JULY 2018

Summer
Welding
Projects
Fabrication
Update
Cordless Tools
American Welder:
Celebrating Welding’s
Diverse Population
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
July 2018 • Volume 97 • Number 7 CONTENTS
FEATURES
34 Evaluating FCAW-G Electrodes
A fabricator discusses what he has learned about 44
gas-shielded flux cored arc welding electrodes
B. Gulas

38 Projects You Can Do This Summer

Use these instructions to help you tap into your
creative side — K. Campbell

44 Cordless Tools for Today’s Fab Shops

Today’s battery technology provides cordless tools
with more power and performance in a lighter,
smaller package — A. Derché

THE AMERICAN WELDER

84 Women Who Weld®: Lighting the Way Out of 88 Women Welders Behind the Arc
Poverty These female industry veterans offer support,
Classes through Women Who Weld are a first step advice, and serve as role models for younger
toward well-paying jobs in the Detroit, Mich., area women wanting to enter the welding industry
K. Pacheco K. Astin

84 88

WELDING RESEARCH SUPPLEMENT

207-s Characterization of P92 Steel Weldments in
As-Welded and PWHT Conditions
Postweld heat treatment resulted in enhanced
ductility of shielded metal arc welded P92 steel
joints — N. Saini et al.
214-s Fiber Laser Welding of 1700-MPa,
Ultrahigh-Strength Steel
Welding speed was the dominant factor that
affected appearance quality in these ultrahigh-
strength steel laser welded joints — C. Luo et al.

JULY 2018 / WELDING JOURNAL 3

DEPARTMENTS
6 Editorial 54 Certification Schedule
8 Press Time News 55 Society News
10 International Update 57 Tech Topics
12 News of the Industry 63 Section News
18 Business Briefs 80 Guide to AWS Services
20 Laser Welding Q&A 82 Personnel
22 Stainless Q&A American Welder
26 RWMA Q&A 92 Learning Track
28 Product & Print Spotlight 96 Fact Sheet
48 Conferences 99 Classifieds
50 Coming Events 100 Advertiser Index On the cover: Metropolitan
Community College Welding
Student Nora Cobb practices her
grinding skills on pipe. (Courtesy
of Alex Matzke.)

OFFICERS WELDING JOURNAL

President Dale Flood
TRI TOOL Inc.
Vice President Thomas J. Lienert
Los Alamos National Laboratory
Vice President Robert Roth
RoMan Manufacturing Inc.
Vice President Richard Polanin
Illinois Central College
Treasurer Carey Chen
Cincinnati Incorporated
Executive Director and CEO Matt Miller
American Welding Society
DIRECTORS
T. Anderson (At Large), ITW Welding North America
U. Aschemeier (Dist. 7), Subsea Global Solutions
J. R. Bray (Past President), Affiliated Machinery Inc.
T. Brosio (Dist. 14), Major Tool & Machine
J. Burgess (Dist. 8), General Electric
D. A. Desrochers (Dist. 1), Old Colony RVTHS
D. L. Doench (At Large), Hobart Bros. Co.
D. K. Eck (At Large), Praxair Distribution Inc.
K. Fogleman (Dist. 16), Consultant
P. H. Gorman (Dist. 20), Retired
M. Hanson (Dist. 15), Consolidated Precision Products
S. A. Harris (Dist. 4), Altec Industries
R. L. Holdren (At Large), ARC Specialties
T. Holt (Dist. 18), Tech Corr USA Management
J Jones (Dist. 17), Harris Products Group
M. Krupnicki (Dist. 6), Mahany Welding Supply Co. Inc.
D. Lange (Dist. 12), Northeast Wisconsin Tech. College
S. Lindsey (Dist. 21), City of San Diego
J. T. Mahoney (Dist. 5), American Arc Inc.
S. M. McDaniel (Dist. 19), Big Bend Community College
D. L. McQuaid (Past President), D. L. McQuaid and
Associates Inc.
D. K. Miller (At Large), Lincoln Electric
S. Moran (Dist. 3), American Hydro Corp.
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
M. Sherman (Dist. 10), SW&E LLC
M. Skiles (Dist. 9), Airgas Inc.
W. J. Sperko (At Large), Sperko Engineering Services
K. Temme (Dist. 2), Matrix NAC
P. I. Temple (Dist. 11), Energy Wise Consulting LLC
J. A. Willard (Dist. 13), Kankakee Community College
Publisher/Editor Mary Ruth Johnsen
Editorial
Sr. Editor Cindy Weihl
Features Editor Kristin Campbell
Associate Editor Katie Pacheco
Assistant Editor Roline Pascal
Peer Review Coord. Sonia Aleman
Publisher Emeritus Jeff Weber
Design and Production
Production Manager Zaida Chavez
Assistant Production Manager Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
Sr. Advertising Sales Exec. Sandra Jorgensen
Sr. Advertising Sales Exec. Annette Delagrange
Manager of Sales Operations Lea Owen
Sr. Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Sonia Aleman
saleman@aws.org
MARKETING ADVISORY COUNCIL
(MAC)
D. Doench, Chair, Hobart Brothers Co.
S. Bartholomew, Vice Chair, ESAB Cutting Systems
S. Samuels, Secretary, American Welding Society
D. Brown, AGONOW
C. Coffey, The Lincoln Electric Co.
D. DeCorte, RoMan Mfg. Inc.
S. Fyffe, Astaras Inc.
L. Kvidahl, Ingalls Shipbuilding
D. Marquard, IBEDA Superflash Compressed
S. Moran, American Hydro
M. Muenzer, ORS Nasco
E. Norman, EDCO Industries LLC
R. Roth, RoMan Mfg. Inc.
F. Saenger, Consultant
M. Smickenbecker, Matheson
S. Smith, Weld-Aid Products
E. Stone, Weiler Corp.
A. Sepulveda, Hypertherm
D. Wilson, Wilson and Associates
T. Lienert, Los Alamos National Laboratory
J. Bray, Ex Officio, Affiliated Machinery Inc.
C. Chen, Ex Officio, Cincinnati Incorporated
M. Miller, Ex Officio, American Welding Society
aws.org
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and inclusion is essential to achieving excellence
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4 WELDING JOURNAL / JULY 2018

EDITORIAL
Got Robotic Welding Skills? Bring Out
Your Competitive Side
Welding competitions have been a part
of the welding industry for decades. They
not only provide opportunities for stu-
dents to showcase their welding skills to
their peers, but also to others in
attendance.
Typical welding competitions define
specific weld joints, materials, and posi-
tions to perform specified welding
processes. In this format, contestants
generally perform welding tasks individu-
ally. In the past few years, these competi-
tions have morphed into team events
Sean P. Moran where members will be charged with a
AWS District 3 Director task to either fabricate a specified project
or possibly a theme project with physical
size restrictions.
As the welding industry becomes more
focused on operational efficiencies, we’ve
seen a continued use of robotics and au-
tomation. With this in mind, the question
was presented as to the feasibility of con-
ducting a welding competition with the
use of robotics. Just like students who
develop personal skill sets to perform
manual welding, there are many students
who develop personal skill sets to operate
welding robots. Therefore, in an effort for
these students to showcase their skills,
the ability to offer a competition was
seen as feasible.
The Student Robotic Welding Compe-
“As the welding tition, sponsored by the American Weld-
industry becomes ing Society, started in 2016. I have served
as its chairman since its inception.
more focused on Even though it’s only the summer, fall
operational will be here before we know it. On Octo-
efficiencies, we’ve ber 9–11 at the RTP – Robotics Technolo-
seen a continued gy Park (alabamartp.org), in Tanner, Ala.,
use of robotics and near Huntsville, student contestants will
automation. With again have the chance to show their ro-
botic arc welding skills and knowledge
this in mind, the during a two-and-a-half day competition.
question was RTP provides factory training cells for
presented as to the each of the robot brands.
feasibility of The competition involves a series of
conducting a project-based activities, requiring hands-
on robotic skills, along with technology
welding competition fundamentals and industrial safety writ-
with the use of ten examinations. Each of the series of
robotics.” activities and written exams is based on a
2-h time frame.
Contestants are required to have a
thorough knowledge of robotic program-
ming, safety, and weld inspection. All
6 WELDING JOURNAL / JULY 2018
portions of the contest are judged on
comprehension, ability, and accuracy of
robot execution and quality of the com-
pleted welded project.
The welded project, which is assem-
bled and welded in a series of four activi-
ties and four different robotic cells, tests
the student’s ability to follow design
drawings and instruction, set up a series
of four individual robotic cells, program
all robot instructions, and define and use
correct welding parameters for weld size
requirements.
Also, this competition challenges stu-
dents with the concept of a specific proj-
ect-based objective and four different ro-
bot platforms. Each contestant is provid-
ed with a set of precut and formed mate-
rials along with a set of instructions to
construct a functioning object in a series
of four operations. Each of the operations
is performed on one of four different
brands of robots.
Competitors are challenged with the
call-outs of specific assembly instructions
for each robot operating system. The con-
cept of different robots demonstrates the
student’s ability to transfer the knowl-
edge of one operating system to another.
In addition to the contest project, each
competitor will be required to complete
two 50-question written examinations.
The first tests knowledge of safety con-
cepts for both welding and robot systems.
The second tests knowledge of the princi-
ples and practices of robotic systems as
well as the gas metal arc welding process.
The competition is open to all students
enrolled in an accredited institution that
provides instructional programs in robotic
arc welding through either secondary or
postsecondary educational institutions.
Contestants are required to submit a stu-
dent application for participation and a
prescreening evaluation test verifying basic
competency of robot safety and operations.
In addition to the requirement of being en-
rolled in an accredited institution, all stu-
dents are required to be under the age of
23 upon the date of the competition.
If you meet the requirements and
think you’ve got what it takes, why
not put your robotic welding skills to
the test by entering this upcoming
competition? WJ
PRESS TIME NEWS
Six Nations Polytechnic to Start
Welders Program for Low-Income
Women; Tuition-Free Training Provided
Six Nations Polytechnic, a postsecondary organization
established in Canada’s most populous First Nation, has re-
cently been approved for funding, up to a maximum of
$307,295 over two years, to start the We Are Welders Pro-
gram. This endeavor will be for low-income women, under
the Women’s Economic Security Program, and sponsored by
the Ontario Ministry of the Status of Women. Since opening
its Brantford Campus, located in Ont., Canada, in 2016,
staff have been working to identify and fulfill local needs in
Brantford, Brant County, and Six Nations for trades
workers.
The objective of this tuition-free program is to provide
soft and practical skills, safety training, technical skills, and
personal support for participants to gain local employment
as a welder. In addition, it will provide theory, hands-on,
and virtual training at the Brantford Campus.
“With three cohorts over two fiscal years, this project
aims to respond, quickly, to an increased demand for
welders by training and employing 30 new qualified welders
in the City of Brantford and Brant county region,” said Re-
becca Jamieson, president and CEO of Six Nations Polytech-
nic. “We know there is a gap in skilled trades workers locally,
and this program helps to fill part of that gap.”
The 28-week course is comprised of six modules includ-
ing career awareness, team building, soft and life skills,
welding, employment readiness and empowerment, and a
paid work placement. The curriculum content, with work-
shops and resources, aim to remove barriers, build confi-
dence, acquire skills, and prepare participants for a career as
a welder.
The first cohort was expected to start in June. Interested
applicants will soon be able to apply through Six Nations
Polytechnic and community agencies. For more details, visit
snpolytechnic.com.
ASM International Honors Weld Mold
On May 17, ASM
International, Materi-
als Park, Ohio, pre-
sented Weld Mold
Co., Brighton, Mich.,
its ASM Historical
Landmark Award for
2017. In attendance
Fred Schmidt (right), president, ASM for the event were
International, presents the 2017 His- ASM International
torical Landmark Award to Darryl dignitaries, represen-
Hammock, CEO, Weld Mold Co. tatives from the city
of Brighton and state
of Michigan, Weld
Mold officials and employees, and other guests.
Weld Mold was recognized for developing and innovating
the flood welding process for weld die repair. Matt Kiilunen
(1905-1990), its founder (1945), was personally responsible
for revolutionizing the process.
8 WELDING JOURNAL / JULY 2018
This historical landmark designation recognizes sites and
events that have played a prominent role in the discovery,
development, and growth of metals, metalworking, and all
engineered metals.
National Science Foundation Awards
Substantial Grant for Welder Education
Monroe County Community College (MCCC), Monroe,
Mich., has received a $224,906 grant from the National Sci-
ence Foundation, Alexandria, Va., for a project titled “Ad-
vanced Welder Education.” Its goal is to increase the region’s
supply of qualified welders, with advanced levels of education,
who can further research, develop, and innovate the field. The
three-year project is expected to end May 31, 2021.
“This award builds on the momentum created by four
years of grant-funded welding training completed by MCCC
earlier this decade through a $1.79 million Department of
Labor Community-Based Job Training Grant,” said Dr. Kojo
A. Quartey, MCCC president.
The community college will transition the offering of
entry-level welding instruction, known as American Welding
Society AWS-QC-10, to area high schools, according to
Parmeshwar Coomar, dean of MCCC’s applied science and
engineering technology division. It will still offer some
entry-level welding classes, yet its focus will be on teaching
advanced-level welding standards (AWS-QC-11) and incor-
porating the latest additions to these standards recently set
forth by AWS.
Partnering with local high school career and technical ed-
ucation instructors to help them implement the entry-level
welding (AWS-QC-10) standards at the high schools will
help MCCC develop a direct articulation credit pathway,
where students can earn up to ten credits toward MCCC’s
welding program while still in high school.
Miller Donates $10,000 to Nuts, Bolts
& Thingamajigs Foundation’s
Manufacturing Camp Grant Program
Miller Electric Mfg. Co. LLC, Appleton, Wis., is support-
ing twelve 2018 summer manufacturing camps in the state
of Wisconsin with a $10,000 donation to Nuts, Bolts &
Thingamajigs® (NBT), the Foundation of the Fabricators &
Manufacturers Association, Int’l.
The donation will allow approximately 200 students,
aged 12–16, to be introduced to the manufacturing process
from design through production. Camps allow students to
make something with their own hands, sparking their imag-
ination and encouraging them to consider a career in manu-
facturing. This summer, NBT will support a record number
of 90 camps across the United States.
“Miller Electric Mfg. Co. believes welding is a key process
to the future of manufacturing. We are proud to provide
camp and scholarship donations for the young people to
connect with a career in such fields. Welding is a key part to
the manufacturing economy, and we need these future lead-
ers to keep it going,” said Bruce Albrecht, vice president,
global innovation & technology, Miller Electric Mfg. Co.
LLC. WJ
INTERNATIONAL UPDATE
Training Center in Republic of Congo Launches
Plan to Modernize Vocational Training
The Don Bosco Vocational Training Center has implemented
a project to support the modernization of vocational training
by increasing teacher training, purchasing new equipment,
and creating new courses.
The Don Bosco Vocational Training Center in Brazzaville,
the capital of the Republic of Congo, has recently launched a
project to develop the skills of teachers, purchase new equip-
ment, and create new vocational training workshops. The
project, which officially launched in May and will run
through October, aims to improve teachers’ training and in-
crease student enrollment by 3000 over the next three
years.
To support teachers, Salesian missionaries will expand
the library, address current problems related to the trans-
port of teachers to and from school, and increase educator
salaries. The plan will also offer teachers scholarships to
continue their education and improve their skills.
Additionally, funding will be used to purchase new equip-
ment for courses in electrotechnical, air conditioning and
heating systems, lathing and welding, and carpentry. The
project will also purchase new tools for the creation of a
driving school within the auto mechanics course to ensure
graduating students pass the driver’s test and earn their dri-
ver’s license.
Lastly, the training center intends to start new courses
in construction, renewable energies, as well as maintenance
of computers and networks, electronic, and audiovisual
equipment.
Hyperloop Begins Construction of Passenger
and Freight System in France
Hyperloop Trans-
portation Technolo-
gies (HyperloopTT),
a California-based
transportation and
technology company,
has begun construc-
tion of a full-scale,
passenger-ready cap-
The full-scale Hyperloop tubes ar-
rive at the company’s Toulouse re- sule near its research
search and development center. and development
center in Toulouse,
10 WELDING JOURNAL / JULY 2018
France. The passenger-freight capsule is currently near com-
pletion at Carbures in Spain and scheduled for delivery to
the facility this summer for assembly and integration.
The two-phase process will begin with a closed 320-m
system that will be operational this year. A second, full-scale
system of 1 km elevated by pylons at a height of 5.8 m will
be completed in 2019.
“Five years ago, we set out to solve transportation’s most
pressing problems: efficiency, comfort, and speed. Today we
take an important step forward to begin to achieve that
goal,” said HyperloopTT CEO Dirk Ahlborn. “Hyperloop is
more than just displays of rapid acceleration and more than
just breaking speed records. The real opportunity is to create
an efficient and safe system with an unparalleled passenger
experience.”
Kemppi Unveils Robotic Welding
Application Center in China
Kemppi, headquar-
tered in Lahti, Fin-
land, has opened up a
robotic welding appli-
cation center in Kemp-
pi China’s subsidiary
facilities in Beijing,
China, to strengthen
its robotic welding
business and speed up
its growth in Asia.
The new Beijing-based Kemppi ro- The center is
botic welding application center is equipped with the
equipped with the company’s ro- company’s range of ro-
botic welding equipment. botic welding equip-
ment and robots from
well-known manufac-
turers. In the center, visitors can see the welding automa-
tion systems in action.
Robotic welding and Asia are both strategic focus areas for
Kemppi. Kemppi had its first deliveries to China already at the
end of the 1980s and has invested significantly in robotic
welding solution development during the past years. The ro-
botic welding application center is a natural next step in serv-
ing the important and fast-growing robotic welding markets in
China and Southeast Asia even better,” said Hannu Jokela, vice
president Asia Pacific and export sales, Kemppi Oy.
Xiris Opens European Office in Germany to
Better Support Local Customers
Xiris Automation Inc., Burlington, Ontario, Canada, a
provider of quality control solutions for welding and tube
and pipe industries, has opened a European sales and serv-
ice office in Ratingen, Germany, near Düsseldorf, to better
support its growing customer base in Europe.
As part of this initiative, the company will now be able to
offer annual recertification services of their weld inspection
systems used in the tube industry from the Ratingen office,
helping customers achieve optimal equipment performance
and drive quality assurance. WJ
NEWS OF THE INDUSTRY
Introducing the Newest AWS ATFs:
Performance Instruction & Training,
Elgin and Hampshire High Schools
Performance Instruction & Training (PIT), Mooresville,
N.C., along with Elgin High School (School District U-46),
Elgin, Ill., and Hampshire High School (District 300), Hamp-
shire, Ill., have earned the American Welding Society’s
(AWS) Accredited Test Facility (ATF) distinction. This pro-
gram establishes minimum requirements for test facilities,
their personnel, and equipment to qualify for accreditation
to test and qualify welders. Accredited Test Facilities also
play an integral part in the operation of the AWS Certified
Welding program, proving they have the resources to test
welders to this nationally recognized and accepted program.
PIT, founded in 2003, is a pit crew training facility owned
by Thomas C. DeLoach Jr. Realizing the need for welders in
racing and other industries, a curriculum was recently devel-
oped focusing on motorsports and more skill sets; this led to
“Pit Weld U Powered by Miller Welders,” a 16-week course.
Now, with PIT’s certified welder program, students and
experienced welders can test to be certified under specific
AWS codes. Companies can also certify or maintain certifica-
tion for their staff under AWS codes. “As one of only a few
ATFs in North Carolina, we have separated ourselves from
other schools offering welding programs, but [with] no op-
tion for AWS certification,” said Trent Schanen, PIT’s direc-
tor of event logistics and welding school operations.
“Currently, we’re offering certification testing dates
monthly, focusing primarily on testing under AWS D1.1 and
AWS D1.3 Codes, and will be diversifying in the near future.
As we grow, we’ll also offer on-site testing options,” Schanen
A student at Performance Instruction & Training, Mooresville,
N.C., perfects his technique. (Courtesy of Trent Schanen.)
12 WELDING JOURNAL / JULY 2018
At Elgin High School, Elgin, Ill., students try virtual-reality
welding. (Courtesy of Nick Moran.)
continued. “Furthermore, we plan to expand our welding
course offerings beyond our sole 16-week course, and per-
haps offer other welding services as well.”
In addition, both Elgin and Hampshire High Schools are
the second and third U.S. high school facilities to earn the
AWS ATF status.
“This credential will allow our welding program to offer
students an AWS welding certification test upon graduation,
putting them on a firm career path,” said Nick Moran, a
welding instructor and QA specialist for School District U-
46, who is also an AWS Certified Welding Inspector. “We
aim to make our students career ready, and able to begin
work in any field where welding skill is in demand.”
Moran noted students train on several equipment brands
to stay current with welding/cutting technologies.
For more information on the process to achieve ATF ac-
creditation, visit aws.org/certification/accreditedtestfacilities.
— Kristin Campbell (kcampbell@aws.org), features editor
Alcoa and Rio Tinto Reveal Carbon-Free
Aluminum Smelting Process
Alcoa Corp., Pittsburgh, Pa., and Rio Tinto, London, UK,
have revealed a process to make aluminum that produces
oxygen and eliminates direct greenhouse gas emissions from
the traditional smelting process.
During this announcement, executives from both compa-
nies as well as from Apple were joined by Canadian Prime
Minister Justin Trudeau and Premier of Québec Philippe
Couillard.
Elysis, a joint venture company, will further develop the
new process with a technology package planned for sale
starting in 2024. To be headquartered in Montreal, with a
research facility in the Quebec’s Saguenay–Lac-Saint-Jean
region, it will develop and license the technology.
The business will sell proprietary anode and cathode ma-
terials. Vincent Christ, who has more than 30 years’ experi-
ence at Rio Tinto Aluminium, has been named its CEO.
Canada and Quebec are each investing $46.1 million in
Elysis. Apple is providing $9.9 million. Alcoa and Rio Tinto
will invest $42.3 million cash over the next three years.
Rex-Cut Abrasives Marks 90 Years
in Manufacturing
Rex-Cut Abrasives is cele-
brating 90 years in business. Its
specialty abrasive material was
invented in 1928. Over the
following nine decades, the
Massachusetts-based company
engineered, refined, and cus-
tomized cotton-fiber abrasive
products for metalworking
industries.
“At our 90-year mark, we are
reflecting on our history, dedi-
cated team, and recognizing
our loyal business partners,”
said President Bob Costa. “We
Edward Hurst, Rex-Cut’s
have a total of 228 distributors
founder, invented the
technique of embedding that have been with us for over
abrasive grain in nonwo- 20 years, and we wouldn’t have
ven cotton fiber. reached this milestone without
their help.”
In 1928, Edward Hurst, a
MIT graduate and process engineer, invented the technique
of embedding abrasive grain in nonwoven cotton fiber while
working for United Cotton Products. The original product
was named Fluff-Tex, and a patent was filed for the manu-
facturing process in 1935.
In 1960, Hurst retired from United, and his son, Robert
H. Hurst, took over management. The business changed

JULY 2018 / WELDING JOURNAL 13


This recent photo at the company’s booth during FABTECH
shows (from left) Claude Gelinas, chairman of the board of
directors; Jon Blake, R&D manager; and Tim Borges, sales
manager, North American distribution.
hands several times before being called Rex-Cut Products in
1969. Up until the early 1970s, it manufactured and sold
only bulk rolls of fabric for conversion to large abrasive com-
panies. Its first finish products were Type 27 grinding
wheels; abrasive discs to sharpen gardening tools and lawn
mower blades were second. Type 1 wheels followed, and
mounted points began being manufactured years later.
In 1978, the company built a 60,000-sq-ft facility in the
Fall River Industrial Park, where it still operates. In 2008,
14 WELDING JOURNAL / JULY 2018
Rex-Cut was sold to the employees as a 100% employee
stock ownership plan company. It began doing business as
Rex-Cut Abrasives in 2011.
Industrial Arts Institute Holds Regional
High School Welding Competition
The Industrial Arts Institute, Onaway, Mich., sponsored
its 2nd Annual Regional High School Welding Competition
on April 20. This event was offered at no cost to high
schools throughout Michigan. Competitors chose one of
three processes in shielded metal arc welding (SMAW), flux
cored arc welding (FCAW), or gas metal arc welding
(GMAW). Several welding professionals served as judges.
For GMAW, 1st place went to Zach Gildner, Cheboygan
High School Career Tech Program; 2nd, Caleb Evanzo, Mont-
calm ISD Career Center; and 3rd, Chase Vandenbos, Wex-
ford/Missauke Career Tech Center. For FCAW, 1st place was
earned by Sean Sikkema, Wexford/Missauke Career Tech
Center; 2nd, Tyler Atkinson, Cheboygan High School Career
Tech Program; and 3rd, Grant Spray, Cheboygan High School
Career Tech Program. For SMAW, 1st place went to Jacob
Gow, Industrial Arts Institute/GMCA-NM high school work
based learning welding program; 2nd, Conner Mann, Cheboy-
gan High School Career Tech Program; and 3rd, Robert Ni-
ester, Industrial Arts Institute/GMCA-NM high school work
based learning welding program.
This year, 72 high school students from ten welding pro-
grams competed. The 1st-, 2nd-, and 3rd-place finishers re-
 Earning 1st place at the Industrial Arts Institute’s welding
competition are (from left) Jacob Gow, SMAW; Sean Sikkema,
FCAW; and Zach Gildner, GMAW. Also photographed is Thomas
Moran, founder of the Industrial Arts Institute.

ceived prizes and a $1000 scholarship to attend the insti-

tute’s comprehensive industrial welding program. First-
place finishers got the Thor Award and received $500. Every
participating student earned a $500 scholarship to attend
the institute’s comprehensive industrial welding program.

ShipTech 2018 Brings Together Navy

and Industry Leaders

ShipTech 2018 featured an array of technical and general-

session speakers. Pictured is Rear Admiral David J. Hahn.

Nearly 300 people attended ShipTech 2018 in

Charleston, S.C. This two-day defense manufacturing con-
ference is held for the domestic shipbuilding industry, its
supplier base, the U.S. Navy Program Offices, and the U.S.
Navy-sponsored shipbuilding research programs.
Attendees and speakers shared details about the Navy’s
shipbuilding priorities and industry’s latest manufacturing
technology developments. Keynote addresses were given by
Rear Admiral David J. Hahn, chief of naval research, Office
of Naval Research, and Rear Admiral Lorin C. Selby, chief
engineer and deputy commander for ship design, integra-

JULY 2018 / WELDING JOURNAL 15

 tion, and naval engineering, Naval Sea Systems Command.
Panel discussions focused on lead ship vs. follow-on ship
cost differential and integrated warfare systems, which in-
cluded leaders in key Navy program offices and industry.
Technical sessions featured briefs and posters in joining
technologies, production processes, shipbuilding processes
and technologies, additive manufacturing, and robotics.

Industry Notes
• Fischer Technology has opened a Chicago, Ill., sales and
service facility. Craig Kuchta, the new representative and
technical advisor for this office, has more than 20 years of
technical instrumentation sales and support of products
by many manufacturers. The company’s regional offices
support its line of test and measurement instrumentation.

• Fume-extraction vendor ULT LLC, Mequon, Wis., and

Florida-based GulfTech Enterprises – Casiba Group
have joined forces. Since March, GulfTech has focused on
sales and service of ULT’s air-treatment solutions in Florida
and southern Georgia. The representative will provide
extraction and filtration-technology equipment for laser
and welding fumes, plus address additive manufacturing
industries.

• Peggy Del Fabbro, CEO of M. Davis & Sons, Wilmington,

Del., recently announced it has acquired a Messer Cutting
Systems Evolution® plasma cutting table. The equipment
enables fabrication specialists to produce smooth edge
quality and precision hole cutting. Also, the table provides
a larger volume of plate cutting in-house, with materials to
be cut from 1.5 in. for carbon steel to 1 in. for stainless
steel.

• VCOM, a high-tech educational technology enterprise,

has become the latest global partner of WorldSkills In-
ternational. Established in the Guangdong Province of
China more than 20 years ago, its training products are
used in 2000 vocational schools and colleges, technical
schools, and public training centers across the country.

• Micronor Inc., Camarillo, Calif., a manufacturer of fiber

optic kinetic sensors for industrial and medical applica-
tions, has been certified under global quality standard ISO
9001:2015. The company earned certification from regis-
trar TUV Nord USA. WJ

Do You Have Some News to Tell Us?

If you have a news item that might interest the readers
of the Welding Journal, send it to the following address:
Welding Journal Dept.
Attn: Kristin Campbell
8669 NW 36 St. #130
Miami, FL 33166.
Items can also be sent via fax to (305) 443-7559 or
by email to kcampbell@aws.org.

16 WELDING JOURNAL / JULY 2018

BUSINESS BRIEFS
Huntington Ingalls Industries’ Employees are
Honored by the Manufacturing Institute
Three female em-
ployees at Virginia-
based Huntington
Ingalls Industries’
Newport News
Shipbuilding divi-
sion were recog-
nized by the Manu-
facturing Institute
for their achieve-
ments in science,
technology, engi-
Newport News Shipbuilding employ-
ees (from left) Kelli Gilliam, Marissa neering, and pro-
Webb, and Danyelle Saunders were duction at the 2018
honored at the 2018 STEP Ahead Women in Manu-
Awards in Washington, D.C. (Photo facturing STEP
courtesy of the National Association Ahead Awards.
of Manufacturers.) Kelli Gilliam, fore-
man/craft instruc-
tor; Danyelle Saun-
ders, engineering manager; and Marissa Webb, industrial
engineer, were among 130 women honored during an
awards reception in Washington, D.C. Saunders was also rec-
ognized as a STEP Ahead Award honoree, and Gilliam and
Webb were recognized as emerging leaders.
The STEP Ahead Awards honor women who have demon-
strated excellence and leadership in their careers and repre-
sent all levels of the manufacturing industry, as well as en-
couraged women to mentor and support the next generation
of female talent to pursue manufacturing careers.
Toyota and Mazda Choose Alabama for New
$1.6 Billion Manufacturing Facility
Mazda Motor Corp. and Toyota Motor Corp. have chosen
Huntsville, Ala., as the site for their new $1.6 billion joint-
venture company named Mazda Toyota Manufacturing
U.S.A. Inc. (MTMUS).
The facility is projected to produce 150,000 units of Maz-
da’s crossover model and 150,000 units of the Toyota Corol-
la. The plant is scheduled to open in 2021 and employ up to
4000 people.
“The new plant, which will be Toyota’s 11th manufacturing
facility in the U.S., not only represents our continuous com-
mitment in this country, but also is a key factor in improv-
ing our competitiveness of manufacturing in the U.S.,” said
Hironori Kagohashi, executive general manager of Toyota
and executive vice president of MTMUS.
In collaboration with the state of Alabama and the city of
Huntsville, full-scale construction of the facility is expected to
start in 2019.
CWB Group Celebrates 70 Years, Rebrands
Under One Name
The CWB Group, a not-for-profit organization providing
18 WELDING JOURNAL / JULY 2018
welder certification, management systems registration, and
training services, has recently celebrated 70 years in the
Canadian welding industry. Following on the heels of its an-
niversary, the company is transitioning all of its business
units to unite them under one brand: CWB. The organiza-
tion announced the initiative will help industry more easily
identify their complete offerings and better allow clients to
learn about all of the services they have to offer.
“We’re excited about our new unified brand identity for
our various service offerings,” said Craig Martin, vice presi-
dent of public safety. “It’s a visual reflection of CWB Group’s
commitment to see the Canadian welding sector be sustain-
able and successful in the years ahead both through the de-
livery of value-added services and as a strong voice to pro-
mote and advocate for our industry.”
Metal Fatigue Solutions Opens Headquarters
in New York City’s Empire State Building
Metal Fatigue Solutions, Las Vegas, Nev., a producer of non-
destructive examination and structural health monitoring
technology systems for civil and industrial infrastructure, has
opened an office in New York City’s Empire State Building.
Its newly established east coast regional headquarters will
serve as a user base for companies or projects in New York,
New Jersey, Connecticut, and Maryland. It will also provide
access to Washington, D.C., where the company consults
with officials at the Department of Transportation and oth-
er federal agencies overseeing the nation’s civil infrastruc-
ture, which encompasses bridges, aviation, wind turbines,
oil rigs, and pipelines.
Recent Acquisitions
• RoboVent, Sterling Heights, Mich., has procured Air Fil-
tration Holdings LLC, Columbus, Ohio. The air filtration
company previously acquired Maryland-based Viskon-Aire, a
manufacturer of air filtration products, and Illinois-based
Permatron, a provider of custom, technology-driven air fil-
tration solutions.
• Non-Destructive Testing Products Group, St. Catharines,
Ontario, a distributor of nondestructive examination and
aviation equipment and supplies, has acquired Infinitex
Corp., an ultrafiltration technology manufacturer. Infinitex
operations in Clarence Center, N.Y., will remain in place dur-
ing the transition and existing distribution, and user agree-
ments will not be affected.
• Clean technology company, MagneGas Corp., Tampa,
Fla., has bought Trico Welding Supply, an industrial gas and
welding supply distributor in the Sacramento, Calif., market.
• George Industries, Endicott, N.Y., a designer and manu-
facturer of engineered aerospace, defense, and industrial
components, has purchased Numerical Precision, Wheeling,
Ill., a manufacturer of close-tolerance components for satel-
lites, aircraft, as well as aerospace and defense programs. WJ
LASER WELDING Q&A
Q: We are a metal fabrication
company providing full manufac-
turing capability of small (up to 2
in. diameter) and large (up to 60
in. diameter) components. The
volume may be low (ten assem-
blies/day) to high (ten assem-
blies/min). Our company is
planning to add laser manufac-
turing technology to our capabil-
ity. Are there some guidelines in
choosing a laser and optics? The
information available from the
suppliers’ trade literature is not
clear.
A: This is a very good question.
During an economy where companies
are seeing increased demand for their
products, and the ramp-up time for
increased capacity is very short, se-
lecting new manufacturing equipment
as well as qualifying the equipment
and the process, will understandably
create anxiety.
The following is the suggested way
to approach the selection of the laser
and the laser beam delivery optics for
laser welding:
1. Material. Identify the charac-
teristics of the materials to be laser
welded. This information is available
and has been covered in this column
previously. Check the Classification of
Materials (Refs. 1, 2) for the power
density values required to couple the
laser beam with the surface of differ-
ent materials. More on this later.
2. Weld penetration and AR1 re-
quirement. These help to define the
temporal characteristics of the laser
power and laser weld process.
Pulsed laser power is able to pro-
duce good quality conduction welds
with penetration from  0.001 in.
(0.025 mm) to approximately 0.060
in. (1.5 mm) in class II metals (carbon
steel, stainless steel, titanium, and so
forth) and from  0.001 in. to approx-
imately 0.030 in. (0.76 mm) in class I
metals (copper, aluminum, tungsten,
and so forth). The recommended val-
ue of AR is between 0.6 and 1.0. For
example, if the weld bead is 0.020 in.
(0.5 mm) wide, the weld penetration
should be between 0.012 in. (0.3 mm)
and 0.020 in. (0.5 mm). So, if greater
penetration is required for the 0.020-
1
Aspect ratio of the weld.
20 WELDING JOURNAL / JULY 2018
Table 1 — Summary of the Weld Parameters
Pulsed Conduction
w in. 0.020
p in. 0.020
AR # 1.0
Overlap % 80.0
E joules 4.67
t s 0.0155
PR pulse/s 50.0
v in./min 12.0
P(a) W 233.0
P(p) W 301.0
volume in.3/min 0.006
in.-wide weld, continuous wave (CW)
power must be used.
Continuous wave laser power is
able to produce good quality keyhole
welds up to 0.600 in. (15.2 mm) deep
in class II and 0.120 in. (3.0 mm) in
class I metals. In the previous exam-
ple, the 0.020-in.- (0.5-mm-) wide
weld may be produced with a weld
penetration of 0.050 in. (1.3 mm)
deep and an AR value of 2.5.
3. Volume of metal to be weld-
ed. The volume of the material to be
processed defines the average power
of the laser. Comparison of the vol-
ume of metal welded with the same
laser in the pulsed versus power mode
is provided in Table 1.
4. Selection of the beam deliv-
ery optics. The equipment designer
will determine what optics to use to
collimate the laser beam, what fiber
optic cable to use to deliver the beam
to the target, and so forth. What you
should be concerned about is the di-
ameter of the focused beam and the
spatial profile of the laser beam as it is
focused on the target.
Pulsed laser power. To compute
the energy per pulse and the pulse
width for delivering the correct power
density to the target, we need to re-
member that the diameter beam as fo-
cused on the target will be approxi-
mately 80% of the bead width.
Referring to the above example, to
produce a bead width of 0.020 in. (0.5
mm), the beam diameter should be
0.016 in. (400 m). The 400-m spot
may be produced with a 400-m fiber-
optic cable and the correctly chosen
optics. Optical fibers of this diameter
typically deliver a spatial profile that
is uniform (top hat). Assuming class II
BY SIMON L. ENGEL
CW Conduction CW Keyhole
0.020 0.020
0.020 0.050
1.0 2.5
n/a n/a
n/a n/a
n/a n/a
n/a n/a
197.0 394.0
750.0 5000.0
n/a n/a
0.039 0.197
metals and the desired power density
value of 1.5 E  06 W/in.2, the compu-
tation using the formulas provided in
a recent column (Ref. 2) and incorpo-
rated in mathematical algorithms
(Ref. 3) yields the following laser weld
parameters:
For w  0.020 in., p  0.020 in. (AR
 1.0), 80% overlap, use E  4.67
joules, t  0.0155 s, PR  50 Hz; travel
speed  12 in./min. Average power 
233 W; peak power  301 W. The vol.
of metal melted  0.006 in.3/min.
Continuous wave laser power.
At the optimal welding speed, the re-
lationship between the bead width
and the diameter of the laser beam is
the same as in pulsed laser welding.
So are the comments about the optics.
The difference is in the power density
values. For keyhole welding, the de-
sired power density is approximately
2.5 E  07 W/in.2. This requirement
defines the minimum CW power
(threshold) needed to achieve the
power density for keyhole weld.
Therefore, Pmin for the 0.050-in. weld
penetration, keyhole weld  5000 W;
and Pmin for the 0.020-in. weld pene-
tration, conduction weld  300 W.
Higher power is recommended be-
cause the operating range of lasers is
10100% of full power.
Based on published data (Ref. 3),
the following laser weld parameters
may be used:
For w  0.020 in., p  0.020 in., use
750 W at 197 in./min (5 m/min); vol.
melted  0.039 in.3/min (three times
the average power used in pulsed weld-
ing, but 6.5 times the volume melted).
This is understandable because in
pulsed welding, the weld nuggets over-
lap the previous weld nuggets.
 For w  0.020 in., p  0.050 in., use
5000 W at 394 in./min (10 m/min);
vol. melted  0.197 in.3/min.

