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December 2014

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
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December 2014 • Volume 93 • Number 12 CONTENTS
FEATURES
40 Improving GMAW Efficiency through Shielding Gases
Practical recommendations are made to improve
welding operations through the use of argon-based
shielding gases — D. Sarma
46
46 A Technology to Increase SAW Productivity
The use of an electrically isolated welding wire
helps to increase deposition rates in submerged arc
welding — H. Raudsepp

48 A Must in Today’s Workplace: Weld­Quality Monitoring


Point-of-use monitoring and postweld verification
are two methods for improving weld quality
M. Albright
40 48

THE AMERICAN WELDER


80 Heat Tint Poses Corrosion Hazard in Stainless Steel
Advice is given on ways to eliminate heat tint
when welding stainless steel — M. Fletcher

84 Welding Program Revitalized


A welding program is reborn and a dedicated
teacher inspires his students to look to the future
as welders — A. Cullison

88 Considerations for Selecting Shop Grinders


84 88
The author evaluates different types of grinder
power sources and suggests which is best
A. H. Krieg

WELDING RESEARCH SUPPLEMENT


443­s Characterization of Multilayered Multipass Friction A Numerical Model for the Prediction of Phase
Stir Weld on ASTM A572 G50 Steel Transformation­Induced Compressive Residual
A butt/lap joint configuration was friction stir Stresses
welded and its mechanical properties were Numerical analysis using the software Sysweld was
evaluated for the best welds — Y. C. Lim et al. performed on gas metal arc welds made with low-
transformation-temperature welding wires
451­s Friction Stir Welding of Extruded Powder T. Alghamdi and S. Liu
Metallurgy Al Allloy
It was demonstrated that friction stir welding produced 472­s Improvement of Process Robustness in Weld
joints without voids or discontinuities and a refined Bonding of Galvanized DP780 Steel
microstructure in the stir zone — A. Elrefaey et al. A variable electrode force was used in this study to
widen the weld lobe — Y. S. Zhang et al.
458­s Low Transformation Temperature Welding
Consumables for Residual Stress Management:

DECEMBER 2014 / WELDING JOURNAL 3


DEPARTMENTS
6 Editorial 59 Society News
8 Washington Watchword 60 Tech Topics
10 Press Time News 61 Errata D1.2/D1.2M:2014
12 International Update Amendment Notice
16 News of the Industry 75 Guide to AWS Services
22 Business Briefs 78 Personnel
24 Letters to the Editor The American Welder
26 Brazing Q&A 90 Learning Track
28 Aluminum Q&A 94 Fact Sheet
34 Product & Print Spotlight 96 Welding Journal Index
On the cover: A welding operator oversees a
52 Coming Events 112 Classifieds submerged arc tandem welding application
56 Certification Schedule 114 Advertiser Index in which two twin wire heads are placed in
sequence to achieve wire deposition rates of
up to 83.7 lb/h. (Photo courtesy of ESAB
Welding & Cutting Equipment, Florence, S.C.)

R. W. Roth (At Large), RoMan Manufacturing, Inc. C. Coffey, Lincoln Electric


N. Saminich (Dist. 21), NS Inspection and Consulting D. DeCorte, RoMan Mfg.
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co. S. Fyffe, Astaras, Inc.
T. A. Siewert (At Large), NIST (ret.) D. Levin, Airgas
J. Stoll (Dist. 18), Bohler Welding Group U.S. R. Madden, Hypertherm
OFFICERS H. W. Thompson (Dist. 2), UL, Inc. D. Marquard, IBEDA Superflash
President Dean R. Wilson R. P. Wilcox (Dist. 11), Ford Motor Co. J. F. Saenger Jr., Consultant
Welldean Enterprises J. A. Willard (Dist. 13), Kankakee Community College S. Smith, Weld­Aid Products
M. R. Wiswesser (Dist. 3), Welder Training & D. Wilson, Welldean Enterprises
Vice President David J. Landon Testing Institute J. N. DuPont, Ex Off., Lehigh University
Vermeer Mfg. Co. L. G. Kvidahl, Ex Off., Northrop Grumman
Ship Systems
Vice President David L. McQuaid WELDING JOURNAL D. J. Landon, Ex Off., Vermeer Mfg.
D. L. McQuaid and Associates, Inc. S. P. Moran, Ex Off., Weir American Hydro
Publisher — Andrew Cullison
E. Norman, Ex Off., Southwest Area Career Center
Vice President John R. Bray Editorial R. G. Pali, Ex Off., J. P. Nissen Co.
Affiliated Machinery, Inc. Editorial Director Andrew Cullison
N. Scotchmer, Ex Off., Huys Industries
Editor Mary Ruth Johnsen
Treasurer Robert G. Pali R. W. Shook, Ex Off., American Welding Society
Associate Editor Howard M. Woodward
J. P. Nissen Co. Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coor. Melissa Gomez American Welding Society
Executive Director Ray W. Shook 8669 NW 36 St., # 130, Miami, FL 33166­6672
American Welding Society Publisher Emeritus Jeff Weber
(305) 443­9353 or (800) 443­9353
Design and Production
DIRECTORS Production Manager Zaida Chavez Welding Journal (ISSN 0043­2296) is published monthly by
the American Welding Society for $120.00 per year in the United
U. Aschemeier (Dist. 7), Subsea Global Solutions Sr. Production Coordinator Brenda Flores States and possessions, $160 per year in foreign countries: $7.50
R. E. Brenner (Dist. 10), CnD Industries, Inc. Manager of International Periodicals and per single issue for domestic AWS members and $10.00 per single
issue for nonmembers and $14.00 single issue for international.
D. J. Burgess (Dist. 8), Alstom Power Electronic Media Carlos Guzman American Welding Society is located at 8669 NW 36th St., # 130,
N. C. Cole (Past President), NCC Engineering Miami, FL 33166­6672; telephone (305) 443­9353. Periodicals
G. Fairbanks (Dist. 9), Fairbanks Inspection & Advertising postage paid in Miami, Fla., and additional mailing offices. POST­
MASTER: Send address changes to Welding Journal, 8669 NW
Testing Services National Sales Director Rob Saltzstein 36th St., # 130, Miami, FL 33166­6672. Canada Post: Publications
T. A. Ferri (Dist. 1), Victor Technologies Sr. Advertising Sales Exec. Sandra Jorgensen Mail Agreement #40612608 Canada Returns to be sent to
Bleuchip International, P.O. Box 25542, London, ON N6C 6B2,
K. Fogleman (Dist. 16), Consultant Sr. Advertising Sales Exec. Annette Delagrange Canada.
P. H. Gorman (Dist. 20), Sandia National Laboratories Manager of Sales Operations Lea Paneca Readers of Welding Journal may make copies of articles for
Sr. Advertising Production Manager Frank Wilson personal, archival, educational or research purposes, and which
S. A. Harris (Dist. 4), Altec Industries are not for sale or resale. Permission is granted to quote from arti­
K. L. Johnson (Dist. 19), Vigor Shipyards cles, provided customary acknowledgment of authors and sources
J. Jones (At Large), The Harris Products Group
Subscriptions is made. Starred (*) items excluded from copyright.
Copyright © 2014 by American Welding Society in both
Subscriptions Representative Tabetha Moore
J. Knapp (Dist. 17), Gas and Supply printed and electronic formats. The Society is not responsible for
tmoore@aws.org any statement made or opinion expressed herein. Data and infor­
T. J. Lienert (At Large), Los Alamos National Laboratory mation developed by the authors of specific articles are for infor­
D. E. Lynnes (Dist. 15), Lynnes Welding Training PUBLICATIONS, EXPOSITIONS, mational purposes only and are not intended for use without inde­
C. Matricardi (Dist. 5), Welding Solutions, Inc. pendent, substantiating investigation on the part of potential users.
S. P. Moran (At Large), Weir American Hydro
MARKETING COMMITTEE
K. A. Phy (Dist. 6), K. A. Phy Services, Inc. D. L. Doench, Chair, Hobart Brothers Co.
W. R. Polanin (At Large), Illinois Central College S. Bartholomew, Vice Chair, ESAB Welding
W. A. Rice (Past President), OKI Bering & Cutting Prod.
R. L. Richwine (Dist. 14), Ivy Tech State College J. D. Weber, Secretary, American Welding Society
D. J. Roland (Dist. 12), Airgas USA, LLC, D. Brown, Weiler Brush
North­Central Region T. Coco, Victor Technologies International

4 WELDING JOURNAL / DECEMBER 2014


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EDITORIAL

AWS Continues to Innovate

When I took office as president of the measurement of research impact.


American Welding Society just a year ago, I The recent FABTECH expo in Atlanta
unveiled my theme of “continuous improve- was the biggest ever held outside of Chica-
ment through innovation.” As it turned out, go. And next year’s Chicago show has al-
2014 was a year of remarkable innovation at ready broken all records for exhibitor space
AWS. reservations.
Today, I thank the entire Society — its This year, hundreds of Certified Welding
70,000-plus members, more than 1000 Inspector candidates benefited from new
committee members, Board of Directors, online training from AWS Learning, prepar-
160 Sections, 38 international agents, in- ing them better than ever before for live
dustry partners, hundreds of scholarship seminars, examination, and, ultimately,
donors, and 130 dedicated staff members — their new professional responsibilities.
for coming through with so many innova- One of my priorities has been the fulfill-
Dean R. Wilson tions that are making history for our mis- ment of a Master Welder credential. We want
AWS President sion “to advance the science, technology, to recognize those special welders who work
and application of welding and allied joining to perfect their craft. This year, more than
and cutting processes.” While that’s the So- 10,000 stakeholders were surveyed to provide
ciety’s historic mission, this year we infor- guidance for a blue-ribbon task group that is
mally expanded it to “advancing the people developing the Master Welder program.
of welding.” Continuous improvement requires great
By all measures, 2014 has been a great staff and a strong technology infrastruc-
year for AWS and its mission. We surpassed ture. A new chief information officer, Emilio
all our financial goals and we are surpassing Del Riego, is leading a multimillion-dollar
our nonfinancial goals, as well. modernization of AWS’s IT system and web
Even more significantly, we have set the technology.
stage for elevating AWS up to a much higher With all these improvements in place,
level, with an impressive list of innovations AWS is poised to launch the most signifi-
and improvements. As president, I kept you cant innovation of all. The Society has de-
informed through a series of video updates voted a year to advancing the people of
on our progress for the first time ever. welding, with new career management
Continuous improvement through inno- tools, including stackable credentials, class-
vation has been demonstrated in the sales room and online training, and secure, effi-
and marketing areas, with a brand-new cient placement for qualified jobseekers.
branding strategy, complete with an updat- Our goal is to provide welding professionals
ed logo, a soon-to-be unveiled new website, with continuous career enhancement tools
and a reorganized sales force that is active from recruitment to retirement.
around the world. This will be a game-changer in how
“This will be a We have launched an AWS Asia office in welders are hired, how they obtain valuable
game­changer in China, with three AWS employees there. skills and credentials, and how they will be
That gives us a brick-and-mortar presence empowered to perform better and earn
how welders are in Hong Kong and Beijing. And our recent more over their careers.
hired, how they ob­ international agency meeting at our beauti- Next month is the launch date for this
tain valuable skills ful headquarters demonstrated expanded amazing innovation. Whether you are an
and credentials, relationships with dozens of educational employer, an employee, a student, or an ed-
and how they will and industry partners from 17 countries. ucator, you need to be ready to activate your
be empowered to It’s all about the people of welding. We profile on this powerful and secure system.
introduced an AWS customer satisfaction This represents a revolution in how we work
perform better and survey that gives us new metrics to work to- in our industry, and it’s a superb demon-
earn more over ward to exceed member expectations. stration of what we can gain from continu-
their lifetime.” Following are just a few of what AWS has ous improvement through innovation.
accomplished this year: Again, I thank everyone in the AWS fami-
The value of the research content in this ly around the world for a very successful
Welding Journal has more than tripled since year of advancing the science, technology,
2008, according to the standard academic application, and people of welding. WJ

6 WELDING JOURNAL / DECEMBER 2014


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WASHINGTON WATCHWORD
BY HUGH K. WEBSTER

