position along with
two continuous permanent magnet tracks. pended from the platform to isolate it from gun velocities and accelerations along the

Fig. 7 Manipulability ellipses at points A, B, and C. Fig. 8 Manipulability ellipse of the platform as the theta of the plat-
form changes about the weld joint.
path. A smooth trajectory requires, at a The length of the track is given by l while angle and travel angle are removed from
minimum, the ability to specify both robot the distance between the centerline of the the system kinematics.
position and velocity throughout the path tracks is given by 2b. To consider the posi- Considerations for gun velocity: To
motion. The kinematic arrangement of tion kinematics, assume that the robot provide smooth trajectories offered by the
the MRWS defines the geometric position frame translates along the weld axis (x) by reference system, the MRWS must match
WELDING RESEARCH
and velocity characteristics, and this is val- a distance d1,MRWS, while the gun manip- the velocity capabilities of the reference
idated by comparing these capabilities in ulator translates in a direction transverse system. While validation of the MRWS
turn with an accepted reference system. to the weld axis in the plane of the surface. gun positioning capability was intuitive
For this work, the reference system is a Then, a kinematic description of gun mo- and involved a direct comparison of the
fixed-base track system with mobile car- tion with the work angle and travel angle geometric positioning behavior of the
riage. These fixed-track systems are well removed is given as MRWS with the reference system, consid-
accepted for mechanized weld processes eration of the velocity behavior is less in-
(for example, Bug-O, Gullco, and Koike 1 0 0 d1, MRWS tuitive. However, the process will proceed
track systems) (Ref. 14). in a similar manner by comparing the ma-
0 1 0 d2, MRWS
Considerations for gun position: For I
TTMRWS = (1) nipulability ellipsoids (Ref. 15) of the
theoretical validation of gun position con- 0 0 1 d3,M MRWS to the reference system. The ma-
MRWS

trol, the gun manipulator on the MRWS 0 0 0 1 nipulability ellipsoid is a geometric repre-
must span the gun position space provided sentation of the velocity characteristics of
by the reference system while avoiding inte- where d1,MRWS is the robot translation a manipulator based on a singular value
rior singularities (positions on the interior along the weld joint from the mobile unit, decomposition of the Jacobian matrix of
of the workspace in which the robot loses d2,MRWS is the translation of the toolbar the manipulator where the singular vec-
one or more degrees of freedom (dof)). The and d3,MRWS is the translation along the tors define the direction, and the singular
position kinematics of the MRWS system gun (plunge). values define the magnitude of the axes of
are compared to that of the reference sys- Figure 5 presents a kinematic diagram the manipulability ellipse (Refs. 15, 16).
tem. Note that for this comparison, the of a fixed-base track system for mecha- When placed in context with the welding
mechanisms to control the work angle, nized welding. This kinematic description process, a manipulability ellipse defined in
travel angle, and gun plunge (tip depth) are of the gun motion from the reference sys- the plane of the welding surface gives a
considered common to both systems, and tem is given as measure of the maximum end-effector ve-
are not included in this analysis. locity that can be achieved based on a unit
The MRWS is a mobile manipulator 1 0 0 d1,,refS set of input joint velocities. Motion in any
system consisting of a 2-deg-of-freedom desired direction within the welding plane
0 1 0 d2,,ref
tracked mobile platform connected in se- TTI ref = (2 ) can be found as the length of a line paral-
0 0 1 d3,,ref
ries with a 3-deg-of-freedom Prismatic- lel to that direction that passes through
Revolute-Prismatic (P-R-P) serial gun ma- 0 0 0 1 the center of the ellipse and is bounded by
nipulator. Prismatic and revolute refer to its edges (Ref. 16). For purposes of vali-
the type of single-degree-of-freedom Comparing Equations 1 and 2 demon- dation, the MRWS system is said to be val-
joints used to form the gun manipulator. It strates that the MRWS spans the gun po- idated for motion control if its manipula-
is assumed that the mobile platform is on sition space of the reference system as bility ellipse spans a majority (75% or
a planar surface. Figure 4 provides a long as more) of the corresponding manipulabil-
schematic of the MRWS with gun manip- ity ellipse for the reference track-based
ulator. Frames {I}, {R}, and {T} denote d1,MRWS d1,ref system. The comparisons are performed
the inertial, robot chassis centroid, and d2,MRWS d2,ref in the following manner. Based on the
gun tip frames, respectively, and repre- d3,MRWS d3,ref (3) kinematic arrangement of the MRWS
sents the rotation of {R} with respect to (shown in Fig. 4) and reference system
{I}. The left and right tracks are actuated which can be satisfied by the mechanical (shown in Fig. 5), the kinematic relation-
with inputs l and r, while d2, w, d3 are system design. Further, it is noted that no ships between joint level and gun velocity
the inputs to the P-R-P gun manipulator. interior singularities exist when the work are described in the form of the manipu-

Fig. 10 Macroscopic picture of the as-deposited weld bead.
lines) are compared at which fixed-track mechanization is used.

various locations rela- In addition to gun-mounting location,
tive to the MRWS plat- the MRWS kinematics demonstrates de-
form. In this figure, an pendence on the orientation between the
outline of the MRWS platform longitudinal axis and weld axis
is shown for scale pur- (, Fig. 3). The manipulability ellipse of
poses. From Fig. 6, the the MRWS with gun located at point A
manipulability of the (Fig. 6) is compared with the fixed track
MRWS is seen to be system for increasing values of from 5 to
symmetric about the 35 deg in Fig. 8, and the area of intersec-
local frame {R} x and y tion is constant at 79%. From Fig. 8, it can
Fig. 9 Average magnetic field strength in the plate due to tractive magnets.
axes of the MRWS be seen that the effect of MRWS orienta-
platform. Three location is a rotation of the manipulability el-
WELDING RESEARCH
tions are identified on lipse and does not change the area of in-
lator Jacobian (see appendix for details). Fig. 6 in which to consider gun placement tersection with the manipulability ellipse
A singular value decomposition of the sys- in detail: point A (leading edge of MRWS of the fixed-track system. Thus, this
tem Jacobians is then carried out to define platform), point B (corner of MRWS plat- demonstrates that the MRWS provides ac-
the manipulability ellipse of each respec- form), and point C (side of MRWS plat- ceptable motion for all weld applications
tive manipulator. The results are shown form). Each gun location is shown in de- and is invariant to the alignment between
for the output axes lying in the plane of the tail in Fig. 7. From Fig. 7, it can be seen the MRWS platform and the weld joint.
welding surface as shown in Figs. 68. that in all three positions, the manipula-
From the kinematic solution, it is noted bility ellipse of the MRWS with gun ma- Tractive Magnet Interaction with the
that in a fixed-base track system, the manipulator largely spans that manipulability Welding Process
nipulability ellipse is a unit circle and in- of the fixed-track system kinematics. The
variant with respect to actual mounting minimum coverage occurs at location A, The MRWS generates tractive forces
position of the gun while on the MRWS, where the MRWS manipulability ellipse with the welding surface through a track
the gun mounting location does play a role intersects 79% of the fixed track manipu- consisting of a series of permanent mag-
in determining the manipulability of the lability ellipse. This implies, based on the nets. The number and density of these
gun. This is shown in Fig. 6, where the ma- proposed criteria of 75% minimum cover- tractive magnets are much greater than
nipulability ellipse of the MRWS (solid age, that the MRWS provides acceptable that commonly found on fixed-track weld-
lines) and the fixed track system (dashed motion control for all weld applications in ing systems. The introduction of a mag-
netic field to the welding process can in-
terfere with the welding process through
Table 1 Effects of Magnetic Arc Blow on Different Welding Processes magnetic arc blow and must be investi-
gated to determine positions where the
Welding Process 010 gauss 1020 gauss 2040 gauss More than 40 gauss magnetic flux will not interfere with the
welding arc. The MRWS track is designed
GTAW no effect arc instability arc blow severe arc blow to contain the magnetic field generated by
GMAW no effect no effect arc instability arc blow the magnetic feet to a small region en-
SAW no effect no effect no effect arc instability compassing the tracks, and to position the
welding process outside of this region. To
evaluate the track design, a finite element
Table 2 Welding Process Parameters analysis (FEA) model of the MRWS-
generated magnetic field is studied, vali-
Welding Parameters dated with empirical data, and used to de-
fine acceptable locations for the welding
Current (A) 110 gun. The acceptable regions are defined as
Voltage (V) 17.5 those that demonstrate a magnetic field less
Wire Speed (in./min) 120 than the allowable field as identified for typ-
Trim Setting 0.97
ical welding processes. These values are
Gas Flow Rate, ft3/h 35
shown for a variety of welding processes in
(95%Ar + 5%O2)
Travel Speed (in./min) 2 to 4 Table 1, which is adapted from Ref. 17.
Contact Tip to Work Distance (in.) 1/2 (nominal) An analysis of the magnetic field asso-
Electrode 0.045 ER70S-6E ciated with the tracks of the MRWS ad-
Forward Torch Angle (deg) 12 hering to -in.-thick steel is presented in
Fig. 9. The plot color scale for FEA results