Summary
1. There is a significant difference
between the productivity of pulsed
power welding and CW power welding.
2. When the required weld penetra-
tion is achievable with conduction
welding and the number of units to be
welded is low, a laser of a few hundred
W of average power and good pulsing
capabilities would work well. Good
pulsing capability implies easy pro-
gramming of the pulse parameters.
3. If you need to produce laser
welds with AR larger than 1.5 (key-
hole welding), then a laser in the pow-
er range of 5000–6000 W is the right
choice. The good news is that the
higher power CW solid-state lasers
(fiber lasers, disk lasers, and direct
diode lasers) may be pulsed and make
pulsed welds, too. Also, the cost of the
laser does not change linearly with its
power rating. So going from 500 to
5000 W does not mean price increase
times ten.
4. The most important characteris-
tics of the beam delivery optical sys-
tem are its ability to produce the re-
quired diameter of the focused laser
beam and a spatial profile, which
should be uniform across the laser
beam, called top hat. WJ

References

1. Engel, S. L. 2016. Laser welding

Q&A. Welding Journal 95(9): 20, 21.
2. Engel, S. L. 2018. Laser welding
Q&A. Welding Journal 97(3): 20, 21.
3. Engel, S. L. Laser Welding Tech-
nology — Engineering Manual. HDE
Technologies Inc., Elk Grove, Calif.

SIMON L. ENGEL is president of HDE

Technologies Inc., Elk Grove, Calif. He
serves as vice chair of the AWS C7C
Subcommittee on Laser Beam Welding and
Cutting and is a member of the US TAG for
ISO/TC44/SC10/WG9 on Hybrid Welding. He
is also a senior member of the Laser
Institute of America and a life member of
the Society of Manufacturing Engineers. He
is considered a specialist in industrial laser
applications and has been in the business
for 40 years. Questions may be sent to
Simon Engel, c/o Welding Journal, 8669 NW
36 St., #130, Miami, FL 33166-6672, or via
email at simon_of_hde@yahoo.com.

JULY 2018 / WELDING JOURNAL 21

STAINLESS Q&A
BY DAMIAN J. KOTECKI

centration during bending in the than the corresponding base metal,

Q: We are in the planning stages
to qualify a gas metal arc weld-
ing procedure to weld 316L stain-
less steel to 2205 duplex
stainless steel. It seems that we
can run the procedure qualifica-
tion using 316L filler metal or
2209 filler metal. Does it matter
what type of filler metal we use?
A: It does matter. The concern
would be how the filler metal choice
affects the ease of passing a side bend
test. There will be a significant
strength mismatch across the joint in
either case. This leads to strain con-
weaker material beside the fusion
boundary.
Table 1 lists the chemical composi-
tion requirements for 316L and 2205
base metals according to ASTM A240,
as well as ER316L and ER2209 filler
metals according to AWS A5.9/A5.9M.
Table 2 lists the base metal mechanical
property requirements for 316L and
2205. There are no mechanical proper-
ty requirements specified for the two
filler metals, but there is readily avail-
able data showing typical values for
these filler metals, which are also list-
ed in Table 2.
The weld metal tends to be stronger
particularly in regards to yield
strength. Typical yield strength for
316L base metal is about 35 ksi (240
MPa). If ER2209 filler metal is used
for the 316L to 2205 joint, the mis-
match in yield strength at the 316L
base metal/2209 filler metal interface
will be about 35/80 ksi. However, if
ER316L filler metal is used, the mis-
match at the ER316L filler metal/
2205 base metal interface will be
about 55/80 ksi, which is appreciably
less of a mismatch. When there is a
mismatch in yield strength, there is a
tendency in many standard bend test
jigs to develop a kink in the weaker

Table 1 — Chemical Composition Requirements

Composition, wt-% (single value is maximum)

Alloy
C Mn Si Cr Ni Mo Cu N

316L 0.030 2.00 0.75 16.0–18.0 10.0–14.0 2.00–3.00 – 0.10

2205 0.030 2.00 1.00 22.0–23.0 4.5–6.5 3.0–3.5 – 0.14–0.20
ER316L 0.03 1.0–2.5 0.30–0.65 18.0–20.0 11.0–14.0 2.0–3.0 0.75 –
ER2209 0.03 0.50–2.00 0.90 21.5–23.5 7.5–9.5 2.5–3.5 0.75 0.08–0.20

22 WELDING JOURNAL / JULY 2018

Table 2 — Base Metal Mechanical Property Requirements or Typical Weld Metal Values

Alloy Tensile Strength ksi (MPa) Yield Strength ksi (MPa) % Elongation

316L 70 (485) 25 (170) 40

2205 95 (655) 65 (450) 25
ER316L 80 (550) 55 (380) 40
ER2209 95 (655) 80 (550) 30

Fig. 1 — Typical bottom-ejecting guided bend test fixture. (Source: Fig. 6.1, AWS
B4.0:2016.)

Fig. 2 — Typical bottom-guided bend test fixture. (Source: Fig. 6.2, AWS B4.0:2016.)

material, and the kink can lead to tear-
ing at the interface due to the strain
concentration.
One way to combat this tendency to
develop a kink at the interface be-
tween weaker and stronger metals is
to change from the normal three-point
bending configuration that occurs in a
bottom-ejecting guided bend test fix-
ture (Fig. 1) or bottom-guided bend
test fixture (Fig. 2) to a wrap-around
guided bend test fixture (Fig. 3). The
wrap-around fixture forces all parts of
the bend test specimen to stretch es-
sentially the same amount regardless
of variations in yield strength within
the specimen.
In addition to the concern about
kinking of the test specimen when
there is a strength mismatch within
the test specimen, each of the three
bend test fixtures offers a concern in
conducting the test. The test specimen
in the bottom-ejecting fixture tends to

JULY 2018 / WELDING JOURNAL 23

 the clamping force be sufficient to pre-
vent the clamp from slipping as the
roller wraps around the mandrel.
In summary, use of ER316L filler
metal will result in less strength mis-
match across the 316L to 2205 joint
than will use of ER2209 filler metal. In
any case, use of the wrap-around guid-
ed bend test fixture will minimize the
tendency for kinking of a bend test
specimen in which there is a strength
mismatch. The use of ER316L filler
metal with a wrap-around guided bend
test fixture will maximize the likeli-
hood of passing the bend test without
incident. WJ

DAMIAN J. KOTECKI is president, Damian

Fig. 3 — Typical wrap-around guided bend test fixture. (Source: Fig. B.3, AWS
B4.0:2016.)
spring rather violently when it exits
the fixture. Tethering of the test speci-
men or some sort of enclosure around
the fixture can be used to prevent this
springing of the test specimen from
harming someone or damaging equip-
ment. With the bottom-guided bend
test fixture, the test specimen tends to
become stuck when the test is com-
pleted. Then it is sometimes necessary
to pry the specimen loose, which may
also result in somewhat violent spring-
ing of the specimen when it comes
loose. With the wrap-around fixture,
spring of the test specimen is general-
ly not an issue, but it is necessary that
Kotecki Welding Consultants Inc. He is a
past treasurer of the IIW and chair of the
AWS A5D Subcommittee on Stainless Steel
Filler Metals, member of the D1K
Subcommittee on Stainless 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 Allied
Materials, and served as AWS president
(2005–2006). Questions may be sent to
Damian J. Kotecki c/o Welding Journal, 8669
NW 36 St., # 130, Miami, FL 33166-6672, or
via email at damian@damiankotecki.com.

24 WELDING JOURNAL / JULY 2018

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RWMA Q&A
Q: How does water quality im-
pact the life of resistance weld-
ing equipment?
A: Water plays an important role in
the life of resistance welding equip-
ment. Water is used as the primary
cooling source for the welding zone, sil-
icon controlled rectifiers, electrodes,
and welding tips. Proper cooling can
prevent overheating, improve welding
tensile values, extend the life of equip-
ment, and prevent downtime due to
mushrooming or surface distortion.
To cool the welding equipment,
these types of sources are sometimes
utilized:
• Feeding water direct from the tap
or well water directly to the welding
equipment;
• Feeding the water from cooling
towers directly to the equipment; and
• Using a closed-loop water chiller.
Turning on the tap may seem like an
easy option to use cool water for weld-
ing processes, but it is a flow-through
option that has many costly issues. If
the water is not processed through a
self-contained water recirculator or a
closed-loop vapor compression chiller, it
will not recirculate the water, and it will
go directly into the drain. Plus, munici-
pal water can contain lime and mineral
deposits that cause corrosion.
Water without the use of industrial
inhibited glycol can pose significant
areas of concern with water quality,
such as corrosion, scale or deposits,
and biological fouling — Fig. 1.
1. Corrosion. This is a loss of base
materials through gradual degrade
from chemical and/or electrochemical
attack. In addition, the corrosion
process creates troublesome suspend-
ed solids into the process stream.
2. Scale or deposits. There are two
general types: Inorganic mineral and
suspended solids sludge. Either one of
these deposits can create an insulating
layer that reduces heat transfer. Anoth-
er undesirable result is the creation of a
corrosive under layer, which will re-
strict flow, limiting the ability to re-
move heat from the process.
3. Biological fouling. The prolif-
eration of biological organisms, micro-
biological or macrobiological, will
cause similar issues as corrosion —
Fig. 2.
Using well water may seem like a
26 WELDING JOURNAL / JULY 2018
BY RASCHELL M. HICKMOTT AND BONNIE MARTENS
Fig. 1 — This evaporator coil corroded
because glycol and inhibitor were not
used during operation, which resulted
in calcium buildup.
free option, but again, like municipal
water, it is laden with mineral deposits
that will cause corrosion and damage
the equipment. Plus, the temperature
of the water needs to be taken into
consideration. Too cold of tempera-
tures can cause condensation. Conden-
sation occurs when the dew point, the
temperature at which water vapor will
condense, is above the process water
temperature. This is a common issue in
the summer when dew point tempera-
tures can be above 70°F, or in areas of
warmer climates. This can cause con-
densation on the welder’s transformer,
which can cause it to short out, or cre-
ate condensation on the electrode
holders that will drip puddles of water
causing a safety hazard. Using a closed-
loop vapor compression chiller with an
industrial inhibitor glycol can provide
many benefits including temperature
control with dew point tracking as well
as preventing corrosive elements in the
system.
Cooling towers have been a com-
mon way to supply cooling water to
welders, but they present a unique set
of problems, including inconsistent
process water temperatures, due to
varying ambient air temperatures. Ad-
ditionally, cooling towers cannot
maintain the appropriate water flow
that is necessary for welding process-
es. When more water-cooled machines
are added to a system, additional
pumps must be added to the central
cooling system to be effective.
Using a mixture of industrial inhib-
ited glycol and water is recommended
whenever possible to improve the wa-
ter quality. Ethylene and propylene are
the two standard types of inhibited
glycols used.
Fig. 2 — Image is of a filter strainer
coated with biological growth, better
known as slime. Using inhibited glycol
will prevent growth.
It’s important to note most equip-
ment manufacturers will offer recom-
mendations or restrictions on the wa-
ter additives to be used in their equip-
ment. Following those recommenda-
tions typically enhances the overall
production uptime as well as the serv-
ice life of the equipment.
Industrial glycols have inhibitors
that also will prevent formation of
scale and corrosion while protecting
metals such as brass, copper, steel,
cast iron, and aluminum. Water sys-
tems treated with an inhibited glycol
will also be protected from algae and
bacteria that can grow and degrade the
fluid system performance.
There are a few tips to consider
when using industrial inhibited glycols:
• Do not mix glycols;
• Do not use automotive-grade
antifreeze;
• Check local environmental
regulations;
• Consider ethylene glycol for most
standard industrial applications;
• Consider propylene glycol for
user-contact applications;
• Know the difference between eth-
ylene and propylene glycol; and
• Understand that the specific ap-
plication drives the water/glycol mix
percentage used.
 Do not mix glycols. Because mix-
ing different types or brand names of
glycol can result in some inhibitors pre-
cipitating out of the solution, do not
mix glycols. Mixing glycols also will gel
and clog filters and prevent proper flow
rates. If switching glycol types, it will be
necessary to run a thorough flush and
clean of the fluid system. Once that is
done, it is okay to change over.
Do not use automotive-grade
antifreeze. Glycols used in automo-
tive-grade antifreeze do not have the
right type of inhibitors and are not de-
signed for industrial applications. Us-
ing automotive-grade antifreeze in the
chiller process can cause problems
with heat transfer or fluid flow. Also,
many automotive glycols contain sili-
cate-based inhibitors that can coat
heat exchangers, attack pump seals, or
form a flow-restricting gel.
Check local environmental reg-
ulations. Check state and local codes
when selecting the process fluid. Cer-
tain areas may have environmental
regulations concerning the use and
disposal of glycol or other additives.
• Ethylene glycol is good for com-
mon welding applications.
• Ethylene glycol can be used where
Table 1 — Recommended Glycol/Water Mixture
Application Glycol %
Indoor chiller and process 30
Outdoor chiller/low temp. 50
low toxicity content is not required.
• Propylene glycol provides general-
ly the same freeze protection and cor-
rosion/algae prevention levels as eth-
ylene glycol, but it has a lower level of
toxicity.
• Also, propylene glycol is more
readily disposable than ethylene and
safer to handle.
Know the difference between
ethylene and propylene glycol. At
very cold temperatures, propylene gly-
col becomes more viscous, changing
the heat exchange rate slightly. Ethyl-
ene is more widely used due to its low-
er purchase price, making it more eco-
nomically feasible for factories with
significant purchasing volumes.
Understand that the application
drives the water/glycol mix per-
centage. The location of the chiller
and environmental concerns must be
taken into account when selecting the
Water % Freeze Point
70 5°F/-15°C
50 -35°F/-37°C
proper mixture of glycol and water for
the chiller process.
• A cooling system located com-
pletely indoors, with no chance of
freezing, will require less glycol.
• A cooling system located out-
doors, where low temperatures can
cause the fluid to freeze and piping to
burst, will require more glycol.
The glycol percentage figures in
Table 1 will apply to any brand of eth-
ylene or propylene glycol. WJ
RASCHELL M. HICKMOTT is regional sales
manager and BONNIE MARTENS is
marketing specialist at Dimplex Thermal
Solutions, Kalamazoo, Mich. Send your
comments and questions to Raschell M.
Hickmott c/o Welding Journal, 8669 NW
36 St., #130, Miami, FL 33166-6672, or via
email at rhickmott@dimplexthermal.com.
JULY 2018 / WELDING JOURNAL 27
PRODUCT & PRINT SPOTLIGHT Highlighting Fabrication

Automated Handling System serve additional lasers on the shop

Facilitates Metal Fabrication
floor. Standard systems are available
with four to ten shelves and will ac-
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density systems add up to another six
shelves, and all shelves are rated to
handle up to 6600 lb each.

The Multiaxis Rapid Cincinnati
Handling (MARCH) system offers au-
tomated material handling for metal
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designed for use with the company’s
lasers to reduce operating costs and in-
crease productivity and safety. It’s also
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tional components to grow with a
business, or to accommodate specific
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dard or high-density configurations,
the handling system ranges from sim-
ple load/unload to those with expand-
able towers, output stations, over/un-
der carts, and conveyors. It can also
Cincinnati Incorporated
e-ci.com/automation
(513) 394-7595
Mounting Tools Perform Pipe
Severing and Beveling
The Commando series models of
portable outer-diameter mounting
tools simultaneously sever and bevel
pipes in preparation for welding. Ideal
for maintenance applications where a
section of pipe or valve needs to be cut
out and replaced, its ten models cover
the size range of DIN 50 to 1200 (2- to
48-in. pipe). The aluminum bodies of
the CS split frame series are designed
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ing/beveling tools include automatic
tool feed, pneumatic and hydraulic
power options, as well as use for
compound bevels, counterboring, and
facing.
Magnatech LLC
magnatechllc.com
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The ITSA Annual Membership Meeting

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28 WELDING JOURNAL / JULY 2018

Threaded Arbor Cut-Off
Wheels Increase Efficiency
and gas exploration and civil engineer- Mobile Analyzer Provides
ing projects. In tests, it has been Metal Grade Confirmation
shown to be 20–30 times faster than
conventional arc welding while also
The portable Spectrotest arc/spark
utilizing less power. Furthermore, it
mobile metal analyzer delivers results
leads to low-heat-input welds that re-
when an exact metal analysis is re-
sult in reduced distortion and the op-
quired, materials are difficult to iden-
tion to perform nondestructive testing
tify, or there is a large number of sam-
immediately after welding.
ples to be tested. The analyzer’s high-
Cambridge Vacuum Engineering
ebflow.com — continued on page 31
01223 800 861

The ISO 9001-certified 41⁄2-in. cut-

off wheel features a threaded arbor
for quicker and easier wheel changes.
Designed to be used with right-angle
grinders, the aluminum-oxide, type
27 wheels are ideal for metal cutting,
abrasion, and fabrication, as well as
body work and general repair work on
ferrous materials.

Forney Industries Inc.

forneyind.com
(800) 521-6038

Technology Enables EBW

without a Vacuum Chamber

The Ebflow technology enhances

the efficiency of large-scale projects by
performing electron beam welding
(EBW) without a vacuum chamber. It
features a local coarse vacuum that can
be transported to and operated on
site. Its design simplifies the process
of thick-section welding in the manu-
facture of a range of large structures
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JULY 2018 / WELDING JOURNAL 29

PRODUCT & PRINT resolution optical system works for a
range of elements, including nitrogen,
SPOTLIGHT lithium, sodium, and all elements nec-
— continued from page 29 essary for complete or spot metal
analysis. With predefined calibration
packages and the iCAL 2.0 diagnostics
software, the metal analyzer can per-
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day’s testing, while ensuring stable
performance, and maintain the same
standardization regardless of most
temperature shifts.
SPECTRO
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Report Forecasts Growth for
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The increasing demand for an inte-
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Wiseguy Research Consultants Pvt. Ltd.
wiseguyreports.com
(339) 368-6938
Video Shows the Features of
a Powered Manipulator
The quick-look powered manipula-
tor video showcases the key benefits
and features of a specialized modular
fixture. With the weldment secured
to the table top using any of the com-
pany’s 400-plus standard modular
components, the operator can use a
JULY 2018 / WELDING JOURNAL 31
push button pendant, foot control
switch, or an automated program to
move the part to various positions.
Also included is a built-in ground con-
nector to protect the controls from
damage during the welding process.
Bluco Corp.
bluco.com
(800) 535-0135
Fiber Laser Cuts Ferrous and
Nonferrous Material
The LS 3015 GC fiber laser uses in-
tegrated flying optics to cut through
ferrous and nonferrous materials, in-
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cluding steel, stainless steel, alu-
minum, brass, and bronze. Its features
include a small footprint, making it
suitable for most facilities; continual
monitoring for processing parameters;
an upgraded system; and a high-rigidi-
ty frame for enhanced stability and
edge quality. The laser also delivers
lower power consumption and operat-
ing costs, as well as reduced mainte-
nance time.
Murata Machinery USA Inc. ing, creates a flat, stable base for
muratec-usa.com
working on flat surfaces, such as shop
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Evaluating FCAW-G Electrodes
Thin-sheath, high-fill-ratio electrodes
broaden parameter range, create high
operator appeal
W
hat can you learn about fabri-
cating heavy weldments with
large-diameter cored elec-
trodes from someone who holds a
master of fine arts in sculpture? Quite
a bit if that person also holds qualifica-
tions to requirements of AWS D1.1,
Structural Welding Code — Steel, and
AWS 14.1, Specification for Welding of
Industrial and Mill Cranes and Other
Material Handling Equipment.
“There are hundreds of different
Some of Rubin’s gas-shielded flux cored arc weld beads. The ’39 Ford pickup he restored sits in the background.
34 WELDING JOURNAL / JULY 2018
gas-shielded FCAW [flux cored arc
welding] electrodes, and many compa-
nies make them. Within any given
product line, there are a lot of differ-
ent choices and nuances to each elec-
trode. Finding the right electrodes for
my operation took several years of tri-
al and error,” said Dave Rubin, owner
of Farm Fabrication in Lebanon, Ohio.
Rubin evaluated FCAW-G elec-
trodes for their ability to reduce the
need for nonvalue-added activities
BY BOB GULAS
such as grinding and preheating, elim-
inating piping porosity, all-position
performance, weld pool control, pa-
rameter flexibility, and weld bead ap-
pearance. He eventually selected an
AWS E71T-1 electrode featuring a
thinner sheath and higher fill ratio be-
cause “this technology creates a very
forgiving all-position electrode.”
Comparatively new, thin-sheath
FCAW electrodes offer a different set
of benefits compared to thick-sheath
 Fig. 1 — Cored wires with a thin sheath
concentrate the arc energy in a
smaller area. This creates a broader
“sweet spot” for parameter settings
and makes the electrode more forgiv-
ing as operators adjust voltage and
wire feed speed.

electrodes (Fig. 1), as will be described

later in this article.

Renaissance Welder
Rubin chose the name Farm Fabri-
cation as an homage to the hard- Fig. 2 — Farm Fabrication specializes in heavy weldments for cranes, infrastructure,
working, fix-anything work ethic of heavy repair, and steel industries.
the American farmer. However, rather
than farm equipment, the company State University in New York (2001) AK Steel’s Middletown Works. While
specializes in heavy weldments for and then a master of fine arts in sculp- much of the mill welding used E7018
cranes, infrastructure, heavy repair, ture from the University of Washing- electrodes, because the expansive en-
and steel industries — Fig. 2. ton in Seattle, Wash. (2004). vironment was more like a construc-
Rubin works out of a 2400-sq-ft However, after relocating to his tion site than a shop, Rubin said he
shop he designed himself, moving wife’s home town of Lebanon, located quickly learned the nuances of large-
heavy weldments with a 20,000-lb between Dayton and Cincinnati, Rubin scale, high-capacity overhead cranes
gantry crane and a fork truck with a needed to earn a living and found em- — Fig. 3.
6500-lb capacity. Most of his work in- ployment at a local welding shop. For “Being hands-on with repairing
volves A36 plates from 1⁄4 to 8 in. thick, the next four years, he predominantly cranes for four years taught me where
but his nonindustrial projects include used FCAW and gas metal arc welding to look for stress points, cracks, and
metal sculptures, a restaurant build (GMAW) processes. With the opportu- what would fail and what would not,”
with a 90-ft metal bar, bottle and wine nity for a pay raise, Rubin became lead he recalled. As an example, he pointed
racks, and a restored 1939 Ford pick- welder for a crane service company at out that cranes in the mill’s hot strip
up. In short, Rubin is a bit of a Renais-
sance welder, applying multiprocess
welding, fabricating, and design skills
and equipment to anything he sets his
mind to.
Growing up in New York’s Hudson
Valley region, Rubin was introduced to
shielded metal arc welding (SMAW)
from his father. He started out “just
gluing junk together” before moving
on to 55-gal drum barbecues and fix-
ing trailers (as a side note, his two
sons have started down the same path,
with Rubin introducing them to
SMAW at ages eight and six). Rubin’s
craftsmanship includes woodworking
skills developed alongside his father,
who renovated historic homes, and an
appreciation of art from his mother,
an accomplished musician and wool
spinner. Literally putting his hands to
work, Rubin pursued his bachelor of Fig. 3 — Dave Rubin, owner of Farm Fabrication, understands the nuances of welding
large-scale, high-capacity overhead crane components using the FCAW-G process.
fine arts in sculpture from Plattsburgh

JULY 2018 / WELDING JOURNAL 35

area are subject to a combination of
extreme heat and moisture that causes
faster wear than the cooler, dryer ar-
eas of the mill, such as the caster and
basic oxygen furnace departments.
In 2013, with support from others
who recognized his heavy equipment
repair and fabrication skills, Rubin
started his own company. He works
alone and values the direct line of
communication with customers.
“I am the eyes, ears, hands, and
mind of the operation, and that goes a
long way when talking to clients,” he
said. “Because of my crane experience
and welding skills, customers have a
lot of faith in my work.”
Farm Fabrication focuses on con-
tract work with repeat customers. Ru-
bin doesn’t have off-the-street, walk-
in trade. In fact, except for a discrete
logo on the mailbox, passersby would
not know a welding shop exists, as it is
tucked on the back of the five-acre lot
behind the family’s home.
Filler Metal Selection
Fabricating and repairing heavy com-
ponents effectively in a shop environ-
ment requires selecting filler metals
that provide high deposition rates and
travel speeds. For most heavy applica-
tions, a cored electrode provides the
best combination of high metal deposi-
tion while reducing overall heat input
compared to using a solid electrode.
Table 1 — Comparison of 1⁄16-in. E71T-1 Electrodes Using 75% Argon/25% CO2 Shielding Gas
All tests with
75/25 mixed gas
Low end
High end
Voltage range
Current range
WFS range
Table 2 — Comparison of 1⁄16-in. E71T-1 Electrodes Using 100% CO2 Shielding Gas
All tests with
100% CO2
Low end
High end
Voltage range
Current range
WFS range
Notes: Electrodes with a T-1 classification must have a minimum low temperature toughness of 20 ft/lb min at 0°F, where those with a T-9 classification have a
toughness of 20 ft/lb min at –20°F. The “D” designated a seismic classification and the H8 indicates the maximum milliliters of diffusible hydrogen per 100 g of weld
metal. Thin-sheath technology is also used on other electrode classifications as well, including T-12.
36 WELDING JOURNAL / JULY 2018
For heavy components that can be
welded in the 1F, 2F, and 1G positions,
Rubin uses a metal cored electrode
with an AWS E70-6M H4 classification
in 0.052 in. and occasionally 1⁄16 in.
diameters. While metal cored elec-
trodes work well for in-position work,
they cannot weld out of position — at
least without using a pulsed GMAW
system, and many welding experts be-
lieve pulsing with metal cored elec-
trodes creates more problems than it
solves, not the least of which is added
complexity.
“Metal cored electrodes run cleaner,
with no slag and very little spatter or
smoke. When I can put parts in posi-
tion, I run metal cored electrodes,” Ru-
bin said. “However, you can’t run it
out of position because the [pool] is
too molten. For heavy weldments that
require out-of-position welding, as Fig. 4 — This 1⁄16-in.-diameter, thin-
well as complex weldments that re- sheath FCAW-G electrode uses a fast-
quire moving around a part and weld- freezing slag system that provides
ing in all positions, FCAW-G elec- excellent weld pool control for uphill
trodes really shine. I don’t waste time welding.
flipping the part.”
Rubin uses an FCAW-G electrode tion of alloys and deoxidizers), shield-
with an AWS E71T-1M-D/T-9M-D ing gas choice, and a fast-freezing slag
classification, which is commonly used system that supports all-position
for applications that include structural welding — Fig. 4.
steel, light and heavy equipment, rail-
cars, barges, petrochemical, and off-
shore components. These FCAW-G Thin-Sheath E71T-1
electrodes provide the best combina-
tion of results because more factors Earlier generations of FCAW-G
can contribute to the solution: metal electrodes have a relatively thicker
sheath, filler composition (a combina- sheath. With a higher ratio of steel to
Electrode #1 Electrode #2 Electrode #3
E71T-9M-H8 E71T-1CH8, 1MH8/-9CH8 E71T-1M-D/T-9M-D
178 A (122 in./min) 178 A (114 in./min) 175 A (118 in./min)
262 A (220 in./min) 245 A (197 in./min) 276 A (228 in./min)
22.7–26.2 22.0–25.5 22.0–26.5
84 A 67 A 101 A
98 in./min 63 in./min 110 in./min
Electrode #1 Electrode #2 Electrode #3
E71T-9C-H8 E71T-1C E71T-1C-DH*/T-9C-DH8
165 A (126 in./min) 162 A (114 in./min) 160 A (114 in./min)
195 A (153 in./min) 245 A (197 in./min) 270 A (240 in./min)
25.2–56.5 21.2–26.2 19.7–26.5
30 A 83 A 101 A
27 in./min 83 in./min 126 in./min

Fig. 5 — The deoxidizers in a high-per-
formance FCAW-G electrode will toler-
ate rust and mill as well as create
slag that begins to self-release after
60 s.
Fig. 6 — Welding procedure specifica-
tions required preheating this heavy
component to 150°F.
filler, they maximize deposition rates.
However, since the steel sheath carries
the welding current, electrodes with a
thicker sheath require more voltage
for the same wire feed speed or less
wire feed speed for the same voltage.
As a result, these electrodes have a
narrower operating range, or what op-
erators consider the “sweet spot.” Fur-
thermore, higher deposition rates are
not always the best solution for maxi-
mizing overall productivity.
As an alternative, electrode manu-
facturers developed FCAW-G elec-
trodes with a thinner sheath and high-
er fill ratio. With FCAW electrodes, the
steel sheath carries the welding cur-
rent. Electrodes with a thicker sheath
require more current for the same wire
feed speed. These wires will produce
higher deposition rates; however, they
have a narrower operating range. As a
result, manufacturers developed
FCAW-G electrodes with a thinner
sheath and higher fill ratio.
“A thinner sheath concentrates the
current in a smaller area. Operators
can use higher wire feed speeds to in-
crease deposition without increasing
amperage and heat input compared to
a thick sheath wire,” explained Chad
Kosta, an ESAB account manager and
welding engineer working with Rubin.
“Experienced operators like Rubin can
push the parameters toward the high-
er side to achieve higher deposition
rates, or he can set his parameters
once and then switch between the flat
and uphill positions without returning
to the wire feeder to adjust settings.”
For operators with less experience
or who feel more comfortable with
lower parameters, thin-sheath elec-
trodes enable them to make welds
with excellent sidewall fusion and
good penetration yet still have an
arc with enough energy to prevent
spatter.
Testing Wires
Characteristics of FCAW-G elec-
trodes differ between manufacturers
and product lines. To illustrate this
point, application engineers evaluated
parameter windows for several differ-
ent thin-sheath E71T-1 electrodes,
welding uphill using 1⁄16-in.-diameter
electrodes. They evaluated the mini-
mum and maximum amperages where-
in an acceptable fillet weld could be de-
posited, with a 1⁄4-in. fillet on the low
end and a 5⁄16-in. fillet on the high end.
The criteria included acceptable bead
appearance, maintaining predeter-
mined fillet size, and minimum spat-
ter and convexity (maximum convexi-
ty on the 1⁄4-in. fillet was 5⁄64 in., while
the 5⁄16-in. fillet had a maximum con-
vexity of 3⁄32 in.).
The results in Table 1 and 2 demon-
strate the different ranges of various
electrodes.
“With the right thin-sheath elec-
trode, I can really go across the spec-
trum with heat and wire feed speed,”
Rubin said. “I can move parameters
around quite a bit and retain all the
promised performance benefits.”
Tests were conducted using E71T-
1/T-9 electrodes designed for use with
75% argon/25% CO2 shielding gas and
100% CO2 shielding gas. Using mixed
gas (Rubin’s choice) generally creates a
softer arc and reduces spatter, where
the reactive CO2 gas creates a hotter,
harsher arc and more spatter. Histori-
cally, using a mixed gas and FCAW-G
electrodes with a fast-freezing slag and
when welding in cold and humid envi-
ronments sometimes led to porosity.
As the silicon and manganese in the
filler composition evacuate impurities
to the weld surface, whether moisture
or other contaminants, the gases and
contaminants become trapped under
the slag and create porosity.
Newer generations of FCAW-G elec-
trodes have had their filler formulas
updated to address these issues. Those
designed for 100% CO2 now operate
with less spatter, whereas those de-
signed for mixed gas reduce porosity
issues caused by impurities.
“I used to be frustrated because I
spent a lot of time grinding out porosi-
ty,” Rubin said. “The deoxidizers in the
electrodes nowadays help me reduce
prep time. The metal doesn’t necessar-
ily have to be ground down to a mirror
finish. The higher levels of weld bead
appearance are really pretty neat, too,
plus the slag releases easier. In fact,
the slag usually starts to self-release
after letting the weld cool for about a
minute. A quick hit with a wire wheel
easily cleans it off” — Fig. 5.
In some applications, some FCAW-
G formulations may also eliminate the
need to preheat the joint to drive off
moisture. However, weld procedures
for most of Rubin’s applications call
for a preheat temperature of 150°F
— Fig. 6.
Kosta added, “When evaluating
electrodes, conduct tests in ambient
conditions and on joints that mimic
real parts as much as possible. There’s
a huge difference between welding in a
lab and welding in the real world
where temperature, moisture, and
wind can affect results.”
“There’s a constant conversation
among welding operators about elec-
trode selection,” said Rubin. “Unfortu-
nately, there’s a lot of misinformation,
and some of my issues were my own
fault. That’s where working with an
electrode expert helps. When I was
fighting porosity, I was not factoring
in electrode type in relation to surface
preparation. After being introduced to
the electrode I’m running now, I was
honestly scared of using something
new. I was not about to weld on cus-
tomer parts. I used some heavy scrap
plate and made lots of test welds. Only
after experiencing how this thin-
sheath electrode worked as promised
did I use it on money-making parts.” WJ
BOB GULAS (bgulas@esab.com) is business
product manager, ESAB Welding & Cutting
Products, Hanover, Pa.
JULY 2018 / WELDING JOURNAL 37
Projects You Can Do This Summer
Step-by-step instructions for four DIY creations
BY KRISTIN CAMPBELL

T
his summer, tap into your creative side by welding
various home-made projects. You can keep them for
yourself, save them for future gifts, or even donate
them for fundraisers. And if you know of any teenagers
looking to do something productive while they’re out of
school, why not get them involved? Fun summer creations
from a hot-water tank BBQ grill to a brazed fighter plane
(as described in this article) can be crafted using a variety
of skills and materials.
Before you start, please remember safety comes first. Be
sure to follow practices outlined in the American National
Standards Institute (ANSI) Standard, Z49.1:2012, Safety in
Welding, Cutting, and Allied Processes.
Now, just like mixing a fresh batch of lemonade to keep
you hydrated on a sunny day, here are recipes to build
unique projects you can be proud of.

Hot-Water Tank BBQ Grill

Tim J. DeVargas (faulknerweld@
yahoo.com), a welding instructor at the
T. L. Faulkner Career Technical Center,
Prichard, Ala., and the previous AWS
Mobile Section chairman, detailed
how to construct a hot-water tank
BBQ grill.
This model features thicker,
durable, and long-lasting metal, De-
Vargas explained, because in the
south, BBQs are popular. The benefits
of building it are two-fold for stu-
dents; they learn to work one step at
a time and gain cutting/measuring
experience.
“You can also make some good
money for your program,” DeVargas
said, given the grill costs about $50 to
make and sells for $100.
Materials
• Hot-water tank
• Four pieces of 11⁄4- or 11⁄2-in. square
tubing for the legs, approximately 36
in. long
• 11⁄2-in. angle iron for a bottom
shelf, additional piece to make a cross
member
• 14- or 16-gauge metal for leg caps,
circle with vent holes, circle for vent
cap
• ½- or ¾-in. flat expanded metal
for the inside cooking surface tray,
along with another piece of this mate-
rial to fit in the tank’s end pieces, then
one more piece for the utensil shelf
• Two 6- or 8-in. bearing-type,
hard-rubber wheels
• 1-in. angle iron for the top and
bottom shelves, shelf supports, cross
braces, and utensil shelf
• ¾-in. raised expanded metal for
the charcoal trays
• Two bolts and nuts (length and
size of the wheel bearings) with one
5
⁄16-in. bolt and nut, one 1⁄4-in. bolt, nut
and spring, and two bullet-style hinges
• 3- to 4-in. pipe for an exhaust
vent approximately 6 to 8 in. long
• 1-in. square tubing to make han-
dles for the vent side Fig. 1 — This hot-water tank will be
• ½- to 1-in.-flat bar to both frame turned into a grill.
the door and make a doorstop
• An old chipping hammer to fabri- plasma cutting device, all the fittings.
cate a door handle Weld cap all the fitting holes, previ-
• High-heat paint (meant for grills) ously cut, using gas metal arc welding
(GMAW) with a 0.035- or 0.045-in.
Building Process wire. Grind and clean all the edges and
welds.
Remove all fittings from your hot- Cut, four times, 11⁄4- or 11⁄2-in. square
water tank — Fig. 1. Also, remove the tubing for the legs, approximately 36
outer shell from the tank, and use a in. long (one side 45 deg, the other
plasma cutting device to cut this into side flat). Measure the tank to lay out
pieces. Caution: Insulation is flamma- and weld the four legs to it.
ble and will flare as you cut this outer Measure and cut 11⁄2-in. angle iron
shell, so remove all foam insulation for a bottom shelf, approximately
using a scraping tool. Cut out, using a halfway between the floor and bottom

38 WELDING JOURNAL / JULY 2018

 Fig. 2 — The grill’s shaping up with four
legs, a bottom shelf, two bearing-type,
hard-rubber wheels, and weld caps.
Fig. 5 — A 3-in. circle with vent holes.
of the grill. Weld (angle up) to all four
legs, and weld in cross member (angle
iron down) for mesh support. Cut and
weld ½- or ¾-in. flat expanded metal
inside of the bottom tray.
Use two, 6- to 8-in. bearing-type,
hard-rubber wheels on one set of legs,
marking and welding the bolts to put
on the wheels (cut off excess with a
band saw). For stability, weld caps to
the bottom of the other legs — Fig. 2.
Mark and cut out a grill door, just
above half of the tank, using a plasma
cutting device.
Measure the length and width of
the tank, approximately 3 to 4 in.
above the bottom. Using 1-in. angle
iron, cut and build two square/rectan-
gle shelves (for charcoal). Cut and weld
(angle up) ¾-in. raised expanded met-
al. With the expanded metal, cut two
half (moon) pieces to cover the curve
in the tank, and weld one to each char-
coal tray — Figs. 3, 4.
Fabricate a 3-in. circle with vent
holes, then line it up on the bottom of
Fig. 3 — T. L. Faulkner Student Chris- Fig. 4 — Trevor Wainwright, also a stu-
tian Boone plasma cuts an interior dent at T. L. Faulkner, uses GMAW with
grill piece. a 0.045-in. wire to work on the grill.
Fig. 6 — A 3- to 4-in. pipe for an ex-
haust vent approximately 6 to 8 in. Fig. 7 — Welded handles on the grill’s
long. vent side.
the tank, and using bolt in center, bolt
it to the tank — Fig. 5. Tack weld the
nut as well.
Cut two pieces of 1-in. angle iron
the length of the tank, excluding the
curve. Clamp the first piece of angle
iron to the door opening, approxi-
mately 11⁄4 in. below its lip (angle
down), and spot weld using GMAW or
shielded metal arc welding. Use a small
level to mark the tank’s backside rest-
ing on the front angle. Hold up the
other previously cut angle iron, upside
down, and spot weld in place.
Cut two pieces of 1-in. angle iron
across the tank’s width, weld (angle
down) the bottom of the angle at the
top level of the front and back pieces.
Also, cut a ½-in.-flat expanded metal
to fit in the tank’s end pieces, from
the curve to the cross, and tack weld in
position.
Measure the distance on the cook-
ing surface, length and width, then
Fig. 8 — The finished, painted hot-
cut and build two square/rectangle
water tank BBQ grill.
shelves, loose enough to be easily lift-
JULY 2018 / WELDING JOURNAL 39
ed up. Invert (angle down) and cut and
weld ½-in.-flat expanded metal to the
shelf (grilling surface).
Cut 3- to 4-in. pipe for an exhaust
vent approximately 6 to 8 in. long —
Fig. 6. Also, cut and fabricate a cap, us-
ing a 1⁄4-in. bolt and nut with spring,
weld to the inside top of the vent pipe
to keep pressure on it.
Weld handles, using 1-in. square
tubing, on the vent side — Fig. 7.
Using bullet-style hinges, weld the
door into position.
Using ½- to 1-in.-flat bar, frame the
door to cover the opening from cutting
out the door.
Fabricate a doorstop, for when lift-
ing the door, from 1-in.-flat bar.
Fabricate a handle, out of an old
chipping hammer, that’s modified for
this purpose and weld it to the door.
Build a rectangle, three-sided shelf,
to weld in front using ½-in.-flat ex-
panded metal.
Sand and paint the hot-water tank
BBQ grill with high-heat paint de-
signed for grills — Fig. 8.

