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AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
January 2013
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January 2013 Cover_4/06 Cover 12/13/12 10:28 AM Page C1
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To be the preferred supplier of welding
positioning equipment to Liebherr USA, you
have to do a lot of things right. And Koike
Aronson does.
The Virginia facility of Liebherr, one of
the worlds leading manufacturers of mining
equipment, has been buying welding
positioners from Koike for years. Some of the
original machines are still in operation, reports
Jim Farley, project manager. And the service support
is terrific. When it comes to responsiveness we can
get directly to a person who can help.
The guys on the floor are sold on Koike, too.
I love the Head and Tailstock, says Fabrication
Lead Man Charles Moler. Koike worked with us
so it was designed to fit our needs and reduce
set-up time for each rotation.
Koike Aronson, Inc./Ransome Arcade, NY USA 800-252-5232
www.koike.com
Weve had such outstanding success
with Koike that we havent spoken to
anyone else.
Left to Right:
Jim Farley
Project Manager
Charles Moler
Fabrication Lead Man
Jim Pfizenmayer
Fabrication Supervisor
Robert Egloff
Fabrication Manager
Koike Aronson Ransome
Head and Tailstock positioning
a Liebherr mining truck frame.
Weve had such outstanding success
with Koike that we havent spoken to
anyone else.Jim Farley, Project Manager
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koike aronson_FP_TEMP 12/11/12 2:44 PM Page 1
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camfil farr_FP_TEMP 12/11/12 3:10 PM Page 2
3 WELDING JOURNAL
CONTENTS
28 FABTECH 2012
Weldings premier marketplace, education, business,
networking, awards, skills, and personal recognition all
came together at this grand exhibition
A. Cullison et al.
38 What You Should Know about Hybrid Laser Arc Welding
Take a look at the pros and cons of this unique combination
of lasers and gas metal arc welding
P. Denney
42 Effect of Tool Angle on Friction Stir Weldability of AISI 430
The parameters for getting the best weld in austenitic stainless
steel are studied
M. B. Bilgin et al.
48 Benefits of Remote Laser Welding in the Automotive Industry
Remote laser beam welding is shown to have advantages in
welding high-volume components
T. Ryba et al.
54 Friction Stud Welding of Dissimilar Metals
A milling machine was used to produce a sound joint between
a steel stud and aluminum plate
G. Zhang et al.
Welding Journal (ISSN 0043-2296) is published
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
$14.00 single issue for international. American
Welding Society is located at 8669 Doral Blvd., Ste.
130, Doral, FL 33166; telephone (305) 443-9353.
Periodicals postage paid in Miami, Fla., and addi-
tional mailing offices. POSTMASTER: Send address
changes to Welding Journal, 8669 Doral Blvd.,
Suite 130, Doral, FL 33166. Canada Post: Publi-
cations Mail Agreement #40612608 Canada Re-
turns to be sent to Bleuchip International, P.O. Box
25542,London, ON N6C 6B2
Readers of Welding Journal may make copies of
articles for personal, archival, educational or
research purposes, and which are not for sale or
resale. Permission is granted to quote from arti-
cles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
excluded from copyright.
Departments
Editorial ............................4
Press Time News ..................6
News of the Industry ..............8
International Update ............12
Stainless Q&A ....................14
RWMA Q&A ......................20
Product & Print Spotlight ......22
Letter to the Editor ..............58
Coming Events....................60
Certification Schedule ..........62
Conferences ......................64
Welding Workbook ..............70
Society News ....................73
Tech Topics ......................76
Guide to AWS Services ........94
Personnel ........................98
Classifieds ......................104
Advertiser Index ................106
1-s Interfacial Microstructure of Diode Laser Brazed AZ31B
Magnesium to Steel Sheet Using a Nickel Interlayer
The brazeability of a magnesium alloy to steel was improved
with an electro-deposited microlayer of Ni
A. M. Nasiri et al.
11-s Processing Effects on the Friction Stir Weld Stir Zone
The understanding of the correlation between microstructural
evolution and the varying thermomechanical cycles a weld
undergoes is further advanced with this study
J. Schneider et al.
20-s Evaluation of Heat-Affected Zone Hydrogen-Induced
Cracking in Navy Steels
Critical stress ratio and embrittlement index were determined for
high-strength steels in an evaluation of hydrogen-induced cracking
in the heat-affected zone
X. Yue and J. C. Lippold
Features
Welding Research Supplement
28
48
38
January 2013 Volume 92 Number 1
AWS Web site www.aws.org
On the cover: Laser welding of a powertrain component. (Photo cour-
tesy of TRUMPF, Inc., Farmington, Conn.)
January 2013_Layout 1 12/13/12 3:45 PM Page 3
EDITORIAL
As most of you know, there is a dire shortage of skilled and educated welders and
other welding professionals, particularly in manufacturing and energy production. The
shortage of skilled welding personnel has reached a critical level. By 2019, it is estimat-
ed there will be a need for at least 239,000 new and replacement welding professionals.
To meet the shortage, we need to improve the image of welding to draw more people
into our field. We also need to train these new people and provide additional education
opportunities for those who have already chosen welding as their profession. The pay
is good, but increased skills and education can lead to even better compensation.
Traci Tapani, copresident of Wyoming Machine, has described her companys and
the countrys need for welders in an article published in The New York Times. For the
past 19 years, she and her sister have been copresidents of a sheet metal company they
inherited from their father in Stacy, Minn.
Many years ago, people learned to weld in various ways they did not under-
stand metallurgy, modern cleaning and brushing techniques, and how different metals
and gases, pressures, and temperatures had to be combined. Moreover, in small man-
ufacturing businesses like hers, explained Tapani, we do a lot of low-volume, high-
tech jobs, and each one has its own design drawings. So a welder has to be able to read
and understand five different design drawings in a single day.
Women are an underused resource in welding in the United States. According to the
Dept. of Labor, women represent only 6% of the U.S. welding and brazing workforce
and only 2% of welders are women. History has shown that women have stepped up in
times of need. Everyone has heard of Rosie the Riveter, but there was also Wendy the
Welder and Barbara the Brazer. Welding and brazing are great occupations for women
as well as men. There are many opportunities in many different types of work. We just
need to publicize those opportunities and showcase the role models we already have.
Thus, lets celebrate women in welding and recognize those women who are the role
models and the trendsetters. One of those role models is a young female welder whose
great-grandmother welded during World War II and whose grandfather welded in a
shipyard. She is proud to follow in their footsteps. Another is a trainer who sums up the
opportunities in this way, Theres an opportunity in this industry to have a career for
life. You can work on the manufacturing floor or in the field as a welder, or as an iron-
worker building a stadium. You can become an engineer and develop welding products
or travel around the country as a Certified Welding Inspector. There are also women
CWIs, welding engineers, welding engineering technicians, welding quality assurance
professionals, nuclear and nonnuclear welders, materials engineers who do welding and
brazing, welding sales reps, CEOs, COOs, members of the AWS board of directors,
chairs and past chairs of AWS Sections, and speakers at Section meetings and interna-
tional conferences. Thus, we already have good female role models, but we need to do
a better job of getting the word out about them. We need to encourage women in all
ways and in all employment categories of our profession. I challenge you to be a men-
tor to a capable woman welding professional. Give her some encouraging words, or bet-
ter yet, give her an opportunity.
This year I am proud to annouce that the AWS Foundation now offers two new
scholarships that have been endowed specifically for capable females to improve their
skills and education. In addition, Airgas is offering a
discount for all female card-carrying members of
AWS in honor of the companys female leaders. This
year, lets celebrate women in welding and help fill
the need for properly skilled and educated welding
professionals who will make our country proud.
JANUARY 2013 4
Officers
President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
U. Aschemeier (Dist. 7), Miami Diver
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
R. E. Brenner (Dist. 10), CnD Industries, Inc.
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (At Large), Tri Tool, Inc.
S. A. Harris (Dist. 4), Altech Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (Dist. 17), Victor Technologies
W. A. Komlos (Dist. 20), ArcTech, LLC
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), Desert Rose H.S. and Career Center
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Zephyr Products, Inc.
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Women: An Underused
Resource in Welding
Nancy C. Cole
AWS President
Editorial January 2013_Layout 1 12/12/12 2:28 PM Page 4
/ Made for the TransSteel Series, the VR 5000 Case
is a wirefeeder that feels most at home in maritime
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Withstanding the toughest requirements, its 100%
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PRESS TIME
NEWS
AWS Holds Open House to Celebrate World Headquarters
More than 200 guests attended an open house celebration held at the American Weld-
ing Societys (AWS) new world headquarters in Doral, Fla., on November 30. The reno-
vated, 122,482-sq-ft building has five stories and offers space for future growth.
Over the past few years, AWS has seen a significantly increasing interest from across the
globe in attaining AWS certifications, standards, and membership, said Ray Shook, execu-
tive director, AWS. Weve launched a global initiative that will allow us to better serve the
welding community, and our new modern headquarters is one of the primary steps to be-
coming more accessible to our members.
During the event, AWS President William A. Rice Jr. showed a photo journey through
the organizations 93-year history. In addition, Rice announced that he along with his wife,
Cherry, donated $50,000 for a new scholarship intended to help women interested in weld-
ing careers. The AWS Foundation will match that amount for a total of $100,000.
Also, a 6-ft-tall bronze welder sculpture donated to AWS by Bill and Cherry Rice
was unveiled. Noted artist Gregory Johnson of Cumming, Ga., created the welder that
weighs more than 225 lb and kneels on top of a base made by D&D Mobile Welding and
Fabrication, Inc., Fort Lauderdale, Fla. The figure resides in the first floor lobby of the
AWS headquarters building.
Im thrilled. It has met and exceeded my expectations, Johnson said of the sculp-
ture, adding he is humbled AWS visitors will see his artistry.
Creating the sculpture took about 200 hours, spanning over the course of two months.
Johnson first made an armature using threaded rods and braided copper wire, then
pressed clay onto this form. He then kept refining and detailing his work. As a refer-
ence, he looked at welders attire, including a helmet, jacket, gloves, pants, and shoes.
The bronze welder holds a gas metal arc welding gun in its right hand. Eagle Bronze,
Inc., Lander, Wyo., performed the mold and casting duties, which Johnson oversaw.
Among the attendees were AWS leadership, consisting of current officers, board
members, and past presidents, as well as international counterparts and agents, ven-
dors, and community members. Speakers included The Honorable Michael Bileca,
Florida House of Representatives, and Miguel Otero, deputy chief of staff for Congress-
man Mario Diaz-Balart. Diaz-Balart has an office in the building. The event video is at
http://videos.aws.org.
The day concluded with AWS employees guiding visitors around the building where
they met spokespersons from each department. Lunch was catered by Carolina Ale
House, a tenant, and served on the second floors covered patio area.
Lincoln Electric Acquires Businesses from ITT
Lincoln Electric Holdings, Inc., Cleveland, Ohio, has acquired the Kaliburn, Burny,
and Cleveland Motion Control (CMC) businesses from ITT Corp. Terms of the transac-
tion were not disclosed, but all three businesses are consolidated in a headquarters and
manufacturing operation in Ladson, S.C. The combined annual sales in 2011 were $35
million. The three operations employ approximately 140 people.
JANUARY 2013 6
MEMBER
Publisher Andrew Cullison
Publisher Emeritus Jeff Weber
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coordinator Melissa Gomez
Design and Production
Production Manager Zaida Chavez
Senior Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Paneca
Senior Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Sylvia Ferreira
sferreira@aws.org
American Welding Society
8669 Doral Blvd., Doral, FL 33166
(305) 443-9353 or (800) 443-9353
Publications, Expositions, Marketing Committee
D. L. Doench, Chair
Hobart Brothers Co.
S. Bartholomew, Vice Chair
ESAB Welding & Cutting Prod.
J. D. Weber, Secretary
American Welding Society
D. Brown, Weiler Brush
T. Coco, Victor Technologies International
L. Davis, ORS Nasco
J. Deckrow, Hypertherm
D. DeCorte, RoMan Mfg.
J. R. Franklin, Sellstrom Mfg. Co.
F. H. Kasnick, Praxair
D. Levin, Airgas
E. C. Lipphardt, Consultant
R. Madden, Hypertherm
D. Marquard, IBEDA Superflash
J. F. Saenger Jr., Consultant
S. Smith, Weld-Aid Products
D. Wilson, Well-Dean Enterprises
N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrup Grumman Ship Systems
D. J. Landon, Ex Off., Vermeer Mfg.
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
N. Scotchmer, Ex Off., Huys Industries
R. W. Shook, Ex Off., American Welding Society
Copyright 2013 by American Welding Society in both printed and elec-
tronic formats. The Society is not responsible for any statement made or
opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not in-
tended for use without independent, substantiating investigation on the
part of potential users.
Ribbon cutting ceremony participants at the AWS
open house were (from left) Executive Director
Ray Shook; Treasurer Robert Pali; Vice Presi-
dent-Elect Dave McQuaid; Vice Presidents
David Landon and Dean Wilson; President-
Elect Nancy Cole; and President William Rice.
Noted artist Gregory Johnson poses
next to the bronze welder he sculpted
that resides in the first floor lobby of
the AWS headquarters building.
PTN January 2013_Layout 1 12/12/12 2:04 PM Page 6
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greiner_FP_TEMP 12/11/12 2:42 PM Page 7
NEWS OF THE
INDUSTRY
Green River Community College Students
Weld Junction Boxes to Curb Wire Theft
The city of Auburn, Wash., and Green River Community Col-
lege teamed up to fight the growing problem of copper wire theft
in the city by welding junction boxes shut.
Thieves were stripping our street light junction boxes cost-
ing the city thousands of dollars to repair, said Mayor Pete Lewis.
They opened these boxes, cut the splices, and pulled out wire
from box to box. Each junction has three wires that run 100150
ft through an underground conduit to the next junction box.
According to Glenda Carino, Auburns public affairs and mar-
keting manager, the project started on Oct. 10 and finished Nov.
14 with a total of 15 actual work days. There were approximately
an average of 5 students per day for an estimate of between 500
and 600 man hours. The actual number of boxes welded was 1833.
JANUARY 2013 8
Student Gilbert Serrano performs shielded metal arc welding
in the Trades and Advanced Technology Center on the Santa
Fe Community College campus. Jeremy Fiedler serves as his
instructor. (Photo courtesy of Barbara Woltag.)
The training needs of two large local organizations,
as well as nationwide demand, have led to creating a new
welding degree program at Santa Fe Community Col-
lege (SFCC), Santa Fe, N.Mex.
An Associate in Applied Science degree in welding
will be offered starting in the spring 2013 semester. A
welding certificate is also available.
The program is possible in large part thanks to the
support of Los Alamos National Security, LLC, which
anticipates the need for welders for construction proj-
ects planned for Los Alamos National Laboratory
(LANL) over the next 15 years.
Originally, the college developed a welding training
program to meet the needs of LANL and Caterpillar
Santa Fe, a manufacturer of products that reduce diesel
engines exhaust emission levels, that has also supported
the programs development. When Caterpillar purchased
the former CleanAIR Systems in 2010, no welding train-
ing existed in the community; the company provided the
college with funds to support a welding lab on campus,
which will now allow it to offer a full welding degree pro-
gram.
We believe that Santa Fe Community College needs
to launch these high-skill and high-wage training pro-
grams because it is the colleges responsibility to become
the economic engine for Santa Fe. This collaboration
with our partners will advance our economy and provide
new employment for years to come, said SFCC Presi-
dent Ana M. Guzmn.
In addition, SFCCs Dean of Economic and Work-
force Development and Director of the Sustainable Tech-
nologies Center, Randy Grissom, stated the colleges
Trades and Advanced Technology Center is prepared to
expand with local demand.
For more information, visit www.sfcc.edu.
Need for Training Leads to New Welding Degree
Program at Santa Fe Community College
To prevent the theft of cop-
per wire from street light
junction boxes in the City
of Auburn, Washington,
Green River Community
College students and Pub-
lic Works mentors welded
them shut. As pictured in
action, a welder uses the
shielded metal arc process.
NI January 2013_Layout 1 12/12/12 2:52 PM Page 8
9 WELDING JOURNAL
Scott Schreiber, who heads the colleges welding program,
also mentioned the opportunity for students to work side by side
with city crews is invaluable. This is the first time field mentor-
ships have been offered, Schreiber said.
Additionally, Carino pointed out that city crews were happy
with the students outstanding job, and as of press time, there
were no reports of new wire theft from these junction boxes since
the project began.
ESAB Partners with KUKA Robotics
ESAB, Florence, S.C., a manufacturer of welding and cutting
equipment and welding filler metals, is partnering with KUKA
Robotics, Shelby Township, Mich., whose robots are used in a
range of industries.
Our relationship with KUKA will enable us to create prod-
ucts and services that offer greater value and solutions to the ro-
botic arc welding customers and make our automation facility
even more capable of providing wide-ranging services and solu-
tions to the welding community, said George Learmonth, VP
of ESAB Automation.
Austal Lays Jackson (LCS 6) Keel
Austal recently held a keel-laying ceremony for the third
Independence-variant Littoral Combat Ship (LCS), Jackson
(LCS 6).
Dr. Katherine Holmes Cochran, the ships sponsor, welded
her initials as the keel authenticator, assisted by J. B. Craig III,
an A Class welder. Cochran, an associate professor at the Uni-
versity of Southern Mississippi, is the daughter of U.S. Senator
Thad Cochran, a native of Pontotoc, Miss., currently holding his
sixth term in office.
Due to Austals modular approach to ship manufacture, 35 of
the 37 modules used to form this 127-m aluminum trimaran de-
sign are already being assembled. Four modules have been moved
Katherine Holmes Cochran, daughter of Mississippi Senator Thad
Cochran, and Austal USA welder J. B. Craig III weld her initials
as part of the keel-laying ceremony for Jackson (LCS 6).
For info go to www.aws.org/ad-index
NI January 2013_Layout 1 12/12/12 2:53 PM Page 9
JANUARY 2013 10
from Austals Module Manufacturing Facility, three of which are
erected in the final assembly bay in their prelaunch position.
Jackson (LCS 6) is the first of ten Independence-variant
Littoral Combat Ships awarded by the Navy to Austal as prime
contractor, said Craig Perciavalle, Austal USAs senior VP of
operations.
Koike Aronson Acquires Majority Interest in
Brazilian Welding Positioners Manufacturer
Koike Aronson, Inc./Ransome, Arcade, N.Y., a subsidiary of
Koike Sanso Kogyo, Tokyo, Japan, recently announced the pur-
chase of the majority of shares of Biondi Maquinas, Dispositivos
E Ferramentas LTDA, Jaboticabal, Brazil, a manufacturer of
welding positioners and similar equipment, made through its sub-
sidiary, Koike Aronson Brasil Business Consulting LTDA.
The new company is named Koike Aronson Biondi
Maquinas, Dispositivos E Ferramentas Do Brazil, LTDA. The
current owners, Nelson Biondi and Evandro Faccio, will remain
with the company, with Mr. Biondi retaining a minority holding.
A new facility is planned to be built in Jaboticabal to accommo-
date the growing demand for Koike and Biondi products in Brazil.
Also, in related news, the largest weld positioner Koike has
created, a 130-ton model, has now been installed and is operable
at Harbin Electric Corp., Qinhuangdao City, China (as pictured).
Rob Flaig served as the companys on-site coordinator, assisted
by Matt Hopkins. The $1.5 million device is set to weld and clad
component parts for a new nuclear reactor in that region. It can
hold, rotate, and tilt 550,000 lb.
Boy Scouts Earn Welding Badges
Thanks to Local Tech Center and 3M
Nine Boy Scouts earned welding merit badges with assistance
from the Northeast Metro District 916 Career and Technical Cen-
ter, White Bear Lake, Minn., and 3M Co., St. Paul, Minn.
Representatives from 3M, including Don Garvey, a construc-
tion industrial hygienist, Derek Baker, a welding technical serv-
ice specialist, and Kim Gates, a welding marketing manager, sup-
plied the classroom portion regarding welding safety, personal
protective equipment, and different types/mechanics of welding
with their common uses. At Northeast Metros welding lab, Tony
Waldner provided welding instruction and coaching.
The Scouts got hands-on time with the gas metal arc welding
gun. The merit badge requires they scribe their initials on a car-
bon steel plate and cover the initials with a weld bead; cover a
small plate with weld beads side by side; and tack and weld two
plates with a square groove butt joint, a T joint with fillet welds
and a lap joint with fillet welds on both sides.
The Scouts were excited to learn a new skill, and several ex-
pressed interest in the possibility of making it a career, especially
when discussing current job opportunities.
Chrysler Group Invests $240 Million to
Increase Engine Production, Adds Jobs
Chrysler Group LLC will invest nearly $240 million to increase
engine capacity and add about 1250 new jobs at several Michi-
gan facilities.
Sergio Marchionne, Chrysler Group chairman and CEO, con-
firmed the company would make investments and add jobs at the
following local plants: Mack I Engine Plant, $198 million to pro-
duce the Pentastar (V-6) engine; Mack I Engine Plant, adding
up to 250 new jobs, subject to market conditions; Trenton North
Engine Plant, investing an additional $40 million to add a flexi-
ble production line that can run the Pentastar engine and Tiger-
shark (I-4) engine; and Warren Truck Assembly Plant, adding
1000 new jobs on a third crew in March 2013 to produce the 2013
Ram 1500.
Detroit Mayor Dave Bing, other local officials, and UAW Vice
President General Holiefield joined employees to celebrate the
news at the Mack I Engine Plant.
Mack Avenue Plant Manager Bob Hollingsworth recently spoke at
the Mack 1 Engine Plant. Chrysler Group LLC Chairman and CEO
Sergio Marchionne was also present to announce a $240 million
investment for engine production. (Photo courtesy of Chrysler.)
As shown above, now installed and operable at Harbin Electric in
China, is the 130-ton weld positioner fabricated by Koike. It is set
to weld and clad component parts for a new nuclear reactor.
Welding instructor Tony Waldner of Northeast Metro and Boy Scouts
from Troop 200 show off their welding skills, which are part of earn-
ing their welding merit badges.
continued on page 102
NI January 2013_Layout 1 12/12/12 2:55 PM Page 10
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INTERNATIONAL
UPDATE
Canadian College to Enhance Its Trades
Facilities
Camosun College in British Columbia, Canada, expects to re-
ceive more than $29 million from the Ministry of Advanced Ed-
ucation to renew and enhance its existing trades facilities at the
Interurban Campus. John Yap, minister of Advanced Education,
Innovation and Technology, and Ida Chong, minister of Aborigi-
nal Relations and Reconciliation, announced the funding, which
will assist the college to create a state-of-the-art Trades Learn-
ing Centre for Excellence.
The facility will include a new marine and metal trades center
to house welding, sheet metal, metal fabrication, and shipbuilding
and repair programs; new mechanical trades center to house heavy-
duty, commercial truck transport and automotive service techni-
cian programs; repurposing of the Jack White Trades Building to
house electrical, plumbing and piping trades, and future renewable
energy programs; repurposing of the John Drysdale Trades Build-
ing as a new technology and innovation center that will also house
a general-purpose classroom space and trades equipment storage;
new central student commons facility to serve the combined trades
centers; expanded and reconfigured trades yard space, outdoor
storage, and construction project areas with improved accessabil-
ity; and upgrade to electrical service for existing trades buildings.
The new facilities, according to Yap, will encourage more and
more young people to consider careers in the trades.
Genesis Systems Opens New Office in
Japan
Genesis Systems Group, a robotic workcells integrator, recently
announced the establishment of a sales office in Nagoya, Japan.
Genesis Systems Group Japan, KK, will lead the companys efforts
to strengthen its global footprint and better serve new and existing
Japanese clients. The office will be led by Tadaji Seko, who served
Toyota Corporation as a trainer of the Toyota Production System,
manager of Production Engineering, and deputy chairman of in-
formation discussions, and Junko Fukutome who started with Gen-
esis in 2005 and most recently has worked as its liaison in Japan.
Wheelabrator Group Expands to Mexico
Wheelabrator, a provider of equipment-support services,
opened WG Plus de Mexico, a new 34,000-sq-ft manufacturing
and aftermarket parts and service facility, in Monterrey. The fa-
cility supports regional original equipment manufacturing and
aftermarket sales as well as equipment manufacturing operations
for the global customer base. This expansion provides heavy-duty
manufacturing, secondary light assembly operations, and after-
market support to service the increased demands for all of the
Americas. Robert E. Joyce Jr., president and CEO, Norican
Group, said, Our investment plans are to continue to expand
our company globally to meet the growing demands and needs
of our customers.
Canadian Fabricator to Build Plant in
Montana
ADF Group, Inc., a fabricator of structural steel and steel
components in Montreal, Canada, approved an estimated $24
million plan to build a new 100,000-sq-ft structural steel fabrica-
tion complex on 100 acres of industrial land located in Great
Falls, Mont. Its annual fabrication capacity is estimated at more
than 25,000 tons. Adjacent to the new facility, ADF will set up a
large structural steel fabrication and preassembly yard to rapidly
and effectively serve new sectors and fast growing markets.
In addition to expanding westward, the investment will give
ADF access to the U.S. public infrastructures market segment.
Jean Paschini, chairman of the board and CEO, said, During
the past months, we have studied many other sites to set up a sec-
ond plant, and we have chosen Great Falls in Montana for its
strategic geographic location. Situated at 160 km from Albertas
border, the city of Great Falls will allow ADF to pursue its de-
velopment both in Canada and the United States. The new plant,
equipped with state-of-the-art machinery, is expected to be op-
erating by the second half of 2013.
Camosun College student Jenny Albrecht prepares Advanced
Education, Innovation & Technology Minister John Yap and
Aboriginal Relations & Reconciliation Minister Ida Chong for a
welding demo.
Wheelbrator opened a new 34,000-sq-ft service facility in Mon-
terrey, Mexico.
Artist rendering of ADFs structural steel fabrication plant to be
built in Great Falls, Montana.
JANUARY 2013 12
Jan Intl Update_Layout 1 12/13/12 9:19 AM Page 12
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victor 2_FP_TEMP 12/11/12 3:11 PM Page 13
STAINLESS
Q&A
BY DAMIAN J. KOTECKI
Q: I have been told that nitrogen is an es-
sential ingredient in duplex stainless steel
weld metal. But I understand that nitro-
gen is only an accidental impurity in other
stainless steel weld metal. Is this correct,
and if so, why is it essential in duplex
stainless steel?
A: You have been told correctly. There are
two factors involved. The first has to do
with pitting corrosion resistance. There is
a well-accepted formula for a Pitting Re-
sistance Index (PRE
N
).
PRE
N
= %Cr + 3.3(%Mo + %W/2)
+ 16%N
As the PRE
N
increases, the pitting re-
sistance increases. Duplex stainless steels
are often used in chloride-containing envi-
ronments, including the higher alloy
grades in seawater. The higher alloy
grades of duplex stainless steel, often re-
ferred to as superduplex, have a PRE
N
greater than 40. As you can see, the coef-
ficient for nitrogen in the above formula is
much larger than for any other element.
The superduplex stainless steels typically
contain about 0.25%N, or more.
But pitting corrosion resistance is only
part of the story concerning nitrogen in
duplex stainless steels and their weld met-
als. In weld metal in the as-welded condi-
tion, nitrogen is the critical element for ob-
taining a proper phase balance between
ferrite and austenite. There remains a lot
of discussion about what amount of ferrite
(remainder austenite) is appropriate for
best properties, but most engineers will
agree that the range of 30 to 70 Ferrite
Number or 22 to 50% ferrite (higher fer-
rite content is allowed with inert gas-
shielded processes) provides the best com-
bination of properties, particularly corro-
sion resistance, toughness, and ductility.
Nitrogen is critical because it is the only
useful alloying element that is an intersti-
tial atom rather than a substitutional
atom. Interstitial atoms are much smaller
than the matrix alloy element atoms iron,
chromium, nickel, molybdenum, and pos-
sibly tungsten. As a result, nitrogen can
diffuse more than 100 times faster than the
other atoms. Nitrogen promotes austenite
formation by diffusing out of the ferrite as
the virtually 100% ferrite weld metal cools
at temperatures above 1040C (1900F).
Under ordinary arc welding cooling condi-
tions, only nitrogen diffuses fast enough to
partition appreciably between ferrite and
austenite. This was very well demon-
strated in the work of Ogawa and Koseki
(Ref. 1).
Unfortunately, when the work of
Ogawa and Koseki was published in the
Welding Journal, color printing in the Re-
search Supplement was not in use, and the
element partitioning was illustrated by
color-coded maps, so it was difficult to ap-
preciate exactly what was going on in the
black and white reproductions, and I think
very few people did appreciate it. How-
ever, Ogawa and Koseki also presented
their work a year later in Commission IX
of the International Institute of Welding,
as IIW Document IX-1600-90, and I was
fortunate enough to obtain a copy with
color. Three figures extracted from that
work serve to illustrate the importance of
nitrogen, and these are reproduced
herein.
Fig. 1 2205 base metal as hot-rolled. A Microstructure; B 22% Cr; C 6% Ni; D
3% Mo; E 0.12% N.
Fig. 2 Autogenous 2205 GTA weld metal, as-welded. A Microstructure; B 22% Cr;
C 6% Ni; D 3% Mo; E 0.12% N.
JANUARY 2013 14
A
A B C
E
D
B C
E D
Stainless Q+A Jan_Layout 1 12/12/12 2:25 PM Page 14
Figure 1 shows the microstructure of
the 2205 duplex stainless steel base metal
as hot-rolled. The lighter etching phase is
the austenite and the darker etching phase
is the ferrite. Then it includes Cr, Ni, Mo,
and N distributions obtained by a scanning
electron microscope (SEM) of exactly the
same area as the microstructure, color
coded so that red indicates high concen-
tration, yellow to green indicates nominal
composition concentration of each ele-
ment, and blue indicates low concentra-
tion. The nominal composition is also
given in the figure. It is easily seen that Cr
and Mo are concentrated in the ferrite,
while Ni and N are concentrated in the
austenite. It is noteworthy that, in the case
of nitrogen, the blue color indicates virtu-
ally zero percent nitrogen in the ferrite.
That is, the nitrogen has almost entirely
left the ferrite in favor of the austenite
during hot-rolling.
Figure 2 shows the microstructure and
alloy element distribution of an autoge-
nous GTA weld made in the same base
metal, containing 0.12% nitrogen, using
the same color coding. Austenite appears
only as particles along the grain bound-
aries of the very large ferrite grains that
formed during solidification, and as a few
scattered particles within the ferrite
grains. Then the color maps of Cr, Ni, and
Mo indicate virtually no partitioning of
those alloy elements they are distrib-
uted at virtually the nominal composition
level throughout the microstructure
but the nitrogen map clearly shows nitro-
gen concentrated in the grain boundary
austenite.
In the ferrite immediately beside the
grain boundary austenite, the blue color
indicates virtually zero nitrogen as the ni-
trogen there had enough time to diffuse to
the austenite. Farther from the grain
boundary austenite, the yellow to green
color indicates near-nominal nitrogen
concentration on average. In fact there are
scattered chromium nitride particles that
appear as dark specks in the microstruc-
ture (Fig. 2A) that formed within the fer-
rite when the nitrogen could not escape
from the ferrite to the austenite during
cooling. Even though there is 0.12% N
present in this composition, the phase
distribution is not acceptable; the weld is
brittle.
Figure 3 shows the microstructure and
alloy element distribution of an autoge-
nous GTA weld made in an identical base
metal composition except that the nitro-
gen is increased to 0.18%. As in the case
of the 0.12% N weld metal, austenite ap-
pears as particles outlining the original
ferrite grain boundaries, but there are also
numerous austenite plates throughout the
interior of the ferrite grains. Then the
color-coded maps of Cr, Ni, and Mo indi-
cate only very slight partitioning of these
elements (most clearly seen in the Mo dis-
tribution where the grain boundary
austenite regions are more clearly blue).
But the nitrogen partitioning is complete
the ferrite regions are all blue while the
austenite regions are all red. The higher
nitrogen of the Fig. 3 weld metal as com-
pared to the Fig. 2 weld metal made the as-
welded weld metal ductile by producing
much higher austenite content.
In practice, filler metal manufacturers
tend to include extra nickel to improve
toughness and assist in the development of
austenite, but the nitrogen is the essential
alloy element for providing weldability.
Reference
1. Ogawa, T., and Koseki, T. 1989. Ef-
fect of composition profiles on metallurgy
and corrosion behavior of duplex stainless
steel weld metals. Welding Journal 68(5):
181-s to 191-s.
15 WELDING JOURNAL
DAMIAN J. KOTECKI is president,
Damian Kotecki Welding Consultants, Inc.
He is treasurer of the IIW and a member of
the A5D Subcommittee on Stainless Steel
Filler Metals, D1K Subcommittee on Stain-
less Steel Structural Welding; and WRC
Subcommittee on Welding Stainless Steels
and Nickel-Base Alloys. He is a past chair of
the A5 Committee on Filler Metals and Al-
lied Materials, and served as AWS president
(20052006). Send questions to damian@
damiankotecki.com, or Damian Kotecki,
c/o Welding Journal Dept., 8669 Doral
Blvd., Ste. 130, Doral, FL 33166.
Fig. 3 Autogenous 2205 GTA weld metal, as-welded. A Microstructure; B 22% Cr;
C 6% Ni; D 3% Mo; E 0.18% N.
For info go to www.aws.org/ad-index
A B C
E D
Stainless Q+A Jan_Layout 1 12/12/12 2:26 PM Page 15
Friends and Colleagues:
The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image and
impact of the welding industry. Election as a Counselor shall be based on an individuals career of
outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in the
welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the welding
industry. The individuals organization shall have shown an ongoing commitment to the industry, as
evidenced by support of participation of its employees in industry activities.
Leadership of or within an organization that has made a substantial contribution to training and
vocational education in the welding industry. The individuals organization shall have shown an
ongoing commitment to the industry, as evidenced by support of participation of its employee in
industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this
issue of the Welding Journal. The deadline for submission is July 1, 2013. The committee looks
forward to receiving these nominations for 2014 consideration.
Sincerely,
Lee Kvidahl
Chair, Counselor Selection Committee
Counselor Letter 2013_Layout 1 12/12/12 9:16 AM Page 16
Nomination of AWS Counselor
I. HISTORY AND BACKGROUND
In 1999, the American Welding Society established the honor of Counselor to recognize indi-
vidual members for a career of distinguished organizational leadership that has enhanced the
image and impact of the welding industry. Election as a Counselor shall be based on an
individuals career of outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in
the welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the
welding industry. (The individuals organization shall have shown an ongoing
commitment to the industry, as evidenced by support of participation of its employees
in industry activities such as AWS, IIW, WRC, SkillsUSA, NEMA, NSRP SP7 or other
similar groups.)