Fig. 11 Stress vs. displacement overlay.
Table 3 Ultimate Tensile Strength Data Table 4 Root Bend Convex Surface Void
Summary Size Summary
Reduced Section Tensile Test Data (ksi) Root Bend Test Void Size (in.)
Base Metal 1 73.5 Void 1 0.040
Base Metal 2 73.2 Void 2 0.020
Weld Sample 1 73.9 Void 3 0.045 Fig. 12 Macroscopic surface of the root bend test
Weld Sample 2 75.0 Void 4 0.034 sample.
WELDING RESEARCH
Weld Sample 3 74.1 Void 5 0.028
Weld Sample 4 75.7
Weld Sample 5 75.3
are defined so that the gray region is an av- process requirements for GMAW and performed on 0.5-in.-thick ASTM A36
erage magnetic flux greater than 10 gauss GTAW applications that are employed on structural steel using a B-U2a-GF groove
while the blue regions are less than 10 other mechanized platforms. type with 0.125-in. steel backing. The weld
gauss. Therefore, the gun should not be lo- groove had a 45-deg angle and a root
cated in gray regions due to potential mag- MRWS Empirical Verification opening of in. The electrode used was
netic arc interaction (a magnetic flux 0.045-in.-diameter ER70S-6E, and the gas
higher than 10 gauss). All blue areas Empirical Verification Overview mixture was 95% argon 5% oxygen at a
around the tracks are suitable regions for flow rate of 35 ft3/h. Three weld passes
any of the welding processes listed in Table This section presents an empirical were completed, each using a trapezoidal
1. The numerical analysis is reinforced basis for verifying the MRWS for a spe- weave pattern. The welding machine was
with physical testing of the MRWS in the cific welding process. The process chosen utilized in pulse program mode with set-
same arrangement. The MRWS was was a GMAW vertical groove weld on tings of 17.5 V, 110 A, 120 in./min wire
placed on a large (assumed semiinfinite, mild steel with uphill progression, 3G-PF. speed, and 0.97 trim setting. The MRWS
given robot size to sheet ratio) -in.-thick This weld process was viewed as a com- settings used were 24 in./min travel
sheet of steel and an AlphaLab, Inc., DC mon weld joint performed in a typical speed, 0.5-in. contact tip-to-work distance
Gaussmeter M1HS was used to measure shipyard. The empirical test is based on (CTWD), and 12 deg of forward gun
the normal component of magnetic flux the American Welding Society (AWS) angle. Weave speed and dwell times were
around the mobile platform. The meter procedure qualification for a vertical varied during the process to create a uni-
readings were compared with the numeri- groove weld. The test methods required form bead.
cal analysis and demonstrated strong for a groove weld are visual examination, Once welded, a visual inspection was
agreement with the FEA results. Further- tension test, and guided bend test (root performed, and metallurgical samples
more, in-service welding has been done in bend) (Ref. 11). All tests performed com- were removed. The steel backing was re-
a variety of gun positions in the blue re- ply with the American National Stan- moved, and the plate was machined flat
gion shown in the FEA plots. During these dards Institute (ANSI) AWS (eliminating the curvature due to welding
welds, no visible magnetic arc blow was D1.1/D1.1M:2002 standards (Ref. 12). distortion). Tensile and root bend test
seen, and no defects typical of magnetic The experimental setup and equipment specimens were then cut from the welded
interference were found. are outlined followed by the experimen- plate in accordance with the AWS specifi-
The results of this analysis and physical tal results. Accordingly, a detailed dis- cation. Reduced section tensile samples
testing demonstrate that the MRWS offers cussion of how the samples compared to were loaded using an MTS 810 servo-
suitable regions for gun positioning that will the AWS specifications are presented. hydraulic load frame. All samples were
satisfy the limits of all welds demonstrated loaded until failure at a constant displace-
in Table 1. In particular, the focused appli- Experimental Setup and Procedure ment rate of 0.200 in./min. Base metal re-
cations for the MRWS are the short-arc duced section tensile samples were also
GMAW process (second row) and pulse-arc The test samples were fabricated using prepared to get a more accurate value of
GMAW process (similar requirements to the MRWS with a Lincoln Electric Power the tensile strength of the A36 steel whose
gas tungsten arc welding (GTAW), first row, Wave 455 welding machine, and Power published tensile strength has a wide
Table 1). Therefore, these analyses demon- Feed 10 wire feeder, set up for pulsed range of 58,00079,800 lb/in.2 of possible
strate that the MRWS meets the weld spray gas metal arc welding. The weld was values. Root bend test samples were also