Manufacturing Skills Legislation improvement. The analysis should include the scope, effec-
tiveness, and potential for redundancy of federal manufac-
Introduced turing programs and tax incentives. Apparently, there is
presently no official catalog of all federal programs designed
Inspired by the Race to the Top program created by the to support U.S. manufacturing, nor even a comprehensive
Department of Education, which created competition list of agencies charged with executing laws that affect
among schools to improve student metrics, a so-called “Race manufacturing.
to the Shop” legislation has been introduced in the House
and Senate. The Manufacturing Skills Act (S. 2897/H.R.
5564) would create an annual $100 million competitive White House Announces Three New
grant to support initiatives to strengthen the manufactur- Manufacturing Initiatives
ing workforce and address regional skills challenges. Grants
would be awarded to up to five states and five metropolitan Three new federal agency actions designed to strengthen
areas with the strongest and most comprehensive proposals. advanced manufacturing have been announced by the White
Each winner would receive up to $10 million over a three- House.
year period. The state or metropolitan area that receives the • The Departments of Defense, Energy, and Agriculture
grant would also be required to provide at least 50% of the and NASA have announced more than $300 million expen-
grant’s value in matching funds. The grants would be in- ditures for three technologies identified as critical to U.S.
tended to help promote reforms in workforce education and competitiveness: advanced materials including composites
skills training, under the administration of the Secretaries and bio-based materials, advanced sensors for manufactur-
of Commerce, Labor, Education and Defense, and the Direc- ing, and digital manufacturing.
tor of the National Science Foundation. • The National Science Foundation, the Department of
Energy, and NASA are developing “technology testbeds”
CTE Legislation Introduced in the Senate within federal research facilities where companies can de-
sign, prototype, and test a new product or process.
• This fall, the Department of Labor will launch a $100
Two Senate bills have recently been introduced on a bi- Million American Apprenticeships Grant Competition to
partisan basis, designed to boost career and technical educa- spur new apprenticeship models and scale effective ones in
tion. The Career and Technical Education Opportunity Act high-growth fields such as advanced manufacturing.
(S. 2795) would extend eligibility for federal student loans • The Department of Commerce’s Manufacturing Exten-
to short-term career and technical education programs that sion Partnership will build new capabilities at its state-based
do not meet the current program length requirements under centers and pilot a competition for $130 million over five
Title IV of the Higher Education Act. This extended eligibili- years across ten states to help small manufacturers adopt
ty for federal aid would provide increased access to courses new technologies and bring new products to market.
that provide students with industry-recognized credentials.
The Creating Quality Technical Educators Act (S. 2867)
would create a CTE teacher-training grant partnership to re- New STEM Resource Released
cruit and train high-quality CTE teachers. The goal would be
to foster partnerships between high-needs secondary The National Science Board, which is part of the National
schools and postsecondary institutions to create one-year Science Foundation, an independent government agency,
teacher residencies for CTE teachers. Through grants in the has released an interactive, online resource featuring new
Higher Education and Opportunity Act of 2008, many and updated data and graphics about STEM education and
teacher residency partnerships already exist between post- workforce in the U.S. and providing facts on topics such as
secondary institutions and local schools to train prospective student proficiency, college degrees in STEM fields, and jobs
educators, but none is CTE focused. CTE teacher residencies in science-related occupations. The resource features 60 cen-
created through the Creating Quality Technical Educators tral questions, organized by education level and the work-
Act would target mid-career professionals in related techni- force, with multiple data points, graphs, and maps providing
cal fields, as well as recent college graduates, veterans, or the answers to each question. The new resource is available
currently licensed teachers with a desire to transition to a at www.nsf.gov/nsb/sei/edTool.
CTE focus.
Export Import Bank Renewed
GAO Directed to Assess Federal Congress has quietly reauthorized the Export Import
Manufacturing Programs Bank for at least one more year. The bank, which provides fi-
nancing and insuring to foreign buyers of U.S.-made goods,
A bipartisan group of U.S. Senators has asked the Gov- has been the subject of much debate as to its ongoing value
ernment Accountability Office (GAO) to analyze federal and viability, with defenders and detractors along the politi-
manufacturing policies and provide recommendations for cal spectrum. WJ

HUGH K. WEBSTER, AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE — Contact the AWS Washington Government Affairs Office at 1747 Pennsylvania
Ave. NW, Washington, DC 20006; e­mail hwebster@wc­b.com; FAX (202) 835­0243.

8 WELDING JOURNAL / DECEMBER 2014


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PRESS TIME NEWS

Aiken Technical College Receives $195,000 Oak Ridge National Laboratory Research
Nuclear Regulatory Commission Grant to Reveals Unique Capabilities of 3­D Printing
Start Nuclear Welding Program
Researchers at the Department of Energy’s Oak Ridge
National Laboratory (ORNL), Oak Ridge, Tenn., have re-
cently demonstrated an additive manufacturing method to
precisely control the structure and properties of metal
components.
Ryan Dehoff, staff scientist and metal additive manu-
facturing lead at the Department of Energy’s Manufactur-
ing Demonstration Facility at ORNL, presented the re-
search at the Materials Science & Technology 2014 confer-
ence in Pittsburgh, Pa.
“We can now control local material properties, which
will change the future of how we engineer metallic compo-
nents,” Dehoff said. “This new manufacturing method
takes us from reactive design to proactive design. It will
help us make parts that are stronger, lighter, and function
better for more energy-efficient transportation and energy
production applications such as cars and wind turbines.”
The researchers demonstrated this method using an
ARCAM electron beam melting system where successive
layers of a metal powder are fused together by an electron
The new nuclear welding systems program at Aiken Technical beam into a 3-D product. By manipulating the process to
College will help fill the need for qualified nuclear welders in the manage the solidification on a microscopic scale, the re-
Central Savannah River Area. Pictured above, a student prac­ searchers demonstrated 3-D control of the microstructure
tices his skills in a welding lab at the college. of a nickel-based part during formation.
“We’re using well-established metallurgical phenomena,
A $195,000 grant from the U.S. Nuclear Regulatory Com- but we’ve never been able to control the processes well
mission will enable Aiken Technical College, Aiken, S.C., to enough to take advantage of them at this scale and at this
design and implement a nuclear welding systems program level of detail,” added Suresh Babu, the University of Ten-
on campus. It will also meet the critical demand for qualified nessee-ORNL governor’s chair for advanced manufactur-
nuclear welders in the Central Savannah River Area. ing. “As a result of our work, designers can now specify lo-
The one-year, intensive pipe welding technology program cation- specific crystal structure orientations in a part.”
will serve as a stand-alone program for experienced welders Other contributors to the research are ORNL’s Mike Kir-
or an add-on certificate for students who plan to continue ka and Hassina Bilheux; University of California Berkeley’s
their nuclear welding education. Additionally, it will be de- Anton Tremsin; and Texas A&M University’s William Sames.
signed to meet industry welding standards and supported
with equipment, a mock-up industrial welding setting, and
online modules that cover nuclear welding specific topics.
Once developed, the program will join many others to be Recreational Vehicles Maker Expanding,
taught in the college’s Center for Energy & Advanced Manu- Creating 125 New Jobs
facturing currently under construction. This $8.5 million,
36,000-sq-ft facility will house the college’s welding, mecha- KZRV, LP, a maker of towable recreational vehicles, has
tronics, radiation protection technology, and nuclear quality plans to expand its operations in Shipshewana, Ind., creat-
systems programs. It’s expected to open for classes next fall. ing up to 125 new jobs by 2017.
In 2009, the Nuclear Energy Institute’s Workforce Report The company will invest up to $4.83 million to con-
cited a short- and long-term need for craft workers due to struct and equip a new 80,750-sq-ft lamination facility in
nuclear construction projects at the Department of Energy’s Shipshewana. This dedicated area, to be fully operational
Savannah River Site, as well as commercial sites in South by late spring 2015, will allow the company to increase its
Carolina and Georgia. Also, the study projected 1146 craft production capacity for lamination, aluminum frame weld-
workers trained in nuclear welding systems would be needed ing, and towable recreational vehicle assembly.
by 2020 in the Central Savannah River Area. Currently, KZRV (www.kz-rv.com) employs more than 360
The demand for nuclear welders is important to meet the full-time Indiana associates. It intends to begin hiring alu-
workforce needs of the Mixed Oxide Fuel Fabrication Facili- minum welders and general assembly workers in late spring
ty and Salt Waste Processing Facility at the Savannah River 2015. Interested applicants may apply in person at the com-
Site, plus the construction of new nuclear reactors operated pany’s human resources office in Shipshewana, Ind. WJ
by Southern Co. at Plant Vogtle in Waynesboro, Ga., and
SCANA Corp. at V.C. Summer Nuclear Power Station near
Columbia.

10 WELDING JOURNAL / DECEMBER 2014


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Welding Filler Metals for
Lasting Connections

voestalpine Böhler Welding


www.voestalpine.com/welding
Welding Filler Metals for
Lasting Connections

voestalpine Böhler Welding


www.voestalpine.com/welding
INTERNATIONAL UPDATE

Nizi International Acquires Chemalloy Czech Republic, Spain, Great Britain, Belgium, and the U.S.
The busy atmosphere reflected the overall positive outlook
Nizi International, Luxembourg, a distributor of base of the sheet metal working sector. The exhibition survey
metals and foundry products, and Chemalloy Company, Inc., showed that companies assess the current business climate
Bryn Mawr, Pa., a manufacturer of custom-sized alloys, met- as more favorable than two years ago.
als, minerals, and chemicals and supplier of metal powders, Nicola Hamann, managing director of Mack Brooks Exhi-
have reached a nonbinding agreement that Nizi is to acquire bitions, the show organizers, said, “The prevailing mood at
substantially all of the business and assets of Chemalloy. the show was positive throughout. There was lively trading
Chemalloy will continue as a separate entity within the Nizi activity in the eight exhibition halls and many exhibiting
Group, operating under the Chemalloy brand. Chemalloy companies reported large numbers of international business
President and CEO Tony Demos and the company’s manage- contacts and buoyant sales figures. A first analysis of the ex-
ment team plan to provide a seamless transition of the hibitor survey shows that participating companies were
Chemalloy business to the Nizi Group. highly satisfied with the outcome of EuroBLECH 2014. A
Though the core market of Nizi has been Europe, the ac- vast majority of exhibitors were able to fully or largely reach
quisition of Miller and Company in 2012 strengthened the their target groups; they praised the quality of trade visitors
position of the group in the U.S. foundry market. The acqui- and the internationality of the audience.”
sition of Chemalloy, which is expected to close before the
end of the year, will further strengthen the Nizi Group in Program Helps Employers Resolve Skill Shortages
North America.
Regarding the acquisition, Dag Teigland, chairman of Nizi
International, said, “Nizi International represents our long- In response to the skills shortage challenges facing Alber-
term industrial commitment toward the metal industry and ta employers, the Canada-Alberta Job Grant (CAJG) pro-
we have high ambitions for the future development of the gram was recently announced, which will offer substantial
Nizi Group. With a strong financial platform, a highly dedi- funding support for employers to upgrade the skills of cur-
cated organization, and a robust business model, Nizi is well rent and new employees. The program, which places the de-
positioned for growth and further geographical expansion. cisions about required training in the hands of employers,
Chemalloy fits right into this strategy. In addition, both will provide up to $10,000 in direct costs such as tuition and
companies represent proud industrial traditions and share a other mandatory fees, books, and supplies for each trainee,
lot of the same values. Tony Demos has done a remarkable with employers covering a minimum one-third of the cost.
job in developing Chemalloy over the last decades and we Employers can receive a maximum $300,000 grant per year.
thank him for his trust in us to take over his company. To- In anticipation of the announcement, SAIT Polytechnic
gether, we will continue to offer a reliable and competitive has put in place a team of specialists dedicated to helping
supply of raw materials to our customers.” employers with the grant application process. “The job grant
program is closely aligned to SAIT’s real-world, hands-on
training and we’ve identified dozens of SAIT programs that
EuroBLECH 2014 Attracts International Audience meet the funding criteria,” said Rod Miller, associate vice
president of corporate training at SAIT. “We’re also well-
positioned to customize training to an employer’s specific
needs.”
To qualify, training will be more than 25 h long and will
be completed within 52 weeks of the approval date. It can-
not replace existing training offered by an employer, and it
must be delivered by a third-party provider such as SAIT.
Training can be full-time or part-time and can be delivered
in the classroom, at the workplace, or online.

Shiloh Industries Expands Stamping


EuroBLECH 2014 hosted 59,600 trade visitors and exhibitors from Business into Central Mexico
38 countries.
Shiloh Industries, Inc., a supplier of lightweighting, noise
EuroBLECH 2014, the 23rd International Sheet Metal and vibration products, recently announced its acquisition
Working Technology Exhibition, was recently held in of Radar Industries, Warren, Mich. The purchase leverages
Hanover, Germany. 59,600 attended to learn about the lat- Radar Industries’ tooling technologies, stamping capabili-
est technology trends for sheet metal processing. A record ties, and key customer relationships, and expands its exist-
number of 1573 exhibitors from 38 countries put a wide ing manufacturing capacity to include Central Mexico and
range of products and live machine demonstrations on dis- Michigan.
play, on a total net floor space of 87,500 m2. The acquisition includes three metal stamping plants —
EuroBLECH 2014 attracted a more international audi- two located in Warren, Mich. and the other in Celaya, Mex.
ence than previous years. Visitor survey data showed that It also includes a sales and technical center, also in Warren.
top visitor countries outside Germany were the Nether- Radar is comprised of approximately 325 workers in the U.S.
lands, Austria, Switzerland, Poland, Sweden, Turkey, the and Mexico. WJ

12 WELDING JOURNAL / DECEMBER 2014


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NEWS OF THE INDUSTRY

Sheet Metal Welding Conference XVI back. “The automotive industry is being challenged with cre-
ating lighter-weight structures, requiring welding profes-
Highlights Premiere Resistance, Laser, sionals to stay informed as technology changes,” Poss said.
and Arc Welding Advancements At the traditional vendor display event, held the evening
of October 23, more than 30 booths represented various
welding equipment and technology companies. Susann
Morfino of MJM Sales, Inc., organized the gala. Guests visit-
ed the exhibits, networked, and tasted hors d’oeuvres.
In addition, on October 21 (before the conference began),
the Aluminum Welding Workshop at R & E Automated Sys-
tems, LLC, Macomb, Mich., attracted 75 participants. This
tutorial covered resistance spot welding of aluminum with
several product overviews and equipment demonstrations.
The biennial SMWC will be held again in 2016. Proceeds
support the AWS Detroit Section scholarships and educa-
tional programs. For more details, visit www.awsdetroit.org.