Birdhouse
Heather Grys-Luecht (heather.
grysluecht@mstc.edu), the manager of
continuing education at Mid-State
Technical College’s Wisconsin Rapids
Campus, gave birdhouse building
guidelines. This project enables prac-
ticing basic skills.
Last year, as a collaborative effort
between Mid-State Technical College’s
School of Advanced Manufacturing &
Engineering, and the Continuing Edu-
cation Department, a two-night metal
garden sculpture community educa-
tion class took place — Fig. 9. The
premise was to give community mem-
bers, many of whom had never experi-
enced a manufacturing-like environ-
ment, a chance to learn skills and use a Fig. 9 — Attendees in Mid-State’s metal garden sculpture class last year look on as
their instructor demonstrates how to assemble and tack weld birdhouses.
medium for artistic expression.
“The first few times we ran the
class, the majority of the participants
were female and over the age of 50,
but ages ranged from 12 years old
(with a parent) to over 70,” Grys-
Luecht said. This success led the col-
lege to create a 32-h, eight-week class
on welding for the home and garden.
“It has been exciting to see so much
interest in our welding classes and to
see students, men and women alike,
progress in skill level and creativity
over such a short period of time,”
added Michael Schultz, Mid-State in-
dustrial mechanical technician pro-
gram instructor.

Materials

• 14-gauge mild steel sheet cut into
these dimensions: 6  8.8 in., bent up
to 90 deg, for the bottom; 7.5  11 in.,
also bent up to 90 deg, for the top/
roof; 4.5  4.5 in., with a circle cut in
it, for the front wall; and 4.5  4.5 in.
for the back wall
• ¼-in. mild steel rod, 2 in. long, for
the perch
• A semicircle in 14-gauge mild steel
Fig. 10 — The birdhouse blueprint specifying its various parts and dimensions.
sheet, with an outer radius of 1.0000 house components, including the
and an inner radius of 0.6250, for the top/roof, bottom, back wall, front wall,
hanger perch, and hanger — Figs. 10, 11.
Note: Components for this project
Building Process were precut on a computer numerical
control plasma table, but materials
Following what’s specified in the may be precut using manual methods
blueprint, gather all the precut bird- — Fig. 12. Remove any sharp edges or

40 WELDING JOURNAL / JULY 2018

 Fig. 11 — All the precut components.
Fig. 14 — The roof is attached, along
with the perch next to the center cut-
out.
slag from plasma-cut edges; a chipping
hammer for slag and a file to remove
burrs are all that’s needed.
Using gas metal arc welding
(GMAW), with 75%/25% argon/CO2
shielding gas and 0.035-in. E70S-6
filler wire, tack the front and back
walls on to the bottom section, with
three evenly spaced tacks on each side
Darth Vader TIE Fighter Fire Pit
Daymon Gast (dgast@lw210.org),
who has 18 years of high school welding
teaching experience in Illinois, wants
the force to be with you while creating a
Star Wars-inspired, Darth Vader TIE
fighter fire pit. He works at Lincoln-Way
Central and East High Schools, where
his students are used to making various
welded projects, and is an adjunct weld-
ing instructor at Joliet Junior College.
“Any Star Wars fan instantly con-
nects with what we’ve built here. It
gets immediate attention and instant
requests for the opportunity to own
Fig. 12 — A computer numerical con-
trol plasma table was used to cut
pieces.
Fig. 15 — The top hanger’s in place.
— Fig. 13. Make the tack welds on the
inside of the birdhouse for a cleaner
look.
Place the perch approximately ¼ in.
into the hole, in the front wall, and
weld from the inside.
Finish welding the walls to the bot-
tom from the inside with two stitch
welds, ¾ to 1 in. long, evenly spaced
along the inside seams.
Evenly space the overhang of the
the next one we build,” Gast said. He
also knew it would motivate future
students to begin thinking of what
their welding skills could create.
Gast provided the following in-
structions on making this 28 in. long
 21 in. high  12 in. deep fire pit —
Fig. 17. It weighs 45 lb.
Materials
• A cylinder tank (either a new
propane or an old, no longer working
air compressor cylinder tank)
Fig. 13 — Use GMAW to tack the front
and back walls onto the bottom
section.
Fig. 16 — A birdhouse that’s been dec-
oratively welded.
top/roof and tack weld it to the walls.
Place a short stitch weld, about 1½
in. long, at the center of each roof/wall
seam in the front and back — Fig. 14.
Center the hanger on the peak of
the roof and tack weld both sides of
each connection point — Fig. 15.
To finish your birdhouse, paint it or
decoratively weld it to your personal
taste — Fig. 16.
• One 24  24 in., 16-gauge sheet
metal
• Approximately 14 ft of 0.120-in.
wall thickness, 1-in. square tubing
• 2.5 ft of 5  5 in. thin-wall square
tubing, or more sheet metal, to make
the two horizontal wing supports
• 3 ft of 7⁄16-in. smooth rod
• A very small section of 6-in. pipe
for the top
• A short amount of 2-in. Schedule
40 pipe, and perhaps some small-
diameter Schedule 40 pipe, to make
the blasters in front
JULY 2018 / WELDING JOURNAL 41
 • Expanded metal for the fire pit’s
top
• High-temperature paint (meant
for BBQs)

Building Process

Because the fire pit is made from a

propane cylinder, Gast recommends
purchasing a new tank never filled
with propane. These retail for $25–30.
If you prefer to use a previously
filled propane cylinder, even though
it’s empty, never cut into it without
consulting AWS F4.1:2017, Safe Prac-
tices for the Preparation of Containers
and Piping for Welding, Cutting, and
Allied Processes.
An alternative to the fuselage of the
fire pit would be a used air compressor
tank. “You will, at a certain point in
this project, want to burn off the fac-
tory-applied paint using an oxyacety-
lene rosebud heating torch tip,” Gast
explained.
Cut the project parts with a plasma
arc cutting device or small tip oxy-
acetylene torch. Fig. 17 — This Star Wars-inspired, Darth Vader TIE fighter fire pit is 28 in. long  21 in.
Because the metal is relatively thin, high  12 in. deep.
he recommends using gas metal arc
welding (GMAW) with a 0.030-in. wire form the heavy work, and a 40-grit zir- you don’t get the wings even, you can
and 75%/25% argon/CO2 gas. conia flap disk to polish it. use your angle grinder cut-off wheel to
“You’ll have some great welds on Don’t forget to cut holes through cut the tacks. Be sure to put the tacks
clean metal with this arc process, as the blaster guns, where they are at- in open areas, so that they can be cut
long as you remember to burn away tached to the tank, as they will glow if needed,” Gast said.
and clean off all the original paint red with flames. Expanded metal to put on top of
from the cylinder,” Gast said. “Later, The geometry of the angles is diffi- the fire pit makes a convenient place
you’ll want to use a high-temperature cult, but if you end up with joint open- to heat a few hot dogs at a time.
BBQ paint in black on the outside to ings, they can be filled using a stitch- “Budget a week to build, and it’s a
be able to have a hot fire in it.” weld technique with your GMAW gun. good team-building exercise; you’ll
The welds on the wings need to be “The other major challenge you’ll need someone to help with it,” Gast
flush ground. Use angle grinders fitted face is propping the fighter wings up said of this project.
with an abrasive grind wheel to per- in order to spot weld it temporarily. If

Brazed Fighter Plane

After describing how to make the
fire pit, Daymon Gast also detailed cre-
ating a brazed fighter plane — Fig. 18.
“We have ROTC in our high school,”
Gast said of the inspiration behind
making this. “Several of my welding
students are proudly in it and are even
pursuing careers in the Air Force after
high school.”
Materials
• One spark plug
• 16-gauge steel for the wings and
tail fins
• A large washer for the base
• 1⁄8-in. ER70S or RG45 rod that has
been coiled and cut
• Clear coat paint
Building Process
Gast noted a computer numerical
control plasma cutting table is used to
mass produce the wings and tail fins
for this project. The process leaves
some dross/slag; however, that needs
to be polished with a 40-grit zirconia
flap disk on an angle grinder.
Using a low fuming brazing rod, 1⁄16
3
or ⁄32 in. diameter, braze the fighter
plane’s pieces together. The base’s
large washer needs to be attached to
the 1⁄8-in. ER70S or RG45 rod, then the
two side wings and three tail fins need
to be joined onto the spark plug (for
the wings, you can choose underneath
or on the sides of the plane’s fuselage).
Avoid getting your base metal too
hot during heating, and make sure
both pieces at the weld joint are at a

42 WELDING JOURNAL / JULY 2018

 Dear Readers:
The Welding Journal encourages
an exchange of ideas through
letters to the editor. Please send
your letters to the Welding Journal
Dept., 8669 NW 36 St., #130,
Miami, FL 33166. You can also reach
us by fax at (305) 443-7559 or by
sending an email to Roline Pascal at
rpascal@aws.org.
Reprints
Custom reprints of Welding Journal
articles, in quantities of 100 or
more, may be purchased from
Jill Kaletha, national account
executive, Mossberg & Co. at
(800) 428-3340, ext. 149 or
(574) 289-9253, ext. 149.
You can also send an email to
jkaletha@mossbergco.com.

Fig. 18 — Using just a few materials,

including a spark plug and 16-gauge
steel, this brazed fighter plane comes
together.

proper temperature. “I tell my stu-

dents that each piece at the joint
should be dull red, not red hot. You
will also have a much easier time if you
can get someone to help you. A second
set of eyes and hands, along with good
communication skills, are a blessing.”
He likes how the planes look un-
painted, so he typically requests stu-
dents paint them with a clear coat.
“The project is quite small and
can take as little as an hour to build,”
Gast concluded. “We made this a new
project just this year to celebrate the
success of our ROTC program and to
give some diversity to our brazing
projects.” WJ

KRISTIN CAMPBELL (kcampbell@aws.org) is

features editor of the Welding Journal.

Figs. 1–8 are courtesy of Tim J. DeVargas;

9–16, Heather Grys-Luecht; and 17, 18,
Daymon Gast.

JULY 2018 / WELDING JOURNAL 43


Cordless Tools for
Today’s Fab Shops
These products provide a number of
advantages and allow operators to
work anywhere
C
ordless power tools have been
progressively taking over the
market (see lead photo). Today,
manufacturers as well as construction
and industrial end users are entwined
with cordless power tools, but around
60 years ago, a cordless power tool
wasn’t even an option.
Cordless tools were introduced in
the early 1960s with drills, using
heavy nickel-cadmium (Ni-Cd) batter-
ies at low voltages (4 V). These tools
did not offer much power nor runtime,
but where needed, they offered a solu-
tion. Progressively, technology im-
proved and the range of tools broad-
ened as well as the adoption of cord-
less tool use. Nonetheless, cordless
tools never really conquered the
heavy-duty construction and industri-
al space because of Ni-Cd technology
limitations, such as memory effect re-
ducing the runtime and the life of the
44 WELDING JOURNAL / JULY 2018
batteries, drop in voltage through the
discharge cycle, weight, self-discharge
rates, and other issues.
The market has changed a lot in the
past 10 to 15 years since lithium-ion
batteries were developed and started
taking over the cordless tool market.
Lithium-ion batteries offer more pow-
er and performance in a lighter, small-
er package with the ability to handle
tough industrial applications, and they
are longer lasting and quicker to
charge. The memory effect is now a
thing of the past; batteries can be
charged and discharged at any time
without performance loss. Some man-
ufacturers even started offering an un-
limited warranty, regardless of the
number of charging cycles.
Since 2015, the use of new lithium
high-density cells (LiHD) has allowed
larger tools, like 6-in. and even 9-in.
cordless grinders, to become major
Cordless beveling
tools offer versatility
while allowing for
precise chamfering
and clean cold
processing of metal.
BY ANTOINE DERCHÉ
contenders in the cordless market.
LiHD cells are slightly larger and
longer than traditional cells, offering
higher power output and storage capa-
bility. Together with optimized battery
pack architectures, they open doors
for cordless applications never imag-
ined before.
Learn about the pros of going cord-
less in this article.
Air and Electric Tool
Background Details
There are numerous benefits to go-
ing cordless. Pneumatic air hoses and
electrical extension cords can pose
hazards at job locations. One of the
most common job-site injuries is due
to tripping hazards; it’s the third most
common cause of worker downtime.
By eliminating the need for air hoses
and extension cords, this is one safety

Fig. 1 — Cordless rivet guns are now as fast as pneumatic models.
consideration that can be eradicated
instantly.
Also, if users find themselves in a
situation where the cord or hose is not
long enough, and they try to make it
reach farther, they could cause materi-
als or other tools in the workspace to
be knocked over, creating a more dan-
gerous environment for their cowork-
ers.
Air lines can also pose a challenge if
the pressure and airflow requirements
of the tool being used is not met. This
can lead to the tool performing im-
properly or even failing. Futhermore,
maintaining a compressor for air tool
use can be costly and noisy. For in-
stance, even if the proper airflow and
pressure are delivered by the compres-
sor, both values significantly drop af-
ter the hundreds of feet (and some-
times even miles) of pneumatic lines
that can run throughout a factory or
shipyard. In addition, compressors and
air lines need a lot of maintenance, es-
pecially in humid environments and
climates, increasing the operating
cost. The cost associated with air lines
is often overlooked when making a
tool-buying decision. Cordless is
cheaper to operate in the long term,
even though the upfront cost may
seem higher.
When working with electric-corded
tools, using the incorrect length and
gauge extension cord, or simply a low-
quality cord, can starve a tool of volt-
age, making it inefficient. The voltage
can drop significantly and reduce the
RPM of the motor, which limits the ca-
pacity of the motor to cool itself down.
This leads to premature wear on the
tool, even for tools equipped with elec-
tronic protection. Heavy-duty exten-
sion cords are also expensive, and the
setup time involved is longer, especial-
ly if the user needs to move to a new
workstation or location.
Additionally, when an operator is
required to use a tool on scaffolding, a
ladder, or tethered to a structure in
the air, cordless tools give them the
option to work anywhere and at any
time. A good rule to follow is this: If
the operator is working in an area and
needs to move more than 3 ft in any
direction, go cordless.
The Cordless Movement
Fifteen years ago, who would have
imagined that cordless drills would be
mainstream? Yet today, no mainte-
nance, repair, and overhaul operator,
plumber, or electrician would not even
think of “plugging in” to a wall socket
when there’s a cordless option avail-
able. Only a very small amount of pro-
duction applications still justifies the
need for corded tools. There are even
powerful cordless job-site vacuums
that can be carried anywhere, avoiding
constant plugging and unplugging.
Portable Performance
Cordless power tools are easier to
maneuver with and, by definition, to-
tally portable. This is their main
strength. Modern batteries offer up to
4.0 Ah in a compact 18-V, five-cell flat
battery pack or 8.0 Ah in a standard
ten-cell pack, which is plenty of run-
time for most common applications.
This includes drilling, riveting, bevel-
ing, cleaning work with a high-torque
die grinder, and 9-in. cordless grinding
and cutting.
Charger Characteristics
Charging technologies are also
adapting to the industrial world. If one
charger is not enough for the number
of workers on a job site, some manu-
facturers offer multibay chargers,
which can charge up to eight batteries
at the same time. Multibay chargers
are ideal for metal cutting and grind-
ing because there’s always a battery
charged and waiting to be used.
For high-use applications, fast
chargers are now available from some
manufacturers, reducing the charging
time of larger batteries from more
than two hours to less than one hour.
Air-cooled systems allow the user to
place a hot battery in the charger and
for it to start charging in virtually no
time after it is removed from the tool.
The charger’s built-in-fan system
quickly cools the inside of the battery
pack as it begins the charging cycle.
This kind of charger allows the battery
to survive more charge and discharge
cycles.
Heavy-Duty Considerations
There are fewer and fewer times
when the benefits of using a corded
tool outweigh going cordless, especial-
ly when it comes to heavy-duty pro-
duction jobs, or if an end user is in a
static heavy-duty environment.
Sometimes it may not make sense
to replace a corded tool with a cordless
one. Examples include a chop saw sta-
tioned in a shop, a large angle grinder
or production grinder with high-power
needs, or a metal drill used for drilling
large holes at a high frequency. How-
ever, with the advent of more power-
ful cordless tools, these examples are
becoming less and less prevalent.
Cordless and Metal
Fabrication
When it comes to metal fabrication,
welding is the heart of the process. A
handful of manufacturers offer spe-
cialized, fully integrated cordless solu-
tions for before and after welding. Be-
cause lithium high-density batteries
allow for larger tool operation and
longer runtime, there are now numer-
ous cordless specialty tools available.
JULY 2018 / WELDING JOURNAL 45
Rivet Guns, Beveling, and
Much More
Metal fabricators can use cordless
tapping tools, which allow the user
one continuous motion that automati-
cally changes the rotation of the motor
and produces a perfectly threaded hole
in a few seconds. There are also cord-
less rivet guns that make riveting
work quick and easy — Fig. 1.
Cordless beveling tools offer unlim-
ited versatility while allowing for pre-
cise chamfering and clean cold pro-
cessing of metal. Some manufacturers
offer cordless flat-head angle grinders
with a low profile for working on welds
in hard-to-reach locations.
Fig. 2 — High-speed cordless drills/drivers are used in metal fabrication for fast
High-speed cordless drills are now drilling and accurate fastening applications.
used in metal fabrication for quick
and accurate fastening applications —
Fig. 2. There are plenty of other cord-
less tool options available for metal
fabricators, such as burnishers, die
grinders, pipe and tube sanders, and
band saws, so a shop no longer needs
to be completely tied down with cords
and hoses.

Evolving Technology
Premium tool manufacturers have
helped the cordless market grow with
better batteries and cordless tools that
last longer and are able to handle the
most demanding applications.

Battery Benefits
A focus is no longer just on the
mainstream, light-duty tools for elec-
tricians and plumbers, but on solu-
tions for metal fabrication and the in-
dustrial workplace. Manufacturers
concentrate on developing advanced
battery technology, where energy
management at the cell level during
the charge and discharge cycles en-
hances the life of the battery packs.
These manufacturers also focus on
systems that air-cool batteries to pro-
tect the charging cells against thermal
deterioration even after heavy use.
They further concentrate on de-
signing components inside the battery
that allow for higher current delivery
without resistance, maximizing the
power output and life of the tool. The
18-V standard battery packs now can
deliver up to 1600 or 3200 W when
combined in a 36-V configuration.
This kind of power opens the door to
Fig. 3 — The development of new batteries offering more output power makes way
for the introduction of more powerful motors.
all sorts of industrial applications with
very little limitation.
Metabo Corp., West Chester, Pa.,
offers a battery with a microchip that
allows it to communicate with the tool
and battery charger. The ongoing com-
munication ensures each battery cell is
evenly charged and discharged every
time, extending the life of the battery
and protecting the tool being used.
The development of new batteries
offering more output power makes
way for the introduction of more pow-
erful motors — Fig. 3. The 1600-W
machines are now available on 18-V
platforms; that’s the equivalent of up
to a 13-A corded tool, or up to 3200 W
for a 36-V machine. This breakthrough
makes industrial applications that
were simply not an option a few years
ago possible.
Conclusion
Simply put, the future of power
tools is cordless. It is only a matter of
time before technology catches up to
the need for even more powerful,
longer lasting, and compact batteries
for a more diverse future in cordless
industrial applications. WJ
ANTOINE DERCHÉ
(aderche@metabousa.com) is the director
of marketing and product management,
Metabo Corp., West Chester, Pa.

46 WELDING JOURNAL / JULY 2018

CONFERENCES

IIW 2018 Annual Assembly and 2018 Welding Summit

International Conference
July 15–20
Bali, Indonesia
The annual event will take pace at Vali Nusa Dua Conven-
tion Center, Bali, Indonesia. In conjunction with the IIW
General Annual Assembly, the International Conference
aims to provide a forum for networking and knowledge ex-
change among scientists, researchers, and industry related
to welding and joining. Topics to be covered during the con-
ference include advanced welding processes and technolo-
gies; welding automation and simulations; design and fabri-
cation; inspection and quality assurance of welded products;
corrosion and surface protection of welding; personnel de-
velopment and qualifications; business aspects of welding;
and special sessions on maritime, transportation, and off-
shore industries. For those involved in welding and related
practices. This year’s theme is “Advanced Welding and Smart
Fabrication Technologies for Efficient Manufacturing
Processes.”
Oct. 16 and 17
League City, Texas
This summit, cosponsored by the AWS Houston Section,
brings the best quality information and construction weld-
ing professionals together for a series of interactive presen-
tations on how more value can be brought to welding opera-
tions and the best ways to execute successful welding proj-
ects. Topics covered will include welder training and per-
formance; using advanced equipment and procedures to im-
prove quality, productivity, and safety; and fundamental
project success. A career fair will be held on Oct. 17 from 3
to 5 pm. WJ
For more information, please contact the AWS Conferences and
Seminars Business Unit at (800) 443-9353, ext. 213, or email
cbrowne@aws.org. You can also visit the Conference Department
website at aws.org/conferences for upcoming conferences and
registration information.

WELDING
S UMMI T
American Welding Society®
aws.org

–2 0 18–
October 16 – 17, 2018
South Shore Harbour Resort & Conference Center
League City, TX

BRINGING
G VA
ALUE TO YOUR WELDING OPERAT
O TION
• Meet Indusstr y Experts • Network with
w Peers • Discuss Coommon Issues
• Gain PDH Credits • Attend Career Fair
Proogram Toopics:
Keynote Adddress
• Welder Training & Welder
e Performance
• Field Hea t Trea tmentt: An Essential Variable in Welding “Weldingg Yoour Teeam Life”
• Non-Destructive Examina tion: Cost vs Value
• Importance of Accuraa te Welding Procurement DAV
VID RUTTHERFORD
• Outsourcing Work Sccope and Recognizing Scope Split Foormer Navy S SEAL Motivational Speaker,
• Fundamental Projectt Success Author,, Peerform
mance Coach, and Host

$ OFF
$50 O ADMISSION BEFORE SEPTEMBER
R1
Co-sponsored by
REG
G ISTER
S NO
O W! American Welding Society®
HOUSTON SECTION
aws.org/summitreg
wss org/s
org/summitreg
g/ mmitreg
iit g Endorsed by the AWS D10 Committee on Piping and Tuubing

48 WELDING JOURNAL / JULY 2018

 American Welding Society®
FOUNDATION

GRADUAATTE RESEARCH FELLOWSHIPS

To: Professors Engaged in Joining Research
Subject: Request for Proposals for 2019 AW
WS Fellowships
The American Welding Society (AWS) seeks to foster university research in joining and to recognize outstanding faculty and studdent talent. We are
again requesting your proposals for consideration by AWS.
It is expected that the winning researchers will take advantage of the opportunity to work with industry committees interested in the
t research topics
and report work in progress.
Recipients are encouraged to submit the results of their work for presentation at the annual AWS professional program. If the authors
a believe the
results of their research are unique and would be an important contribution to the welding literature, the authors are encouraged to submit a relevant
paper for publication in the Weelding Journall (contingent on successful peer review).
Please note there are important changes in the schedule which you must follow in order to enable the awards to be made in a timely fashion.
Proposals must be received at American Welding Society by August 31, 2018. New Fellowships will be announced at FABTECH
A in November.

THE AWARDS
A
The Fellowships or Grants are to be in amounts of up to $25,000 per year. Proposals may be funded for a period of up to three years, however,
progress reports and requests for renewal must be submitted for the second and third years. Renewal by AWS will be contingent on demonstration
of reasonable progress in the research or in graduate studies.
The AWS Fellowship is awarded to the student for graduate research toward a Masters or Ph.D. Degree under a sponsoring prrofessor at a North
American University. The qualifications of the Graduate Student are key elements to be considered in the award. The academicc credentials, plans
and research history (if any) of the student should be provided. The student must prepare the proposal for the AWS Fellowsship. However, the
proposal must be under the auspices of a professor and accompanied by one or more letters of recommendation from the sponssoring professor or
others acquainted with the student's technical capabilities. Should the student selected by AWS be unable to accept the Fellowshhip or continue with
the research at any time during the period of the award, the award will be forfeited and no (further) funding provided by AWS. The bulk of AWS
funding should be for student support. AWS reserves the right not to make awards in the event that its Committee finnds all candidates
unsatisfactory.

RESEARCH TOPICS
Topics for the AWS Fello wship may span the full range of the joining industr y. Proposals for both a pplied and fundamental research topics
are welcome. The Committee may recommend topics to be considered and these will be posted at aws.org/graduatefelloowships.

DETTAIL
A LS
The Propposal should include: 6.Current Sta
S tus of Relevant Research
1. Exxecutive Summary 7.Technicaal Plan of Action
2. Annnualized Breakdown of Funding Required and 8.Qualifications of Researchers
Puurpose of Funds (Student Salary, Tuittion, etc.) 9.Pertinentt Literature References and Related
3. Maatching Funding or Other Support foor Intended Publicatioons
Reesearch 10. Special Equipment
E Required and Availability
4. Duuration of Project 11. Statemennt of Critical Issues Which Will Influeence
5. Staatement of Problem and Objectives Success or Failure of Research
In additioon,
o , tthee pproposal
oposa must
ust incclude:
1. Stuudent's Academic History, Resume and Transcript (Both undergraduatee and graduate)
2. Reecommendation(s) Indicating Qualifications for Research must include one o or more letters of recommendation
froom the sponsoring professor or otheers acquainted with the student's teechnical capabilities
3. Brief Section or Commentary on Impoortance of Research to the Welding Community
C and to AWS, including
Technical Merit, National Need, Long Term Benefits, etc.
4. Staatement Regarding Probability of Suuccess

The technical portion of

o the proposal should not exceed fiffteen typewritten pages. The page limit for the proposal is twenty-five typewritten pages.
The title page, which may include the executive summarry, is not included in the page counnt limit. The maximum file size for the proposal is 2
megabytes. Proposalss that exceed either the page limit or file size limit will be considered non-conforming and will not be evvaluated. Proposal
should be typed in a minimum of 12-point font in Times, Times New Roman, or equivalent. Proposals received after the deadline will not be
evaluated. Proposals should be sent electronically by August 31, 2018 to John Douglass, Associate Director, AWS Foundation at jdouglass@aws.org.

aws.org
COMING EVENTS
U.S., CANADA, MEXICO EVENTS
ITW Welding Instructors Conference. July 17–19. Fox Valley
Technical College, Appleton, Wis. This three-day profession-
al development workshop for welding instructors focus on
creative teaching ideas, innovative technologies, and new
teaching tools. The conference will feature speakers from
the American Welding Society, NOCTI, and Oshkosh Corp.,
as well as engineers from Miller Electric and Hobart Broth-
ers. Visit millerwelds.com.
7th Global Automotive Lightweight Materials Detroit
Summit. Aug. 21–23. COBO Center, Detroit, Mich. This
year’s summit will focus on implementing lightweighting in-
novations and optimizing multimaterial architectures for
electric, autonomous, and next-generation internal combus-
tion engine vehicles. The three-day event will provide a mix
of in-depth technical sessions, case study-led presentations,
and panel discussions on the hottest issues. There will also
be an adjoining exhibition hall showcasing the latest tech-
nologies, advanced materials, and manufacturing processes
for Body in White. Visit global-automotive-lightweight-
materials-detroit.com.
50 WELDING JOURNAL / JULY 2018
INTERNATIONAL EVENTS
IIW 2018 Annual Assembly and International Conference.
July 15–20. Bali Nusa Dua Convention Center, Bali, Indone-
sia. This conference provides a forum for networking and
knowledge exchange among scientists, researchers, and in-
dustry related to welding and joining. Topics that will be
covered include advanced welding processes and technolo-
gies; welding automation and simulations; design and fabri-
cation; inspection and quality assurance of welded products;
corrosion and surface protection of welding; personnel de-
velopment and qualifications; business aspect of welding;
and special sessions in maritime, transportation, and off-
shore industries. Visit iiw2018.com.
Aluminium 2018 — 12th World Trade Fair & Conference. Oct.
9–11. Messe Düsseldorf, Germany. Spread across six exhibi-
tion halls, global players, specialists, and innovative compa-
nies will showcase the industry’s complete range from alu-
minum production to machines and plants for processing to
finished goods and recycling. Visit aluminium-messe.com/en/.
First International Conference on Defence Technology
(ICDT). Oct. 21–25. Beijing Friendship Hotel, Beijing, China.
The conference brings together different aspects of defense
technology including energetic materials, materials behavior
and properties, advanced manufacturing techniques, impact
mechanics, and electromagnetic launch technologies. Visit
icdt.cos.org.cn.

22nd IAS Steel Conference. Oct. 23–25. Rosario, Santa Fe,

Argentina. This conference is intended for researchers, man-
ufacturers, suppliers, and users in the steel industry around
the world to review the progress and achievements made in
recent years; assess new developments in steel research, pro-
duction, and application; meet new challenges; and promote
further international exchange and cooperation. Visit
siderurgia.org.ar/conf18.

EuroBLECH 2018 — 25th International Sheet Metal Working

Technology Exhibition. Oct. 23–26. Hanover Exhibition
Grounds, Germany. The meeting place for experts and top
decision makers in the sheet metal working industry, the ex-
hibition will cover technology sectors including sheet metal,
semifinished and finished products, handling, separation,
forming, flexible sheet metal working, tube/section process-
ing, joining, welding, additive manufacturing, surface treat-
ment, processing of hybrid structures, tools, quality control,
CAD/CAM/CIM systems, factory and warehouse equipment,
as well as R&D. Visit euroblech.com.

EDUCATIONAL OPPORTUNITIES

Advanced Fundamentals & Brazing by Design. Philadelphia,

Pa. Two-and-a-half days of classes covering the essential
theoretical aspects of brazing technology combined with
real-life applications and case studies. Visit
lucasmilhaupt.com.

Business Electronics Soldering Technology. Classes held in

Chicago, Ill.; Detroit, Mich.; Minneapolis, Minn.; Cleveland,
Ohio; and Huntsville, Ala., or can be coordinated onsite at
your facility. Contact BEST at (847) 797-9250 to register.

Certification Classes and Seminar. Steel Tank Institute/

Steel Plate Fabricators Association offers upcoming
courses: STI/SP001 Aboveground Tank System Inspector
Training: Aug. 20–24; Sept. 17–21; Oct. 29–Nov. 2; and
Dec. 10–14. Cathodic Protection Inspection Training and
Certification: Aug. 14, 15; Oct. 2, 3; and Oct. 23, 24. Steel
Water Storage Tank Seminar: Aug. 9. Visit steeltank.com.

E­Courses in Destructive and Nondestructive Testing of

Welds and Other Welding­Related Topics. Online video
courses taken at one’s own pace offer certificates of comple-
tion and continuing education units. Contact Hobart Insti-
tute of Welding Technology; (800) 332-9448;
welding.org/product-category/online-courses/.

JULY 2018 / WELDING JOURNAL 51

ESAB Welding and Cutting Distributor Instructor­Led
Training. Year-round training at Denton, Tex.; West
Lebanon, N.H.; Traverse City, Mich.; Hanover, Pa.; and Salt
Lake City, Utah. Online e-Learning training available at
training.victortechnologies.com, email trainingteam@esab.com.
European Modern Furnace Brazing School. Oct. 9–11. Pon-
tardawe, Wales, UK. Wall Colmonoy presents a three-day
seminar offering knowledge and practical application on
brazing design, metallurgical aspect/brazing operation,
brazing atmosphere and furnace equipment, brazing mate-
rial selection and applications, and quality control. Contact
Jordan Brace at brazingschool@wallcolmonoy.co.uk, or call
+44 (0) 1792 860622, or visit wallcolmonoy.com/
brazingschool.
EWI Event Central. EWI presents classes and training for
summer 2018 at its Columbus, Ohio, headquarters. Courses
include Fundamentals of Welding Engineering, Aug. 13–17,
plus Sheet Metal Forming, Sept. 10, 11.
GE Industrial Computed Tomography (CT) Operator Course.
Learn to operate the 3D technology that is becoming more
prominent in industrial quality control and metrology.
Lewistown, Pa., (315) 554-2039; geinspectionacademy.com.
52 WELDING JOURNAL / JULY 2018
Hypertherm Cutting Institute Online. Includes video tutori-
als, interactive e-Learning courses, discussion forums, webi-
nars, and blogs. Visit hypertherm.com; hyperthermcutting
institute.com.
Industrial Laser Training. Technical training and support
offered for users of industrial lasers in manufacturing,
education, and research. Regularly scheduled classes in laser
welding, laser cutting, and drilling. HDE Technologies Inc.;
(916) 714-4944; laserweldtraining.com, laser-cutting-drilling-
training.com.
INTEG Courses. Courses in NDE disciplines to meet certifica-
tions to Canadian General Standards Board or Canadian Nu-
clear Safety Commission. The Canadian Welding Bureau;
(800) 844-6790; cwbgroup.org.
Laser Safety Online Courses. Courses include Medical Laser
Safety Officer, Laser Safety Training for Physicians, Indus-
trial Laser Safety, and Laser Safety in Educational Institu-
tions. Laser Institute of America; (800) 345-2737; lia.org.
Laser Safety Training Courses. Courses based on ANSI
Z136.1, Safe Use of Lasers. Orlando, Fla., or customer’s site.
Laser Institute of America; (800) 345-2737; lia.org.
— continued on page 98
 American Welding Society®
EDUCATION
aws.org

DON’T TR UST
U YOUR WELDING
EDUCAATTION
N TO JUSTT ANYONE .
AWS
W offers the most accurrate, relevaant, and well-researchedd seminars in the weldingg industry.
When it comes to your career deevelopment, why not put it in the most capable haands?
Opportunities too further yoour education and careerr are heading your way.

Sign up
u for an AAW
WS educational semiinar near you today!