prepared from the same weld sample. The Reduced section tensile samples: AWS and traditional, track-based mechanized
bend samples were bent in a hydraulic states that the tensile samples can break in weld tools. The motion-control capability
guide bend test fixture with a main die di- the welded area as long as tensile strength (which stems from the kinematic arrange-
ameter of 1.50 in. and deformed to an in- is no less than the published minimum ten- ment) of the MRWS was validated by com-
cluded angle of 80 deg. The convex surface sile strength of the base material, in this paring the ability to track smooth trajec-
was then inspected for inclusions and dis- case A36 structural steel whose published tories as defined by the reference system
continuities as called for in the AWS tensile strength is 58,00079,800 lb/in.2. through comparison of the positioning
specification. This published range is very large and, and velocity characteristics. When com-
therefore, base metal tensile samples are paring the positioning capability, it was
Test Data included to get a better understanding of demonstrated that the MRWS can meet
the tensile strength of the base metal. Fig- the positioning requirements at the design
Visual inspection of the as-deposited ure 11 shows the stress vs. displacement stage through range of motion of the
welds was completed using macroscopic overlay plot of seven reduced section ten- transverse and plunge axes. When com-
and microscopic devices. The microstruc- sile samples, five welded and two base paring the velocity capability, it was noted
ture of the weld cross section was studied metal samples. It is shown that the welded that the MRWS met the imposed require-
to investigate the weld nugget and pene- samples reached a higher stress level than ments with a manipulability ellipse that
tration depth. The force-displacement the base metal samples, the red horizontal spanned 75% or more of the reference
tensile test data were converted to stress- line of the graph represents the maximum manipulability ellipse for all gun locations
displacement by using the initial starting value for the base metal samples. It should and orientation of the MRWS to the weld
cross-sectional area from each sample. be noted that the welded samples did joint. This is deemed as an acceptable (val-
Matlab software was used for data pro- break in the welded area; however, post- idated) standard. The magnetic field in-
cessing and to extract the maximum ten- failure inspection did not reveal any inclu- teraction was tested by again comparing
sile strength value of each sample data set. sions or areas with incomplete fusion. possible gun locations with an allowable
Table 3 outlines the maximum tensile Root bend samples: AWS states that the magnetic field induced by the magnetic
strengths of the samples. The welded ten- convex surface of the bent sample should tracks. This comparison showed the
sile samples did break in the weld area and be examined for surface discontinuities, MRWS was well within the limits for all
WELDING RESEARCH
were subsequently inspected for any in- all discontinuities shall not exceed the fol- welding types defined. Finally, an empiri-
complete fusion or inclusions that would lowing dimensions: 0.125 in. measure in cal weld test was performed to AWS and
have acted as a failure initiation site. The any direction on the surface, 0.375 in. ASME specifications. All tests called for
samples were found to have complete fu- the sum of the greatest dimension of all by the AWS qualification were met or ex-
sion and no inclusions were visible on the discontinuities exceeding 0.031 in. but less ceeded by the weld performed by the
macroscopic scale. The root bend test than or equal to 0.125 in., 0.250 in. maxi- MRWS demonstrating a verified system
samples were inspected for any disconti- mum corner crack length. The tested sam- for this weld configuration. This is an im-
nuities or voids on the convex surface of ples show very little discontinuities on the portant step forward for the introduction
the sample. Table 4 shows the representa- convex surface and had no corner crack- of mobile robotic fabrication in unstruc-
tive void measurements on convex surface ing. Figure 12 shows a macroscopic view of tured environments. The ability for
for the bend test samples; only a small the convex surface with the major discon- mobile welding robots to perform welds
number of voids are visible and all voids tinuities highlighted; the vertical lines are that can be certified and pass stringent
were measured using digital calipers. positioned just outside of the root of the qualifications is an essential step in in-
weld to base metal interface, which is creasing the level of automation in un-
Test Results and Discussion barely visible. No edge cracking was seen, structured manufacturing environments.
and this is a clear indication of the pene-
Here, each individual area of the AWS tration depth of the root pass achieved References
specification is addressed with its appropri- using the MRWS.
1. Ang, M. H. Jr., Lin, W., and Lim, S. 1999.
ate test data. The acceptance criteria is Walk-through programmed robot for welding
given followed by how the MRWS test sam- Conclusions in shipyards. Industrial Robot, Vol. 26, No. 5, pp.
ple met the requirements for qualification. 377388.
Visual inspection of the as-deposited weld: The MRWS is a mobile welding robotic 2. Gonzalez De Santos, P., Armada, M. A.,
AWS states the weld should be free of platform designed to perform the same and Jimenez, M. A. 2000. Shipbuilding with
cracks, all craters shall be filled to full cross types of welds currently mechanized using Rower. IEEE Robotics and Automation Maga-
section of the weld, the face of the weld fixed-track systems. The advantage of the zine, Vol. 7, No. 4, pp. 3543, Dec.
should be flush with the surface of the base MRWS is that it eliminates the majority of 3. Luk, B. L., Cooke, D. S., Galt, S., Collie,
metal and merge smoothly with the base setup time associated with fixed-track sys- A. A., and Chen, S. 2005. Intelligent legged
climbing service robot for remote maintenance
metal, no undercut should exceed 0.031 in., tems. The MRWS can eliminate a large
applications in hazardous environments. Robot-
and, finally, the root shall be inspected and portion of the nonvalue-added time in set- ics and Autonomous Systems, Vol. 53, No. 2, pp.
there should be no evidence of cracks, in- ting up for a mechanized weld. This paper 142152, Nov. 30.
complete fusion, or inadequate joint pene- demonstrates the validity of the MRWS in 4. Albus, J., Bostelman, R., and Dagalakis,
tration. Figure 10 shows a macroscopic pic- performing GMAW-type welds on plate N. 1993. NIST RoboCrane. Journal of Robotic
ture of an as-deposited weld and the steel. This validation process consisted of Systems, Vol. 10, No. 5, pp. 709724, July.
polished and etched cross section of a weld two parts: theoretical validation consider- 5. Mulligan, S., Melton, G., Lylynoja, A.,
performed with the MRWS. The macro- ing kinematic arrangement, motion con- and Herman, K. 2005. Autonomous welding of
scopic photograph shows adequate weld re- trol capability, and magnetic interaction, large steel fabrications. Industrial Robot: An In-
ternational Journal, Vol. 32, No. 4, pp. 346349.
inforcement and no visual cracks, under- and empirical verification based on the
6. Kam, B. O., Jeon, Y. B., and Kim, S. B.
cuts, or voids. The cross section of the weld AWS qualification standards for a 3G-PF 2001. Motion control of two wheeled welding
nugget, as-deposited (etched with Nital so- vertical groove weld. For theoretical vali- mobile robot with seam tracking sensor. Proc.
lution), has adequate penetration of all dation, kinematic arrangement and mag- ISIE 2001 IEEE Int. Symposium on Industrial
three passes and there are no voids or in- netic field interaction are identified as the Electronics, Vol. 2, pp. 851856.
complete fusion of the weld. primary differences between the MRWS 7. Pan, J., Yan, B., Gao, L., Zhang, H., Lu,

Q., and Jin, K. 2005. Crawl type robot tackles

difficult jobs. Welding Journal 85(1): 50. v R = R R K q (A3) vT = v R +vT +I R
d R = Jq (A8)
8. OToole, A., and Canfield, S. L. 2010. De- I I eq 1 I I R T
veloping a kinematic estimation model for a
where vRI is the velocity of {R} with re- or
climbing mobile robotic welding system. Proc.
of the 2010 ASME International Design Engi- spect to {I} given in the {I} frame, RRI =
neering Technical Conferences, Montreal, Que., Rz() the rotation operator project {R} to
Canada, Aug. 1518, DETC2010-28878. {I} and R R
9. Canfield, S. L., Beard J. W., and RI K 1 RI J 1
K vT
= Jq = q1 + R q2
Munukutla, S. 2003. A mobile robot for auto-
mated boiler tube inspection. Thermal Power K =
( )
1 3 2

I R
R I K 2 R I J 2
Generation Best Practices & Future Technologies eq
K 2 3 2
( ) ( )
T
International Conference, New Delhi, India, R R S o K
Oct. 1013. + I n 2 q
y r y r 1
10. Canfield, S. L., Beard, J. W., Coffey, M. ric lic O
32
R., and Halcomb, S. M. 2005. Robotic inspec- x r x r
tion in power plants. ISA 51st Annual Instru-
mentation Symposium, Knoxville, Tenn., May
=
1
ic
0
ic
0 (A4)
R

(
R I K 1 + S on K 2 R I J 1
R
( ) )
q
10.
11. AWS B2.1:2005, Specification for Weld- (
y y 0
ric lic ) 0
=

RRK
I 2
R R J 1
I 2
q2
(A9)
ing Procedure and Performance Qualification. 0 0
Miami, Fla.: American Welding Society.
12. ANSI/AWS D1.1/D1.1M:2002, Struc- r r
tural Welding Code Steel. Miami, Fla.: Amer- where S(on) is the skew symmetric matrix
with xic, ylic, yric the coordinates locating
ican Welding Society.
13. Steinmeier, D. 2009. Validating the re-
the instant centers of the contact portion of on, and on is given as the fourth column
sistance welding process. Welding Journal of the left and right track in the {R} frame. of the homogenous transformation TTR.
88(12): 42. The direct kinematics of the manipula- This yields the MRWS system Jacobian
14. Product Case Study File; Langfields Sec- tor portion of the MRWS can be written as matrix as
WELDING RESEARCH
tion Welds - Pipe KAT Orbital Welding System.
2011. www.gullco.com/weldingautomationspe- vR = J q (A5)
T TM 2
cialapplications.html. j j s ss d sc
11 12 w 3 w
15. Spong, M. W., Hutchinson, S., and where vRT is the velocity of {T} with re- j j c cs d cc
Vidyasagar, M. 2006. Robot Modeling and Con- 21 22 w 3 w
spect to {R} given in the {R} frame, and 0 0 0 c d s
trol. Hoboken, N.J.: John Wiley and Sons, Inc.
J =
w 3 w
(A10)
0 0 0 c 0
16. Gardner, J. F., and Velinsky, S. A. 2000.
Kinematics of mobile manipulators and impli- J
r
0 0 0 s 0

= 1
r
cations for design. Journal of Robotic Systems J 0 0 0
TM J ylic y ric y y
17(6), pp. 309320, June. lic ric
2
17. Blakeley, P. J. 1991. Magnetic arc blow
Causes and remedies. Welding & Metal Fab- 0 0 0
rication, Vol. 59, No. 7, pp. 401404, Aug./Sept.