— Kristin Campbell, associate editor

Posing for a group portrait at the Sheet Metal Welding Confer­ Washington State Community College
ence XVI (from left) are Mike Palko (2010 chair), Michael Poss Debuts New Welding Lab
(2014 chair), and Mark D. Gugel (2012 chair).

One-hundred and eighty attendees recently gathered to


learn the latest developments presented during the Sheet
Metal Welding Conference (SMWC) XVI held October 22–24
at Schoolcraft College VisTaTech Center, Livonia, Mich.
Sponsored by the American Welding Society’s (AWS)
Detroit Section, this highly regarded event took place in co-
operation with the Resistance Welding Manufacturing Al-
liance, a Standing Committee of AWS; EWI; and the Ad-
vanced Laser Applications Workshop.
Alan Taub, chief technical officer, American Lightweight
Materials Manufacturing Innovation Institute, and profes-
sor, material science and engineering, University of Michi-
gan, gave the keynote speech. “Challenges in Manufacturing
a Multi-Material Vehicle” focused on gas prices; vehicle
weight reductions; advanced high-strength steels; alu- Welding instructor Josh Horner is shown in the beginning process
minum; and joining/assembly themes. “We’ve gotten better of building Washington State Community College’s welding lab.
at designing, engineering, manufacturing and are not talk-
ing about single material vehicles anymore,” Taub said. Chal-
lenges for future body construction include the need to be Dr. Bradley Ebersole, president of Washington State
able to join any combination of materials in any form with Community College, Marietta, Ohio, recently welcomed area
low cost, high stiffness, durability, and corrosion resistance. dignitaries to cut a ribbon at the school’s new welding lab
During the conference’s technical sessions — chaired by where students will have the ability to earn American Weld-
academic, automotive, and other industry leaders — nearly ing Society certifications.
50 papers were presented. These titles represent the covered “The demand for qualified welders in eastern and south-
processes: Resistance Welding of Lightweight BIW Metals; eastern Ohio is higher than ever due to the increased do-
Resistance Welding II: Control; Adhesives and Fastening; mestic energy production in both Marcellus and Utica shale
Laser Welding I: Welding Process; Arc Welding I: Light- formations. Recognizing this opportunity, Washington State
weight Metals; Resistance Welding III: Steels; Arc Welding II: Community College launched a one-year welding certificate
Steels/Laser Welding: Evaluation; Laser Welding II: Process program,” said Congressman Bill Johnson.
Monitoring and Simulation; and Solid State Welding. This certificate includes shielded metal arc welding, gas
Michael Poss, senior project engineer – laser joining, ad- metal arc welding, gas tungsten arc welding, plate and pipe
vanced technology and welding, General Motors Co., served welding, as well as set-up techniques. Safety and hands-on
as SMWC XVI chair. “I was pleased we met the interest level experience are priorities, too.
of attendees. They came away with a good education of the Welding instructor Josh Horner is ASME certified, a
topics,” Poss said. He also shared what keeps people coming graduate of the West Virginia University Parkersburg weld-

16 WELDING JOURNAL / DECEMBER 2014


ing program, and has numerous years of experience working
in area fabrication shops. He mentioned being excited about
offering extra lab hours and evening with daytime classes.
Local industries will be looking for individuals who are
able to fill welding positions. Additionally, other local indus-
tries that supply equipment and services to oil companies
are looking for welders.
There are many employment opportunities that a one-
year welding certification from the community college can
be applied to, including fabrications, power and chemical
plants, pipeline and drilling, plus riverboats.

Union Pacific Railroad Invests $29 Million


to Strengthen Infrastructures
Union Pacific Railroad, Omaha, Neb., will strengthen Ne-
braska’s transportation infrastructure by investing $11 mil-
lion in the rail line between Grand Island and Gibbon, Neb.
The railroad will replace 78,400 concrete railroad ties and in-
stall 14,400 tons of rock ballast.
In addition, Union Pacific Railroad will strengthen
Kansas’ transportation infrastructure by investing $18 mil-
lion in the rail line between Paola and Parsons, Kan. It will
replace 77,000 railroad ties, install 39,200 tons of rock bal-
last, and renew the surfaces at 118 road crossings. Crews
will also replace nearly 12 miles of rail in various locations
between Paola and Parsons.
Both projects, funded entirely by the company without
taxpayer dollars, are scheduled to be done by mid-December.

United States Naval Ship Fall River


Gets Delivered

The joint high­speed vessel United States Naval Ship Fall River, as
seen above, completes acceptance trials testing and evaluations
in the Gulf of Mexico. (U.S. Navy photo.)

The U.S. Navy recently accepted delivery of a joint high-


speed vessel, the future United States Naval Ship Fall River,
from the Austal USA shipbuilder.
“Today, the Navy received a tremendous asset,” said
Strategic and Theater Sealift Program Manager Capt. Henry
For info, go to www.aws.org/ad­index
DECEMBER 2014 / WELDING JOURNAL 17
Stevens. “The addition of Fall River to the fleet will enhance
our forward presence and ability to bolster global security
from the sea by quickly transporting significant resources to
a wide array of geographic regions throughout the world in
time of need.”
The Fall River has a core crew of 22 civilian mariners who
operate and navigate the ship as part of the U.S. Navy’s Mili-
tary Sealift Command. This delivery also follows completing
its builder’s and acceptance trials in July.
Joint high-speed vessels are noncombatant transport
ships built from a commercial design with limited modifica-
tions for military use.

Richmond Community College Graduates


Get ‘Back to Work’ as Ferro Fab Welders
Ferro Fab, Hamlet, N.C., a manufacturer of specialized
metal components, has added two new welders to its work- Pictured (from left) are Ferro Fab welder Anthony Allred, Rich­
force who recently received their welding certificates from mond Community College Director of Customized Training Lee
Richmond Community College, also located in Hamlet. Eller, Ferro Fab Plant Manager Malcolm McLester, and Ferro Fab
Anthony Allred and Ronald Legrande attended the col- welder Ronald Legrande with a giant spool built by welders at
lege through a grant program called North Carolina Back-to- the Hamlet­based industry.
Work. It helps long-term unemployed or underemployed in-
dividuals receive skills training to pursue new careers. The er, this program has helped find good candidates to hire.
grant covers tuition and supplies for individuals who qualify. “While we like to hire people who have work experience, this
“Getting this job has been excellent help to me and my is a good starting point for these guys. We get them in here
family,” said Allred. He added that welding is challenging, and get them exposed to the work and integrated into the
but he picked up on the new skill rather quickly. business. We like to promote within, so there are opportuni-
According to Malcolm McLester, Ferro Fab plant manag- ties to advance up the ladder.”

For info, go to www.aws.org/ad­index


18 WELDING JOURNAL / DECEMBER 2014
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until recently, jobs like these always involved costly and time-
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Publication Regarding Thoriated


Tungsten Electrodes
The International Institute of Welding, Commission VIII
Health and Safety, recently published a report in which it
makes recommendations regarding the use of thoriated
tungsten electrodes. The abstract can be seen and the full re-
port purchased for $39.95 at http://link.springer.com/arti-
cle/10.1007/s40194-014-0197-9.
In March, the AWS Safety and Health Committee
updated its Fact Sheet 27 on Thoriated Tungsten
Electrodes. The fact sheet can be downloaded free of
charge at www.aws.org/technical/facts/fact-27-201405.pdf.

Industry Notes
• Support the Enlisted Project, a San Diego-based mili-
tary focused 501(c)(3) nonprofit, was recently presented a
check for more than $74,000 from the Gas and Welding
Distributors Association at its 2014 annual convention as
part of the organization’s gives back program to support lo-
cal charities in the meeting’s host city. The other nonprofit
selection was Warrior Foundation - Freedom Station.

• Laboratory Testing, Inc., Hatfield, Pa., has added mois-


ture analysis to its list of materials testing services offered.

— continued on page 110

For info, go to www.aws.org/ad­index


DECEMBER 2014 / WELDING JOURNAL 19
Friends and Colleagues:

The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image
and impact of the welding industry. Election as a Counsel shall be based on an individual’s
career of outstanding accomplishment.

To be eligible for appointment, an individual shall have demonstrated his or her leadership in
the welding industry by one or more of the following:

• Leadership of or within an organization that has made a substantial contribution to the


welding industry. The individual’s organization shall have shown an ongoing
commitment to the industry, as evidenced by support of participation of its employees
in industry activities.

• Leadership of or within an organization that has made a substantial contribution to


training and vocational education in the welding industry. The individual’s
organization shall have shown an ongoing commitment to the industry, as evidenced
by support of participation of its employees in industry activities.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at
wreeve@aws.org at AWS headquarters in Miami, or simply follow the instructions on the
Counselor nomination form located at http://www.aws.org/awards/fellow_counselor.html.
Please remember, we all benefit in the honoring of those who have made major contributions to
our chosen profession and livelihood. The deadline for submission is July 1, 2015. The
Counselors Committee looks forward to receiving numerous Counselor nominations for 2016
consideration.

Sincerely,

Lee Kvidahl
Chair, Counselor Selection Committee
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 promoting and sustaining the professional stature of the field. Election as a
Fellow of the Society is based on outstanding accomplishment and technical impact of the
individual. Such accomplishments will have advance the science, technology and application of
welding, as evidenced by:

• Sustained service and performance in the advancement of welding science and


technology
• Publication of papers, articles and books which enhance knowledge of welding
• Innovative development of welding technology
• Society and 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 profession consistent with the
standards set by the existing Fellows. In particular, I would make a special request that you
look to the most senior members of your Section or District in considering members for
nomination. In many cases, the colleagues and peers of these individuals who are the most
familiar with their contributions, and who would normally nominate the candidate, are no long
with us. I want to be sure that we take the extra effort required to make sure that those truly
worthy are not overlooked because no obvious individual was available to start the nomination
process.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at
wreeve@aws.org at AWS headquarters in Miami, or simply follow the instructions on the
Fellow nomination form located at http://www.aws.org/awards/fellow_counselor.html. Please
remember, we all benefit in the honoring of those who have made major contributions to our
chosen profession and livelihood. The deadline for submission is July 1, 2015. The Fellows
Committee looks forward to receiving numerous Fellow nominations for 2016 consideration.

Sincerely,

Thomas M. Mustaleski
Chair, AWS Fellows Committee
BUSINESS BRIEFS

Alcoa Opens Aluminum­Lithium manufacturing of plastic injection tooling); Oregon State


Aerospace Plant in Indiana University (to develop two alternative mold fabricating ap-
proaches and evaluate for functionality, precision, and cost
reduction potential); and the University of Texas at Arling-
ton (to develop a manufacturing system that will au-
tonomously prepare small motor subsystems and assemble
the motor components).

ASTM International Reveals New Brand Identity


ASTM International, West Conshohocken, Pa., intro-
duced its new brand identity at the fall meetings of the orga-
nization’s board of directors in Seoul, South Korea. In addi-
tion to being a large standards-creating organization, it cur-
rently offers training, proficiency testing, and certification.
The new purpose statement, ‘Helping our world work
better,’ articulates succinctly why the organization exists as
well as its primary ambition. The logo that has served for
more than 100 years was also refined, resulting in a less an-
gular and more contemporary monogram. A video showing
ASTM standards improving lives around the world is posted
Alcoa’s aluminum­lithium plant in Lafayette, Ind., produces third­ on the organization’s YouTube channel.
generation aluminum­lithium alloys for the aerospace industry,
including for the Airbus A380 and A350, as pictured here. (©AIR­
BUS S.A.S. 2013 ­ photo by exm company/F. LANCELOT.)
Thermal Spray Technologies to Expand
Alcoa has recently launched an aluminum-lithium plant Thermal Spray Technologies, Inc., is expanding its facility
in Lafayette, Ind., where third-generation aluminum-lithium in Sun Prairie, Wis., representing an $11.5 million project
alloys are produced for the aerospace industry. expected to create about 200 new jobs.
The Lafayette cast house, next to its extrusion plant, can The company purchased a 92,000-sq-ft building near its
produce more than 20,000 metric tons (44 million lb) of alu- existing facility in the Sun Prairie Business Park, which will
minum-lithium annually — making it the largest facility of undergo a complete renovation. Construction is under way
its kind in the world, according to the company. with a completion date projected for early 2015.
Alcoa’s materials scientists invented a majority of the al- The expansion, which ultimately will triple the size of the
loys produced at the facility as well as the casting equipment company’s workforce, is in response to increased customer
and processing technology. The company offers various alu- demand. It will also enable installation of industrial coating
minum-lithium products, including extruded, forged, and and machining technology.
rolled parts. It produces single-piece wing skins, including The Wisconsin Economic Development Corp. is providing
for wide-body airplanes, fuselage skins, wing stringers, floor the company with up to $750,000 in Economic Develop-
beams, seat tracks, and other components. ment Tax Credits over the next three years.
The plant opening will also create 75 new positions.
“Alcoa is building upon our state’s strong manufacturing
tradition, creating even more good-paying jobs that will en-
gage a skilled Indiana workforce,” said Indiana Lt. Gov. Sue Recent Acquisitions
Ellspermann.
• Wall Colmonoy Corp., Madison Heights, Mich., a manufac-
turer of surfacing and brazing products, castings, and engi-
neered components, has announced the acquisition of
Walmart U.S. Manufacturing Innovation Franklin Bronze & Alloy Co., Inc., a provider in the invest-
Fund to Award $10 Million in Grants ment casting industry. The company will be renamed
Franklin Bronze Precision Components, LLC, and become a
The first grant recipients of the Walmart U.S. Manufac- wholly owned subsidiary of Wall Colmonoy.
turing Innovation Fund’s $10 million commitment, which
will extend over the next five years, have been announced. • Tech Air, Danbury, Conn., a distributor of industrial/
Seven research and development institutions were award- specialty gases and related welding supplies, has recently
ed a total of $4 million in grants to create new processes, acquired US Oxygen & Supply, Arlington, Tex., along with
ideas, and job creation that will foster an increase in Ameri- Specialty Air Technologies, Long Beach, Calif. “Tech Air now
ca’s manufacturing footprint. operates through 25 branch and fill plant locations and is
Included among the winners are Indiana University-Pur- serving customers in the Northeast, Southeast, Southwest,
due University at Indianapolis (to advance and accelerate and West,” said Myles Dempsey Jr., the company’s CEO. WJ
the industrial implementation of metal 3D printing for the