AWS
W CERTIFIEDD WELDING INSPECTOR SEMINARS
Location Seeminar Date Exam Date Deadline Location Seminar Date Exam
am Date Deadline

San Francisco, CA Auug. 26-31 Sep. 1 Jul. 23 Kankakee, IL Oct. 14-19 Octt. 20 Sep. 10
Beaumont, TX
Beaumont Auug.
ug 26-31
26 31 Sep 1
Sep. Jul.
Jul 23 Denver, CO Oct.
Oct 21
21-26
26 Octtt. 27 Sep. 17
Sep
Nashville, TN Seep. 9-14 Sep. 15 Aug. 6 Des Moines, IAA Oct. 21-26 Octt. 27 Sep. 17
Portland, OR Seep. 9-14 Sep. 15 Aug. 6 Cleveland, OH
H Oct. 28-Nov. 2 Novv. 3 Sep. 24
Pittsburgh, PA Seep. 16-21 Sep. 22 Aug. 13 Sacramento, CA
C Nov. 4-9 Novv. 10 Oct. 1
Houston, TX Seep. 16-21 Sep. 22 Aug. 13 Dallas, TX Nov. 4-9 Novv. 10 Oct. 1
Kansas City, MO Seep. 23-28 Sep. 29 Aug. 20 Charlotte, NC Nov. 11-16 Novv. 17 Oct. 8
New Orleans,
Orleans LA Seep
ep. 23
23-28
28 Sep.
Sep 29 Aug. 20
Aug Reno,
Reno NV Nov. 25-30
25 30 Decc. 1 Oct
Oct. 22
Long Beach, CA Seep. 30-Oct. 5 Oct. 6 Aug. 27 Orlando, FL Nov. 25-30 Dec. 1 Oct. 22
Tuulsa, OK Seep. 30-Oct. 5 Oct. 6 Aug. 27 Houston, TX Dec. 2-7 Dec. 8 Oct. 29
Ann Arbor, MI Seep. 30-Oct. 5 Oct. 6 Aug. 27 Los Angeles, CA
C Dec. 2-7 Dec. 8 Oct. 29
Newark, NJ Occt. 7-12 Oct. 13 Sep. 3 Richmond, VA Dec. 9-14 Dec. 15 Nov. 5
Chattanooga, TN Occt. 7-12 Oct. 13 Sep. 3 Miami, FL Dec. 9-14 Dec. 15 Nov. 5

For a complete lissting please visit aws.orgg/cwisc

g scchedule
h
CERTIFICATION SCHEDULE
CERTIFICATION SEMINARS, CODE CLINICS, AND EXAMINATIONS

Note: The 2018 schedule for all certifications is posted online at Location Seminar Dates
aws.org/w/a/registrations/prices_schedules.html. Phoenix, AZ July 15–20
San Diego, CA July 29–Aug. 3
Orlando, FL Aug. 12–17
Certified Welding Inspector (CWI) Boston, MA Aug. 26–31
Denver, CO Sept. 9–14
Location Seminar Dates Exam Date Dallas, TX Sept. 23–28
Waco, TX July 8–13 July 14 Appleton, WI Oct. 7–12
Louisville, KY July 8–13 July 14 Omaha, NE Oct. 21–26
Houston, TX July 15–20 July 21 New Orleans, LA Oct. 28–Nov. 2
Phoenix, AZ July 15–20 July 21 Seattle, WA Nov. 11–16
Cleveland, OH July 15–20 July 21
Philadelphia, PA July 15–20 July 21
Baton Rouge, LA July 22–27 July 28 Certified Welding Educator (CWE)
Helena, MT July 22–27 July 28 Seminar and exam are given at all sites listed under Certified
Omaha, NE July 22–27 July 28 Welding Inspector. Seminar attendees will not attend the Code
Seattle, WA July 29–Aug. 3 Aug. 4 Clinic portion of the seminar (usually the first two days).
Chicago, IL July 29–Aug. 3 Aug. 4
Charlotte, NC Aug. 5–10 Aug. 11
Dallas, TX Aug. 12–17 Aug. 18 Certified Welding Sales Representative
San Diego, CA Aug. 12–17 Aug. 18 (CWSR)
Salt Lake City, UT Aug. 12–17 Aug. 18 CWSR exams are given at Prometric testing centers. More
Minneapolis, MN Aug. 19–24 Aug. 25 information at aws.org/certification/detail/certified-welding-
Miami, FL Aug. 19–24 Aug. 25 sales-representative.
San Francisco, CA Aug. 26–31 Sept. 1
Beaumont, TX Aug. 26–31 Sept. 1
Nashville, TN Sept. 9–14 Sept. 15 Certified Welding Supervisor (CWS)
Portland, OR Sept. 9–14 Sept. 15 CWS exams are given at Prometric testing centers. More infor-
Pittsburgh, PA Sept. 16–21 Sept. 22 mation at aws.org/certification/detail/certified-welding-supervisor.
Houston, TX Sept. 16–21 Sept. 22
Kansas City, MO Sept. 23–28 Sept. 29
New Orleans, LA Sept. 23–28 Sept. 29 Certified Radiographic Interpreter (CRI)
Long Beach, CA Sept. 30–Oct. 5 Oct. 6 The CRI certification can be a stand-alone credential or can
Tulsa, OK Sept. 30–Oct. 5 Oct. 6 exempt you from your next 9-Year Recertification. More in-
Detroit, MI Sept. 30–Oct. 5 Oct. 6 formation at aws.org/certification/detail/certified-radiographic-
S. Plainfield, NJ Oct. 7–12 Oct. 13 interpreter.
Chattanooga, TN Oct. 7–12 Oct. 13
Chicago, IL Oct. 14–19 Oct. 20 Location Seminar Dates Exam Date
Denver, CO Oct. 21–26 Oct. 27 Dallas, TX July 16–20 July 21
Des Moines, IA Oct. 21–26 Oct. 27 Kansas City, MO Aug. 20–24 Aug. 25
Cleveland, OH Oct. 28–Nov. 2 Nov. 3 Philadelphia, PA Sept. 17–21 Sept. 22
Atlanta, GA Oct. 28–Nov. 2 Nov. 3 Pittsburgh, PA Oct. 15–19 Oct. 20
Sacramento, CA Nov. 4–9 Nov. 10
Dallas, TX Nov. 4–9 Nov. 10
Charlotte, NC Nov. 11–16 Nov. 17
Reno, NV Nov. 25–30 Dec. 1 Certified Robotic Arc Welding (CRAW)
Orlando, FL Nov. 25–30 Dec. 1 OTC Daihen Inc., Tipp City, OH; (937) 667-0800, ext. 218
Houston, TX Dec. 2–7 Dec. 8 Lincoln Electric Co., Cleveland, OH; (216) 383-4723
Los Angeles, CA Dec. 2–7 Dec. 8 Wolf Robotics, Fort Collins, CO; (970) 225-7667
Norfolk, VA Dec. 9–14 Dec. 15 Milwaukee Area Technical College, Milwaukee, WI;
Miami, FL Dec. 9–14 Dec. 15 (414) 456-5454
College of the Canyons, Santa Clarita, CA; (651) 259-7800,
ext. 3062
9-Year Recertification Seminar for CWI/SCWI Ogden-Weber Applied Technology College, Ogden, UT;
For current CWIs and SCWIs needing to meet education re- (800) 627-8448
quirements without taking the exam. The exam can be taken
at any site listed under Certified Welding Inspector.

IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm your course status before
making travel plans. 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 website at aws.org/certification/docs/schedules.html. For information on AWS seminars
and certification programs, or to register online, visit aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.

54 WELDING JOURNAL / JULY 2018

BY KATIE PACHECO — kpacheco@aws.org
National and District Officers Nominated for 2019
The 2017–2018 Nominating Com-
mittee has announced its slate of can-
didates who will stand for election to
American Welding Society (AWS) na-
tional offices for the 2019 term, which
begins Jan. 1, 2019.
Nominated are the following candi-
dates: Thomas J. Lienert for president;
Robert W. Roth, W. Richard Polanin,
and Dennis K. Eck for vice presidents;
Carey Chen for treasurer; and Walter
J. Sperko and Sayee Raghunathan for
directors-at-large. One president,
three vice presidents, one treasurer,
and two directors-at-large are to be
elected.
The National Nominating Commit-
tee was chaired by Past President
David L. McQuaid. Serving on the
committee with McQuaid were Tony
Anderson, Debbie L. Doench, Michael
A. Krupnicki, David J. Landon, Samuel
J. Lindsey, Dave E. Lynnes, Tom
Mustaleski, Ron C. Pierce, Eftihios Sir-
adakis, Michael Sebergandio, Mike
Skiles, and Jerry Uttrachi. Chelsea L.
Steel served as secretary.
The Nominating Committees for
Districts 1, 4, 7, 10, 13, 16, 19, and 22
have selected the following candidates
for election/reelection as district di-
rectors for the three-year term Jan. 1,
2019–Dec. 31, 2021. The nominees
Thomas Lienert Robert Roth
president vice president
Walter Sperko Sayee Raghunathan
director­at­large director­at­large
SOCIETY NEWS
are Douglas Desrochers, Dist. 1; Lynn
Showalter, Dist. 4; Larry Heckendorn,
Dist. 7; Mike Sherman, Dist. 10; Ron-
ald Ashelford, Dist. 13; Karl Fogleman,
Dist. 16; Shawn McDaniel, Dist. 19;
and Robert Purvis, Dist. 22.
Thomas Lienert, nominated to
serve as president, is a technical staff
member and a R&D engineer 4 at Los
Alamos National Laboratory. He is
also an active member and officer of
several national-level committees, has
served as chairman of the AWS New
Mexico Section, and is currently a
member of the Executive Committee
of that Section.
Robert Roth, nominated to serve as
vice president, is a member of the
AWS Executive and Finance Commit-
tees, WEMCO, and RWMA. He is also
president and CEO of RoMan Manu-
facturing Inc., an AWS-sustaining
member company. He also serves on
the boards of various organizations
and nonprofit corporations.
Richard Polanin, nominated to
serve as vice president, is a retired
professor and program chair of the
manufacturing engineering technolo-
gy and welding technology programs
at Illinois Central College. He is cur-
rently coprincipal investigator for
Weld-Ed and chair of the AWS Peoria
Richard Polanin
vice president
Douglas Desrochers Lynn Showalter
Dist. 1 director Dist. 4 director
Section. He is also an active member
of several AWS Committees.
Dennis Eck, also nominated to
serve as vice president, is general sales
manager for Praxair in the greater
Houston area. He has been involved
with the AWS Houston Section for 27
years, serving as chairman, first and
second vice chairman, treasurer, and
secretary. He was also a part of the
Membership Committee for seven
years.
Carey Chen, nominated to serve as
treasurer, is president, CEO, and board
vice chairman of Cincinnati Incorpo-
rated. He currently serves as treasurer
on the AWS Board of Directors and the
Foundation Board of Trustees. He is
also a member of the AWS Audit and
Compensation Committees, as well as
chair of the Finance Committee.
Walter Sperko, nominated as direc-
tor-at-large, is president of Sperko En-
gineering Services Inc. He has been in-
volved with the AWS Carolina Section
since the 1970s, serving as chair sever-
al times, and is currently an officer of
that Section. He is also a member of
the D10 Committee on Piping and
Tubing as well as vice chair of the
Technical Activities Committee.
Sayee Raghunathan, also nominat-
ed as director-at-large, is an engineer-
Dennis Eck Carey Chen
vice president treasurer
Mike Sherman
Dist. 10 director
JULY 2018 / WELDING JOURNAL 55
SOCIETY NEWS
Ronald Ashelford
Dist. 13 director
ing specialist at Saudi Aramco in Saudi
Arabia. He was the chair of the AWS
Saudi Arabian Section and credited
with reinvigorating that Section,
which is 200-members strong. He is
also the Fellow of seven institutes. He
has worked for TWI Ltd. in Cambridge,
UK; J. Ray McDermott Middle East
Inc. in Dubai; and Advani-Oerlikon
Ltd. in India.
Douglas Desrochers, nominated to
serve as Dist. 1 director, has worked as
a welding instructor at Old Colony Re-
gional Vocational Technical High
School for 23 years. He is also an AWS
Certified Welding Inspector (CWI) and
an AWS Certified Educator (CWE). An
AWS member since 2000, he has
served as the chair, secretary, treasur-
er, and technical representative of the
AWS Central Massachusetts/Rhode Is-
land Section.
Lynn Showalter, nominated to
serve as Dist. 4 director, is a welding
engineer 4 with Newport News Ship-
building, a division of Huntington In-
galls Industries. He has served on the
AWS Tidewater Section since 1992,
with two terms as chairman and six
AWS Bylaws Article IX, Section 3
Section 3. Nominations.
Nominations, except for Executive
Director and Secretary, shall proceed as
follows:
(a) Nominations for District Direc-
tors shall be made by the District Nom-
inating Committees [see Article III, Sec-
tion 2(c)]. The National Nominating
Committee shall select nominees for
the other offices falling vacant. The
names of the nominees for each office,
with a brief biographical sketch of each,
shall be published in the July issue of
the Welding Journal. The names of the
56 WELDING JOURNAL / JULY 2018
Karl Fogelman Shawn McDaniel
Dist. 16 director Dist. 19 director
years as deputy director. He has also
been an AWS CWI test supervisor for
26 years.
Larry Heckendorn has been nomi-
nated to serve as Dist. 7 director. Bio
and photo not available.
Mike Sherman, nominated to serve
as Dist. 10 director, is the owner of a
full-service welding/fabrication facili-
ty. He has served two terms as the
Cleveland Section chair and one term
as the first vice chair, as well as one
term as the second vice chair of the
Northeast Pennsylvania Section. He
also served as the contract welding su-
pervisor on the ARES project for
NASA Glenn.
Ronald Ashelford, nominated to
serve as Dist. 13 director, is a retired
40-year member of Ironworkers LU-
498, Rockford, Ill. He is currently a
welding instructor at Rock Valley Col-
lege as well as a member of the Weld-
ing Advisory Committee. He has
served as chair of the Blackhawk Sec-
tion for four years, as well as secretary
for 24 years.
Karl Fogelman, nominated to serve
as Dist. 16 director, has been Section
members of the National Nominating
Committee shall also be published in
this issue of the Welding Journal, along
with a copy of this Article IX, Section 3.
(b) Any person with the required
qualifications may be nominated for
any national office by written petitions
signed by not less than 200 members
other than Student Members, with sig-
natures of at least 20 members from
each of five Districts, provided such pe-
titions are delivered to the Executive
Director and Secretary before August
26 for the elections to be held that year.
A biographical sketch of the nominee
Robert Purvis
Dist. 22 director
chairman twice, second vice chairman
once, treasurer five times, Awards
Committee member three times, sec-
retary twice, and deputy district direc-
tor four times during his 34-year
tenure with AWS. He has also served
on several AWS D1.1 committees.
Shawn McDaniel, nominated to
serve as Dist. 19 director, is a welding
instructor at Big Bend Community
College, as well as an AWS CWI and
CWE. He has served as chairman of
the Puget Sound Section, and is in-
volved with the Inland Empire and
Spokane Sections. For his dedication,
he has been awarded various District
and Section awards.
Robert Purvis, nominated to serve
as Dist. 22 director, is employed as an
AWS CWI and CWE for the California
Dept. of Corrections and Rehabilita-
tion at Folsom State Prison. Previous-
ly, he worked as an ironworker/welder
with the Local 433 in Los Angeles. He
has also served as chairman of the
Sacramento Valley Section, where he
is still a member of the Executive
Board. WJ
(and acceptance letter) shall be provid-
ed with the petition. Any such nominee
shall be included in the election for
such office. A District Director may be
nominated by written petitions signed
by at least ten members each from a
majority of the Sections in the District,
provided such petitions are delivered to
the Executive Director and Secretary
before August 26 for the elections to be
held that year. A biographical sketch
and acceptance letter of the nominee
shall be provided with the petition. Any
such nominee shall be included in the
election.

Nominations Sought for National Officers
American Welding Society (AWS)
members who wish to nominate candi-
dates for President, Vice President,
Treasurer, and Director-at-Large on
the AWS Board of Directors for the
term starting Jan. 1, 2020, may either
1. Send their nominations electron-
ically by Sept. 30, 2018, to Chelsea L.
Steel at csteel@aws.org, c/o John R.
Bray, chairman, National Nominating
TECH TOPICS
Opportunities to Contribute to
AWS Technical Committees
The following committees welcome
new members. Some committees are
recruiting members with specific in-
terests in regard to the committee’s
scope, as marked below: Producers (P),
General Interest (G), Educators (E),
Consultants (C), and Users (U). For
more information, contact the staff
member listed or visit aws.org/
library/doclib/Technical-Committee-
Application.pdf.
S. Borrero, sborrero@aws.org, ext.
334. Definitions and symbols, A2
Committee (E). Titanium and zirco-
nium filler metals, A5K Subcommit-
tee. Piping and tubing, D10 Com-
mittee (C, E, U). Welding practices
and procedures for austenitic
steels, D10C Subcommittee. Alu-
minum piping, D10H Subcommittee.
Chromium molybdenum steel pip-
ing, D10I Subcommittee. Welding of
titanium piping, D10K Subcommit-
tee. Purging and root pass welding,
D10S Subcommittee. Low-carbon
steel pipe, D10T Subcommittee. Or-
bital pipe welding, D10U Subcom-
mittee. Duplex pipe welding, D10Y
Subcommittee. Joining metals and
alloys, G2 Committee (E, G, U). Reac-
tive alloys, G2D Subcommittee (G).
R. Gupta, gupta@aws.org, ext. 301.
Filler metals and allied materials,
A5 Committee (E). Magnesium alloy
filler metals, A5L Subcommittee.
P. Portela, pportela@aws.org, ext.
311. High energy beam welding
and cutting, C7 Committee (C, E, G).
Hybrid welding, C7D Subcommittee
(G). Robotic and automatic weld-
SOCIETY NEWS
Committee, or didate, including a written statement
2. Present their nominations in per- by the candidate as to his or her will-
son at the open session of the Nation- ingness and ability to serve if nomi-
al Nominating Committee meeting nated and elected, letters of support,
scheduled for 2:00 to 3:00 p.m., Tues- and a 5 × 7-in. head-and-shoulders col-
day, Nov. 6, 2018, at the Georgia or photograph.
World Congress Center, Atlanta, Ga., Note: Persons who present nomina-
during the 2018 FABTECH Expo. tions at FABTECH must provide 20
Nominations must be accompanied copies of biographical materials and
by biographical material on each can- written statements.
During a Finance Committee meeting held on April 27 at the Amara Cay Hotel and Resort
in Islamorada, Florida, AWS Treasurer Carey Chen (center) presented former AWS Execu­
tive Director Ray Shook (left) and his wife, Sandy Shook, with an award to thank them for
their dedication to AWS and the Committee.
ing, D16 Committee (C, E). Welding Committee (C, E, G, U).
in sanitary applications, D18 Com- A. Alonso, aalonso@aws.org, ext.
mittee (C, E, G). Additive manufac- 299. Resistance welding, C1 Com-
turing, D20 Committee (C, E, G). mittee (C, E, G, U). Friction welding,
J. Molin, jmolin@aws.org, ext. 304. C6 Committee (C, E). Automotive
Structural welding, D1 Committee welding, D8 Committee (C, E, G, U).
(E). Sheet metal welding, D9 Com- Resistance welding equipment, J1
mittee (C, G). The D9 Committee on Committee (C, E, G, U). Welding in
Sheet Metal is recruiting consultants, the aircraft and aerospace indus-
producers, and general interest try, D17 Subcommittee (C, E, G).
members. S. Hedrick, steveh@aws.org, ext.
D. Gaschler, dgaschler@aws.org, ext. 305. Metric practice, A1 Committee
306. Methods of weld inspection, (C, E). Mechanical testing of welds,
B1 Committee (C, E). Brazing and B4 Committee (E, G, P). Joining of
soldering, C3 Committee (C, E, G). plastics and composites, G1 Com-
Welding in marine construction, mittee (C, E, G). Personal & facili-
D3 Committee (C, E, G, U). Welding ties qualification, PFQC Committee
of machinery and equipment, D14 (C, E, G). Safety and health com-
JULY 2018 / WELDING JOURNAL 57
SOCIETY NEWS
mittee, SHC Committee (E, G).
J. Rosario, jrosario@aws.org, ext. 308.
Procedure and performance qualifi-
cation, B2 Committee (E, G). Thermal
spraying, C2 Committee (C, E, G, U).
Oxyfuel gas welding and cutting, C4
Committee (C, E, G). Welding iron
castings, D11 (C, E, G, P, U). Railroad
welding, D15 (C, E, G, U). The D15
Committee on Railroad Welding is re-
cruiting educators, users, consultants,
and general interest members.
Technical Committee
Meetings
All AWS Technical Committee
meetings are open to the public. Con-
tact staff members listed below or call
(800/305) 443-9353 for information.
July 17, 18. D15C Subcommittee
on Track Welding. Memphis, Tenn.
The D15 Committee on Railroad Weld-
ing is recruiting educators, users, con-
sultants, and general interest mem-
bers. Contact: J. Rosario, ext. 308,
jrosario@aws.org.
The D9 Committee on Sheet Metal
is recruiting consultants, producers,
and general interest members. Con-
tact: J. Molin, jmolin@aws.org, ext. 304.
Standards for Public Review
AWS was approved as an accredited
standards-preparing organization by
the American National Standards In-
stitute (ANSI) in 1979. AWS rules, as
approved by ANSI, require that all
standards be open to public review for
comment during the approval process.
This column also advises of ANSI ap-
proval of documents.
B2.1-1-314:20XX, Standard Welding
Procedure Specification for Naval Applica-
tions (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root of
Carbon Steel (S-1), 1⁄8 inch [3 mm]
through 1-1⁄2 inch [38 mm] Thick, MIL-
MS-1 and MIL-70S-2, in the As-Welded
or PWHT Condition, Primarily Pipe for
Naval Applications. New Standard.
$136.00. ANSI public review expires
7/16/18. Contact: J. Rosario, ext. 308,
jrosario@aws.org.
B2.1-1-315:20XX, Standard Welding
Procedure Specification for Naval Applica-
tions (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root
Followed by Shielded Metal Arc Welding
of Carbon Steel (S-1), 1⁄8 inch [3 mm]
through 1-1⁄2 inch [38 mm] Thick, MIL-
MS-1 MIL-70S-2, and MIL-7018-M in
the As-Welded or PWHT Condition, Pri-
marily Pipe for Naval Applications. New
Standard. $136.00. ANSI public review
expires 7/16/18. Contact: J. Rosario,
ext. 308, jrosario@aws.org.
B2.1-8-321:20XX, Standard Welding
Procedure Specification for Naval Applica-
tions (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root of
Austenitic Stainless Steel (S-8), 1⁄8 inch [3
mm] through 1-1⁄2 inch [38 mm] Thick,
MIL-3XX, in the As-Welded Condition,
Primarily Pipe for Naval Applications.
New Standard. $136.00. ANSI public
review expires 7/16/18. Contact: J.
Rosario, jrosario@aws.org, ext. 308.
B2.1-8-322:20XX, Standard Welding
Procedure Specification for Naval Applica-
tions (SWPS-N) for Gas Tungsten Arc
Welding with Consumable Insert Root
Followed by Shielded Metal Arc Welding
of Austenitic Stainless Steel (S-8), 1⁄8 inch
[3 mm] through 1-1⁄2 inch [38 mm] Thick,
MIL-3XX and MIL-3XX-XX, in the As-
Welded Condition, Primarily Pipe for
Naval Applications. New Standard.
$136.00. ANSI public review expires
7/16/18. Contact: J. Rosario, ext. 308,
jrosario@aws.org.

AWS District 20 Presents a Plaque to Salt Lake Community College

AWS District 20 Director Pierrette Gorman presented the Grant Plaque to Salt Lake Community College (SLCC) during a Section meeting on
May 17. In September, the college is planning to dedicate its new building and computer lab to Sam Gentry, former executive director of
the AWS Foundation, who passed away on Aug. 5, 2017. Pictured (from left) are Bob Udy, AWS Utah Section treasurer and SLCC instructor;
Eric Heiser, SLCC’s dean of the School of Applied Technology and Technical Specialties; and Pierrette Gorman.

58 WELDING JOURNAL / JULY 2018

 SOCIETY NEWS
MEMBERSHIP ACTIVITIES
New AWS Supporters Division 5 Steel Inc. Linn Benton Community College
P.O. Box 6058 6500 SW Pacific Blvd.
Sustaining Members Starke, FL 32091 Albany, OR 97321

ETI – Ewer Testing & Inspection Inc. Prestressed Concrete North Central Kansas Technical
1131 S. 22 St. Construction LLC College
Bismarck, ND 58504 P.O. Box 311 2205 Wheatland Ave.
etitesting.com Newton, KS 67114 Hays, KS 67601
ETI Ewer Testing & Inspection Inc.
offers more than 40 years of experience Stahl Premier Welding Academy
in the nondestructive examination and 3201 W. Old Lincoln Wy. 15255 Gulf Freeway 141-D
inspection field, including welding pro- Wooster, OH 44691 Houston, TX 77034
cedure and performance qualifications
per AWS, ASME, and API codes. United Rentals Inc. Prospect Education – Charter
6929 E. Greenway Pky. College LLC
Fermi National Accelerator #200 750 Sandhill Rd., Ste. 100
Laboratory Scottsdale, AZ 85254 Reno, NV 89521
Kirk Rd. and Wilson St.
Batavia, IL 60510 Raymondville Agriculture Science
fnal.gov Educational Institution Department
Members 419 FM 3168
LSI Inc. Raymondville, TX 78580
6111 Technology Ct. Alvin C. York Institute
Jacksonville, FL 32221 701 N. Main St.
lsijax.com P.O. Box 70 Supporting Company
LSI Inc. provides training and tech- Jamestown, TN 38556 Members
nical support services to the U.S. gov-
ernment, foreign militaries, and the Associated Builders & Contractors Active Aircraft Welding Inc.
defense industry with trained, experi- New Mexico 23905 Clinton Keith 114-519
enced, and skilled personnel, who are 2821 Broadway Blvd. NE Wildomar, CA 92562
supported by modern technologies Albuquerque, NM 87107
and methods. Camtek Software
Creek Wood High School 492 Eastland Dr.
Maersk Olie og Gas A/S 3499 TN 4N C Decatur, GA 30030
Amerika Plads 29 Charlotte, TN 37036
Copenhagen, Hovedstaden SEC Soluciones Estructurales S.A.
Denmark, 2100 ECK – Welding Training Center de C.V.
maersk.com P.O. Box 52224, Riqqa Carretera Federal Mexico Puebla KM
Mangaf, Al Ahmadi 96.5, Puebla, Juan C. Bonilla
Novelis Inc. Kuwait City, 53462 Mexico, 72640
1950 Vaughn Rd.
Kennesaw, GA 30144 Fayette County Area Vo-Tech Sky Climber LLC
novelis.com 175 Georges Fairchance Rd. 1800 Pittsburgh Dr.
Uniontown, PA 15401 Delaware, OH 43015
RDI Oilfield Fabrication
1560 River Rd. Glen High School
Fruita, CO 81521 1320 Collaborative Wy. Welding Distributor
rdironworks.com Leander, TX 78641 Company Members
Jefferson State Community College MagneGas Welding Supply
Affiliate Companies 2601 Carson Rd. 11885 44 St. N.
Birmingham, AL 35215 Clearwater, FL 33762
Apella S.A.
101, Dim. Christou Mpeka St. Kelliher School District ULT LLC
Spata, Attiki 19004 345 4 St. NW 6000 W. Executive Dr., Ste. K
Greece Kelliher, MN 56650 Mequon, WI 53092

JULY 2018 / WELDING JOURNAL 59

SOCIETY NEWS
AWS Member Counts
June 1, 2018
Sustaining.................................593
Supporting ...............................341
Educational...............................829
Affiliate.....................................684
Welding Distributor ...................61
Total Corporate .......................2508
Individual ...........................57,767
Student + Transitional ...........11,467
Total Members ....................69,234
Member-Get-A-Member
Campaign
Listed here are the members partic-
ipating in the 2018 Member-Get-A-
Member Campaign. The campaign
runs from Jan. 1 to Dec. 31, 2018.
Members receive 5 points for each In-
dividual Member and 1 point for every
Student Member they recruit.
For campaign rules and a prize list,
please see page 65 of this Welding Jour-
nal. Standings as of May 21. For more
information, call the AWS Membership
Dept. at (800) 443-9353, ext. 480.
F. A. Cea, Columbus — 60
A. D. Dillon, Detroit — 59
M. A. Centeno, Nevada — 59
D. Box, Pascagoula — 49
B. Newcomb, Madison-Beloit — 39
C. Cosentino, Pittsburgh — 35
H. H. Hughes, Wheeling — 35
D. S. Beecher, San Diego — 34
M. Krupnicki, Rochester — 32
B. P. Brandmeir, Lehigh Valley — 29
M. D. Stein, Detroit — 29
A. M. Young, Detroit — 27
J. W. Morris, Mobile — 27
R. Riggs, Tulsa — 24
O. N. Boylan, Cleveland — 23
M. J. Lannom, Long Beach/Orange
County — 22
D. R. Jacobs, NW Penn. — 20
G. L. Gammil, NE Mississippi — 20
C. A. Donnell, Northwest Ohio — 19
G. D. Wentland, Sacramento — 18
T. A. Harris, Johnstown-Altoona — 18
Nominate AWS Members to be Profiled
The Welding Journal is celebrating the diversity of its
members by profiling two AWS members each month in its
Society News section. Nina Choy and Aleasha Hladilek are
profiled on page 62.
60 WELDING JOURNAL / JULY 2018
D. A. Saunders, Lakeshore — 16
R. Young, Iowa — 16
D. Melton, Greater Huntsville — 15
J. L. Stokes, Dayton — 15
S. Toops, Central Texas — 15
C. A. Renfro, Chattanooga — 14
M. J. Jones, Saginaw Valley — 14
O. Serrano, Ecuador — 14
B. M. Scherer, Cincinnati — 13
B. A. Cheatham, Columbia — 12
G. T. Rolla, Los Angeles/Inland
Empire — 12
E. R. Krestakos-Fromson,
Indiana — 11
S. Smalley, Mid-Plains — 11
District Director Awards
The District Director Award pro-
vides a means for District Directors to
recognize individuals and corporations
who have contributed their time and
effort to the affairs of their local
Section and/or District.
District 1 Director Doug Desroch-
ers will present awards to Thomas Fer-
ri, Boston Section; Timothy Kinna-
man, Central Mass./Rhode Island Sec-
tion; Albert Moore, Connecticut Sec-
tion; Geoff Putnam, Green & White
Mountain Section; Paul McClay, Maine
Section; and Michel Marier, Montreal
Section.
District 3 Director Sean Moran will
present awards to Ed Calaman, York-
Central Penn. Section; Justin Heis-
tand, Lancaster Section; and Jason
Deiter, Lehigh Valley Section.
District 4 Director Stewart Harris
will present an award to Joseph Flynn,
Northeast Carolina.
District 7 Director Uwe Aschemeier
will present awards to Don Stoll, Pitts-
burgh Section; Bruce Scherer, Cincin-
nati Section; Larry Barley, Dayton Sec-
tion; Jim Worman, Columbus Section;
George Bodnar, Tri-State Section;
Michael Pawelczyk, Wheeling Section;
Harry Bennear, Johnstown-Altoona
Section; and Randy Dull/EWI, Colum-
To nominate an AWS member, submit a statement about
what makes the nominee a noteworthy member, the nomi-
nee’s contact information, and a photo of the nominee to
Katie Pacheco, kpacheco@aws.org.
bus Section.
District 8 Director Joshua Burgess
will present awards to Robert O’Neal,
Nashville Section; William Hoskins,
Northeast Tennessee Section; Robert
Thomas, Holston Valley Section; Dusti
Jones, Chattanooga Section; and Joe
Smith, Greater Huntsville Section.
District 13 Director John Willard
will present awards to Jeff Crompton
and Mark Stevenson, JAK Section;
George Blaine, Ron Ashelford, Larry
Clevenger, and Ryan Forsell, Black-
hawk Section; as well as Bernie Pi-
otrowski, Jo-Ann Piotrowski, and Paul
Leadingham, Illinois Valley Section.
District 15 Director Mike Hanson
will present awards to Randy Washen-
esky, Ryan Dall, and Clayton Arens,
Arrowhead Section; as well as Thea
Bunde, Jay Gerdin, Mike Carey, Kelvin
Jones, Pam Lesemann, and Scott Stu-
daker, Northwest Section.
Actions of the Districts
Council
On May 20, after due considera-
tion, Districts Council approved the
charter of the AWS Central Florida-
Orlando Section, District 5.
The AWS Mississippi Valley Sec-
tion, District 14, was disbanded for
noncompliance with the requirements
of an active AWS Section.
The following AWS Student Chap-
ters were also approved for Charter:
Trident Technical College Student
Chapter, District 5; Haleyville City
School District Student Chapter, Dis-
trict 8; Laurel Technical Institute Stu-
dent Chapter, District 10; Alma High
School Student Chapter, District 11;
Houston Community College Student
Chapter, District 18; Hayden-Ray High
School Student Chapter and Los Sol-
dadores de East Tech Student Chapter,
District 21; and Yanbu Industrial Col-
lege Student Chapter, Saudi Arabia In-
ternational Section.
 SOCIETY NEWS
Scholarship Honors Fallen Welder
By Melanie Patterson, public relations chair, AWS Greater Huntsville Section

ers, so they donated $8000 to AWS’s Brian Keeton, welding instructor at

Too Mitchell is shown at his job at Red­
stone Arsenal in Huntsville, Ala. Mitchell
died on Feb. 14 at the age of 24. His par­
ents donated money to create the Too
Mitchell Memorial Scholarship for the
AWS Greater Huntsville Section.
On April 19, the parents of Too
Mitchell signed the paperwork to cre-
ate the Too Mitchell Memorial Schol-
arship. Mitchell died on Feb. 14 in a
car accident at the age of 24. His par-
ents, JoRudi and Betsy Trapp of Phil
Campbell, Ala., wanted his memory
to live on in the form of helping oth-
Greater Huntsville Section. Most of
those funds came from Mitchell
himself.
“He had most of it in savings,” Bet-
sy said.
Randy Hammond, vice chairman of
the Greater Huntsville Section, said
AWS will match that amount, bringing
the total of the scholarship to $16,000.
This will allow the section to award a
$1000 scholarship to a student every
year for 16 years.
“This is for him to be remembered
and for others to have a chance,” said
Betsy.
Watching her son thrive in his job,
Betsy saw how welding can be a great
career.
“Welding can take you a lot of
places,” she said. “He made good mon-
ey. He loved his job; he lived and
breathed his job.”
Mitchell worked at Redstone Arse-
nal in Huntsville, Ala. He learned to
weld at Northwest Shoals Community
College in Phil Campbell, Ala. He grad-
uated from the welding program in
2013.
the college, said Mitchell was “the best
student I’ve ever had.”
Keeton also said Mitchell had been
extremely competitive. “If you wanted
to make him mad, tell him somebody
could weld better than him,” Keeton
said with a laugh.
According to Hammond, the Too
Mitchell Memorial Scholarship is the
third Section-named scholarship for
the Greater Huntsville Section. The
other two Section-named scholarships
are the Greater Huntsville Section
Scholarship and the Rayburn Johnson
Scholarship.
Students who live in the Greater
Huntsville Section can apply for all
three scholarships from August 1,
2018, to March 1, 2019.
Through the Too Mitchell Memorial
Scholarship, the legacy of a young Ala-
bama welder will serve other new
welders for many years to come.
For more information about this
scholarship and others in the section,
contact Randy Hammond at
rhammond@aidt.edu.

District 18 Conference Held in El Paso

On May 4 and 5, AWS Sections gathered for the District 18 Conference held in the Wyndham Hotel at the El Paso Airport. Held for the first
time in El Paso, Tex., the event also changed the rotation of Sections that host the conference for the first time in 35 years. The El Paso Sec­
tion was praised for doing a wonderful job hosting the Conference.

JULY 2018 / WELDING JOURNAL 61

SOCIETY NEWS
AWS Member Profile
Nina Choy
Nina Choy’s initial life plan didn’t
involve being an engineer. Armed with
a bachelor’s in civil engineering from
Colorado State, she joined the U.S.
Air Force hoping to branch into law
enforcement.
“I didn’t think I wanted to be an en-
gineer,” she said. “But they said, ‘You
don’t get to pick. You have an engineer-
ing degree, so you’ll be an engineer.’”
Looking back, Choy is thankful the
military didn’t give her an option.
“I was exposed to the practical as-
pects of engineering, so I got to do
AWS Educator Member Profile
Aleasha Hladilek
Aleasha Hladilek’s route to welding
wasn’t a linear one. After earning a
bachelor’s degree in anthropology, she
set her sails toward the trades and en-
rolled in an automotive program at
Wisconsin Indianhead Technical Col-
lege (WITC). The decision unveiled a
propensity for welding.
“After graduating and working in
the field for a year, I decided to go
back to school for welding because I
had gained some experience gas metal
arc welding [GMAW] exhaust systems
and found I really enjoyed welding,”
62 WELDING JOURNAL / JULY 2018
hands-on work with our heavy-equip-
ment operators, carpenters, and
welders,” she explained. “I really liked
being out in the shop and on the field.
It showed me a side of engineering I
wasn’t aware of when I was in school.”
After finishing her stint in the Air
Force, Choy began working as a materi-
als engineer for the California Depart-
ment of Transportation (Caltrans),
where she focused on steel fabrication
issues and project management. She
also became an AWS Certified Welding
Inspector.
Ten years later, Choy is still with
Caltrans, but today she performs quali-
ty management for the structures de-
sign division. Because of her diverse in-
dustry experience, Choy is able to help
bridge knowledge gaps.
“A lot of engineers don’t have a fa-
miliarity with steel fabrication and
welding, so it’s nice to facilitate that
conversation so they understand what’s
going on in the shop,” she said.
As an engineer, Choy has worked on
several skyscraping projects, such as
the San Francisco-Oakland Bay Bridge
she said. “Also, the welding jobs I was
hearing about paid better.”
Hladilek graduated from a yearlong
welding program and worked in the
mines, where she performed shielded
metal arc welding (SMAW) with the
Millwright Union. The experience al-
lowed her to land a full-time job per-
forming gas tungsten arc welding
(GTAW) for the aerospace industry.
During this time, she also discov-
ered a knack for teaching while work-
ing part-time for welding and automo-
tive technical college programs. The
experience inspired her to earn a mas-
ter’s degree in career and technical
education.
“My part-time teaching job became
my full-time job, and I’ve continued to
work part-time and summers in the
welding industry both as a welder fab-
ricator and as a welding inspector after
passing my AWS Certified Welding In-
spector and Educator exams,” she said.
With ten years of teaching experience
in her professional tool box, Hladilek
currently works as a welding instruc-
tor and program director for WITC.
and the Gerald Desmond Bridge in
Long Beach.
“Regardless of whether you’re an en-
gineer, an inspector, or a welder, you
can point at a project like that and
proudly say, ‘I worked on that,’” she
said. “We’re so lucky in this type of in-
dustry because our achievements and
hard work impacts so many people.”
Choy is also vice chair of the
AASHTO/AWS D1J Subcommittee on
Bridge Welding and a member of the
D1 Task Group 7 on Tubulars.
“It’s exciting because you are sur-
rounded by knowledgeable people from
different sectors in the industry, so
there’s a lot of cross communication
and learning from one another,” she ex-
plained. “It’s also an opportunity to
change the industry and bring new in-
novations into the code so that others
may use it.”
Despite her engineering prowess to-
day, Choy describes her younger self as
being “a horrible student” because she
needed extra help in her shop classes.
“If my shop teacher could see where I
am today, he would be very surprised.”
She teaches the one-year accelerated
technical welding program, which pro-
vides students with a ready-to-work
technical diploma.
“It’s rewarding to be a part of stu-
dents developing the skills and confi-
dence to find a life-changing, reward-
ing career after their graduation,” she
said.
Hladilek also teaches oxyfuel and
plasma cutting; basic and advanced
GMAW, GTAW, SMAW, and flux cored
arc welding (FCAW); blueprint reading
for welders; and fabrication.
Her students make sauna stoves,
trailers, and tables to raise funds for
jackets and class trips. This year, her
students will be building archways to
aid the college’s remodeling efforts.
Hladilek is also working to set up
her own complete welding and fabrica-
tion shop at home.
“I enjoy working on all sorts of new
and challenging side projects in my
free time,” she said. “From boats to
experimental airplanes, artistic rail-
ings to signage for local businesses.”
BY CINDY WEIHL — cweihl@aws.org
SECTION NEWS
NEW JERSEY
District 1 Summary: O’Leary brought samples of
an “L” bracket he cut using a plasma April 18
Douglas A. Desrochers, director machine and then bent for meeting at- Location: Pantagis, Scotch Plains, N.J.
(508) 763-8011 tendees to evaluate. Temme gave at- Presenter: Matt Dillon, owner, Ship to
dadaws@comcast.net tendees a rundown on the Section’s
June District conference.
CENTRAL
MASSACHUSETTS/RHODE
ISLAND
March 29
Location: Old Colony Regional Voca-
tional Technical High School,
Rochester, Mass.
Presenter: Jennifer Lee, craft safety
and development coordinator, Notch
Mechanical Constructors
Summary: Welding students from Old
Colony, along with invited Diman Re-
gional Vocational Technical Welding
Student Colbey Pouliot and his Weld- CENTRAL MASSACHUSETTS/RHODE CENTRAL MASSACHUSETTS/RHODE
ing Instructor Kevin DeSousa, compet- ISLAND — Freshmen Welding Stu- ISLAND — Seniors Benjamin Lavoie
ed together in the 20th Annual Notch dents (from left) Lauren Eldridge, and Zachary Papadakis completed
Mechanical Pipe Welding Challenge. Colby Medeiros, and Anthony Wolff, the remaining welding and added the
along with junior Welding Student 1
⁄2-in. rebar for the concrete pad that
May 18 Nicholas Valentino, finished off a bend will be poured at a later date. Then
of bike rack mounts they helped they cleaned the entire bike rack in
Location: Old Colony Regional Voca- preparation for priming and painting.
fabricate.
tional Technical High School,
Rochester, Mass.
Summary: Welding students designed,
fabricated, and welded a bike rack for
their school.