1 d s c with
18. Diverse Technologies. 2009. Magnetic 3 w w

effect on the welding process. home.btcon-
nect.com/diversetech/layer2/zeropr.htm, Dec. 11. =

0 d c
3 w
sw
2

(A6)
j =
(
r d c y c + l s + x s c cd
2 ric 0 ic 2 3 ) (A11)
Appendix
0
0
1
0
0
0
11
(y lic
y
ric )

0 0 0
The MRWS is a 5-deg-of-freedom mo-
bile manipulator with input vector q is is the Jacobian of the gun manipulator, j =
(
r d c y c + l s + x s c cd
2 ric 0 ic 2 3 ) (A12)
given as whose pose is described relative to the {R}
frame as
12
(y lic
y
ric )
q

q = 1 (A1)
0 l
q2

s
1 0
0
j =
(
r d s y s l c x c c sd
2 ric 0 ic w 3 ) (A13)
0 c d
with

d
2
T
T
R
= w
c
w
0 s l
2 (A7)
21
(y lic
y
ric )
l w w 1
q = , q = (A2) 0
1
r 2
w 0 0 1
d 3
where cw = cos(w), sw = sin(w), l0, l1 are j =
(
r d s + y c + l c + x c + c sd
2 lic 0 ic w 3 ) (A14)
and l, r are left/right track inputs and d2, the offsets along xR and zR, respectively, to
the gun and w = /2 when the work
22
( y y
lic ric )
w, d3 are the inputs to the P-R-P gun ma-
nipulator. The direct kinematics of the angle is ignored.
() ()
mobile tracked portion of the robot sys- The kinematics of the base (A3) and
manipulator (A5) can now be combined to c = cos , s = sin (A15)
tem can be given (Ref. 8) as
define the kinematics of the mobile ma-
nipulator as

Li 12-12_Layout 1 11/9/12 1:29 PM Page 346
Double Stage Plasma Arc Pipe

Welding Process
An innovative arc process is developed to produce consistent complete joint
penetration pipe welds of desired inner diameter convexity on open root joints
at all positions with 50% heat input reduction
BY X. R. LI, Z. SHAO, AND Y. M. ZHANG
ABSTRACT form a keyhole or deep narrow cavity

(Ref. 5). By doing this, the plasma jet is
Plasma arc welding (PAW) keyhole mode uses highly penetrating plasma jets to pro- able to heat the workpiece through the
duce narrow inner diameter (ID) beads but causes bead irregularity, undesirable wetting whole thickness, giving keyhole PAW high
angles, and spatter. For the melt-in mode, plasma jets are less penetrating and greater penetration capability (Ref. 6). On the
heat inputs are needed to achieve the needed penetration. As a result, wider weld beads other hand, melt-in mode, with reduced
are produced similarly as gas tungsten arc welding (GTAW). For orbital pipe welding, re- penetration capability, is suitable for join-
duced heat inputs and weld pools are needed to reduce the ID convexity around 12 ing thin sections (0.0251.5 mm or
WELDING RESEARCH
oclock and achieve the needed convexity around 6 oclock. To this end, a novel PAW 0.0010.060 in.), making fine welds at low
mode, namely the double-stage PAW, is proposed that uses a keyhole stage to build a par- currents, and joining thicker sections (up
tially penetrated keyhole and then a melt-in stage to finally reach complete joint pene- to 3 mm or 0.125 in.) at high currents. The
tration. While the keyhole stage helps reduce the heat inputs and weld pools, the melt-in operation of melt-in mode is similar to
stage finishes the complete penetration at reduced impacts from the plasma jets pro- that of GTAW process.
ducing the desired weld bead geometry and regularity. A closed-loop control system has Repeated experiments show that weld
been developed to adaptively determine the duration of the melt-in stage using arc sig- beads made by keyhole PAW typically
nals to assure the complete joint penetration. Extensive experiments have been con- have relatively large and irregular ID
ducted on stainless steel pipes around the full circumferance producing smooth weld (inner diameter) reinforcements associ-
beads of moderate width with no spatter. In comparison with keyhole PAW, bead geom- ated with a considerable amount of spat-
etry and regularity are significantly improved with slightly increased net heat inputs. In ter. On the other hand, those made by
comparison with melt-in PAW and GTAW, the net heat input is reduced approximately melt-in PAW show large ID weld beads
40% resulting in 40% reduction in ID weld bead width. that may cause excessive convexity around
12 oclock and concavity around 6 oclock.
ear relationship with the arc voltage under To resolve these issues, the authors pro-
Introduction
the same welding current. As a result, a pose the double-stage PAW process, which
measurement of arc voltage may indicate combines keyhole and melt-in mode into
Plasma arc welding (PAW) introduced a single welding procedure.
the arc length more accurately to better re-
by Gage in 1957 (Ref. 1) offers certain ad-
flect the penetration. In this paper, the
vantages. As an extension of gas tungsten
transferred arc PAW is studied for pipe Experimental System
arc welding (GTAW), PAW uses a constrict-
welding.
ing nozzle/orifice to create a plasma arc that A controlled PAW system is illustrated
The transferred arc PAW process typi-
has a higher heat density. This increased in Fig. 2. In the control system (left block
cally operates in either keyhole or melt-in
heat density not only provides higher arc in Fig. 2), control/feedback signals are iso-
(conduction) mode (Ref. 3). The special
temperatures, but also a much stronger arc lated and filtered to avoid possible dam-
torch used in PAW has a constraining ori-
force. In general, its most widely used con- ages to the embedded control
fice (Ref. 4) designed to deliver a highly
figuration is the transferred arc PAW, in system/computer and reduce noises. The
constrained plasma jet. Keyhole mode can
which the plasma arc is formed between the embedded controller is programmed to
obtain much deeper penetration com-
tungsten electrode and workpiece as shown obtain feedback signal measurements
pared with other arc welding processes. In
in Fig. 1. Its welding current is generally set from the welding process. The control al-
this mode, the plasma jet melts the work-
to be direct current electrode negative gorithm considers these measurements as
piece and displaces the molten metal to
(DCEN) in order to provide better control controller inputs and calculates to deter-
of the energy release (Ref. 2). In addition, mine the output that is the welding cur-
since the plasma arc is highly constricted rent. A Thermal Arc PWH-3A plasma
compared with electrical arcs in GTAW KEYWORDS welding torch was selected to conduct
process, the arc length has an excellent lin- PAW experiments. The torch was powered
Keyhole Mode by a constant current (CC) welding ma-
X. R. LI, Z. SHAO, and Y. M. ZHANG are with chine. The polarity of the power supply
Adaptive Intelligent Systems, LLC, Lexington, Melt-in Mode
Penetration Control was set to be DCEN. The torch was water-
Ky. Y. M. ZHANG (ymzhang@engr.uky.edu) is
also with the Department of Electrical and Com- Pipe Welding cooled by the coolant recirculator inside
puter Engineering and Institute for Sustainable Net Heat Input the power supply. Pure argon was used as
Manufacturing, University of Kentucky, Lexing- the shielding gas, plasma gas, as well as
ton, Ky. backside purging gas for the pipe. Also, to

Li 12-12_Layout 1 11/9/12 1:29 PM Page 347
Fig. 2 Structure of the controlled PAW experimental system.
Fig. 1 Basic principle of the plasma arc welding process.

A
avoid possible operation variations, all ex- current needs to be in-
WELDING RESEARCH
periments were conducted with an orbital creased considerably
pipe welding system. in order to produce
To demonstrate the effectiveness of the complete penetration
proposed double stage PAW process, on same joints. The B
Schedule 10 Grade 304 stainless steel pipes melt-in mode thus can
with 3.5-in. OD (outer diameter) was se- only be used to weld Fig. 3 Weld bead made by the keyhole PAW process. A Front side of
lected to conduct the experiments. Its alloy pipes with thicknesses the weld; B back side of the weld.
composition is listed in Table 1. Square butt much less than those
joints without an intentional root opening that can be welded implemented, and tested for the control of
were welded without filler metal. with the keyhole mode. In addition, since the keyhole PAW process (Refs. 912).
heat input is increased, the weld pool be- With the control system developed in Ref.
Observation of Problems comes large and sometimes collapses may 13, welding parameters can be adjusted to
occur. Experimental results are presented generate a consistent weld bead in the
The PAW process gives different per- below to demonstrate these issues with presence of various disturbances. Its prin-
formances in keyhole and melt-in modes. these two modes. ciple is to pulse the welding current to in-
For keyhole mode, the highly constricted tentionally produce a varying weld pool
arc is capable of reaching complete joint Welds Made in Keyhole Mode and associated varying arc voltage and
penetration rapidly. However, due to the then determine the weld penetration
high-penetration capability, the weld bead The weld beads produced by keyhole depth from the arc voltage measurements
produced with keyhole mode tends to have PAW are sensitive to a number of welding (Ref. 14). During the peak current period,
large ID reinforcement (convexity on the parameters including welding speed, weld- the welding torch stays at the same spot to
backside bead). At the same time, there ing current, flow rate and composition of gain accurate measurement of arc length
may be spatter blown out of the weld pool plasma/shielding gas, electrode setback, from the arc voltage signal and to deter-
by the strong plasma jet. On the other hand, torch standoff distance, etc. (Refs. 7, 8). mine if the desired penetration has been
for melt-in mode, its moderate penetration Extensive studies have been conducted on achieved. During the low-current base pe-
capability resembles that of the GTAW keyhole PAW at the University of Ken- riod, the torch moves for a certain fixed
process, which is capable of generating tucky Welding Research Laboratory. Ef- distance to the next spot and waits for the
smooth weld beads. However, the welding fective methods have been proposed, next pulsing control period.
Table 1 Alloy Composition (%) of Grade Table 2 Major Welding Parameters for Keyhole PAW Specimen
304 Stainless Steel Pipes
Parameter Value Unit
Carbon 0.08
Manganese 2.0 Base period 800 ms
Silicon 0.75 Base current 20 A
Phosphorus 0.045 Peak period Adjusted ms
Sulfur 0.03 Peak current 110 A
Chromium 18.0~20.0 Travel speed 1.22 mm/s
Molybdenum 2.00~3.00 Shielding gas flow rate 15 ft3/h
Nickel 8.0~12.0 Plasma gas flow rate 2.0 ft3/h
Nitrogen 0.10 Electrode setback 2.0 mm
Orifice diameter 1.75 mm