22 WELDING JOURNAL / DECEMBER 2014


For Info, go to www.aws.org/ad­index
LETTERS TO THE EDITOR

Welding Efforts Donated to AWS CWI and CWE In addition, what is the practical
Museum and Memorial Ship Ivy Tech Community College welding current range in terms of ei-
Evansville, Ind. ther “average current” or “rms cur-
Earn High Praise rent?” Stated another way, what is the
This letter is in response to Melissa Gomez’s
practical wire feed speed range?
article, “Volunteers Repair Historic Navy Droplet Oscillation Research By use of the droplet and wire di-
Warship,” published on pages 96–98 of the mensions reported, and a cycle dura-
Supplement Gets Discussed tion of 50 msec, I calculated a feed rate
Welding Journal’s September 2014 issue. It
details the welding skills volunteered by stu­ as follows:
This correspondence references the part I
dents from Ivy Tech Community College to experimental study, and part II modeling Let D0 = wire diameter = 0.8 mm
the LST­325, a decommissioned U.S. Navy and analysis, of the “Active Metal Transfer and D1 = droplet diameter = 1.0–1.3
tank landing ship. Control by Utilizing Enhanced Droplet Oscil­ mm (see pages 216-s and 329-s previ-
lation” research supplements by J. Xiao, G. ously cited).
J. Zhang, W. J. Zhang, and Y. M. Zhang in the When, for example, we choose D0 =
Thank you so much for a wonderful- Welding Journal’s August 2014 (pp. 282­s to 0.8 mm, D1 = 1.0 mm, duration = 50
ly written article! My Welding Journal 291­s) and September 2014 (pp. 321­s to msec.
has made its rounds here at the college 330­s) issues. A response is also provided. Then let D1 = 1.25D0 drop volume,
and gotten my program a great deal of V1 = π (1/6) (1.25)3D03 wire volume, V0
attention from inside and outside the The authors did a good job describ- = π (1/4)D02L where L = length of wire
college. I’ve even had calls from poten- ing their investigations. However, I consumed to make a droplet.
tial students asking if they will get to have a few questions and comments. When V0 = V1 by rearrangement,
work on the ship if they enroll. I love What was the duration of a com- L = (2/3) (1.25)3D0 = 1.04 mm (approx-
the quotes from the students and John plete typical droplet transfer cycle? imately 1.0 mm).
Engstrom (vice president, board of di- By my observation of their oscillo- For a 50 msec cycle, the feed rate is
rectors, USS LST Ship Memorial). You grams, figures, and charts, it seems as about 47 in./min when D1 = 1.3 mm
did a fantastic job! if the duration ranged from 50 to 60 and D0 = 0.8 mm, D1 = 1.625D0.
msec per cycle. (This range seems to Then L = (2/3) (1.625)3D0 = 2.29
John C. Durbin agree with an article in the Welding mm.
Program Chair, Industrial Technology Journal’s July 2013 issue, pp. 205-s to For a 50 msec cycle, the feed rate is
Assistant Professor, Welding Specialty 217-s, concerning the same subject.) about 108 in./min.
For a feed rate range of 47–108
in./min, an 0.8-mm steel wire uses an
average current of less than 50 A (see
Welding Handbook, Vol. 2, p. 179, 9th
edition). This is a very limited welding
INDUCTION HEATING SYSTEMS range if my sample calculations above
Sales, Rentals, Lease Programs are correct.
Also, what is the practical welding
Weld Preheating, current range the authors expect with
Post-Weld Heat Treatment,
Coating Removal, Shrink Fit,
this type of metal transfer?
Liquid- and Air-Cooled Systems
August F. Manz
AWS Fellow
Union, N.J.

I am happy that our papers drew your


attention. I regret that they did not pro-
vide certain details.
The analysis and calculation you per-
formed are correct, and it is true that our
average current is less than 50 A. Our
For info, go to www.aws.org/ad­index

goal was actually to reduce the current as


much as we can while still transferring
droplets in desired way. Hence, being less
than 50 A exemplified the effectiveness of
our method.

YuMing Zhang, PhD


Professor and Director of Welding
Research Laboratory
University of Kentucky
reddarc.com/ihs 1-866-733-3272 Lexington, Ky.

24 WELDING JOURNAL / DECEMBER 2014


For Info, go to www.aws.org/ad­index
BRAZING Q&A
BY TIM HIRTHE

Processes, available as a free download


Q: We are making a joint between a braided copper (Cu) cable and a Cu from the American Welding Society
post/rivet using a filler metal of 95% cadmium (Cd) and 5% silver (Ag). The website www.aws.org.
flux we are using leaves a residue and the design of the assembly makes it dif­ My first recommendation is to re-
ficult, if not impossible, to clean. The problem is that the residue is very corro­ place the Cd/silver (Ag) alloy with
sive. It is a riveted, electrical connection so it does not require significant something else. Assuming you are go-
strength, just good electrical properties. Since we are joining Cu, it has been ing to continue to use it until an alter-
suggested we use a solder and a noncorrosive rosin­based flux. These assem­ native is qualified, I’ll address the flux
blies operate at an elevated temperature and we need to perform our joining issue.
operation at 600°F (315°C) minimum so we have ruled out soldering. We have This filler metal has a melting range
investigated flux materials on the market that are used for joining Cu to alu­ of 640°–740°F (338°–393°C). I am not
minum (Al) that have noncorrosive residues. If they are good on Cu to Al, we sure which flux you are using, but it
wonder whether they can be used on Cu to Cu. It seems Cu to Cu should be most likely contains one of several
easier to join. They appear to be in an acceptable temperature range also. chlorides and may even contain hy-
What do you recommend? drochloric acid. These types of fluxes
are commonly used with higher-
temperature filler metals used above
A: First, I must address your use of through dust and fumes. These can be 400° to about 800°F (205° to 425°C).
cadmium (Cd). Historically, Cd was generated in the brazing and soldering This type of flux is needed to be active
commonly found in metal-joining processes. For as long as you work in this range. As you can tell from
workplaces, but as its toxicity became with this Cd-bearing filler metal, you these ingredients, there will be signifi-
better understood, its use has de- must make sure the work areas are cant corrosion if left on the parts.
clined. Cadmium is one of six sub- properly ventilated and that safe- Fluxes have specific temperature
stances specifically restricted in the handling procedures are in place to en- ranges in which they are active.
European Restriction of Hazardous sure employee safety. Guidance on this General-purpose brazing fluxes do
Substances directive (RoHS). The most is available from ANSI Z49.1:2012, not become active until about 1000°F
dangerous forms of exposure are Safety in Welding, Cutting, and Allied (537°C), which is considerably higher

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26 WELDING JOURNAL / DECEMBER 2014


than your operation. The only other group. They are higher in temperature, This column is written sequentially by TIM
fluxes that are active between the low- generally melting between 1100° and P. HIRTHE, ALEXANDER E. SHAPIRO, and DAN
temperature solder range and the 1300°F (593°–704°C), but they need KAY. Hirthe and Shapiro are members of and
Kay is an advisor to the C3 Committee on
general-purpose brazing fluxes are no flux for Cu-to-Cu brazing. Being Cu Brazing and Soldering. All three have con­
the aluminum (Al) fluxes. This is why based, and perhaps having a bit of Ag tributed to the 5th edition of AWS Brazing
your question is very reasonable. in them, depending on the alloy select- Handbook.
In general, Al fluxes do not work on ed, the electrical properties should be Hirthe (timhirthe@aol.com) currently
serves as a Brazing & Soldering Manufactur­
other alloy systems. As you illustrate acceptable. ers Committee (BSMC) vice chair and owns his
with your question, however, there are In summary, the temperature range own consulting business.
some materials that are capable of you are using has limited options for Shapiro (ashapiro@titanium­brazing.com)
is brazing products manager at Titanium
joining Al to other metals such as Cu. fluxing, but there are viable alterna- Brazing, Inc., Columbus, Ohio.
It has also been known that some Al tives to the Cd/Ag alloy currently be- Kay (dan.kay@kaybrazing.com), has more
brazing processes can bond to stain- ing used. For safety and health rea- than 40 years of experience in the industry,
and operates his own brazing training and
less steel as found in the cookware in- sons, as well as manufacturing flexibil- consulting business.
dustry. In the case of Al to Cu, the ity, an alternative should be sought. WJ Post your questions for use in this column
filler metals are zinc (Zn) based. These on the Brazing Forum section of the BSMC
website www.brazingandsoldering.com.
have similar melting temperatures to
the filler metal you are using now.
There are commercially available
fluxes for Al in the temperature range

3,000
you are looking for. Unfortunately, the
noncorrosive aspect is a bit deceiving.
If you are joining Al to Al, the flux
residues can be noncorrosive. After

CONTRACTORS
joining, there are Al compounds that
are left on the components. When you

100,000
join something other than Al base
metals, the Al in the residue will create
a galvanic cell. In your case, if you
swap out the chloride-bearing flux for

IRONWORKERS
one of these Al fluxes, you swap out
chloride corrosion for galvanic corro-
sion. They are not an option.
There really are no viable noncorro-
sive fluxes in the temperature range
that you are faced with using the
Cd/Ag alloy. It takes you back to trying
to replace the alloy. Other than Al al-
loys, the only other reasonable choice
is a Zn-based material. The most com-
mon are in the Zn-tin group. You need
high Zn content as the most common
ones with intermediate amounts of Zn
have melt ranges that are as low as
390°F (200°C). Others need to be ap-
proached with caution as many also
contain Cd, which would defeat the
purpose of changing alloys to elimi-
nate it.
There is a series of active solders

Ironw
nw
workers
kers
that you might want to investigate.
They are solders with alloying addi-
tions that make them wet a variety of
materials without flux. They require a
small abrasive action while the solder SAFETY, QUALITY,
Y, PRODUCTIVITY
UCTIVITY
is molten to activate the bonding orkers.org | www.impact-ne
www.ironwork -net.org
process, thus the term active solder. I
am not sure that there is a high-
temperature option for your applica-
tion but it might be worth trying.
Your best option may be to go to a
low-temperature Cu/phosphorus (P)
alloy. These are in the AWS BCuP
For info, go to www.aws.org/ad­index