District 2
Ken Temme, director
(856) 264-8377
kenneth.temme@gmail.com

LONG ISLAND
May 10
Location: Wantaugh, N.Y. LONG ISLAND — May Section meeting attendees included (from left) Tom Gartland,
Presenters: Ray O’Leary and Ken Paul Rochon, District 2 Director Ken Temme, Harland Thompson, Section Chair Brian
Temme Cassidy, Ray O’Leary, Alex Duschere, Israel Rosado, and Levi Gejada.

CENTRAL MASSACHUSETTS/RHODE ISLAND — Pictured (from left) are Jennifer Lee, Notch Mechanical; Old Colony Welding Instruc-
tor Lance Davenport; Old Colony Students Dylan DeMedeiros; Ben Lavoie; Jospeh LaPointe; Joshua Smolinsky; Zachary Papadakis;
Jenna Desrochers; Kaitlyn Kroninger; Diman Regional Vo-Tech Student Colbey Pouliot; Welding Instructor Kevin DeSousa; and Dis-
trict Director Douglas A. Desrochers.

JULY 2018 / WELDING JOURNAL 63

SECTION NEWS
Shore Cranes
Summary: Dillon gave a brief and in-
teresting history of Ship to Shore
cranes, their evolution, and future
modifications.
PHILADELPHIA
April 25
Location: Salem County Vo-Tech,
Woodstown, N.J.
Summary: The AWS Careers in Weld-
ing Trailer visited Salem County Vo-
Tech. Students in Welding Instructor
Stephanie Hoffman’s class had the op-
portunity to explore the trailer.
PHILADELPHIA/DORCHESTER
CAREER AND TECHNOLOGY
CENTER STUDENT CHAPTER
March 24
Location: Dorchester Career and Tech-
nology Center, Cambridge, Md.
Summary: Dorchester Career and
Technology Center (DCTC) and the competition, information, and lunch
Philadelphia Section hosted its annual for the competitors. Prizes were do-
welding competition. Six high schools nated by Rick Keen and the Keen Com-
from across Maryland with welding pressed Gas Co., AWS, Miller Electric,
programs brought two to three stu- and local fabrication shop C and K
dents each for a total of 15 competi- Lord. Certified Welding Inspectors
tors. Participants came from Cecil, Alex Gagnon and Shaun Smith over-
Wicomico, Dorchester, Carroll, and saw the contest and judging.
Anne Arundel counties. The school’s
welding department overflowed with
parents, students, instructors, AWS
members, and trade school representa-
tives. Students learned about school
choices, scholarships, and educational
and employment opportunities. Spe-
cial guests in attendance included
Janet Piechocki, Hobart Institute of
Welding; Daniel Fillipelli, welding en-
gineering student, Penn Technical Col-
lege; AWS District 2 Director Ken NEW JERSEY — Seen at the Section
Temme; Frank Sragota; and Philadel- meeting are (from left) Matt Dillon, VP
northeast ZPMC USA, and James F.
phian Section Chair Harry Graham. Dolan, Dolan Associates Inc.
The Philadelphia Section provided
supporting prizes, materials for the

PHILADELPHIA/Dorchester Career
PHILADELPHIA/Dorchester Career and Technology Center Student Chapter — and Technology Center Student
Contest organizers and Welding Instructors (first and second from left) Christopher Chapter — CWIs Shaun Smith and
Baker and Harry Graham are seen with Rick Keen of Keen Compressed Gas (far Alex Gagnon, along with Penn Techni-
right) and contest winners (center from left) Dylan Ickes, 3rd place, Wicomico cal College graduate Daniel Fillipelli
County; Tyler Hickey, 2nd place, Cecil County; and Tyler Arnold, 1st place, Cecil County. judged the welding contest.

PHILADELPHIA — Salem County Vo-Tech Welding Instructor Stephanie Hoffman and her students posed in front of the AWS Ca-
reers in Welding Trailer when it visted their school in April.

64 WELDING JOURNAL / JULY 2018


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q New Member Initiation Fee ...........................................................................................................................................$12
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OPTIONS AVAILABLE TO AWS INDIVIDUAL MEMBERS ONLY: 14 q Technician
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A.) OPTIONAL Book Selection (Choose from 25 titles; up to a $192 value; includes shipping & handling) 11 q Consultant
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ONLY ONE SELECTION PLEASE. For more book choices visit https://app.aws.org/membership/books 18 q Customer Service
q Jefferson’s Welding Encyc.(CD-ROM only) q Design & Planning Manual for Cost-Effective Welding q Welding Metallurgy q Welding Inspection Handbook 19 q Other

Welding Handbook Selections: q WHB (9th Ed., Vol. 5) q WHB (9th Ed., Vol. 4) q WHB (9th Ed., Vol. 3) q WHB (9th Ed., Vol. 2) q WH (9th Ed., Vol. 1) Technical Interests (Check all that apply)
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NOTE: Dues include $17.30 for Welding Journal subscription and $4.00 for the AWS Foundation.
G q Arc welding
H q Brazing and soldering
I q Resistance welding
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K q Cutting
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REV. 11/16
 SECTION NEWS
District 3 ganized the contest and awards pre-
sentations with Davis acting as master
Sean Moran, director of ceremonies for the festivity. District
(717) 885-5039 3 Director Sean Moran was in atten-
sean.moran@ahydro.com dance for the event.

LANCASTER
April 19
Location: Lancaster County Career &
Technology Center, Mt. Joy, Pa.
Summary: Lancaster County Career &
Technology Center hosted the Penn-
sylvania state SkillsUSA welding com-
petition. The competition allowed stu-
dent welders from across the state to
compete in various welding/cutting
projects to determine who would rep-
resent Pennsylvania in the national
competition. AWS Lancaster and York
members from various industries vol- LANCASTER — A student prepares to READING — District Director Sean
unteered their time to judge the com- gas tungsten arc weld during the Moran (left) presented Vice Chair Craig
petitors, including District 3 Director SkillsUSA Pennsylvania state welding Davis with the AWS Meritorious Sec-
competition. tion CWI Award.
Sean Moran, Paul Muffuletto, Brent
Zimmerman, John Shellenberger,
Jesse Parker, and Contest Chairman
and Lancaster Section Secretary Dave
Watson. The Section thanks the com-
panies that donated the material to
make the competition possible includ-
ing Butler Mfg., High Steel Structures,
and Lincoln Electric.

READING
April 24
Location: Osgood’s Grill & Bar,
Robesonia, Pa.
Summary: Section members gathered
to present certificates and prizes to
the participants of the Reading Sec-
tion Welding Contest held in March.
The recipient of the Reading Section
Millennium Scholarship Karl
Machamer, was in attendance and ac-
cepted his award. Section Chair Hugo
Garcia and Vice Chair Craig Davis or-
READING — Craig Davis (right) honored
Pennoni Associates with a plaque of
READING — Section Foundation Rep-
recognition expressing appreciation
resentative David Hibshman (left) pre-
for the valued support the company
sented the Reading Section
has given to the Section. Len Nardone
Millennium Scholarship in the amount
(left), inspection and testing division
of $1250 to Karl W. Machamer (right).
chief, accepted the award.

READING — Reading Section Welding Contest winners included (from left) Rylee Shafer, Level 2, 4th place; Andrew Lake, Level 1, 4th
place; Gabriel Burris, Level 3, 3rd place; Bailey Kerns, Level 3, 1st place; Andrew Kreis, Level 2, 1st place; Jack Yengo, Level 2, 2nd place;
Sethen Batz, Level 1, 1st place; Caleb Rapp, Level 1, 2nd place; and Kenneth Anderson, Level 3, 4th place.

JULY 2018 / WELDING JOURNAL 67

SECTION NEWS
WASHINGTON DC
March 27
Location: Montgomery College Weld-
ing Lab, Rockville, Md.
Presenter: Max Williams, district sales
manager, Mid-Atlantic, Hypertherm
Inc.
Summary: Meeting attendees enjoyed
pizza, drinks, and cookies, followed by
Williams’s presentation titled “Plasma
Cutting — Past, Present, and Future.”
Attendees then moved into the weld-
ing lab where Williams demonstrated
the plasma arc cutting process and al-
lowed attendees with personal protec-
tion equipment to try it themselves.
District 4
Stewart A. Harris, director
(919) 824-0520
stewart.harris@altec.com
CHARLOTTE
May 4
Location: Charlotte, N.C.
Presenter: Bruce Lanier, quality con- donations that helped make the event
trol manager, SteelFab Inc. a success. Elected Section members in
Summary: The nine-year Certified attendance included Chair Daryl Peter-
Welding Inspector class toured son, 1st Vice Chair Tom McCormack,
SteelFab. Lanier and Dale Chance wel- 2nd Vice Chair Bradley Wickline, Treas-
comed the class and gave a tour of the urer Ray Monson, and Secretary Al
facility. Sedory.
District 5
Joseph T. “J. T.” Mahoney, director
(352) 727-0366
Joseph.jt.mahoney@gmail.com
FLORIDA WEST COAST
May 5
Location: Bloomingdale Golfers Club,
Valrico, Fla.
Summary: The Section celebrated its
25th Scholarship Fundraiser Golf Tour-
nament. Sixty members and guests
participated in this year’s event, which
raised more than $3000 in scholarship WASHINGTON DC — Section 1st Vice
funds for welding students. The mon- Chair Becky Lorenz (right) thanked
ey will be distributed after the 2018 guest speaker Max Williams, district
sales manager, Hypertherm Inc.
fall semester. The Section thanks all
the golfers, company sponsors, and

FLORIDA WEST COAST — Golfers posed before starting the 25th Florida West Coast Section Scholarship Fundraiser Tournament.

CHARLOTTE — Nine-year Certified Welding Inspector students toured SteelFab. Seen are (front row from left) Dale Chance (assis-
tant manager, SteelFab), Derreld Yost, Allen West, Jaob Aldrich, Thomas Greene, Malick Simon, Joe Hoban, David Leapley, Chris J.
Fernandez, Marshall Gaddis, Freddie Shivdat, and Instructor Ron Theiss. Second row (from left) are Robert Lockamy, James Goans,
Mark Mikula, Andre Cummings, Ryan Tauer, Brennon Pope, Tim Edson, Jeff Clark, Jason Freeman, John LaPoint, Dave Johnson, and
Bruce Lanier (quality control manager, SteelFab). Back row (from left) are Chuck Recker, James Marsh, Carl Jenkins, Harvy Galloway,
Robin Purvis, Derek Kendrick, Charles Preston, Patrick Houston, Steve Renner, Dean L. Coulson, Brent Walsh, and Craig Wicks.

68 WELDING JOURNAL / JULY 2018


NORTH CENTRAL FLORIDA
February 13
Location: Bradford-Union Vo-Tech,
Starke, Fla.
Presenter: Jeff Iles, sales and applica-
tions engineer, Fronius USA
Summary: More than 35 members and
students attended the Section’s Febru-
ary meeting, which began with a meal
prepared by the culinary arts depart-
ment of Bradford-Union Vo-Tech. The
group then went into the welding area
and tried out several Fronius ma-
chines. After the welding demonstra-
tions, there were door prizes, a 50/50
raffle, and nine AWS student member-
ships were awarded.
April 26
Location: Southern Technical School
of Welding, Orlando, Fla.
Summary: District Director JT Ma-
honey visited with Section members
and students at Southern Technical
School of Welding and described the
advantages of becoming an AWS stu-
dent member.
May 8
Location: E-One, Ocala, Fla.
Presenter: Chris Lashley, VP, general
manager, E-One
Summary: Forty-four members and
guests attended this annual Section
meeting. New Section officers were
elected and District 5 Director JT Ma-
honey presented four District Director
Awards. Lashley gave a presentation
on the history of his company and
then led a plant tour.
NORTH CENTRAL FLORIDA — District Director JT Mahoney (second from right) visited
Southern Technical School of Welding Instructors (from left) Julio Gomez, Sandy
Bishop Jr., and Lewis Phillips as well as Career Services Advisor Jessica Sierra.
SECTION NEWS
District 6 der coat line, onsite assembly and dis-
tribution, as well as saws and bending
Michael Krupnicki, director equipment. All of the company’s oper-
(585) 705-1764 ations are based out of Columbus.
mkrup@mahanyweld.com
District 7 District 8
D. Joshua Burgess, director
Uwe Aschemeier, director (931) 260-7039
(786) 473-9540 djoshuaburgess@gmail.com
uwe@sgsdiving.com
COLUMBUS
April 25
Location: Rogue Fitness,
Columbus, Ohio
Summary: Section members were led
on a tour of Rogue Fitness, a supplier
of American-made strength and condi-
tioning equipment. The facility has a
variety of equipment including manu-
al and robot welding, flat and tube
lasers, various CNC lathes, a new pow-
NORTH CENTRAL FLORIDA — E-One
staff (from left) Bryson Ward, CWI;
Mark Vernon, production manager;
Chris Lashley, VP/general manager;
and Rendy Wolford, welding
supervisor.
NORTH CENTRAL FLORIDA — Jeff Mc-
Cubbins, Airgas Store SO26 store
manager, received the AWS District Di-
rector Award.
NORTH CENTRAL FLORIDA — Section
Chair Howard Record received the
AWS District Director Award.
NORTH CENTRAL FLORIDA — Josh Es-
posito, Marion Technical College, re-
ceived a District Director Award.
JULY 2018 / WELDING JOURNAL 69
SECTION NEWS
NASHVILLE
February 15
Summary: Welding students from the
Tennessee College of Applied Technol-
ogy – Hartsville won first place in the
Tennessee Welding Fabrication
SkillsUSA competition.
District 9
Michael Skiles, director
(337) 501-0304
michaelskiles@cox.net
AUBURN-OPELIKA
April 11
Location: Eufaula, Ala.
Summary: The Section held its April
meeting at the American Buildings Co.
Frank Smith was presented with his
25-Year Silver Member Award before
members were led on a company tour.
NASHVILLE — Tennesee College of Applied Technology – Hartsville students (from
left) Raymond Sullivan, Jimmy Richmond, and Baxter Smith won the Tennesee Weld-
ing Fabrication SkillsUSA Competition.
AUBURN-OPELIKA — Section members are seen during their tour of American Buildings Co.
70 WELDING JOURNAL / JULY 2018
MOBILE
May 12
Location: ArcPro Pipe Welding School,
Theodore, Ala.
Summary: ArcPro Pipe Welding School
hosted the final AWS Mobile Section
meeting of the season in conjunction
with its open house. The day started
off with a Boy Scout Welding Merit
Badge training for Troop 85 of Mobile.
The Saturday meeting included weld-
ing demonstrations, food, music, and
door prizes. In addition to door prizes
provided by ArcPro, the Section held a
student door prize drawing based on
the number of meetings students had
attended for the year. Braden Ground,
a welding student at Pensacola State
College, won first place and received a
Hobart Handler welding machine
courtesy of the Section. Additionally,
James Tinsley won a Lincoln Electric
Gear Pack, and Addison Hendricks
won a Miller welding helmet donated
by Morris and Marine Consulting LLC.
The Section thanks ArcPro staff for
hosting and providing both lunch and
the Scout training. They are especially
thankful to Alex Kraft, Joe Johnson,
and Nicholas Cooper for putting the
event together. Industry sponsors
were also recognized. In closing, Mike
Magazzu, incoming chair, presented
Tim DeVargas with a plaque of appre-
ciation in recognition of his services as
Mobile Section chair for 2017–2018.
NEW ORLEANS
March 6
Location: Café Hope Restaurant,
Gretna, La.
Presenter: Dale Flood, AWS president
Summary: The Section’s March meet-
ing was sponsored by Gas & Supply
Inc. and Ricky “Mousey” Chiasson,
president. The meeting coincided with
President Flood’s visit. He delivered a
presentation on the mechanizing of
the welding industry and gave an up-
date on AWS headquarters activities.
AUBURN-OPELIKA — Frank Smith (left)
was presented with a 25-Year Silver
Member Award.
 SECTION NEWS
The Section is appreciative to District
9 Director Mike Skiles for taking the District 10
time to participate in the meeting. Mike Sherman, director
Door prizes were donated by Gas & (216) 570-9348
Supply Inc. There was also a 50/50 raf- mike@shermanswelding.com
fle with proceeds dedicated to Section
student activities.

MOBILE — Section Chair Tim DeVargas

(right) presented ArcPro representa-
tives (from left) Alex Kraft and Nick
Cooper with an Industry Sponsorship
Certificate.

MOBILE — Boy Scout Troop 85 watches a demonstration during the Section’s Boy
Scout Welding Merit Badge training.

MOBILE — First Vice Chair Mike Maga-

zzu (left) presented Section Chair Tim
NEW ORLEANS — District Director Mike Skiles (left) and Section Chair Aldo Duron DeVargas with a plaque of apprecia-
(center) presented a speaker recognition award to AWS President Dale Flood. tion for his service to the Section.

NEW ORLEANS — Seen with the greater New Orleans staff of Gas & Supply Inc. during the sponsor recognition awards were (front,
center from left to right) Section Chair Aldo Duron, AWS President Dale Flood, and Gas & Supply Co. President Ricky “Mousey”
Chiasson.

JULY 2018 / WELDING JOURNAL 71

SECTION NEWS
May 10
District 11 Location: Detroit, Mich.
tion, District, and National levels.
Three Section Appreciation awardees
Phillip Temple, director Presenter: Chris Conrardy, interim were recognized, including Amanda
(734) 546-4298 executive director, LIFT Technology Davis, Donnie Crist, and Andre Young.
nwcllc_ptemple@att.net Institute The two industry sponsors recognized
Summary: The Detroit Section were RoMan Mfg. and Obara USA.
DETROIT Award/Technical Night was held at the District Director Phil Temple present-
April 19 LIFT Technology Institute. Each year, ed the awards. After the recognition,
Location: Ukrainian Cultural Center, the Section’s awards committee with Conrardy, gave an introduction about
Warren, Mich. help from the Section’s executive and the institute followed by a facility tour.
Presenters: Thomas Webb, general membership committees nominate
manager; Robert Addington, VP of in- members to receive awards at the Sec-
ternational sales; and Chris Kerchkof,
sales manager, Eureka Welding Alloys
Summary: The Section’s biannual Edu-
cational PDH Night was attended by
approximately 20 energetic and curi-
ous welding personnel. The tool & die
welding exposition consisted of Eure-
ka Welding’s three presenters. Their
combined 95 years of experience with
the company went hand in hand with
the company’s 92-year-old history.
Tool and die past vs. present, applica-
DETROIT — Eureka Welding Alloys’s DETROIT — Guest speaker Chris Con-
tions and processes, and automated presenters (from left) Robert Adding- rardy spoke to Section members
solutions for today were explained. ton, Chris Kerchkof, and Nate Miller. about the LIFT Technology Institute.

DETROIT — Members and guests are seen at the Section’s Educational PDH Night in April.

DETROIT — District Director Phil Temple (far right) gathered with Section award recipients.

72 WELDING JOURNAL / JULY 2018

 SECTION NEWS

RACINE-KENOSHA — Section members and students toured Lynch Display Vans. The company manufactures emergency re-
sponse and commercial specialty vehicles.

District 12 District 13 District 14

Dale Lange, director John Willard, director Tony Brosio, director
(715) 732-3645 (815) 954-4838 (765) 215-7506
dale.lange@nwtc.edu kustom_bilt@msn.com tbrosio@yahoo.com

RACINE-KENOSHA ST. LOUIS

March 19
Location: Burlington, Wis.
Presenters: Nicolle Jelinski, human re-
sources representative, and Nathan
Gerlich, plant operations manager,
Lynch Display Vans
Summary: Section members and weld-
ing students from the Gateway Techni-
cal College Elkhorn campus toured the
custom fabrication shop at Lynch Dis-
play Vans. The company is a global
manufacturer of emergency response
and commercial specialty vehicles.
CHICAGO
May 16
Location: Moraine Valley Community
College, Palos Hills, Ill.
Presenter: Mike Vanovermeir, MFE
Rentals
Summary: Vanovermeir gave a presen-
tation on the application and newest
technology in drone inspection as well
as a demonstration.
April 19
Location: Lewis and Clark Community
College, Ed Weber Workforce Center,
Godfrey, Mo.
Presenter: Dale Flood, 2018 AWS
president
Summary: The Section acknowledged
the area’s top students at its annual
Student Night by awarding several
thousand dollars in scholarships.
Flood, who is a member of Terre
Haute, Indiana’s Plumbers & Pipefit-
ters Local Union 157, was the featured
speaker.

CHICAGO — Seen at the May meeting are (from left) Mike Vanovermeir, guest speaker; James Greer, AWS past president; Joe
Grelewicz, Orbital Engineering; and Section Chair John Hesseltine.

JULY 2018 / WELDING JOURNAL 73

SECTION NEWS

ST. LOUIS — The Section’s outstanding students met with AWS President Dale Flood. Students (pictured and not pictured) included
Clint Penny Jr., Ironworkers Local 392; Donald Koleson; Devin Hill, Jefferson College ATS; .Joe Candela, Jackson Bjornstad Jefferson
College; Josh R. Ruch, Southern Illinois Carpenters Joint Apprenticeship; Cathy Cook; Kyle Trunko, Ranken Technical College; Cory
Blair; Joseph Sapienza, Collinsville Area Vocational Center; Mark Anderson; Sierra Fox, Ironworkers Local 396; Jim Hunt; Jason Berry,
St. Charles Community College; Mike Kamp; Nathan Moist, Vatterott College Fairview Heights; Rick Beavers; Chris T. Elizondo, Lewis
& Clark Community College; Travis Jumper; Bruce Edward Yarbrough, IBEW Local 309; and Mike Stuart.

ST. LOUIS — AWS President Dale Flood acknowledged Section Scholarship recipients including (pictured and not pictured) Ian
Schwander ($1500 St. Louis Section Scholarship); Tyler Richard McIver ($1500 Hil Bax Memorial Scholarship); Colby Eilers ($1500
Garner Kimbrell Honorary Scholarship); Darvis Bell ($750 AWS Scholarship); Nathan Moist ($750 AWS Scholarship); Chris T. Elizondo
($750 AWS Scholarship); Brandon Smith ($750 AWS Scholarship); James Langley ($750 AWS Scholarship); Jake Weber ($750 AWS
Scholarship); Courtney Schaefer ($750 AWS Scholarship); Tony J. Zedolek ($750 AWS Scholarship); Bradley Hamilton ($750 AWS
Scholarship); Rocky A. Tucker ($750 AWS Scholarship); Stephan Weekly ($750 AWS Scholarship); Chris Musket ($750 AWS Scholar-
ship); and David Neunaber ($500 Pat Cody Memorial Scholarship).

ARROWHEAD — Winners of the Section’s 2018 Behind the Mask Welding Competition included (from left) Kyle Powers, Central
Lakes College, SMAW 3rd place; Alan Pietila, Central Lakes College, SMAW 1st place; Sonny Bonner, Mesabi Range College, GMAW 3rd
place; Jessie Nissila, Mesabi Range College, GMAW 2nd place and GTAW 2nd place; Greg Rider, Central Lakes College, SMAW 2nd
place, GMAW 1st place, and GTAW 3rd place; and Tristan Hulke, Central Lakes College, GTAW 1st place.

74 WELDING JOURNAL / JULY 2018


District 15
Michael Hanson, director
(763) 221-5951
mikhan318@comcast.com
ARROWHEAD
January 17
Location: Mesabi Range College,
Eveleth, Minn.
Summary: The Section held its first
Behind the Mask Welding Competi-
tion. Randy Washenesky, Ryan Dall,
and Clayton Arens coordinated and
hosted the competition. There were
more than 50 students and profession-
als that competed in one or multiple
contests using different welding
processes. There were also many
prizes that were donated by Cliffs,
Range Steel Fabricators, R. C. Fabrica-
tors, FS Welding & Fabricating, Der-
rick Corp., Wilfley, Mesabi Range Col-
EASTERN IOWA — Section members and students are seen during the CNH Industrial tour.
NEBRASKA — Tour host Mark Caine (far left) is pictured with Section members and students.
SECTION NEWS
lege, and Minneapolis Oxygen.
District 16
Karl Fogleman, director
(402) 677-2490
fogleman3@cox.net
EASTERN IOWA
April 19
Location: CNH Industrial, Burlington,
Iowa
Summary: The Section organized a
tour of CNH Industrial. The plant
builds light construction and agricul-
tural equipment such as tractor loader
backhoes, utility tractors, industrial
forklifts, and draper headers for com-
bines. District 16 Director Karl Fogle-
man and Deputy District Director Rick
Hanny joined the group of Section
members and students from Daven-
port West High School for the tour.
NEBRASKA
March 22
Location: Drake-Williams Steel –
Structural Division, Omaha, Neb.
Presenter: Scott Blankman, east region
general manager, Matheson Tri-Gas
Summary: Members were taken on a
facility tour and Blankman gave a
presentation titled, “Shielding Gas...Is
It Really that Important?” Forty-two
people attended the event, including
three instructors, students, and indus-
try personnel. Drake-Williams spon-
sored the tour and a brown bag
luncheon.
District 17
J Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
JULY 2018 / WELDING JOURNAL 75
SECTION NEWS
CENTRAL ARKANSAS
April 11
Location: Whole Hog Café,
Little Rock, Ark.
Summary: Section members met to go
over financials, new scholarship infor-
mation, and the planning of the first
annual Central Arkansas AWS Fishing
Tournament. The date for the tourna-
ment will be August 25 on Lake
Quachita.
EAST TEXAS
April 26
Location: Tyler Junior College,
Tyler, Tex.
Presenter: Richard Johnston, commer-
cial diver, The Ocean Corp.
Summary: The Section received a fan-
tastic first-hand description of the
commercial diving industry today.
Johnston discussed water treatment
EAST TEXAS — Guest speaker Richard Johnston (far left) is seen with (from left)
Section Chair Bryan Baker, District 17 Director J Jones, and Section Vice Chair Andy
Stormer.
NORTH TEXAS — Section Chair
Chelsey Morris (right) presented an
award to Andrew Brewer, 1st place win-
ner of the North Texas Welding Rodeo
solo events.
76 WELDING JOURNAL / JULY 2018
plants, offshore platform demolition,
welding repair excavation, assembly,
and inspection. He also discussed the
commercial diving industry’s physical
and mental demands for accomplish-
ing the tasks of the underwater weld-
ing environment. Participants had the
opportunity to practice shielded metal
arc welding underwater and burn ma-
terial with an oxygen lance.
NORTH TEXAS
April 17
Location: UA Pipefitters and Plumbers
Local 100, Garland, Tex.
Summary: The Section held its first
annual North Texas Welding Rodeo.
Students from Hill College, Tarrant
County College, and Texas State Tech-
nical College competed in both indi-
vidual and team events that had them
welding in wacky and strange posi-
NORTH TEXAS — Hill College Welding
Instructor Brian Bennett (left) and Tar-
rant County College Welding Instructor
Doug Barnett cut the first-place tro-
phy in half after their students tied for
the coveted spot.
tions. The union, Dewalt, and Lincoln
Electric were sponsors of the event.
District 18
Thomas Holt, director
(409) 721-5777
tholt@techcorr.com
District 19
Shawn McDaniel, director
(509) 793-5182
shawnm@bigbend.edu
BRITISH COLUMBIA
March 28
Location: UAPIC, Delta, British Co-
lumbia, Canada
Presenter: Dave Ruston, Acuren Group
Summary: The evening consisted of a
catered dinner at UAPIC, followed by
BRITISH COLUMBIA — Section Chair
Bernard Booth (left) presented a
speaker gift to Dave Ruston.
BRITISH COLUMBIA — Section Chair
Bernard Booth (left) presented a
speaker gift to John Fiorini.

Ruston’s presentation titled “Introduc-
tion to Advanced NDT Methods.” Ap-
proximately 25 people were in
attendance.
April 19
Location: UAPIC Delta, British Colum-
bia, Canada
Presenter: John Fiorini, Enistech Inc.
Summary: Following a dinner, Fiorini
made a presentation titled “TIG
Brush Stainless Steel Weld Cleaning
System.”
SPOKANE
April 25
Location: Spokane Community Col-
lege, Spokane, Wash.
Presenter: John Lopez, Lincoln
Electric
Summary: Lopez amazed Section
members and guests with a presenta-
tion on hardfacing that included short
SPOKANE — Guest presenter John
Lopez spoke to Section members
about hardfacing.
COLORADO — Section board members (from left) Jeremy Mowry, Norma Escobedo, and Steve Unrein posed with presenters Jesse
Grantham, Richard Campbell, Tom Kienbaum, Bob Teuscher, Greg Garcia, and Anish Poudel.
videos and pictures of various hardfac-
ing types and operations. The non-
technical presentation was easy to fol-
low and very well received. It solicited
numerous follow-up questions.
May 16
Location: Spokane Community Col-
lege, Spokane, Wash.
Presenter: Justin Hoffman,
owner/president, Hoffman Mfg.
Summary: Section members voted in
the five new electable Section board
members for 2018–2019. Following
the vote, Hoffman showed and ex-
plained several of his company’s mine
ventilation and maintenance support
systems. The company also does cus-
tom fabrication modifications for vari-
ous clients to meet their specific de-
mands or requirements for tight and
close tolerances.
SPOKANE — Chris Walker, Section 1st
vice chair, presented a thank you gift
to guest speaker Justin Hoffman.
SECTION NEWS
District 20
Pierrette H. Gorman, director
(505) 440-6284
pierrette@comcast.net
COLORADO
March 8
Location: Red Rocks Community Col-
lege, Lakewood, Colo.
Summary: The Section hosted its 9th
Annual Symposium – Welding the
Rockies. Topics and presenters includ-
ed “Welds Hold the World Together”
by Drew White, Wolf Robotics; “De-
signs for Welding” by Anish Poudel,
Transportation Technology Center;
“Materials for Welding” by Stephen
Liu, Colorado School of Mines;
“Processes for Welding” by Jerry
Jones, EnergynTech; “Quality of
Welds” and “Visual Inspection of
Welds” by Richard Campbell, Bechtel;
“Surface Inspection of Welds” by Greg
Garcia, EVRAZ; and “Volumetric In-
spection of Welds” by Jesse Grantham,
WJMG.
April 12
Location: Denver, Colo.
Presenter: James R. Hannahs, PE, CM-
fgE, CWI, Verity Technical Consultants
Summary: Hannahs presented a dis-
cussion on the history of NASCAR fab-
rication, a review of how the cars are
built today, the materials used, weld-
ing processes applied, and showed a
video of a race at the Talladega Super-
speedway demonstrating the impor-
tance of these items.
JULY 2018 / WELDING JOURNAL 77
SECTION NEWS
NEW MEXICO
May 10
Location: Central New Mexico Com-
munity College, Albuquerque, N.M.
Presenter: Jeff Rodelas, principal
member of the technical staff in the
metallurgy and material joining group,
Sandia National Laboratories
Summary: Rodelas presented an
overview of laser welding fundamen-
tals, including some of the unique re-
quirements this joining technique im-
poses on the weld joining geometry
and alloys to be joined.
SANTA FE COMMUNITY
COLLEGE STUDENT CHAPTER
April 27
Location: Santa Fe Community Col-
lege, Santa Fe, N.M.
Summary: Three area high schools and
12 students participated in a high
school welding competition. The pur-
pose of the competition was to give
students an opportunity to compete
locally and better prepare for their fu-
ture SkillsUSA competition participa-
tion. Each student completed three
projects including oxyacetylene cut-
ting, gas metal arc, and shielded metal
arc welding. Local vendors and AWS
members served as judges.

COLORADO — Presenter James Hannahs spoke to Section members and guests about welding and driving NASCAR racing cars.

NEW MEXICO — Section members enjoyed a presentation on laser welding by Jeff Rodelas from Sandia National Laboratories.

Santa Fe Community College Student Chapter — Students from three area high schools competed in a welding competition at
Santa Fe Community College.

78 WELDING JOURNAL / JULY 2018


District 21
Sam Lindsey, director
(858) 740-1917
slindsey@sandiego.gov
LONG BEACH/ORANGE
COUNTY
April 26
Location: Encore Specialty and Indus-
trial Gas Facility, Signal Hill, Calif.
Summary: Encore Specialty and Indus-
trial Gas opened its doors to host the
Section’s Student Scholarship Night.
Tours of the facility were given by Fa-
cility Manager A. C. Goins. Represen-
tatives from several companies were
on hand providing demonstrations
and presentations. The highlight of
the evening was a presentation of the
AWS Section Scholarship Awards to re-
cipients Walter Ching, Ashley Moore,
Stephen Clamp, and Daniel Vasquez.
Approximately 100 people attended
the event.
SECTION NEWS
District 22 Presenter: Mark Bell, PE, Bell
Metallurgy
Kerry E. Shatell, director Summary: Bell gave a presentation ti-
(925) 866-5434 tled “Welding on In-Service Pipelines”
kesia@pge.com to 33 members and guests during a
buffet dinner meeting.
DISTRICT 22 CONFERENCE
April 28
Location: Clovis Community College,
Herndon Campus, Clovis, Calif.
Summary: Section officers represent-
ing the San Francisco, Sacramento,
and Central Valley Sections met for
their annual conference. Attendees
conducted a number of business items
and awarded $30,000 in scholarships
to 19 students across the District.
John Douglass, associate director,
AWS Foundation, served as the na-
tional AWS representative for the
meeting. SAN FRANCISCO — Three generations
of District 22 Directors gathered at the
April meeting. Seen (from left) are Rob
SAN FRANCISCO Purvis (incoming 2019), Kerry Shatell
April 11 (present), and Mark Bell (1997–2003).
Location: Chevy’s Restaurant,
Emeryville, Calif.

LONG BEACH/ORANGE COUNTY — The Section’s Student Scholarship Night was made possible by (from left) Neal Lembke, Hector
Carbajal, Justin Fox, David Stark, A. C. Goins, Warren Lozano, Ben Anderson, Mike Lannom, Paul Anderson, and Eric A. Budwig.

District 22 Conference — Representing District 22 at the annual conference were (from left) Ray Atnip, Ken Morris, Sacramento
Section Chair Jerry Wentland, Rob Purvis, District Director Kerry Shatell, Central Valley Section Chair Randy Emery, and Chris Huff.