Li 12-12_Layout 1 11/9/12 1:29 PM Page 348
A B
Fig. 4 Weld bead made by the melt-in PAW process. A Front side of the weld; B back side of the weld.
pipe. At the same time, solidified weld

beads on the ID of the pipe exhibited geo-
metrical irregularities and excessive con-
vexities (over 2 mm reinforcement).
Welds Made in Melt-in Mode
As comparison, experiments with melt-

in mode PAW were also conducted. The
equipment, controller, as well as control al-
gorithms remained the same. To consider-
ably reduce the penetration capability,
WELDING RESEARCH
welding parameters were modified as listed

in Table 3. A typical specimen welded with
melt-in mode is shown in Fig. 4.
To reduce the penetration capability,
the orifice diameter was increased and the
plasma gas flow rate was reduced. Due to
the weakened arc force, a larger heat input
had to be used by increasing the welding
Fig. 5 Principle of the double-stage PAW process. current in order to achieve the desired
penetration. After these adjustments, the
process could operate in melt-in mode and
produce complete penetration, but it re-
One of the specimens welded by con- sembled the behavior of the GTAW
trolled keyhole PAW was produced with process.
major welding parameters listed in Table With fine-tuned welding parameters,
2. Its weld bead is shown in Fig. 3. complete joint penetration welds were pro-
To operate in keyhole mode, a relatively duced under melt-in mode. The weld bead
small orifice diameter is needed. A rela- was smooth without undercut and large
tively large plasma gas flow rate is also Fig. 6 Flowchart for the proposed double-stage convexity, similar to that made by the
needed to further enhance the penetration PAW procedure. GTAW process. The smooth weld bead met
capability of the plasma jet. Then, the com- visual inspection requirements. However,
plete joint penetration can be obtained due to the weak penetration capability,
through the strong penetration capability of tained by punching a hole with a strong
complete penetration can only be guaran-
the plasma jet. The resultant weld beads on plasma jet inside the liquid weld pool such
teed in a small welding speed range, which
both sides are narrow (compared with that a small portion of the melted metal in-
makes it difficult for manual welding prac-
GTAW). However, strong penetrating side the weld pool may be blown away as
tice. Furthermore, the HAZ is large because
plasma jets also cause problems for keyhole spatter. Immediately after welding, small
the weld penetration is achieved by conduc-
mode. Complete joint penetration is ob- particles of spatter were found inside the
tion of heat under melt-in mode. The ex-
cessive heat input (compared with keyhole
mode) generates a large weld pool, which
Table 3 Welding Parameters for Melt-In PAW Process Test may occasionally collapse.
Parameter Value Unit Double-Stage PAW Process

Base time 600 ms
The double-stage PAW process is pro-
Base current 30 A
posed to avoid problems and combine ad-
Peak time Adjusted ms
vantages in keyhole and melt-in modes.
Peak current 125 A
Travel speed 1.22 mm/s
Principles of Operation
Shielding gas flow rate 15 ft3/h
Plasma gas flow rate 1.0 ft3/h
In GTA pipe welding, a human welder
Electrode setback 2.0 mm
may adjust the welding current to com-
Orifice diameter 2.06 mm
pensate for changes in welding conditions

Li 12-12_Layout 1 11/9/12 1:29 PM Page 349
A B
Fig. 7 Top position weld bead made by the double-stage PAW process. A Front side of the weld; B back side of the weld.
A B
WELDING RESEARCH
Fig. 8 Side position weld bead made by the double-stage PAW process. A Front side of the weld; B back side of the weld.
(welding position, joint opening, etc.). For welding parameters and control parame- ture studies) is fitted by the least square
PA pipe welding, due to the narrow range ters; method;
of operable welding current, a pulsing 2) Output the base current Ib for the 7) The slope of the fitted curve is then
welding current is preferred. A pulsing base period Tb; compared with a predetermined criterion.
current also makes the weld pool dynamic 3) Output the first peak current Ip1 for If the slope is larger than the criterion (de-
and the resultant dynamic weld pool pro- the first peak period of Tp1. Both Ip1 and sired penetration is not reached), go to
vides the basis for the penetration control Tp1 are empirically determined; Step 5. Otherwise, jump to Step 2 to start
method proposed in this paper. 4) Switch to the second peak current the next control pulse period.
To be specific, the proposed pulsing Ip2 and then wait for a short period (typi- The flowchart in Fig. 6 further illus-
PAW process has two periods: peak and cally less than 50 ms); trates the above control scheme.
base. Each peak period has two stages. The 5) Sample the arc voltage and calculate The period and parameters for the first
first stage is to use a keyhole mode type of an average each 10 ms as the voltage stage determine how deeply the penetra-
operation to penetrate rapidly. However, measurement Vp; tion is established. A deeper first-stage
this stage stops before the keyhole fully pen- 6) For each four consecutive Vp meas- penetration reduces the heat input of the
etrates to the backside of the workpiece in urements (e.g., at t1, t2, t3, t4, as in Fig. 5), proposed process and width of the result-
order to prevent the problems in a normal a linear model (or high order models in fu- ant weld beads but increases the chance
keyhole mode aforementioned. Then, a
melt-in mode type of operation follows as Table 4 Welding Parameters for Double Stage PAW Process
the second stage to continue and finish the
establishment of complete joint penetration Parameter Value Unit
but in a smoother and slower manner with a
much lower penetration capability. The Base period 800 ms
weaker penetration capability similar as in Base current 20 A
GTAW can produce smooth complete joint First stage period 200 ms
penetration welds eliminating the geomet- First stage current 110 A
rical irregularities. That is, the first stage Second stage period Adjusted ms
achieves a penetration depth with a minimal Second stage current 60 A
heat input and the second stage finishes the Penetration criterion 0.0 for side position
complete penetration establishment process 0.2 for top position V/s
using an arc similar to a GTA weld. Smooth 0.4 for bottom position
and relative narrow welds may be produced Travel speed 1.22 mm/s
in the second peak stage. The base period Shielding gas 100% Argon
further reduces the heat input to freeze the Shielding gas flow rate 15 ft3/h
liquid metal before the next peak period be- Plasma gas 100% Argon
gins. The proposed method is illustrated in Plasma gas flow rate 2.0 ft3/h
Fig. 5. Purging gas 100% Argon
A preliminary control scheme with ref- Standoff distance 3.0 mm
erence to Fig. 5 is proposed as follows: Electrode setback 2.0 mm
1) Initialization of process, including Orifice diameter 1.75 mm

Li 12-12_Layout 1 11/9/12 1:29 PM Page 350
B
A
Fig. 9 Bottom position weld bead made by the double-stage PAW process. A Front side of the weld; B back side of the weld.
Weaving torch orbital welding test Weaving torch orbital welding test
WELDING RESEARCH
Fig. 10 Measured variables from the double-stage welding process on Fig. 11 Measured variables from double-stage welding process on top position
the top position sample pulse No. 1. sample pulse No. 2.
Table 5 Measurements of Weld Bead Geometry for Three Positions
Welding Position Top Side Bottom
OD bead width (mm) 9 8 9