DECEMBER 2014 / WELDING JOURNAL 27


ALUMINUM Q&A
BY TONY ANDERSON

minum designations are listed in the 5. In accordance with the require­


Q: Below are the questions and Aluminum Association’s International ments of AWS D1.2/D1.2M:2008,
answers for the quiz published in Alloy Designations and Chemical Com- Structural Welding Code — Alu­
the Welding Journal’s October position Limits for Wrought Alu- minum, what is the minimum tensile
2014 Aluminum Q&A column. The
minum and Wrought Aluminum Alloys strength required when conducting a
names of the ten winners are also
— also known as the Registration reduced section tension test on Alclad
posted.
Record Series Teal Sheets. This infor- 3003­H112 tube 1⁄2 in. thick?
mation is available as a free download A — 11 ksi
1. Which of the following American at www.aluminum.org/resources/indus- B —14 ksi
landmarks, built in 1884, has an alu­ try-standards. Click on the Teal Sheets. C — 15 ksi
minum pyramid cap on its top? D —13 ksi
A — Lincoln Memorial 3. Which of the following alu­ The answer is D. Table 3.2 of AWS
B — Washington Monument minum alloys has been cooled from D1.2/D1.2M:2008 clearly shows 3003-
C — Jefferson Memorial an elevated temperature shaping H112 (M21) tube of all thickness to
D — Benjamin Franklin Memorial process (not cold worked after cool­ have a minimum tensile strength re-
The answer is B. The capstone of ing) and naturally aged to a substan­ quirement of 13 ksi.
the Washington Monument is made of tially stable condition?
aluminum, which was at the time A — 6463-T1 6. Which of the listed aluminum
(1884) a precious metal (see Fig. 1). B — 6063-T2 filler metal classifications would be
C — 6351-T4 the most appropriate to weld 5052
D — 6063-T5 base metal that is going to be used in
E — 6061-T6 a service environment with a sus­
The answer is A. The Alloy and tained elevated temperature of
Temper Designation System for Alu- 250°F?
minum (ANSI H35.1 / H35.1(M) — A — ER5356
2013) clearly shows the T1 temper is a B — ER4043
material that was cooled from an ele- C — ER5556
vated temperature shaping process D — ER5183
and naturally aged to a substantially The answer is B. The sustained ele-
stable condition. This temper is not vated temperature for aluminum al-
cold worked to improve strength after loys is recognized as being between
cooling. The T2 temper is essentially 150º and 350ºF. If 5xxx series base
the same temper, but cold worked af- metal or filler metal with more than
ter cooling to improve strength. 3% magnesium (Mg) content is sub-
4. In accordance with the require­ jected to prolonged exposure to these
ments of AWS D1.2/D1.2M:2008, temperatures, precipitate can form
Structural Welding Code — Alu­ within it that is highly anodic to the
minum, what is the bending diameter Al-Mg matrix. This continuous grain
Fig. 1 — Setting the aluminum capstone
to be used for base Alloys 7005 and boundary network of precipitate pro-
on the top of the Washington Monu­
ment. The capping ceremony was con­ 2219 when conducting a guided bend duces susceptibility to stress corrosion
ducted in December 1884, and the test? cracking (SCC) and the potential for
formal dedication of the monument was A — 6t premature component failure.
in February 1885. Both were given front­ B — 8t The 5052 base metal contains less
page publicity in the nation’s newspa­ C — 10t + 1⁄8 in. than 3% Mg and is therefore suitable
pers, and the aluminum point or apex D — It is different for each alloy. for use at prolonged elevated tempera-
was honorably described. Hundreds of The answer is B. Figure 3.13 of ture. ER5356, ER5556, and ER5183,
thousands, perhaps millions, of people
who had never before even heard about
AWS D1.2/D1.2M:2008 clearly shows however, are all filler metals that con-
aluminum now knew what it was. the 7005 (M27) and 2219 (M24) to tain more than 3% Mg (around 5%
both have a bending diameter of 8t. Mg). While they could be used to weld
Additional information: Clause 5052 base metal, none is suitable for
2. In what year was the filler metal 3.8.1.7, Special Bending Conditions, prolonged elevated temperature serv-
Alloy 4043A registered with the Alu­ shows that the 7005 (M27) shall be ice. Filler metal ER4043 contains no
minum Association? bend tested within two weeks of weld- Mg and is therefore suitable for use at
A — There is no such aluminum filler ing (this is because of the natural ag- elevated temperature. Arguably, the
metal alloy. ing capability of this base metal) and ER5554 filler metal could be a good or
B — 1954 2219 (M24) shall be annealed before even better choice for this application
C — 1976 bending (this is because of the major as it has a maximum Mg content of
D — 1981 changes in ductility within the weld 3%, making it suitable for prolonged
The answer is C. The registration area of this base metal when in the as- elevated temperature service, and it
dates for all the international alu- welded condition). also has improved strength and tough-

28 WELDING JOURNAL / DECEMBER 2014


ness when compared to ER4043 (un-
fortunately, it was not one of the an-
swer options given for this question).

7. What would be the most appro­


priate aluminum filler metal to weld
6061­T6 base metal that 1) is going to
be clear coat anodized after welding,
2) is required to be a good color
match with the base metal after an­
odizing, and 3) will be going into a
service environment with a sustained
elevated temperature of 270°F?
A — ER5356
B — ER4043
C — ER6061
D — ER5554
The answer is D. With this ques-
tion, we have two important consider-
ations — color match after anodizing
and sustained elevated temperature
service. Although the ER5356 has
more than 3% Mg and would give a
very good color match after anodizing,
it is unsuitable for elevated tempera-
ture service. The ER4043 is suitable
for elevated temperature service; how-
ever, because it contains 5% silicon
(Si), the weld would turn very dark
gray after anodizing, producing a very
bad color match with the 6061 base
metal. There is no such filler metal as
ER6061. The 6061 alloy is very suscep-
tible to hot cracking, and such a filler
metal would invariably be extremely
problematic. That leaves us with the
ER5554; this filler metal has a maxi-
mum Mg content of 3%, making it
suitable for prolonged elevated tem-
perature service. It also has no Si addi-
tions, which makes it suitable for post-
weld anodizing applications using the
6061 base metal.

8. What is the minimum ultimate


tensile strength of 7075­T651 plate in
1
⁄2 in. thickness as specified in the Alu­
minum Association’s Aluminum Stan­
dards and Data 2013?
A — 78 ksi
B — 82 ksi
C — 94 ksi
D — 100 ksi
The answer is A. Table 7.2, Me-
chanical Property Limits — Heat-
Treatable Alloys of Aluminum Stan-
dards and Data (page 7-18), shows the
minimum ultimate tensile strength of
7075-T651 to be 78 ksi.

9. What is the typical ultimate ten­


sile strength of 7075­T651 plate at 75˚ For info, go to www.aws.org/ad­index

DECEMBER 2014 / WELDING JOURNAL 29


and –320˚F, respectively, as specified exposed to direct contact from the
in the Aluminum Association’s Alu­ welding arc and the possibility of cop-
minum Standards and Data 2013? per inclusions being created in the
A — 70 and 65 ksi root of the weld. Copper inclusions are
B — 73 and 60 ksi undesirable from a corrosion and
C — 83 and 102 ksi cracking potential standpoint.
D — 75 and 55 ksi
The answer is C. Table 2.2, Typical 11. In accordance with the require­
Tensile Properties at Various Tempera- ments of AWS D1.2/D1.2M:2008,
tures of Aluminum Standards and Structural Welding Code — Alu­
Data (page 2-9), shows the typical ulti- minum, the use of anti­spatter com­
mate tensile strength of 7075-T651 to pound is prohibited unless
be 83 ksi at 75ºF (room temperature) A — It is hydrogen free.
and 102 ksi at –320ºF (cryogenic tem- B — It is applied more than 1 in. away
perature). from the welded joint.
Additional information: Many ma- C — Approved by the Engineer.
terials when subjected to very low D — Specified by the welding inspec-
temperatures undergo changes in their tor.
physical structure, which severely lim- The answer is C. AWS
its their usefulness in cryogenic appli- D1.2/D1.2M:2008 clearly states in
cations. Many steels, for example, be- Clause 4.23, Anti-Spatter Compound,
come extremely brittle. The use of anti-spatter compound is
Aluminum alloys have an unusual prohibited unless approved by the En-
ability to maintain their ductility and gineer. It is generally accepted that
resistance to shock loading at extreme- anti-spatter compounds have the po-
ly low temperatures approaching ab- tential to introduce hydrocarbons into
solute zero. As temperature decreases the welding area and cause porosity
below room temperature, aluminum’s problems, and for this reason, their
tensile and yield strengths actually in- use is prohibited. However, if the Engi-
crease, and the ductility and tough- neer feels that the use of antispatter
ness of most alloys increase as well. compound is acceptable, he/she may
Even at the lowest test temperatures approve its use.
available, in liquid helium at –452ºF
(–273ºC), strength remains high and 12. Gas tungsten arc welding direct
ductility and toughness remain well current electrode negative with pure
above values at room temperature for helium shielding gas is seldom used to
most alloys. For this reason, alu- weld aluminum, but when it is used,
minum is used in many applications welds would typically have which of
that are very cold. For example, many the following characteristics?
liquid natural gas (LNG) tankers carry A — Good cleaning action
vast amounts of LNG in very large B — Deep and narrow penetration but
welded aluminum spheres. no cleaning action
C — Very low heat input
10. In accordance with the require­ D — Shallow and wide penetration for
ments of AWS D1.2/D1.2M:2008, very thin sheet welding.
Structural Welding Code — Alu­ The answer is B. The ideal gas tung-
minum, temporary backing made of sten arc welding (GTAW) welding arc
copper shall not be used if supplies the maximum amount of heat
A — It is more than 1 in. wide. into the base metal and minimum into
B — The weld joint has a 1⁄32-in. open- the electrode. It also provides arc
ing or larger. cleaning to remove the aluminum ox-
C —It is less than 99.97% pure copper. ide in advance and to the sides of the
D — The weld joint has a root opening weld pool. Each of the three modes
less than 1⁄32 in. that can be used (alternating current,
The answer is B. AWS AC; direct current electrode negative,
D1.2/D1.2M:2008 — Clause 4.7.4, DCEN; and direct current electrode
Temporary Backing, clearly states that positive, DCEP) lacks one or more of
copper can only be used as a tempo- these requirements to some degree.
rary backing material if the joint being The DCEN arc concentrates about
welded has a 1⁄32-in. (1-mm) opening or 80% of its heat into the weld pool.
less. This is in order to prevent the This results in relatively deep and nar-
copper backing material from being row weld penetration using a small
For info, go to www.aws.org/ad­index
30 WELDING JOURNAL / DECEMBER 2014
electrode, but it does not provide arc
cleaning. On the other hand, a DCEP
arc gives excellent cleaning action, but
only about 20% of its heat goes into
the weld pool, and the remaining 80%
that goes to the electrode is removed
by cooling water and wasted. Weld
penetration is shallow and wide, and
the electrode must be large. As a com-
promise between these two extremes,
a balanced wave AC arc gives adequate
cleaning action for most applications
and divides the arc heat about evenly
between electrode and weld pool.
Weld penetration and bead shape are
also, as expected, compromises be-
tween welds made with the two DC
modes.

Winners
I would like to thank all who partic-
ipated in this aluminum quiz. I was
very impressed with the response and
quality of the answers. I received
many comments as to how individuals
had enjoyed researching the correct
answers, and many indicated that re-
sponding to the quiz was both educa-
tional and fun. What a great combina-
tion!
The ten winners, selected at ran-
dom from all who sent me 100% cor-
rect answers, are listed below.

Kyle Williams, Alcoa Center, Pa.


Justin Williams, Indiana, Pa.
Sergio Antonio Muñoz Pinzón,
Bucaramanga, Colombia
Danfer De la Cruz, Lima, Perú
Greg Smith, La Mesa, Calif.
Tim Kinnaman, West Kingston, R.I.
Bruce B. Sabourin, B.C., Canada
Liam Rostock, Ross-shire, Scotland
Kate Collard, Ross-shire, Scotland
Jordan Williams, Indiana, Pa.

TONY ANDERSON is director of aluminum


technology, ITW Welding North America. He
is a Fellow of the British Welding Institute
(TWI), a Registered Chartered Engineer with
the British Engineering Council, and holds
numerous positions on AWS technical com­
mittees. He is chairman of the Aluminum As­
sociation Technical Advisory Committee for
Welding and author of the book Welding
Aluminum Questions and Answers currently
available from the AWS. Questions may be
sent to Mr. Anderson c/o Welding Journal,
8669 NW 36th St., #130, Miami, FL 33166­
6672; tony.anderson@millerwelds.com.

For info, go to www.aws.org/ad­index


DECEMBER 2014 / WELDING JOURNAL 31
PRODUCT & PRINT SPOTLIGHT
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The Mentor Visual iQ VideoProbe™,
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borescope can help plant operators from aerospace or automotive applica- for Joining and Repair
improve the probability of detection tions to metals processing or fabrica- Applications
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ergonomic buttons, and menu- Bruker Elemental
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nicians to connect directly with ex-
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share screens and images of the in-
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Comes in Four Models periods of stress relief. Both wires
provide higher deposition rates than
The 2nd generation of the compa- solid wires, assisting in increased
ny’s S1 TITAN hand-held XRF analyzer travel speeds, and offer a high-
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camera, as well as small spot collima- joining and repair applications with a
tor. The Detector ShieldTM has been variety of materials, including AISI
made standard for all models. Also, 4130 and 4140. Intended for use with
the patented SharpBeamTM collimator DCEP polarity, the wires can be used
technology remains a standard feature in single and multipass welding appli-
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800 use a thin-film window and The Ironworker App, developed by www.hobartbrothers.com
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34 WELDING JOURNAL / DECEMBER 2014


Electromechanical Testers EBook Available for ments, combined with excerpts from
ANSI standards. The eBook platform
Offer Safety Functions Mechanical and offers the ability to bookmark, page
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Industrial Press
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The AGS-X series of electromechan-


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mentally friendly. They are for nonde-
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Guidelines for Submitting a Welding Journal
Feature Article
Have you ever thought about writing a feature article for consideration in
the Welding Journal? If so, our staff stays on the lookout for original, noncom-
mercial, practical, and hands-on stories. Take a look at our editorial calendar —
available as part of the American Welding Society’s Media Kit at
www.aws.org/wj — to see what topics will be highlighted in future issues as well
eter, it presents a choice for welding as the editorial deadlines. Potential ideas to focus on could include a case study,
automatic or semiautomatic fillet recent company project, tips for handling a particular process, and so on.
welds on ship panels, barges, or any Here’s an easy breakdown of our guidelines:
plate that has been coated with rust • The text of the article should be about 1500 to 2000 words and provided in
preventive primer or noncoated plate a Word document.
that has rusted. • Line drawings, graphs, and photos should be sent as high-resolution jpg or
tiff files with a resolution of 300 or more dots per inch.
Select­Arc, Inc. • Plan on about one figure for every 500 words, and provide captions for
www.select­arc.com every image. Also, if a nice lead photo is available, please include it for review.
(800) 341­5215 • The authors’ names, along with the companies they work for and their po-
sitions, should be listed.
If you’d like to discuss a particular idea or e-mail a submission for evaluation,
Dust Collector Features please contact Editor Mary Ruth Johnsen at mjohnsen@aws.org or Associate Ed-
Cleaning System itor Kristin Campbell at kcampbell@aws.org.