Leadership of or within an organization that has made substantial contribution to training
and vocational education in the welding industry. (The individuals organization shall
have shown an ongoing commitment to the industry, as evidenced by support of partici
pation of its employees in industry activities such as AWS, IIW, WRC, SkillsUSA, NEMA,
NSRP SP7 or other similar groups.)
II. RULES
A. Candidates for Counselor shall have at least 10 years of membership in AWS.
B. Each candidate for Counselor shall be nominated by at least five members of
the Society.
C. Nominations shall be submitted on the official form available from AWS
headquarters.
D. Nominations must be submitted to AWS headquarters no later than July 1
of the year prior to that in which the award is to be presented.
E. Nominations shall remain valid for three years.
F. All information on nominees will be held in strict confidence.
G. Candidates who have been elected as Fellows of AWS shall not be eligible for
election as Counselors. Candidates may not be nominated for both of these awards
at the same time.
III. NUMBER OF COUNSELORS TO BE SELECTED
Maximum of 10 Counselors selected each year.
Return completed Counselor nomination package to:
Wendy S. Reeve
American Welding Society
Senior Manager
Award Programs and Administrative Support
Telephone: 800-443-9353, extension 293
SUBMISSION DEADLINE: July 1, 201
8669 Doral Blvd., Suite 130
Doral, FL 33166
3
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(please type or print in black ink)
COUNSELOR NOMINATION FORM
DATE_________________NAME OF CANDIDATE________________________________________________________________________
AWS MEMBER NO.___________________________YEARS OF AWS MEMBERSHIP____________________________________________
HOME ADDRESS____________________________________________________________________________________________________
CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________
PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________
TITLE/POSITION____________________________________________________________________________________________________
BUSINESS ADDRESS________________________________________________________________________________________________
CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________
ACADEMIC BACKGROUND, AS APPLICABLE:
INSTITUTION______________________________________________________________________________________________________
MAJOR & MINOR__________________________________________________________________________________________________
DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________
LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________
SIGNIFICANT WORK EXPERIENCE:
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE
SELECTED AS AN AWS COUNSELOR ACCOMPANY THE NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY
BE INCORPORATED WITHIN THE CITATION CERTIFICATE.
**MOST IMPORTANT**
The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All in-
formation and support material provided by the candidates Counselor Proposer, Nominating Members and peers are considered.
SUBMITTED BY:
PROPOSER_______________________________________________
AWS Member No.___________________
The proposer will serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include a
detailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the can-
didate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition
to the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the sig-
natures are secured, the total package should be submitted.
NOMINATING MEMBER:___________________________________Print Name___________________________________
AWS Member No.______________
NOMINATING MEMBER:___________________________________Print Name___________________________________
AWS Member No.______________
NOMINATING MEMBER:___________________________________Print Name___________________________________
AWS Member No.______________
NOMINATING MEMBER:___________________________________Print Name___________________________________
AWS Member No.______________
CLASS OF 2014
SUBMISSION DEADLINE JULY 1, 2013
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harris_FP_TEMP 12/11/12 2:42 PM Page 19
JANUARY 2013 20
RWMA
Q&A
BY TOM SNOW
Q: Our company needs extra spot weld-
ing capacity because production is increas-
ing. We have an old spot welding machine
in storage that has not run in years. Should
I try to get it going or buy a new one?
A: As with many things in life, it all de-
pends.
Spot welding machines are among the
most durable of production machines and
the three Rs of machine maintenance
can easily be applied repair, retrofit,
or rebuild.
That being said, some brands of spot
welding machines are better than others
and an old, light-duty machine may not be
worth fixing.
To begin finding the answer to your
question, check to see if your machine is
suitable for the anticipated welding appli-
cation. As an example, if you need to weld
two pieces of 12-gauge mild steel, a little
10-kVA foot-operated rocker arm machine
is not going to get the job done properly.
Charts are readily available listing var-
ious combinations of amperage (heat) and
pressure (forging force) required for
welding various material thickness com-
binations. Hopefully your machine has
enough capacity to achieve a Class A
weld, which optimizes strength and ap-
pearance by using proper force, high am-
perage, and short weld time.
Also, if your application involves pro-
jection welding, such as resistance weld-
ing nuts or studs, an air-operated vertical
action press-type welding machine with
the proper diameter cylinder is the way to
go. A rocker arm spot welding machine,
although typically less expensive, applies
weld force with a rocking action and will
not set down the projections evenly.
And speaking of rocker arm spot weld-
ing machines, be wary of installing longer
arms if the existing arms are too short to
reach all the welds on your deepest part.
Because the spot welding electrode tips
are typically on the wrong end of the
air-operated fulcrum mechanism, increas-
ing the arm length robs the machine of
weld force capability.
As an example, one representative
heavy-duty rocker arm spot welding ma-
chine built to RWMA Size 3 specifications
can produce 2250 lb of weld force at 80
lb/in.
2
of incoming air pressure with an 18-
in. throat depth, whereas extending the
throat to 36 in. reduces the maximum
available force to 1150 lb, a loss of more
than a half-ton of forging capability.
Likewise, as the throat depth or verti-
cal shut height (gap) between arms is in-
creased, the available welding amps at the
tips will decrease due to the larger sec-
ondary loop. In other words, a spot weld-
ing machine with an 18-in. throat depth
will produce significantly more amps than
the same machine with 36-in. arms
installed.
The same rocker arm spot welding ma-
chine spec sheet referenced in our exam-
ple shows that a 50-kVA machine with 18-
in. arms installed produces 22,100 second-
ary amps at full power settings, whereas
the same machine with a 36-in. throat pro-
duces 15,700 A. This could be the differ-
ence between making a good or bad weld.
Once youve determined that your
welding machine in storage is suitable for
the application, examine its condition.
Many older resistance spot welding
machines are built better than new ones,
so a heavy-duty resistance welding ma-
chine thats 2040 years old should not
be ruled out.
A veteran American-made spot
welding machine built to RWMA specifi-
cations is often superior to some of the
light-duty imported machines on the mar-
ket today. However, if the welding ma-
chine is more than 1015 years old, it
would probably benefit from being retro-
fitted with a new control that includes all
the latest features Figs. 1, 2.
Virtually all spot welding machine con-
trols sold today have fully programmable
functions, such as pulsation and upslope,
that were once expensive options. If youre
trying to weld heavy material thicknesses
and/or coated steel, those two options are
often a big help in achieving good welds.
Also, these days its advisable to convert
spot welding machines from mechanical
contactors or mercury-filled ignitrons to
modern SCR contactors. Just be sure to
dispose of the ignitrons properly and
legally.
And if you want to greatly improve the
safety of the machine, a spot welding ma-
chine control is now available with a soft
touch safety feature that senses if some-
thing nonmetallic is between the tips, such
as a finger, and retracts the tips before
weld force is applied. This protects your
operator from serious finger injury and
also includes the ability to dress your elec-
trodes under low force.
Once youve gotten a retrofit welding
machine control on order, if needed, its
time to address the condition of the ma-
chine itself. Resistance welding machines
are relatively simple to fix if you under-
stand the basics of electricity, pneumat-
ics, and mechanics.
Here are the systems to check as you
inspection and repair the machine as
needed or go through the process to com-
pletely strip and rebuild the machine.
Welding Transformer: The Heart
of the Machine
Spot welding machine transformers
have no moving parts and often run for
Fig. 1 Example of a heavy-duty press-
type combination spot and projection weld-
ing machine suitable for rebuilding.
Fig. 2 The same press-type welding ma-
chined after being stripped and rebuilt to
like-new specifications, including the in-
stallation of a new control with program-
mable functions.
RWMA January 2013_Layout 1 12/12/12 3:01 PM Page 20
21 WELDING JOURNAL
decades if not abused. Abuse includes
overheating due to excessive duty cycle
operation, lack of adequate water flow,
and internal water saturation due to water
leaks or condensation.
If your welding transformer is water-
cooled, check to make sure the small-
diameter internal copper water cooling
tubes are not clogged, crushed, or leak-
ing. If the machine has been run on city
or well water, minerals can accumulate
over the years just like excessive choles-
terol clogs our arteries. Chemicals are
available to clear clogs in water cooling
lines, but sometimes the transformer
needs to be disassembled so the water
lines can be replaced.
Shorted-out spot welding machine
transformers can be rebuilt, but its best
to send them to a specialist rather than
your local electric motor repair shop.
Secondary Connections
Spot welding machines are designed to
generate heat at the weld zone due to the
resistance of the material being welded,
but every other source of resistance
from the transformer out to the electrodes
(tips) should be minimized. This is sig-
nificant because the welding transformer
converts the incoming power of 220 or 440
V into extremely low secondary voltage,
typically only 68 V, that pushes the high
welding amperage through the welding
machines secondary circuit. Any form of
unwanted resistance in the loop restricts
the flow of welding current to the work.
Although its a lot of work, disassem-
bling the welding machines copper sec-
ondary loop connections and removing
the accumulated oxide is a task that should
be done annually.
If a connection in the welding machine
secondary has gotten loose and arced out
over time, the contacting surfaces will
need to be remachined flat and smooth.
Various conductive pastes are available
that are designed to improve conductivity
and reduce oxidation by coating the mat-
ing surfaces prior to reassembly. For the
ultimate in conductivity, secondary con-
nections can also be silver plated.
If the flexible copper shunts that con-
duct electricity from the transformer to
the moving part of the welding machine
have broken copper sheets or show arc-
ing at the connecting surfaces, they should
be replaced. Replacement shunts are not
extremely expensive and are usually the
weakest link in conducting the necessary
high welding current through the
secondary.
Pneumatic System
As the metal reaches the molten state
during the spot welding process, delivery
of consistent force and fast forging follow-
up is critical to good weld quality. Most
spot welding machines used in production
are air-operated, so check the air system
for smooth operation. Air cylinders are
simple to repair and relatively inexpen-
sive to replace, so dont ignore those im-
portant components.
Also, check to make sure there is a
working filter, regulator, lubricator
(FRL), and gauge installed on the incom-
ing air supply. Restriction of air to the
welding machine through a clogged FRL
can cause poor follow-up during the weld.
This results in excessive metal expulsion
(flash), reduced electrode life, and incon-
sistent weld quality. If in doubt, replace
the FRL.
Mechanical System
On rocker arm spot welding machines,
check for worn pivot points and replace
bearings as needed. An easy way to check
for problems is to grab the arm out at the
end and shake it from side to side. There
should not be much slack.
On vertical press type spot welding ma-
chines, you can check the ram mechanism
for wear with a similar side-to-side and
front-to-rear method, but on machines
with roller rams, its also advisable to re-
move the sheet metal that typically cov-
ers the ram area and look for wear on the
ways and/or rollers Fig. 3. Roller bear-
ings can seize up and wear the ways. Once
again, these mechanisms are relatively
simple to repair.
The old-style quill press welding ma-
chine rams typically seen on U.S.-made
machines from the 1940s and some ma-
chines being imported today are often
metal on metal and can be more challeng-
ing to repair if lubrication has been ig-
nored over the years and wear is heavy.
Rather than spending money to repair one
of these rams, it might be time to scrap
the machine and use the proceeds to buy
a new one.
Thats the saving grace of old spot
welding machines most of them are
loaded with copper and, if salvaged prop-
erly, can provide a nice down payment on
another machine.
And, as always, an experienced spot
welding machine dealer can help guide
your decision-making process and provide
the needed material to get your old spot
welding machine back into production.
TOM SNOW is CEO, T.J. Snow Co., Inc.,
Chattanooga, Tenn., a member company
of the RWMA, a permanent AWS standing
committee. Send your comments and
questions to Tom Snow at
TomSnow@tjsnow.com, or mail to Tom
Snow, c/o Welding Journal, 8669 Doral
Blvd., Ste. 130, Doral, FL 33166.
DO YOUR OWN TESTING
www.fischerengr.com ! (937)754-1750
Bend Testers - Bend Specimen Cutting
Fixtures - Coupons -Tensile Testers
BT1C
BT1B
Visit our website
for all sizes and
models available
BSC-1PLT
TT1
Fig. 3 A press-type resistance welding
machine ram that needs to be repaired.
For info go to www.aws.org/ad-index
RWMA January 2013_Layout 1 12/12/12 3:03 PM Page 21
PRODUCT & PRINT
SPOTLIGHT
Robotic Laser Cutting
Software Tools Available
The RobotStudio Cutting PowerPac is
an add-on to RobotStudio, the companys
3D offline simulation programming tool,
which allows operators to generate and
modify program cutting paths based on
part geometry and CAD models. It sup-
ports the optimization of cutting pro-
grams, setup of interface signals, and man-
agement of cutting process data. In addi-
tion, RobotWare Cutting is a robot con-
troller add-on that features tools for the
integration of peripheral equipment,
robot tuning and calibration, and pro-
gramming complex paths and shapes. It is
compatible with most common laser cut-
ting equipment brands and has an intu-
itive graphical user interface that provides
the flexibility to switch automatically and
quickly between different product series.
ABB
www.abb.com
(248) 391-8622
Modular System Equipped
with Inflatable Bladders
The I-Purge inflatable modular blad-
der system, U.S. and foreign patents pend-
ing, is equipped with interchangeable
components, including inflatable bladders
(modules A and B) with a spark-resistant
exterior cover and heavy-duty interior in-
flatable bag. Quick connect interchange-
able fittings snap in place and are corro-
sion resistant. A stainless steel harness has
extended lengths available and easily nav-
igates through pipes. Also showcased are
proprietary relief valve technology, and a
tri-flow inner tubing system (blue, black,
and exhaust hose) improves the efficiency
of gas flow in and out of the purge area.
Aquasol Corp.
www.aquasolwelding.com
(800) 564-9353
Direct Diode Laser Offers
Ultrahigh Brightness
The company designed the TeraBlade
2000, a 2-kW ultrahigh-brightness direct
diode laser, specifically for cutting steel
and other metals in industrial applica-
tions. It operates at 970 nm, features a
JANUARY 2013 22
The DP direct drive series, a new generation of friction
welding machines, produce all types of drill pipes. A light-
weight, quick release tooling system has been added so there
is no need for changeovers using cranes, and an updated, in-
process optical measurement device provides accurate TIR
data for every component. In addition, the company devel-
oped an in-cycle, internal boring tool for removing flash from
narrow-diameter tool joints, meaning the process can be per-
formed on the same machine without transferring the com-
ponents elsewhere for a separate operation. The environ-
mental friendly machine includes redesigned hydraulic packs
with energy-saving, variable speed drives, nonpriming pumps,
and low noise guard booths. Also, they are equipped with
forge clamps for friction welding an unlimited range of pipe
sizes and lengths. They use a closed loop control system for
monitoring the weld head speed and position.
Thompson
www.thompson-friction-welding.com
(586) 466-6180
Friction Welding Machines
Feature Quick Release Tooling System
P and P January 2013_Layout 1 12/13/12 12:57 PM Page 22
23 WELDING JOURNAL
100-micron output fiber, and a platform
scalable up to 6 kW.
TeraDiode
www.teradiode.com
(978) 952-2501
Animated Movie Highlights
Pipe Manufacturing
The advertising design firm has cre-
ated an animated movie with 3D motion
graphics, photographs, and text that pres-
ent the American Steel Pipe ERW manu-
facturing process. Included are images of
the steel roll loading, edging, forming,
welding, seam annealing, cutting, and in-
spection processes at the plant. The pres-
entation is available as a continuous HD
video for YouTube and iPad
use, a loop-
ing Flash swf file for trade show exhibit
monitors, and a navigable Flash swf for
the corporate Web site.
Ninetimes
www.ninetimes.com
(707) 494-3883
GMA Gun Liner System
Reduces Downtime
The Quick Load Liner Au-
toLength system minimizes downtime
and prevents quality problems associated
with incorrect GMA gun liner length. It
can be used with guns equipped with these
liners, specifically the Bernard T-Gun
semiautomatic gun and Tregaskiss ro-
botic GMA guns. Also, it helps reduce
wire-feeding problems and decreases
meltbacks, along with premature contact
tip failure and wear associated with mis-
alignment between the liner and contact
tip. A spring-loaded module housed in-
side the power pin applies constant pres-
sure on the liner, keeping it seated prop-
erly in the retaining head at all times. The
system allows for up to 1 in. forgiveness
and accommodates liner movement dur-
ing welding.
Tregaskiss
www.tregaskiss.com
(877) 737-3111
iPhone App Contains
Safety Information
The company has launched an appli-
cation for iPhones
s to the
heroes and
their loyal
sidekicks.
Rob and his
loyal sidekick,
the Axcess
450
MillerWelds.com
The Power of Blue
[ ]
No weld job is too diffcult,
too daring, or too daunting
for this dynamic duo!
For Info go to www.aws.org/ad-index
miller electric_FP_TEMP 12/11/12 2:45 PM Page 59
COMING
EVENTS
API 2013 Inspection Summit & Expo. Jan. 710. Galveston Is-
land Convention Center, Galveston, Tex. American Petroleum In-
stitute. www.api.org/inspectionsummit.
Automate 2013 Show and Conf. Colocated with ProMat 2013.
Jan. 2124. McCormick Place, Chicago, Ill. Robotics Industries
Assn., AIA Advancing Vision + Imaging, and Motion Control
Assn. www.automate2013.com.
LAM 5th Annual Laser Additive Manufacturing Workshop.
Feb. 12, 13. Hilton Houston North Hotel, Houston, Tex. Ameri-
can Welding Society is a cooperating society in this event. AWS
members receive discounted registration. www.lia.org/confer-
ences/lam.
Solar POWER-GEN Conf. and Expo. Feb. 1315. San Diego
Convention Center, San Diego, Calif. www.solar-powergen.com.
WEMCO/RWMA Co-Located Annual Meeting. Feb. 2123.
Saddlebrook Resort, Wesley Chapel, Fla. Cosponsored by AWS
standing committees WEMCO, an association of welding equip-
ment manufacturers, and RWMA, Resistance Welding Manufac-
turing Alliance. Contact wemco@aws.org; FAX (305) 442-7451.
AWS 8th Shipbuilding Conf. Feb. 26, 27. Wyndham Riverfront
New Orleans, New Orleans, La. Sponsored by the American
Welding Society (800/305) 443-9353, ext. 264; www.aws.org/con-
ferences.
2nd Intl Conf. on Manufacture Engineering, Quality and Pro-
duction System (ICMEQP 2013). Feb. 27, 28. Feng Chia Univer-
sity, Hong Kong, China. www.icmeqp-conf.org/.
Adhesion Society Annual Meeting & Expo. March 36. Hilton
Daytona Beach Oceanfront Resort, Daytona Beach, Fla. www.ad-
hesionsociety.org/Meeting/meeting.htm.
ASQ Lean and Six Sigma Conf. March 4, 5. Pointe Hilton Tapa-
tio Cliffs Resort, Phoenix, Ariz. Sponsored by American Society
for Quality (ASQ). http://asq.org/conferences/six-sigma/program/
index.html.
ASNT 22nd Annual Research Symposium. March 1821. The
Peabody Memphis, Memphis, Tenn. American Society for Non-
destructive Testing. www.asnt.org.
ILSC Intl Laser Safety Conf. March 1821. Doubletree by
Hilton, Orlando, Fla. Laser Institute of America. www.lia.org/ilsc.
AeroDef Manufacturing and Composites Manufacturing 2013.
March 1921. Long Beach Convention Center, Long Beach, Calif.
Society of Manufacturing Engineers. www.aerodefevent.com.
Weld Cracking Conf. March 26, 27. Las Vegas, Nev. Sponsored
by the American Welding Society (800/305) 443-9353, ext. 264;
www.aws.org/conferences.
13th Annual Lean and Six Sigma Conf. March 4, 5. Phoenix, Ariz.
asq.org/conferences/six-sigma/program/index.html.
[MC]
2
2013 MTConnect: Connecting Manufacturing Conf. April
10, 11. Hyatt Regency, Cincinnati, Ohio. MTConnect Institute.
www.mtconnectconference.org.
GAWDA 2013 Spring Management Conf. April 1316. Grand
Hyatt Hotel and Convention Center, River Walk, San Antonio,
Tex. Gases and Welding Distributors Assn. www.gawda.org.
Society of Vacuum Coaters SVC TechCon 2013. April 2025.
Rhode Island Convention Center, Providence, R.I. www.svc.org.
JOM-17, Intl Conf. on Joining Materials. May 58. Konven-
tum Lo Skolen, Helsingr, Denmark. Institute for the Joining of
Materials (JOM) in association with the IIW. Cosponsored by
AWS, TWI, Danish Welding Society, Welding Technology Insti-
tute of Australia, University of Liverpool, Cranfield University,
Force Technology, and ABS (Brazilian Welding Assn.). E-mail
Osama Al-Erhayem at jom_aws@post10.tele.dk; www.jominsti-
tute.com/side6.html.
INTERTECH 2013, Superabrasive Materials, Principles, and
Applications for the Aerospace and Defense Industries. May 68.
Hyatt Regency Baltimore Harbor Hotel, Baltimore Md. Indus-
trial Diamond Assn. www.intertechconference.com.
POWER-GEN India & Central Asia, Renewable Energy World
Conf. & Expo, and HydroVision India. May 68. Bombay Exhi-
bition Centre, Goregaon, Mumbai, India. www.power-genindia.
com/index.html.
IIE Annual Conf. and Expo. May 1822. Caribe Hilton, San Juan,
Puerto Rico. www.iienet2.org/annual2.
NOTE: A DIAMOND ( ) DENOTES AN AWS-SPONSORED EVENT.
JANUARY 2013 60
TECHNICAL TRAINING
The Hobart Institute of Welding Technology
offers our comprehensive Technical Training
courses through the year! Upcoming start-dates:
Prep for AWS Welding Inspector/Educator Exam
Jan 21 : Mar 11 : Apr 15 : May 13 : Jun 17 : Jul 15
Prep for AWS Certified Welding Supervisor Exam
Jun 3 : Sep 30
Liquid Penetrant & Magnetic Particle Inspection
Feb 18 : Jun 10 : Aug 5 : Sep 30
Arc Welding Inspection & Quality Control
Mar 4 : May 6 : Sep 9 : Oct 21 : Nov 18
Welding for the Non Welder
Feb 11 : May 28 : Jul 29 : Sep 3 : Oct 28
Welding Instructor Course
Jul 8
Visual Inspection
Apr 2 : Aug 20 : Oct 15
1-800-332-9448
or visit us at www.welding.org
for more information.
2013 Hobart Institute of Welding
Technology, Troy, OH
St. of Ohio Reg. No. 70-12-0064HT
For info go to www.aws.org/ad-index
CE Jan._Layout 1 12/13/12 9:10 AM Page 60
61 WELDING JOURNAL
44th Steelmaking Seminar Intl. May 1922. Tau Grande
Hotel Termas & Convention Arax, Estncia Parque do Barreiro,
s/n Arax - Minas Gerais, Brazil. Held by Brazilian Metallurgi-
cal, Materials, and Mining Assn. www.abmbrasil.com.br.
Pipeline Conf. June 4, 5. Houston, Tex. Sponsored by the Amer-
ican Welding Society (800/305) 443-9353, ext. 264;
www.aws.org/conferences.
Codes and Standards Conf. July 16, 17. Orlando, Fla., Spon-
sored by the American Welding Society (800/305) 443-9353, ext.
264; www.aws.org/conferences.
12th Intl Conf. on Application of Contemporary Non-Destructive
Testing in Engineering. Sept. 46. Grand Hotel Metropol, Por-
toroz, Slovenia. Sponsored by The Slovenian Society for Non-De-
structive Testing. www.fs.uni-lj.si/ndt.
66th IIW Annual Assembly and Intl Conf. on Automation in
Welding. Sept. 1117. Essen, Germany. Organized by DVS (Ger-
man Welding Society). www.dvs-ev.de/IIW2013/.
ASM Heat Treating Society Conf. and Expo. Sept. 1618. Indiana
Convention Center, Indianapolis, Ind. www.asminternational.org/
content/Events/heattreat/.
18th Intl Schweissen & Schneiden Trade Fair. Sept. 1621. Messe
Essen, Essen, Germany. Sponsored by DVS (German Welding
Society). www.messe-essen.de/en/messeessen/index.html.
16th Annual Aluminum Conf. Sept. 17, 18. Chicago, Ill. Spon-
sored by the American Welding Society (800/305) 443-9353, ext.
264; www.aws.org/conferences.
POWER-GEN Brasil 2013, HydroVision Brasil, and DistribuTech
Brasil. Sept. 2426. Transamerica Center, So Paulo, Brazil.
www.power-gen.com.
WESTEC. Oct. 1517. Los Angeles Convention Center, Los An-
geles, Calif. The Society of Manufacturing Engineers. www.weste-
conline.com; (800) 733-4763.
FABTECH 2013. Nov. 1821, McCormick Place, Chicago, Ill.
This exhibition is the largest event in North America dedicated to
showcasing the full spectrum of metal forming, fabricating, tube
and pipe, welding equipment, and myriad manufacturing tech-
nologies. American Welding Society. www.fabtechexpo.com;
(800/305) 443-9353, ext. 264.
Educational Opportunities
Laser Vision Seminars. Jan. 23, 24; Feb. 20, 21; March 20, 21,
April 24, 25; Maty 22, 23; June 19, 20; Aug. 28, 29, Oct. 2, 3; Nov.
6, 7; Dec. 4, 5. Servo-Robot, Inc. www.servorobot.com.
Laser Welding and Equipment Fundamentals. Jan. 17. EWI,
Columbus, Ohio. Call (614) 688-5049, e-mail education@ewi.org.
Introduction to Ultrasonic Joining. Feb. 7. EWI, Columbus,
Ohio. Call (614) 688-5049, e-mail education@ewi.org.
ASM Intl Courses. Numerous classes on welding, corrosion, fail-
ure analysis, metallography, heat treating, etc., presented in
Materials Park, Ohio, online, webinars, on-site, videos, and
DVDs; www.asminternational.org, search for courses.
Automotive Body in White Training for Skilled Trades and
Engineers. Orion, Mich. A five-day course covers operations,
troubleshooting, error recovery programs, and safety procedures
for automotive lines and integrated cells. Applied Mfg.
Technologies; (248) 409-2000; www.appliedmfg.com.
TipSavers
vv rs rs ee v
F
p
SS S B O J . . U R O FO
For info go to www.aws.org/ad-index
For info go to www.aws.org/ad-index
CE Jan._Layout 1 12/13/12 9:10 AM Page 61
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION SEMINAR DATES EXAM DATE
New Orleans, LA Feb. 1015 Feb. 16
Waco, TX Feb. 1015 Feb. 16
San Diego, CA Feb. 24March 1 March 2
Atlanta, GA Feb. 24March 1 March 2
Mobile, AL March 38 March 9
Kansas City, MO March 38 March 9
Houston, TX March 38 March 9
Norfolk, VA March 38 March 9
Milwaukee, WI March 38 March 9
Birmingham, AL March 1015 March 16
Indianapolis, IN March 1015 March 16
Portland, OR March 1015 March 16
Miami, FL March 1722 March 23
Chicago, IL March 1722 March 23
Boston, MA March 1722 March 23
Mobile, AL Exam only March 23
Rochester, NY Exam only March 23
York, PA Exam only March 23
Corpus Christi, TX Exam only April 6
Springfield, MO April 712 April 13
Dallas, TX April 712 April 13
Miami, FL Exam only April 18
Minneapolis, MN April 1419 April 20
Las Vegas, NV April 1419 April 20
Syracuse, NY April 1419 April 20
San Francisco, CA April 2126 April 27
New Orleans, LA April 2126 April 27
Nashville, TN April 2126 April 27
Annapolis, MD April 28May 3 May 4
Detroit, MI April 28May 3 May 4
St. Louis, MO Exam only May 4
Fresno, CA May 510 May 11
Miami, FL May 510 May 11
Albuquerque, NM May 510 May 11
Oklahoma City, OK May 510 May 11
Corpus Christi, TX May 510 May 11
Knoxville, TN Exam only May 18
Birmingham, AL June 27 June 8
Hutchinson, KS June 27 June 8
Spokane, WA June 27 June 8
Miami, FL Exam only June 13
Bakersfield, CA June 914 June 15
Pittsburgh, PA June 914 June 15
Beaumont, TX June 914 June 15
Corpus Christi Exam only June 29
Hartford, CT June 2328 June 29
Orlando, FL June 2328 June 29
Memphis, TN June 2328 June 29
Certified Welding Supervisor (CWS)
LOCATION SEMINAR DATES EXAM DATE
New Orleans, LA April 1519 April 20
CWS exams are also given at all CWI exam sites.
9-Year Recertification Seminar for CWI/SCWI.
No exam given. For current CWIs and SCWIs needing to meet
education requirements without taking the exam. The exam can be
taken at any site listed under Certified Welding Inspector.
LOCATION SEMINAR DATES
Denver, CO Feb. 1015
Dallas, TX March 1015
Miami, FL April 712
Sacramento, CA April 28May 3
Charlotte, NC May 510
Pittsburgh, PA June 27
Certified Radiographic Interpreter (CRI)
LOCATION SEMINAR DATES EXAM DATE
Seattle, WA Feb. 25March 1 March 2
Houston, TX April 1519 April 20
Las Vegas, NV May 610 May 11
Miami, FL June 37 June 8
The CRI certification can be a stand-alone credential or can
exempt you from your next 9-Year Recertification.
Certified Welding Sales Representative (CWSR)
CWSR exams will be given at CWI exam sites.
Certified Welding Educator (CWE)
Seminar and exam are given at all sites listed under Certified
Welding Inspector. Seminar attendees will not attend the Code
Clinic portion of the seminar (usually the first two days).
Certified Robotic Arc Welding (CRAW)
The course dates are followed by the location and phone number
Feb. 26; June 1721, Dec. 913 at
ABB, Inc., Auburn Hills, MI; (248) 3918421
Feb. 25March 1; May 2024, Aug. 1923, Dec. 26 at
Genesis-Systems Group, Davenport, IA; (563) 445-5688
March 4, Oct. 14 at
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Feb. 1115, April 2226, July 1519, Oct. 2125 at
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Jan. 21, March 25, May 20, July 22, Sept. 23, Nov. 18 at
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at:
MATC, Milwaukee, WI; (414) 297-6996
Certified Welding Engineer; Senior Certified Welding
Inspector
Exams can be taken at any site listed under Certified Welding
Inspector. No preparatory seminar is offered.
International CWI Courses and Exams Schedules
Please visit www.aws.org/certification/inter_contact.html.
Certification Seminars, Code Clinics, and Examinations
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.
JANUARY 2013 62
Cert Schedule January_Layout 1 12/11/12 3:35 PM Page 62
Reserve your spot now at
LAS VEGAS
WHETHER YOURE AN OWNER OR A CONTRACTOR,
EVERY SECOND OF THIS WORLD-CLASS EVENT IS PACKED WITH INFORMATION DESIGNED
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impact_FP_TEMP 12/11/12 2:43 PM Page 63
CONFERENCES
8th Shipbuilding Conference
February 2627
New Orleans, La.
The technical program will feature presentations on advanced
welding processes, NDE, materials, robotics, and mechanized
welding for shipbuilding applications. Presenters will discuss new
flux cored welding electrodes for high-yield steels, a new ap-
proach to reduce diffusible hydrogen content in the weld zone,
aluminum applications, and welding tractors that can be used for
all-position welding that do not require tracks. Other presenta-
tions will address the integration of robotics and welding power
supplies, hybrid laser welding in shipyards, and the use of portable
robots to join thick steel plating. A keynote speaker will open
the event with an overview of welding technology in shipyards.
Weld Cracking Conference
March 2627
Las Vegas, Nev.
Much to their chagrin, most welding engineers have witnessed
a crack or two or even more in the welds fabricated at their plants.
That is serious. Most weld cracks can be prevented. All it takes is
more practical knowledge. Were the cracks caused by hydrogen dif-
fusion, residual stress, some mix-up in heat treating, misuse of elec-
trodes in dissimilar metal welds, or some unexplained problem with
the heat-affected zone? To find out what it takes to eliminate weld
cracks, make plans to hear the experts at this conference, who will
be armed with solutions to many of your problems.
Pipeline Conference
June 45
Houston, Tex.
Welding has always been an integral part of pipeline construc-
tion. It all goes back to the days when hand-held oxyacetylene
torches were used to join pipes in the field. Much has happened
since, and what has happened or, better yet, is happening will be
the topics of this conference. Some of the key subjects that will
be covered include welding of high-strength X80 pipe steels, the
many orbital processes that are seeing applications in pipeline
spreads and offshore barges throughout the world, and hybrid
laser arc welding.
Codes and Standards Conference
July 1617
Orlando, Fla.
This conference will feature information about the AWS D1
Structural Welding Code Steel, ASME Boiler and Pressure Ves-
sel, and API pipeline codes, plus MIL and ISO standards, poten-
tially the most valuable documents available to manufacturers
and fabricators of welded products. Information will be provided
about the planning and execution of various welding processes,
as well as useful data for designers, inspectors, and QC
specialists.
16th Annual Aluminum Conference
September 1718
Chicago, Ill.
A distinguished panel of aluminum-industry experts will sur-
vey the state of the art in aluminum welding technology and prac-
tice. You will also have several opportunities to network infor-
mally with speakers and other participants, as well as visit an ex-
hibition showcasing products and services available to the alu-
minum welding industry. Aluminum lends itself to a wide variety
of industrial applications because of its light weight, high strength-
to-weight ratio, corrosion resistance, and other attributes. How-
ever, because its chemical and physical properties are different
from those of steel, welding of aluminum requires special
processes, techniques, and expertise.
For more information, please contact the AWS Conferences
and Seminars Business Unit at (800) 443-9353, ext. 264, or
e-mail zoliva@aws.org. You can also visit the Conference De-
partment Web site at www.aws.org/conferences for upcoming
conferences and registration information.
JANUARY 2013 64
AWS Trailer Highlights Welding Careers
The AWS Careers in Welding Trailer offers many attractive features to get young people excited about welding industry careers.
In particular, the mobile exhibit showcases the following:
Five VRTEX 360 welding simulators that feed computer-generated data with a virtual welding gun and helmet equipped
with internal monitors;
Interactive educational exhibits, including a display wall featuring 11 industry segments with trivia questions, fun facts, and in-
dustry artifacts;
Day in the Life of a Welder exhibit with videos depicting real-life environments in which welders work;
Life-size welder highlighting welding as a safe profession;
Social media kiosk; and
Welding scholarship information.
The 53-ft, single expandable trailer designed and built by MRA experiential tours and equipment covers 650-sq-ft of exhibit space.
To learn more and view its schedule, visit www.explorewelding.com.