OD reinforcement (mm) 0.5~0.8 0.2~0 0.5~0.8
ID bead width (mm) 4~5 4~5 4~5
ID reinforcement (mm) 0.3~0.8 0~0.2 0.3~0.7
bead widths and heat inputs and the toler- pression increases further. The develop-
ance to possible keyhole occurrences. ment of the weld pool in the second stage
In the second stage, the welding current is may finally reach an equilibrium due to the
reduced from that in the first stage, resulting reduced heat input and arc pressure, in
in a smaller arc force and less penetration which the desired weld pool widths on both
capability. However, although the weld pool sides of the pipe are achieved, correspon-
depression is reduced, it is still pronounced ding to the second stage peak welding cur-
and greater than that in GTAW. This still rent setting. Also, with the reduced arc force
pronounced local depression of the weld in the second stage, the weld bead is also
pool under the plasma jet relates the devel- smooth at this equilibrium. In order to stop
Fig. 12 Comparison of overall peak period for opment of the weld pool depression to arc the second peak period at the equilibrium, a
all three welding positions. length. As a result, the arc voltage may closed-loop control is needed to determine
measure the dynamic development of the the weld pool development by sampling and
for the occurrence of normal keyholes and weld pool in the second stage and be used to analyzing the arc voltage signal in real-time.
corresponding problems. A less deep first- control and achieve smooth weld beads with The penetration criterion defined in the
stage penetration increases the heat input acceptable bead widths on both sides of the control algorithm reflects the desired arc
and width of the weld beads but reduces pipe. From the beginning of the second voltage slope near the equilibrium. By
the chance for the occurrence of normal stage, the second peak current continues to changing the criterion in a small range, the
keyholes and corresponding problems. supply heat input into the weld pool. As a heat input in each pulse can be adjusted to
They need to be experimentally deter- result, the ID width of the weld pool may compensate the influence from different
mined based on the requirements on weld still increase such that the weld pool de- welding positions.

Li 12-12_Layout 1 11/9/12 1:29 PM Page 351
Table 6 Comparison of Net Heat Input in Unit Weld Bead Length
Welding Process Keyhole PAW Melt-in PAW Double Stage PAW GTAW
Base period time (ms) 800 600 800 N/A

Base period current (A) 20 30 20 N/A
Base period voltage (V) 18 19 18 N/A
First stage peak period time (ms) 250 350 200 N/A
First stage peak period current (A) 110 125 110 N/A
First stage peak period voltage (V) 25 26 25 N/A
Second stage peak period time (ms) N/A N/A 300 N/A
Second stage peak period current (A) N/A N/A 60 N/A
Second stage peak period voltage (V) N/A N/A 21 N/A
GTAW current (A) N/A N/A N/A 120
GTAW arc voltage (V) N/A N/A N/A 17
Travel speed (mm/s) 1.22 1.22 1.22 1.22
Total heat input (J/mm) 999 2021 1246 1672
Arc efficiency (%) ~47 ~47 ~47 ~67
Net heat input (J/mm) 470 950 586 1120
Typical backside bead width (mm) 3~4 ~10 5~6 9~11
Switching PAW Mode large time delay compared with the previously, two pieces of 3.5-in. OD
needed pulse period of welding current. Schedule 10 pipes were fitted without root
For experiments conducted with a sin- The valve reaction to the control signal opening. A set of optimal welding param-
WELDING RESEARCH
gle (either keyhole or melt-in) mode, the and the flow rate change from the gas sup- eters as listed in Table 4 were obtained
plasma torch configuration and welding ply to the torch end both take time. There- based on repeated experiments. The weld-
conditions can be set up in advance and fore, similar to torch configuration, the ing current was reduced from 110 A in the
then be kept unchanged during the entire plasma gas flow rate is set to a level that is first stage to 60 A in the second stage in
welding process. However, for the pro- just sufficient for keyhole operation. the peak period. With longer time dura-
posed double-stage PAW method, the The welding current controls the pene- tion than the first stage, the quasi-melt-in
PAW process needs to switch from keyhole tration capability and heat input of the second stage can provide sufficient heat
to melt-in mode in real-time. For pipe plasma arc. With a reduced welding current, input to finish with a smooth full penetra-
welding, complete joint penetration is the the heat input may become insufficient to tion weld bead.
first priority, and the plasma torch should achieve complete joint penetration if a sin- The penetration criterion indicates the
be configured to assure it. The challenge gle melt-in mode is used. However, since slope of arc voltage used to determine if
is how to switch from keyhole to melt-in the complete penetration penetration is al- the second stage period needs to continue
mode with a torch configured for keyhole most achieved in the first stage, the estab- or stop. Once the increase on the arc volt-
mode. This question can be simplified as lishment process for complete joint age starts to decrease or stop, an equilib-
how to reduce the penetration capability penetration penetration may still be able to rium status may have been established for
of plasma arc during welding operation. To continue and finish with the reduced heat the given second stage current such that
find an acceptable solution, several key input. This operation status is considered a the second stage needs to stop to start the
factors affecting penetration capability quasi-melt-in mode. As an electrical pa- base period to cool the liquid metal down.
should be considered. rameter, the welding current can be easily The criterion is changed according to
The physical configuration of the adjusted by the control system in real-time. welding position because the equilibrium
plasma torch is one of the most important Therefore, the transition from keyhole to is the balance among the penetration
factors in determining penetration capa- quasi-melt-in mode is switched by adjusting state, arc pressure, and welding position
bility. A smaller orifice diameter can pro- the welding current. dependent gravitational force. The change
vide better mechanical constriction. There are other welding conditions and in this criterion achieved weld bead con-
Larger electrode setback can achieve sim- parameters that also affect the penetration sistence with the welding position.
ilar effects. However, during welding op- capability, such as coolant recirculation At the beginning of each experiment, the
eration, it is not practical to change any of rate, overall torch size and rating, and dis- plasma torch rested at the starting point,
them. Hence, the torch configuration is so tribution of plasma gas. However, in com- and welding current increased gradually
determined that the penetration capabil- parison with the parameters/variables from zero to the initial welding current (e.g.,
ity is just sufficient for keyhole operation. aforementioned, their real-time adjust- 60 A) in a period called initialization period,
The plasma gas flow rate is another key ments are even more difficult. typically around 5 to 10 s. This period was
factor determining the penetration capa- performed as pre-heating, and routine pe-
bility. The PAW process is sensitive to this Experiment Results and Analysis riods for the proposed double-stage process
parameter. A simple adjustment of plasma start after the end of the initialization pe-
gas flow rate from 2.0 to 1.0 ft3/h can con- With the algorithm proposed above, riod. For pulsing operation, the plasma
siderably reduce the penetration capability extensive tests were conducted with dif- torch movement also changed in different
and change the operation mode from key- ferent welding and control parameter welding current level. In the first and sec-
hole to melt-in. It is technically possible to combinations to find optimal parameters. ond stage peak period, the torch rested to
use an adjustable flow control valve, and gain penetration and accurate arc voltage
the gas flow rate can be controlled by ex- Experimental Condition and Setup measurements. In the base period, the torch
ternal electrical signals. However, this flow moved along the pipe joint at a constant
rate control mechanism has a relatively For 304 stainless steel pipe described speed to the next spot.