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Automatic gas metal arc welding
in progress. (Photo courtesy of
The Linde Group.)

Improving
GMAW
Efficiency
through
Shielding
Gases
Practical recommendations are offered
for improved efficiency, quality, and BY DIGANTA SARMA
lower costs through use of argon-based
mixed shielding gases

M
any manufacturing compa- account end applications and manu- time; as well as being an environmen-
nies work as “lean” organiza- facturing variability as well as econom- tally friendlier process with signifi-
tions today. This means that ic considerations to ensure the welded cantly lower particulate fume forma-
small- and medium-sized companies structure is produced in the most opti- tion rates, carbon monoxide emis-
have to keep their focus on producing mal way and is free from risk of fail- sions, and so on.
while at the same time allocating re- ure. Components are typically fabricat-
sources or time to find increasingly ef- ed from a designed set of cut-to-shape Factors Related to
fective ways of working in order not to plate or sheet steel, castings, extru- Shielding Gas Choice
miss the opportunities that exist to sions, forgings, etc., and the variability
improve their efficiency, quality, and starts when individual components The welding arc, a highly efficient
cost savings. progress through the manufacturing but complex phenomenon, consists of
Semiautomatic or automatic gas value chain. varying amounts of ionized gases and
metal arc welding (GMAW) is one of This article deals with optimization metal vapor, which means the physical
the main production technologies for and improvement in efficiency while properties of the process gases have a
many manufacturing companies. How- using simple single-wire GMAW both direct and immediate impact on the
ever, advances in technology, weld de- in semiautomatic and robotic applica- arc (Ref. 2). In addition, the process
sign, and quality assurance are not tions, using argon-based, two-compo- gases also contact the hot metal, a
easily adopted. This results in ineffi- nent shielding gases. Benefits of using highly reactive area, in which the
cient or overwelding of both fillet and such gases include attainment of spray chemical and metallurgical effects of
butt-joint welds, especially T-joints in metal transfer mode, giving increased the gases also play an important role.
fillet welds, which is the most em- welding speeds and higher productivi- Ionization occurs directly in the case
ployed type of joint in welded struc- ty, lower fabrication costs, and signifi- of the monoatomic inert gases, Ar and
tures. Because of its geometry, this cantly reduced oxidation leading to He. Diatomic or polyatomic gases,
type of joint is often overwelded and smoother, high-quality, less oxidized such as H2 or CO2, have to be initially
twice or three times as much volume weld surfaces, less elemental losses disassociated in the arc, a process that
must be filled with metal as is needed through the arc, resulting in improved requires additional energy — Fig. 1.
for the desired size. That increases not mechanical properties; flatter fillet The less energy required for these
only direct costs and weight but also weld profiles with less weld metal processes, the easier it is to ignite the
the shrinkage force and distortion that waste compared to convex CO2 fillets; arc. If components that are compara-
add other costs (Ref. 1). A systems ap- significantly lower spatter rates lead- tively difficult to ionize, such as He or
proach is necessary, which takes into ing to reduced wastage and cleanup CO2, are present, the welding voltage
has to be increased accordingly. How-
ever, this additional electrical energy
is released again in the form of recom-
lonization energy, eV Dissociation Energy, eV
bination energy, which can both im-
prove heat input and increase welding
speed.
Depending on the gas, the proper-
ties of the plasma change, and as a
consequence, the weld joints them-
selves also differ distinctly. The radial
profiles of the emission coefficients of
an iron line, argon line, or atomic oxy-
gen line, respectively, have been deter-
mined for 100% CO2 and an Ar + CO2
mix (Ref. 2). These profiles indicate es-
tablishment of a metal vapor arc core
e
en

xid

m
og

ge
io

that has a broader profile under CO2


liu
e

n
yg
dr

go
-d

tro

He
Hy

on
Ox

Ar
Ni

but is more focused in the center for


rb
Ca

Ar. The measured iron line emission


was near to its norm maximum in the
Fig. 1 — Dissociation and ionization energy of the shielding gas components, eV (parame- case of CO2. From this fact, tempera-
ters for ignition properties, welding voltage, and arc energy). tures around 8000K and a metal vapor

DECEMBER 2014 / WELDING JOURNAL 41


Fig. 2 — Thermal conductivity of different shielding gas components. (Heat transfer from
the arc to the base depends on the thermal conductivity of different gases. Helium and hy- Fig. 3 — Rear and front assembly of two
drogen offer particularly high thermal conductivity values.) wheelers for the project.

molar fraction above 75% in the arc the two components He and H2 signifi- quire a lower level of these deposits,
center could be roughly estimated for cantly improve process efficiency. the active gas components in the Ar-
this case. Estimations of the electrical Good thermal conductivity has a posi- based multicomponent gas mixes are
conductivity and the arc field indicate tive effect on joint geometry, wetting, reduced after taking into considera-
the current path must include not only degassing of the molten pool, and tion requirements regarding fusion,
the metal vapor arc core but also outer welding speed. Figure 2 shows details penetration, and number of pores. In
hot regions dominated by welding gas of thermal conductivities of various the case of a higher quantity of CO2,
properties in the case of Ar. According- components in a shielding gas mix. All carbon pickup may occur, depending
ly, more energy in a more focused re- these are important, especially as it on the type of base material.
gion should be transmitted to the has been established that better weld Purity levels and mixing accuracies
workpiece in the case of CO2. The en- toe geometry results in better fatigue play a vital role. Shielding gases are
ergy transfer should be lower and dis- resistance (Ref. 4), which is the largest standardized in AWS A5.32/
tributed over a larger region in the reason for failure of welded joints in A5.32M:2011, Welding Consumables —
case of an Ar + CO2 gas mixture. ships. Investigations have shown that Gases and Gas Mixtures for Fusion Weld-
It has now been shown that the this geometry is adversely affected due ing and Allied Processes, and ISO 14175
oxygen index only weakly correlates to spatter-induced incomplete fusion (which has the same title as A5.32).
with fume formation rate (FFR) (Ref. in GMAW using CO2 gas. These standards specify, among other
3). A strong correlation of increasing Carbon dioxide and oxygen are things, the minimum quality require-
FFR with increasing CO2 concentra- both active, oxidizing gases. Especially ments of the components and mix-
tions in argon-based shielding gases at high temperatures, they react quick- tures. However, depending on the ma-
was obtained. This was attributed to ly with materials present to form ox- terial, process, method, and quality re-
the influence of CO2 on metal transfer ides. In appropriate quantities, metal quirements, higher qualities may be
and arc characteristics, decreasing arc oxides can improve arc stability, which necessary. Therefore, for the current
stability, where increased CO2 content is put to good use in several multicom- project, shielding gas of the type ISO
would promote larger droplets, longer ponent gas mixtures. However, if a 14175 M21-ArC-18 (Ar + CO2) has
detachment times, higher arc tempera- larger percentage of active gases is been used.
tures, and, consequently, increased present, for example, GMAW of car-
fume generation. It has also been bon steels, the resulting increase in ox- Background
found that shielding gas composition idation generates additional heat. The
had no obvious effect on fume compo- product of oxidation, otherwise The company under study manufac-
sition. However, enrichment of Mn in known as “slag” or “silicate,” is often tures front and rear assembly units for
the fume composition was observed. found on the surface of the joint. Oxy- two-wheeled vehicles — Fig. 3. These
Some of the arc’s heat is transferred gen as a shielding gas component has a components are made of carbon steels
to the workpiece via the plasma gas greater oxidizing effect than the same (ERW St. 30, 37 Grades CRC-D and
flow. Especially at high temperatures, quantity of CO2. If quality demands re- HRC-D). Material thickness usually

42 WELDING JOURNAL / DECEMBER 2014


age of total weld cost
6) Power cost expressed as a per-
centage of total weld cost
7) Labor cost expressed as a per-
centage of total weld cost.
Manual inputs used were weld
length and gas flow rate (measured us-
ing installed gas flow meters at the
company, which were installed in low-
pressure gas distribution lines at each
welding point). All welders were con-
tracted welders who were prequalified.
The shielding gas used was an
argon/CO2 mixture (80:20). Both the
front and rear frame assemblies were
welded using 0.8- and 1.2-mm-diame-
ter type AWS A5.18 ER 70S-6 solid
wire. The welding power source used
Fig. 4 — Components of weld costs. was an inverter-based, 400-A machine.
Flat and horizontal welding positions
were used.
varies from 0.6 mm (clip wire throttle) When the total weld cost (Fig. 4)
Weld Trial Methodology was determined, the welding wire was
to 2.6 mm (pipe L section) and feature
lap and butt joints welded using the found to be the largest component.
Weld process parameters for rear For this computation, wire price was
GMAW process. Filler material con- and front frame assembly were cap-
sists of 0.8- and 1.2-mm-diameter considered at $0.94/kg for the 1.2-
tured using automatic data loggers. mm-diameter wire and $0.98/kg for
AWS A5.18 ER70S-6 solid wire in The data loggers measure current,
spools. The welding specification the 0.8-mm-diameter wire; power cost
voltage, wire feed rate, and arc time. was set at $0.13/kWH; and labor cost
states the welds should have a mini- These figures were then fed into a
mum penetration of 20% of total at $0.57/h. For these calculations, only
weld cost tool developed by Linde to the primary process (welding) time
thickness, weld parameters are arrive at weld cost components and
150–180 A, 20–30 V, and 12–15 L/min was considered. Other items such as
other key process indicators. Weld tri- setup time, auxiliary process time,
gas flow rate. The company estimates als were conducted using both robots
it consumes 92 g of welding wire for buffer time, etc., were not included.
and manual welding. Seventy-one weld This result is different from what is
every meter of welding and 650 m3 of trials were conducted (Table 1). The
shielding gas for every ton of compo- observed in developed countries,
observations from these trials were where labor makes up as much as 78%
nent fabricated, numbers it would like used to determine the following
to bring down to 80 g and 500 m3, re- of the cost, followed by 20% for filler
process parameters: metal, 1% for shielding gas, and an-
spectively. The objective of the exer- 1) Wire feed rate (m/min)
cise was to identify and implement other 1% for other costs (Ref. 5).
2) Wire consumed per meter of
ways to reduce process costs and im- weld (g/m)
prove efficiency while achieving these 3) Gas consumed per meter of weld Results
goals. (m3/m)
While 32 welders were engaged in 4) Gas consumed/wire deposited Gas Flow Rate
rear frame assembly, welding 4895.6 (m3/ton)
m/day and producing 2350 frames/ 5) Wire cost expressed as a percent- It was observed that the flow rate
shift, 25 welders were engaged in the
front frame assembly welding 4103
m/day and producing 2400
frames/shift. Table 1 — Summary of Results from 71 Weld Trials

Project Details Component Type Rear and Front Remarks


Assembly Frames
The project objectives were as
follows: Wire consumed per 89.52
meter of weld, g/m
1) Determine economics of the
welding operation.
Gas consumed per 0.03
2) Recommend steps to ensure
meter of weld, m3/m
long-term weld cost savings as defined
previously.
Gas consumed/wire 355.2 Significant
3) Recommend ways to improve
deposited, m3/ton Reduction
weld process efficiency.