Conferences January 2013_Layout 1 12/14/12 10:20 AM Page 64
For Info go to www.aws.org/ad-index
trumpf_FP_TEMP 12/11/12 2:47 PM Page 65
Friends and Colleagues:
I want to encourage you to submit nomination packages for those individuals whom you feel
have a history of accomplishments and contributions to our profession consistent with the standards
set by the existing Fellows. In particular, I would make a special request that you look to the most
senior members of your Section or District in considering members for nomination. In many cases,
the colleagues and peers of these individuals who are the most familiar with their contributions, and
who would normally nominate the candidate, are no longer with us. I want to be sure that we take
the extra effort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nomination process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issue
of the Welding Journal. Please remember, we all benefit in the honoring of those who have made
major contributions to our chosen profession and livelihood. The deadline for submission is July 1,
2013. The Committee looks forward to receiving numerous Fellow nominations for 2014
consideration.
Sincerely,
Thomas M. Mustaleski
Chair, AWS Fellows Selection Committee
Fellow Letter 2013_Layout 1 12/12/12 9:16 AM Page 66
Fellow Description
DEFINITION AND HISTORY
The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for
distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional
stature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of the
individual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by:
Sustained service and performance in the advancement of welding science and technology
Publication of papers, articles and books which enhance knowledge of welding
Innovative development of welding technology
Society and chapter contributions
Professional recognition
RULES
1. Candidates shall have 10 years of membership in AWS
2. Candidates shall be nominated by any five members of the Society
3. Nominations shall be submitted on the official form available from AWS Headquarters
4. Nominations must be submitted to AWS Headquarters no later than July 1 of the year prior to that in
which the award is to be presented
5. Nominations will remain valid for three years
6. All information on nominees will be held in strict confidence
7. No more than two posthumous Fellows may be elected each year
NUMBER OF FELLOWS
Maximum of 10 Fellows selected each year.
AWS Fellow Application Guidelines
Nomination packages for AWS Fellow should clearly demonstrate the candidates outstanding contributions to the advance-
ment of welding science and technology. In order for the Fellows Selection Committee to fairly assess the candidates qualifica-
tions, the nomination package must list and clearly describe the candidates specific technical accomplishments, how they con-
tributed to the advancement of welding technology, and that these contributions were sustained. Essential in demonstrating the
candidates impact are the following (in approximate order of importance).
1. Description of significant technical advancements. This should be a brief summary of the candidates most
significant contributions to the advancement of welding science and technology.
2. Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited
in (1). Where possible, papers and articles should be designated as to whether they were published in
peer-reviewed journals.
3. Inventions and patents.
4. Professional recognition including awards and honors from AWS and other professional societies.
5. Meaningful participation in technical committees. Indicate the number of years served on these committees and
any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.).
6. Contributions to handbooks and standards.
7. Presentations made at technical conferences and section meetings.
8. Consultancy particularly as it impacts technology advancement.
9. Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology.
10. Participation on organizing committees for technical programming.
11. Advocacy support of the society and its technical advancement through institutional, political or other means.
Note: Application packages that do not support the candidate using the metrics listed above
will have a very low probability of success.
Supporting Letters
Letters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These
letters should address the metrics listed above and provide personal insight into the contributions and stature of the
candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.
Return completed Fellow nomination package to:
Wendy S. Reeve
American Welding Society
Senior Manager
Award Programs and Administrative Support
Telephone: 800-443-9353, extension 293
SUBMISSION DEADLINE: July 1, 2013
8669 Doral Blvd., Suite 130
Doral, FL 33166
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FELLOW NOMINATION FORM
DATE_________________NAME OF CANDIDATE________________________________________________________________________
AWS MEMBER NO.___________________________YEARS OF AWS MEMBERSHIP____________________________________________
HOME ADDRESS____________________________________________________________________________________________________
CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________
PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________
TITLE/POSITION____________________________________________________________________________________________________
BUSINESS ADDRESS________________________________________________________________________________________________
CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________
ACADEMIC BACKGROUND, AS APPLICABLE:
INSTITUTION______________________________________________________________________________________________________
MAJOR & MINOR__________________________________________________________________________________________________
DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________
LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________
SIGNIFICANT WORK EXPERIENCE:
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE
SELECTED AS AN AWS FELLOW ACCOMPANY NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE IN-
CORPORATED WITHIN THE CITATION CERTIFICATE.
SEE GUIDELINES ON REVERSE SIDE
SUBMITTED BY: PROPOSER_______________________________________________AWS Member No.___________________
Print Name___________________________________
The Proposer will serve as the contact if the Selection Committee requires further information. Signatures on this nominating form, or
supporting letters from each nominator, are required from four AWS members in addition to the Proposer. Signatures may be acquired
by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should
be submitted.
NOMINATING MEMBER:___________________________________NOMINATING MEMBER:___________________________________
Print Name___________________________________ Print Name___________________________________
AWS Member No.______________ AWS Member No.______________
NOMINATING MEMBER:___________________________________NOMINATING MEMBER:___________________________________
Print Name___________________________________ Print Name___________________________________
AWS Member No.______________ AWS Member No.______________
CLASS OF 201
SUBMISSION DEADLINE July 1, 201
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Join us in New Orleans for an exciting look into the world of shipbuilding!
Our featured speakers will cover a multitude of topics including robotics
and mechanized welding for shipbuilding applications, aluminum
applications, advanced welding processes and much more.
AWS Conferences & Exhibitions:
8
th
Shipbuilding Conference
February 26-27, 2013 / Wyndham Riverfront New Orleans
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 264.
Highlights
Learn about the progress of new and innovative
developments in shipbuilding.
Network with industry peers to discuss the best solutions for
business growth.
Information on new and emerging technologies being
developed for shipbuilding applications.
AWS Conference attendees are awarded 1 PDH
(Professional Development Hour) for each hour of
conference attendance. These PDHs can be applied
toward AWS recertifications and renewals.
February 26-27, 2013
Shipbuilding Confer
th
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shipbuilding conference_FP_TEMP 12/10/12 3:39 PM Page 69
WELDING
WORKBOOK
Friction welding (FRW) is a solid-state process that produces
a weld when two or more workpieces, rotating or moving rela-
tive to one another, are brought into contact under pressure to
produce heat and plastically displace material from the faying
surface (weld interface).
The main variations of friction welding are direct drive fric-
tion welding (FRW-DD), inertia friction welding (FRW-I), and
friction stir welding (FSW). However, FSW features substantial
differences in mechanics from the other two processes and is not
covered here.
In direct drive friction welding, the welding machine supplies
the energy required to make the weld through a direct motor
connection for a preset period of the welding cycle. The stored
rotational kinetic energy of the welding machine supplies the en-
ergy required to make an inertia friction weld.
Following are some of the terms and definitions related to
friction welding:
Friction speed. The relative velocity of the workpieces at the
time of initial contact.
Friction force. The compressive force applied to faying sur-
faces during the time there is relative movement between the
workpieces from the start of welding until the application of the
forge force.
Friction time. The duration of time from the application of
friction force until the application of forge force.
Friction upset distance. The decrease in length of workpieces
during the time of friction welding force application.
Forge (upset) force. The compressive force applied to the weld
after the heating portion (friction stage) if the welding cycle is
essentially complete.
Forge (upset) distance. The total reduction in the axial length
of the workpieces from the initial contact to the completion of
the weld.
Figure 1 shows the basic steps in the friction welding process.
As shown in Fig. 1A, one workpiece is rotated and the other held
stationary. When the appropriate rotational speed is reached,
the two workpieces are brought together (B) under axial force.
Abrasion at the weld interface heats the workpiece locally and
upsetting (axial shortening) starts, as shown in (C). These two
steps occur during the friction stage. Finally, rotation of the work-
piece ceases and upset force (D) is applied to consolidate the
joint. This occurs during the forging stage.
Advantages
Following are some operational and economic advantages of
friction welding:
No filler metal is required for all similar and most dissimilar
material joints
Flux and shielding gas are not normally required
Solidification defects and porosity are normally not a concern
The process is environmentally clean due to the minimization
of sparks, smoke, or fumes
Surface cleanliness is not as critical compared to other welding
processes
Offers narrow heat-affected zones
Well suited for joining most engineering materials and dissimi-
lar metal combinations
In most cases, the weld is at least as strong as the weaker of the
two materials being joined (high joint efficiency)
Operators are not required to have manual welding skills
Easily automated for mass production
Short cycle times
Requires minimal plant requirements such as space, electric
power, and special foundations.
Limitations
Following are some limitations of friction welding:
In general, one workpiece must have an axis of symmetry and
be capable of rotation about that axis
Alignment of the workpieces may be critical to developing uni-
form frictional heat
Preparation of the interface geometry may be critical to achiev-
ing proper heat balance
Capital equipment and tooling costs are high, but payback pe-
riods typically are short for high-volume production.
JANUARY 2013 70
Datasheet 337
Excerpted from the Welding Handbook, Vol. 3, ninth edition.
Advantages and Limitations of Friction Welding
Fig. 1 Basic sequence of friction welding.
A
B
C
D
Welding Workbook January 2013_Layout 1 12/13/12 12:48 PM Page 70
buyers guide_FP_TEMP 12/10/12 3:09 PM Page 1
awo.aws.org
Mathematics is a necessary part of a welding professionals activities. However, math can be
complicated and confusing for beginners, and difficult for adults who havent used math principles
awhile. This course provides a combination of clear step-by-step verbal and visual explanations that
make each mathematical concept easy to understand and remember. Topics include place 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
process. Eighteen PDHs are provided through this course toward AWS recertification.
Online Math for Welders Course
Sample seminar at awo.aws.org/seminars/math-for-welders-level-1
Online Math for W
Online Math for W
elders Course Online Math for W
elders Course
whole numbers, fractions, decimals and mixed
simplification, estimation, measurement, and the
make each mathematical concept easy to unde
This course provides a combination of cl awhile.
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awo math_FP_TEMP 12/10/12 3:36 PM Page 72
SOCIETYNEWS SOCIETYNEWS
73 WELDING JOURNAL
AWS Elects National and District Officers for 2013
David J. Landon
vice president
David L. McQuaid
vice president
Robert G. Pali
treasurer
Nancy C. Cole
president
Dean R. Wilson
vice president
Sean P. Moran
director-at-large
Thomas J. Lienert
director-at-large
The American Welding Soci-
ety elected its incoming slate of
national and District officers
Nov. 12 in Las Vegas, Nev., dur-
ing FABTECH. The officers take
their posts on Jan. 1, 2013.
Nancy C. Cole was elected
president. An AWS Fellow and
Life Member, she has served
three terms as a vice president.
Before forming her own com-
pany, she was program manager
and contract manager at Oak
Ridge National Laboratories. At
ABB Combustion Engineering,
she developed welding elec-
trodes, fluxes, and flux cored
wires, where she was awarded
three patents. Cole served as
chair of the AWS Technical Ac-
tivities, Fellows, and C3 Brazing
and Soldering Committees. She
has received the AWS Honorary
Member, Dr. Ren Wasserman,
and McKay-Helm Awards.
Dean R. Wilson was elected
to a third term as a vice president.
Wilson is president of Well-Dean
Enterprises, a company related
to health, safety, and welding
products and industry consulting.
Earlier, he was director of weld-
ing business development at
Jackson Safety Products, and
served as president/owner of Wil-
son Industries from 1987 to 2007.
He has worked on numerous
AWS standing committees, in-
cluding WEMCO (An Associa-
tion of Welding Manufacturers)
where he served as chair in 2005.
David J. Landon was elected
to serve a second term as a vice
president. Since 1992, he has
worked as manager of welding
engineering and missions sup-
port at Vermeer Mfg. Co. and is
an AWS Senior Certified Weld-
ing Inspector. Previously, he op-
erated Landons Welding Serv-
ices performing failure analyses,
inspections, and welder training.
Earlier, he worked as a welding
engineer for Chicago Bridge and
Iron Co. He has served on many
AWS technical committees and
as a Delegate to the IIW Com-
mission XIV, Welding Education
and Training.
David L. McQuaid was
elected to his first term as a vice
president. Currently, he heads D.
L. McQuaid and Associates, Inc.,
which he founded in 1999. He has
chaired the AWS D1 Structural
Welding and the Technical Activ-
ities Committees. At American
Bridge Div. of U.S. Steel Corp.,
he served as senior welding engi-
neer and corporate engineer. In
2009, he received the American
National Standards Institute
Finegan Standards Medal for his
outstanding contributions to in-
dustrial standards.
Robert G. Pali was reelected
treasurer. He is vice president,
secretary, and COO of J. P. Nis-
sen Co. Pali is currently vice chair
of the AWS Finance Committee
and a member of the AWS Pub-
lications, Expositions, and Mar-
keting Committees. He has
served on the WEMCO (An As-
sociation of Welding Manufac-
turers) executive board, National
Nominating Committee, and nu-
merous subcommittees and pres-
idential task forces. From 1965
to 1978, he worked for Bethle-
hem Steel Corp. in analytical
chemistry and plant operations
research. In 2006, he received the
AWS National Meritorious
Award.
Thomas J. Lienert was elected
to serve as a director-at-large. He
is a Certified Welding Inspector
(CWI) and a technical staff mem-
ber, Materials Science Technol-
ogy Div., at Los Alamos National
Laboratory. Lienert is a Princi-
pal Reviewer and member of the
AWS Technical Papers Commit-
tee, and chairs the AWS Welding
Handbook chapters on Friction
Stir Welding and Stainless and
Heat-Resisting Steels, and is on
the C6 Committee on Friction
Welding and the AWS Higher
Education Committee. Lienert is
also vice chair of the Education
Committee, and serves on the
Technical Activities Committee.
Sean P. Moran has been
elected to serve as a director-at-
large. He is a welding engineer
at Weir American Hydro in York,
Pa. Earlier, he served as a busi-
ness development manager and
a welding engineer at Hobart
Brothers Co., an ITW company.
He has worked ten years as a
welding instructor in both
public and private institu-
tions, is a Certified Welding
Inspector, Certified Weld-
ing Educator, and Certified
Welding Supervisor. Moran
is a vice chair of the Educa-
tion Scholarship Commit-
tee and the Volume 3 Hand-
book Committee, is chair of
the Product Development,
and a member of the D1
Committees.
Society News January_Layout 1 12/13/12 10:36 AM Page 73
JANUARY 2013 74
Thomas A. Ferri has been
elected to serve a second term as
District 1 director. He is a CWI
and has been an AWS member for
more than 30 years. He is district
manager New England for Victor
Technologies. He served four
terms as Boston Section chair,
certification chair for seven years,
and most recently as education
chair. He serves as a welding con-
sultant to many companies in
Massachusetts and is a member of
the advisory committees at five
vocational technical schools.
Stewart A. Harris has been
elected to serve as District 4 di-
rector. He is a CWI and CWE,
is quality assurance group
leader and leader of the Weld
Solutions Team at Altec Indus-
tries, Creedmoor, N.C. He has
held all executive posts at the
Triangle Section, and served
the past four years as deputy
District 4 director. He has re-
ceived many awards, most re-
cently the District nomination
for the National Dalton E.
Hamilton Memorial CWI of
the Year Award.
Uwe W. Aschemeier has been
elected to serve as District 7 di-
rector. He is a CWI and an IIW-
certified International Welding
Engineer, and is with Miami
Diver. Earlier, he was with H. C.
Nutting, A Terracon Co., in
Cincinnati, Ohio. He has served
as chair of the Cincinnati Section,
deputy Dist. 7 director, and mem-
ber of the B1 Committee on
Methods of Inspection and sev-
eral Structural Welding Code sub-
committees. He has received the
District Meritorious and the Dis-
trict Dalton E. Hamilton Memo-
rial CWI of the Year Awards.
Robert E. Brenner has been
elected to serve as District 10 di-
rector. He is a CWI and a QC in-
spector at CnD Industries, Inc.,
Canton, Ohio, where he has
worked since 1991. At the facility,
he has coordinated the safety pro-
gram, established the OSHA li-
brary, and conducted safety train-
ing sessions for the employees. For
ten consecutive years, he spear-
headed and won the OSHA Sharp
Award for the company. Earlier,
he was weld shop supervisor at Re-
public Steel in Massillon, Ohio.
John A. Willard has been
elected to serve as District 13 di-
rector. He is a CWI, serves at
Kankakee Community College,
Kankakee, Ill., administering the
DOT Highway Construction Ca-
reers Training Program, and is
also studying for a degree in weld-
ing. Until last year, he co-owned
Accurate American Inspecting
and Consulting. He has 35 years
experience at Ironworkers Local
465 in Kankakee as an apprentice
coordinator, and has served as
chair of the JAK Section for ten
years where he remains active.
Dennis A. Wright, who has ful-
filled David Landons term as Dis-
trict 16 director, has been elected
to his first full term. He is an AWS
Distinguished Member, CWI, and
CWE. He owns his own business,
Wright Welding Technologies. He
also works in the general job shop
at Zephyr Products, Inc., Leaven-
worth, Kan., training penitentiary
inmates to weld using the AWS
SENSE program. In the U.S. Navy
he served as a journeyman
welder/fitter in a shipyard.
Ken L. Johnson has been
elected District 19 director. He
has served 31 years in the welding
trades, primarily at Todd Pacific
(now Vigor) Shipyards. He began
as a structural welder and is cur-
rently in the welding engineering
department. For the past 15 years,
he has been a welding supervisor
for the U.S. Navy and commercial
projects, and has taught evening
welding classes at Renton Techni-
cal College for the past 17 years.
Johnson has held officer posts at
the Puget Sound Section and
chairs the D3 Committee on
Welding in Marine Construction.
Kerry E. Shatell has been
elected District 22 director. He is
a CWI and CWEng, and holds a
masters degree in welding engi-
neering. Currently, he is a senior
welding engineer for Pacific Gas
& Electric Co. Earlier, he was a
welding engineer for Procter &
Gamble Co., a welder trainer for
Precision Castparts Corp., and a
pipefitter apprentice for UA
Local 598. He has served most of-
ficer posts at the Sacramento Sec-
tion. His awards include the Dis-
trict Dalton E. Hamilton Memo-
rial CWI of the Year Award.
Ken L. Johnson
District 19 director
Kerry E. Shatell
District 22 director
Dennis A. Wright
District 16 director
John A. Willard
District 13 director
Robert E. Brenner
District 10 director
Uwe W. Aschemeier
District 7 director
Stewart A. Harris
District 4 director
Thomas A. Ferri
District 1 director
Society News January_Layout 1 12/12/12 4:12 PM Page 74
American Welding Society represen-
tatives met with leaders of the Indone-
sian Welding Society (IWS) and U.S. gov-
ernment officials at the Ted Weiss Fed-
eral Building in New York City Sept. 25
to sign a cooperation agreement aimed
at implementing AWS certification pro-
grams in Indonesia. The agreement also
references plans for the future establish-
ment of a training center in Indonesia to
provide training and certification for
welders and welding instructors in that
country. Participating at the meeting
from American Welding Society were
Vice President Dean Wilson, Jeff Weber,
senior associate executive director, and
Jeff Kamentz, corporate director of in-
ternational sales. The principal represen-
tative from IWS was Achdiat Atmaw-
inata, president. Representing the U.S.
Department of Commerce were Craig
Allen, deputy assistant secretary for Asia,
and David Gossack, counselor for com-
mercial affairs.
75 WELDING JOURNAL
AWS to Cooperate with Indonesian Welding Society in Personnel
Certification and Education
Achdiat Atmawinata (seated at left), IWS president, and Dean Wilson (seated at right), AWS vice president, are shown with representatives of
the Indonesian Welding Society, American Welding Society, and the U.S. Department of Commerce.
November 1, 2013, is the deadline for
submitting nominations for the 2014 Prof.
Koichi Masubuchi Award.
This award is presented each year to
one person, 40 years old or younger, who
has made significant contributions to the
advancement of materials joining through
research and development. Nominations
should include a description of the candi-
dates experience, list of publications,
honors, and awards, and at least three let-
ters of recommendation from fellow re-
searchers. This award is sponsored by the
Dept. of Ocean Engineering at Massachu-
setts Institute of Technology (M.I.T.), this
award includes a $5000 honorarium.
E-mail your nomination package to
Todd A. Palmer, assistant professor, The
Pennsylvania State University,
tap103@psu.edu.
Candidates Sought for Welding-Related Awards
William Irrgang Memorial Award
This award is given to the individual who has done the most
over the past five years to enhance the Societys goal of advanc-
ing the science and technology of welding. It includes a $2500
honorarium and a certificate.
Honorary Membership Award
This award acknowledges eminence in the welding profession,
or one who is credited with exceptional accomplishments in the
development of the welding art. Honorary Members have full
rights of membership.
Nat. Meritorious Certificate Award
This award recognizes the recipients counsel, loyalty, and
dedication to AWS affairs, assistance in promoting cordial rela-
tions with industry and other organizations, and for contribu-
tions of time and effort on behalf of the Society.
George E. Willis Award
This award is given to an individual who promoted the ad-
vancement of welding internationally by fostering cooperative
participation in technology transfer, standards rationalization,
and promotion of industrial goodwill. It includes a $2500 hono-
rarium.
Intl Meritorious Certificate Award
This honor recognizes recipients significant contributions to
the welding industry for service to the international welding com-
munity in the broadest terms. The award consists of a certificate
and a one-year AWS membership.
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.
Society News January_Layout 1 12/12/12 4:13 PM Page 75
JANUARY 2013 76
Standards Approved by ANSI
A9.5:2013, Guide for Verification and
Validation in Computation Weld Mechan-
ics. New. 10/30/12.
D14.9/D14.9M:2013, Specification for
the Welding of Hydraulic Cylinders. New.
10/30/12.
D15.2/D15.2M:2013, Recommended
Practices for the Welding of Rails and Re-
lated Rail Components for Use by Rail Ve-
hicles. Revised. 10/30/12.
D17.2/D17.2M:2013, Specification for
Resistance Welding for Aerospace Applica-
tions. Revised. 10/30/12.
C4.6M:2006 (R2012) (ISO 9013:2002
IDT), Thermal Cutting Classification of
Thermal Cuts Geometric Product Spec-
ification and Quality Tolerances. Reaf-
firmed. 10/30/12.
Standards for Public Review
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute
(ANSI) in 1979. ANSI requires that all
standards be open to public review for
comment during the approval process.
The following Reaffirmed Standards
are submitted for public review. The ex-
piration date is 1/14/13. Draft copies, $25
each, may be ordered from R. ONeill,
roneill@aws.org, (305) 443-9353, ext. 451.
B2.1-1-003:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Metal Arc Welding (Short Circuit-
ing Transfer Mode) of Galvanized Steel (M-
1), 18 through 10 Gauge, in the As-Welded
Condition, with or without Backing
B2.1-1-004:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Metal Arc Welding (Short Circuit-
ing Transfer Mode) of Carbon Steel (M-1,
Group 1), 18 through 10 Gauge, in the As-
Welded Condition, with or without Backing
B2.1-8-005:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Metal Arc Welding (Short Circuit-
ing Transfer Mode) of Austenitic Stainless
Steel (M-8, P-8, or S-8), 18 through 10
Gauge, in the As-Welded Condition, with or
without Backing
B2.1-1/8-006:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Metal Arc Welding (Short Circuit-
ing Transfer Mode) of Carbon Steel to
Austenitic Stainless Steel (M-1 to M-8, P-8,
or S-8), 18 through 10 Gauge, in the As-
Welded Condition, with or without Backing
B2.1-1-007:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Galva-
nized Steel (M-1), 18 through 10 Gauge,
in the As-Welded Condition, with or with-
out Backing
B2.1-1-008:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Carbon
Steel (M-1, P-1, or S-1), 18 through 10
Gauge, in the As-Welded Condition, with or
without Backing
B2.1-8-009:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Austenitic
Stainless Steel (M-8, P-8, or S-8), 18 through
10 Gauge, in the As-Welded Condition, with
or without Backing
B2.1-1/8-010:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Carbon
Steel to Austenitic Stainless Steel (M-1, P-1
or S-1 to M-8, P-8, or S-8), 18 through 10
Gauge, in the As-Welded Condition, with or
without Backing
B2.1-1-011:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Shielded Metal Arc Welding of Galva-
nized Steel (M-1), 10 through 18 Gauge, in
the As-Welded Condition, with or without
Backing
B2.1-1-012:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Shielded Metal Arc Welding of Carbon
Steel (M-1, P-1, or S-1 to M-1, P-1, or S-1),
10 through 18 Gauge, in the As-Welded
Condition, with or without Backing
B2.1-8-013:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Shielded Metal Arc Welding of Austenitic
Stainless Steel (M-8, P-8, S-8, Group 1), 10
through 18 Gauge, in the As-Welded Con-
dition, with or without Backing
B2.1-1/8-014:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Shielded Metal Arc Welding of Carbon
Steel to Austenitic Stainless Steel (M-1 to
M-8/P-8/S-8, Group 1), 10 through 18
Gauge, in the As-Welded Condition, with
or without Backing
B2.1-1/8-227:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding of Carbon
Steel (M-1/P-1, Groups 1 or 2) to
Austenitic Stainless Steel (M-8/P-8,
Group 1),
1
16 through 1
1
2 Inch Thick,
ER309(L), As-Welded Condition, Prima-
rily Pipe Applications
B2.1-1/8-228:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Shielded Metal Arc Welding of Carbon
Steel (M-1/P-1/S-1, Groups 1 or 2) to
Austenitic Stainless Steel (M-8/P-8/S-8,
Group 1),
1
8 through 1
1
2 Inch Thick,
E309(L) -15, -16, or -17, As-Welded Con-
dition, Primarily Pipe Applications
B2.1-1/8-229:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding followed by
Shielded Metal Arc Welding of Carbon Steel
(M-1/P-1, Groups 1 or 2) to Austenitic
Stainless Steel ( M-8/P-8, Group 1),
1
8
through 1
1
2 Inch Thick, ER309(L) and
E309(L) -15, -16, or -17, As-Welded Con-
dition, Primarily Pipe Applications
B2.1-1/8-230:2002 (R20XX), Standard
Welding Procedure Specification (SWPS) for
Gas Tungsten Arc Welding with Consumable
Insert Root of Carbon Steel (M-1/P-1,
Groups 1 or 2) to Austenitic Stainless Steel
(M-8/P-8, Group 1),
1
16 through 1
1
2 Inch
Thick, IN309 and ER309(L), As-Welded
Condition, Primarily Pipe Applications
B2.1-1/8-231:2002 (R20XX), Standard
Welding Procedure Specification (SWPS)
for Gas Tungsten Arc Welding with Con-
sumable Insert Root followed by Shielded
Metal Arc Welding of Carbon Steel (M-1/P-
1/S-1, Groups 1 or 2) to Austenitic Stain-
less Steel (M-8/P-8/S-8, Group 1)
1
8 through
1
1
2 Inch Thick, IN309, ER309, and E309 -
15,- 16, or -17, or IN309, ER309(L), and
ER309(L) -15, -16, or -17, As-Welded Con-
dition, Primarily Pipe Applications
ISO Standards for Public Review
Copies of the following Draft Interna-
tional Standards are available for review
and comment through your national stan-
dards body, which in the United States is
ANSI, 25 W. 43rd St., 4th Floor, New York,
NY 10036; (212) 642-4900. Any comments
regarding ISO documents should be sent
to your national standards body. In the
United States, if you want to contribute
to the development of International Stan-
dards for welding, contact A. Davis,
adavis@aws.org, (305) 443-9353, ext. 466.
ISO/DIS 14114 Gas welding equip-
ment Acetylene manifold systems for
welding, cutting, and allied processes
General requirements
ISO/DIS 25980 Health and safety in
welding and allied processes Transpar-
ent welding curtains, strips, and screens for
arc welding processes
Technical Committee Meetings
Note: All of the following meetings will
be held at AWS World Headquarters in
Doral, Fla. All AWS technical committee
meetings are open to the public. To attend
a meeting, contact the secretary listed.
Jan. 23. Committee on Personnel and
Facilities Qualification. S. Hedrick, ext.
305.
Feb. 4, 5. B4 Committee on Mechani-
cal Testing of Welds. B. McGrath, ext. 311.
Feb. 6. International Standards Activi-
ties Committee. A. Davis, ext. 466.
Feb. 6, 7. Technical Activities Commit-
tee. A. Alonso, ext. 299.
Feb. 26March 1, D1 Committee
meetings. For details, call B. McGrath,
ext. 311, or visit www.aws.org/WPZD8B.
Tech Topics
Society News January_Layout 1 12/12/12 4:14 PM Page 76
77 WELDING JOURNAL
New AWS Supporters
SUSTAINING MEMBER
Lincoln College of Technology
11194 E. 45th Ave.
Denver, CO 80239
Representative: Eric T. Drobney
www.lincolncollegeoftechnology.com
Lincoln College of Technology teaches
students of all ages to weld using an eight-
stage program designed to move them into
the welding industry well rounded in the
GMA, GTA, FCA, and SMA welding
processes. Students learn these tech-
niques beginning with emphasis on safety
and proper equipment setup. The courses
are based on AWS standards with an em-
phasis on code compliance.
AFFILIATE COMPANIES
Applied Cryo Technologies
7150 Almeda Genoa
Houston, TX 77075
DM & C Steel Corp.
10949 Schmidt Rd.
El Monte, CA 91733
Eastern Oklahoma Fabrication
27355 State Hwy. 112
Cameron, OK 74932
Fedorki Performance Systems Ltd.
PO Box 1534
Brockville, ON K6V6E6
Canada
Great Lakes Mechanical Services, Inc.
1221 Commerce Dr., Ste. 400
Crete, IL 60417
Howell Industries
1650 Swisco Rd.
Sulphur, LA 70665
Killick Group Ltd.
19 Dundee Ave.
Mount Pearl, NL A1N4R6, Canada
Peddinghaus Corp.
300 N. Washington Ave.
Bradley, IL 60915
Playcore
150 Playcore Dr.
Fort Payne, AL 35967
Tech Fab
7450 Miller Rd. 2, Houston, TX 77049
SUPPORTING COMPANIES
ALFRA USA LLC
120 Prairie Lake Rd.
East Dundee, IL 60118
Axis Inspection Group Ltd.
1239 Manahan Ave., Unit B
Winnipeg, MB R3T5S8
Canada
EDUCATIONAL INSTITUTIONS
Certified Welding
16 Walnut St.
West Warwick, RI 02893
Daingerfield Lone Star ISD
200 Tiger Dr.
Daingerfield, TX 75638
Davis Applied Technology College
550 E. 300 S.
Kaysville, UT 84037
Hallettsville High School
200 N. Ridge St.
Hallettsville, TX 77964
North Bend High School
2323 Pacific Ave.
North Bend, OR 97459
Savannah Technical College
5717 White Bluff Rd.
Savannah, GA 31405
Spooner High School
801 Hwy A
Spooner, WI 54801
Tallahassee Community College
444 Appleyard Dr.
Tallahassee, FL 32304
Texas State Technical College
West Texas
300 Homer K. Taylor Dr.
Sweetwater, TX 79556
Welding Skills Workshops
181 S. Wineville Ave., Unit A
Ontario, CA 91761
D14 Committee on Machinery and
Equipment seeks professionals in the de-
sign, production, engineering, testing, and
safe operation of machinery and equipment
to prepare and revise its documents. E.
Abrams, eabrams@aws.org; ext. 307.
C2 Committee on Thermal Spraying
seeks educators, general interest, and users
to update its documents. E. Abrams,
eabrams@aws.org; ext. 307.
D16 Committee on Robotic and Auto-
matic Welding seeks general interest and
educators to help revise its documents. B.
McGrath, bmcgrath@aws.org; ext. 311.
D17J Subcommittee seeks members to
help revise D17.3/D17.3M, Specification
for Friction Stir Welding of Aluminum Al-
loys for Aerospace Applications. Contact A.
Diaz, adiaz@aws.org; ext. 304.
J1 Committee on Resistance Welding
Equipment seeks educators, general inter-
est, and users to help develop its documents
on controls, installation and maintenance,
calibration, and resistance welding fact
sheets. E. Abrams, eabrams@aws.org; ext.
307.
A5L Subcommittee on Magnesium
Alloy Filler Metals to assist in updating its
document. R. Gupta, gupta@aws.org, ext.
301.
C4 Committee on Oxyfuel Gas Welding
and Cutting seeks general interest and ed-
ucators to help review its documents. Con-
tact E. Abrams, eabrams@aws.org; ext. 307.
D14H Subcommittee on Surfacing and
Reconditioning of Industrial Mill Rolls to
revise AWS D14.7, Recommended Practices
for Surfacing and Reconditioning of Indus-
trial Mill Rolls. E. Abrams, eabrams@
aws.org; ext. 307.
D8 Committee on Automotive Welding
seeks members to help prepare standards
on all aspects of welding in the automotive
industry. E. Abrams, eabrams@aws.org;
ext. 307.
D10P Subcommittee for Local Heat
Treating of Pipe seeks members. B. Mc-
Grath, bmcgrath@aws.org; ext. 311.
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.
American Welding Society members
will receive a discounted fee to attend the
Laser Institute of America (LIA) 5th An-
nual Laser Additive Manufacturing Work-
shop to be held Feb. 12 at Hilton Houston
North Hotel in Houston, Tex. The two so-
cieties have signed a cooperating society
agreement wherein AWS is listed as a Co-
operating Society for the event and AWS
members receive the LIA member dis-
count. For complete information, visit
www.lia.org/conferences/lam.
Laser Additive Manufacturing Workshop Offers Discounted Fee to AWS Members
Society News January_Layout 1 12/12/12 4:14 PM Page 77
JANUARY 2013 78
Member-Get-A-Member Campaign
Listed are the members participating in
the 20122013 campaign. Standings as of
11/16/12. See page page 85 of this Welding
Journal for campaign rules and prize list or
visit www.aws.org/mgm. For information,
call the Membership Department
(800/305) 443-9353, ext. 480.
Winners Circle
Sponsored 20 or more new Individual Mem-
bers per year since June 1, 1999. The super-
script denotes the number of times the mem-
ber achieved Winners Circle status if more
than once.