Li 12-12_Layout 1 11/9/12 1:29 PM Page 352
The ultimate goal is to use the double- rent to achieve the keyhole and penetration second stages) of all pulses under three
stage process for the 5G fixed position, in rapidly. It can be observed from both Figs. different welding positions are compared
which the pipe joint is fixed and the plasma 10 and 11, after a short transitional stage and illustrated in Fig. 12.
torch moves around the joint circumfer- (around 50 ms), arc voltage starts to in- It can be seen, although there is varia-
ence. In the beginning, only the top position crease, which means that the plasma arc is tions in the peak period for each given
was tested to prove the feasibility of the making penetration pushing the weld pool welding position, their average values re-
method. Then, side and bottom/overhead surface toward the backside of the pipe flect the different settings of the penetra-
positions were tested. It was found that al- joint. At the end of the first peak period, the tion criteria. The penetration criteria for
though the same penetration criterion can arc voltage tends to continue to increase. If all three positions are 0.0 for side position,
still produce complete joint penetration in the keyhole stage continues after this point, 0.2 for top position, and 0.4 for bottom po-
all positions. By changing the penetration complete joint penetration would be sition. The averaged peak period exactly
criterion according to the welding position, achieved at keyhole mode, but the associ- reflected the penetration criterion setting.
more consistent weld beads around the pipe ated problems would also occur. Instead of The variation of peak period during each
joint circumference were achieved. Typical continued strong arc force, welding current pulse in a given welding position reflects
experiment results for these three positions is switched to a lower level into the quasi- the weld pool condition, weld joint varia-
are demonstrated in next section. In the fu- melt-in second stage. With reduced pene- tion, and specific welding position.
ture, an accelerometer will be installed on a tration capability and heat input, the weld
manual plasma welding torch. In this way, pool first bounces back from deep keyhole Heat Input Analysis
penetration criterion can be adjusted auto- and then the complete joint penetration es-
matically with the changing welding posi- tablishment is finished under the weaker arc With previous experimental results,
tion. force resulting in smooth weld beads. comparisons were made for heat inputs de-
From Figs. 10 and 11, it is noticed that livered to the workpiece (net heat input)
Double-Stage PAW Experiment Results the arc voltage reduced considerably after among GTAW process and three PAW
and Analysis the switching from first to second peak pe- process operation modes, i.e., keyhole,
riod. This reduction is caused by the melt-in, and double-stage modes. A number
Closed-loop controlled experiments bouncing back of the weld pool and also of studies have been conducted to investi-
WELDING RESEARCH
were conducted for top, side, and bottom the reduction in the welding current. Dur- gate the heat input and arc efficiency in arc
positions. By changing penetration crite- ing the quasi-melt-in second stage, extra welding processes (Refs. 1518). For the
rion in a small range, smooth and consis- heat input is added to the weld pool and proposed double-stage PAW process, the
tent welds with similar backside weld the arc length tends to increase. This trend primary objective was to produce complete
beads were obtained for all three posi- is reflected by the slow increase of the arc joint penetration with reduced net heat
tions. The produced weld beads are illus- voltage, since the arc length and arc volt- input. Arc efficiency gives a quantitative
trated in Figs. 79. The measured weld age have a linear relationship under a con- measurement of the fraction of total arc en-
bead geometry is listed in Table 5. stant welding current. By the end of ergy delivered to the workpiece. The total
By visual inspection, the backside weld second peak period, the weld pool has energy generated by the power supply can
bead widths for all three positions are be- reached an equilibrium status, in which be easily calculated based on the arc voltage
tween those produced by keyhole and melt- the heat input cannot make any further and welding current measurement. Refer-
in mode alone. Compared with keyhole weld pool development (arc length in- ring to the arc efficiency results from (Ref.
mode, the weld bead made by double-stage crease). The process then switches to the 16), a general comparison is possible for
PAW has less reinforcement on the backside base period for the weld pool to solidify PAW and GTAW processes.
and no spatter. This indicates that complete while preparing for the next control cycle. As introduced earlier, all three modes of
penetration is guaranteed by the first peak By repeating this process, consistent com- PAW process were operated in a pulsing
period, but there is no over penetration plete joint penetration weld beads can be manner. Not only welding current, the
(large reinforcement) due to the quasi-melt- produced. travel of the plasma torch was also pulsing
in second peak period. On the other hand, It can be observed that the second peak (staying still in the base period while move
compared with melt-in mode, the backside period in Fig. 11 lasts 100 ms longer than during the peak period). In order to com-
weld bead width made by double-stage in Fig. 10. This increase of duration was pare with continuously moving GTAW
PAW is narrower, which means reduced automatically determined by the control process, net heat input in unit length was
heat input and less chance to get melt algorithm. It might have been caused by a used. The calculated total energy input and
through. In addition, due to automatically less deep penetration established during arc efficiency from Ref. 6 were used first to
controlled heat input/second peak period, the first stage. More heat input was determine the energy delivered into the
the weld beads produced in all three posi- needed from the second peak period in workpiece. Travel speed and manner were
tions have similar bead width on both sides order to reach the equilibrium status. then taken into consideration to calculate
of the pipe joint, which in turn verified the Therefore, longer time was needed for the the net heat input in unit length. A compar-
control effect. Therefore, by visual inspec- arc voltage slope to become flat (arc volt- ison is made and listed in Table 6.
tion alone, the double-stage PAW process age stop increasing). Similar adjustments In Table 6, all the period times and weld-
not only successfully combined the advan- in the second peak period time were typi- ing currents were records from the embed-
tages of keyhole and melt-in mode cal in welding experiments for all three po- ded controller. For the arc voltage,
processes, but also successfully eliminated sitions. Therefore, the proposed control variations existed under a constant welding
the problems with those two processes. algorithm can effectively adjust the heat current, and only the average value was
During double-stage PAW experi- input in each pulse to ensure the estab- used to determine total energy input. Travel
ments, welding current and arc voltage sig- lishment of smooth complete joint pene- speed was set to constant on the orbital pipe
nals were also measured and recorded by tration weld beads. welding system and can be considered ac-
data acquisition system. Figures 10 and 11 For different welding positions around curate. Although a range is needed for pre-
illustrate two typical pulses selected from the circumference, different penetration cise calculation with arc efficiency, it is
a welding experiment on top position. criteria were set to reflect different re- sufficient to compare using only average arc
At the beginning of each pulse, the first quirements for heat input. The average efficiency for each process because their net
peak period applied 110 A of welding cur- peak period time (including both first and heat inputs differ significantly.

Li 12-12_Layout 1 11/9/12 1:29 PM Page 353
For the PAW process, plasma arc col- ated with keyhole PAW and melt-in PAW Materials Processing Technology 52: 6875.
umn generates considerably more heat to produce the desired complete joint pen- 6. Zhang, Y. M. 2001. Stochastic modeling
compared with the GTAW process. Using etration welds. of plasma reflection during keyhole arc weld-
the same welding current, the arc voltage The double-stage PAW process reduces ing. Measurement Science and Technology 12:
19641975.
for the PAW process is much larger than the weld pool width and heat input ap-
7. The Procedure Handbook of Arc Welding.
that of GTAW, which can be seen in Table 6. proximately 50% from the GTAW. 1973. The Lincoln Electric Company, Cleve-
However, the majority of the arc column The feedback control of the second land, Ohio.
heat is not transferred into the workpiece. stage period helps achieve the desired con- 8. Howard, B. C. 1989. Modern Welding
From net heat input data in Table 6, it sistence of welds despite the difference in Technology, 2nd ed. New Jersey: Prentice Hall.
can be clearly observed that the four the weld position. 9. Liu, Y., and Zhang, Y. 2007. Control of
processes under comparison can be divided The voltage-based control of the sec- dynamic keyhole welding process. Automatica
into two groups. The one with the net heat ond stage period is suitable for implemen- 43: 876884.
input around 1000 J/mm includes melt-in tation at manufacturing sites. 10. Liu, Y., and Zhang, Y. 2003. Modeling
and control of quasi-keyhole arc welding
PAW and the GTAW processes. This ex- Experiments confirmed the effective-
process. Control Engineering Practice 11:
plains why the melt-in PAW produces welds ness of the proposed double-stage PAW 14011411.
similar to those using the GTAW process. process and its feedback control method. 11. Lu, W., Lin, W. Y., and Zhang, Y. M.
Although the plasma arc voltage is larger 2004. Nonlinear interval model control of quasi-
under the same welding current, its net heat keyhole arc welding process. Automatica 40:
Acknowledgment
input delivered to the work-piece is compa- 805813.
rable to that of the GTAW. Keyhole and 12. Zhang, Y. 2001. Stochastic modeling of
This work is funded by the Navy SBIR plasma reflection during keyhole arc welding.
double-stage PAW processes are in the
Program under contract N00024-08-C- Measurement Science and Technology 12:
group with a net heat input around 500
4111 and the Kentucky Cabinet for Eco- 19641975.
J/mm. As a result, the weld beads with
nomic Development (CED) Office of 13. Li, X. 2010. Model predictive control
smaller backside width were produced.
Commercialization and Innovation under over manual pipe welding process on stainless
Compared with keyhole PAW mode, the steel. Electrical Engineering. PhD, Lexington,
agreement KSTC-184-512-08-048.
double-stage PAW does not increase the net University of Kentucky, pp. 91118.
WELDING RESEARCH
heat input delivered in to the workpiece. 14. Li, X., Heusman, J., Kvidahl, L., Hoyt,
The combination of two modes of PAW not References P., and Zhang,Y. 2011. Manual keyhole PAW
only reduced net heat input (compared with with application. Welding Journal 90(12): 258-s
melt-in mode), but also significantly im- to 264-s.
proved the weld bead (compared with key- 1. Pires, J. N., Loureiro, A., and Bolmsjo, G. 15. Fuerschbach, P. W., and Knorovsky, G.
2006. Welding Robots: Technology, System Issues A. 1991. A Study of melting efficiency in plasma
hole mode), with smaller backside
and Applications, Springer. arc and gas tungsten arc welding. Welding Jour-
reinforcement, moderate backside width, 2. C. L. Jenney, A. OBrien, eds. 2001. Weld- nal 70: 287297.
and no spatter. ing Handbook, 9th ed. American Welding Soci- 16. DuPont, J. N., and Marder, A. R. 1995.
ety, Miami, Fla. Thermal efficiency of arc welding processes.
Conclusions 3. Messler, R. W. 1999. Principles of Weld- Welding Journal 74: 406416.
ing: Processes, Physics, Chemistry, and Metal- 17. Giedt, W. H., Tallerico, L. N., and Fuer-
lurgy, John Wiley. schbach, P. W. 1989. GTA welding efficiency:
The double-stage PAW process has
4. Welding Handbook. 1990. Vol. 2, 9th ed., calorimetric and temperature field measure-
been proposed, designed, and imple- Welding Process, American Welding Society, ments. Welding Journal 68: 2832.
mented as a novel welding process. Doral, Fla. 18. Berezovskii, B. M. 1979. The thermal ef-
The innovative double-stage PAW 5. Martikainen, J. 1995. Conditions for ficiency of the process of penetrating metals
process successfully combines the advan- achieving high-quality welds in the plasma-arc with a welding arc at the surface. Automatic
tages and eliminates the problems associ- keyhole welding of structural steels. Journal of Welding 10: 1821.
Authors: Submit Research Papers Online
Peer review of research papers is now managed through an online system using Editorial Man-
ager software. Papers can be submitted into the system directly from the Welding Journal page on
the AWS Web site (www.aws.org) by clicking on submit papers. You can also access the new site
directly at www.editorialmanager.com/wj/. Follow the instructions to register or log in. This online
system streamlines the review process, and makes it easier to submit papers and track their progress.
By publishing in the Welding Journal, more than 69,000 members will receive the results of your
research.
Additionally, your full paper is posted on the American Welding Society Web site for FREE ac-
cess around the globe. There are no page charges, and articles are published in full color. By far, the
most people, at the least cost, will recognize your research when you publish in the world-respected
Welding Journal.