DECEMBER 2014 / WELDING JOURNAL 43


utilized was almost twice the recom-
mended rate. Lowering this rate re-
sulted in reduction in actual flow at
nozzle end, which affected weld quali-
ty. The weld pool must be fully covered
with shielding gas until the weld has
solidified. Key factors on which gas
flow rate depends include nozzle size,
joint type, contact tip protrusion,
torch angle, travel speed, drafts, tip-
nozzle concentricity, spatter buildup
on the nozzles, gas diffuser design and
condition, nozzle neck seal, shielding
gas type, and material being welded.
Assuming the effect of all factors con-
stant, the recommended shielding gas
flow rate follows:
1) Mid-range 0.8/1.00 mm wire at
90–220 A: 8–20 L/min
2) High-current 1.0/1.2 mm wire at Fig. 5 — Example of weld parameter variation.
220–400 A: 15–30 L/min.
For robotic welding (solid and cored
wires) 10–20% is added to the above
gas flow rates. Installing a gas leak de- ingly, resulting in nearly 34% reduc- Recommendations
tection system and installing a suit- tion in deposited wire weight/meter
(Table 2). It was observed during the trials
able device for delivering accurate flow
point control ensures an optimized gas that gas flow at the weld gun nozzle
flow rate and results in further cost Process Control end was insufficient although flow
savings. was set at 30 L/min. It is important to
Variation in deposited weld lengths optimize gas flow rate by any or all of
vs. the stipulated design as well as ap- the following to ensure that weld costs
Weld Parameters do not increase:
plication of different weld parameters
(current and voltage) affect the con- • Supply system leak detection
Welding parameters like voltage,
sumption of wire as well as in some • Welding set leak detection
wire feed speed/current, electrode ex-
cases the depositing of either excess or • Accurate outlet point flow control
tension, etc., play a vital role in deter-
inadequate amount of weld metal. A and elimination of surge flow.
mining optimum weld size and desired
study of weld parameters used at the Optimization of wire feed rates for
production rate. Welding voltage/cur-
same weld stations but at different both manual and robotic welding is
rent, wire feed rate, and contact tube-
points in time also showed differences recommended to avoid overwelding
to-work distance are variables for en-
that need to be eliminated — Fig. 5. In and improve efficiency: Weld parame-
suring optimum deposition rate and
Fig. 5, we observed variations in both ters are to be set up as per recommen-
travel speed for a productive fillet
current and voltage as well as the dation for a fixed deposition rate and
weld. The most important setting is
amount of wire consumed for a stan- welders should strictly maintain weld
wire feed rate, which governs the re-
dard length of welding, carried out by setting; the range of broad weld set-
producible weight of the deposited
different welders at different points in tings should be reduced to ±10% for
weld metal and is also important in
time. A standard operating procedure, better process control. Since an argon-
guarding against an excessive deposi-
if introduced, would ensure that such based mixed gas is being used, such
tion rate. The volt/ampere values cor-
variations are minimized, thereby en- optimization and control of weld pa-
related with wire feed rate are merely
suring optimum wire consumption, rameters can be easily communicated
guidelines. They vary with contact
which has been shown to be the high- to all welders and supervisory
tube-to-work distance, particularly for
est contributing factor to the overall personnel.
manual welding since changes in dis-
cost of welding. Control of wire waste and wire con-
tance are unavoidable when manipu-
lating the welding gun. Deviations of
around 10% are possible at constant
wire feed speeds.
To illustrate the impact of correct Table 2 — Experimental Work on Weld Parameter Selection
parameter setting on wire deposition
and consumption, we undertook weld- Wire Diameter, mm 0.8 mm 1.2 mm Remarks
ing of the front frame assembly at Weld Length, mm 140 140
Current, A 209 249
one identified station, using 1.2-mm-
Voltage, V 30.2 25.7
diameter wire, replacing the 0.8-mm-
Deposited Wire 155 102 –34%
diameter wire hitherto used and also
Weight, g/m
optimized the weld parameters accord-

44 WELDING JOURNAL / DECEMBER 2014


sumption optimization are other key possible by addressing each factor in a tical emission spectroscopy. Journal of
factors in reining in unwarranted well laid out and scientific manner Physics D: Applied Physics.
expenses. while working with the welders and 3. Carpentar, K. R., Mohagham, B.
Communication and engagement supervisors who are motivated by the J., and Norrish, J. 2009. Analysis of
with welders is necessary to ensure all improvement that is brought on by fume formation rate and fume particle
of these. A holistic and humane ap- these actions. WJ composition for gas metal arc welding
proach is recommended. (GMAW) of plain carbon steel using
Acknowledgments different shielding gas compositions.
ISIJ International Vol. 49, No. 3.
Conclusion The author wishes to thank col- 4. Report of the 17th International
leagues at India and the project team Ship and Offshore Structures Con-
Several ways exist to improve effi- at the site for their support during this gress. August 16–21, 2009, Seoul, Ko-
ciency and quality of gas-shielded study through practical suggestions rea. Vol. 2, Committee 3, Materials
welding such as automation, advanced regarding weld sample selection, and Fabrication.
power sources, as well as the latest measurement, and data analysis. 5. Proceedings of the ASME Interna-
weld consumables and shielding tional Design Engineering Technical Con-
(mixed) gases. While doing semiauto- References ferences and Computers and Information
matic or robotic welding using the in Engineering Conference. 2007.
GMAW process using a two-compo- 1. Hudec, Z. 2010. Optimization of
nent shielding gas, it is important to source wire gas system for efficient ro-
understand and establish the weld bot welding. Int. J. Multidisci. Des. Op-
costs involved and the factors that de- tim 4(7): 107–116.
termine them. This can be established 2. Wilhelm, G., Gott, G., Schopp, DIGANTA SARMA (diganta.sarma@linde.com)
is head of Applications & Market Development,
through simple methods and analysis H., and Uhdandt, D. 2010. Study of South & East Asia, Linde Gas Asia Pte Ltd.,
of the results opens up avenues for im- the welding gas influence on a con- Singapore.
provement. Step improvements are trolled short-arc GMAW process by op-

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DECEMBER 2014 / WELDING JOURNAL 45


A Technology to Increase
SAW Productivity
A global offshore industry manufacturer
realizes 60% increase in submerged arc BY HANNES RAUDSEPP

welding deposition rates

N
orwegian winch specialist I.P. clude shipyards, ship owners, and oil The welding procedure specifica-
Huse (www.iphuse.no) reaches companies — Fig. 3. The Harøya facto- tions (WPS) employed by the company
deposition rates of 55 lb/h for ry has approximately 130 employees. in production produce averages be-
its submerged arc welding (SAW) tween 44 and 55 lb/h, using a single
operation using a single power source power source, while maintaining heat
and a welding head that incorporates Welding with New Technology input below 76 kJ/in. and welding
patent pending “cold” electrode speeds at 33 in./min. Using a single
technology. I.P. Huse currently has four welding cold electrode welding head, it has
Historically, twin arc welding has stations employing the integrated cold achieved up to 67 lb/h and above in fill
been the most productive SAW process technology in its SAW process. One of passes, and the welds satisfy ISO
in terms of deposition rates. Twin arc the stations has been upgraded with a 15614 and impact toughness require-
welding is accomplished using two new 1000/A AC/DC inverter power ments for offshore applications.
wires in the same contact device, con- source to further increase productivi- Prior to implementing this technol-
nected to the same power source and ty. The company also employs cored ogy, the focus on consistent improve-
same polarity. wires to maximize deposition rates ment ensured that it was already
The cold electrode technology inte- and weld quality with this process. achieving the optimal productivity
grates a third electrically insulated
“cold” wire between and parallel with
the two hot wires in the same contact
device (Fig. 1). The cold wire feed
speed is controlled independently
from the hot wires with integrated
software resident in the control unit.
The cold wire melts from the excessive
energy generated by the arcs from the
two hot wires. This technology can in-
crease deposition rates up to 100%
and in some applications provides
even higher deposition rates.

Anchoring the Norwegian


Offshore Industry
Located on the island of Harøya on
the Norwegian west coast, I.P. Huse
has a business history dating back to
the beginning of the last century. To-
day, the company is a world leader in
the design and manufacture of winch-
es for anchor-handling vessels — Fig.
2. The company also manufactures
winches for the ocean-going tugs that
tow oil platforms. These massive
winches can exert a pulling force in ex- Fig. 1 — Welding head with two parallel “hot” wires and an electrically isolated
cess of 600 tons. Typical customers in- middle “cold” wire.

46 WELDING JOURNAL / DECEMBER 2014


Fig. 2 — A row of 600-ton winches for anchor handling in Fig. 3 — Mooring winches for drilling rigs.
vessels.

available using a twin arc welding


process. The results the company has
achieved using the integrated cold
electrode process is impressive when Integrated Cold Electrode:
compared to other common SAW
setups. For a typical 2-in. (50-mm)
single-sided V-groove with a 45-deg
The Process
included angle, the company achieved
productivity gains of up to 200%, com- Unlike other cold wire SAW methods, using an integrated cold electrode en-
pared to a single-wire SAW operation. sures that the cold wire is always melted in the twin arcs. The melting position
Even compared to a typical tandem of the cold wire will always adapt to the arc if the welding conditions change,
wire operation, the cold electrode unlike other cold wire setups. The cold wire feed speed is software controlled
welding technology offered a 100% along with the twin constant amperage (CA) regulation to further stabilize the
productivity advantage in fill passes. process. As a result, the process is unaffected by variations in electrode exten-
sion, and by variations in arc length.
Simple Set Up The cold wire feed speed is set as a ratio of hot wire feed (cwfr % = cold wire
feed ratio). This is automatically controlled by the integrated software in the
The setup of the process controller control. Only one additional parameter must be set, the cwfr.
for the system requires only the set- The cwfr range is between 10 and 100%, typically using cwfr 50–100%. The
ting of a single additional parameter cold wire is automatically controlled by a patent-pending regulation method
prior to welding, the cold wire feed in full CA mode, which improves process stability and adapts to changes in
ratio. welding conditions.
It is possible for the welder to ad- Heat input will always limit welding productivity as the base metal can only
just the amount of “cold wire” used in handle a certain amount of heat. The integrated cold electrode process uses
the weld, without having to change the excess heat to melt the “cold” wire. This results in up to 50% higher deposition
active parameters and heat input. The rate in fill passes compared to twin-wire process with the same heat input.
welder has control over the reinforce- The stabilizing effect of this process allows welding speed to be increased
ment height, ensuring a flat cap with while either maintaining or reducing heat input.
good wetting. Preventing overfilling In conventional applications and joint types, welding speed can be in-
also saves on consumables. creased to above 40 in./min while maintaining heat input and process stabili-
The integrated cold electrode tech- ty. With this process, welding speeds up to 70 in./min can be achieved de-
nology was developed by ESAB under pending on the application.
the tradename ICE™. I.P. Huse’s suc- The integrated cold electrode process reduces the total energy in the weld-
cess with it has led to it initiating ment. Lower heat input provides less distortion and increases the mechanical
plans to upgrade additional welding properties in some base metals and applications. Lowering the total energy in
stations with this process. WJ heating the object also reduces the cooling time, so there is no excess time to
wait for the interpass temperature to drop.
The speed and productivity of this technology results in reduced flux con-
HANNES RAUDSEPP M.Sc., IWE, is Welding
Application Manager SAW/FSW, ESAB
sumption, on average of 20% and in some cases up to 45%, depending on the
Global Automation. application.
A Must in Today’s Workplace:
Weld-Quality Monitoring
Today’s technology delivers better means BY MATTHEW ALBRIGHT
to monitor and verify weld integrity

Fig. 1 — Point-of-use monitoring tools


can guide an operator through required
welds on a part in a step-by-step manner.

48 WELDING JOURNAL / DECEMBER 2014


I
t has been said that “change is the The world has changed, and those for business or personal use, can be
only constant in life” (Ref. 1). Not who know the welding process best are connected and accessed globally. Man-
only is this statement true, but earning their retirement (Ref. 2). “The ufacturers of welding equipment are
change is comprehensive, extending Great Recession” has changed hiring leveraging these trends and providing
its reach into every facet of our world. tactics, and caused many companies to tools to their customers that are more
As the realm of manufacturing under- reevaluate the qualifications required comprehensive in nature and easier to
goes consistent change, manufacturers for general manufacturing positions use than in the past. By taking advan-
are faced with new challenges and (Ref. 3). Global competition has be- tage of the technology now available,
must adapt to changing times. Weld- come more intense, putting additional manufacturers can begin to shorten
ing operations is one specific area pressure on American companies to the distance that has been created by
where manufacturers are being remain price competitive (Ref. 4). In taking a craft approach to welding op-
pressed to take a hard look. addition, America’s perception of skill- erations.
based careers has been altered over the For simplicity of discussion, weld-
course of time, and many agencies quality monitoring tools can be divid-
Welding Shifts from both private and public are working to ed into two general categories: point-
Craft to Process change this trend (Refs. 5, 6). The of-use monitoring tools and postweld
combination of these changes has verification tools.
Welding is often one of the most made it extremely difficult for many A point-of-use monitoring tool such
misunderstood manufacturing disci- manufacturers who have viewed weld- as Lincoln’s Weld Sequencer™ software
plines. It can be perceived as a dark art ing as a craft. The good news is that (Fig. 1) is used to guide the operator
wielded by the few brave enough to while the manufacturing world has step by step through the assembly
learn the skills, and mastered by even been changing, so too have the tools process, while providing immediate
fewer. Certainly an exaggeration, but that enable manufacturers to control feedback on how well the operator is
the fog that sometimes surrounds this welding not as a craft but as a process. following the predetermined path. For
process leads to distancing of the man- example, these tools can halt the weld-
agement team from welding opera- ing operator during the assembly
tions. This distance can lead to view- Technology Aids process and, if quality issues surface,
ing the application of welding in man- Process Monitoring ensure that the products do not leave
ufacturing as a craft, putting the oper- the workstation without approval
ator in the position of being the sole Technology is amazing, and one from an inspector or foreman. These
source of knowledge, and, unnecessar- need not look far to see the value that types of tools also have several other
ily, the highest contributing factor to the ever-changing face of technology benefits, including
quality. Fast forward to the 21st cen- adds to our daily existence. Informa- • Simply presenting instructions on
tury and this approach has led to real tion is being transferred at a stagger- how to assemble complex parts,
problems. ing pace, and most devices, whether which can simplify training efforts

Fig. 2 —Postweld verification


tools can be used to collect
data on welding operations
and support operator and
part traceability.