E. Ezell, Mobile
10
J. Compton, San Fernando Valley
7
J. Merzthal, Peru
2
G. Taylor, Pascagoula
2
L. Taylor, Pascagoula
2
B. Chin, Auburn
S. Esders, Detroit
M. Haggard, Inland Empire
M. Karagoulis, Detroit
S. McGill, NE Tennessee
B. Mikeska, Houston
W. Shreve, Fox Valley
T. Weaver, Johnstown/Altoona
G. Woomer, Johnstown/Altoona
R. Wray, Nebraska
Presidents Roundtable
Sponsored 919 new Individual Members
M. Pelegrino, Chicago 16
E. Ezell, Mobile 12
R. Fulmer, Twin Tiers 10
W. Blamire, Atlanta 9
A. Tous, Costa Rica 9
P. Strother, New Orleans 9
Presidents Club
Sponsored 38 new Individual Members
D. Galiher, Detroit 7
W. Komlos, Utah 7
J. Smith, San Antonio 6
C. Becker, Northwest 5
L. Webb, Lexington 4
A. Bernard, Sabine 3
P. Brown, New Orleans 3
D. Buster, Eastern Iowa 3
C. Daon, Israel 3
G. Gammill, NE Mississippi 3
D. Jessop, Mahoning Valley 3
A. Winkle, Kansas City 3
D. Wright, Kansas City 3
R. Wright, San Antonio 3
Presidents Honor Roll
Sponsored 2 new Individual Members
P. Host, Chicago
W. Larry, Southern Colorado
E. Norman, Ozark
A. Sam, Trinidad
D. Saunders, Lakeshore
A. Vogt, New Jersey
J. Vincent, Kansas City
M. Wheeler, Cleveland
L. William, Western Carolina
W. Wilson, New Orleans
R. Zabel, SE Nebraska
Student Member Sponsors
Sponsored 3 or more new AWS Student
Members.
B. Scherer, Cincinati 39
W. England, West Michigan 33
H. Hughes, Mahoning Valley 31
R. Hammond, Greater Huntsville 27
S. Siviski, Maine 24
B. Cheatham, Columbia 23
T. Geisler, Pittsburgh 23
C. Kochersperger, Philadelphia 23
M. Arand, Louisville 22
G. Gammill, NE Mississippi 21
R. Munns, Utah 18
S. Lindsey, San Diego 17
J. Falgout, Baton Rouge 16
E. Norman, Ozark 16
D. Pickering, Central Arkansas 13
R. Zabel, SE Nebraska 13
J. Daugherty, Louisville 12
C. Morris, Sacramento 12
R. Richwine, Indiana 12
S. Robeson, Cumberland Valley 12
R. Hutchinson, Long Beach/Or.Cty. 11
D. Saunders, Lakeshore 11
A. Theriot, New Orleans 10
A. Duron, Cumberland Valley 10
J. Boyer, Lancaster Section 9
G. Seese, Johnstown-Altoona 8
C. Schiner, Wyoming 8
C. Gilbertson, Northern Plains 8
J. Dawson, Pittsburgh 7
R. Udy, Utah 7
R. Vann, South Carolina 7
T. Buckley, Columbus 6
R. Fuller, Green & White Mts. 6
T. Shirk, Tidewater 6
A. Badeaux, Washington, D.C. 5
P. Host, Chicago 5
K. Temme, Philadelphia 5
W. Wilson, New Orleans 5
C. Chifici, New Orleans 4
J. Reed, Ozark 4
G. Siepert, Kansas 4
P. Strother, New Orleans 4
R. Zadroga, Philadelphia 4
S. Liu, Colorado 3
G. Lunen, Kansas City 3
Districts Council Actions and Membership Awards Notices
Actions of the Districts Council
On Nov. 11, after due consideration,
Districts Council approved the disband-
ment of the Cuautitlan Izcalli Section,
District 18.
Charters were approved for the Stu-
dent Chapters at Strom Thurmond Ca-
reer Center, District 5, and Blackhawk
Technical College, District 12.
The Shasta College Student Chapter,
District 22, was approved for reinstate-
ment.
Approved for disbandment were the
Student Chapters at Southeast Commu-
nity College, District 16; Ozark Mountain
Technical Center, District 17; Mount Ver-
non High School, District 19; and Cholla
High Magnet School, District 21.
Membership Promotion Winners
Announced
A special membership promotion was
held at the AWS Membership Booth dur-
ing FABTECH, in Las Vegas. Everyone
who joined or renewed their membership
for two years or longer received their
choice of uniquely designed T-shirts or a
limited edition American Welder patch,
and were also entered in a raffle to win a
$100 VISA gift card or an AWS duffle bag.
The VISA card winners included Ryan
Compton, Castaic, Calif.; Brian Henrick-
son, Minneapolis, Minn.; and Mike
Myers, Nikiski, Alaska. David Ennis,
Winder, Ga., received the duffle bag.
District Director Award Presented
The District Director Award provides
a means for District directors to recognize
individuals and corporations for contribut-
ing time and resources to the affairs of the
local Section and/or District.
District 9 Director George Fairbanks
has nominated James Carnell, Baton
Rouge Section, for the this award.
AWS Member Counts
December 1, 2012
Sustaining ......................................553
Supporting.....................................352
Educational ...................................608
Affiliate..........................................485
Welding Distributor........................50
Total Corporate ..........................2,048
Individual .................................58,118
Student + Transitional ...............10,165
Total Members.........................68,283
Society News January_Layout 1 12/12/12 4:15 PM Page 78
79 WELDING JOURNAL
SECTIONNEWS
SECTIONNEWS
District 1
Thomas Ferri, director
(508) 527-1884
thomas_ferri@Victortechnologies.com
Shown at the Boston Section vendor night event are (from left) Pat Fogarty, Nick Ryan, Alex Bill, Nick Stillwater, Megan Custer, Rick Costa,
and Jim Carey.
Shown at the Central Mass./Rhode Island Section event are from left (front) Jeffrey Bar-
boza, Zachery Smith, Instructor Douglas Desrochers, and Timothy Hurley; (back) Matthew
Alger, Nathaniel St. John, Nicholas Demling, Michael McGraw, and Antonia Baravella.
Bill Campbell (center) is shown with Dave Paquin (left), Boston Section chair, and Tom
Ferri, District 1 director.
BOSTON
NOVEMBER 5
Activity: The Section participated in a ven-
dor night event hosted at Joseph P. Keefe
Regional Technical School in Framing-
ham, Mass. Representatives from Fraser
& Malloy, Miller Electric, Victor Tech-
nologies, Pferd Abrasives, Arc One, and
Edmar Abrasives offered demonstrations
of stud welding, arc welding, and abrasive
products. Bill Campbell received the CWI
of the Year Award from District 1 Direc-
tor Tom Ferri and Dave Paquin, Section
chair.
CENTRAL MASS./R.I.
NOVEMBER 9
Activity: The Section members partici-
pated in the annual 8th grade career
awareness days designed to introduce stu-
dents to the many vocations and courses
available in welding. Instructor Douglas
Desrochers and his students in the weld-
ing and joining technologies program ex-
plained and demonstrated the gas metal
arc and gas tungsten arc welding processes.
The event was held at Old Colony Vo-Tec
High School in Rochester Mass.
Society News January_Layout 1 12/12/12 4:16 PM Page 79
JANUARY 2013 80
MAINE
OCTOBER 25
Activity: The Section members visited
Eastern Maine Community College in
Bangor to tour its welder training facili-
ties. A highlight was the weld testing cen-
ter where Tom Giles discussed the proce-
dures for destructive testing of welds, and
the welder performance qualifications re-
quired at the college.
TRIANGLE & NE CAROLINA
OCTOBER 23
Activity: The Section members toured
Nash Tech Community College in Nash,
N.C. Pitt Community College displayed its
mobile welding lab at the event. Russell
Wahrman from Wake C. C. discussed how
belonging to AWS has improved his career
and the activities of his schools Student
Chapter. Bobby Perkins, Northeastern
Carolina Section chair, presented Ted
Clayton the Section CWI of the Year
Award, and the Section Educator Award
to Russell Wahrman.
PHILADELPHIA
NOVEMBER 15
Speaker: Ken Moyer, metallurgist
Topic: How grain structure affects the weld
characteristics
Activity: The program was held at Villaris
Lakeside Restaurant in Sicklerville, N.J.
Shown at the Maine Section tour are (from left) Jim Kein, Chris Maseychik, Mike Burgess, Tom Giles, Robb Smith, Mark Merry, Mark
Legel, Reggie Munson, Joel Stanley, Mark Searle, and Patrick Blackie. Photo by Pat Kein, vice chair.
Attendees are shown at the Triangle Section tour of Nash Tech Community College.
Bobby Perkins (left), NE Carolina Section
chair, is shown with Ted Clayton.
Russell Wahrman (right) is shown with
Bobby Perkins, NE Carolina Section chair.
Metallurgist Ken Moyer (left) is shown with
Ken Temme, Philadelphia Section chair.
District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com
District 4
Stewart A. Harris, director
(919) 824-0520
Stewart.Harris@Altec.com
District 3
Michael Wiswesser, director
(610) 820-9551
mike@welderinstitute.com
Society News January_Layout 1 12/12/12 4:16 PM Page 80
81 WELDING JOURNAL
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
District 7
Uwe Aschemeier, director
(513) 351-3545
uwe@miamidiver.com
District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com
Shown at the Columbia Section program are (from left) Larry Dowd, District 5 Director
Carl Matricardi, and Rick Shannon.
Shown at the North Florida Section meeting in September are (from left) Allen Garber, Bob
Bitzky, Doug Yates, Drew Duffy, and Shelby Smith.
Shown at the South Carolina Section program are (from left) C. Ray Pearre, Chair Gale
Mole, and Bill Creek.
Shown at the Northern New York Section
program are (from left) Bob Strugar, speaker
Dale Kapuscinski, and Chair Larry Hidde.
Speaker Bill Myers (right), an AWS past pres-
ident, is shown with Charles Crumpton,
Florida West Coast Section chair.
COLUMBIA
OCTOBER 18
Speaker: Michael Daley
Affiliation: Owen Steel
Topic: Welding-related documents, welder
qualification and certification require-
ments
Activity: District 5 Director presented the
CWI of the Year Award to Tommy Dowd,
received in his absence by Larry Dowd.
The event was held at Arclabs in Colum-
bia, S.C., hosted by Rick Shannon.
FLORIDA WEST COAST
NOVEMBER 14
Speaker: Bill Myers, welding engineer
Affiliation: Dresser Industries (ret.)
Topic: Welding cast iron
Activity: The event was held for 21 atten-
dees at Frontier Steakhouse in Tampa, Fla.
NORTH FLORIDA
SEPTEMBER
Activity: The Section members visited
Commercial Diving Academy in Jack-
sonville, Fla.
SEPTEMBER 20
Speaker: Bob Bitzky, training and process
manager
Affiliation: ESAB Welding & Cutting
Topic: Spray and short circuit welding
processes
SOUTH CAROLINA
OCTOBER 18
Activity: The Section met at Trident Tech-
nical College in North Charleston, S.C.,
for a demonstration of blacksmithing tech-
niques. The presenters were C. Ray Pearre
and Bill Creek from the Philip Simmons
Artisans Blacksmith Guild.
NORTHERN NEW YORK
NOVEMBER 6
Speaker: Dale Kapuscinski, district sales
manager for New York state
Affiliation: The Lincoln Electric Co.
Topic: Welding technology advancements
Activity: Chair Larry Hidde presented Bob
Strugar the past chairmans award.
Society News January_Layout 1 12/12/12 4:17 PM Page 81
JANUARY 2013 82
District 8
Joe Livesay, director
(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
Pittsburgh Section members are shown at the November program.
Pittsburgh Section members shown at FABTECH (from left) are Bill Kashin, District 7 Di-
rector Don Howard, AWS Vice President-Elect Dave McQuaid, and Ed Yevick.
Speaker Timothy Andreychek (left) is shown
with John Menhart, Pittsburgh Section chair.
CINCINNATI
NOVEMBER 6
Speaker: Uwe Aschemeier, senior welding
engineer
Affiliation: Miami Diver, LLC
Topic: Repair of a product tanker
Activity: The program was held at the
Corinthian Restaurant in Cincinnati,
Ohio, for 25 attendees.
NOVEMBER 19
Activity: Several Pittsburgh Section mem-
bers promoted the Sections activities at
the FABTECH show in Las Vegas, Nev.,
including AWS Vice President-Elect Dave
McQuaid, District 7 Director Don
Howard, Bill Kashin, and Ed Yevick.
CHATTANOOGA
OCTOBER 16
Activity: The Section members visited Al-
stom Power in Chattanooga, Tenn. Julio
Tolaini, welding group head, discussed a
welding monitoring system. Doug Donald-
son, material identification specialist, and
Randy Theriot, welding qualification su-
pervisor, at Partek Laboratories, Houma,
La., demonstrated the TVC ALX II weld-
ing data monitoring and recording system.
COLUMBUS
SEPTEMBER 13
Activity: The Section members joined
members of other local technical societies
at The Ohio State University to attend a
workshop on how to interview effectively
presented by several local employers and
college students. The speakers included
Tom Ramsay, Elizabeth Brannon, and
Greg Boyer.
SEPTEMBER 26
Speaker: Jean-Vi Lenthe, author
Topic: Flying into Yesterday: My Search
for the Curtiss-Wright Aeronautical Engi-
neering Cadettes
Activity: The program was held at The
Ohio State University in Columbus, Ohio.
PITTSBURGH
NOVEMBER 13
Speaker: Timothy Andreychek, engineer
Affiliation: Westinghouse Electric Co.
Topic: Improving corrosion-resisting com-
ponents for the AP1000 nuclear reactor
Activity: The program was held at Spring-
field Grille in Mars, Pa.
Julio Tolaini discussed weld monitoring at
the Chattanooga Section program.
Society News January_Layout 1 12/12/12 4:17 PM Page 82
83 WELDING JOURNAL
NASHVILLE
OCTOBER 9
Activity: District 8 Director Joe Livesay
presented the AWS Extraordinary Weld-
ing Award to Preston Farabow, a
Knoxville-area artist, for his stainless steel
sundial sculpture Marking Time. The pres-
entation was made at the I-40 Smith
County Welcome Center in Buffalo Val-
ley, Tenn., where the sculpture is on per-
manent exhibition.
NE MISSISSIPPI
SEPTEMBER 12
Activity: The Section held its program in
Starkville, Miss. Denny Cole received the
Section Meritorious Award. David Car-
wyle received the Section Dalton E. Hamil-
ton Memorial CWI of the Year Award.
SEPTEMBER 20
Activity: The NE Mississippi Section met
with Ron Martucci, salesman, The Lincoln
Electric Co., for a demonstration of the
VRTEX360 virtual reality arc welder
trainer technology.
OCTOBER 25
Activity: The NE Mississippi Section mem-
bers toured the Babcock & Wilcox West
Point, Miss., facility. David Hutchins,
welding engineer, conducted the program.
Doug Donaldson (left) and Randy Theriot
are shown at the Chattanooga Section event.
Preston Farabow (right) receives the AWS
Extraordinary Welding Award from Joe
Livesay, District 8 director.
The NE Mississippi Section members are shown during their tour of Babcock & Wilcox Co. in October.
Northeast Mississippi Section members are shown at their September 20 event.
Shown at the NE Mississippi September 12 program are (from left) Chuck Robertson, Denny
Cole, David Carwyle, and Robbin Shull.
Society News January_Layout 1 12/12/12 4:18 PM Page 83
JANUARY 2013 84
Attendees at the NE Tennessee Section tour are (from left) Caleb Anderson, Lucas Hicks, Charles Leopper, John Folk, presenter Patrick
Werner, Bruce Lowery, Brent Shattles, Joshua Burgess, David Hoff, Philip Bodanza, Lloyd Cadd, District 8 Director Joe Livesay, Darren
Nail, Jim Werner, Chris Hayes, Paul Pipkin, Daniel Conner, and Jonaaron Jones.
Shown at the Acadiana Section program are (from left) Chair Mike Skiles, Gary Wilson,
Sam Newton, Abby Bergeron, and David Reid.
Shown at the Birmingham Section program are (from left) Secretary Chris Williams, Treas-
urer Nicholas Thomas, Vice Chair Chris Guined, Chair Randall Standridge, Program Chair
Rushton Syphurs, and Membership Chair Kendall Allen.
NE TENNESSEE
OCTOBER 23
Activity: The Section members toured the
Materials Engineering & Testing Corp. in
Oak Ridge, Tenn. Patrick Werner, presi-
dent, conducted a shop tour including the
waterjet cutting, Charpy impact testing,
weld X-ray, and chemical analysis areas.
Attending were Joe Livesay, District 8 di-
rector, and members from other AWS Sec-
tions.
District 10 Roundtable
NOVEMBER 3
Activity: The District presented its first
CWI Roundtable as a forum for CWIs to
share their experiences and opinions. The
12 attendees discussed four topics: what
CWIs do, steps to audit for code compli-
ance, how to get the job done, and han-
dling controversies. Participating were
Louis Verhas, Lance Besse, Pam Michal-
ski, Thomas Kostreba, Dan Donaldson,
ACADIANA
OCTOBER 16
Activity: More than 70 representatives of
local businesses and welding students at-
tended the Sections meeting held at
Cameron Corp. in Ville Platte, La. Chair
Mike Skiles made a presentation about
AWS and local welding opportunities.
Welding Supervisor Gary Wilson and
Manufacturing Manager Sam Newton con-
ducted a tour of the facilities.
BIRMINGHAM
NOVEMBER 13
Activity: The Section held a Chat with the
President program at Lawson State Com-
munity College. College President Perry
W. Ward recognized the various student
organizations and discussed job opportu-
nities and financial support programs.
MOBILE
NOVEMBER 1
Speaker: Ryan ODell, district manager
Affiliation: Miller Electric Mfg. Co.
Topic: Weld data monitoring
Activity: Welding students from Locklin
Technical Center attended the program.
The event was held at Original Oyster
House in Spanish Fort, Ala.
Speaker Ryan ODell (left) is shown with
Johnny Dedeaux, Mobile Section chair.
District 10
Robert E. Brenner, director
(330) 484-3650
bobren28@yahoo.com
District 9
George Fairbanks Jr., director
(225) 473-6362
ts@bellsouth.net
Society News January_Layout 1 12/12/12 4:18 PM Page 84
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Mr. Ms. Mrs. Dr. Please print Duplicate this page as needed
Last Name______________________________________________________________________________
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Were you ever an AWS Member? YES NO If YES, give year_____and Member # ____________
Primary Phone ( )____________________ Secondary Phone ( ) ____________________
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If yes, Members name:_________________________________ Members # (if known): ______________
From time to time, AWS sends out informational emails about programs we offer, new Member benefits, savings opportunities and
changes to our website. If you would prefer not to receive these emails, please check here
Type of Business (Check ONE only)
A Contract construction
B Chemicals & allied products
C Petroleum & coal industries
D Primary metal industries
E Fabricated metal products
F Machinery except elect. (incl. gas welding)
G Electrical equip., supplies, electrodes
H Transportation equip. air, aerospace
I Transportation equip. automotive
J Transportation equip. boats, ships
K Transportation equip. railroad
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N Misc. repair services (incl. welding shops)
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assns.)
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Job Classification (Check ONE only)
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assistant)
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Technical Interests (Check all that apply)
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G Arcwelding
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I Resistance welding
J Thermal spray
K Cutting
L NDT
M Safety and health
N Bending and shearing
O Roll forming
P Stamping and punching
Q Aerospace
R Automotive
S Machinery
T Marine
U Piping and tubing
V Pressure vessels and tanks
W Sheet metal
X Structures
Y Other
Z Automation
1 Robotics
2 Computerization of Welding
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87 WELDING JOURNAL
Lane Smerglia, Jim Myers, Dave Cook,
Mark Demchak, Bob Gardner, Gary
Smerglia, and Richard Harris, District 10
director. The District 10 roundtable was
held at Babcock & Wilcox Commercial in
Euclid, Ohio.
MAHONING VALLEY
OCTOBER 17
Activity: The Section executive committee
and Student Chapter officers met to plan
activities for the coming season. The meet-
ing was held at Rachels Restaurant in
Austintown, Ohio.
NOVEMBER 8
Speaker: Robert Matteson, director of
technology
Affiliation: Taylor-Winfield Technologies
Topic: Resistance welding basics and
equipment
Activity: About 70 members and guests at-
tended this program, held at Columbiana
County Career Center in Columbiana,
Ohio.
NORTHWESTERN PA.
OCTOBER 9
Speaker: Carl Peters, director of educa-
tion
Affiliation: The Lincoln Electric Co.
Topic: Education and careers in welding
Activity: The program, held at Erie Insti-
tute of Technology in Erie, Pa., was at-
tended by 42 members and guests.
NOVEMBER 6
Activity: The Northwestern Pa. Section
members and guests toured the Eriez fa-
cility in Erie, Pa. Christine Williamson,
human resources manager, presented a
history of the magnetics company and led
the tour for the 50 attendees.
District 11
Robert P. Wilcox, director
(734) 721-8272
rmwilcox@wowway.com
Shown are some of the participants at the District 10 CWI Roundtable event.
Central Michigan Section members and Boy Scouts are shown at the Merit Badge Clinic
event held in September.
Christine Williamson is shown with Tom
Kostreba, Northwestern Pa. Section chair,
during the November Eriez tour.
Speaker Carl Peters (left) is shown with Tom
Kostreba, Northwestern Pennsylvania Sec-
tion chair, at the October meeting.
The Mahoning Valley Section executive committee and Student Chapter officers are shown
at their planning meeting in October.
CENTRAL MICHIGAN
SEPTEMBER 22, 23
Activity: The Section members conducted
a Boy Scout Merit Badge Clinic at Lans-
ing Community College in Lansing, Mich.
The program qualified 14 boys to earn
their welding merit badges. Participating
were Catherine Lindquist, Craig Barnes,
Roy Bailiff, Bill Eggleston, and Jeff
Haynes.
Society News January_Layout 1 12/12/12 4:19 PM Page 87
JANUARY 2013 88
District 12
Daniel J. Roland, director
(715) 735-9341, ext. 6421
daniel.roland@us.ncantieri.com
District 13
John Willard, director
(815) 426-2997
kustom_bilt@msn.com
Madison-Beloit Section members are shown during the tour of Stoughton Trailers.
Shown during the Lakeshore Section tour are (from left) Chair Milt Kemp, Dick Brown,
Andy Schmitt, and Mark Stenz.
Eric Stiles discussed welding robots for the
Detroit Section members.
A Student Chapter member competes in the
virtual welding contest held by the Madison-
Beloit and Racine-Kenosha Sections.
Dan Wellman (left) is shown with presenter
Mike Klos during the Detroit Section tour.
Willie Petzrick (left) and Kenneth Hunter are
shown at the Madison-Beloit Section program.
DETROIT
NOVEMBER 8
Activity: The Section members and guests
visited IPG Photonics-Midwest in Novi,
Mich., to tour the facility. Mike Klos, gen-
eral manager, and Eric Stiles, applications
manager, discussed intelligent robots for
materials-joining applications. The event
attracted 75 attendees.
NORTHWEST OHIO
JULY 6
Activity: The Section held its annual Don-
ald J. Leonhardt golf outing in Toledo,
Ohio, for 64 participants. The event co-
chairs were Mike Rogers, Tony Duris, and
Mark Scalise. The event benefits scholar-
ships for Owen Community College.
LAKESHORE
OCTOBER 11
Activity: The Section members toured the
Miller Implement Co. in St. Nazianz, Wis.,
to observe the manufacture of agricultural
sprayer application equipment. The din-
ner and meeting were held at Knox Silver
Valley Restaurant in Manitowoc, Wis., for
25 attendees.
MADISON-BELOIT
OCTOBER 17
Activity: The Section members toured
Stoughton Trailers in Stoughton, Wis., to
study the manufacture of grain haulers,
vans, domestic containers, container chas-
sis, platform trailers, converter dollies, and
flatbeds.
MADISON-BELOIT and
RACINE-KENOSHA
NOVEMBER 7
Activity: Members of the two Sections met
at Blackhawk Technical College in
Janesville, Wis., for a hands-on vendors
night activity including industry represen-
tatives from Lincoln Electric, Miller Elec-
tric, ESAB, Fronius, Airgas, and Hyper-
therm. The college welding shop was avail-
able for students and guests to work with
the various welding processes. The college
and the Student Chapter hosted a welding
contest using a VRTEX 360 virtual arc
welding training equipment.
Society News January_Layout 1 12/12/12 4:20 PM Page 88
89 WELDING JOURNAL
District 14
Robert L. Richwine, director
(765) 378-5378
bobrichwine@aol.com
Attendees are shown at the joint Chicago Section-ASNT chapter program.
The Ivy Tech C. C. Student Chapter members are from left (front row) Dustin Johnson,
Dustin Hawkins, Cory Rix, and Andrew Gibson, (standing) Aaron Rich, Jonathan See, Wil-
son Smith, Advisor Martina Miller, Terrence Smith, Justin Lui, Josh Noble, Thomas Faucett,
Bethann Neal, and Advisor Bob Richwine, District 14 director.
The Iowa Section members are shown with the candidates who earned their Boy Scout welding merit badges in November.
Craig Tichelar (left) is shown with Chicago
Section Chair Pete Host.
Stuart Kleven (left) received a speaker plaque
from Pete Host, Chicago Section chair.
CHICAGO
OCTOBER 17
Speaker: Stuart Kleven, inspector
Affiliation: Alloyweld Inspection Co.
Topic: The Laser Interferometer Gravita-
tion Observatory project
Activity: This was a joint meeting with
members of the local chapter of ASNT.
Craig Tichelar was presented an appreci-
ation award for his services as chairman.
Ivy Tech C.C.
Student Chapter
OCTOBER
Activity: The first AWS Student Chapter
in the state of Indiana met at the college.
The advisors are welding instructor Mar-
tina Miller and Bob Richwine, District 14
director. The Student Chapter members
attending included Dustin Johnson,
Dustin Hawkins, Cory Rix, Andrew Gib-
son, Aaron Rich, Jonathan See, Wilson
Smith, Terrence Smith, Justin Lui, Josh
Noble, Thomas Faucett, Malcom Duncan,
and Bethann Neal.
Society News January_Layout 1 12/12/12 4:20 PM Page 89
JANUARY 2013 90
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
IOWA
NOVEMBER 3
Activity: The Section sponsored its first
Boy Scout welding merit badge event in
Waterloo, Iowa. Participating were mem-
bers of the Boy Scout troops from
Scheffield, Cedar Falls, New Hampton,
Bettendorf, Winthrop, Iowa City, Laporte
City, Van Horne, Clear Lake, Charles City,
and Mason City. The Section members
working the event were Greg Allison, Jor-
dan Mason, Andy Morrison, Andy
Suprenant, Jonathan Lowery, Jeff
Jantzen, and Kelly Jantzen.
KANSAS CITY
NOVEMBER 8
Speaker: Taylor Christmas, ASCE Stu-
dent Chapter president
Affiliation: University of Missouri, Kansas
City Engineering School
Topic: Details of past and upcoming bridge
building competitions
Activity: About 60 members and guests at-
tended this program, held at the univer-
sity in Kansas City, Mo.
NEBRASKA
OCTOBER 31
Activity: The Section presented money
from its scholarship fund to Burke High
School Industrial Technology Teachers Joe
Nebraska Section members and industrial technology students are shown at Burke High School.
Shown during the Oklahoma City Section
tour are (from left) Keith Theesen, Chair
Cary Reeves, and Tony Solics.
Matt Terell observes a student using the vir-
tual welding machine at the Oklahoma City
Section program.
Speaker Sgt. Tom Bell (left) is shown with
Paul Wittenbach, Tulsa Section vice chair.
Shown at the Houston Section October program are (from left) Cary Roth, speaker Walt
Stein, David Mesle, and Barney Burks.
Houston Section Chair Justin Gordy (left)
and Treasurer Barney Burks are shown at
the October program.
Society News January_Layout 1 12/12/12 4:20 PM Page 90
91 WELDING JOURNAL
Olafson and Andy Schatzberg for the pur-
chase of equipment needed for the
schools welding education program. Offi-
ciating were Chairman Chris Beaty, Vice
Chair Eric Nordhues, and Treasurer Rich
Hanny.
OKLAHOMA CITY
OCTOBER 11
Speaker: Matt Terell, technical represen-
tative
Affiliation: The Lincoln Electric Co.
Topic: The VRTEX 360 virtual arc weld-
ing trainer
Activity: The Section members and weld-
ing students and Instructor Keith Theesen
from Caddo Kiowa Technology Center had
a hands-on training session with the vir-
tual welding equipment. The meeting con-
cluded with a tour of the Trinity Industries
rail car manufacturing operations, hosted
by Tony Solics.
TULSA
SEPTEMBER 25
Speaker: Sgt. Tom Bell
Affiliation: Tulsa Police Dept.
Topic: Industrial crime prevention
HOUSTON
OCTOBER 17
Speaker: Walt Stein, consultant
Affiliation: Metallurgical Process Control
Topic: Procurement of welding materials
Activity: The program was held at Bradys
Landing in Houston, Tex.
OCTOBER 27
Activity: The Houston Section hosted its
fall seminar for 48 participants at NCI
Building Systems in Houston, Tex. The
theme was Welding Quality Management
for the Modern Fabricator. Education
Chair Saty Segu, and speakers James Shel-
ton, Ron Theiss, Fred Schweighardt, and
Harry Harrison presented the program.
ALASKA
OCTOBER 24
Activity: The Section members and weld-
ing students from local colleges toured
Unique Machine LLC in Anchorage,
Alaska. The facility offers CNC machin-
ing centers providing drill pipe threading
services for the oilfield, construction, min-
ing, and fishing industries.
PORTLAND
OCTOBER 23
Activity: The Section members toured
Oregon Metal Slitters in Portland, Ore.
Chris Holzgang led the tour of the rolling
and cutting steel sheet facility.
PUGET SOUND
NOVEMBER 1
Speaker: Ches King, west coast manager
Affiliation: Lloyds Register North America
Topic: Ship classification and its role in
ship construction
Activity: Kevin McGuire was awarded a
$500 Section scholarship. It was an-
nounced that the Everett C. C. Student
Chapter hosted a welding workshop for
First Robotics high school teams. More
than 70 people attended. Steve Pollard,
Chair Dan Sheets, and Treasurer Steve
Nielsen provided technical assistance.
Presenters at the Houston Section seminar are (from left) Saty Segu, James Shelton, Ron
Theiss, Fred Schweighardt, and Harry Harrison.
Attendees are shown during the Alaska Section tour of Unique Machine.
District 19
Ken Johnson, director
(425) 957-3553
kenneth.johnson@vigorshipyards.com
District 17
J. Jones, director
(940) 368-3130
jjones@Victortechnologies.com
District 18
John Bray, director
(281) 997-7273
sales@afliatedmachinery.com
Chris Holzgang (blue hat) is shown with
Portland Section members in October.
Speaker Ches King (left) is shown with Ken
Johnson, Puget Sound Section chair.
Society News January_Layout 1 12/12/12 4:21 PM Page 91
JANUARY 2013 92
Attendees are shown at the Puget Sound Sections Everett C. C. Student Chapter workshop.
Kevin McGuire (left) receives a scholarship
from Puget Sound Section Treasurer Steve
Nielsen (center) and Steve Pollard.
Presenter Gene Burr (left) chats with John
Steele, Colorado Section chair, at the Sep-
tember tour.
Ronda and Todd Peterson conducted the
Colorado Section members on a tour of their
facilities in October.
Shown at the New Mexico State University Artweld Competition are (from left) Epimenio
Hernandez, Casey SuhVari, and Jesus Hernandez.
Samuel Colton (left) is shown with Charles
Vega Schmidt, his host while traveling in
Spain.
District 20
William A. Komlos, director
(801) 560-2353
bkoz@arctechllc.com
COLORADO
SEPTEMBER 13
Activity: The Section members toured
Eaton Metal Products in Denver, Colo.,
to study the various welding processes re-
quired to manufacture above-ground stor-
age tanks. Gene Burr presented a histori-
cal overview of the company and its man-
ufacturing techniques.
OCTOBER 11
Activity: The Colorado Section members
toured Peterson Machining, Inc., in Boul-
der, Colo. The facility displayed its multi-
axis CNC milling and lathe equipment and
capabilities to run prototype and short to
long run production and product develop-
ment and tooling services for the medical,
aerospace, and research industries. Own-
ers Ronda and Todd Peterson conducted
the program.
Society News January_Layout 1 12/12/12 4:21 PM Page 92
93 WELDING JOURNAL
Samuel Colton poses with welding students at Juan de Herrera welding school in Spain.
Nanette Samanich (center), District 21 director, is surrounded by AWCIWT Student Chapter members, welding industry representatives,
and Ocotillo District boy scouts who earned their welding merit badges during the Welding Thunder 2012 event.
NEW MEXICO
NOVEMBER 1
Activity: The Section members attended
the first biannual Artweld Competition
held at Carlsbad Museum and Art Center.
The event was sponsored by the welding
department at New Mexico State Univer-
sity, Carlsbad, N.Mex. Taking top three
prizes for their welded entries were Jesus
Hernandez, Casey SuhVari, and Epimenio
Hernandez.
SAN DIEGO
AWCIWT Student Chapter
SEPTEMBER 27NOVEMBER 6
Activity: Samuel Colton, professor of
welding and Advisor for the Arizona West-
ern College Institute of Welding Technol-
ogy Student Chapter, accepted an invita-
tion to present a paper at the Spanish
Welding Society conference in Madrid,
Spain. His host while in Spain was Charles
Vega Schmidt. He also made a presenta-
tion for the students at Juan de Herrera
welding school and participated in demon-
strations at the Lincoln Electric Co. Dis-
tribution Center open house event held in
Madrid. The AWS San Diego Section,
Miller Electric Co., and others contributed
to making Coltons trip possible.
OCTOBER 20
Activity: Advisor Samuel Colton Sr. and
the AWCIWT Student Chapter members
worked with Ocotillo District boy scouts
to earn their welding merit badges during
the Welding Thunder 2012 event. The
merit badge counselors were Larry Leb-
sock, Gonzalo Huerta Sr., Gonzalo Huerta
Jr., and Samuel Colton Jr. Assisting were
District 21 Director Nanette Samanich
and representatives from Miller Electric
and ESAB.
District 22
Kerry E. Shatell, director
(916) 683-0315
kesi@pge.com
District 21
Nanette Samanich, director
(702) 429-5017
nan07@aol.com
Society News January_Layout 1 12/12/12 4:22 PM Page 93
JANUARY 2013 94
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
Nancy C. Cole
nccengr@yahoo.com
NCC Engineering
2735 Robert Oliver Ave.
Fernandina Beach, FL 32034
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Sr. Associate Executive Director
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
Chief Financial Officer
Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
Executive Assistant for Board Services
Gricelda Manalich.. gricelda@aws.org . . . . .(294)
Administrative Services
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
IT Network Director
Armando Campana..acampana@aws.org . .(296)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
Human Resources
Director, Compensation and Benefits
Luisa Hernandez.. luisa@aws.org . . . . . . . . .(266)
Director, Human Resources
Dora A. Shade.. dshade@aws.org . . . . . . . . .(235)
International Institute of Welding
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
GOVERNMENT LIAISON SERVICES
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors fed-
eral issues of importance to the industry.