JULY 2018 / WELDING JOURNAL 79

 GUIDE TO AWS SERVICES
American Welding Society® Welding Journal Structural Welding, Sheet Metal Welding, Welding
8669 NW 36 St., #130 Publisher/Editor and Brazing in Aerospace
Miami, FL 33166-6672 Mary Ruth Johnsen.. mjohnsen@aws.org . . . . .(238)
(800/305) 443-9353; Fax: (305) 443-7559 Program Managers
Phone extensions are in parentheses. Society News Editor
Katie Pacheco.. kpacheco@aws.org . . . . . . . . . . .(275) Darrill Gaschler..dgaschler@aws.org . . . . . . . . .(306)
AWS PRESIDENT Brazing and Soldering, Methods of Weld In-
Dale Flood. . . . . . . .floodaws@tritool.com Section News Editor spection, Welding in Marine Construction, Welding
Tri Tool Inc. Cindy Weihl..cweihl@aws.org . . . . . . . . . . . . . . .(256) of Machinery and Equipment
3041 Sunrise Blvd., Rancho Cordova, CA 95742
Inspection Trends Editor Peter Portela.. pportela@aws.org . . . . . . . . . . . .(311)
ADMINISTRATION Carlos Guzman..cguzman@aws.org . . . . . . . . . .(348) High-Energy Beam Welding, Robotics Welding,
Executive Director Welding in Sanitary Applications, Additive Manu-
Matt Miller.. mmiller@aws.org . . . . . . . . . . . . . .(207) Welding Handbook Editor facturing, Structural Subcommittees on Bridge
Kathy Sinnes.. ksinnes@aws.org . . . . . . . . . . . .(255) Welding and Titanium, Friction Welding
Senior Associate Executive Directors
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . .(253) MARKETING COMMUNICATIONS Jennifer Rosario.. jrosario@aws.org . . . . . . . . . .(308)
Chief Marketing Officer Oxyfuel Gas Welding and Cutting, Railroad
John Gayler.. gayler@aws.org . . . . . . . . . . . . . . .(472) Sofia Samuels.. ssamuels@aws.org . . . . . . . . . . .(419) Welding, Thermal Spraying, Welding Iron Castings,
Welding Qualification
Chief Financial Officer/ MEMBER SERVICES
Chief Administrative Officer Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(480) CUSTOMER OPERATIONS
Gesana Villegas.. gvillegas@aws.org . . . . . . . . . .(252) Program Specialists
Senior Associate Executive Director Vivian Pupo . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(362)
Chief Marketing Officer Cassie Burrell.. cburrell@aws.org . . . . . . . . . . . .(253) Vanessa Vasquez . . . . . . . . . . . . . . . . . . . . . . . . .(361)
Sofia Samuels..ssamuels@aws.org . . . . . . . . . . . .(419) Answer customer questions about AWS.
Corporate Director
Asssociate Director, Executive Office Rhenda Kenny... rhenda@aws.org . . . . . . . . . . .(260) AWS FOUNDATION INC.
Chelsea Steel.. csteel@aws.org . . . . . . . . . . . . . . .(293) Serves as a liaison between members and AWS aws.org/w/a/foundation
headquarters. General Information
Program Administrator, Executive Office (800/305) 443-9353, ext. 212, jdouglass@aws.org
Jessenia Martinez.. jmartinez@aws.org . . . . . .(343) CERTIFICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(273) Chairman, Board of Trustees
Administrative Services William A. Rice.. brice@oki-bering.com
Corporate Director Senior Associate Executive Director
Hidail Nuñez..hidail@aws.org . . . . . . . . . . . . . . .(287) John Gayler..gayler@aws.org . . . . . . . . . . . . . . . .(281) Executive Director, Foundation
Monica Pfarr.. mpfarr@aws.org . . . . . . . . . . . . . . . . . .(461)
HUMAN RESOURCES EDUCATION SERVICES
Director Corporate Director Associate Director, Foundation Services
Gricelda Manalich.. gricelda@aws.org . . . . . . . .(208) Patrick Henry..phenry@aws.org . . . . . . . . . . . . .(226) John Douglass.. jdouglass@aws.org . . . . . . . . . . . . . . .(212)

INTERNATIONAL INSTITUTE OF WELDING TECHNICAL STANDARDS SALES

Senior Coordinator Managing Director The AWS Foundation is a not-for-profit 501(c)(3)
Sissibeth Lopez . . sissi@aws.org . . . . . . . . . . . . .(319) Michael Walsh...mwalsh@aws.org . . . . . . . . . . .(350) charitable organization established to provide support
Liaison services with other national and interna- AWS Bookstore, Subscription Sales, and AWS for the educational and scientific endeavors of the Amer-
tional societies and standards organizations. Reseller Management ican Welding Society. Promote the Foundation’s work
with your financial support.
GOVERNMENT LIAISON SERVICES Customer Service...customerservice@aws.org . .(280)
Hugh Webster .... hwebster@wc-b.com
Webster, Chamberlain & Bean, Washington, D.C. STANDARDS DEVELOPMENT
(202) 785-9500; Fax: (202) 835-0243 Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(340)
Monitors federal issues of importance to the
industry. Managing Director — Standards Development
Annette Alonso.. aalonso@aws.org . . . . . . . . . . .(299)
CONVENTION AND EXPOSITIONS Technical Committee Activities, Additive
Director, Convention and Meeting Services Manufacturing, Welding Qualification
Matthew Rubin.....mrubin@aws.org . . . . . . . . . .(239)
Director — International Activities
ITSA — INTERNATIONAL THERMAL Andrew Davis.. adavis@aws.org . . . . . . . . . . . . . .(466)
SPRAY ASSOCIATION International Standards Activities, American
Program Manager Council of the International Institute of Welding
Alfred Nieves....anieves@aws.org . . . . . . . . . . . .(467)
Manager, Safety and Health
RWMA — RESISTANCE WELDING MANUFACTUR- Stephen Hedrick.. steveh@aws.org . . . . . . . . . . .(305)
ING ALLIANCE Metric Practice, Safety and Health, Joining of
Program Manager Plastics and Composites, Personnel and Facilities
Adrian Bustillo....abustillo@aws.org . . . . . . . . . .(295) Qualification, Mechanical Testing of Welds

WEMCO — ASSOCIATION OF WELDING Program Managers II

MANUFACTURERS Stephen Borrero... sborrero@aws.org . . . . . . . . .(334)
Program Manager Definitions and Symbols, Structural Subcom-
Keila DeMoraes....kdemoraes@aws.org . . . . . . .(444) mittees on Reinforcing Steel and Stainless Steel,
Joining of Metals and Alloys, Piping and Tubing,
Learning Sales Representative Automotive, Resistance Welding, Resistance Weld-
Efram Abrams.. eabrams@aws.org . . . . . . . . . . .(307) ing Equipment

Corporate Director, Global Sales Rakesh Gupta.. gupta@aws.org . . . . . . . . . . . . .(301)

Jeff Kamentz..jkamentz@aws.org . . . . . . . . . . .(233)
Oversees international business activities;
certification, publications, and membership.
PUBLICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . . .(275)
Filler Metals and Allied Materials, International
Filler Metals, UNS Numbers Assignment, Arc Weld-
ing and Cutting Processes, Computational Weld
Mechanics
Jennifer Molin.. jmolin@aws.org . . . . . . . . . . . .(304)

80 WELDING JOURNAL / JULY 2018

PERSONNEL

Community College of ers committee with Omaha STEM mately 800 students. Since 2007, Mc-
Denver Hires Former Ecosystem, which works with families, Cane has held several leadership posi-
government, science centers and muse- tions at Bishop State Community Col-
Alum as Instructor ums, education partners, businesses, lege, Mobile, Ala. She most recently
and nonprofits to develop and imple- served as dean of instructional servic-
A former alum ment solutions to citywide workforce es and was responsible for all academic
of the Community challenges. programs across the four campuses.
College of Denver, She was also associate dean of instruc-
Colo., Jessica tion at Jefferson Davis Community
Schechter, has College in Brewton, Ala.
been hired as an NAM Elects GE Appliances
instructor there. Chief Operating Officer to
Schechter started Board of Directors
off as a stay-at- Damen Appoints President of
home mom and The National the Netherlands Chapter of
self-employed jew- Association of WISTA
elry maker, after Manufacturers
J. Schechter (NAM), Washing- Sylvia Boer,
she earned a jew-
elry-making cer- ton, D.C., has head of communi-
tificate from the American Jewelers elected Melanie cations for Damen
Institute in Portland, Ore. In 1998, Cook to its board Shipyards Group,
she earned an associate of arts degree of directors to ad- has been appoint-
in industrial design from the Art Insti- vance a manufac- ed president of the
tute of Colorado. In 2014, she enrolled turing policy agen- Netherlands chap-
in the Community College of Denver, da that promotes ter of the Women’s
majoring in fabrication welding. She growth and pros- International
was one of four female students in the M. Cook perity for all Amer- Shipping and
program with 60 men. While at school, icans. Cook is chief Trading Associa-
she worked as a fabricator for Demi operating officer of GE Appliances, tion (WISTA).
Urge from 2015 to 2017. Soon after, Louisville, Ky., a Haier company, and is S. Boer Boer has been a
Schechter completed an associate of part of the GE Appliances executive member since
applied science in fabrication welding council. She is responsible for end-to- 2008 and joined the organization’s
and has now started working as an in- end operating mechanisms, operational board in 2013. WISTA has 3000 mem-
structor for the program. She is cur- excellence, competitiveness, and infor- bers in 40 countries from diverse mar-
rently pursuing her bachelor of arts mation technology to align with overall itime-related organizations. Its chap-
degree in anthropology with a minor business objectives. For 22 years, she ters around the world aim to support
in women’s studies. has held various roles in the company. women in the industry via regular
meetings, workshops, presentation
speeches, and company visits. The
Metropolitan Community Huntington Ingalls Hires Netherlands chapter was founded in
College Names Director of Director of Education 2000 and currently has 140 members
from across the maritime industry.
Workforce and IT Innovation
Huntington In-
Metropolitan galls Industries,
Community Col- Newport News,
lege (MCC), Oma- Va., has appointed
ha, Neb., has Latitia D. McCane
named Victoria as director of edu- Reprints
Novak as director cation for The Ap-
of workforce and prentice School at Custom reprints of Welding Journal
IT innovation, Newport News articles, in quantities of 100 or
where she will aim Shipbuilding. Mc- more, may be purchased from
to drive public-pri- Cane is responsi- Jill Kaletha, national account
vate partnerships ble for the overall executive, Mossberg & Co. at
to enhance the L. D. McCane leadership, vision,
V. Novak Omaha area’s labor and strategic di- (800) 428-3340, ext. 149 or
pool by developing rection of craft training, academic de- (574) 289-9253, ext. 149.
relationships with businesses and en- livery, student services, accreditation,
trepreneurs who can collaborate with and recruitment for the school, which You can also send an email to
MCC students. In addition, Novak provides comprehensive four- to eight- jkaletha@mossbergco.com
serves as chairperson of the stakehold- year apprentice programs for approxi-

82 WELDING JOURNAL / JULY 2018

THE AMERICAN WELDER

Women Who Weld®: Lighting the

Way Out of Poverty
This Detroit-based nonprofit organization is BY KATIE PACHECO

teaching in-need women how to weld and

find employment

O
nce described as the poorest ma-
jor city in the United States, De-
troit, Mich., is home to more
than 200,000 people living below the
poverty line (Refs. 1, 2). According to
the Detroit Free Press, it currently
ranks number five in a study of impov-
erished communities (Ref. 3). Con-
tributing to the poverty crisis is the
city’s high unemployment rate.
Despite its gaunt financial health,
and the decline of its automotive in-
dustry, the Motor City still enjoys a
burgeoning manufacturing industry,
with more than 6200 skilled trade jobs
expected to be available each year
through 2022 (Ref. 4). However, in
spite of growing job opportunities,

René practices gas metal arc welding during a Women Who Weld® week-long class. She is now a full-time welding operator in
Ann Arbor, Mich.

84 WELDING JOURNAL / JULY 2018

 Fig. 1 — Former coinstructor Tylah Fortson (left) admires
Tiffany’s weld penetration during the Women Who Weld six-
week course. Tiffany is now employed as a full-time produc-
tion welder in Detroit.
many Detroiters don’t have the skill
set required to secure those jobs.
One organization is stepping up to
the plate by tackling both the poverty
crisis and the skills shortage: Women
Who Weld®. Women Who Weld is a
501(c)(3) nonprofit organization that
teaches women sought-after welding
skills and helps them attain gainful
employment in the industry (see lead
photo).
“The automotive, aerospace, de-
fense, energy, construction, and trans-
portation industries still have a major
presence in and around Detroit, and
they have a dire need for welders,” ex-
plained Samantha Farr, Women Who
Weld founder and lead instructor. “It is
therefore extremely important to train
women to weld and become a part of
the industrial workforce, otherwise
women will miss out on well-paying
opportunities.”
The following details how this
Detroit-based organization is using
welding to lead women out of poverty
and bolster the welding industry.
Providing Training Options
for Diverse Needs
Women Who Weld knows that not
all women have the same needs. To
meet the varied financial demands and
professional goals of its diverse popu-
lation, Women Who Weld offers three
training modes: the six-week course,
the week-long class, and the single-day
workshop.
Fig. 2 — Amanda practices gas tungsten arc welding during
the Women Who Weld week-long class. She is now a full-time
production welder in Detroit.
Six-Week Intensive Training Course
The six-week option offers a subsi-
dized training program for unemployed
or underemployed women from 18 to
40 years of age to help them establish a
career in welding and advanced manu-
facturing, free of charge — Fig. 1.
“The majority of the participants in
the subsidized training program are
single mothers in their twenties who
reside in Detroit — some in temporary
shelters — and have difficulty finding
or maintaining part-time employment
and rely on public assistance,” said
Farr. “Some were formally incarcerated
and have few family or friends to turn
to for guidance.”
Offered once a year, this course is
funded entirely through donations
and grants, and requires participants
to undergo a two-part interview
process to determine their dedication
to pursing a career in welding.
With a maximum capacity of ten
participants, the program provides
hands-on training in gas metal arc
welding, which is a high-demand
process in Detroit. So they’re ready for
entry- or intermediate-level jobs, the
women are further instructed on how
to weld different metals in various po-
sitions; operate multiple metalworking
tools and machines; read blueprints;
and use angle finders and measuring
tapes. The women are also taught safe-
ty and welding terminology, as well as
the makeup and properties of differ-
ent metals, materials, and gases.
To help graduates lead successful
professional and financial lives, stu-
dents are offered résumé and inter-
view preparation, financial literacy
and home-buying workshops, tours of
off-site production facilities, and op-
portunities to meet hiring employers.
In some cases, food, transportation,
and child care have been provided to
eliminate barriers to success.
Week-Long Intensive Training Class
The week-long option is a low-cost
training class for any-aged woman in-
terested in learning how to perform
gas metal, gas tungsten, and shielded
metal arc welding — Fig. 2. According
to Farr, this class mostly serves under-
employed women who possess the
means to pay for training. Held
throughout the year, it has a maxi-
mum capacity of six participants. Like
the six-week course, the week-long
class also provides résumé and inter-
view preparation to facilitate students’
transition into full-time jobs.
Single-Day Introductory Workshop
The single-day workshops provide
basic training in gas metal arc welding
for 15 participants while informing
them about opportunities in the in-
dustry — Fig. 3. Primarily held in
Michigan, the single-day workshops
have also been offered in other states,
and recently in southern California,
with great success.
JULY 2018 / WELDING JOURNAL 85

Fig. 3 — Women Who Weld Founder Samantha Farr (center)
provides full-group instruction during a single-day workshop.
“The workshops are always really
fun and filled with a mix of women
who hold different occupations, such
as architects, waitresses, teachers, stu-
dents, doctors, artists, engineers, re-
tirees, etc.,” said Farr.
Funds from both the week-long
classes and the single-day workshops
are used to subsidize the cost of the
six-week training course.
Unveiling New Possibilities
Those involved with Women Who
Weld report that the organization
helps unfold a new life.
Ashley Manska was “unhappy” be-
fore learning to weld. As a bartender,
she wasn’t making ends meet and felt
dissatisfied, but she didn’t know how
to change her situation. Although
there are welders in her family, she
hadn’t considered it as a career path
until a customer showed her a Women
Who Weld news clipping.
“A lot of people from my generation
were told to go straight to college and
not get their hands dirty,” explained
Manska.
Manska completed the course in
July 2017, and describes having a
proud sense of accomplishment as well
as a positive outlook for the future.
“I never graduated from anything
before. I felt like I was starting a
brand-new life, and I had a lot more
confidence,” she said. “I was in the pro-
gram with a lot of women from the
shelter, and we were in a bad place in
life. Samantha gave us the opportunity
86 WELDING JOURNAL / JULY 2018
Fig. 4 — Shown is a gas metal arc welded coupon produced
by a student in the Women Who Weld six-week subsidized
course. Students in the course come away equipped with the
skills required to attain full-time welding jobs.
to turn our lives around and change all
aspects of our lives; it wasn’t just a
new career.”
Today, Manska is a welder for W In-
ternational, Madison Heights, Mich., a
full-service manufacturer of large
complex metal fabrications to serve
the aerospace, automotive, commer-
cial, defense, and energy markets.
She’s excited about new endeavors,
and recently became certified to weld
government projects.
“Before I was living paycheck to
paycheck, and now things are better,”
she said. “I love what I do, and it
makes me happy.”
Former Women Who Weld coin-
structor Tylah Fortson also describes
seizing new opportunities after work-
ing with the organization for three
months in 2017. As a coinstructor, she
expanded her knowledge base and ex-
perience by performing a range of
tasks she had never done before, such
as helping to secure donations; scout-
ing different manufacturing business-
es and welding jobs in the area; work-
ing with Farr to create a class syllabus,
daily schedules, blueprints, and practi-
cal and written tests; training partici-
pants how to prep their workpieces
using various tools; conducting lec-
tures; and fostering a team-oriented
workspace.
“It gave me the opportunity to
learn, not just how to teach, but how
to combat the participant’s negative
perception of welding,” she said. “I
have a better understanding of how to
talk to women to help them overcome
their fears of the machinery and the
space, and just give it a try.”
Fortson is currently pursuing a
bachelor’s in welding engineering at
The Ohio State University. She is also
an intern for General Electric’s avia-
tion division in Cincinnati, Ohio. She
credits her time with the organization
for giving her an academic advantage.
“My experience with Women Who
Weld helped me land the internship,
and it’s helping me while I’m there as
well,” Fortson said.
Spurring life-changing opportuni-
ties is what motivates Farr to reach
more women and continue to grow the
organization.
“Every time I receive a text, email,
or phone call from a graduate telling
me they’ve been promoted or have be-
come certified in a new position, or
that they credit Women Who Weld
with saving their lives, it makes me
smile,” said Farr. “Knowing that all
these women have this skill, a job they
enjoy going to every day, and confi-
dence in their ability to positively im-
pact their career path makes it all
worth it.”
Building a Strong Workforce
Graduates of the six-week course
and the week-long class receive a certi-
fication of completion to share with
hiring companies. According to Farr,
these graduates possess the skills re-
quired by industry to fulfill full-time
or apprenticeship positions right away
— Fig. 4. To date, the organization has
trained more than 100 women
through a combination of its three
training models, of whom 15 complet-
ed its intensive training programs and
obtained full-time jobs in the industry.
“Women Who Weld has a 100%
program completion rate and a 100%
program-to-employment rate,” said
Farr. “All graduates of the six-week
and week-long intensive training pro-
grams in 2017 obtained full-time jobs
as a welder within several weeks of
completing the program.”
She states that the average starting
salary for its graduates is $15 an hour,
with many promoted to more than
$20 an hour within the first year.
Producing female welders doesn’t
just benefit the individual, it also bol-
sters the industry, which predicts that
thousands of welding jobs will remain
unfilled due to a shortage in skilled
workers.
“It was looked down upon to get
into the skilled trades, and now there’s
no one to fill these empty spots, so
there’s a lot of openings,” said Manska.
The shortage in welders hurts the
profit margins of local businesses that
risk losing contracts due to slow out-
puts. This problem can encourage
businesses to leave Detroit.
“I want to see talent flourish in
Detroit and for it to remain competi-
tive and retain businesses and jobs for
its residents,” said Farr. “The women
occupying these positions have helped
these businesses improve their output,
diversify their workforce, and develop
a culture and environment that is
inviting to women and men alike.”
Due to the high quality of welders
the program has produced, hiring em-
ployers and recruiters often contact
the organization when they have open
positions to fill.
Creating a Support Network
Graduates of the six-week course
leave the program with a strong sup-
port system ready to guide them as
they traverse the unfamiliar terrain of
the welding workplace. When advice is
needed or questions arise, Farr is only
a call away.
“These women are entering a male-
dominated industry, and it can be in-
timidating to some,” said Farr. “They
know they can reach out to me any
time to discuss issues they might be
facing on the job.”
Graduates also have each other. Ac-
cording to Manska, a special bond is
formed between the women who com-
plete the six-week course.
“We were really tight afterward,
and I still keep in contact with most of
them,” she said. “It’s really comforting
because in this industry you can strug-
gle with being a woman in the field,
and it’s nice being able to call a class-
mate and talk about that experience
and know that they understand.”
To show her support of the pro-
gram’s future students, Manska re-
turned to Women Who Weld for one
day to offer advice.
“It’s motivational for women to
meet other women who are in the
field, so I wanted to talk to them and
give them pointers,” she said.
Growing to Expand its Reach
There are several changes on the
horizon for Women Who Weld. Soon,
the organization will be opening its
own training facility in Detroit. Cur-
rently, it operates remotely in private
businesses, community colleges, and
maker spaces. According to Farr, hav-
ing a dedicated space will make it easi-
er for participants who rely on public
transportation to attend. The facility
will be equipped with welding ma-
chines donated by Fronius.
In the future, Farr plans to offer
more classes and workshops in cities
across the country, expand its six-
week subsidized course to twice annu-
ally, and hire another instructor to
meet the growing demand. These
plans will “help more women break out
of their cycle of poverty and achieve
economic security through a career in
welding,” explained Farr.
The organization expects to train
nearly 300 women in 2018 and be-
yond. However, to accomplish its aim
and further its reach, the organization
also hopes to secure more donations.
According to Farr, it costs the organi-
zation $6000 per person to run the
six-week subsidized course, which
amounts to $60,000 for a full class of
ten students.
“The cost per student covers all pre-
and postoperations, ongoing support-
ive services, and costs associated with
welding equipment, consumables, elec-
tricity, gas, materials, and PPE [person-
al protective equipment],” said Farr.
She also hopes to secure donations
in the form of welding tables, helmets,
screens, metalworking tools, welding
wire, and welding materials.
“A donation of funds or supplies
will enable Women Who Weld to con-
tinue our welding training programs,
as well as grow and scale our opera-
tions to reach and train more women
to weld and obtain living-wage jobs in
our industry,” explained Farr.
To help women feel more comfort-
able working in the welding industry,
Farr also dreams of playing a role in
the design of welding jackets and
gloves that better fit women’s bodies.
Conclusion
For many women in Detroit, Mich.,
hope comes in the shape of a welding
torch. Through its three training
modes, Women Who Weld is creating
future generations of female welders
and empowering them with skills that
lead to good-paying jobs, thus helping
them to escape poverty. In a world
where thousands of high-paying weld-
ing jobs are going unfilled, it’s impor-
tant to provide women opportunities
to end their poverty and the welder
shortage.
For more information about
Women Who Weld, visit its website at
womenwhoweld.org or contact Saman-
tha Farr at info@womenwhoweld.org. To
see what the organization is up to, fol-
low it on Instagram. WJ
References
1. Bouffard, Karen. 2015. Census bu-
reau: Detroit is poorest big city in U.S.
detroitnews.com/story/news/local/
michigan/2015/09/16/census-us-uninsured-
drops-income-stagnates/32499231/.
2. Census Reporter. censusreporter. org/
profiles/16000US2622000-detroit-mi/.
3. Witsil, Frank. 2018. Metro Detroit’s
poverty gets worse despite city’s comeback.
freep.com/story/news/local/michigan/de-
troit/2018/04/26/detroit-poverty-getting-
worse/553439002/.
4. Anders, Melissa. 2017. Help wanted:
Closing Michigan’s skilled trades gap.
detroitchamber.com/help-wanted-closing-
michigans-skilled-trades-gap/.
KATIE PACHECO (kpacheco@aws.org) is
associate editor of the Welding Journal.
All photos are courtesy of Women Who
Weld®.
JULY 2018 / WELDING JOURNAL 87
THE AMERICAN WELDER
Women Welders Behind the Arc
These women are showing they can hold
their own in a male-dominated profession
Television Personality and Lincoln Electric Spokesperson Jessi Combs works to break down barriers for the next generation of
female welders.
F
or Lili Kammeyer, a welding tech-
nology student at Davis Technical
College (Davis Tech) in Kaysville,
Utah, the message that women are
welcome in welding matters.
“I’m very girly,” Kammeyer said.
“Going into the welding classroom,
people would say, ‘You know cosmetol-
ogy is that way, right? Are you sure
you’re in the right place?’ and I’d say,
‘Uh-huh, I’m in welding.’”
Her classmate, Oriahna Stockham,
agreed. “When I started the program, I
didn’t even think about being ‘a girl in
the welding department,’” Stockham
said. “I just thought welding looked
88 WELDING JOURNAL / JULY 2018
cool, and then I realized, ‘Oh, there are
no other girls here.’”
Although it may be easier for a
woman to start welding than it used to
be, shadows of the male-only welding
club remain, making it difficult for
women to get jobs or promotions in
the industry. That’s why the work of
pioneers like Lisa Byall is so vital. As
role models for younger women in
welding, industry veterans offer sup-
port and advice to younger welders.
When Byall, a portfolio manager of
welding consumables at Lincoln Elec-
tric, began her career in welding, she
dealt with her share of doubters.
BY KAYLIE ASTIN
“Being female, certainly 25 years
ago, in this industry was a rarity,” Byall
remembered.
When she was hired, Byall took her
training seriously. But some of her cus-
tomers and coworkers weren’t so sure.
“I got asked if I got my job because I
was female or because of who I knew,”
Byall recalled. “These questions were
not asked of my male counterparts.”
Jenny Farney, a sales engineer from
Lincoln Electric, also encountered sex-
ism in the industry, especially at the
start. Farney was 23 when she re-
placed a man who had just retired.
“There was a lot of pushback from
customers who had been working with
my predecessor,” Farney remembered.
“They had to work with this fresh-out-
of-college young woman, and many of
the customers were initially hesitant
to find value in my knowledge.”
Jessi Combs, landspeed record
holder, Lincoln Electric spokesperson,
and well-known television personality,
is used to being one of a few women in
a predominantly male field — Fig. 1.
She was the only woman in her custom
automotive fabrication program, fin-
ishing first in her class.
Unfortunately, some women never
get a chance to prove their capabilities,
because they don’t get hired in the
first place. Women frequently tell
Combs that she’s lucky she never had
to search for a job in the “real world.”
Combs acknowledges her path has
been easier than most because she
started working in television right af-
ter she graduated from technical
school, but her position as a television
personality is precisely what enables
her to create change. She often talks to
employers about hiring women.
“The biggest response that I get is
that women are a distraction in the
male environment,” Combs said. “I re-
mind them that they cannot prove a
decrease in productivity without giv-
ing it a go. Try hiring women and see
what happens.”
When employers look past un-
founded fears and hire a woman,
Fig. 1 — Combs works to create change for women
in the welding industry.
sometimes for the first time, the risk
pays off. Women often bring unique
problem-solving and communication
skills to their jobs, and many have a
gift for detail, which proves to be a
very valuable asset in the industry.
Sometimes, being smaller than men
can be an advantage when a weld re-
quires working in a confined space.
Not a Men’s Club
Anymore
Being a woman in the welding in-
dustry now isn’t as unusual as it used
to be. Byall thinks being a woman
helped her career more than it hurt.
“Being female allows you to be no-
ticed and remembered,” Byall said. Af-
ter 25 years in the industry, she has
seen positive changes. “The world has
become more aware of gender equality.
Corporations are educating their em-
ployees on these matters as well,” she
continued.
These changes benefit the industry
as increased numbers of workers are
needed to offset retiring baby
boomers. Combs likes to believe part
of women’s increased interest in weld-
ing comes from Lincoln Electric’s
female-friendly gear.
“Girlfriends and wives are shopping
with their husbands and boyfriends,
and they see how the welding gear is
made for a woman, and it lights up a
Fig. 2 — The first female graduating class from Lincoln Electric Welding
School, ca. 1940s. (Photo courtesy of Lincoln Electric.)
bulb that says, ‘Oh! I can do this, too!
They’re making stuff for us, and there
is a place for us,’” said Combs.
Standing on Other
Women’s Shoulders
Breaking new ground as a welding
career woman isn’t easy, but today’s
welders aren’t the first welding pio-
neers. During World War II, as the Al-
lied Nations’ demand for welding in-
creased, Lincoln Electric hired large
numbers of women — Fig. 2. Combs
credits wartime welders as inspiration
for her red and white polka dot “Jessi
the Welder” helmet (see sidebar).
“Rosie the Riveter is a fictional char-
acter, but she showed that women are
capable, that women were getting their
hands dirty. We wanted to pay homage
to those women who have helped build
the brand, who changed the way
women worked,” Combs explained.
Mentors and Coaches
Many female welders are also in-
spired by people who see their poten-
tial at an early age and bolster their
credibility. For example, Farney credits
her mother, father, and teachers for
encouraging her interests, introducing
her to new opportunities, and nurtur-
ing her passion for the sciences. In her
early years at Lincoln Electric, a man-
JULY 2018 / WELDING JOURNAL 89
ager helped Farney develop confidence
in herself.
“My manager was very supportive,
and though he would get comments
on the side such as, ‘Hey, can we work
with somebody else? This girl’s really
green,’ he encouraged those people to
give me a chance, reminded them that
they were green once, and encouraged
me to have the confidence that I knew
the material,” Farney related.
For Davis Tech’s female welding
students, it helps that someone be-
lieves in them. Nick Price, a welding
instructor at Davis Tech, is such a fan
of his female students’ skills that he
asked Kammeyer and Stockham if
they knew any other women they
could bring into the program. They
found Heather Morgan, a friend from
church and lacrosse, and together the
three women formed Davis Tech’s first
all-female high school welding fabrica-
tion team for the SkillsUSA competi-
tion — Fig. 3.
“Nick [Price] has been our biggest
cheerleader,” Kammeyer said. “He has
confidence in us.”
“I can definitely say this was the
strongest high school team I’ve ever
put together in the seven years I’ve
been at Davis Tech,” Price asserted.
Stockham, Morgan, and Kammey-
er’s welding fabrication team won first
place at the regional level of the
SkillsUSA competition — Fig. 4. Fig. 3 — Shown (from left) are Oriahna Stockham, Heather Morgan, and Lili Kam-
They aren’t the only high-achieving meyer. These next generation of female welders formed an all-female high school
female welders to come out of Davis welding fabrication team for the SkillsUSA competition.
Tech recently. Madison Dennison, an-
other Davis Tech welding student, took
tenth place in the national SkillsUSA
competition for her sculpture of a
dragon atop the Empire State Building.
Angel White Quills, a Davis Tech alum-
nus, was hired as a Big West Oil Refin-
ery union-apprenticeship welder at the
age of 19.

A Little Help From their

Friends
Without some encouragement, tal-
ent might go unrecognized, and leaders
like Byall intend to make sure that nev-
er happens. Byall helps other women in
the industry just as others have done
for her. She is a founding member of
Women in STEM at Lincoln Electric.
“The group’s goal is to break the
isolation that women in STEM fields
may feel,” Byall said. The group offers
networking events, mentoring, and Fig. 4 — Davis Technical College’s first all-female welding fabrication team won first
speakers to help women connect. place at the regional level of the SkillsUSA competition.

90 WELDING JOURNAL / JULY 2018

 Lincoln Electric also created a diver-
sity council to support and encourage
cultural, gender, and life diversity. The
council promotes diversity as not only
essential, but beneficial.
Farney is also involved with making
her industry more female friendly. She
supports female students competing
in SkillsUSA and other educational
programs. She’s involved with the
James F. Lincoln Foundation, which
offers textbooks at low cost. Farney
speaks to students interested in pur-
suing nontraditional careers.
Smashing Stereotypes
Ultimately, however, the responsi-
bility for success rests with the women
themselves.
“I never hid behind the fact that I am
a woman, nor did I ever use it as an ex-
cuse,” Byall said. She surrounds herself
with mentors, finds positive people, and
develops key relationships. Byall also
creates new challenges for herself so
she’s always learning and improving.
Farney has her own ways to deal
with the doubters. “Despite my near-
decade in the industry, men will still
ask me upon introduction, ‘Do you
even know how to weld?’” Farney said.
“And my polite response has grown to
be, ‘Yes, sir, I do all processes, and I
also passed my 2G, 5G, 6G pipe tests
on the first go.’”
That skill-based confidence helps
others take Farney seriously. She is not
as easily intimidated as she was when
she started her job, and tells other
women to trust their own abilities.
“We wear our confidence on our
shoulders, knowing that our past ac-
complishments will lead to future
ones,” she said.
The Future is Female
If current trends are any indication,
the future for women in welding is
promising. “There are so many women
behind the arc, in research, engineer-
ing, and development creating these
products,” Farney said. “One of my
proudest moments as a female in this
industry was being in a roomful of
four male engineer clients with two fe-
male product engineers and myself on
a conference call.”
Davis Tech’s younger welders also
believe that their welding future is
bright. “My brother and I were wan-
dering through a couple welding
booths at a job fair, and I was at a trail-
er manufacturing stand, and my
brother was with me,” Stockham relat-
ed. “The employer was looking at my
brother, and said, ‘Oh, so you’re a
welder?’ and I said, ‘No, no, that’s me.
I’m a welder.’ And he said, ‘That’s so
cool! I need another woman welder.
You should come work for me.’”
When women challenge male-only
stereotypes, it creates new opportuni-
ties for themselves and the women
who follow. Breaking down barriers
might be a risk, but that’s the kind of
danger Lisa Byall, Jenny Farney, Jessi
Combs, and the next generation of fe-
male welders thrive on. WJ
KAYLIE ASTIN (Kaylie.Astin@davistech.edu)
is a copywriter at Davis Technical College,
Kaysville, Utah.

Women Welding Gear Helps Overcome Barriers

You could say Jessi Combs likes danger. After all, she sends a message that the industry sees women, takes their
tackled a nine-day off-road rally through the Sahara Desert needs into account, and wants them to be a part of its work-
armed only with a compass and a hand-drawn map. As a Lin- force. Currently, the U.S. Department of Labor estimates
coln Electric spokesperson and television personality with that 2–3% of welders are women. As more women enter the
credits including The List: 1001 Car Things to Do Before You welding industry, employers like Lincoln Electric are helping
Die, Mythbusters, All Girls’ Garage, Overhaulin’, and Xtreme women overcome barriers.
44, Combs is already smashing stereotypes. She definitely
knows her way around welding equipment as well. But the
gear? That’s another story.
“There was never any welding leather that was small
enough to fit my narrower shoulders and shorter arms. I felt
like I was drowning in them constantly. And the gloves were
just too big. I had no dexterity whatsoever,” Combs said.
So when Combs heard that Lincoln Electric was redesign-
ing its welding gear, she jumped at the chance to be in-
volved. Creating a female line was another way she believed
she could help women feel like they belonged.
When it came to welding gear, safety was Combs’s first
priority. She went to work making gloves snug enough for
women. She helped the company’s product development
team cut jackets that fit women’s shoulders, cut off at their
wrists and tapered in at their waists.
Jenny Farney is happy the new gear helps women be
safer on the job. “If the sleeves are too big or the jacket is too
loose, it can be a safety issue,” she said. “Having something Combs worked closely with Lincoln Electric to design welding
that fits your body and doesn’t drag on hot metal or catch gear for women. She also pays homage to wartime female
on equipment is definitely an advantage.” welders with her red and white polka dot “Jessi the Welder”
helmets.
But it’s not only about safety. The new welding gear

JULY 2018 / WELDING JOURNAL 91

THE AMERICAN WELDER LEARNING TRACK

NYHS Marine Systems Technology Welding

Program Dives into Billion Oysters Project
The marine systems technology welding program at BY ROLINE PASCAL

New York Harbor School has been making waves

both in the lab and the field

A
t 8:00 a.m., hundreds of stu-
dents from Urban Assembly
New York Harbor School (NYHS)
ride the waves on a ferry to take them
to an island for first period class. The
high school, which was originally es-
tablished in 2003 in Bushwick, Brook-
lyn, and named afer the New York
Harbor, has a maritime-themed aca-
demic program where students can
earn technical credentials in one of
seven marine fields offered.
New York Harbor School stands out
with its unique location and its water-
focused curriculum. In 2010, the
school relocated to Governor’s Island
to give students direct harbor access,
as well as cut down on the hundreds of
hours they were spending on subways
and buses to make their way to the
shore, especially for freshmen, who
visit 17 different waterside spots
throughout the year. More than 524 of
its students commute on a daily basis,
taking the nearly 8-min ferry ride to
the island.
The public high school infuses the
standard New York State Education
Department curriculum with water-
related topics, exposing students to
the New York Harbor, as well as the
Hudson and East River. Students at
the school go out into the harbor,
dubbed their “outdoor laboratory,”
every Tuesday and Thursday.
Students enroll in one out of seven
career and technical education (CTE)
programs (vessel operations, ocean en-
gineering, marine systems technology,
professional/scientific diving, ad-
vanced marine biology research, aqua-
culture, and the most recent addition,
marine policy) to focus on for the rest
of their high school career. This can
lead to industry certification in marine
Welding Instructor Clarke Dennis demonstrates how to make a shielded metal arc science or technology and includes
weld for his marine systems technology welding students. work-based learning experiences,