NI December 2012_Layout 1 11/9/12 11:11 AM Page 354
$6450.3&13*/54
$6450.3&13*/54
$VTUPNSFQSJOUQSPEVDUTPGBSUJDMFTBOEGFBUVSFTGSPN
8FMEJOH+PVSOBMDSFBUFQPXFSGVMNBSLFUJOHUPPMTUIBUU
TFSWFBTJOTUBOUMZDSFEJCMFFOEPSTFNFOUT
5BLF"EWBOUBH
PGZPVS&EJUPSJB
&YQPTVSF
6TFSFQSJOUTUPNBYJNJ[F
ZPVSNBSLFUJOHJOJUJBUJWFTBOE
TUSFOHUIFOZPVSCSBOETWBMVF

SEPT. 1621, 2013
ESSEN GERMANY

YOUR HUBS TO OTHER MARKETS:

ARABIA CHINA

JAN. 7 10, 2013 JUNE 18 21, 2013
DUBAI SHANGHAI

RUSSIA BRAZIL

JUNE 25 28, 2013 OCT. 1 4, 2013
MOSCOW SO PAULO
RUSSIA INDIA
MAY 2014 SEPT. 18 20, 2014
ST. PETERSBURG MUMBAI
Essen Trade Shows c/o GACC, Karen Vogelsang

1500 Front Street, Suite B-1, Yorktown Heights, NY 10598, USA
Fon: +1. 9 14. 9 62-13 10, Fax: +1. 9 14. 9 62-13 20
karen@essentradeshows.com Call 866.879.9144 or
www.schweissen-schneiden.com
sales@fosterprinting.com
354-s DECEMBER 2012

arcos_FP_TEMP 11/7/12 3:33 PM Page C3
Arcos Electrodes
Meet Exacting Military
and Nuclear Standards.
We Can Meet Yours, Too!

When critical welding conditions necessitate To learn more about the many reasons you should
performance without compromise, you can depend insist on Arcos high alloy, stainless and nickel
on Arcos to provide you with a comprehensive line electrodes for your essential welding applications,
of premium quality high alloy, stainless and nickel call us today at 800-233-8460 or visit our website
electrodes to conform to your stringent requirements. at www.arcos.us.
You can be assured of our commitment to superior Arcos Industries, LLC
welding products because Arcos quality meets or {ViU
>i]*nx
exceeds demanding military and nuclear application *i\xxU>\xx
specications. Arcos dedication to excellence has
earned these prestigious certications:
U ASME Nuclear Certicate # QSC448
U ISO 9001: Certied
U Mil-I 45208A Inspection
U Navy QPL

lincoln electric_FP_TEMP 11/7/12 3:43 PM Page C4
Portable Plasma
ma Cutting Macch
CNC Cutting Systems
Robotic Tuube Cuutting and Pro

WJ 2012 12 PDF

Uploaded by

Copyright:

Available Formats

WJ 2012 12 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WJ 2012 12 PDF

Uploaded by

Copyright:

Available Formats

December 2012 Cover_4/06 Cover 11/12/12 9:27 AM Page C1

For Info go to www.aws.org/ad-index

WeldOffice is a registered trademark of ASMEIX Corporation dba C-SPEC

WPQ - Create and manage multi-code welder qualification records.

NDE - Simple, fast and accurate nondestructive examination and visual

Turbo-INT - Instantly resolves code disputes involving welding procedures,

For Info go to www.aws.org/ad-index

CONTENTS December 2012 Volume 91 Number 12

Program Aids in Modeling Welding Thermodynamics

78 From the Lab to the Production Floor: Students Learn It All

Welding Research Supplement

78 showed improved weld metal properties

Meeting the Welding Officers

Vice President Nancy C. Cole

For more information, visit www.esabna.com/esab-warrior or scan this QR code.

ESAB Welding & Cutting Products / esabna.com / 1.800.ESAB.123

WASHINGTON BY HUGH K. WEBSTER

Manufacturing Competitiveness Act Bill Introduced to Limit Reach of

FROM SIMPLE SOFTWARE

The XT series of iCNCs from Victor Thermal Dynamics brings cutting

We Bring Intelligence to the Table. TM

For Info go to www.aws.org/ad-index

Copyright 2012 by American Welding Society in both printed and elec-

ulators along with interactive educational exhibits. Descriptions of each award-winning

Oil and Gas High Alloy Joining

Marking Time Sundial Earns AWS Extraordinary Welding Award

AWS District 8 Director Joe Livesay presented the Societys

(Bottom) At a ceremony on October 9, AWS District 8 Director Joe

Mechanic on a Mission Honored as a

/ Battery Charging Systems / Welding Technology / Solar Electronics

For info go to www.aws.org/ad-index

In addition, Children Changing the World, a documentary about

Advanced Resistance and Automotive

Arabia Essen 2013

said, pointing out its impact.

ASTM Launches New Initiative to Address

LEADERS & INNOVATORS

Advanced Products, Systems & Solutions

Over 250 NGT Systems Installed Worldwide

1BDPJNB $"64"]UFM 

A: This is an interesting question, particu-

For info go to www.aws.org/ad-index

selected for each joint design and clear-

PRODUCT & PRINT

Software Platform Features New Baseline Cost Models

Environmentally Safe it is safer for workers and the environment

Walter Surface Technologies

Software Integration Allows

The company and Metamation have

Weld Simulator Combines

of tools to select from, provides photos of

For info go to www.aws.org/ad-index

chance to explore this career path and also

Software Helps Improve

RobotExpert software, a robotic sim-

For info go to www.aws.org/ad-index

For info go to www.aws.org/ad-index

For info go to www.aws.org/ad-index For info go to www.aws.org/ad-index

Metal Fabricator Publishes

1BDPJNB $"64"]UFM