CONVENTION and EXPOSITIONS
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
Director, Convention and Meeting Services
Matthew Rubin.....mrubin@aws.org . . . . . . .(239)
ITSA International Thermal
Spray Association
Senior Manager and Editor
Kathy Dusa.kathydusa@thermalspray.org . . .(232)
RWMA Resistance Welding
Manufacturing Alliance
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
Brazing and Soldering
Manufacturers Committee
Jeff Weber.. jweber@aws.org . . . . . . . . . . . . .(246)
GAWDA Gases and Welding
Distributors Association
Executive Director
John Ospina.. jospina@aws.org . . . . . . . . . .(462)
Operations Manager
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401)
INTERNATIONAL SALES
Managing Director, Global Exposition Sales
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . .(297)
Corporate Director, International Sales
Jeff P. Kamentz..jkamentz@aws.org . . . . . . .(233)
Oversees international business activities involving
certification, publication, and membership.
PUBLICATION SERVICES
Department Information . . . . . . . . . . . . . . . . .(275)
Managing Director
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
National Sales Director
Rob Saltzstein.. salty@aws.org . . . . . . . . . . .(243)
Society and Section News Editor
Howard Woodward..woodward@aws.org . .(244)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
MARKETING COMMUNICATIONS
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Section Web Editor
Henry Chinea...hchinea@aws.org . . . . . . . . .(452)
MEMBER SERVICES
Department Information . . . . . . . . . . . . . . . . .(480)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between Section members and AWS
headquarters.
CERTIFICATION SERVICES
Department Information . . . . . . . . . . . . . . . . .(273)
Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all inter-
national certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Certification Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification pro-
grams, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Director, Education Development
David Hernandez.. dhernandez@aws.org . . .(219)
AWS AWARDS, FELLOWS, COUNSELORS
Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards, Fellow, Counselor nom-
inees.
TECHNICAL SERVICES
Department Information . . . . . . . . . . . . . . . . .(340)
Managing Director
Andrew R. Davis.. adavis@aws.org . . . . . . .(466)
International Standards Activities, American Coun-
cil of the International Institute of Welding (IIW)
Director, National Standards Activities
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Manager, Safety and Health
Stephen P. Hedrick.. steveh@aws.org . . . . . .(305)
Metric Practice, Safety and Health, Joining of Plas-
tics and Composites, Welding Iron Castings, Per-
sonnel and Facilities Qualification
Managing Engineer, Standards
Brian McGrath .... bmcgrath@aws.org . . . . .(311)
Structural Welding, Methods of Inspection, Me-
chanical Testing of Welds, Welding in Marine Con-
struction, Piping and Tubing
Senior Staff Engineer
Rakesh Gupta.. gupta@aws.org . . . . . . . . . .(301)
Filler Metals and Allied Materials, International
Filler Metals, UNS Numbers Assignment, Arc
Welding and Cutting Processes
Standards Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Thermal Spray, Automotive, Resistance Welding,
Machinery and Equipment
Stephen Borrero... sborrero@aws.org . . . . .(334)
Brazing and Soldering, Brazing Filler Metals and
Fluxes, Brazing Handbook, Soldering Handbook,
Railroad Welding, Definitions and Symbols
Alex Diaz.... adiaz@aws.org . . . . . . . . . . . . . .(304)
Welding Qualification, Sheet Metal Welding, Air-
craft and Aerospace, Joining of Metals and Alloys
Patrick Henry.. phenry@aws.org . . . . . . . . . .(215)
Friction Welding, Oxyfuel Gas Welding and Cut-
ting, High-Energy Beam Welding, Robotics Weld-
ing, Welding in Sanitary Applications
Senior Manager, Technical Publications
Rosalinda ONeill.. roneill@aws.org . . . . . . .(451)
AWS publishes about 200 documents widely used
throughout the welding industry
Note: Official interpretations of AWS standards
may be obtained only by sending a request in writ-
ing to Andrew R. Davis, managing director, Tech-
nical Services, adavis@aws.org.
Oral opinions on AWS standards may be ren-
dered, however, oral opinions do not constitute of-
ficial or unofficial opinions or interpretations of
AWS. In addition, oral opinions are informal and
should not be used as a substitute for an official
interpretation.
AWS FOUNDATION, Inc.
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
Gerald D. Uttrachi
Executive Director, Foundation
Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Corporate Director, Workforce Development
Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
The AWS Foundation is a not-for-profit corpora-
tion established to provide support for the educa-
tional and scientific endeavors of the American Weld-
ing Society.
Promote the Foundations work with your financial
support. Call (800) 443-9353, ext. 212, for complete
information.
Society News January_Layout 1 12/12/12 4:22 PM Page 94
AWS Conferences & Exhibitions:
AWS invites you to join us in Las Vegas to expand 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 Conference attendees are awarded 1 PDH (Professional Development Hour)
for each hour of conference attendance. These PDHs can be applied toward AWS
recertifications and renewals.
Weld Cracking Conference
March 26-27, 2013 / Las Vegas
For the latest conference information and registration visit our web site
at www.aws.org/conferences or call 800-443-9353, ext. 264.
cracking as well as provide information on preventive measures.
knowledge! Our featured presenters will explore the many causes of weld
WS invite AAW
cracking as well as provide information on preventive measures.
knowledge! Our featured presenters will explore the many causes of weld
WS invites you to join us in Las
cracking as well as provide information on preventive measures.
knowledge! Our featured presenters will explore the many causes of weld
egas to expan VVe WS invites you to join us in Las
cracking as well as provide information on preventive measures.
knowledge! Our featured presenters will explore the many causes of weld
egas to expand your weld cracking
knowledge! Our featured presenters will explore the many causes of weld
egas to expand your weld cracking
recertifications and renewals.
for each hour of conference attendance.
WS Conf AAW
Network with industry peers to discuss the best solutions for business growth.
Gain practical knowledge on the types and causes of weld cracking.
recertifications and renewals.
for each hour of conference attendance.
WS Conference attendees are awarded 1 PDH (Professional Development Hour)
Network with industry peers to discuss the best solutions for business growth.
Gain practical knowledge on the types and causes of weld cracking.
These PDHs can be applied toward for each hour of conference attendance.
WS Conference attendees are awarded 1 PDH (Professional Development Hour)
Network with industry peers to discuss the best solutions for business growth.
Gain practical knowledge on the types and causes of weld cracking.
A These PDHs can be applied toward
WS Conference attendees are awarded 1 PDH (Professional Development Hour)
Network with industry peers to discuss the best solutions for business growth.
Gain practical knowledge on the types and causes of weld cracking.
WS AAW
WS Conference attendees are awarded 1 PDH (Professional Development Hour)
Network with industry peers to discuss the best solutions for business growth.
or the latest conference information and registr F
ws.org/conferences .a wwww. at
or the latest conference information and registr
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ation visit our web site
cracking conference_FP_TEMP 12/10/12 3:38 PM Page 95
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):
Affiliation:
Address:
City:
State/Province:
Zip/Mail Code:
Country: Email:
Name (Full Name):
Affiliation:
Address:
City:
State/Province:
Zip/Mail Code:
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
and/or certificate programs at time
of submittal.
Presentation need not represent
actual experimental work. Rather,
emphasis is placed on
demonstrating a clear
understanding of technical
concepts and subject matter.
Practical application is important
and should be demonstrated.
For students enrolled in
baccalaureate engineering or
engineering technology programs
at the time of submittal.
Poster should represent the
students own experimental work.
Emphasis is place on
demonstrating a clear
understanding of technical
concepts and subject matter.
Practical application and/or
potential relevance to the welding
industry is important and should
be demonstrated.
For students enrolled in graduate
degree programs in engineering or
engineering technology at time of
submittal.
Poster should represent the
students own experimental work.
Poster must demonstrate technical
or scientific concepts. Emphasis is
placed on originality and novelty of
ideas presented.
Potential relevance to the welding
industry is important and should be
demonstrated.
For anyone working in the welding
industry or related field.
Poster must demonstrate technical
or scientific concepts. Emphasis is
placed on original contributions
and the novelty of the presentation.
Potential relevance to the welding
industry is important and should be
demonstrated.
(E) High School
Junior or Senior high school
students enrolled in a welding
concentration at the time of
submittal.
Presentation should represent
technical concepts and application
to the welding industry.
Practical application and creativity
are important and should be
demonstrated.
Pages 96&97_FP_TEMP 12/12/12 9:24 AM Page 96
Check the category that applies:
(A) Student 2-yr. or
Certificate Program
(B) Student 4-yr.
Undergraduate
(C) Graduate
Student
(D) Professional (E) High School
Poster Title (max. 50 characters):
Poster Subtitle (max. 50 characters):
Abstract:
Introduction (100 words) Describe the subject of the poster, problem/issue being addressed and its practical implications for the welding
industry.
Technical Approach & Results (200 words) Explain the technical approach. Summarize the work that was done as it relates to the subject of
the poster.
.
Conclusions (100 words) Summarize the conclusions and how they could be used in a welding application.
Return this form, completed on both sides, via email to mventura@aws.org
MUST BE RECEIVED NO LATER THAN April 19, 2013
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Pages 96&97_FP_TEMP 12/12/12 9:25 AM Page 97
PERSONNEL
JANUARY 2013 98
Noble Gas Hires New Staff
Noble Gas Solu-
tions, Albany, N.Y.,
has named Rob
Collins business de-
velopment specialist
for the companys
medical and spe-
cialty segment, and
Kevin ORourke and
Mitch Evans cus-
tomer service spe-
cialists. ORourke
previously worked at Woolferts Roost
Country Club. Evans most recently was
customer service advocate for Wellpoint.
IPC Names Principal
Engineer
IPC Association Connecting Elec-
tronics Industries, Bannockburn, Ill.,
has named Jasbir Bath principal engineer
within its assembly technology area. Bath,
who has about 20 years of experience in
the research and development of solder-
ing, surface mount, and packaging tech-
nologies using tin-lead and lead-free sol-
ders, is with Bath and Associates Consul-
tancy LLC, providing process consulting
and training services for the electronics
manufacturing industry.
ONeal, Inc., Hires Process
Department Head
ONeal, Inc., Greenville, S.C., a design
and construction firm, has hired Stella
Dominguez as a process department head.
Dominguez previously served as a biofuels
project engineer with BP-Biofuels in
Houston, Tex.
M. K. Morse Names
Regional Sales Manager
The M. K. Morse Co., Canton, Ohio, a
supplier of saw blades and power tool ac-
cessories, has named James Reid III re-
gional sales manager for the eastern
United States. Reid previously worked as
a sales manager and sales director in the
cutting tools industry.
Gateway Fills Key Post
Gateway Safety,
Cleveland, Ohio, has
appointed Greg
Schmidt to the
newly created posi-
tion of product de-
velopment manager,
concerned with eye,
face, head, hearing,
and respiratory pro-
tection. Previously,
Schmidt worked for
Applied Industrial
Technologies as product manager for
tools, safety, and general industrial prod-
ucts. Earlier, he served Rockwell Automa-
tion as a product manager and design
engineer.
Wall Colmonoy Staffs Its
European Headquarters
Wall Colmonoy Ltd. (UK), Pontar-
dawe, Wales, has appointed Kevin Nolan
managing director, Philip Tilston chief fi-
nancial officer, Steve Leahey operations
director, Mark Harrison continuous im-
provement manager, Nick Clark machine
shop business unit manager, John Lap-
ping sales manager for alloy products,
Richard Shaw sales manager for compo-
nents, and Alun Rodge technical manager.
FMA Elects Officers
Fabricators & Manufacturers Associa-
tion, International, Rockford, Ill., has
elected Burke Doar chairman of the
board. Doar, who is vice president, sales
and marketing at TRUMPF, Inc., became
active on the board in 2005. Serving as vice
chairs are Carlos Rodriguez-Borjas with
Feralloy Corp. and Edwin Stanley with
GH Metal Solutions. Al Zelt, with ASKO,
Inc., serves as secretary/treasurer.
TRUMPF Designates NW
Sales Representative
TRUMPF, Inc., Farmington, Conn.,
has named Christopher Gildehaus North-
west direct sales representative, specifi-
cally for the northern parts of California
and Nevada. Previously, Gildehaus
worked in financial brokerage services in
the Boston, Mass., area.
Watts Specialties Appoints
Pipe Sales Manager
Watts Specialties, Puyallup, Wash., has
appointed David Carr sales manager,
based in Houston, Tex. With more than 27
years of experience in industrial sales of
pipe equipment, Carr will be responsible
for managing the companys pipe-cutting
machinery industry.
IMS WaterJet Hires Shop
Foreman
IMS WaterJet,
Inc., a supplier of
waterjet cutting sys-
tems, has hired
Thomas DeMatteo
as shop foreman at
its new facility in Wa-
terbury, Conn. With
nearly 30 years of
manufacturing expe-
rience, DeMatteo
previously worked at
Radiall USA as a CNC toolmaker and
tooling engineer.
Folkerts Joins Battelle
Battelle, Tampa, Fla., has hired John
Folkerts, major general (ret.), U.S. Air
Force, to lead its business with Special Op-
erations Forces to further the companys
business with Dept. of Defense Special
Operations Forces.
Obituaries
Keith Van Loon Flood
Keith Van Loon Flood, 68, died Sept. 22
in Albany, N.Y. Flood was an AWS Life
Member who served many years as treas-
urer of the Northern New York Section.
Rob Collins Mitch Evans
Kevin ORourke
Greg Schmidt
Philip Tilston Steve Leahey
Thomas DeMatteo
continued on page 100
Personnel Jan._Layout 1 12/13/12 10:38 AM Page 98
general corporate_FP_TEMP 12/10/12 3:10 PM Page 99
He graduated from
Christian Brothers
Academy (CBA) in
1961 then completed
his studies at Albany
Business College.
He joined The Lin-
coln Electric Co.
where he worked 42
years as a district
sales manager be-
fore retiring in 2005.
He was active with
the CBA Alumni Association and Parents
Association, served as scoutmaster for
Schenectady County Council Troop 47,
and coached and managed his sons
Colonie Little League baseball team.
During his retirement years, he enjoyed
meeting with cadets at West Point and his
friends at the Army Reserve Unit Com-
pany A 413QM Battalion, golfing, and va-
cations at Ocean Grove, N.J. He is sur-
vived by Sharon, his wife of 50 years, two
sons, a sister, and four grandchildren. Do-
nations to his memory may be made to
CBA, 12 Airline Dr., Albany, NY 12205.
Jay Chennat
Jay Chennat died Aug. 25. Active with
the Detroit Section, he was well known in
the laser-processing industry. He was a
long-time welding engineering technical
spacialist at Ford Motor Co. in Transmis-
sion Operations, and later at Advanced
Manufacturing working with body laser
applications. He previously worked for
Lumonics, Foro Energy, and held various
other consulting positions. He received
his masters degree in welding engineer-
ing from The Ohio State University,
served as chair of the AWS Subcommittee
on Laser and Electron Beam Welding,
and was chairman of the Welding Hand-
book chapter on laser beam cutting. He
presented many papers at AWS, ICA-
LEO, ALAW, and other conferences, and
held patents in welding. He is survived by
his wife and two daughters.
Jerry Howard Hope
Jerry Howard
Hope, 72, died Sept.
7 at his home in Ren-
ton, Wash. An AWS
Life Member, he
was very active in
AWS national and
Puget Sound Sec-
tion activities. He
served as Section
chair 19851986,
and received the
Section and District
19 Meritorious awards on several occa-
sions. He served on the Certification
Committee, Certification of Welding In-
spectors Subcommittee, Test Supervisor
Instructors Subcommittee, and per-
formed as an AWS test supervisor for 15
years. Hope was born in Ventura, Calif.,
graduated from Pine Valley High School
in Halfway, Ore., and served in the U.S.
Navy before moving to Renton. After re-
tiring from Boeing, Hope served his local
community and remained active with
AWS. He is survived by two sisters, a
brother, a daughter, a son, and five grand-
children. Donations to his memory may be
made to AWS Puget Sound Section, PO
Box 2923, Everett, WA 98213-2923, c/o
Jerry Hope Memorial Scholarship Fund.
Edwin F. Crane
Edwin F. Crane died Sept. 13 in St.
Louis, Mo. He joined the American Weld-
ing Society in 1953, was an AWS Life
Member who was active with the St. Louis
Section. He is survived by two sons, three
grandchildren, and two great-grandchil-
dren. Donations to his memory may be
made to Webster Groves Baptist Church,
308 Summit Ave., St. Louis, MO 63119, or
to the The First Tee of Greater St. Louis,
PO Box 15175, St. Louis, MO 63110.
Thurman Dale Hesse
Thurman Dale Terry Hesse, 73, died
Nov. 16 in Madison, Wis. He was a mem-
ber of the Madison-
Beloit Section, an
AWS Life Member,
served eight years as
a District director,
and was a member
of numerous techni-
cal committees. He
received his bache-
lors degree at the
University of Wis-
consin (UW)-Plat-
teville and masters
at UW-Stout. He
taught welding and metallurgy at MATC
for more than 30 years.
Jerry Hope
Keith Flood
Thurman Hesse
JANUARY 2013 100
continued from page 98
PERSONNEL
amperage rating charts. Full-page spreads
offer photos, diagrams, and detailed in-
formation on the products and consum-
ables.
Bernard Welding Equipment
www.bernardwelds.com
(800) 946-2281
Programming System
Generates Tool Paths
The LaCam3D offline programing sys-
tem enables process developers and end-
users to generate tool paths quickly, even
for laser material deposition (LMD) tasks
that have nonstandard welding strategies.
The generated paths are translated into
machine code and can be tested for possi-
ble collisions via a machine simulation.
The system provides functionalities for
LMD strategies that enable the LMD se-
quence and welding direction of individ-
ual paths to be modified. It comes with a
simulation tool that can check in advance
whether the planned LMD process will
cause the laser processing head to collide
with the part.
Fraunhofer Institute for Laser
Technology ILT
www.ilt.fraunhofer.de/en.html
+49 241 8906-0
Guides for Cutting Pipes
Come in Five Sizes
The Pipe-Pro cutting guides come in
five sizes with four cutting templates on
each guide. To use, place around the pipe,
mark the desired angle, remove, then cut.
They work for various pipe cutting needs,
including fencing, corrals, handrails, or
race cars.
Nation Wide Products
www.pipeproguides.com
(800) 797-3709
PRODUCT & PRINT
SPOTLIGHT
continued from page 26
Personnel Jan._Layout 1 12/12/12 2:37 PM Page 100
awo.aws.org
Online Welding Safety Certificate Course
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
OSHAestimates that
4 out of every 1,000
welders will
experience a fatal
injury or accident over
their working lifetime
Online elding Safet W Online y Certificate Course elding Safety Certificate Course y Certificate Course
their working lifetime
injury or accident over
experience a fatal
welders will
4 out of every 1,000
estimates that A OSH
their working lifetime
injury or accident over
experience a fatal
4 out of every 1,000
estimates that
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Sample seminar at awo.aws.org/seminars/safety
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Sample seminar at awo.aws.org/seminars/safety
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Sample seminar at awo.aws.org/seminars/safety
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
their working lifetime
Three-hour self-paced course covers electric shock, vision and skin protection,
Earn PDHs and increase your ability to improve safety and health of your welding operations.
Sample seminar at awo.aws.org/seminars/safety Sample seminar at awo.aws.org/seminars/safety Sample seminar at awo.aws.org/seminars/safety
awo safety_FP_TEMP 12/10/12 3:36 PM Page 101
International Institute of Welding Launches
White Paper
The International Institute of Welding (IIW) launched its
White Paper, Improving Global Quality of Life through Optimum
Use and Innovation of Welding and Joining Technologies.
The document, available online at http://publ.com/6lULyGu,
was developed by IIW experts in the fields of materials welding
and joining technologies, training and education, as well as de-
sign and assessment of welded structures. It describes strategic
challenges and agendas for the welding industries, personnel, sci-
entists, and end-users through the next 10 years (20122021).
The agenda also details strategies for improving quality of life
through using new materials, design, and advanced joining tech-
nologies to reduce manufacturing cost and improve structural
performance and life-cycle via better personnel, inspection, and
integrity assessment rules while meeting the societal expecta-
tions in health, safety, environmental, and growth issues. Its pub-
lication has been sponsored by several sources, including the
American Welding Society.
Deere to Invest in Improvements
Deere & Co. will invest approximately $58 million to enhance
operations at John Deere Seeding, Moline, Ill., where the com-
pany manufactures planting equipment. It will be made in con-
junction with the implementation of a new factory master plan
targeting efficiency and quality enhancements. Improvements
include increased automation and robotics use. Currently, this
division has approximately 800 employees and does not antici-
pate a big change to total employment as a result of the
announcement.
Industry Notes
The owners of JWF Industries, Johnstown, Pa., established a
scholarship in honor of their late father, John J. Polacek Sr.
In partnership with Pennsylvania Highlands Community Col-
lege, the scholarship will be offered to new and currently en-
rolled students in the welding program. For more details and
an application, due by Jan. 31, email scholarship@jwfi.com.
North Idaho College has been awarded a $2.97 million grant
intended to create an aerospace center. It is expected to cre-
ate 520 new jobs by 2015, according to grant application pro-
jections. The college anticipates offering courses by fall 2013.
Markal, Elk Grove Village, Ill., unveiled a new, multilingual
Web site at www.markal.com featuring the Find a Marker
online search tool, plus an updated product database.
CONCOA, Virginia Beach, Va., a designer and manufacturer
of gas controls, is celebrating its 25th anniversary. The com-
pany commemorated the occasion with a luncheon, open
house, and guided facility tours.
Rolled Alloys recently opened Richburg, S.C., facility has
reached full operating status. The 33,000-sq-ft service center
features an inventory of stainless steel bar stock. Also, the
company opened its new facility in Windsor, Conn. This
40,000-sq-ft service center will replace the current location.
The Manufacturing Institute has partnered with the Preci-
sion Machined Products Association to expand Right Skills
Now, a fast-track machining training program aligned to the
National Association of Manufacturers-Endorsed Manufac-
turing Skills Certification System.
Georgian American Alloys, Inc., Miami, Fla., has recently ac-
quired the membership interests of CC Metals & Alloys, a
producer and supplier of high-grade ferrosilicon alloys, from
affiliated Optima Group LLC in exchange for company
shares.
Siemens Industrys Metallurgical Services Offline Mainte-
nance group expanded capacity at its Benton Harbor, Mich.,
facility for roll overlaying and steelmaking technology.
Joining Technologies, Inc., East Granby, Conn., an industrial
laser applications and welding services provider, is celebrating
its 20th anniversary. The company was founded by Michael
Francoeur.
Bernard and Tregaskiss partnered to launch a new branding
initiative. Bernard will now offer only semiautomatic gas
metal arc guns, while the Tregaskiss brand will be focused on
robotic gas metal arc guns and peripherals.
At Austin Polytechnical Academy, Chicago, Ill., Mayor Rahm
Emanuel recently announced the city will invest $1.25 mil-
lion in advanced manufacturing education programs led by
the Chicago Manufacturing Renaissance Council.
PFERD Inc., a subsidiary of August Rggeberg GmbH & Co.,
Marienheide, Germany, and Superior Abrasives, Dayton,
Ohio, reported Superior has been acquired by the Rggeberg
Group. It will be named Superior Abrasives LLC.
Kalamazoo Valley Community College, Kalamazoo, Mich., is
offering Machine Tool Operator, CNC Operator, and Weld-
ing Certificates. For more information, visit www.kvcc.edu.
The National Safety Council launched the Campbell Institute.
Believing environmental, health, and safety management is at
the core of business vitality, it is committed to helping move
organizations forward on their continuous improvement goals.
Taylor-Wharton International, LLC, a technology, service,
and manufacturing network for gas applications, is relocat-
ing its corporate headquarters from Mechanicsburg, Pa., to
Minneapolis, Minn., adding 2530 new jobs.
Thanks to local support and Americas Farmers Grow Rural
Education
SM
, Tully Central School District, N.Y., received a
$10,000 grant to get students interested in the industry by
purchasing welding equipment for agriculture mechanics and
construction courses at the junior high and high schools.
IMS WaterJet, Inc., moved its HQ to a new location in Wa-
terbury, Conn. The larger site will enable rapidly producing,
designing, and fabricating elaborate, specialized machines.
JANUARY 2013 102
NEWS OF THE INDUSTRY
continued from page 10
NI January 2013_Layout 1 12/12/12 2:54 PM Page 102
Join us in Houston for the debut of the AWS Pipeline Welding Conference! Our featured
speakers will cover a multitude of topics including the welding of high-strength X80 pipe
steels, orbital processes used in pipeline construction throughout the world, the new FRIEX
system from Belgium and many other exciting topics.
AWS Conferences:
Pipeline Conference
June 4
th
5
th
/ Houston
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 224.
Highlights
Learn about the progress of new and innovative developments
in pipeline welding.
business growth.
AWS Conference attendees are awarded 1 PDH (Professional
Development Hour) for each hour of conference attendance.
and renewals.
pipeline conference_FP_TEMP 12/10/12 3:45 PM Page 103
SERVICES
JANUARY 2013 104
CLASSIFIEDS
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
CERTIFICATION
& TRAINING
CWI PREPARATORY
Guarantee Pass or Repeat FREE!
80+ HOUR COURSE
MORE HANDSON/PRACTICAL APPLICATIONS
Pascagoula, MS Jan. 28Feb. 8
Houston, TX Jan. 1425
Houma, LA Feb. 18Mar. 1
Ellijay, GA Mar. 1122
56+ HOUR COURSE
EXTRA INSTRUCTION TO GET A HEAD START
Pascagoula, MS Jan. 31 Feb. 8
Houston, TX Jan. 1725
Houma, LA Feb. 21Mar. 1
Ellijay, GA Mar. 1422
40 HOUR COURSE
GET READY FAST PACED COURSE!
Pascagoula, MS Feb. 48
Houston, TX Jan. 2125
Houma, LA Feb. 25Mar. 1
Ellijay, GA Mar. 1822
Test follows on Saturday at same facility &
includes additional self study for weekend
FOR DETAILS CALL OR E-MAIL:
(800) 489-2890
info@realeducational.com
Also offering: 9Year CWI Recertification,
RT Film Interpretation, MT/PT/UT Thickness,
Welding Procedure Fundamentals,
CWS, SCWI, Advanced Inspection Courses
2013
Place Your
Classified Ad Here!
Contact Frank Wilson,
Senior Advertising
Production Manager
(800) 443-9353,
ext. 465
fwilson@aws.org
Put Your Products and
Services to Work in the April 2013
Welding Marketplace
Spread the word on your company around the world by promoting a
full-color photo of your newest and hottest welding product or
services to more than 80,000 AWS members and customers in the
famous welding product photo guide, WELDING MARKETPLACE.
As an extra bonus your ad will be posted on the AWS Web site with
an active link to your Web site. Also a digital link of Welding
Marketplace will be sent to more than 69,000 AWS members. Make
AWS members your customers! Closing date is February 15, 2013
Call the AWS sales team at: (800) 443-9353, Rob
Saltzstein at ext. 243, salty@aws.org or Lea Paneca at
ext. 220, lea@aws.org
CUSTOH
RPRINTS
R
C
P U J E & S V P ::P O F Q 0
S T N I R P
H O T S U
F S V T P Q Y & M B J S
s o | a s r o 4 4 1 9 . 9 7 8 . 6 6 8 | | a C
P U J E & S V P ::P O F Q 0
m o c . g o | t o | r p r o t s o ffo
F S V T P Q Y & M B J S
JAN 2013 WJ CLASSIFIEDS_Classified Template 12/14/12 8:31 AM Page 104
JOE FULLER LLC
We manufacture tank turning rolls
3ton through 120ton rolls
www.joefuller.com
email: joe@joefuller.com
Phone: (979) 277-8343
Fax: (281) 290-6184
Our products are made in the USA
EQUIPMENT FOR SALE OR RENT
For sale or rent
The worlds very
best portable end
prep tools and
abrasive saws
800-343-6926
www.escotool.com
105 WELDING JOURNAL
MITROWSKI RENTS
Made in U.S.A.
Welding Positioners
1-Ton thru 60-Ton
Tank Turning Rolls
Used Equipment for Sale
www.mitrowskiwelding.com
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
Place Your
Classified Ad Here!
Contact Frank Wilson,
Senior Advertising
Production Manager
(800) 443-9353,
ext. 465
fwilson@aws.org
JAN 2013 WJ CLASSIFIEDS_Classified Template 12/13/12 9:02 AM Page 105
JANUARY 2013 106
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460
Astaras, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
www.e3tungsten.com . . . . . . . . . . . . . . . . .web contact only
Atlas Welding Accessories, Inc. . . . . . . . . . . . . . . . . . . . .24
www.atlaswelding.com . . . . . . . . . . . . . . . . .(800) 962-9353
AWS Education Services . . . . . . . .69, 72, 95, 101, 103, 107
www.aws.org/education/ . . . . . . . . . . . . . . . .(800) 443-9353
AWS Membership Services . . . . . . . . . . . . . . . . . . . .71, 99
www.aws.org/membership/ . . . . . . . . . . . . . .(800) 443-9353
Camfil Farr Air Polution Control . . . . . . . . . . . . . . . . . . .2
www.camfilfarrapc.com . . . . . . . . . . . . . . . .(800) 479-6801
Champion Welding Alloys . . . . . . . . . . . . . . . . . . . . . . . .15
www.championwelding.com . . . . . . . . . . . . .(800) 321-9353
Commercial Diving Academy . . . . . . . . . . . . . . . . . . . . . .25
www.commercialdivingacademy.com . . . . .(888) 974-2232
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
www.cor-met.com . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
Diamond Ground Products, Inc. . . . . . . . . . . . . . . . . . . .53
www.diamondground.com . . . . . . . . . . . . . .(805) 498-3837
Divers Academy International . . . . . . . . . . . . . . . . . . . . .23
www.diversacademy.com . . . . . . . . . . . . . . .(800) 238-3483
Fischer Engineering Co. . . . . . . . . . . . . . . . . . . . . . . . . . .21
www.fischerengr.com . . . . . . . . . . . . . . . . . .(937) 754-1750
Fronius Perfect Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .5
www.fronius-usa.com . . . . . . . . . . . . . . . . . .(810) 220-4414
Gedik Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
www.gedikwelding.com . . . . . . . . . . . . . .+90 216 378 50 00
Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
www.greinerindustries.com . . . . . . . . . . . . .(800) 782-2110
Gullco International, Inc. - U.S.A. . . . . . . . . . . . . . . . . . .61
www.gullco.com . . . . . . . . . . . . . . . . . . . . . . .(440) 439-8333
Hardface Technologies by Postle Industries . . . . . . . . . .57
www.postle.com . . . . . . . . . . . . . . . . . . . . . . .(216) 265-9000
Harris Products Group . . . . . . . . . . . . . . . . . . . . . . . . . . .19
www.harrisproductsgroup.com . . . . . . . . . .(800) 733-4043
Hobart Institute of Welding Technology . . . . . . . . . . . . .60
www.welding.org . . . . . . . . . . . . . . . . . . . . . .(800) 332-9448
IMPACT (North American Ironworkers) . . . . . . . . . . . .63
www.impact-net.org/www.ironworkers.org .(800) 545-4921
Intercon Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . . . .24
www.intercononline.com . . . . . . . . . . . . . . .(800) 665-6655
Koike Aronson, Inc./Ransome . . . . . . . . . . . . . . . . . . . . . .1
www.koike.com . . . . . . . . . . . . . . . . . . . . . . .(800) 621-4025
Lincoln Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC
www.lincolnelectric.com . . . . . . . . . . . . . . . .(216) 481-8100
Midalloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
www.midalloy.com . . . . . . . . . . . . . . . . . . . . .(800) 776-3300
Miller Electric Mfg. Co. . . . . . . . . . . . . . . . . . . . . . . . . . .59
www.MillerWelds.com . . . . . . . . . . . . . . . . .(920) 734-9821
OTC Daihen, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
www.daihen-usa.com . . . . . . . . . . . . . . . . . .(888) 682-7626
Select Arc, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC
www.select-arc.com . . . . . . . . . . . . . . . . . . . .(937) 295-5215
Thermal Arc Technologies . . . . . . . . . . . . . . . . . . . . . . . .11
www.ThermalArcOnTheMove.com . . . . . . .(866) 279-2628
Thermal Dynamics/Victor Technologies . . . . . . . . . . . . .13
www.thermaldynamicsautomation.com . . .(866) 279-2628
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
www.us.trumpf.com . . . . . . . . . . . . . . . . . .web contact only
Uniweld Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .61
www.uniweld.com . . . . . . . . . . . . . . . . . . . . .(800) 323-2111
Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
www.weldengineering.com . . . . . . . . . . . . . .(508) 842-2224
Weld Hugger, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
www.weldhugger.com . . . . . . . . . . . . . . . . . .(877) 935-3447
IFC = Inside Front Cover
IBC = Inside Back Cover
OBC = Outside Back Cover
Visit the AWS Interactive Ad Index: www.aws.org/ad-index
ADVERTISER
INDEX
JAN 2013 WJ CLASSIFIEDS_Classified Template 12/13/12 9:01 AM Page 106
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
awo welding fundamentals_FP_TEMP 12/10/12 3:37 PM Page 107
PROFESSIONAL PROGRAM ABSTRACT SUBMITTAL
ANNUAL FABTECH SHOW
Chicago, IL - November 18-21, 2013
Submission Deadline: March 29, 2013
(Complete a separate submittal for each paper to be presented.)
Primary Author (Full Name):
Affiliation:
Mailing Address:
City: State/Province Zip/Mail Code Country:
Email:
Co-Author(s):
Name (Full Name):
Affiliation
Address:
City:
State/Province
Zip/Mail Code
Country: E-Mail:
Name (Full Name):
Affiliation:
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Introduction
Prized for its excellent strength-to-
weight ratio, magnesium and its alloys are
currently under intense investigation for
use in many applications in the automo-
tive and aerospace industries (Refs. 13).
However, steel sheet is still the most com-
monly used material in the automotive in-
dustry for fabrication of autobody struc-
tures. The ability to make hybrid
structures of magnesium alloy and steel
sheet would be desirable for many appli-
cations in the automotive industry, be-
cause the overall weight of the autobody
could be reduced resulting in better fuel
efficiencies and lower environmental im-
pact. Therefore, there is increasing inter-
est in identifying and developing new tech-
niques and processes that can be used to
make dissimilar joints between magne-
sium alloys and steel sheet (Refs. 39).
Joining magnesium alloys to steel by
conventional fusion welding technologies
is difficult due to the large difference in
the melting points between Mg (649C)
and Fe (1538C). In addition, the boiling
point of magnesium is only 1091C, so di-
rect contact with molten steel causes cata-
strophic vaporization of the magnesium
(Refs. 38). Moreover, the maximum solid
solubility of Fe in Mg is estimated to be
only 0.00041 at.-% Fe (Ref. 6) and wetting
of steel by molten magnesium is very poor
(Ref. 8).