92 WELDING JOURNAL / JULY 2018


Fig. 1 — Welding Instructor Clarke Dennis and his students from the afterschool
welding program.
ranging from student learning in the
school classroom to a real-world,
work-related context.
The demand for well-trained ma-
rine engineers, marine mechanics, ma-
rine technicians, and welders/metal
fabricators is extremely high. The ma-
rine systems technology program at
NYHS offers an entry way into these
hands-on and highly technical career
fields.
Marine Systems
Technology Program
The marine systems technology
(MST) program prepares students for
a career in a broad field of trades in-
cluding woodworking, engine mainte-
nance, composites, electrical, plumb-
ing and sanitation, heating and cool-
ing, and metalworking and welding,
among others.
Students have the opportunity to
receive their Safe Boater’s license, re-
ceive cerification as a marine service
technician after passing the exam
from the American Boat and Yacht
Council (ABYC), and accumulate up to
nine college credits from Kingsbor-
ough Community College maritime
technology program. They are also re-
quired to complete an internship in
the maritime industry. The program
partners with New York City’s mar-
itime community and uses New York
Harbor’s marine resources to prepare
students for college and careers.
One of the many things that puts
the marine systems technology pro-
gram in the forefront is Metal Work-
ing and Welding Instructor Clarke
Dennis. He has allowed the program to
expand the welding and metalworking
curriculum.
Meet the Welding Instructor
Welding Instructor Clarke Dennis’s
passion for the industry has allowed
the program to thrive. His path toward
the industry began 23 years ago.
“I started welding in 1995. I was
working in the studio of a steel sculp-
tor in Indianapolis, Ind.,” Dennis said.
“After a few years, I started welding for
a local theater in Indianapolis building
scenery and structural welding for au-
tomated scenic units. I really wanted
to expand my horizons, so I enrolled
in the local Ironworkers Union Ap-
prenticeship, Ironworkers Local #22.
After my first year in the apprentice-
ship, I transferred to Memphis, Tenn.,
Local #167.”
Dennis graduated from the Iron-
workers Local Union #167 apprentice-
ship program, and is a journeyman
ironworker.
“In Memphis, I started to really
work toward becoming AWS certified.
I was often doing detail welding on
structural and ornamental ironwork. I
also ran a stud welding truck for a
short time for a company, Contract
Steel,” Dennis continued.
While in Memphis, he joined a
blacksmithing club known as the River
Bluff Forge Council, an affiliate of the
Artist Blacksmiths Association of
North America.
“I did a lot of welding for Memphis
area blacksmiths and also for the Na-
tional Ornamental Metal Museum,
now known as the Metal Museum,”
Dennis said.
The NYHS teacher moved to New
York City in 2003 and worked for
Showman Fabricators. He also worked
as a welder for Hudson Scenic Studio,
a company that provides custom sce-
nic fabrication, automation, and paint-
ed drops for the live entertainment in-
dustry, for a couple of years. In 2014,
Dennis volunteered at the South
Street Seaport Museum.
“I did various maritime related met-
alworking tasks, from forging new rig-
ging parts for a historical ship to fabri-
cating gates to fitting and welding
parts on ships. I was recruited by a
captain named Aaron Singh to come
check out a maritime high school
where he worked just across the har-
bor. That’s where I met my teaching
mentor and great friend Brendan Mal-
one,” recalled Dennis.
Malone is the head of the Marine
Systems Technology Department at
NYHS. He has been a marine trades
teacher for 17 years. Prior to entering
teaching, he ran his own marine sys-
tems company for 15 years, then
worked at New York City’s South
Street Seaport Museum as a ship-
wright and waterfront foreman, en-
trusted with heading up the mainte-
nance and restoration of the museum’s
fleet of historic vessels. In 2017, he
won the Harbor Freight Tools for
Schools Prize, which came with a
$100,000 check for Malone and the
school to share.
“For two years, I worked as an in-
dustry professional with students. I
focused on the tangible skills of the
welding trade. I also focused on the
soft skills that help graduates get and
keep jobs. Last year, I decided I wanted
to teach full-time. After going through
a certification process with New York
State and City Departments of Educa-
tion, I finally became a full-time career
and technical education teacher at
New York Harbor School,” Dennis con-
cluded.
In his limited time at the school, he
JULY 2018 / WELDING JOURNAL 93
 Fig. 2 — These female welding students make up half of Dennis’s class, emphasizing
the growth of women breaking into the welding industry. A female welder is using
shielded metal arc welding (SMAW) to work on a gabion (right).
has already proven to be a valuable as-
set there and with his students. Most
recently, he received the Outstanding
CTE Teacher Award.
The Curriculum
The first two semesters of all seven
programs is a foundation class for the
CTE programs. This allows freshmen
to get a taste of the programs in addi-
tion to their regular academics. They
are introduced to elements of all the
programs to think about which pro-
gram best suits their interests and
goals. In the spring of their freshman
year, they rank their program choices
in order of preference. In their sopho-
more year,the students choose the
CTE program they will focus on for
the rest of their high school career.
This leads to industry certification
in marine science or technology
and includes work-based learning
experiences.
Marine systems technology students
begin their sophomore year with the
marine systems technology I course
during the fall semester and the marine
systems technology II/marine propul-
sion systems course in the spring se-
mester. They also begin to sign up for a
MST-related afterschool program (boat-
building, vessel maintenance, welding,
and waterfront club) — Fig. 1.
During their junior year, students
take the third course of marine sys-
tems technology/marine electrical sys-
tems during the fall and marine sys-
tems technology IV/workplace safety,
94 WELDING JOURNAL / JULY 2018
plumbing, and metalwork in the
spring semester. In the summer, inter-
ested juniors in good academic stand-
ing can have a junior summer intern-
ship. This internship is at least 54 h
and can offer students one credit.
“Students intern at local marine
services companies, The South Street
Seaport Museum, Billion Oyster Proj-
ect, and GMD Shipyard,” said Dennis.
Upon senior year, MST students
prepare for graduation and the real
world. They take marine systems tech-
nology V — composites, project plan-
ning, customer service, college/post-
secondary pathways, and marine sys-
tem technology VI/senior project, ma-
rine service technology SkillsUSA as-
sessment. This includes final prepara-
tion and completion of the ABYC Ma-
rine Systems exam, SkillsUSA/senior
project, and an internship, among oth-
er modules.
Students participate in real-world
learning as they progress, beginning
with visits to shipyards, marinas, boat-
yards, and manufacturing facilities,
advancing to applied maritime studies
where they work in the field under the
direction of their teachers and in con-
junction with industry partners. The
culmination of these experiences is an
internship, with specific technical
learning goals formulated by the stu-
dent, teacher, and workplace mentor.
Throughout those years, students will
have been introduced to a variety of
welding processes.
“Sophomores learn shielded metal
arc welding, basic woodworking, and
Fig. 3 — A MST welding student uses
SMAW to practice making stringer
beads.
internal combustion engine theory.
Juniors learn flux-cored arc, gas tung-
sten arc, gas metal arc welding, marine
electronics, and fiberglass work. Sen-
iors spend the first half of the year re-
fining skills and applying them to
their senior projects. The second half
is spent in internships,” affirmed Den-
nis.
In 2003, industry input led to the
formation of the MST program. Now
with the increasing needs of local in-
dustry and its unique curriculum, the
program is never short on students
vying for a seat.
“MST has 68 students enrolled at
this time. We generally have fewer
spots available than number of appli-
cants,” said Dennis.
As tides are turning and women are
forging into welding as a future career,
Dennis proudly emphasizes half of his
class is female — Fig. 2.
The Facility
In addition to using the harbor as
their “laboratory,” MST students also
use the welding shop to receive quality
learning and training. The 1000-sq-ft
lab facility, located on their water-
front, features advanced technology
allowing students to learn welding as
well as blueprint reading, measuring,
and fabrication skills related to local
and maritime industry.
The facility includes a variety of
welding machines, personal protective
equipment, metalworking equipment
and tools, supplies, and equipment for

Fig. 4 — Dennis and a welding student
take turns heating a piece of plate
with an oxyacetylene rosebud torch
tip, forging the plate into a dish shape
to later be welded into a sculptural
anchor.
gas metal arc welding (GMAW), gas
tungsten arc welding (GTAW), shielded
metal arc welding (SMAW), as well as
plasma and oxyacetylene cutting
processes — Fig. 3.
“We rely heavily on two Miller Syn-
crowave® 210s,” confirmed Dennis.
“We also have three other GMAW ma-
chines (two Miller, one Lincoln), one
Lincoln ‘tombstone’ welding machine,
one Miller plasma cutter, and two oxy-
acetylene torch rigs. Also available are
two anvils and a forge” — Fig. 4.
The program is currently working
on providing individual welding
booths for the facility. Dennis also as-
serted since the purchase of the Miller
Trailblazer 325, students will be able
to work on projects outside of the
shop. One of the first projects will be
to repair a broken basketball goal.
Billion Oyster Project
The Billion Oyster Project (BOP) is
a long-term, large-scale plan to restore
one billion live oysters to New York
Harbor. It has been based at NYHS
since its inception and is the nucleus of
one of the largest marine restoration
programs and a worldwide model for
engaging youth in urban marine
ecosystem restoration.
Oysters were once abundant in
New York City, but decades of over-
harvesting and pollution led to their
near-extinction. Now, the BOP initia-
tive shows public school students how
Fig. 5 — The MST welding team will be
turning tons of steel into 422 gabions.
Pictured are two female welders
working on a gabion.
to help bring them back to the city’s
harbor, with the goal of restoring a bil-
lion oysters by 2035.
The marine science and technology
school continues to serve as the pro-
duction hub of BOP, providing facili-
ties, expertise, and a corps of dedicated
students to support these large-scale
efforts.
The World is their Oyster
New York Harbor School works
very closely with the Billion Oyster
Project in many disciplines. The stu-
dents grow, monitor, and research oys-
ters and their habitats through intern-
ships, volunteer work, and their re-
spective CTE program.
“Our students get hands-on train-
ing welding cages that will contain
oyster shells that will eventually be-
come reef structures in the New York
City area waterways,” Dennis af-
firmed. “We are currently building 422
steel cages called gabions that measure
24  24  24 in. They are built from a
1
⁄2-in. round steel rod. We use SMAW to
weld the gabions together” — Fig. 5.
The program works hand in hand
with BOP by planting oysters that fil-
ter the water and build reefs that help
to protect the land. The job of these
cages is twofold.
“Oyster larvae attach themselves to
vacant shells. Oysters filter 50 gal of
water per day,” Dennis explained. “The
idea is that we are planting a billion
living filters to help clean New York
Harbor and other area waterways. The
second job is that these structures
eventually become so crusted with
oysters that they become reefs. These
reefs help to protect the land from
storm surge. Think Hurricane Sandy.”
As a welding teacher and fabricator,
Dennis uses the BOP’s oyster restora-
tion projects as a teaching opportuni-
ty. He helps build the oyster reef struc-
tures as well as repairs and maintains
the school/BOP’s fleet of boats.
The mission of the Billion Oyster
Project is “restoration through educa-
tion through restoration.” By building
these structures and repairing vessels
in the BOP/NYHS fleet, the students
are learning a trade and giving back to
their community at the same time.
Accomplishments for BOP
With support from Kamco, the BOP
made major improvements including a
new, remote-setting facility with four
1200-gal tanks and a new industrial
plankton machine. The Governor’s Of-
fice of Storm Recovery cofunded the
remote-setting unit and were the sole
funder of the plankton machine. In
2017, the BOP had their first full in-
house spawn, larvae rear, and sets
with adult oysters from Erie Basin,
Great Kills Harbor, and Head of Bay.
Together, their team of restoration
project managers, outreach coordina-
tors, scientists, field technicians, pro-
fessional divers, captains and boat
crew, and many interns and volunteers
from public schools including NYHS
made more than 70 trips to the field to
collect data and maintain their re-
search projects.
With the Environmental Policy
Clinic, BOP worked with the NYHS to
launch a new career and technical edu-
cation program, marine policy, which
joined the lineup of CTE programs of-
fered at the marine-themed school.
For more information and to do-
nate to the Billion Oysters Project, go
to billionoysterproject.org/donate/. WJ
For more information on the
marine systems technology
program, contact Clarke Dennis,
MST/Welding Teacher, New
York Harbor School at
rcdennis@newyorkharborschool.org.
ROLINE PASCAL (rpascal@aws.org) is
assistant editor of the Welding Journal.
JULY 2018 / WELDING JOURNAL 95
THE AMERICAN WELDER FACT SHEET

Intro to Laser Beam Drilling

Laser beam drilling is a pulsed operation involving higher
power densities and shorter dwell times than laser cutting.
Holes are produced by single or multiple pulses. Laser beam
drilling is a cost-effective alternative to mechanical drilling,
electro-chemical machining, and electrical-discharge ma-
chining for making holes of relatively shallow depth. Al-
though lasers designed for cutting are used for drilling, it is
most efficiently done with lasers designed for drilling. With
these high-energy, repetitively pulsed lasers, cutting can be
performed by using the laser to drill a series of very closely
adjoining holes. Hole diameters produced by laser beam
drilling typically range from about 0.075 to 1.5 mm (0.003
to 0.060 in.).
Laser beam drilling produces clean holes with small layers
of recast, that is, metal melted during drilling that may cling
to the inside surfaces of the hole. When large holes are re-
quired, a trepanning technique is utilized in which the laser
beam is used in a cutting mode to produce a circle with the
required diameter. However, the beam is first used in a
drilling mode to drill a hole from which the cutting process
starts. This hole-drilling or piercing operation uses a higher
gas pressure and a higher peak-power repetitively pulsed
beam than is required after the piercing operation, when the
beam may revert to a lower peak power or even to a continu-
ous operation to perform the cutting operation.
The high-intensity pulsed outputs from solid-state lasers Fig. 1 — Shown is a Nd:YAG laser drilling a lubrication hole in a
with short wavelengths, such as those produced by Nd:YAG, piston rod of an engine. (Photograph courtesy of TRUMPF
Nd:glass, and ruby, are more suitable for drilling. In indus- Inc.)
trial operations, the Nd:YAG laser predominates in the laser
drilling of metals — Fig. 1. CO2 lasers are commonly used focusing device. The aperture may be used to increase the
for drilling nonmetallic materials such as ceramics, compos- energy density and improve the beam intensity distribution
ites, plastics, and rubber. of the focused beam, which may be beneficial for drilling
The laser drilling of metal requires a pulsed laser with the applications.
beam focused to power densities greater than 105 W/mm2
(6.5 W/in.2 × 107 W/in.2). When the focused beam strikes a Advantages of Laser Beam Drilling
surface, material is melted and volatilized, and the molten
and vaporized material is ejected, forming a hole through Laser beam drilling shares most of the advantages of
the workpiece. The depth of the hole normally achieved is laser cutting. Laser drilling is especially advantageous when
approximately six times the diameter of the hole. Multiple the required diameters of the holes are smaller than 0.5 mm
pulses may be required to completely penetrate the thick- (0.020 in.), and when holes are to be made in areas inacces-
ness of the material. Materials up to 25 mm (1 in.) thick can sible to conventional tools. Beam entry can be at glancing
be drilled. angles to the surface, a situation in which mechanical tools
would be susceptible to breakage.
Laser Beam Focusing Additional advantages of laser beam drilling include the
following:
For drilling, short focal-length lenses are used to focus
the high-peak-power optical beams from the pulsed lasers to 1. Short drilling times;
spot sizes on the order of 0.6 mm (0.024 in.) in diameter to
achieve the required power density levels. 2. Adaptability to automation;
Low beam divergence can be achieved by specifically con-
figured laser resonators. Low beam divergence enhances 3. Ability to penetrate difficult-to-drill materials; and
drilling characteristics and depth by improving the reflective
propagation of the laser beam into the hole being drilled. 4. No tool wear resulting from contact with the work-
Beam diameter is controlled by changing the aperture of the piece, as is the case in mechanical drilling. WJ

Excerpted from the Welding Handbook, Ninth edition, Volume 3, Welding Processes, Part 2.

96 WELDING JOURNAL / JULY 2018



Friends and Colleagues:

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
n sustaining the proffessiona
promoting and nal stature of the field. Election as a Fellow of
o the Society is
n ng accomplishments and the technical impact of the individual. Such
based on outstandi
accomplishments will have advanced the science, technology and application of wellding, as
evidenced by:

•
Sustained service and perfor

o mance in the advanc
n ement of welding science and
technology
•
Publication of papers, articles and books which enhaanc
n e knowledge oof welding
•
Innovative development of welding technology
•
Society and Section contributions
•
Professional recognitions

I want to encourage you to submit nomination packages for those individuals whom you feel have a
history of accomplishments and contributions to our proffession consistent with the standards set by
the existing AW WS Fellows. In particular, I would make a special request that, in considering members
for nomination, you look to the most senior members of your S Section or District. In many cases, the
colleagues and peers of these individuals who are the most faam miliar with their contributions, and who
would normally nominate the candidate, are no longer with us. I waant to be sure that we make the
extra efffort required to ensure that those truly worthy are not overlooked because no obvious
individual was available to start the nominating process.

For specifics on nomination requirements, please contact Chelsea Steel at csteel@aw ws.org at AWS
headquarters in Miami, or simply foollow the instructions on thhe Fellow nomination foorm located at
www.aws.org/fellow. Please remember, we all benefit in the honor
h ing of those who have made major
contributions to our chosen profeession and livelihood. The deaadline for submission is August 1,
2018. The Fellows Committee looks forward to receiving numerous Fellow nominations for 2019
consideration.

Sincerely,
Dr. Charles V. Robino
Chair, AWS Fellows Committee
COMING EVENTS
— continued from page 52
Laser U — Online Education Portal. Offers practical information
to use on the job. Topics range from 3D printing to drilling,
welding, wireless and optical product requirements, and many
others. Visit Laser Institute of America; lia.org/laseru.
Laser Vision Seminars. Two-day classes, offered monthly
and on request, include tutorials and practical training. Pre-
sented at Servo-Robot Inc., St. Bruno, QC, Canada. For
schedule, cost, and availability, email info@servorobot.com.
NDE Classes. Moraine Valley Community College, Palos
Hills, Ill., offers NDE classes in PT, MT, UT, RT, radiation
safety, and eddy current, as well as API 510 exam prep and
weld inspection. Contact (708) 974-5735; wdcs@
morainevalley.edu; morainevalley.edu/NDE.
NDT Courses and Exams. Brea, Calif., and customers’ loca-
tions. Level I and II and refresher courses in PA, UT, MP, ra-
diation safety, radiography, visual, etc. Test NDT LLC;
(714) 255-1500; testndt.com.
Online Education Courses. Topics include Introduction to
Die Casting ($99), Metal Melting and Handling ($99), Prod-
uct Design ($59), Energy Training ($19), Dross Training
($19), Managing Dust Hazards ($19), and Safety (free).
North American Die Casting Assoc.; (847) 808-3161;
diecasting.org/education/online.
OSHA Training Courses and Webinar. Rockford, Ill. Rockford
Systems has added OSHA-authorized health and safety
courses to its training curriculum: OSHA 10-Hour General
Industry Course, OSHA 30-Hour General Industry Course,
OSHA 1910.1200 Hazard Communication Course, and an
ongoing 2½-day Machine Safeguarding Seminar. Contact
(800) 922-7533; rockfordsystems.com.
AWS, Weld-Ed Web Site Promotes Welding Careers
The American Welding Society (AWS) and National
Center for Welding Education & Training (Weld-Ed) web-
site at CareersInWelding.com offers the following details:
people and companies in the welding industry; fun facts;
salary information; industry news; videos; articles; and up-
coming training opportunities, seminars, and events.
Additionally, the site features pages geared directly for
students with scholarship information and a welding
school locator; for welding professionals to build a
98 WELDING JOURNAL / JULY 2018
Plastics Welding School. A two-day course for certification
to European plastics welding standards. Malcom Hot Air
Systems; plasticweldingtools.com.
Preparation for AWS® — CWI®/CWE® Examination. Troy,
Ohio. This two-week class offers nine days of instruction
with the test being administered on the tenth day. Includes
a backpack for the convenience of carrying your books and
other study materials. Contact Hobart Institute of Welding
Technology; (800) 332-9448; welding.org.
Protective Coatings Training and Certification Courses. At
various locations and online. The Society for Protective
Coatings; (877) 281-7772; sspc.org.
Unitek Miyachi Corp. Training Services. Personalized train-
ing services on resistance and laser beam welding and laser
marking; (626) 303-5676; unitekmiyachi.com.
Veterans Goodwill Weld Training Program. South Burling-
ton, Vt., and Eagle River, Wis. AWI and Veterans of
Foreign Wars (VFW) have partnered to offer veterans
complimentary two-day training at AWI facilities. Contact
(802) 660-0600, (715) 337-0122, or awi.edu.
Welding Courses. The Lincoln Electric Co. presents a
range of specialized courses throughout the year at its
Cleveland, Ohio, headquarters. Upcoming courses include
Design of Welded Connections, Steel Structures: Sept. 11;
Steel Weldments: Oct. 23. CWI Prep Course: July 9 and
Oct. 22. Welding Educator’s Workshop, Original: July 9,
Aug. 6, and Oct. 15; Advanced: July 30, Aug. 13, and Oct.
29. Beyond the BoothTM Instructor Course: July 16, 30.
REALWELD® Customer Training: Aug. 9, Oct. 18, and Dec.
13. VRTEX® Customer Training: Aug. 7, Oct. 16, and Dec.
11. Aluminum Solutions, Practical Training: Oct. 30;
Advanced Training: Nov. 6. The Lincoln Electric Co.,
lincolnelectric.com. WJ
résumé, find welding-related jobs, and learn about AWS
certifications; and for educators to discover tips for teach-
ers and guidance counselors, information about curricula,
professional development, and other resources.
This website serves as a valuable tool for students, par-
ents, educators, counselors, and welding professionals. It
also allows visitors to send questions, comments, or ideas
for people profiles.
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JULY 2018 / WELDING JOURNAL 99

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Change of Address? Moving?

Make sure delivery of your
Welding Journal is not interrupted. Con-
tact Kimberly Hugley in the Member-
ship Department with your new
address information:

(800) 443-9353, ext. 262;

khugley@aws.org.

ADVERTISER INDEX
3M Abrasives 16 I.M.P.A.C.T./Ironworker Management Progressive Action Coop. Trust 7
3M.com/3MSilver (866) 266-1235 impact-net.org (800) 545-4921
Abicor Binzel 14 Johnson Mfg. Co. 52
binzel-abicor.com (301) 846-4196 johnsonmfg.com (563) 289-5123
Arcos Industries, LLC Inside Back Cover Lincoln Electric Co. Outside Back Cover
arcos.us (800) 233-8460 lincolnelectric.com (216) 481-8100
Bug-O Systems 21 Miller Electric Mfg. Co. 30
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Camfil Air Pollution Control 2 Nippon Steel & Sumikin Welding Co. Ltd. 1
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CDA Technical Institute 21 Polymet Corp. 43
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Diamond Ground Products Inc. 11, 13 Stäubli Corp. 50
diamondground.com (805) 498-3837 staubli.com (864) 433-1980
Elco Enterprises Inc. 15 TEC Welding Products 51
wire-wizard.com (517) 782-8040 tectorch.com (760) 747-3700
Fischer Engineering Co. 50 TRUMPF 5
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Fischer Technology 22 Ult AG 52
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Flexovit Abrasives 27 Voestalpine Bohler 51
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Harris Products Group 19 Weld Engineering Co. Inc. 29
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Hobart Institute of Welding Technology 13
welding.org (800) 332-9448

100 WELDING JOURNAL / JULY 2018

 SUPPLEMENT TO THE WELDING JOURNAL, JULY 2018
Sponsored by the American Welding Society
Characterization of P92 Steel Weldments
in As-Welded and PWHT Conditions
Room-temperature tensile tests and microhardness
measurements led to improving the ductility of the weld joints
BY N. SAINI, C. PANDEY, M. M. MAHAPATRA, AND R. S. MULIK
ABSTRACT
P92 steels have been developed as a candidate material
for power plant components that operate in a temperature
range of 620°–650°C. A heterogeneous microstructure for-
mation across the P92 weldments makes the weldability of
P92 steel a serious issue. The other problem that arises in
P92 steel weldments is the formation of -ferrite due to the
presence of a higher weight percentage of ferrite stabilizers
such as V and Nb, as well as W and Mo. In the present
work, the shielded metal arc welding (SMAW) process was
utilized to prepare the P92 steel weld joints. After welding,
postweld heat treatment (PWHT) was performed at 760°C
for 2 h. To characterize the weld joints, room-temperature
tensile tests and microhardness measurements were per-
formed in the as-welded and PWHT conditions. The subse-
quent PWHT resulted in a decrease in the hardness gradient
across the weldments. The PWHT resulted in enhancing the
ductility of the weld joints.
KEYWORDS
• P92 Steel • Postweld Heat Treatment (PWHT)
• Hardness • -Ferrite • Tensile Properties
Introduction
Creep strength enhanced ferritic (CSEF) steels are one
of the important candidate materials in power plants due
to excellent physical, thermal, and mechanical properties
(Refs. 1, 2). The CSEF P92 steel was developed in Japan by
Nippon steel (Ref. 3). P92 steel offers enhanced creep
strength, which results from the combination of precipita-
tion and solid-solution hardening (Refs. 4, 5). The P92
steel microstructure consists of a tempered martensitic
structure that derives its stability from finely dispersed V-
https://doi.org/10.29391/2018.97.018
WELDING RESEARCH
and Nb-rich MX (X: C, N) type precipitates inside the ma-
trix region and Fe-, Cr-, and Mo-rich coarse M23C6 precipi-
tates along the prior austenite grain boundaries (PAGBs)
(Refs. 6, 7). The optimum combination of toughness and
creep strength is derived from the stable tempered
martensitic microstructure (Refs. 8, 9). These fine precipi-
tates helped to enhance the long-term creep rupture life of
P92 steel by pinning the movement of subgrain boundaries
(Ref. 10).
In steam generator components, most of the failures oc-
curred in the welded joints, which created the need to study
welded joints (Ref. 11). During welding, the temper marten-
sitic microstructure was adversely altered by the formation
of fresh martensite in the weldments (weld fusion zone +
heat-affected zones) (Ref. 12). During the welding process,
P92 steel showed a great tendency for -ferrite formation
due to the presence of ferrite stabilizers like V, Nb, W, Mo,
and Cr. The presence of -ferrite patches in P92 steel welds
was also observed; a negative effect on mechanical proper-
ties due to notch sensitivity of the -ferrite (Refs. 13, 14). It
is possible to control the formation of retained austenite
and -ferrite by optimizing the base and filler metal compo-
sition (Ref. 15). The high number of ferrite-forming ele-
ments resulted in excessive formation of -ferrite (Ref. 16).
Postweld heat treatment (PWHT) was performed to over-
come the hardness gradient and temper the brittle marten-
site (Ref. 17). The PWHT resulted in a great reduction in
hardness, improving the ductility and toughness of the
weldments (Ref. 18).
Experimental Details
As per the manufacturer, as-received P92 steel was sub-
jected to normalized and tempered conditions. Normalizing
was carried out at 1040°C for 60 min to develop the lath
martensitic microstructure with high dislocation density,
while tempering was performed at 760°C for 2 h for the evo-
JULY 2018 / WELDING JOURNAL 207-s
WELDING RESEARCH
A B
C
Fig. 1 — Microstructure of the following: A and B — As-received
P92 steel; and C — schematic of a prior austenite grain.
Table 1 — Chemical Compositions of As-Received Materials, Wt-%
Element C Mn P S Si Cr Mo
Base 0.10 0.58 0.007 0.003 0.48 9.09 0.42
Filler 0.11 0.60 0.008 0.005 0.19 8.90 0.45
lution of precipitates that provide the microstructure stabil-
ity. The chemical compositions of as-received plates and
filler rod are depicted in Table 1.
The plates sized 150  60  12 mm were prepared from
as-received plates. A V-groove was produced for making
weld joints. The root height and groove angle were taken
as 1.5 mm and 37.5 deg, respectively. Shielded metal arc
welding (SMAW) was utilized to produce P92 steel weld
joints. The P92 steel filler rod (flux coated, 4 mm diame-
ter) was used with a welding current of 140 A and arc volt-
age in the range of 23–26 V. Before welding, preheating
was performed at a temperature of 300°C using flame
heating. Before PWHT, the postweld heating was also per-
formed at 250°C for 40 min to remove the diffusible hy-
drogen content (Ref. 19).
After the postweld heating, postweld heat treatment
(PWHT) was performed at 760°C for 2 h. To characterize
the sample, shaping, grinding, paper polishing, and cloth
polishing were performed. After polishing, samples were
etched in Vilella’s reagent. Samples were characterized us-
ing a field-emission scanning electron microscope (FES-
EM), microhardness tester (Omnitech S. Auto), and verti-
cal tensile testing machine (Instron:5982) techniques. Ac-
cording to ASTM E8/E8M, the transverse flat subsize ten-
sile specimens were prepared with a gauge width of 6 mm
and gauge length of 25 mm (Ref. 20). Room-temperature
tensile tests were performed at a constant cross-head
speed of 1 mm/min. In addition, a Vicker’s microhardness
tester was used for the hardness measurement at a 500-g
load and dwell time of 10 s.
208-s WELDING JOURNAL / JULY 2018, VOL.97
A B
C
Fig. 2 — A — Schematic of the welding passes; B — com-
plete weld joint; and C — cross section of the weld joint.
V Al Nb W Cu Ni N Fe
0.24 0.02 0.07 1.86 0.03 0.30 0.02 Rest
0.22 — 0.06 1.82 0.04 0.35 0.06 Rest
Results and Discussion
As-Received Material
The micrographs of P92 steel in low and high magnifica-
tions are shown in Fig. 1A and B, respectively. The low magni-
fication micrograph consists of PAGBs with packets, laths,
packet boundaries, and blocks of laths, as shown in Fig. 1A.
The distribution and morphology of coarse M23C6-type precipi-
tates and fine MX precipitates at lath boundaries and PAGBs
were clearly seen at higher magnification, as shown in Fig. 1B.
Evolution of precipitates along PAGB, lath blocks, packet
boundaries, and inside intra lath region is shown in schematic
diagram of Fig. 1C. It defines the lath boundaries, packet
boundaries, packet, columnar laths, PAGBs, coarse M23C6 pre-
cipitates, and fine MX precipitates. The ultimate tensile
strength (UTS), % elongation, microhardness, and impact
toughness of as-received P92 steel were measured as 678 ± 10
MPa, 23 ± 2%, 227 ± 4 HV, and 198 ± 8 J, respectively.
Characterization of Weldments
Figure 2A shows the weld joint after welding completion.
The optimized base material microstructure was changed
completely by an applied welding cycle. Based on tempera-
ture experience, the P92 weldments are divided into the
weld fusion zone and narrow heat-affected zones (HAZs).
Narrow HAZs show the continuous microstructure change
due to the varying temperature range, and it is divided into
coarse grain (CG), fine grain (FG), intercritical (IC), and
 WELDING RESEARCH

A B

C D

Fig. 3 — Secondary electron micrographs in the as-welded condition: A — Weld fusion zone; B — CGHAZ; C — FGHAZ; and D — ICHAZ.

overtempered base material. The P92 steel weld showing the
weld fusion zone, various zones formed in the HAZ, and fea-
tures of the weld are shown in Fig. 2B.
A typical untempered columnar lath microstructure of
the weld fusion zone is shown in Fig. 3A. The microstruc-
ture also shows the -ferrite. In P92 steel, a high weight per-
centage of ferrite stabilizer elements like W and Mo pro-
mote -ferrite formation. In P92 steel weldments, the pres-
ence of -ferrite was undesired with respect to poor weld
toughness. The zone adjacent to the weld fusion zone expe-
rienced temperatures much above the transformation tem-
perature (Ac3) and denoted as coarse grain heat-affected
zone (CGHAZ). The dissolution of precipitates occurred at
such a high temperature, which resulted in a higher amount
of carbon (C) and nitrogen (N) in the solid-solution matrix.
The pinning force by the precipitates was also reduced due
to dissolution of precipitates, which resulted in formation of
coarse grains of austenite. Hence, in the as-welded condi-
tion, coarse grain lath martensitic structure was observed in
the CGHAZ, as shown in Fig. 3B. The fine grain heat-affect-
ed zone (FGHAZ) experienced a temperature just above Ac3.
Fewer coarse M23C6 and fine MX precipitates remain
undissolved because the temperature was not capable of
dissolving the precipitates completely, as shown in Fig. 3C.
The size of coarse M23C6 was observed to be varied from 574
to 723 nm with an average precipitate size of 638 ± 62 nm.
The fine MX precipitates are difficult to resolve using the
SEM micrographs. The growth of austenite grain impeded
by these undissolved precipitates resulted in the fine prior
austenite grains (PAGs) structure. Some -ferrite patches
were also observed in the FGHAZ. In P92 steel weldments,
the mild intercritical heat-affected zone (ICHAZ) was found
to be an interesting region, which had a mixed combination
of new prior austenite grains and remaining coarse tem-
pered grains, with some undissolved precipitates and coarse
tempered precipitates, as shown in Fig. 3D.
In the PWHT condition, evolution of dissolved precipi-
tates occurs. After PWHT, the microstructural evolution and
distribution of carbide precipitates in the weldments are
shown in Fig. 4A–D. The PWHT of P92 weldments lead to
the evolution of precipitates and coarsening of existing pre-
cipitates. Evolution of precipitates and coarsening of exist-
ing precipitates in every zone of P92 steel weldments is
shown in Fig. 4A–D. The PWHT results in overtempering of
the base metal. The overtempering does not contribute so
much in microstructural change. Overtempering does not
allow the phase change, but it leads to negligible coarsening
of M23C6-type carbide precipitates.

JULY 2018 / WELDING JOURNAL 209-s

WELDING RESEARCH

A B

C D

Fig. 4 — Secondary electron micrographs after PWHT: A — Weld fusion zone; B — CGHAZ; C — FGHAZ; and D — ICHAZ.

A schematic of microstructure and precipitates evolution

in the FGHAZ for different heating conditions is presented
in Fig. 5. In the as-received condition, packet boundaries,
martensite block, and M23C6 precipitates along PAGBs were
observed. The MX precipitates were also noticed inside the
martensite lath blocks and at martensite block boundaries.
In the FGHAZ, the small-sized M23C6 precipitates and sub-
grains were dissolved during welding. During the PWHT of
P92 steel weldments, the M23C6-type carbides would repre- Fig. 5 — Schematic showing FGHAZ microstructural evolution
cipitate on block boundaries and PAGBs. These M23C6 pre- after PWHT.
cipitates prevent the recrystallization by pinning the bound-
aries. The supersaturated carbon (C) will favor the growth of tates (white particles in the FGHAZ), the percentage of Cr,
undissolved M23C6 instead of the nucleation of new M23C6 W, and Mo was found to be increased and the percentage of
precipitates. For the same reason, the number of newly de- Fe was decreased simultaneously, which confirmed the high-
veloped MX precipitates will be less. This subtle reduction in er weight percentage of Cr, Mo, and W in M23C6-type carbide
MX precipitates results in poor mechanical properties. precipitates. The EDS analysis of coarse particles present at
After PWHT, the higher magnification secondary elec- the PAGBs also confirms the higher weight percentage of Cr,
tron micrograph of FGHAZ shows the distribution of coarse Mo, W, and Fe in M23C6, as shown in Fig. 6C.
globular and cylindrical shaped M23C6-type precipitates at
boundaries and fine spherical MX-type precipitates inside Room-Temperature Tensile Test
the intra-lath region, as shown in Fig. 6A. Figure 6B shows
the line mapping results of various elements present in the The mechanical properties of the weldments were af-
FGHAZ of P92 steel weldment after PWHT. At the precipi- fected by the phase transformations taking place within

210-s WELDING JOURNAL / JULY 2018, VOL.97


Fig. 6 — A — FGHAZ after PWHT; B — line mapping results showing variation of elements; and C — EDS of coarse precipitate pres-
ent on the PAGB.
the weldments during the weld thermal cycle and PWHT.
The engineering stress-strain curve for the welded speci-
mens is shown Fig. 7. In the as-welded condition, the frac-
ture of the tensile specimen was noticed in the soft FGHAZ
region. In the as-welded condition, the ultimate tensile
strength (UTS) and % elongation were measured to be 674
± 18 MPa and 12.5 ± 3.5%, respectively. The ductility of
weldments was measured to be lowest in the as-welded
condition due to the high volume fraction of untempered
lath martensite. After PWHT, the fracture location was
shifted from FGHAZ to the overtempered base zone. After
PWHT, the UTS and % elongation were observed to be in-
creased as compared to the as-welded condition. In the
PWHT condition, the UTS and % elongation were meas-
ured to be 785 ± 25 MPa and 21 ±4%, respectively. The
UTS was observed for the FGHAZ and overtempered base
metal. Fracture from the FGHAZ and overtempered zone
shows the higher strength of the weld fusion zone.
Hardness
The variation of microhardness in the weldments is
governed by the precipitation hardening and solid-solution
strengthening. Variations of microhardness across the weld-
ments for different conditions are shown in Fig. 8.
In the weld fusion zone, the microhardness was meas-
WELDING RESEARCH
ured to be 453 ± 24 HV in the as-welded state. The weld fu-
sion zone undergoes the multipass welding effect, which re-
sulted in a great variation in hardness due to autotempering
of the previous pass by subsequent pass. In the as-welded
condition, a higher hardness in the weld fusion zone is at-
tributed to a presence of higher weight percentage of C and
N in the solution matrix. As it moves away from the weld fu-
sion zone, a gradual decrease in hardness was observed. The
CGHAZ and FGHAZ hardness were measured to be 417 HV
and 403 ± 12 HV, respectively. In the CGHAZ, a higher peak
temperature results in the dissolution of precipitates that
leads to C and N percentage in the solid-solution matrix.
That results in a higher hardness in the CGHAZ among all
HAZs. In the FGHAZ, partial dissolution of precipitates re-
sults in less C and N in solid-solution matrix that leads to
poor hardness of the FGHAZ as compared to the CGHAZ.
After the FGHAZ, a sudden drop was observed in the hard-
ness at the HAZ base boundary.
In the as-welded condition, the ICHAZ was identified as a
soft zone, and hardness was measured to be 214 HV. The
lowest hardness of the ICHAZ is attributed to the presence
of coarse undissolved M23C6 precipitates and overtempering
of martensite. The PWHT results in a considerable reduction
in hardness throughout the weldments. After PWHT, the
weld fusion zone hardness was measured to be 224 ± 6 HV.
The PWHT resulted in a decrease in solid-solution harden-
JULY 2018 / WELDING JOURNAL 211-s
WELDING RESEARCH
Fig. 7 — Engineering stress-strain curve for various tensile
tested specimens.
ing, but at the same time, the evolution of precipitates leads
to precipitation hardening. In the PWHT condition, a reduc-
tion in solid-solution hardening was observed to be domi-
nated over the increase in precipitation hardening that re-
sulted in a decrease in the hardness of the weldments. The
average hardness of CGHAZ and FGHAZ was measured to be
219 and 205 ± 10 HV, respectively. However, the soft ICHAZ
zone still observed in the welded joints leads to poor creep
strength of the P92 steel weldments.
Conclusions
The following conclusions can be made:
• The microstructures of P92 steel weldments were char-
acterized by the untempered lath martensite, lath packets,
lath boundaries, and -ferrite.
• After PWHT, the strength and ductility were increased.
In the PWHT condition, it was observed that the fracture lo-
cation was shifted to overtempered base metal from the
FGHAZ after the room-temperature tensile test.
• The microhardness of subzones of the P92 weldments
showed the great heterogeneity in the microstructure. Maxi-
mum and minimum hardness were measured to be 453 ± 24,
and 214 HV for weld fusion zone and ICHAZ, respectively.
After PWHT, a considerable softening was noticed in each
zone of the P92 steel weldments.
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NITIN SAINI (nit030078@gmail.com), CHANDAN PANDEY, and
RAHUL S. MULIK are with the Department of Mechanical and
Industrial Engineering, Indian Institute of Technology Roorkee,
Uttrakhand, India. MANAS MOHAN MAHAPATRA is with the
School of Mechanical Sciences, Indian Institute of Technol-
ogy, Bhubaneswar, Odisha, India.