The weldability of magnesium to steel
using the hybrid laser-arc welding (Refs. 5,
6, 8, 9) and resistance spot welding (Refs.
4, 7) processes has been examined. Zhao
et al. (Ref. 5) used a hybrid laser-gas tung-
sten arc welding (GTAW) process to join
AZ31B magnesium alloy and 304 stainless
steel. However, oxides that formed at the
interface were found to cause joints with
poor tensile strength. Using the same
welding technique, Liu et al. (Refs. 8, 9)
studied lap joining of AZ31B Mg alloy to
Q235 steel with Sn and Cu interlayers.
Mg
2
Sn and Mg
2
Cu intermetallic com-
pounds were found to form along the grain
boundaries of the Mg alloy when using the
Sn and Cu interlayers, respectively. The
use of Sn and Cu interlayers was reported
as the main reason for the elimination of
gaps along the steel-fusion zone interface
and the improvement of wetting proper-
ties of the steel by molten magnesium
alloy (Refs. 8, 9). Finally, in a recent study,
Liu et al. (Refs. 4, 7) used resistance spot
welding to join AZ31B magnesium alloy
to DP600 Zn-coated steel. They found
that a preexisting transition layer of
Fe
2
Al
5
between the Zn coating and the
steel improved wetting and bonding be-
tween the steel and the magnesium alloy.
Review of the literature suggests that
joining Mg alloys to steel will be possible
provided the temperatures required for
joining are kept below the boiling point of
the magnesium alloy (1091C) and pro-
vided another interlayer element is used
that can interact and promote wetting and
bonding between both immiscible alloys.
For this reason, brazing can be a superior
choice in joining dissimilar metals such as
magnesium and steel because brazing
SUPPLEMENT TO THE WELDING JOURNAL, JANUARY 2013
Sponsored by the American Welding Society and the Welding Research Council
Interfacial Microstructure of Diode Laser
Brazed AZ31B Magnesium to Steel Sheet
Using a Nickel Interlayer
The formation of a nano-scale Fe(Ni) transition layer on the steel during laser
brazing was found to be responsible for the formation of a metallurgical bond
between the steel and magnesium
BY A. M. NASIRI, D. C. WECKMAN, AND Y. ZHOU
KEYWORDS
Laser Brazing
AZ31B Mg Sheet
Steel Sheet
Dissimilar
Intermetallic Compound
A. M. NASIRI(amnasiri@uwaterloo.ca), D. C.
WECKMAN, and Y. ZHOU are with Department
of Mechanical & Mechatronics Engineering, Cen-
tre for Advanced Materials Joining, University of
Waterloo, Waterloo, ON, Canada.
ABSTRACT
The brazeability of AZ31B-H24 magnesium alloy and steel sheet with a microlayer
of electro-deposited Ni in a single flare bevel lap joint configuration has been investi-
gated. The macro- and microstructure, element distribution, and interfacial phases of the
joints were studied by optical microscopy (OM), scanning electron microscopy (SEM),
transmission electron microscopy (TEM), and X-ray diffraction (XRD). Wetting of the
steel by the Mg-Al brazing alloy was improved significantly through the addition of a Ni
electroplated interlayer. Bonding between the magnesium brazing alloy and the steel was
facilitated by the formation of a transition layer composed of a solid solution of Ni in Fe
on the steel followed by a layer of -Mg + Mg
2
Ni eutectic. A band of AlNi intermetal-
lic compound with different morphologies also formed along the steel-fusion zone in-
terface, but was not directly responsible for bonding. Ni electroplating was found to sig-
nificantly improve the brazeability and mechanical performance of the joint. The average
fracture shear strength of the bond reached 96.8 MPa and the joint efficiency was 60%
with respect to the AZ31B-H24 Mg alloy base metal. In all cases, failure occurred in the
fusion zone very close to the steel-fusion zone interface.
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Nasiri Supplement January 2013_Layout 1 12/12/12 1:47 PM Page 1
temperatures are generally lower than the
melting points of both base metals. In ad-
dition, very fast heating and cooling rates
can be used during the brazing process to
minimize the thickness of intermetallic
compounds that might form along the in-
terfaces (Ref. 10).
The benefits of using laser brazing and
laser welding-brazing technologies for
joining dissimilar materials are also be-
coming increasingly recognized due to the
combined attributes of furnace brazing
and laser welding (Ref. 11). With a more
localized energy input and more precise
control of the laser beam energy, high
joining speeds and accompanying high
cooling rates can be realized with minimal
heating of the parts. Also, laser brazing
and laser welding-brazing can prevent or
minimize excessive formation of detri-
mental intermetallic phases. If intermetal-
lic layers can be limited to thicknesses
below 10 m, acceptable joint strengths
and mechanical properties may be ob-
tained (Refs. 1214).
In our previous study (Ref. 15), a diode
laser brazing process was developed for
joining Mg alloy sheet to aluminized steel
sheet where the Al-12Si coating served as
the interlayer. This coating was found to
promote wetting of the steel by the mag-
nesium brazing alloy; however, a preexist-
ing layer of brittle -FeAl
3
along the
braze-steel interface was found to degrade
the mechanical properties of the joint as
failure of the joint always occurred by frac-
ture of this brittle intermetallic layer. Fol-
lowing a review of binary and ternary
phase diagrams, nickel was identified as a
potentially viable interlayer element be-
tween the steel and Mg-9Al-2Zn brazing
alloy used. Therefore, the purpose of this
present study was to investigate the braze-
ability, interfacial microstructure, and me-
chanical properties of the laser brazed
AZ31B-H24 magnesium alloy to steel
sheet with an electrodeposited layer of Ni
on the steel to act as the interlayer ele-
ment. It is expected that development of
this laser brazing technology for joining of
steel-interlayer-Mg alloy combinations
with a strong metallurgical bond between
the steel and Mg alloy will facilitate in-
creased application and use of Mg alloys
in the automotive industry.
Experimental Procedure
In this study, 2-mm-thick commercial-
grade twin-roll strip cast AZ31B-H24 Mg
alloy sheet and 1-mm-thick steel sheet
were used as the base materials. The
chemical compositions of the base materi-
als are given in Tables 1 and 2. A 2.4-mm-
diameter TiBraze Mg 600 filler metal
(Mg-Al-Zn alloy) with solidus and liq-
uidus temperatures of 445 and 600C, re-
spectively, was chosen for this study. The
commercial flux used in the experiments
was Superior No. 21 manufactured by Su-
perior Flux and Manufacturing Co. This
powder flux was composed of LiCl (3540
wt-%), KCl (3035 wt-%), NaF (1025 wt-
%), NaCl (813 wt-%), and ZnCl
2
(610
wt-%) (Ref. 16).
The AZ31B Mg and steel sheets were
cut into 60- 50-mm specimens. Prior to
laser brazing, the oxide layers on the sur-
faces of the magnesium sheets were re-
moved by stainless steel wire brushing. All
the specimens were ultrasonically cleaned
in acetone to remove oil and other con-
taminants from the specimen surfaces.
The edge of each steel sheet was bent
in order to make a single-flare bevel lap
joint after clamping against the magne-
sium sheet. After bending, the steel speci-
mens were cleaned in acetone and then
ground to 1000 grit using SiC abrasive
paper and again ultrasonically cleaned in
acetone. The prepared surfaces were then
immediately electroplated with elec-
trolytic pure nickel. In the Ni electroplat-
ing process, the clean steel sample was the
cathode and graphite was the anode. The
composition of the electroplating solution
and the electroplating conditions are
listed in Table 3. Figure 1A shows a
schematic of the Ni electrodeposition
process used. In order to get a uniform 5-
m-thick Ni layer on the steel, different
cathode current densities and plating
times were tested. Electrodeposition of Ni
using a cathode current density of 120
mA/cm
2
for 10 min was found to provide a
JANUARY 2013, VOL. 92 2-s
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Fig. 1 A Schematic of the Ni electrodeposition process on steel; B
transverse section of the Ni electrodeposited layer on the steel substrate.
Table 1 Measured Chemical Composition of the AZ31-H24 Mg Alloy Sheet and TiBraze Mg 600
Filler Metal (wt-%)
Al Zn Mn Si Mg
AZ31B-H24 3.02 0.80 0.30 0.01 Bal.
TiBraze Mg 600 9.05 1.80 0.18 Bal.
Table 2 Measured Chemical Composition of
the 1-mm-Thick Steel Sheet (wt-%)
C 0.01
Mn 0.5
P 0.010
S 0.005
Fe Bal.
A
B
Nasiri Supplement January 2013_Layout 1 12/12/12 1:44 PM Page 2
5.5 0.9-m-thick pure Ni coating layer
on the steel with a defect-free interface.
Figure 1B shows a SEM micrograph of the
cross section of the nickel-coated steel.
The white layer on top of the steel is the
Ni coating layer. The coating was of uni-
form thickness with a void-free interface.
Energy-dispersive X-ray spectrometer
(EDS) analysis of the electrodeposited
layer on the steel showed a pure Ni coat-
ing layer.
After the electroplating process, the
prebent steel sheet was clamped against
the magnesium sheet to make a single-
flare bevel lap joint as shown in Fig. 2A.
The filler metal was cut into pieces and
preset on the workpiece at the weld inter-
face with some flux before heating and
brazing by the laser beam.
An integrated Panasonic 6-axis robot
and Nuvonyx diode laser system with a
maximum power of 4.0 kW and a 0.5-
12-mm rectangular laser beam intensity
profile at the focal point was used for laser
brazing. This energy distribution is more
suitable for brazing processes compared
with the nonuniform Gaussian-distributed
circular beams generated by CO
2
and
Nd:YAG lasers (Ref. 17). The beam was
focused on top of the filler metal.
In order to limit oxidation, helium
shielding gas was provided in front of the
molten pool with a flow rate of 30 L/min
from a 6-mm-diameter soft copper feed-
ing tube. Laser brazing was performed
using a range of laser powers, travel
speeds, and beam offset positions.
After laser brazing, transverse cross
sections of the brazed specimens were cut
and mounted in epoxy resin. The samples
were then mechanically polished using
300, 600, 800, 1000, and 1200 grades of SiC
grinding papers followed by polishing
using a 1-m diamond suspension. The
polished specimens were etched to reveal
the microstructure of the braze metal and
AZ31B base material. The etchant was
comprised of 20 mL
acetic acid, 3 g picric
acid, 50 mL ethanol,
and 20 mL water (Ref.
18).
Macro- and mi-
crostructures of the
etched joints were ex-
amined using an optical
metallographic micro-
scope. The microstruc-
ture and composition of
different zones of the
joint cross section were
determined using a
JEOL JSM-6460 scan-
ning electron micro-
scope (SEM) and EDS.
Phase characterization
of the phases formed in
the steel-fusion zone in-
terface and on the frac-
ture surfaces was car-
ried out using X-ray
diffraction (XRD)
phase analysis in a
Rigaku AFC-8 diffrac-
tometer with Cu target,
50 kV acceleration volt-
age, and 40 mA current.
A transmission electron microscope
(TEM) foil of the steel-fusion zone inter-
facial region was prepared using a focused
ion beam (FIB) and in-situ lift out tech-
nique. After attaching the TEM foil to a
copper grid, final thinning was performed
on the sample at an acceleration voltage of
30 kV, followed by 10 kV, and 1 kV for the
final polishing step to get a 100-nm-thick
TEM sample. The TEM studies were per-
formed with a JEOL 2010F TEM
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Fig. 2 A Schematic of the laser brazing system used for joining AZ31
Mg and Ni electro-plated steel sheets in the single-flare bevel lap joint config-
uration showing the position of two thermocouples used for temperature
measurements; B schematic of the 5-mm-wide tensile shear test specimen.
Table 3 Composition of Ni Electroplating Solution and Electroplating Parameters
Plating Solution Composition (g/L) Electrodeposition Parameters
NiSO
4
6H
2
O 263 Cathode current density 45120 mA/cm
2
Na
2
SO
4
215 Time 520 min
H
3
BO
3
31 pH 3
Temperature 25C
Anode Graphite (8 cm
2
)
Cathode Carbon Steel (6 cm
2
)
Fig. 3 A laser-brazed Ni electroplated steel/AZ31B joint made using 8
mm/s travel speed and 2.2-kW laser beam power: A Top bead; B
transverse section of the joint.
A
A
B
B
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equipped with an EDS.
As shown in Fig. 2B, 5-mm-wide rec-
tangular-shaped specimens were cut from
the brazed joints and subjected to tensile-
shear tests with a crosshead speed of 1
mm/min. Shims were used at each end of
the specimens to ensure shear loads in the
lap joint while minimizing induced cou-
ples or bending of the specimens. Average
tensile shear strength was calculated from
tensile specimens to estimate the static
mechanical resistance and joint efficien-
cies of the joints.
Results
A photograph of a laser-brazed Ni elec-
troplated steel/AZ31B joint and a typical
cross-sectional view of the joint are shown
in Fig. 3. This brazed joint was made using
2.2 kW laser power, 8 mm/s travel speed,
and 0.2 mm beam offset to the steel side.
The joint exhibited a uniform brazed area
with good wetting of both base materials.
Partial melting of the AZ31B base metal
was observed. In contrast, when bare steel
was used, no bonding occurred between
the steel sheet and the braze alloy fusion
zone (FZ) and wetting of the steel by the
braze metal was very poor (Ref. 15). The
5.5-m-thick Ni electrodeposited layer on
the surface of the steel significantly im-
proved the wetting of the steel by molten
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Fig. 4 Transverse sections of a laser brazed joint. A Optical micrograph
of the entire joint and SEM images in different positions along the steel-FZ
interface; B position A; C position C; D position E; E position F.
Fig. 5 Typical temperature vs. time profiles measured during laser
brazing at the top and bottom side of the joint.
A
C
E
D
B
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Mg-Al filler metal. Detailed microstruc-
tural analysis of the fusion zone and
AZ31B Mg alloy after the laser brazing
process has been reported in our previous
investigation (Ref. 15). This paper focuses
on microstructural analysis of the steel-fu-
sion zone interface.
Microstructural Evolution along the
Steel-FZ Interface
Figure 4 shows the microstructure at
different locations of the steel-FZ inter-
face. The Ni coating was not detected as a
separate layer along the interface after the
LBP, which would suggest that it had en-
tirely melted and gone into solution in the
liquid immediately adjacent to the inter-
face. It was observed that the microstruc-
ture of the FZ-steel interface changed sig-
nificantly across the FZ-steel interface
from the bottom (Position A, Fig. 4B) to
top (Position F, Fig. 4E) side of the joint.
In order to explain this change of mi-
crostructure during the laser brazing
process, temperature distribution across
the interface vs. time was measured during
laser brazing using two thermocouples,
one attached to the top side and the other
to the bottom side of the steel sheet (see
Fig. 2A). According to the measured tem-
perature profiles shown in Fig. 5, the steel
sheet experienced maximum tempera-
tures of 1151.1 and 652.7C on the top
and the bottom side, respectively. There-
fore, a 500C temperature gradient was
measured between the top and bottom
side of the steel sheet during the laser
brazing process, since the laser beam was
focused on the top of the filler metal, as
shown in Fig. 2A (Ref. 15). This tempera-
ture difference and gradient across the
joint interface during the laser brazing
process is believed to be the main reason
for the prominent change of microstruc-
ture across the FZ-steel interface.
As shown in Fig. 4B, at the bottom of
the interface a few diamond-shaped bright
phases were formed near the steel-FZ in-
terface. In order to identify these phases,
a TEM foil was prepared from position B
of Fig. 4A. Figure 6 shows the TEM im-
ages, EDS plot, and selected area diffrac-
tion pattern (SADP) of these submicron
particles. The diffraction pattern shows a
standard diffraction pattern of AlNi (with
BCC structure) with [011] zone axis of the
particle. According to an EDS analysis of
the diamond-shaped bright phases shown
in Fig. 4B, the composition of the particles
was 49.6 1.3 at.-% Ni, 45.4 4.7 at.-%
Al, and 5.0 2.5 at.-% Mg, thus confirm-
ing that the diamond-shaped particles
were mainly composed of AlNi inter-
metallic compound (IMC). Representa-
tive concentration profiles of Ni, Al, and
Mg across one AlNi particle are shown in
Fig. 6D, which indicates that a trace
amount of magnesium was found in this
particle. It has been reported that each of
the Al-Ni binary intermetallics has some
solubility for substitutional magnesium
atoms (Ref. 19).
Figure 7 shows the XRD spectra ob-
tained from the middle of the steel-FZ in-
terface. The area covered by the X-ray
beam was a 300-m-diameter circle. This
XRD result confirmed the existence of
AlNi IMC, Fe, -Mg
17
Al
12
, and -Mg.
The AlNi IMC compound was not found
at the middle of the FZ area, whereas the
XRD pattern in Fig. 7 showed some weak
peaks suggesting that AlNi IMC had
formed mainly at the steel-FZ interface.
It was observed that upon moving from
the bottom to the middle of the interface,
which was associated with increasing tem-
perature, the morphology of the IMC phase
along the interface changed from the dia-
mond-shaped AlNi to a faceted dendritic-
shaped phase (see Fig. 4C, D).
Energy-dispersive X-ray spectrometer
analysis results indicated this dendritic
phase contained 43.0 1.6 at.-% Ni, 52.1
2.0 at.-% Al, and 4.9 0.5 at.-% Mg. This
composition again corresponded with the
AlNi IMC phase. In this area, the first pre-
cipitated phase from the liquid was AlNi
IMC, the same as at the bottom of the joint.
This phase grew steadily in a faceted den-
dritic shape. As the interface temperature
increased with moving from position A to
position E in Fig. 4A, the growth morphol-
ogy of the AlNi phase changed from dia-
mond-shaped to a faceted dendritic shape,
as demonstrated in Fig. 4D. Continuous
growth of the AlNi was observed in this area
with some dendrites having long secondary
dendrite arms (see Fig. 4D).
At the top of the joint (position F in
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Fig. 6 AlNi particle characterization at position B shown in Fig. 4A: A, B TEM images; C SADP in
the [011] zone axis of this particle; D EDS composition line scans across an AlNi particle indicating line
scans of Ni, Al, and Mg.
A
C
D
B
Fig. 7 X-ray diffraction pattern of the steel-FZ
interface.
Nasiri Supplement January 2013_Layout 1 12/12/12 1:44 PM Page 5
Fig. 4A), the morphology of the interfacial
phase changed further and a high volume
fraction of a particle-like phase with the
composition of 48.4 1.4 at.-% Ni, 50.1
1.2 at.-% Al, and 1.5 0.4 at.-% Mg was
detected (Fig. 4E). This phase was also
found to be AlNi IMC phase. It should
also be noted that formation of the AlNi
phase consumed almost all of the Al con-
tent of the melt near the steel-FZ inter-
face. Thus, no -Mg
17
Al
12
was observed
near the interface compared with the cen-
tral part of the FZ.
Solidification of the Remaining Melt
between the AlNi IMC Phase and Steel
At the bottom of the joint, AlNi IMC
first crystallized from the liquid close to
the interface and then supersaturated -
Mg solid solution containing 10.6 3.6
at.-% Ni, 3.2 1.7 at.-% Al, and 2.9
1.5 at.-% Fe (dark regions in Figs. 4B and
8) solidified from the liquid during cooling
along with the AlNi phase. In some loca-
tions between the bottom and middle of
the interface, some gray lamellar phases,
as shown in Figs. 8C and 9, were also ob-
served between the AlNi IMC layer and
the steel. Figure 9A shows the position of
AlNi precipitates with respect to the steel-
fusion zone interface in the prepared sam-
ple during focused ion beaming for TEM
analysis. Figure 9B, C shows TEM images
of this lamellar (plate-like) phase. Ac-
cording to EDS analysis, the white lamel-
lae corresponded to -Mg and the dark
lamellae containing 27.6 7.2 at.-% Ni
and 72.3 7.3 at.-% Mg represented the
Mg
2
Ni stoichiometric intermetallic com-
pound (also confirmed by SADP analysis).
Based on these results, these two phases
next to each other are the Mg-Mg
2
Ni
lamellar eutectic.
Formation of the Mg-Mg
2
Ni lamellar
eutectic was not uniform and continuous
along the interface. As shown in Fig. 8A,
B, in some locations between the steel
and the AlNi IMC layer, Mg
2
Ni crystal-
lized in the form of a lamellar gray phase
and in other locations it was not seen and
a dark solid solution of Mg containing
small amounts of Ni, Al, and Fe was
formed. In the middle portion of the in-
terface, the AlNi phase crystallized first
in the liquid (Fig. 4D). Then, dark -Mg
solid solution containing 5.8 2.1 at.-%
Ni, 1.2 0.3 at.-% Al, and 3.1 0.5 at.-
% Fe formed during cooling along with
AlNi phase. Finally, at the top of the
joint, the AlNi phase precipitated heavily
in the liquid along the interface and then
the remaining liquid solidified during
cooling in the form of -Mg solid solution
(containing 2.4 0.6 at.-% Ni, 0.3 0.1
at.-% Al, and 3.4 0.3 at.-% Fe) along
with and among AlNi particles (see Fig.
4E). Upon moving from the bottom to
the top of the interface, the Fe content of
the remaining liquid between AlNi IMC
and the steel increased from 2.9 to 3.4 at.-
% due to more diffusion of Fe from the
steel side to the FZ at higher tempera-
ture. In contrast, Al and Ni showed op-
posite behaviors due to an increase in the
thickness of AlNi IMC from the bottom
to the top portion of the joint (from 5 to
30 m).
Transition Layer
Based on the TEM analysis, the AlNi
phase did not grow epitaxially on the steel
substrate, but instead nucleated and grew in
the liquid adjacent to the interface and was
surrounded by either -Mg + Mg
2
Ni eu-
tectic phases or just -Mg phase close to the
interface. On the other hand, while it may
appear in Fig. 8 that all of the electroplated
Ni had melted and gone into solution in the
liquid and the -Mg may have nucleated
and grown epitaxially from the steel surface,
it is well known that Mg and Fe are an im-
miscible couple. From a crystallographic
point of view, it is not possible for magne-
sium to nucleate on steel due to the very
large lattice mismatching of Fe and Mg
(Ref. 4). Therefore, another layer or phase
must be responsible for bonding between
the steel and fusion zone.
Further high-magnification mi-
crostructural analysis of the steel-fusion
zone interface was performed by TEM to
find an explanation for the observed in-
terfacial phases. Figure 10A shows a TEM
image of the steel-fusion zone interface. A
continuous nano-interlayer (50200 nm
thick) phase was observed along the inter-
face, which was bonded to the steel side on
one side and to the fusion zone on the
other side. Higher magnification of this
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Fig. 8 SEM images of the steel-FZ interface show the
solidification morphology of remaining melt between
the IMC layer and steel side: A Position A in Fig. 4A
near bottom side; B position B in Fig. 4A; C Mg-
Mg
2
Ni eutectic phases.
A
C
B
A
B
C
Fig. 9 A TEM sample attached to a copper
grid; B, C TEM images of the lamellar phases
formed along the steel-FZ interface.
Nasiri Supplement January 2013_Layout 1 12/12/12 1:44 PM Page 6
layer (as shown in Fig. 10B) confirmed
good coherency between this layer and
steel as well as the fusion zone. According
to EDS point analysis, the Ni content of
the transition layer varied between 17 and
40 at.-%. Figure 10C shows the selected
area diffraction pattern (SADP) on the
transition layer that identified it as Fe(Ni)
solid solution with face-centered cubic
(FCC) structure. Therefore, this layer
proved to be the key factor for realizing a
metallurgical bond between the steel and
fusion zone. Representative concentra-
tion profiles of Fe, Ni, and Mg across the
interface between the fusion zone and the
steel are shown in Fig. 10D. It is evident
from these line scans that Fe, Ni, and Mg
diffused into each other as a result of the
high temperature experienced during the
laser brazing process. As a result, two dif-
fusion or transition layers formed between
the steel and fusion zone. According to the
element distributions of Fe, Ni, and Mg
(see Fig. 10D), in transition layer I with a
thickness of almost 70 nm from the steel
side, the Fe content decreased gradually
while the Ni content increased. In this
layer, solid-state diffusion of Ni and Fe
into each other is believed to control the
overall thickness of this layer.
Another diffusion layer (transition
layer II) was observed in Fig. 10D between
the transition layer I and the fusion zone.
The thickness of this layer was 60 nm. A
slight diffusion of magnesium from fusion
zone into transition layer II was detected.
It would appear that there was sufficient
solubility of the Mg in this Fe(Ni) inter-
layer for diffusion of the Mg to occur and
that wetting and bonding of the -Mg +
Mg
2
Ni eutectic phases had in fact oc-
curred with the thin Fe(Ni) interlayer that
had formed during laser brazing, and not
directly with the steel.
Mechanical Properties
Due to the nonsymmetric configura-
tion of the 5-mm-wide tensile-shear test
specimens (see Fig. 2B), a combination of
shear and tensile forces existed at the in-
terface. Consequently, the joint strengths
are reported here as fracture load, since it
is not possible to separate tensile and
shear stresses. The average tensile shear
strength of the laser brazed steel-Ni-
AZ31B joints using the Mg-Al filler metal
was found to be 153.7 2.7 kgf (or 1506.3
24.5 N). This is 153% higher than ten-
sile shear strength of the laser brazed Al-
coated steel-AZ31B Mg alloy specimens
obtained in our previous study (Ref. 15).
The low standard deviation of the tensile
shear strength of the laser brazed steel-Ni-
AZ31B joints (2.7 kgf) compared with
the laser brazed steel-Al-AZ31B joints
(11 kgf) indicated that the laser brazing
process was inherently stable and repro-
ducible. If only the shear plane is consid-
ered, the average shear strength of the
joints was 96.8 MPa, or 60% of that of
AZ31B-H24 Mg alloy base metal.
All tensile-shear specimens fractured
in the FZ very close to the steel-FZ inter-
face. Typical fracture surfaces of both the
fusion zone side and steel side after tensile
shear testing are shown in Fig. 11. Figure
11A, C are low-magnification SEM micro-
graphs of the fracture surfaces of the fu-
sion zone side and steel side, respectively,
and dimples are shown at high magnifica-
tion in Fig. 11B, D. This uniform distribu-
tion of the dimples is characteristic of duc-
tile fracture surfaces. These fracture
surfaces indicated that the specimens
failed under conditions similar to tensile
test with a strong shear stress component
(tensile-shear test). The effect of shear
stress on the morphology of the dimples is
very evident in these micrographs. The
vertical direction in each of the micro-
graphs is parallel to the direction of the
shear, and the elongation of the dimples
under the action of shear stress is evident
in Fig. 11B, D. The AlNi IMC compound
was not found at the fracture surfaces.
The EDS analysis results of the frac-
ture surfaces of both the steel and FZ side
also indicated that crack propagation dur-
ing the tensile shear tests had occurred en-
tirely in the FZ. Based on the EDS results,
the composition of the fracture surface for
both steel side and FZ side were similar to
the FZ, meaning fracture passed through
the FZ near the steel-FZ interface.
Figure 12 shows the XRD pattern from
the fractured surface of the joint on the
steel side. Fe, -Mg, and AlNi peaks were
seen in this X-ray diffraction result. These
findings were consistent with the SEM and
EDS analysis results.
Discussion
From the above results, the interaction
between the filler metal and surface of the
Ni-plated steel can be explained as follows
(see Fig. 13):
Firstly, the solid-state Ni-plated steel is
in contact with the liquid filler metal (Mg-
Al alloy) at the laser brazing temperature
and, subsequently, the liquid Mg-Al alloy
flows over the Ni surface Fig. 13A.
Secondly, dissolution and diffusion of
Ni atoms into the liquid occur, as shown in
Fig. 13B. At the same time, some solid-
state diffusion of Ni atoms into the steel
also occurs. A slight diffusion of Fe atoms
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A
C
B
D
Fig. 10 A TEM image of the steel-fusion zone interface; B higher magnification of the selected
square area in A; C SADP in the [011] zone axis of the interfacial phase; D EDS line scan analy-
sis of Fe, Ni, and Mg at the steel-fusion zone interface.
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into the liquid was also observed. Mean-
while, Mg atoms from the liquid may
slightly diffuse into the Ni-alloyed steel
side. Therefore, a thin
diffusion or transition
layer forms continu-
ously along the inter-
face between steel and
fusion zone from the
bottom side to the top
side of the joint. This
transition layer is a
solid solution of Ni in
Fe (with low content of
Mg for transition layer
II). This Fe(Ni) solid
solution with FCC
crystal structure is
more favorable for
bonding to Mg than
having a body-cen-
tered cubic (BCC)
phase along the inter-
face. Zhang et al. (Ref.
20) used an edge-to-
edge matching crystal-
lographic model to
predict all orientation
relationships between crystals that have
simple hexagonal close-packed (HCP)
and BCC structures, and they found that
the lattice mismatching of HCP (Mg) and
BCC (Fe) is very large. On the basis of the
observation in our study, a diffusion layer
composed of Fe and Ni with FCC struc-
ture can provide the conditions for the
heterogeneous nucleation of -Mg during
solidification. The result is formation of a
metallurgical bond between the steel and
magnesium alloy. A recent study by Liu et
al. (Ref. 4) showed that a nano-layer of
Fe
2
Al
5
on steel can also be a transition
layer to bond Fe to Mg due to the low en-
ergy interfaces and good match of lattice
sites between Fe and Fe
2
Al
5
as well as Mg
and Fe
2
Al
5
. The same behavior was ob-
served for the Fe(Ni) transition layer in
this study. Formation of a transition zone
was also reported in other studies (Refs.
58) using different joining techniques,
when an interlayer was used between steel
and Mg alloy. These transition layers on
steels were reported to make it possible to
join Mg and steel.
Thirdly, during the solidification
process, the AlNi phase with a high melt-
ing point (1133C) precipitates from the
liquid and grows in a form of faceted den-
drites very close to the interface Fig.
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Fig. 11 SEM images of typical fracture surfaces after the tensile shear test. A, B Fusion zone side at different magnifications; C, D steel side at differ-
ent magnifications.
Fig. 12 X-ray diffraction pattern of the fracture surface of the steel side.
D
C
B A
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13C. These faceted dendrites form due to
kinetic difficulties in forming new planes
of atoms (Ref. 21). In this type of dendrite,
the growing direction of dendrite arms are
ones that are capped by relatively slow
growing planes (usually low-index planes)
(Ref. 21). The slowest growing plane
would be expected to be the closest-
packed planes. Weinberg and Chalmers
(Ref. 22) reported that the axis of a pyra-
mid, whose sides are the most closely
packed planes, is generally the major den-
drite direction. As a result, for AlNi
faceted dendrites with BCC structure, this
direction is <100>. Therefore, the
process of solidification at the middle part
of the joint starts with the nucleation and
growth of the AlNi-faceted dendrites
along the <100> growth direction.
Fourthly, if the Ni content of the re-
maining liquid between the steel side and
formed AlNi precipitates is high enough,
Mg
2
Ni with a melting point of 762C nu-
cleates (see Fig. 13C). Formation of
Mg
2
Ni depends on sufficient Ni concen-
tration in the remaining liquid near the
steel-FZ interface after formation of the
AlNi IMC. The Ni content of the remain-
ing liquid after precipitation of AlNi in-
creases from 2.4 at.-% at the top side of
the interface to 10.6 at.-% at the bottom
portion because formation of the AlNi
IMC layer consumed the Ni atoms near
the interface and the volume fraction of
this phase increased from the bottom to
the top portion of the joint.
Based on the above analysis, high
enough concentration of Ni in the re-
maining liquid close to the bottom side of
the joint after formation of AlNi IMC re-
sulted in formation of the Mg
2
Ni + -Mg
lamellar eutectic in the form of a gray
phase between the AlNi IMC and steel. In
order for this lamellar eutectic to grow,
the local composition of the fusion zone
should be close to the eutectic composi-
tion (10 at.-% Ni, according to the Mg-Ni
binary phase diagram) (Ref. 21). Reac-
tions between Mg in the fusion zone and
Ni along the interface caused formation of
the Mg-Ni eutectic phase. This reaction
can be represented by the following bal-
anced chemical reaction:
L(10 at.-% Ni)508CMg
2
Ni
(33 at.-% Ni)+Mg(0 at.-% Ni) (1)
Therefore, at the bottom of the inter-
face, two reactions occurred; the first one
was precipitation of AlNi from the liquid
and the second was the eutectic reaction
between Mg and Ni in the FZ (reaction 1).
In the case of reaction sequences, first
AlNi forms near the interface and then the
remaining liquid with a low Al content be-
tween the AlNi IMC and steel-FZ inter-
face, which is still rich in Ni, undergoes a
eutectic reaction with Mg and results in
the formation of the lamellar
-Mg + Mg
2
Ni eutectic.
With the formation of the
AlNi IMC layer, diffusion of
Ni atoms from the steel side to
the FZ is blocked. Therefore,
the concentration of Ni in the
remaining liquid between the
interface and preformed AlNi
phase is expected to be higher
than the remaining liquid on
the other side of the AlNi
phase. The result is the forma-
tion of Mg
2
Ni just between
the AlNi phase and steel (see
Fig. 8A, B).
In the top portion of the
interface, with the nucle-
ation and growth of the AlNi
particles, most of the Ni
atoms are consumed. There-
fore, the Ni content of the
remaining liquid would not
be enough for formation of
the Mg
2
Ni phase.
Conclusions
1. With the addition of an
electrodeposited Ni inter-
layer on steel sheet, single
flare bevel lap joints of
AZ31B-H24 Mg alloy to
steel sheet were rendered
possible by the laser brazing
process, and a uniform
brazed area with good wet-
ting and bonding of both base
metals was achieved.
2. Dissolution of the Ni
coating layer during the laser
brazing process led to the
formation of new AlNi IMC
phases and also a Mg-Ni eu-
tectic zone along the inter-
face. The AlNi intermetallic
layers at the steel-FZ inter-
face formed in the sequence
of diamond-shaped, den-
dritic, and nodules from the
bottom to the top portion of
the joint.
3. The formation of a
nano-scale Fe(Ni) transition
layer on the steel by solid-
state interdiffusion between
Fe and Ni during laser braz-
ing was found to be responsi-
ble for the formation of a
metallurgical bond between
the steel and the Mg-Al braz-
ing alloy.
4. The average shear strength of the
joints reached 96.8 MPa, 60% that of the
base metal of AZ31B Mg alloy. Fracture
surface analysis showed that fracture oc-
curred in the FZ close to the steel-FZ
interface.
Acknowledgments
The authors wish to acknowledge sup-
port of the American Welding Society
(AWS) Graduate Fellowship program, the
Natural Sciences and Engineering Re-
search Council of Canada (NSERC), and
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Fig. 13 Formation of transitional layer and intermetallic com-
pounds during laser brazing of Ni-plated steel-AZ31B with Mg-Al
filler metal: A Wetting of the Ni-plated steel by molten filler metal
and dissolution and diffusion of Ni into the FZ and steel substrate; B
formation of the transitional layer and aggregation of Ni along the
interface; C nucleation and growth of AlNi IMC, and epitaxial
growth of the remaining liquid in the form of -Mg + Mg
2
Ni eutectic
onto the thin Fe(Ni) interlayer.
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Magnesium Network of Canada (Mag-
NET) for sponsoring this work. The au-
thors would like to acknowledge the help-
ful comments of Dr. Scott Lawson from
the Centre for Advanced Materials Join-
ing at the University of Waterloo.
References
1. Yan, J., Xu, Z., Li, Z., Li, L., and Yang, S.
2005. Microstructure characteristics and per-
formance of dissimilar welds between magne-
sium alloy and aluminum formed by friction
stirring. Scripta Materialia 53: 585589.
2. Mao, H. K., and Bell, P. M. 1979. Equa-
tions of state of MgO and Fe under static pres-
sure conditions. Journal of Geophysical Re-
search 45334536.
3. Liu, L. 2005. Welding and Joining of Mag-
nesium Alloys, Cambridge, UK: Woodhead
Publishing Ltd.
4. Liu, L., Xiao, L., Feng, J., Li, L., Esmaeili,
S., and Zhou, Y. 2011. Bonding of immiscible
Mg and Fe by coated nanoscale Fe
2
Al
5
transi-
tion layer. Scripta Materialia 65 (11): 982985.
5. Zhao, X., Song, G., and Liu, L. 2006. Mi-
crostructure of dissimilar metal joint with mag-
nesium alloy AZ31B and steel 304 for laser-
tungsten inert gas lap welding. Transactions of
China Welding Institution 27: 12531256.
6. Qi, X., and Song, G. 2010. Interfacial struc-
ture of the joints between magnesium alloy and
mild steel with nickel as interlayer by hybrid laser-
TIG welding. Materials & Design 31: 605609.
7. Liu, L., Xiao, L., Feng, J. C., Tian, Y. H.,
Zhou, S. Q., and Zhou, Y. 2010. The mecha-
nism of resistance spot welding of magnesium
to steel. Metallurgical and Materials Transac-
tions A 41A: 26512661.
8. Liu, L., Qi, X., and Wu, Z. 2010. Mi-
crostructural characteristics of lap joint be-
tween magnesium alloy and mild steel with and
without the addition of Sn element. Materials
Letter 64: 8992.
9. Liu, L. M., and Qi, X. 2009. Effects of cop-
per addition on microstructure and strength of
the hybrid laser-TIG welded joints between
magnesium alloy and mild steel. Journal of Ma-
terials Science 44: 57255731.
10. Lockwood, L., and Shapiro, A. E. 2005.
Brazing of magnesium. Brazing Handbook, 5th
edition, Miami, Fla.: American Welding Society.
11. Sierra, G., Peyre, P., Deschaux Beaume,
F., Stuart, D., and Fras, G. 2008. Steel to alu-
minium braze welding by laser process with Al-
12Si filler wire. Science and Technology of Weld-
ing and Joining 13(5): 430437.
12. Wagner, F., Zerner, I., Kreimeyer, M.,
Seefeld, T., and Sepold, G. 2001. Characteriza-
tion and properties of dissimilar metal combi-
nations of Fe/Al and Ti/Al-sheet materials.
Proc. ICALEO01 (CD-ROM), Jacksonville,
Fla., October, LIA, Orlando, Fla.
13. Miao, Y., Han, D., Yao, J., and Li, F.
2010. Microstructure and interface characteris-
tics of laser penetration brazed magnesium
alloy and steel. Science and Technology of Weld-
ing and Joining 15(2): 97103.
14. Kreimeyer, M., Wagner, F., and Vollert-
sen, F. 2005. Laser processing of aluminum-ti-
tanium-tailored blanks. Optics and Lasers in En-
gineering 43: 10211035.
15. Nasiri, A. M., Li, L., Kim, S. H., Zhou,
Y., Weckman, D. C., and Nguyen, T. C. 2011.
Microstructure and properties of laser brazed
magnesium to coated steel. Welding Journal
90(11): 211-s to 219-s.
16. Material Safety Data Sheet. 2003. Supe-
rior Flux & Mfg. Co. November 11. p. 1.
17. Saida, K., Song, W., and Nishimoto, K.
2005. Diode laser brazing of aluminum alloy to
steels with aluminum filler metal. Science and
Technology of Welding and Joining 10(2):
227235.
18. Vander Voort, G. F. 1999. Metallography
Principles and Practice. Materials Park, Ohio:
ASM International.
19. Belov, N. A., Eskin, D. G., and Avxen-
tieva, N. N. 2005. Constituent phase diagrams
of the Al-Cu-Fe-Mg-Ni-Si system and their ap-
plication to the analysis of aluminum piston al-
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20. Zhang, M. X., Kelly, P. M., Qian, M., and
Taylor, J. A. 2005. Crystallography of grain re-
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21. Flemings, M. C. 1974. Solidification Pro-
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22. Weinberg, F., and Chalmers, B. 1952.
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488502.
AWS Expands International Services
With international membership on the rise, the American Welding Society (AWS)
launched a series of country-specific Web sites known as microsites for members to
access information in their native languages.
Multilingual microsites are now live for Mexico at www.aws.org/mexico, China at
www.aws.org/china, and Canada (English/French) at www.aws.org/canada. They fea-
ture information on services offered by AWS in each country, membership benefits,
exposition information, online education, and access to AWS publications and tech-
nical standards.
Other countries will be added later.
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Introduction
As with most welding processes, fric-
tion stir welding (FSW) produces a non-
homogenous macrostructure whose
regions, illustrated in Fig. 1, include the
heat-affected zone (HAZ), thermome-
chanical-affected zone (TMAZ), and weld
nugget or stir zone (SZ). Each zone is
characterized by a unique microstructure
related to different levels of thermome-
chanical processing. The tool rotation and
travel impart a nonsymmetrical flow pat-
tern that is observed in the nonsymmetric
weld structure of the transverse section in
Fig. 1. The side where the tool rotation
and travel vectors are in the same direc-
tion is labeled the advancing side (AS),
and where they are opposed is labeled the
retreating side (RS). Because FSW is a
solid-state process, correlation of the tem-
perature at the workpiece/weld tool inter-
face with the processing parameters
presents challenges. Understanding of this
correlation is needed for control of the
processing temperature and optimization
of the resulting mechanical properties.
Because the maximum temperature in
FSW is generally considered to be at the
shear interface between the SZ and the
TMAZ (Refs. 13), understanding the
variation in temperature in this region
with respect to processing parameters is
necessary. Numerous studies report the
resulting weld temperature to be most
strongly influenced by the tool rotation ve-
locity (Refs. 27). In addition to under-
standing the temperature, the heating rate
can also affect the kinetics of the phase
changes in age-hardenable alloys such as
the AA2xxx series. Since the FSW process
is considered to involve a large shear strain
at high rates (Refs. 2, 812), the heating or
up-quenching times associated with the
process may be very rapid (Ref. 13).
Determining the temperature at the
workpiece/weld tool interface was directly
approached using embedded thermocou-
ples in 2xxx series aluminum alloys (Refs.
1, 2, 1420), and it has provided informa-
tion on the relative homologous tempera-
ture in the range of 0.80 to 0.90 T
m
(where
T
m
is the melting temperature of the Al
with a value of 933 K). Little variance has
been reported with SZ temperature meas-
urements of 525C in AA2024 (Ref. 17)
and 480520C in AA2195 (Ref. 14),
where the increase in temperature corre-
sponded to an increase in tool rotation.
Positioning the thermocouple close to the
shear zone has noted difficulties due to
potential displacement by the resulting
material flow and response to rapid heat-
ing conditions. Thus, most thermocouple
measurements have been used to validate
a numerical model with extrapolation of
measured temperatures outside the SZ to
the workpiece/weld tool interface. At-
tempts to model the temperature in the
shear region have often resulted in over-
prediction of the weld temperature, which
has been attributed to slippage occurring
at the workpiece/weld tool interface (Refs.
21, 22). While relationships between peak
temperature and processing conditions
have been shown (Refs. 2, 14), they are not
considered to change the overall tempera-
ture field significantly (Ref. 22).
Conversion of weld power to thermal
energy has also being pursued to deter-
mine the weld temperature (Refs. 2327),
and may have validity if the temperature
does not exceed the eutectic or solidus
temperature resulting in tool slippage and
reduced efficiency (Refs. 13, 21).
Since the processing temperature con-
trols the resulting mechanical properties,
as affected by microstructural variations,
interpretation of the resulting grain size
and precipitate state can be used to verify
processing temperatures and provide in-
sight as to the heating conditions, and
hence, strain rate experienced during
FSW of age-hardenable alloys (Refs. 810,
12, 13, 28). Due to the complex nature of
the FSW process, various characterization
methods at different length scales are
often needed to interpret the results. Al-
though much research has been published
on the resulting microstructure and me-
chanical properties of FSW in the age-
hardenable 2xxx series (Refs. 14, 15, 19,
20, 2739), these studies generally charac-
terized a single FSW obtained with a sin-
gle set of processing parameters that
covered a range of tool rotations from 120
to 1040 rev/min. Further adding to the dif-
ficulty of comparing findings, not all stud-
ies document details of the tool design and
processing parameters. Thus, assessing
whether the microstructural evolution ob-
served is due to the material, tool design,
processing parameters, or some combina-
tion is difficult and sometimes results in
conflicting findings. Studies on 2024 (Refs.
Processing Effects on the Friction
Stir Weld Stir Zone
This investigation attempts to understand the true temperature at the
workpiece/weld tool interface
BY J. SCHNEIDER, R. STROMBERG, P. SCHILLING, B. CAO, W. ZHOU, J. MORFA, and O. MYERS
ABSTRACT
While many researchers have carefully mapped out the various microstructural re-
gions of a friction stir weld (FSW), concluding that each region undergoes different
thermomechanical cycles during the process, these studies generally have only con-
sidered one set of FSW parameters. By considering only the shear zone (SZ) over a
range of FSW process parameters, it can be observed that material within this region
is also subjected to different thermomechanical cycles. Whether this results from a
temperature increase with higher rev/min and/or material held for an increased time
at temperature, is still not understood. This study, however, does give insight into the
often conflicting results published regarding the microstructural evolution in a FSW.
KEYWORDS
Aluminum
Friction Stir Welding
Heat-Affected Zone
Shear Zone
Solid-State Welding
J. SCHNEIDER, J. MORFA, and O. MYERS are
with Mechanical Engineering Department, Mis-
sissippi State University, Mississippi State, Miss.
R. STROMBERG is with Hysitron, Inc., Min-
neapolis, Minn. P. SCHILLING is with Mechan-
ical Engineering Department, University of New
Orleans, New Orleans, La. B. CAO and W.
ZHOU are with Advanced Materials Research In-
stitute, University of New Orleans, New Orleans,
La.
Schneider 1-13_Layout 1 12/13/12 1:00 PM Page 11
19, 30, 3335) report a range of complex
precipitate morphologies in the SZ with
coarse particles dissolving providing solute
for postweld natural aging. In contrast,
studies on 2219 report either particle
coarsening (Refs. 3638, 40) and/or the
dissolution of the Al
2
Cu phase in the SZ
(Refs. 15, 20). Nonhomogeneities ob-
served at the macroscale have been attrib-
uted to banding of large constituent
particles, which correspond to tool rota-
tion variations in 2024 (Refs. 41, 42), dif-
ferent tempers of 2219 (Ref. 36), or
overpass repair welds in 2219 (Ref. 38).
While differences in the microstructural
characterization of 2195 in
two different studies were at-
tributed to variations in phase
transformations kinetics as in-
fluenced by FSW process pa-
rameters (Refs. 14, 31), no
systematic study has been con-
ducted to verify.
Conductivity measurements
provide a well-established non-
destructive evaluation (NDE)
technique for determining the
temper of a metal. However, its
sensitivity is affected by varia-
tions in alloy uniformity due to
heat treatment condition, the
degree of cold work, presence
of residual stresses, or effect of
thermal exposure (Refs.
4345). Thus, a combination of
NDE techniques are often used
to evaluate the temper of an
alloy such as combining eddy
current with hardness testing.
While these standard tech-
niques are typically used at the
macroscale where homogeneity
of the thermomechanical pro-
cessing is assumed, characterization at the
microscale can provide insight into nonho-
mogenous variations.
This study evaluated the combined use
of conductivity measurements with hard-
ness testing at the macro and micro length
scales to evaluate the resulting mi-
crostructure in a FSW SZ formed by vary-
ing the tool rotation. The range of tool
rotations in the study was selected based
on earlier studies where a large change in
the resulting SZ strength was observed
(Ref. 46). Microstructural features were
correlated with conductivity and hardness
measurements. The results in this study
were also compared with temperature cal-
culations based on conversion of weld
power to thermal energy (Ref. 27).
Experimental Procedure
Friction stir welds were made in rolled
panels of aluminum alloy 2219-T87 approx-
imately 610 mm long, 152 mm wide, and 6.4
mm thick that were butted together. Nomi-
nal composition of the 2219 alloy (wt-%) is
Cu 6.30%, Mn 0.30%, Zr 0.17%, V 0.10%,
Ti 0.06%, Fe 0.15%, Si 0.10%, and balance
Al. The FSW tool consisted of a 12.7-mm-
diameter UNF left-handed pin, a 30.5-mm-
diameter scrolled shoulder, and a pin length
of approximately 6.2 mm. All FSWs were
performed with a zero degree lead angle
and in-position control. A RM-1 model
FSW machine from Manufacturing Tech-
nology, Inc. (MTI), was used to produce the
welds with the data recorded using a high-
speed National Instruments Data Acquisi-
tion system.
Metallographic specimens were taken
of the transverse section of each FSW seg-
ment. The specimens were mounted and
polished using standard metallurgical pro-
cedures. All samples were etched using
Kellers reagent to document the
macrostructure as recorded with a Nikon
D1 camera. Surface topography was ob-
tained in a scanning probe microscopy
(SPM) using a diamond Berkovich probe
mounted on the Hysitron TI 950. Prior
to SPM, the specimens were mechanically
reground and repolished using 1.0- and
0.5-micron alumina on the pad followed by
colloidal silica.
Indentation experiments were con-
ducted using the Hysitron TI 950 instru-
ment equipped with the nanoECR
(electrical contact resistance) package and
a conductive boron-doped diamond
Berkovich probe with a tip radius of ap-
proximately 150 nm. The nanohardness of
each transverse specimen was measured
across the width approximately 1.3 mm
below the crown surface. One hundred in-
dents with a spacing of 250 m were made
using a 5-s loading to a peak of 10 mN, 5-
s hold, and 5-s unloading segments, which
corresponded to an average indentation
contact depth of 485 nm.
To measure the nanoconductivity, the
nanoECR package was used, which en-
ables simultaneous electrical measure-
ments to be made during standard
nanoindentation testing. During testing, a
fixed voltage was applied to the sample via
a conducting stage and the resultant cur-
rent flow through the sample was meas-
ured through the conducting tip. Voltage
was held constant at 2 V and the measured
current was used to calculate the average
current density based on the contact area
of the indenter at peak loading.
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Fig. 1 Transverse view of a conventional friction stir weld with regions of interest labeled.
Fig. 2 Miniature tensile specimens fabricated from the FSW
nuggets. A Shown are the specimens from the FSW transverse mi-
crostructure with the specimen geometry superimposed; B an end
mill was used to machine the dogbone geometry; C which was then
sliced into individual specimens using wire EDM.
A
B
C
Schneider 1-13_Layout 1 12/13/12 1:00 PM Page 12
Bulk eddy current measurements were
made with Rohmann GmbH Elotest M2
with a probe diameter of approximately
1.3 cm, which was operated at a frequency
of approximately 1 MHz. The values were
recorded as % IACS, where the electrical
conductivity of annealed Cu was refer-
enced as 100% IACS at 20C, and IACS
refers to the International Annealed Cop-
per Standard, which was established in
1913 (Ref. 47). Advertised accuracy of
measurements was 0.1% IACS. Because
the probe diameter was larger than the
weld cross section, some air was picked up.
Although this may have resulted in slightly
lower values for % IACS, the comparative
trend was considered valid.
To evaluate the mechanical properties
of only the SZ of the FSW, tensile speci-
mens were designed with the gauge sec-
tion entirely within the transverse section
of the FSW SZ, as shown in Fig. 2A. The
geometry was first machined, and then
sliced using wire electrical discharge ma-
chining (EDM) into individual specimens
2.0 cm long 0.64 cm wide 0.03 cm thick,
as shown in Fig. 2B and C, respectively.
The tensile specimens were tested in uni-
axial tension using a stepper-motor-driven
miniature tensile tester with a 0.5-kN (100-
lbf) load cell. All tests were run at ambi-
ent temperature at a constant crosshead
velocity of 0.05 mm/min with a data-
acquisition rate of 1 sample per s. The
maximum load (F
max
) was divided by the
initial specimen cross-sectional area (A) to
calculate the engineering stress (). Yield
strength (
YS
) was defined using the
0.02% offset criteria (Ref. 48) and ulti-
mate tensile strength (UTS) was defined
using the maximum load carried by the
specimen cross-sectional area.
A JEOL 6500 F field emission, scan-
ning electron microscope (FE-SEM) with
an Oxford electron backscatter detector
(EBSD) was used to obtain orientation
image maps (OIM) of the SZ. Analysis
was performed in 0.4-m steps over 215-
161-m rectangular areas in the banded
regions of the transverse sections. All
OIM scans were obtained using an excita-
tion condition of 20 kV with a working dis-
tance of 20 mm. EBSD/OIM was used to
determine grain size based on a 5-deg mis-
orientation angle.
Transmission electron microscope
(TEM) foils, 3 mm in diameter, were
punched from the SZ region of the FSW
specimens and were prepared for imaging
using traditional techniques of mechanical
thinning, two-sided dimpling, and ion
milling to electron transparency. Initial
images were obtained in a JEOL JEM-
100CX TEM with a tungsten filament op-
erated at an accelerating voltage of 100 kV
to obtain bright field image (BFI). Com-
plementary higher-resolution BFIs and se-
lected area diffraction (SAD) patterns
were obtained using a JEOL 2010 200
KeV field emission (FE) TEM.
A Rigaku Smartlab X-ray diffractome-
ter (XRD) with Cu-k X-ray was used to
identify the minor phases present in the
aluminum matrix. A continuous scan was
made at a rate of 0.035 deg/min over a 2-
range of 18 to 55 deg.
The SZ temperature was taken to be
that of the workpiece/weld tool interface
or the shear zone. The shear zone tem-
perature was calculated from the meas-
ured experimental torque values using an
alternative heat index (Ref. 27). This nu-
merical approach considered the power
generated by rotating an axial symmetric
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Table 1 Summary of FSW Conditions and Corresponding Shear Strain Rate
RPM Tool Radius Shear Zone Shear
(mm) Thickness Strain Rate
(mm) (s
-1
)
150 6.35 0.13 5 10
4
200 6.35 0.13 6 10
4
300 6.35 0.13 9 10
4
Fig. 3 Flow stress of 2219-T87 vs. temperature
showing a precipitous drop at 0.5T
m
before reach-
ing an almost constant, linear plateau in the range
of 0.7 to 0.9 T
m
(Ref. 50).
Fig. 4 Phase diagram for the Al-Cu binary sys-
tem (Ref. 51).
Table 2 Grain Size as Inferred from EBSD/OIM
Specimen Grain Size (m)
AS RS
150 2.5 1.8
200 2.8 2.6
300 4.1 4.2
A B
Fig. 5 A A low-magnification image of the base metal in which a few large overaged particles
(200500 nm) can be observed; B the higher-magnification image shows the strengthening phases
in the base metal matrix.
Schneider 1-13_Layout 1 12/13/12 1:00 PM Page 13
plug of metal around the tool. By assum-
ing that 100% of the weld torque was con-
verted into thermal energy and contact
conditions remain constant, an energy bal-
ance was used to equate the heat input
(Q
g
) with the heat loss terms as given in
Equation 1. The heat loss terms included
conduction, through the weldment (Q
w
),
anvil (Q
a
), and spindle (Q
sp
), in addition
to convection, which captured the pre-
heating of metal (Q
v
) passing through the
shear surface in advance of the weld.
Q
g
= Q
w
+ Q
a
+ Q
sp
+Q
v
(1)
The resulting relationship given in Equa-
tion 2 was used to determine a FSW tem-
perature from the actual weld torque (M
t
)
(Refs. 27, 49) where was the tool rota-
tion, was the flow stress, R
s
was the ra-
dius of shear surface, R was the radius of
the tool pin, and H was the length of the
tool pin.
(2)
The flow stress () was approximated by
M
t
* T such that as the shear zone temper-
ature approached T
m
, the flow stress ap-
proaches zero (Refs. 27, 49). This linear
approximation was based on Fig. 3, which
plots the flow stress vs. temperature for
AA2219-T87 7 and shows a precipitous drop
at around 0.5 T
m
reaching a constant, linear
plateau at approximately 0.7 T
m
(Ref. 50).
The value of flow stress at T
m
was assumed
to be zero. Thus, considering the range of
published temperature measurements for
FSW Al alloys of 0.8 to 0.9 T
m
, the corre-
sponding flow stress was relatively unaf-
fected by temperature and was considered
linear just prior to reaching T
m
.
Results and Discussion
AA2219 is an Al-Cu alloy whose nom-
inal composition is slightly above the max-
imum solid solubility as shown in the
equilibrium diagram in Fig. 4 (Ref. 51).
This yields a microstructure composed pri-
marily of the saturated -aluminum ma-
trix plus a small amount of excess phase.
The T87 temper used in this study refers
to a heat treatment that artificially ages
the Cu-rich precipitates in the -matrix
through a well-accepted sequence of equi-
librium transformation given in Equation
3, where
ss
refers to a solid solutionized
Al matrix.
ss
GPIGPII (3)
The T8 temper refers to a solid-solution
heat treatment of the phase at 535C,
followed by cold work and artificial aging
at 175C for 18 h (Ref. 52). This results in
a base metal with the main strengthening
metastable phase of phase as shown in
Fig. 5. Figure 5A is a low-magnification
image of the base material microstructure,
which shows a few large Cu-rich particles
around 200500 nm, corresponding to the
excess phase. Figure 5B is a higher mag-
nification image that shows the
strengthening metastable phase with a
reported morphology of tetragonal discs
that are semicoherent with the -alu-
minum matrix (Ref. 53).
The FSW process is considered to
occur at high strain rates and impart a high
strain to the metal surrounding the weld
tool (Refs. 2, 812). Thus, the kinetics of
the dynamic microstructural evolution
would be expected to differ from the static
equilibrium conditions (Refs. 13, 19). The
occurrence of a high strain rate acting on
the metal as it moves around the weld tool
implies very rapid deformational heating
and associated up-quenching followed by
slow cooling. The strengthening precipi-
tates in the base metal undergo coarsen-
ing during the FSW process and eventually
lose their strengthening effectiveness due
to elevated temperatures and/or longer
times at elevated temperatures.
Near the workpiece/weld tool interface,
where the rate of heating was the highest
due to the high shear strain rates, the Cu-
rich phases underwent dissolution. During
the rapid up-quenching, if the eutectic
temperature was exceeded at the work-
piece/weld tool interface, the remaining
phase may have liquated (Refs. 13, 54).
However, if the temperature remained
below the eutectic, an increasing degree of
dissolution of the Cu-rich phases was ex-
pected as the rate of temperature rise in-
creased at the workpiece/weld tool inter-
face, thereby increasing the solute
concentration. At lower strain rate regions
away from the shear zone, the Cu-rich
phases would have continued to coarsen,
depleting the solute from the matrix
(Ref. 19).
Estimations of the strain rate associated
with FSW have been based on various ana-
lytical or numerical models that rely on ma-
terial property databases (Refs. 811) in
addition to use of the Zener-
Holloman parameter, which relates grain
size to strain rate (Ref. 12). These methods
have provided estimates in the range of 10
4
to 10
1
s
1
, respectively, with lower values cal-
culated from the Zener-Holloman method.
Studies have indicated that the grain size at
Q R
R
R
H
R
g
s
=
2
1
3
3
3
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Table 3 Tensile Strength of the FSW SZ Specimens
Specimen Yield Strength Ultimate Tensile Strength
(MPa) (MPa)
150 151 2 269 11
200 163 11 295 11
300 190 2 332 9
PM 396 469
Fig. 6 Macrographs of the FSWs in this study with horizontal line indicating location
of nanoindentations.
Table 4 Bulk Eddy Current Measurements
Specimen Eddy Current
(% IACS)
150 26.2 0.1
200 26.2 0.7
300 22.7 0.1
Schneider 1-13_Layout 1 12/13/12 1:00 PM Page 14
the workpiece/weld tool interface are
smaller than in the FSW wake, which has
been attributed to grain growth during the
slow cooling of the workpiece (Ref. 55). As
grain sizes have been reported to increase
with increasing tool rotation due to post-
weld grain growth, use of the Zener-Hollo-
man method results in an underestimation
of the strain rate. The highest shear strain
rate has been estimated based on a kine-
matic approach that does not rely on an as-
sumption of material properties at the FSW
conditions (Refs. 11, 49). Using this ap-
proach, an estimate of the mean shearing
strain rate () across the shear surface of
thickness () at the workpiece/weld tool in-
terface has been made using Equation 4
(Ref. 11).
(4)
In Equation 4, r is the radius of the shear
surface approximated by the pin tool ra-
dius and is the angular velocity of the
metal inside the shear surface taken to be
approximately the same as that of the tool.
The shear zone thickness, , is estimated
to be on the order of 0.1 times the pin di-
ameter (Refs. 1, 3, 46, 49). The estimated
shear strain rates are summarized in Table
1 showing increasing rates as the tool ro-
tation increases. As the travel speed was
constant in this study at 114 mm/min, the
higher strain rate corresponded to a faster
heating rate at the shear surface sur-
rounding the SZ. Note that this was an in-
stantaneous shear strain rate that the
material experienced as it crossed the
shear zone. Neighboring material adjacent
to the shear zone experienced less shear-
ing, and hence, lower temperatures. The
intertwining of these two flow paths in the
SZ region was reported to result in the
shear textures or onion ring pattern ob-
served in the FSW SZ (Refs. 56, 57)
Macrographs of the etched transverse
sections of the three welds are shown in
Fig. 6. They were repolished to obtain the
SPM surface profiles shown in Fig. 7. Pref-
erential polishing around the harder Cu-
rich particles reveal an increasing number
as the rotation is increased from 150 to
200 rev/min. However, at 300 rev/min, a
decrease in the average size and the vol-
ume fraction of hard Cu-rich particles as-
sumed to be the phase was observed.
This would correspond to an increased
dissolution rate of the phase as the
rev/min, and hence the strain rate, in-
creased above a critical level.
The representative grain size measure-
ments for the three FSWs in this study were
obtained using electron backscattered dif-
fraction (EBSD)/orientation image map-
ping (OIM). Table 2 summarizes the
variation in grain size observed between the
AS and RS of the FSWs. The larger, more
uniform grain size in the 300 rev/min FSW
specimen was consistent with exposure to
higher temperatures or longer cooling times
for the workpiece, similar to other reports
(Refs. 39, 55). Thus, the higher SZ strength
at the higher revs/min cannot be attributed
to Hall-Petch strengthening, but rather to
the precipitate state.
The horizontal dashed line, shown on
the macrographs in Fig. 6, indicate the lo-
cation of the nanoindentations summa-
rized in Fig. 8. While a reduction in hard-
ness was observed for the welds made at
150 and 200 rev/min, the 300 rev/min FSW
had a higher value. Table 3 lists a compar-
ison of the FSW strengths to the base
metal. Although all FSWs had a lower
strength than the base metal, a trend to-
ward increased tensile strength was noted
for the SZ as the tool rotation increased.
Estimating a weld temperature based on
conversion of power to heat, assuming a
100% efficiency and constant contact con-
ditions, predicted a higher temperature at
the higher tool rotation. For natural aging
to occur, Cu-rich phases in the 2219-T87
material would have to dissolve and in-
crease the amount of solute in the -ma-
trix in the wake of the FSW. TEM images
indicated that the phase was dissolved,
thus replenishing the solute in the phase
for postweld natural aging.
On the basis of the hardness data and
corresponding SPM images, there was a sig-
nificant change in either the localized tem-
perature or the heating rate between the
FSWs made at 300 rev/min and the 150 and
200 rev/min. There was no evidence of ex-
ceeding the eutectic temperature, either by
( )
r *
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Fig. 7 SPM images show higher amounts of precipitates on the surfaces of the FSWs made at A 150 rev/min; B 200 rev/min; than on the C 300
rev/min sample surface.
Fig. 8 Nanohardness measurements on FSW samples showing higher hardness at 300 rev/min
due to natural aging.
.
Schneider 1-13_Layout 1 12/13/12 1:00 PM Page 15
a decrease in FSW torque or in the mi-
crostructure. A reduction in the volume
fraction of the phase accompanied by a
coarsening of the phase cannot be ex-
plained by equilibrium kinetics, which
would predict the dissolution of the smaller
particles and coarsening of the larger parti-
cles within a constant temperature field.
Table 4 summarizes the bulk eddy cur-
rent measurements. Similar readings were
obtained for the 150 and 200 rev/min spec-
imens, whereas the 300 rev/min specimen
was significantly lower. It has been re-
ported that the hardness does not have a
1-to-1 correlation with electrical conduc-
tivity in heat-treatable alloys (Ref. 45). At
sufficiently high temperatures, dissolution
of particles increased the amount of solid-
solution solute causing a decrease in elec-
trical conductivity. The increased solute
presence results in natural aging of the
weld nugget postweld thereby increasing
the hardness. This hardness reversion with
decreased electrical conductivity has been
reported in other 2xxx series aluminum al-
loys (Refs. 45, 58) similar to the findings
in this study. Although the combined use
of eddy current and hardness testing was
not generally used for identification of
2xxx series aluminum alloys (Ref. 45), it
was useful for understanding the precipi-
tate state in the difference zones of a
FSWs by correlation with complementary
microscale techniques.
To further probe the bulk eddy current
measurements, corresponding nanocurrent
density measurements were calculated from
indents applied in the center SZ region and
the base metal region which was assumed to
be near the edge of the transverse specimen.
Figure 9 presents a bar graph plot showing
the relative occurrence of each current den-
sity for the SZ (lighter color) and the base
metal (darker color). At all rev/min condi-
tions, a low occurrence of current densities
in the range of 1327 A/mm
2
is observed
only in the SZ region. Comparing Fig. 9A
and B, corresponding to the 150 and 200
rev/min specimens respectively, an increase
can be observed in the occurrence of the
current densities in the range of 1121
A/mm
2
. This increase in higher current den-
sities for the 200 rev/min specimen corre-
sponds to a decrease in the occurrence of
the lower current densities (< 10 A/mm
2
).
For the 300 rev/min specimen in Fig. 9C, the
major occurrence of current densities is in
the range of 15 A/mm
2
with similar behav-
ior noted for the SZ and the base metal.
Very few higher current densities in the SZ
are observed in the narrower range 1822
A/mm
2
.
To understand this variation, individual
current density measurements were made
directly on the Cu-rich particles and com-
pared with the Al matrix as shown in Fig. 10.
As can be observed, a higher current den-
sity range of 1116 A/mm
2
was associated
with the large Cu-rich particles. with a lower
current density range of 17 A/mm
2
was as-
sociated with the matrix. Thus, the his-
tograms can be interpreted as the 150 and
200 rev/min FSWs having a higher concen-
tration of larger Cu-rich particles in the SZ
than in the 300 rev/min FSW. This corre-
sponded with the decrease in eddy current
measurements as the volume fraction of
large Cu-rich particles decreased. This was
also consistent with predominant coarsen-
ing of the phase at lower revs/min and
greater dissolution at the higher revs/min.
To investigate the details of the precip-
itate state, TEM images were obtained as
summarized in Figs. 1113 for FSWs at
150, 200, and 300 rev/min respectively. At
150 and 200 rev/min, a mixed precipitate
state was observed, which included a range
of large Cu-rich precipitates that were
identified as CuAl
2
or phase. Smaller
disc-shaped strengthening precipitates,
ranging from 2050 nm, were also ob-
served in Fig. 11, which coarsen to 50 to
150 nm in Fig. 12. In Fig. 13, for the 300
rev/min specimen, a more uniform coars-
ening of the smaller precipitates was ob-
served, which was also observed in the
superlattice reflections in the accompany-
ing SAD pattern of Fig. 13C due to in-
creased volume fraction (Ref. 20). The
microstructure of the 300 rev/min speci-
men showed almost none of the larger
overaged phase or CuAl
2
precipitates as
compared with Figs. 11 and 12. Instead,
the microstructure was similar to that of
JANUARY 2013, VOL. 92 16-s
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Fig. 9 Histograms of current density from indents performed within the weld nugget and at the outer edge of each sample. High current density outliers are linked
to the presence of Cu-rich precipitates.
Fig. 10 Piezo-automation results confirming higher current density for indents placed on Cu-rich
precipitates.
Table 5 FSW Temperatures Calculated
Using the Alternative Heat Index
Specimen Calculated Temperature
(C)
150 523
200 532
300 542
F
r
e
q
u
e
n
c
y
O
c
c
u
r
e
n
c
e
F
r
e
q
u
e
n
c
y
O
c
c
u
r
e
n
c
e
F
r
e
q
u
e
n
c
y
O
c
c
u
r
e
n
c
e
150 RPM
200 RPM
300 RPM
Schneider 1-13_Layout 1 12/13/12 1:00 PM Page 16
the base metal shown in Fig. 5.
To obtain a bulk characterization of
the precipitate state in the FSW nugget,
corresponding XRD analysis was also
conducted. The XRD data are summa-
rized in Fig. 14 with the minor peaks
identified as the stable phase (Ref. 59).
The phase peaks increased in intensity
for the SZ of the 150 rev/min weld shown
in Fig. 14B, decreased in intensity in Fig.
14C of the 200 rev/min weld, with further
reductions in the 300 rev/min weld in Fig.
14D, which were similar in intensity to
the base metal in Fig. 14A. This bulk
XRD analysis was in agreement with the
TEM images in Figs. 1113.