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JULY 2018 / WELDING JOURNAL 213-s

WELDING RESEARCH
Fiber Laser Welding of 1700-MPa,
Ultrahigh-Strength Steel
This study investigates the appearance, microstructure,
and mechanical properties of laser welded joints
BY C. LUO, Y. CAO, Y. ZHAO, L. ZHAO, AND J. SHAN
ABSTRACT
This paper investigated the appearance, microstructure,
and mechanical properties of laser welded joints for 1700-
MPa, ultrahigh-strength steel (UHSS) with 6 mm thickness.
The results indicate welding speed was the dominant fac-
tor that affected appearance quality. A sound weld without
underfill can be obtained when the speed was limited to
approximately 2–3 m/min. Two softening mechanisms exist
in the heat-affected zone (HAZ). In the intercritical heat-
affected zone (ICHAZ), ferrite appears and the hardness
drops sharply. For the subcritical heat-affected zone
(SCHAZ), the microstructure was tempered martensite with
precipitation of carbides and the high temperature temper
results in the minimum hardness. With a martensitic struc-
ture in the weld metal and a narrow softening zone in the
HAZ, more than a 94% joint efficiency was achieved in ten-
sile testing. Only about a 40-deg maximum bending angle
was obtained during a bend test, as plastic deformation
mainly concentrates in the softening zone due to
nonuniform hardness distribution. The study also found that
the existence of porosities in the joints had significant af-
fects on the ductility, toughness, and fracture mechanism,
but little affect on the joint strength. For the joints without
porosities, the fractures from tensile and bend tests both
initiated at the zone with the minimum hardness and prop-
agated along the 45-deg direction. But when porosities
existed in the joints, fractures occurred completely in the
weld metal, which resulted in a smaller elongation and
bending angle as well as impact energy. However, the
tensile strength was similar to an average value.
KEYWORDS
• Laser Welding • 1700-MPa, Ultrahigh-Strength Steel
• Ferrite • Tempered Martensite • Softening • Fracture
Introduction
Weight reduction with increased strength and perform-
ance is desired to meet the global demand for safe, environ-
mentally friendly, and energy-efficient vehicles. The de-
mand can be satisfied with the use of ultrahigh-strength
214-s WELDING JOURNAL / JULY 2018, VOL. 97
steel (UHSS), which has superior performance without an
extra weight increase (Refs. 1–4). Compared to conventional
carbon-hardened steel, UHSS is stronger, harder, and pos-
sesses a high strength-to-weight ratio as well as good tough-
ness (Ref. 4). The combination of tensile strength up to
1700 MPa and high hardness of more than 500 HV can pro-
vide excellent resistance to penetration and shock (Ref. 5).
Therefore, UHSS is widely used in critical protection sys-
tems such as cash transport vehicles, diplomatic vehicles,
and hull construction (Refs. 5, 6).
As the most essential joining technique used in the auto-
motive industry, the welding process needs to be high effi-
ciency and high quality. Ultrahigh-strength steel is difficult
to weld due to its high hardenability, which makes it prone
to cold cracking, especially for steel with a strength of more
than 1380 MPa (Refs. 7, 8). Currently, the most common
welding process for UHSS is arc welding with filler metal
(Refs. 5, 9, 10). Austenitic and ferritic consumables are of-
ten used since ferrite can improve the stress state (Ref. 11)
and austenite can increase the solubility of hydrogen (Ref.
12), both of which will decrease the cold cracking tendency
of joints. However, the use of undermatching consumables
makes the weld metal become the weak zone of the joints
(Refs. 13, 14). On the basis of related review (Refs. 15–17),
it can be found that the joint efficiency (tensile strength ra-
tio of joints to base metal) is generally lower than 60% for
UHSS with a tensile strength of more than 1500 MPa. Most
of the joints fail in the weld metal since the microstructure
is mainly composed of austenite and -ferrite (Refs. 17, 18).
Some research has been done to improve joint strength by
adjusting the microstructure of the weld metal (Refs.
17–19). Joint efficiency could reach 76% by keeping the
weld at 623 K (350°C) for 6 h to obtain a carbide-free
bainitic microstructure in the weld metal (Ref. 17). The
joints fractured in the heat-affected zone (HAZ) since high-
heat input led to severe softening. However, the joint
strength was still unsatisfactory.
One effective technique to improve joint efficiency is
lowering heat input (Ref. 16). Laser welding has characteris-
tics of high power density and low heat input. The power
density can be up to 108W/cm2 (Ref. 20), which is about
1000 times higher than in conventional arc welding. The in-
fluence of laser heat input on the HAZ is significantly lower
https://doi.org/10.29391/2018.97.019

Fig. 1 — Experimental setup.
and the microstructure degradation is less (Ref. 20). Some
researchers have found that laser welding forms a narrow
weld, a restricted HAZ, and minimized softening in compar-
ison with arc welding of UHSS (Ref. 21). More importantly,
obtaining a martensitic structure in the weld metal
strengthens UHSS joints (Ref. 4). But the high cooling rate
of laser welding is at a great risk to cold cracking since
martensite is sensitive to hydrogen cracks. However, low-
hydrogen welding practices can help to reduce the amount
of hydrogen in the joints (Ref. 22). Compared to arc welding,
laser welding usually works in a clean environment and
melts the base metal instead of the filler metal to fill the
weld, which reduces hydrogen content at the source. Mean-
while, laser welded joints generally have better residual
stress distributions with lower tensile residual stress (Refs.
23, 24) and narrower regions sustaining the tensile residual
stress (Refs. 24, 25). All of the above could be beneficial for
reducing cold crack sensitivity of laser welded joints to some
extent. Among commercial laser systems, fiber laser welding
is the newest with several advantages over other laser types.
Recent studies showed the HAZ and weld metal obtained by
fiber laser welding are narrower than those formed by weld-
ing with other lasers (Ref. 26) and the tensile residual
stresses of joints are the lowest (Ref. 27). Hence, fiber laser
is appropriate for the welding of UHSS.
Currently, a number of research studies about laser weld-
ing of UHSS have been conducted (Refs. 2, 10, 26), but most
of them mainly concentrate on steel plates with strengths
below 1500 MPa. Limited works have been published re-
garding laser welding of UHSS with more than 1500 MPa,
and only thin plates less than 3 mm in thickness are dis-
Table 1 — Main Chemical Composition of Base Metal
Composition C Mn Cr
Percent (wt-%) 0.3 0.3 0.8
Table 2 — Mechanical Properties of Base Metal
Tensile Strength Yield Strength Elongation
1723 MPa 1305 MPa 9.05%
WELDING RESEARCH
cussed (Refs. 3, 4, 28). Mid-thick steel plates generally
means plates with a thickness between 3 and 20 mm. For
laser welding of mid-thick UHSS, there might be some new
problems such as forming defects and property inhomo-
geneity along the thickness direction. In consideration of
the increasing application of stronger and thicker steels, it is
essential to explore the actual laser welding properties of
UHSS more than 1500 MPa with midthickness.
The aim of this paper is to investigate laser welding
characteristics of 1700 MPa UHSS with 6 mm thickness. A
10-kW fiber laser welding system was chosen to conduct the
experiments. The effects of parameters on the formation of
welds were studied. Also, the appearance, microstructures,
and mechanical properties, including microhardness, tensile
strength, and bending property as well as impact perform-
ance of the bead-on-plate joints, were assessed.
Experimental Procedures
In this study, 1700 MPa UHSS plates were used. The
chemical composition and mechanical properties of the base
metal are shown in Tables 1 and 2, respectively. The plates
have dimensions of approximately 200  150  6 mm3. The
experimental setup is shown in Fig. 1. A 10-kW fiber laser
with a beam parameter product of 7.5 mmmrad was used. A
collimation lens of 150 mm, with a focal lens of 300 mm and
a fiber diameter of 200 mm, were employed to produce a fo-
cusing spot diameter of approximately 0.40 mm. Table 3
shows experimental procedures. Full factorial experiments
were performed to study joint quality. The laser power was
from 6 to 10 kW with 1-kW increments, and the welding
speed was from 1 to 6 m/min with 1 m/min increments. The
defocusing distance was 0 mm.
Before welding, samples were cleaned with emery paper
and acetone to remove surface oxide and then held firmly in
a bead-on-plate configuration (Fig. 1). High-purity argon
(99.99%) was used to shield both the top and bottom surface
of samples at a flow rate of 25 and 5 L/min, respectively.
After welding, the cross sections of joints were sliced,
polished, and finally etched with modified Fry’s regent (50
ml HCl  25 ml HNO3  1 g CuCl2  150 ml H2O) for about 3
s. Microstructures of the welded joints were observed using
an optical microscope (OM) and a scanning electron micro-
scope (SEM). The Vickers microhardness test was performed
on the etched cross sections with a load of 500 g for a 15-s
dwell time. The tensile property perpendicular to the weld-
ing direction was evaluated at room temperature. A three-
point bend test was carried out at room temperature with 6
times elbow diameter. Additionally, the Charpy impact test
Mo Ni Si Nb Fe
0.3 0.8 0.3 0.05 other
Impact Toughness (–40°C) Maximum Bending Angle
14.3 J 180 deg
JULY 2018 / WELDING JOURNAL 215-s
WELDING RESEARCH

A B

Fig. 2 — Sample distribution and size for mechanical properties testing. A — Schematic; B — detailed dimensions.

was evaluated at 40C with V-notches located in the middle

of the weld metal. The distribution and size of the test sam-
ples are shown in Fig 2. For each mechanical property test,
three samples were tested to ensure statistical accuracy. Fol-
lowing the tensile, the fracture surface of the tested speci-
mens was examined by SEM. Weld reinforcement on the
face and root regions was removed by manual grinding be-
fore mechanical property tests were carried out.

Experimental Results
Joint Quality
Laser welding of thick section materials without filler
metal is often accompanied by defects such as spatter, root
humping, and pool sagging as well as root concavity, which
would all result in undercut or even underfill (Refs. 29, 30).
Previously, many studies have investigated the defects in
laser welding (Refs. 31–34), but only isolated defects were
generally focused on, and the distribution of defects under
different parameters weren’t discussed. This section shows
the distribution of defects within the process window.
The defect distribution under different parameters is
Fig. 3 — Forming defects distribution under different parame-
ters. The five-pointed stars signify the occurrence of root
humping.
shown in Fig. 3 and the five-pointed stars in it mean that
root humping occurred. The welding appearance under dif-
ferent parameters are shown in Fig. 4. It can be seen that
complete joint penetration welds were obtained, but the
typical forming defects mentioned above emerged under dif-
ferent parameters. As illustrated in Fig. 3, large quantities of
spatter are generated when the welding speed is more than

A B

C D

Fig. 4 — Welding appearance under different parameters. A — Spatters under 8 kW and 4 m/min; B — root humping under 6 kW
and 4 m/min; C — pool sagging under 6 kW and 1 m/min; D — root concavity under 10 kW and 1 m/min.

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Fig. 5 — Appearance and cross section of a joint obtained
under 10 kW and 2 m/min.
4 m/min. The welding appearance can be seen in Fig. 4A.
A lot of spatter is around the weld and obvious underfill
can be seen on the cross section. Furthermore, root hump-
ing is observed under the condition of 6 kW and more than
4 m/min. As shown in Fig. 4B, root humping arose periodi-
cally, and deep underfill appeared on the corresponding top
surface. Moreover, a severe pool sagging defect occurred at 1
m/min with a power of 6 to 8 kW. In Fig. 4C, the whole root
of the weld sags significantly. With a further increase in
laser power, a significant root concavity appeared and the
weld joint showed underfill on both the face and root re-
gions, which means a lot of molten metal is out of the weld.
Consequently, to obtain a sound weld without obvious
forming defects, the welding speed should be limited to 2–3
m/min with a power of 6 to 10 kW. The weld appearance un-
der 10 kW and 2 m/min is shown in Fig. 5. It can be seen
that the full shape without underfill was obtained. Three
sets of parameters were selected to study mechanical prop-
erties of the laser weld joints in accordance with the process
window of the sound weld and shown in Table 4.
Argon pores were found in weld metal under parameter 1
(0.16 kJ/mm). As seen in Fig. 6, there are some pores on the
fracture surface of the weld metal under 0.16 kJ/mm heat
input, and the pores have a smooth inner wall with a spiral
scouring trace. Columnar crystals are clearly observed. It
can be identified as keyhole-type pores, namely argon pores.
The existence of porosity may have some effect on the me-
chanical properties of joints. For parameters 2 and 3, several
cross sections of samples were observed and no porosity
was found.
Table 3 — Experimental Procedure
Step Procedure
1 Performing full-factorial experiments to study joint quality
2 Selecting parameters with a sound weld and welding the UHSS plates within the parameters
3 Carrying out mechanical performance tests with the plates of step 2
Table 4 — Experiment Parameters Chosen for Mechanical Property Test
No. Laser Power (kW) Welding Speed (m/min)
1 8
2 6
3 10
WELDING RESEARCH
A B
Fig. 6 — Magnified SEM photograph of porosity on the frac-
ture surface of the weld metal under 0.16 kJ/mm.
Microstructure
Due to low-carbon content, the base metal microstruc-
ture is mainly composed of lath martensite (Ref. 4). The
cooling rate is one of the most important factors influencing
microstructure. Laser welding has low linear energy and
high cooling rates (2000°–3000°C/s) (Ref. 10), which pro-
motes the diffusionless transformation of the prior austen-
ite into martensite. The microstructures of the laser welded
joint were observed by OM and SEM and are shown in
Fig. 7.
Metallographic examination indicated that the joint is
comprised of a weld metal (WM) and HAZ. As illustrated in
Fig. 7A, the HAZ can be divided into four subregions:
coarse-grained HAZ (CGHAZ), fine-grained HAZ (FGHAZ),
intercritical HAZ (ICHAZ), and subcritical HAZ (SCHAZ).
As shown in Fig. 7A and B, the WM mainly contains lath
martensite. Since the heat flow in the weld metal is highly
directional toward the fusion boundary, the prior austenite
grew to the columnar grains in a certain direction (Ref. 4).
The prior columnar boundary developed during solidifica-
tion is clearly observed in Fig. 7B. Additionally, Fig. 8 reveals
Heat Input (kJ/mm)
3 0.16
2 0.18
2 0.30
JULY 2018 / WELDING JOURNAL 217-s
WELDING RESEARCH

B C

D E

F G

Fig. 7 — These OM and SEM micrographs show the microstructures in different subzones of the welded joints with 0.18 kJ/mm heat
input. A — Joint microstructures; B — WM; C — CGHAZ; D — FGHAZ; E — ICHAZ; F — SCHAZ near ICHAZ; G — SCHAZ.

that the prior austenite grew to the columnar grains in a cer-

tain direction and finally converged at the weld center. The
weld center is almost planar. There is no equiaxed crystal
around the weld center. The WM is mainly composed of
columnar grains with obvious direction. The micrographs at
the same magnification of the base metal and weld metal are
shown in Fig. 9. Compared with the base metal, the size of
lath martensite in the weld metal is slightly smaller due to
the high cooling rate of laser welding.
In the CGHAZ and FGHAZ, the peak temperature during
welding was more than Ac3 and full austenitizing occurred.
As Fig. 7C and D indicate, the major microstructures of the
FGHAZ and CGHAZ are still martensite. That is because the
initial martensite is formed into austenite and then the sub-
sequent cooling causes the austenite to transform into
martensite again (Ref. 4). Since the CGHAZ is adjacent to
the weld interface and the austenitizing is severe, the mi-
crostructure is lath martensite with a large prior-austenite Fig. 8 — OM micrographs showing the microstructures
grain size. The microstructure within the FGHAZ is lath around the weld center.
martensite with a small prior-austenite grain size. The re-
sults agreed with findings of correlational research (Ref. 35). Ac1∼Ac3 (Ref. 36), and the SEM micrographs of the region are
The ICHAZ is obtained when the zone is heated to given in Fig. 10. According to the phase diagram, the marten-

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A B
Fig. 9 — Microstructure of the base metal and weld metal. A — Base metal; B — weld metal.
A B
Fig. 10 — SEM micrographs showing the microstructures in different positions of the ICHAZ. A — ICHAZ; B — A region; C — B region.
Fig. 11 — High-magnification SEM of the tempered martensite
structure in the SCHAZ.
site of the base metal transforms into ferrite and austenite
during the heating process, and carbon is mainly contained
in austenite. After cooling, the austenite in the ICHAZ trans-
forms into martensite (Ref. 37). As illustrated in Figs.7E and
10, the microstructure of the ICHAZ may be comprised of
ferrite and martensite. Similar microstructural features are
reported in previous works on resistance spot welding of ad-
vanced high-strength steels (AHSS) (Refs. 36, 37).
WELDING RESEARCH
C
For the SCHAZ, the peak temperature is below Ac1 and
high-temperature tempering happens. It can be seen in
Fig.7F and G that the microstructure in the SCHAZ could be
tempered martensite. The high-magnification SEM micro-
graphs of the SCHAZ are shown in Fig. 11. Ultrafine precipi-
tates carbides can be found on the matrix of tempered
martensite. Namely, the preexisting martensite decomposes
and precipitates carbides (Ref. 38).
Microhardness
The hardness distributions of joints under different heat
inputs are given in Fig. 12. The microindentations of differ-
ent subregions of a joint with 0.18 kJ/mm heat input are
shown in Fig. 13. As indicated in Fig. 12, the hardness varies
significantly.
The hardness of the WM is approximately 510–530 HV
(Fig. 13A), and slightly higher than that of the base metal
(about 500 HV) due to a smaller size of lath martensite in
the weld metal. For the HAZ, the hardness increased gradu-
ally in the CGHAZ and reached a maximum in the FGHAZ,
where the microstructure is lath martensite with a fine grain
size. As shown in Fig. 13B, the maximum hardness is 578
HV. A sharp decrease occurred in the ICHAZ, which agreed
with a previous report (Ref. 9). The hardness decreased from
574 to 406 HV, which may be in connection with the appear-
ance of ferrite. As illustrated in Fig. 13D, the minimum
hardness is obtained in the SCHAZ instead of the ICHAZ,
and the minimum value is about 345 HV. The hardness in-
JULY 2018 / WELDING JOURNAL 219-s
WELDING RESEARCH
A A
B joint with 0.18 kJ/mm heat input. A — The WM around the
C Tensile Properties
Fig. 12 — The hardness distribution of the joint under different
heat inputs. A — 0.16 kJ/mm; B — 0.18 kJ/mm; C — 0.30 kJ/mm.
creased gradually from the SCHAZ to the base metal and
eventually reached the level of base metal. For arc welded
UHSS with similar strength and thickness, the size of the
soft zone in the HAZ is about 6 to 8 mm (Refs. 14, 16, 17).
As given in Fig. 12, the width of the soft zone is just about
220-s WELDING JOURNAL / JULY 2018, VOL. 97
B
C D
Fig. 13 — The microindentations of different subregions of the
weld center; B — FGHAZ; C — ICHAZ; D — SCHAZ.
1.0 to 2.0 mm, much less than the width of the arc-welded
joint (Ref. 16). The limited size could reduce the influence of
softening on the strength of the joint, but might lead to in-
homogeneous deformation during a bend test.
As is expected, various heat cycles would lead to a differ-
ent softening. As shown in Fig. 12, the width and minimum
hardness of the softening zone are influenced by heat input.
The width of the different joints were 1.31, 1.45, and 1.70
mm, respectively. Additionally, the minimum hardness was
348, 345, and 327 HV, respectively. The high-heat-input weld
exhibited a wider dimension and a more serious hardness
drop in the softening zone compared to low heat input. The
changes indicated that high heat input intensified the HAZ
softening.
Tensile properties of the joints under different welding
parameters are shown in Table 5. It can be found that, while
the elongation is lower for the laser welded joints, the ulti-
mate tensile strength (UTS) remains very close to the base
metal. In this study, the average strength of the joints was
about 1620 MPa, which indicates that the joint efficiency
can be more than 94%, and far exceeds that of arc welding.
The maximum elongation is 4.75%, more than 50% of the
base metal.
The tensile fracture sections of the joints under different
heat input are given in Fig. 14. Because of light corrosion,
only the ICHAZ can be seen clearly. As shown in the figure,
the fracture location shifts from the weld metal to the HAZ
with the increase of heat input. Two distinctive fracture
modes are observed and the corresponding SEM micro-
graphs of the fracture surface are given in Figs. 15 and 16.
For the joint with the 0.16 kJ/mm heat input (parameter
1), the failure was located in the weld metal around the weld
center — Fig. 14A. A number of pores can be seen clearly on
the macroscopic fracture surface — Fig. 15. It is indicated
that porosity in the joints might weaken the weld metal and
finally lead to the fracture in the region instead of the soft-
ening zone. Area measurements revealed that the reduction
 WELDING RESEARCH

Table 5 — Tensile Results of Laser Welded Joints

No. Laser Power Speed Heat Input Tensile Strength Elongation Fraction Initiation
(kW) (m/min) (kJ/mm) σUTS (MPa) A (%) Location Location

1 8 3 0.16 1618.0 3.15 weld metal weld metal

2 6 2 0.18 1623.5 4.75 weld metal/HAZ HAZ
3 10 2 0.30 1618.0 4.55 weld metal/HAZ HAZ
BM — — — 1723.0 9.05 — —

A B C

Fig. 14 — The fracture sections after tensile testing of the joints under different heat inputs. A — 0.16 kJ/mm; B — 0.18 kJ/mm; C —
0.30 kJ/mm.

Fig. 15 — The SEM micrographs of the fracture surface after the tensile test of the joints welded at a heat input of 0.16 kJ/mm.

JULY 2018 / WELDING JOURNAL 221-s

WELDING RESEARCH

Fig. 16 — The SEM micrographs of the fracture surface after the tensile test of the joints welded at a heat input of 0.30 kJ/mm.

Table 6 — Bending Results of Laser Welded Joints

No. Laser Power Speed Heat Input Maximum Bending Angle Bending Fraction
(kW) (m/min) (kJ/mm) (deg) Location

1 8 3 0.16 21.4 Weld metal

2 6 2 0.18 43.8 HAZ
3 10 2 0.30 38.2 HAZ
Base metal — — — 180.0 —

ratio due to porosity is just about 0.65%. As illustrated in
Fig. 15, numerous short tearing ridges are observed on the
fracture surface of the joints. Tiny cleavage planes connect
with each other through the tearing ridge, accompanied by a
secondary crack. All of the above is a typical feature of qua-
si-cleavage mode, which belongs to a brittle transgranular
fracture. Moreover, some small dimples can be observed.
The existence of dimples and tearing ridges means some
plastic deformation occurred before the fracture. Thus, the
fracture mechanism is a dominant brittle fracture, mixed
with a measure of ductile fracture.
For the joints with more than 0.18 kJ/mm heat input
(parameters 2 and 3), the fracture was located in the HAZ
and the weld metal (Fig. 14B and C). Platforms close and
parallel to the ICHAZ can be seen. The microstructure in the
platforms is severely tempered martensite with large
amounts of precipitates carbides, and the hardness is the
lowest. Therefore, the welded joints would break off at the
softened area and then expand to other zones of the joints
(Refs. 4, 39). The overall fracture direction is along 45 deg to
the parallel direction. Various magnification SEM fracture
graphs for the welded specimen are shown in Fig. 16. The
fracture morphology in the platform is similar. It can be
seen that the platform is predominately composed of differ-
ent-sized equiaxed dimples, which are caused by simple ten-
sile loading, and the morphology is usually in accordance
with the characteristic of the fracture center (Refs. 40, 41).
The graphs on the two 45-deg shear planes beside the plat-

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A B
Fig. 17 — The fracture sections of the bending joints under different heat input. A — 0.16 kJ/mm; B — 0.18 kJ/mm; C — 0.30 kJ/mm.
A B
Fig. 18 — The macrographs of bending joints under different heat inputs, A — 0.13 kJ/mm; B — 0.18 kJ/mm; C — 0.30 kJ/mm.
form show small shearing dimples. The dimples have an
elongated parabolic shape, indicating the occurrence of
shearing motion and the final rapid failure of the sample
(Refs. 42, 43). Combined with the minimum hardness on
the platform, it is speculated that the fracture might initiate
at the platform and then extend along the 45-deg bevel. It
could be concluded that the specimen failed in a typical duc-
tile fracture mode. That is why the elongation is larger com-
pared with parameter 1.
Bending and Charpy Impact Properties
A three-point bend test was carried out at the top of the
joints to evaluate the bending property of joints. The results
are shown in Table 6. Compared with the base metal, the
laser welded joints have inadequate bending deformability
with only about a 40-deg bending angle before a complete
fracture was obtained. The base metal can easily realize a
180-deg bending angle without a crack.
The fracture sections and macrograph of bending joints
under different heat input are given in Figs. 17 and 18, re-
spectively. As shown in Fig. 17, two different fracture loca-
tions are observed.
For parameters with a 0.16 kJ/mm heat input (parameter
1), the bending fracture occurred in the weld metal (Figs.
17A and 18A), where the metal is weakened by porosity, just
like the tensile fracture. Since the plasticity of the weld met-
al is very poor with a hardness of more than 500 HV, only a
WELDING RESEARCH
C
C
21.4-deg bending angle was obtained.
For parameters with a heat input of more than 0.18
kJ/mm (parameters 2 and 3), the bending samples fractured
around the softening zone instead of the weld metal. The
larger bending angle (35.8 to 43.8 deg) is achieved because
of better plasticity in the zone. A similar bending angle was
reported in laser welded ARMOX 500T steel (Ref. 9). During
a bend test, the specimen surface had the maximum tensile
stress. Therefore, the fracture might initiate at the top of
around the ICHAZ (Fig.17) where the hardness is the lowest.
The fracture locates in the SCHAZ. The microstructure
around the fracture zone is tempered martensite with differ-
ent temper temperatures. The degree of the temper reduces
progressively away from the weld center. Just like the ten-
sion process, it extended along a 45-deg shear plane in the
initial stage. As the testing proceeded, the fracture turned
around about 90 deg and extended along the 45-deg direc-
tion again (extending stage) since the hardness of the SC-
HAZ increased gradually away from the weld center. Finally,
the samples ruptured along the ICHAZ. The SEM micro-
graphs of the fracture surface on the tension stress zone of
bending samples are given in Fig. 19. On both the 45-deg
bevels, cleavage surface can be seen clearly, which indicates
that the fracture mechanism of the two bevels is a brittle
fracture.
As shown in Figs. 17 and 18, no joints were subjected to
significant plastic deformation and all the joints failed. This
can be explained by the fact that, as illustrated in Fig. 18B
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WELDING RESEARCH
A B
Fig. 19 — SEM micrographs of the fracture surface on the tension stress zone of the bending samples at the heat input of 0.18
kJ/mm. A — 45-deg shear plane in the initial stage; B — 45-deg shear plane in the extending stage.
Table 7 — Impact Results of Laser Welded Joints
No. Laser Power Speed Heat Input
(kW) (m/min) (kJ/mm)
1 8 3 0.16
2 6 2 0.18
3 10 2 0.30
Base metal — — — 14.3
and C, plastic deformation mainly localizes in the softening
zone due to nonuniform hardness distribution. Since the
softening zone of a laser welded joint is narrow, allowable
deformation is insufficient for a larger bending angle before
fracture. Therefore, this may limit the deformability of all
the joints.
The Charpy impact test of the base metal was carried out
and the V-notch was located in the weld center of the joint.
Impact results are shown in Table 7. The impact energies
under different parameters are in the range of 4.3 to 8.7 J,
and the maximum impact energy is more than 60% of the
base metal. The macroscopical fracture surfaces of the base
metal and joints are shown in Fig. 20. The fibrous region is
circled in the figures. It can be seen that the fracture surface
of the base metal is mainly comprised of a fibrous region
and shear lip. However, for the laser welded joints, the frac-
ture surface is composed of a large range of a radia region
and a small range of fibrous region without shear lip, which
indicates that the fracture mechanism is mainly a brittle
fracture. Hence, the impact energy of the joint is much less
than that of the base metal. Since the V-notches located in
the weld center and the entire fracture of joints is almost a
plane, the cracking initiates and propagates around the weld
center. This may result from obvious direction of columnar
grains in the weld center (Fig. 8).
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Impact Energy Impact Fraction
(–40°C, J) Location
4.3 Weld metal
8.7 Weld metal
6.7 Weld metal
—
Discussion
Influence of Parameters on Joint Appearance
As shown in Fig. 3, parameters obviously affect the distri-
bution of forming defects. Spatter mainly occurred in high-
speed welds. It is reported that spatters are caused by the
upward melt flow and friction drag force (Ref. 32). The melt
flow is due to the evaporation-induced recoil pressure, and
the drag force is induced by metallic vapor escaping from the
keyhole (Refs. 32, 44). With an increase in welding speed,
the length of the molten pool is longer and the inclination
of the capillary becomes larger, which would result in
stronger dynamic pressure of the vapor plume and more
spatter (Ref. 45). In this research, smooth and uniform
welds with few spatters can be obtained with a welding
speed below 4 m/min.
Root humping is mainly affected by low heat input under
high welding speed. Relevant studies have demonstrated
that it is associated with the fast downward melt flow (Ref.
33). The molten metal flows rearward under the effect of re-
coil pressure and forms a droplet at the bottom due to iner-
tia. Usually the droplets would be dragged back to the weld
before solidification by surface tension, but small heat input
(6 kW and 4 m/min), with high cooling rate, shortens the

A B
Fig. 20 — Impact fractures of the base metal and joints. A — The base metal; B — 0.16 kJ/mm; C — 0.18 kJ/mm; D — 0.30 kJ/mm.
time of solidification and the droplets are retained in the
form of root humping instead of retuning into the weld. As a
result, root humping occurs and leads to underfill on the
corresponding cross section.
Weld pool sagging is one of the characteristics of a thick
section weld (Ref. 10). Once the melt pool is fully penetrat-
ed, pool sagging occurs. It might be associated with an
amount of molten metal produced by the excessive heat in-
put and the downward melt flow with root humping. Gravi-
ty in the thick-section molten pool is as important as sur-
face tension and recoil pressure. Once the plate is fully pene-
trated, the molten metal flows toward the root of the weld
under the action of hydrostatic pressure from gravity and
the laser beam (Ref. 33). The dimensionless Bond number
represents the ratio of gravitational forces to surface tension
forces (Ref. 46). With the increase of the Bond number, the
relative importance of gravity is becoming obvious. When
the Bond number exceeds threshold levels, namely the grav-
ity is large enough and the surface tension cannot compen-
sate the hydrostatic pressure, pool sagging occurs (Refs. 10,
30, 33). Too low a welding speed with excessive heat input
would aggravate the defect. Maybe that is why serious pool
sagging happened at 1 m/min. With a further increase in
heat input, surface tension is totally unable to balance the
hydrostatic pressure, molten metal is partly out of the weld,
and then a significant root concavity appears (Fig. 4D).
Softening Mechanisms of the HAZ
The results described in the microstructure and micro-
hardness sections indicate that the lath martensite in the
weld metal, CGHAZ, and FGHAZ resulted in hardening of
the joints. But the ICHAZ and SCHAZ showed microstruc-
ture degradation and hardness decreased, which would have
a significant impact on the mechanical behavior of the laser
welded joints. The analysis indicated that there might exist
two softening mechanisms in laser welded UHSS joints.
First, the joints are softened in the ICHAZ since the dual-
phase microstructure of the ferrite and martensite ap-
peared. As shown in Fig. 10A, the ferrite appeared at Ac3 and
reached the maximum quantity at Ac1. The corresponding
volume of martensite deceased gradually as it approached
the SCHAZ, which resulted in a sharp drop in the hardness
WELDING RESEARCH
C D
of the ICHAZ. Second, the UHSS is also softened in the
SCHAZ as the martensite in the original microstructure pre-
cipitates carbides and then forms tempered martensite (Fig.
11). Because the highest temper temperature is slightly low-
er than Ac1, the most heavily tempered martensite appears
in the SCHAZ close to the ICHAZ. Therefore, the most sig-
nificant softening occurs in the zone. With the decrease of
peak temper temperature from the SCHAZ to the base met-
al, the hardness rose gradually, but the SCHAZ still belonged
to the softening zone. The results are consistent with previ-
ous research (Ref. 9).
Fracture Mechanisms of Tensile and Bend Tests
Since the tension stress zone of the bending process is
similar to the tensile process, there exists homogeneity for
the failure of the tensile and bending test. As shown in Figs.
14 and 17, the fractures might both initiate at the softening
zone close to the ICHAZ, where the hardness is the lowest
and the microstructure is tempered martensite under high
temperature. Then the fractures extend along the 45-deg
direction as the tangential stress is the maximal. As the ten-
sile and bend tests have their respective characters, there are
some differences for the initiation location and propagation
path of the fracture. For the bend test, the top and root of
the joints withstand tensile and compressive loadings, re-
spectively. The stress on the specimen surface is the maxi-
mum, so it’s very sensitive to softening. Therefore, the frac-
ture initiates at the joint surface instead of inside. More-
over, the crack propagation paths of tensile and bending
fractures are different. For the tensile test, since the soften-
ing zone is close to the ICHAZ and the ICHAZ is inclined be-
cause of the hourglass weld shape (Ref. 35), the fracture
might have the inertia of extending along the incline into
the weld metal quickly. It could be the reason why the crack
propagated to the weld metal instead of trapping in the soft-
ening zone after initiation. For the bend test, the expanding
process carried on slowly and gradually. The cracking path in
the tension stress zone of the bend samples is all 45 deg in
the SCHAZ, but there is a 90-deg turn, which may result
from increasing hardness away from the weld center. A simi-
lar propagating path was reported and some simulations
about the crack growth trajectory were done (Refs. 47, 48).
JULY 2018 / WELDING JOURNAL 225-s
WELDING RESEARCH
Based on the maximum tangential stress (MTS) criterion
(Ref. 47), the fracture path would deviate from the original
crack line. The maximum tangential stress criterion or the
minimum strain energy density criterion has been frequent-
ly used for predicting the angle of deflection (Ref. 47). For
the 45-deg original crack, the deflecting angle is about 90
deg. In this research, the crack of the bending specimens ex-
tends along the 45-deg shear plane in the initial stage and
then deviates from the crack tip. The deflecting direction is
toward the loading point, namely tends to the weld.
Influence of Porosity on Mechanical Properties
The existence of porosity in joints has significant affects
on the mechanical property of joints. For the tensile test, as
mentioned above, there are some pores in the weld metal of
joints with 0.16 kJ/mm heat input (Fig. 6). However, the
tensile strength of the joints can reach 1618 MPa, very close
to average strength (1620 MPa) under different parameters,
which might mean that the appearance of porosity exhibits
little effect on the strength of joints. For the tensile and
bending fracture, the porosity weakened the weld metal and
led to complete failing in the zone instead of initiating at
the softening zone.
The smaller elongation (3.15%) and bending angle (21.4
deg) are obtained for the joints with porosity. Namely, the
fracture mechanism and ductility are significantly affected.
The existence of pores might also damage the impact prop-
erty of the joints with porosity. That is why the impact ener-
gy under parameter 1 is just about 4.3 J and significantly
lower than other parameters. Related studies have shown
mechanical properties are obviously affected by porosity
(Ref. 49), but the sensitivity of the properties to porosity is
different. Ductility and toughness are highly sensitive and
the value would drop immediately as the porosity appears
(Refs. 50, 51). This may be attributed to stress concentra-
tion and initial cracks at porosity (Ref. 52), but strength is
tolerant of some porosity (Refs. 50, 51, 53, 54). For 5086-
H116 aluminum alloy welds, the tensile strength was not re-
duced until the porosity level increased above a 1% vol-%
(Ref. 50). For Inconel® 690 joints with equal to or less than
1.7% porosity area, the tensile strength is similar to that of
the BM (Ref. 55). Namely, the tensile strength would not
significantly reduce until the porosity exceeds a certain level
(Refs. 50, 55). The reason may be that strength loss is pro-
portional to loss in the cross-section area (Ref. 56). There-
fore, the porosity in the laser welded UHSS joints has signif-
icant effects on ductility, toughness, and fracture mecha-
nism but little on the strength of joints, since the area ratio
of porosity is approximately 0.65%.
Conclusions
Based on the results achieved in this study, the following
conclusions are obtained.
1. Forming defects such as spatter, root humping, and
pool sagging as well as root concavity occur under different
parameters. The welding speed is the main affecting factor.
Sound welds without visible defects are obtained under the
process window of laser power from 6 to 10 kW and a weld-
ing speed from 2 to 3 m/min. Moreover, porosity is found in
226-s WELDING JOURNAL / JULY 2018, VOL. 97
the joints with low-heat input (0.16 kJ/mm).
2. The microstructures and hardness of joints keep a
good corresponding relationship. In the weld metal and the
CGHAZ, the microstructures are predominately lath
martensite with high hardness. The maximum hardness lo-
cates in the FGHAZ, which is consistent with fine equiaxed
martensite. Two softening mechanisms occur in the HAZ. A
sharp hardness decrease occurs in the ICHAZ as it exhibits a
dual-phase microstructure of ferrite and martensite. The
minimum hardness of joints locates in the SCHAZ since the
original microstructure precipitates carbides and forms tem-
pered martensite.
3. More than 94% of the strength and 50% of the elonga-
tion of the base material are achieved in a tensile test. For
the joints with more than 0.18 kJ/mm heat input, the frac-
ture initiates at the softening zone close to the ICHAZ
and propagates to the weld metal and the SCHAZ along the
45-deg direction. The fracture is ductile with equiaxed and
shearing dimples. For the bend test, as the deformation
mainly localizes in the softening zone due to nonuniform
hardness distribution, no joints are subjected to significant
plastic deformation and all bend specimens fail. When heat
input is more than 0.18 kJ/mm, the bending fracture initi-
ates at the top of around the ICHAZ and extends along the
45-deg shear plane with about a 40-deg bending angle. For
the Charpy impact test, all the joints fractured in the form
of brittle mechanism. The maximum impact energy reaches
60% of the base metal.
4. The existence of porosity in joints with 0.16 kJ/mm
heat input has significant effects on the ductility, tough-
ness, and fracture mechanism but little on the strength of
joints. For tensile and bend tests, porosity weakens the weld
metal and leads to fracturing in the WM instead of initiating
at the softening zone. The optimal parameter in this experi-
ment is parameter 2 (6 kW and 2 m/min) with the best
strength (1623.5 MPa), ductility (4.75%), bending angle
(43.8 deg), and impact toughness (8.7 J).
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