Using the torque data from the FSW
panels, an alternative heat index (Ref. 27)
was used to calculate the FSW tempera-
tures as summarized in Table 5. The calcu-
lated temperatures ranged from 0.860.88
T
m
, corresponding to the empirically pub-
lished range of 0.800.90 T
m
for FSW of
AA2xxx alloys (Refs. 1, 2, 1420). The phase
diagram in Fig. 4 for Al-Cu binary system
showed the nominal 6.30% Cu alloy was
slightly above the maximum solid solubility
composition. The and phases can form
a eutectic at a composition of 33.2 wt-% Cu
with a eutectic temperature of 548C. The
calculated temperatures were in agreement
with experimental studies that showed an
increase in peak temperature as the tool ro-
tation increased. However, whether the
small amount of temperature difference was
responsible for the variations observed in
the microstructure is questionable. Rather
than a critical temperature threshold being
crossed, it was proposed that only the ma-
terial flow that crosses the severe shear zone
into the SZ experiences heating rates that
drive the stable phase into dissolution.
Since a constant tool travel was maintained,
the corresponding higher shear strain rate
in addition to the higher tool rotation re-
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Fig. 11 A and B TEM images of the 150 rev/min FSW specimen; C corresponding SAD pattern for the [100]
Al
zone axis of the aluminum matrix.
Fig. 12 A and B TEM images of the 200 rev/min FSW specimen; C corresponding SAD pattern for the [100]
Al
zone axis of the aluminum matrix.
Fig. 13 A and B TEM images of the 300 rev/minFSW specimen; C corresponding SAD pattern for the [100] zone axis of the aluminum matrix. Note
the superlattice reflections in the SAD pattern corresponding to the ' phase.
A
B
C
A
B
C
A B
C
Schneider 1-13_Layout 1 12/13/12 1:10 PM Page 17
sulted in this material staying at tempera-
ture longer. Thus, the high heating rate in-
crease combined with a longer time at
temperature at 300 rev/min resulted in the
dissolution that replenished the solute in
the supersaturated phase for postweld
natural aging.
Based on the macro and micro scale
data, the SZ of the FSW had a mixed state
of stable and metastable Cu-rich phases. To
obtain both dissolved larger particles and
coarsened small particles implied that the
material was subjected to two different tem-
perature fields (Refs. 56, 57). This was ex-
plained using the kinematic model for FSW
in which some material flow lines near the
weld tool crossed a severe high shear rate
region while other material flow lines fur-
ther from the weld tool were subjected to
lower shear rates and hence lower temper-
ature (Refs. 11, 49, 56, 57).
Other researchers have observed de-
creased second phase particle size in the
FSW microstructure corresponding with in-
creased tool rev/min, which was attributed
to fragmentation resulting from the shear-
ing action of the material flow in the FSW
process (Refs. 60, 61). Although agglomer-
ation of particles have also been reported
in a study at higher tool revs/min (Ref. 40),
in addition to a study on second pass repair
FSWs (Ref. 38).
The results in this study were consistent
with another study on the microstructural
evolution in AA2219-T87 (Ref. 15). Al-
though that study (Ref. 15) only reported
one set of unknown FSW parameters, sim-
ilar FSW strengths and precipitate state
were reported that align with the results of
the 200 rev/min specimen in this study. Cor-
relation of microstructural evolution with
the FSW temperature relied on the use of
thermocouples mounted away from the SZ
(Ref. 15). The measured temperature was
extrapolated to the SZ resulting in a esti-
mated value of 475C or 0.8 T
m
, which is
lower than the 532C or 0.86 T
m
tempera-
ture calculated from the FSW data in this
study for the shear zone.
Conclusions
In all the FSWs, a coarsening of the
phase was observed that resulted in the
decreased SZ hardness and tensile
strength. The solute lost from the -ma-
trix due to the coarsening of the phases
was eventually replaced by the dissolution
of the phase at the higher tool rotation,
which promoted postweld natural aging.
Occurrence of coexisting coarsened and
phases in the SZ result from the com-
bined effect of two flow streams of metal,
which were subjected to different thermo-
mechanical processing conditions. Thus,
only the metal flow stream that crossed the
severe shear zone experienced either
higher temperatures or more severe shear
as influenced by the tool rotation. At
higher revs/min, the material also remains
around the tool for a longer time, which
suggests time at temperature was also crit-
ical to the final precipitate state.
Using the alternative heat indexing
method, the calculated temperature at 300
rev/min was estimated to be 542C, which
was close to the 548C eutectic temperature
shown on the Al-Cu phase diagram in Fig.
3. This provided a temperature rate suffi-
cient for up-quenching to dissolve the
phase in the FSW nugget region, but in-
sufficient temperature to cause spontaneous
melting of the phase. The resulting mi-
crostructure was similar to the base metal in
conductivity as shown in Fig. 10 and hard-
ness as shown in Fig. 8. While the calculated
temperatures for the shear zone were not
extreme over the range of FSW parameters
investigated, they did highlight a region
where critical changes in the microstructure
in the SZ occurred. It was speculated that
further increases in FSW rev/min may result
in liquation as evidenced by a drop in weld
power or torque. These FSWs were not per-
formed as higher rev/min conditions in com-
bination with the tool used in this study have
resulted in voids.
The results of these experiments
showed that processing parameters of
FSW have a strong impact on precipitate
position and dispersion, affecting localized
mechanical and electrical properties. Due
to the nonhomogeneity of the resulting
FSW SZ, microscale hardness and con-
ductivity measurements were useful in un-
derstanding the effect of precipitate state
on the resulting electrical properties.
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Introduction
Ship structures are subject to a com-
plex dynamic loading during service that is
superimposed on residual stress present as
a result of fitup and fabrication. There-
fore, high-performance steels for ship
structure applications have been a con-
stant goal pursued by the United States
Navy. In order to meet the requirement
for good combination of high strength and
low-temperature fracture toughness,
high-yield-strength steels (HY series) and
high-strength, low-alloy steels (HSLA se-
ries) have been under development by the
Navy for the last 50 years. Among them,
HY-100, HSLA-100, and HSLA-65 are
used extensively in surface ship and sub-
marine construction today, and they will
continue to be the principal structural ma-
terials in the foreseeable future (Refs.
13).
Navy shipbuilding has been heavily re-
liant on welding as a fabrication tech-
nique, and it has been of great practical
importance to conduct weldability testing
of steels. Among various weldability issues
of high-strength steels, hydrogen-induced
cracking (HIC) (also referred as cold
cracking) in the heat-affected zone
(HAZ) following welding is of concern
(Refs. 46), and thereby it is important to
evaluate the naval steels susceptibility to
HAZ HIC. Within the HAZ, the coarse-
grained HAZ (CGHAZ) is the most sus-
ceptible to formation of untempered
martensite with coarse grain size (Refs. 7,
8), and therefore potentially the most sus-
ceptible to HIC (Ref. 9). Based on the
strong microstructure influence on HIC,
CCT diagrams for the CGHAZ of HY-
100, HSLA-100, and HSLA-65 have been
constructed, as described in an earlier
publication (Ref. 10). In parallel with that
study, the susceptibility to HIC has been
evaluated for the same three steels.
In the present investigation, the im-
plant test is used to evaluate susceptibility
to HIC. The microstructure of the weld
CGHAZ from this test is characterized,
and fractography is conducted to illustrate
the HIC fracture behavior. The HIC test
experimental results will be used to de-
velop a weldability database of current
Navy steels, which can serve as a bench-
mark for the future development of high-
performance steels.
Materials and Experimental
Procedure
HY-100, HSLA-100, and HSLA-65
were provided in the form of rolled plate
by the Naval Surface Warfare Center,
Carderock Division, West Bethesda, Md.
Table 1 summarizes the chemical compo-
sitions of the three steels used in this in-
vestigation. The steel plates were ma-
chined into the implant specimens, whose
dimensions are listed in Table 2.
The implant test used in the present in-
vestigation was first developed by Henri
Granjon at the Institut de Soudure
(French Welding Institute) (Ref. 11). In
the implant test, a cylindrical sample with
a 0.5-in.- (12.7-mm-) long 10-32 UNF
thread on one end is inserted into a clear-
ance hole in the center of the specimen
plate. The other end with a 0.5-in.- (12.7-
mm-) long 1/4-20 UNC thread is inserted
into a threaded connection rod of the
loading system so that it is possible to
apply a tensile load on the specimen after
welding. A weld bead was then deposited
on the top surface of the specimen plate
directly over the threaded sample and
hole, creating a HAZ in the 10-32 UNF
thread region, as shown in Fig. 1.
The thread serves to create a stress
concentration in the HAZ region, thereby
causing HIC to occur in the HAZ instead
of the fusion zone. Two minutes after com-
pletion of welding, the sample is loaded in
tension when the temperature of the weld
assembly is in the range of 100150C.
The tensile load is provided by The Ohio
State University Modified Implant Testing
System (OSU-MITS), as shown in Fig. 2,
which was specially designed and built to
Evaluation of Heat-Affected Zone
Hydrogen-Induced Cracking in Navy Steels
The implant test was conducted on HY-100, HSLA-100, and HSLA-65,
plus the hydrogen-induced cracking susceptibility was quantitatively evaluated
BY X. YUE AND J. C. LIPPOLD
KEYWORDS
Implant Test
Hydrogen-Induced Cracking
CGHAZ Microstructure
Fracture Behavior
HSLA-100
HY-100
HSLA-65
X. YUE (yuexinosu@gmail.com) and J. C. LIP-
POLD are with the Welding Engineering Program
at The Ohio State University, Columbus, Ohio.
Based on a paper presented at FABTECH 2012 in
Las Vegas, Nev., November 1214, 2012.
ABSTRACT
The implant test was conducted on HY-100, HSLA-100, and HSLA-65 to evaluate
their susceptibility to heat-affected zone (HAZ) hydrogen-induced cracking (HIC).
The stress vs. time to failure curve was plotted, and the normalized critical stress ratio
(NCSR) and embrittlement index for each steel were determined, which can be used to
quantitatively evaluate HIC susceptibility. The coarse-grained HAZ (CGHAZ) mi-
crostructure of the three steels was characterized by means of optical and transmission
electron microscopy. In addition, SEM fractography was conducted to study the HIC
fracture behavior. Intergranular (IG), quasi-cleavage (QC), and microvoid coalescence
(MVC) fracture modes were found to occur sequentially during the crack initiation and
propagation process. The fracture behavior observed in the present investigation is in
good agreement with Beachems model. It can be concluded based on the implant test
results that, among the three steels, HY-100 is the most susceptible to HAZ HIC while
HSLA-100 and HSLA-65 exhibit good resistance. The difference in the HIC suscepti-
bility of the three steels is further explained by combining the microstructure charac-
terization of the CGHAZ and fracture behavior. These results can serve as a bench-
mark for the future development of high-performance Navy steels.
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:52 AM Page 20
accurately control loading during the test.
The design of the OSU-MITS ensures the
implant specimen is free of bending, tor-
sion, or shock loading. It has the capabil-
ity of providing tensile loads of up to
10,000 lb (4500 kg), and the entire system
is easily moved. The times to failure for a
series of tests performed at various stress
levels were recorded by a computer
equipped with a data-acquisition system
connected to the OSU-MITS. The load
(stress) applied is then plotted against the
time to failure. The highest stress at which
no failure occurs after 24 h loading is de-
fined as the lower critical stress (LCS),
which is taken as an index to determine
susceptibility to HIC.
Flux cored arc welding (FCAW) was
used to deposit the weld bead on the top
surface of the specimen plates. The weld-
ing consumable used was the 0.047 in. (1.2
mm) Pipeliner111M (AWS E111T1-
GM) provided by The Lincoln Electric Co.
Welding parameters were as follows: 25 V,
current 225235 A, travel speed 12 in./min
(5.1 mm/s), and wire feed speed 300
in./min (127 mm/s). This corresponds to a
heat input in the range of 28.1 to 29.4
kJ/in. (1.11 to 1.16 kJ/mm). Ar + 25%CO
2
is the recommended shielding gas for this
consumable; however, in order to mini-
mize the hydrogen loss, pure argon at a
flow rate of 45 ft
3
/h (21.2 L/min) was used
instead.
Welding with this consumable can pro-
duce diffusible hydrogen content in the
range of 45 mL/100 g for typical perform-
ance as stated in the product specification.
Previous tests show that cracking did not
occur without intentional introduction of
diffusible hydrogen. Then, in order to in-
troduce sufficient diffusible hydrogen to
cause HIC in HAZ, a thin film of lubricat-
ing oil was applied evenly on the specimen
plate surface before welding, and the
amount of oil was carefully controlled each
time. This produced an average diffusible
hydrogen content of 8.1 mL/100 g (four
samples were tested with a standard devia-
tion of 0.2 mL/100 g), which was measured
using the gas chromatograph method in ac-
cordance with AWS A4.3.
Metallographic samples were sec-
tioned perpendicular to the welding direc-
tion through the axis of the implant speci-
mens. Then they were mounted, polished,
and etched with 5% nital and examined
using an optical microscope. The TEM
samples were evaluated in a Philips
CM200 TEM operated at 200 kV. Vickers
hardness measurements were conducted
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Fig. 1 Schematic drawing of the implant test.
Fig. 2 The OSU Modified Implant Testing System (OSU-MITS) and implant specimen. A
Full view of the testing system; B close-up view showing an implant specimen under loading and
an unloaded one on the top right corner; C the implant specimen.
Table 1 Chemical Composition of the Test Steels
Element (wt-%) HY-100 HSLA-100 HSLA-65
C 0.18 0.051 0.074
Mn 0.28 0.90 1.35
Si 0.21 0.25 0.24
P 0.008 0.008 0.011
S 0.002 0.002 0.006
Cu 0.15 1.17 0.25
Ni 2.32 1.58 0.34
Cr 1.37 0.60 0.14
Mo 0.26 0.37 0.06
V <0.01 <0.01 0.058
Nb <0.01 0.017 0.018
Ti <0.01 <0.01 0.012
A
B C
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:52 AM Page 21
on the as-polished samples using a 1-kg
load, in accordance with ASTM E 384-10.
Results and Discussion
Weld Macrostructure and Hardness
Figure 3 shows a transverse section of
a typical test weld taken along the axis of
the implant specimen. The fusion bound-
ary separating the weld metal and implant
specimen is clearly discernable. Due to the
excessive grain growth and possible for-
mation of susceptible (high hardness) mi-
crostructure, HIC will most likely occur in
the CGHAZ region, which is just adjacent
to the fusion boundary. Note that the
HAZ in the implant specimen is much
wider than that in the adjacent plate due
to the difference in heat flow and temper-
ature gradient.
Vickers hardness measurements were
taken along the axis of the implant speci-
mens of the three steels, as shown in Fig.
4AC. The hardness variation from weld
metal to HAZ and the base metal is ap-
parent with the hardness of the weld metal
is in the range of 360 to 380 HV. The
hardness of CGHAZ of HY-100 is
higher than that of the weld metal, which
is in the range of 420 to 440 HV. While
for HSLA-100 and HSLA-65, their
CGHAZ hardness is lower than the weld
metal, in the range of 325 to 340 HV and
300 to 317 HV, respectively. The location
of the CGHAZ, as shown in Fig. 4AC,
is determined by metallographic obser-
vation. It should be noted that the red dot-
ted line is only the approximate boundary
between the CGHAZ and adjacent fine-
grained HAZ (FGHAZ).
Microstructure Characterization of CGHAZ
of the Three Steels
Figure 5 shows the optical and TEM
bright-field microstructure of the
CGHAZ from the HY-100 implant speci-
men. Martensite forms in the CGHAZ of
this steel, and the packet of the martensite
laths (Ref. 12) can be seen in the higher
magnification TEM microstructure, as
shown in Fig. 5B. The dark thin film be-
tween martensite laths is probably re-
tained austenite (Refs. 13, 14). The for-
mation of lath martensite is consistent
with a CGHAZ in HY-100 with hardness
in the range of 420 to 440 HV.
The CGHAZ microstructure of
HSLA-100 is shown in Fig. 6AC. Marten-
site and bainite with a needle-like mor-
phology form in the CGHAZ as shown in
Fig. 6A. Similar to HY-100, because the
carbon content of HSLA-100 is relatively
low (0.051 wt-%), the martensite formed
is of the lath type, whose morphology is
clearly seen in Fig. 6B. It is shown in Fig.
6C that parallel laths with small intra-lath
platelet-like precipitates form in the mi-
crostructure. The precipitates are most
likely cementite, and they are directionally
oriented. This morphology is characteris-
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Fig. 3 Typical implant test specimen sectioned near the implant axis. HY-100. 5% nital etch.
Fig. 4 Vickers hardness measurements taken along
the axis of the implant specimen. A HY-100; B
HSLA-100; C HSLA-65.
Table 2 Specimen Plate/Implant Specimen Dimensions
Specimen Plate
Material A36 Steel
Plate thickness in. (mm) 0.5 (12.7)
Plate width in. (mm) 2 (50.8)
Plate length in. (mm) 4 (101.6)
Length of the test bead in. (mm) 3.5 (88.9)
Hole diameter in. (mm) 0.201 (5.1)
Implant Specimen
Material HY-100, HSLA-100, and HSLA-65
Total length of implant specimen in. (mm) 1 (25.4)
Type of thread 10-32 UNF
Pitch in. (mm) 1/32 (0.79)
Major diameter in. (mm) 0.1900 (4.83)
Minor diameter in. (mm) 0.1517 (3.85)
Thread length in. (mm) 0.5 (12.7)
Thread angle 60 deg
Thread root radius in. (mm) 0.004 (0.1)
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:53 AM Page 22
tic of lower bainite (Ref. 15). Therefore,
the HSLA-100 CGHAZ microstructure is
a mixture of lath martensite and bainite,
which has hardness in the range of 325 to
340 HV.
The CGHAZ microstructure of
HSLA-65 is shown in Fig. 7AC. It can be
seen in Fig. 7A that a small amount of fer-
rite forms along the prior austenite grain
boundaries. The morphology of packets of
parallel laths free of precipitates can be
seen in Fig. 7B, which is the feature of lath
martensite. Similar to HSLA-100, direc-
tionally aligned intra-lath cementite
platelets can be observed in Fig. 7C, which
confirms the presence of lower bainite.
The difference is that these cementite
platelets are coarser than the ones form-
ing in HSLA-100. The formation of a mix-
ture of ferrite, bainite, and martensite re-
sults in a HSLA-65 CGHAZ with the
lowest hardness (300 to 317 HV) among
the three steels.
The Implant Test Results
A series of composite weldments of
specimen plates and steel implants
welded with the same parameters was
subject to different levels of tensile load-
ing after welding, and the time to failure
at each stress level was recorded. These
data were used to generate the implant
test curves for the three steels, as shown
in Fig. 8AC. The tensile stress is equal
to the load divided by the cross-sectional
area of the root diameter of the 10-32
thread. Because the lower critical stress
(LCS) is an important index to quantify
HIC susceptibility, tests run at the high-
est stress at which the implant specimen
does not fail after 24 h tensile loading
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Fig. 5 CGHAZ microstructure of HY-100. A Optical; B bright-field TEM.
Table 3 Implant Test Results
Steel CGHAZ Max CGHAZ Tensile Lower Critical Nominal Yield NCSR
b
Embrittlement
Hardness Strength
a
Stress Strength Index
c
(HV) ksi (MPa) ksi (MPa) ksi (MPa)
HY-100 440 212 (1462) 72 (496) 100 (689) 0.72 0.34
HSLA-100 340 154 (1062) 83(572) 100 (689) 0.83 0.54
HSLA-65 317 145 (1000) 76 (524) 65 (448) 1.17 0.52
(a) The CGHAZ tensile strength is converted from the CGHAZ max hardness using the ASTM hardess conversion chart.
(b) NCSR stands for normalized critical stress ratio, which is the ratio of lower critical stress to nominal yield strength.
(c) Embrittlement index is the ratio of lower critical stress to the CGHAZ tensile strength.
Fig. 6 CGHAZ microstructure of HSLA-100. A Optical; B and C bright-field TEM.
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:53 AM Page 23
were repeated twice to verify the LCS.
The delayed nature of HIC can be seen
from Fig. 8AC, and, as expected, there
is a longer incubation time before im-
plant specimen fracture with lower ap-
plied stress levels. It is also found that at
comparable stress levels, the incubation
time of HY-100 is shorter than that of
HSLA-100.
The implant test results for the three
steels are provided in Table 3. The LCS is
determined to be 72 ksi (496 MPa), 83 ksi
(572 MPa), and 76 ksi (524 MPa) for HY-
100, HSLA-100, and HSLA-65, respec-
tively. Because the three steels have dif-
ferent strength levels, a normalization
procedure for critical stress is required.
Also, in order to avoid the effect of vari-
ation in notch tensile stress on quantita-
tively rating HIC susceptibility, instead of
using the embrittlement index used by
Sawhill (Ref. 16), a normalized critical
stress ratio (NCSR) is used in the present
investigation. This is simply the ratio of
LCS to nominal yield strength of the test
steels (Ref. 17). Therefore, an exact
measure of HIC on percent degradation
from nominal yield strength could be de-
termined. As the nominal yield strength
is 100 ksi (689 MPa), 100 ksi (689 MPa),
and 65 ksi (448 MPa) for HY-100, HSLA-
100, and HSLA-65, respectively. The
NCSR is determined accordingly to be
0.72, 0.83, and 1.17 for HY-100, HSLA-
100, and HSLA-65, respectively.
Beside the NCSR, a new embrittle-
ment index, which is the ratio of the lower
critical stress to CGHAZ tensile
strength, is proposed in the present in-
vestigation to compare the HIC suscepti-
bility of the three steels. Due to marten-
site formation in the CGHAZ, the
maximum CGHAZ hardnesses is 440,
340, and 317 HV for HY-100, HSLA-100,
and HSLA-65, respectively. And they are
much higher than the three steels re-
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Fig. 7 CGHAZ microstructure of HSLA-65. A Optical; B and C bright-field TEM.
Fig. 9 Fracture morphology of HY-100 implant specimen at a stress level of 91.3 ksi (629 MPa) that
failed after 3 min of loading. A General fracture appearance (white arrow indicates the direction of
crack growth); B region I (IG); C region II (QC); D region II (MVC).
Fig. 8 The implant test result curves of the following: A HY-100; B HSLA-100; C HSLA-65.
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 10:15 AM Page 24
spective base metal hardnesses, which
are 283, 284, and 201 HV for HY-100,
HSLA-100, and HSLA-65, respectively.
That means the weld CGHAZ has a
higher tensile strength than the base
metal for the three steels. If the tensile
strength of the CGHAZ can be deter-
mined, then the influence of diffusible
hydrogen on the CGHAZ degradation
can be expressed by the ratio of lower
critical stress to CGHAZ tensile
strength. However, it is difficult to meas-
ure the CGHAZ tensile strength directly
from the implant test, that is because if no
hydrogen is introduced into the weld, the
failure will occur in the lower strength
base metal rather than in the higher-
strength CGHAZ. As a result, the maxi-
mum CGHAZ hardness is converted into
the CGHAZ tensile strength according
to the ASTM hardness conversion chart,
which are determined to be 212 ksi (1462
MPa), 154 ksi (1062 MPa), and 145 ksi
(1000 MPa) for HY-100, HSLA-100, and
HSLA-65, respectively. The embrittle-
ment index is determined accordingly to
be 0.34, 0.54, and 0.52 for HY-100,
HSLA-100, and HSLA-65, respectively.
The higher the embrittlement index, the
lower the HIC susceptibility, which
means the degradation of CGHAZ ten-
sile strength due to diffusible hydrogen is
not serious. Note that the CGHAZ ten-
sile strength is not experimentally deter-
mined but only an approximation; how-
ever, it can still be used as an index to
evaluate the steels HIC susceptibility.
Based on the above implant test re-
sults, both the NCSR and embrittlement
index show that HY-100 undergoes the
most serious degradation due to the ef-
fect of diffusible hydrogen among the
three steels, while HSLA-100 and HSLA-
65 are less susceptible to HIC compared
with HY-100. For HSLA-100 and HSLA-
65, their embrittlement index is almost
the same, that is because of their rela-
tively lower carbon and alloy addition
(lower hardenability as shown in Table 3,
Ref. 10) as well as their finer grain size
compared with HY-100. However, it
should be noted that NCSR of HSLA-65
(1.17) is higher than that of HSLA-100
(0.83), which means the CGHAZ degra-
dation from base metal yield strength due
to the effect of diffusible hydrogen for
HSLA-100 is more severe than HSLA-65.
Thereby, it indicates HSLA-65 has better
resistance to HIC than HSLA-100.
Fracture Behavior
Figure 9AD shows the fracture mor-
phology of the HY-100 implant specimen
at a stress level of 91.3 ksi (629 MPa) that
failed after 3 min of loading. It shows that
the fracture surface can be divided into
three regions, which are region I, region
II, and final failure region. Region I is in
close vicinity to the thread root, where the
highest stress concentration exists. A
coarse intergranular (IG) fracture mode is
dominant in region I, where the grain size
is in the range of 7090 m as shown in
Fig. 9B. It can be concluded that cracking
initiates in the location where CGHAZ
and thread root coincides, or somewhere
closely behind the thread root (Ref. 18), as
a result of stress concentration as well as
the presence of coarse-grained lath
martensite in the CGHAZ. The white
arrow in Fig. 9A indicates the crack prop-
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failed after 12 min of loading. A General fracture appearance (white arrow indicates the direction of
crack growth); B region I (IG); C region II (QC); D region II (MVC).
Fig. 11 Fracture morphology of HSLA-100 implant specimen at a stress level of 102.4 ksi (706 MPa)
that failed after 1.5 min of loading. A General fracture appearance (white arrow indicates the direc-
tion of crack growth); B region I (IG); C region II (QC); D region II (MVC).
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:53 AM Page 25
agation direction. As the crack propa-
gates, region II with different features is
shown on the fracture surface. Both quasi-
cleavage (QC) and microvoid coalescence
(MVC) can be observed in region II,
which are shown in Fig. 9C and D. With
further propagation, overload failure will
take place. Note that the boundaries sep-
arating the three regions are not distinct,
and the division of the fracture surface is
based on the fracture morphology.
Figure 10AD shows the fracture mor-
phology of an HY-100 implant specimen
at a stress level of 80.3 ksi (554 MPa) that
failed after 12 min of loading. Similar to
the sample shown in Fig. 9, three distinct
regions can also be seen on the fracture
surface. The fracture mode at crack initi-
ation in region I is essentially intergranu-
lar. Again, it is shown that the CGHAZ is
the most susceptible to HIC among the
HAZ regions. Relative to the previous
sample, a small difference in fracture mor-
phology exists in that the area of IG fail-
ure increases with decreasing the tensile
loading. Both QC and MVC can be ob-
served in region II, as shown in Fig. 10C
and D.
The fracture morphology of an HSLA-
100 implant specimen at a stress level of
102.4 ksi (706 MPa) that failed after 1.5
min is shown in Fig. 11AD. Similar to
HY-100, the fracture surface can also be
divided into three regions as shown in Fig.
11A. Region I with predominant IG frac-
ture can only be observed in a small area
close to the thread root, as shown in Fig.
11B. In addition to the clear faceted IG
shown on the fracture surface, the prior
austenite grain boundary can also be ob-
served on the thread surface, and it is con-
tinuous across the boundary separating
the fracture surface and thread surface. It
shows that cracking initiates in the
CGHAZ when a critical amount of hydro-
gen diffuses to the stress concentration
area. The prior austenite grain boundary
becomes the weak link under the influ-
ence of both hydrogen and stress so that
the relative grain boundary sliding occurs
in the CGHAZ. That is why the prior
austenite grain boundary can be observed
on the thread surface. In region II, both
QC and MVC fracture modes can be ob-
served as shown in Fig. 11C and D.
By decreasing the tensile stress in
HSLA-100 to 85.8 ksi (592 MPa), the im-
plant specimen failed after 60 min of load-
ing. The fracture morphology of this sam-
ple is shown in Fig. 12AD. It is shown in
Fig. 12B that IG fracture can be observed
in a small area of region I. Both QC and
MVC can be observed in region II, as
shown in Fig. 12C and D.
The fracture morphology of the
HSLA-65 implant specimen is shown in
Fig. 13AD. As shown in Fig. 13B, there is
some faceted IG fracture with a smaller
grain size in region I near the thread root
even though it is not so clear as compared
to the fracture surface of the HY-100
specimen. This is probably because of the
mixture of ferrite, bainite, and martensite
in the CGHAZ. In region II adjacent to re-
gion I, both QC and MVC can be ob-
served, as shown in Fig. 13C and D.
The occurrence of IG, QC, and MVC
fracture modes on the fracture surface
can be explained using Beachems model
(Refs. 19, 20), as shown in Fig. 14. As-
JANUARY 2013, VOL. 92 26-s
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Fig. 12 Fracture morphology of HSLA-100 implant specimen at a stress level of 85.8 ksi (592 MPa)
that failed after 60 min of loading. A General fracture appearance (white arrow indicates the direction
of crack growth); B region I (IG); C region II (QC); D region II (MVC).
Fig. 13 Fracture morphology of HSLA-65 implant specimen at a stress level of 77.5 ksi (534 MPa) that
failed after 23 min of loading. A General fracture appearance (white arrow indicates the direction of
crack growth); B region I; C region II (QC); D region II (MVC).
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:53 AM Page 26
sume when the implant specimen is sub-
ject to loading after welding, the combi-
nation of stress intensity factor and hy-
drogen concentration at the crack tip
corresponds to point a in Fig. 14. The hy-
drogen concentration is not sufficient to
initiate a crack, so cracking will not occur
immediately. During the incubation pe-
riod, atomic hydrogen continuously dif-
fuses to the triaxially stressed region, and
after some time, it will reach the critical
level indicated by point b in Fig. 14. A
crack will then be initiated in the
CGHAZ and grow intergranularly. As
the crack propagates, the stress intensity
factor increases while the hydrogen level
decreases to point c, promoting a QC
fracture mode. As the crack continues to
grow, and if the combination of stress in-
tensity factor and hydrogen concentra-
tion reaches point d, the fracture mode
will change to MVC. If the stress inten-
sity factor continues to increase to the
critical value K
C
, ultimate failure will
take place.
Microstructure and the fracture be-
havior taken together can explain the dif-
ference in HIC susceptibility of the three
steels. As shown from fractography,
cracking will always initiate in the
CGHAZ, and the intergranular fracture
occurs first. For the same welding condi-
tions, the HY-100 CGHAZ microstruc-
ture is high-hardness (420 to 440 HV)
martensite, while a mixture of bainite and
martensite with lower hardness (325 to
340 HV) forms in the HSLA-100
CGHAZ. For HSLA-65, the CGHAZ has
the lowest hardness (300 to 317 HV)
among the three steels as a result of the
presence of ferrite, bainite, and marten-
site.
It has been shown previously (Ref. 10)
that the prior austenite grain size is the
largest in HY-100, and the smallest in
HSLA-65, with HSLA-100 intermediate.
Based on the fracture surface observa-
tions from the implant tests, HY-100 has
the coarsest IG fracture and the largest
area of IG fracture region among the
three steels, while both of these features
are the smallest for HSLA-65. As a result
of different grain size, microstructure
and associated hardness of the CGHAZ
at the same welding condition, the HIC
susceptibility of the three steels is differ-
ent, which is indicated by the value of
NCSR and embrittlement index of the
three steels. Therefore, it can be con-
cluded that HY-100 is the most suscepti-
ble to HIC among the three steels, while
HSLA-65 is the least.
Conclusions
The results of the present investigation
can be summarized as follows:
1. In the present welding condition, the
hardness of the CGHAZ is in the range of
420440, 325340, and 300317 HV for
HY-100, HSLA-100, and HSLA-65, re-
spectively.
2. Lath martensite with a thin film of
retained austenite is observed in the
CGHAZ of HY-100. For HSLA-100, lath
martensite and bainite form in the
CGHAZ. While for HSLA-65, a mixture
of ferrite, bainite, and martensite forms in
the CGHAZ.
3. When the average diffusible hydro-
gen content is 8.1 mL/100 g, the lower crit-
ical stress (LCS) is 72 ksi (496 MPa), 83 ksi
(572 MPa), and 76 ksi (524 MPa) for HY-
100, HSLA-100, and HSLA-65, respec-
tively. The normalized critical stress ratio
(NCSR) is determined accordingly to be
0.72, 0.83, and 1.17 for HY-100, HSLA-
100, and HSLA-65, respectively.
4. A new embrittlement index is pro-
posed, that is the ratio of the LCS and
tensile strength of the CGHAZ, which is
approximated by the hardness. Using this
approach, the embrittlement index is de-
termined to be 0.34, 0.54, and 0.52 for
HY-100, HSLA-100, and HSLA-65,
respectively.
5. Based on morphology and fracture
mode, the fracture surface of the three
steels can be divided into three regions.
In region I, the crack will initiate in the
CGHAZ and grow intergranularly. Both
quasi-cleavage (QC) and microvoid coa-
lescence (MVC) can be observed in re-
gion II. Final failure occurs under over-
load conditions.
6. As the crack initiates and propa-
gates, IG, QC, and MVC fracture mode
will occur in sequence. The observation
of the three fracture modes on the frac-
ture surface can be explained using
Beachems model.
7. Among the three steels, HY-100 has
the coarsest IG fracture and the largest
area of IG fracture, while both of these
are the smallest for HSLA-65.
8. Based on the implant test results,
HY-100 is the most susceptible to HIC
because of the formation of a high-hard-
ness martensitic microstructure and large
prior austenite grain size in the CGHAZ.
HSLA-100 is less susceptible as a result of
formation of bainite and martensite with
lower hardness and smaller grain size.
HSLA-65 shows resistance to HIC, re-
sulting from the mixture of ferrite, bai-
nite, and martensite with the lowest hard-
ness and smallest grain size in the
CGHAZ.
Acknowledgments
The authors gratefully acknowledge the
financial support of the Office of Naval Re-
search, Award No. N000140811000. Grant
Officers: Dr. Julie Christodoulou and Dr.
William Mullins.
The authors would also like to thank
Johnnie DeLoach, Matthew Sinfield, and
Jeffrey Farren with the Naval Surface War-
fare Center Carderock Division, West
Bethesda, Md., for providing the steels used
in this study and valuable discussions re-
garding the weldability of these steels. De-
jian Liu and Geoffrey Taber are acknowl-
edged for their constructive ideas and help
on building the implant testing system.
In addition, Badri Narayanan, John
Procario, and Garr Eberle with The Lin-
27-s WELDING JOURNAL
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Fig. 14 Combined effect of stress intensity factor and hydrogen concentration at crack tip on the frac-
ture mode.
Yue and Lippold Supplement January 2013 corr_Layout 1 12/13/12 9:53 AM Page 27
coln Electric Co. are thanked for provid-
ing the Pipeliner111M welding consum-
able used in the implant test.
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