DECEMBER 2014 / WELDING JOURNAL 49


and improve product consistency;
• Ensuring that correct welding proce-
dures are employed in the right loca-
tions, which can enhance weld quality;
• Verifying the correct weld quantities,
correct weld depositions, and amper-
age/voltage settings, which can help
the operator alter welding behavior;
• Ensuring that operators are working
only on parts they are qualified to
weld, providing the ability to prevent
potential quality issues before they
occur.
Postweld verification tools are used
to collect not only information about
welded assemblies, but also informa-
tion about the welding operation in
general — Fig. 2. These tools do not
stop the welding operator, but rather
send notifications to the correct per-
sonnel regarding welding anomalies.
In addition to notifying management, Fig. 3 — CheckPoint™, a Lincoln Electric production monitoring software package, offers
postweld verification tools provide dashboard views of arc time, consumable usage, weld parameters for each weld, and other
these additional benefits: data.

Fig. 4 — Manufacturing mistakes, identified in recall notices or other actions, can affect the company’s reputation and have a significant fi-
nancial impact on any company.

50 WELDING JOURNAL / DECEMBER 2014


• Providing welding-operation produc- from www.forbes.com/sites/emsi/ Manufacturing WorkForce Development
tivity metrics; 2013/03/07/americas-skilled-trades- Playbook. Chicago: Summit Media
• Helping manufacturers identify qual- dilemma-shortages-loom-as-most-in-de- Group.
ity trends; mand-group-of-workers-ages/ 6. DeloitteTouche Tohmatsu Ltd.;
• Providing accountability metrics for 3. Cappelli, P. 2012. Why Good Peo- The Manufacturing Institute. 2011.
operators; ple Can’t Get Jobs. The Skills Gap and Unwaivering Commitment: The Public’s
• Supporting company traceability ef- What Companies Can Do About It. View of the Manufacturing Industry
forts; Philadelphia: Wharton Digital Press. Today. Deloitte.
• Identifying accurate welding- 4. DeloitteTouche Tohmatsu Ltd. &
consumable usage metrics — Fig. 3. U.S. Council on Competitiveness.
By applying one or both of these 2013. Global Manufacturing Competi- MATTHEW ALBRIGHT is product manager for
welding equipment for The Lincoln Electric Co.,
tools in tandem, manufacturers can tiveness Index. Deloitte. Cleveland, Ohio, www.lincolnelectric.com.
begin to shed light on the mystery of 5. Summit Media Group. 2014.
their welding operations, improve
weld quality and productivity, and es-
tablish proper expectations for their
welding operators.

Welding Operations
Become More
Accountable
In today’s media-saturated environ-
ment, mistakes can become global
knowledge in a matter of minutes.
Manufacturing mistakes, identified in
recall notices or other actions, often
become common knowledge, affecting
a company’s reputation — Fig. 4.
These mistakes can also have a signifi-
cant financial impact on the company.
With the increasing presence of social
media and the growing ability to hold a
company publicly accountable for ac-
tions that may be perceived as negli-
gent, it is becoming more crucial that
companies take the proper steps to
move with changing times to prevent
errors in the manufacturing environ-
ment. Unfortunately, the days are gone
where welding operators had decades
of experience and could bear the bur-
den of being the most critical compo-
nent of influencing weld quality.
The world has changed over the
past couple of decades, and technology
is certainly changing from year to year.
If your company hasn’t taken a look at
the tools available for weld-quality
monitoring, today may be the right
time to begin the journey to update
your welding practices. WJ

References

1. Heraclitus. (n.d.).
goodreads.com/quotes. Retrieved
from goodreads.com:
www.goodreads.com/quotes/537168-
change-is-the-only-constant-in-life
2. Wright, J. 2013 (March 7).
Forbes.com. Retrieved July 10, 2013,
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DECEMBER 2014 / WELDING JOURNAL 51


COMING EVENTS

plications for superabrasives in the automotive and other in-


AWS-SPONSORED EVENTS dustries. Sponsored by Industrial Diamond Assn. of Ameri-
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6th Int’l Brazing & Soldering Conference. April 19–22. Long
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and potential applications, and new developments in these
INTERNATIONAL EVENTS
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manufacturing technologies. (800/305) 443-9353, ext. 264; International Symposium on Engineering Technology, Edu­
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8th Offshore Energy Expo and Conference. Oct. 13, 14. Am-
sterdam RAI, The Netherlands. www.offshore-energy.biz.

EDUCATIONAL OPPORTUNITIES
Laser Additive Manufacturing Workshop. March 4, 5. Col-
lege of Optics and Photonics at the University of Central
Florida, Orlando, Fla. www.lia.org/lam.

E­Courses in Destructive and Nondestructive Testing of


Welds. Online video courses taken at one’s own pace offer
certificates of completion and continuing education units.
Hobart Institute of Welding Technology. hiwt@welding.org;
www.welding.org.

Hypertherm Cutting Institute Online. Includes video tutori-


als, interactive e-learning courses, discussion forums, webi-
nars, and blogs. Visit www.hypertherm.com, www.hyper-
thermcuttinginstitute.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; www.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-
For info, go to www.aws.org/ad­index

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We have two facilities in Texas to provide a total welding


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For info, go to www.aws.org/ad­index For info, go to www.aws.org/ad­index

DECEMBER 2014 / WELDING JOURNAL 53


tions. Laser Institute of America; (800) 345-2737; International Training Institute. (703) 739-7200;
www.lia.org. www.sheetmetal-iti.org.

Laser Safety Training Courses. Courses based on ANSI Servo­Robot Training Seminars. Two-day laser-vision semi-
Z136.1, Safe Use of Lasers, Orlando, Fla., or customer’s site. nars held throughout the year at Servo-Robot, Inc., near
Laser Institute of America; (800) 345-2737; www.lia.org. Montreal, Canada. Seminars include tutorials and hands-on
practical training. For seminar schedule and costs, e-mail
Laser U — Online Education Portal. Offers practical infor- request to info@servorobot.com.
mation to use on the job. Topics range from 3D printing to
drilling, welding, wireless and optical product requirements, Shielded Metal Arc Welding of 2­in. Pipe in the 6G Position
and many others. Visit website for complete information — Uphill. Troy, Ohio. Hobart Institute of Welding Technolo-
and to sign up for modules. Laser Institute of America; gy; (800) 332-9448; www.welding.org.
www.lia.org/laseru.
Soldering Training, Live­Interactive Online Courses. Three
Laser Vision Seminars. Two-day classes, offered monthly courses offered: basic hand soldering, through-hole technol-
and on request, include tutorials and practical training. Pre- ogy, and surface-mount technology. Visit site for course out-
sented at Servo-Robot, Inc., St. Bruno, QC, Canada. For lines, schedules, prices, and to register. Soldering Training &
schedule, cost, and availability, send your request to Certification (STC), www.solderingtraining.com/ online-solder-
info@servorobot.com. ing-training.php.

Machine Safeguarding Seminars. Rockford Systems, Inc.; SSPC Training and Certification Courses. Courses in protec-
(800) 922-7533; www.rockfordsystems.com. tive coatings, abrasive blasting, paint inspector, bridge coat-
ings inspector, surface preparation, NAVSEA inspector, and
Machining and Grinding Courses. TechSolve, www.TechSolve.org. many others. The Society for Protective Coatings;
www.sspc.org.
NACE International Training and Certification Courses. Na-
tional Assoc. of Corrosion Engineers; (281) 228-6223; Thermadyne® Distributor Training. Year-around training at
www.nace.org. Denton, Tex.; West Lebanon, N.H.; Bowling Green, Ky.; and
Chino, Calif. trainingteam@victortechnologies.com.
NDE and CWI/CWE Courses and Exams. Allentown, Pa., and
customers’ locations. Welder Training and Testing Institute; Tool and Die Welding Courses. Troy, Ohio. Hobart Institute
(800) 223-9884; www.wtti.edu. of Welding Technology; (800) 332-9448; www.welding.org.

NDT Courses and Exams. Brea, Calif., and customers’ loca- Unitek Miyachi Corp. Training Services. Personalized train-
tions. Level I and II and refresher courses in PA, UT, MP, ra- ing services on resistance and laser beam welding and laser
diation safety, radiography, visual, etc. Test NDT, LLC; (714) marking; (626) 303-5676; www.unitekmiyachi.com.
255-1500; www.testndt.com.
Vibration Training Short Courses. Presented at locations na-
Online Education Courses. Topics include Introduction to tionwide, customer’s site, and by correspondence. Vibration
Die Casting ($99), Metal Melting and Handling ($99), Prod- Institute; www.vibinst.org.
uct Design ($59), Energy Training ($19), Dross Training
($19), Managing Dust Hazards ($19), Safety (free). North Welding Courses. A wide range of specialized courses pre-
American Die Casting Assn.; (847) 808-3161; www.diecast- sented throughout the year. The Lincoln Electric Co.;
ing.org/education/online. (216) 486-1751; www.lincolnelectric.com.

Plastics Welding School. A two-day course for certification Welding Introduction for Robot Operators and Program­
to European plastics welding standards. Malcom Hot Air mers. This one-week course is presented in Troy, Ohio, or at
Systems; www.plasticweldingtools.com. customers’ locations. Hobart Institute of Welding Technolo-
gy; (800) 332-9448, ext. 5603; www.welding.org.
Protective Coatings Training and Certification Courses. At
various locations and online. The Society for Protective Welding Skills Training Courses. Courses include weldability
Coatings; (877) 281-7772; www.sspc.org. of ferrous and nonferrous metals, arc welding inspection,
quality control, and preparation for recertification of Certi-
Robotics Operator Training. Presented by ABB University at fied Welding Inspectors. Hobart Institute of Welding Tech-
13 locations nationwide. For course titles and locations: nology; (800) 332-9448; www.welding.org. WJ
(800) 435-7365, opt. 2, opt. 4; www.abb.us/abbuniversity.

Safety Training Online. Unlimited training on myriad indus- An Important Event on Its Way?
trial safety course titles. Visit website for complete informa-
tion and previews of several courses; www.safety99.com. Send information on upcoming events to the Welding Journal
Dept., 8669 NW 36th St., #130, Miami, FL 33166. Items can
Service Manager Course. Designed for sheet metal workers also be sent via FAX to (305) 443-7404 or by e-mail to
and HVAC service shop owners. Various locations and dates. woodward@aws.org.

54 WELDING JOURNAL / DECEMBER 2014


For Info, go to www.aws.org/ad­index
CERTIFICATION SCHEDULE Certification Seminars, Code Clinics, and Examinations

Note: The 2015 schedule for all certifications is posted online at Denver, CO July 19–24 July 25
www.aws.org/w/a/registrations/prices_schedules.html. Kansas City, MO July 19–24 July 25
Scottsdale, AZ July 19–24 July 25
Waco, TX July 19–24 July 25
Certified Welding Inspector (CWI) Miami, FL July 26–31 Aug. 1
Milwaukee, WI July 26–31 Aug. 1
Location Seminar Dates Exam Date Sacramento, CA July 26–31 Aug. 1
Long Beach, CA Feb. 8–13 Feb. 14 Corpus Christi, TX Exam only Aug. 1
New Orleans, LA Feb. 8-13 Feb. 14 Anchorage, AK Aug. 2–7 Aug. 8
Seattle, WA Feb. 8–13 Feb. 14 Baton Rouge, LA Aug. 2–7 Aug. 8
Waco, TX Feb. 8–13 Feb. 14 Chicago, IL Aug. 2–7 Aug. 8
Atlanta, GA Feb. 22–27 Feb. 28 Las Vegas, NV Aug. 2–7 Aug. 8
Milwaukee, WI Feb. 22–27 Feb. 28 Philadelphia, PA Aug. 2–7 Aug. 8
Miami, FL Exam only Feb. 26 Seattle, WA Aug. 2–7 Aug. 8
Mobile, AL Mar. 1–6 Mar. 7 Rochester, NY Exam only Aug. 8
Houston, TX Mar. 1–6 Mar. 7 Charlotte, NC Aug. 9–14 Aug. 15
Kansas City, MO Mar. 1–6 Mar. 7 Mobile, AL Aug. 9–14 Aug. 15
Norfolk, VA Mar. 1–6 Mar. 7 Portland, ME Aug. 9–14 Aug. 15
Boston, MA Mar. 8–13 Mar. 14 Minneapolis, IN Aug. 16–21 Aug. 22
Indianapolis, IN Mar. 8–13 Mar. 14 Salt Lake City, UT Aug. 16–21 Aug. 22
Portland, OR Mar. 8–13 Mar. 14 San Antonio, TX Aug. 16–21 Aug. 22
Rochester, NY Exam only Mar. 14 San Diego, CA Aug. 16–21 Aug. 22
Edmonton, AB Canada Exam only Mar. 16
Corpus Christi, TX Exam only Mar. 21 Certified Welding Educator (CWE)
Birmingham, AL Mar. 22–27 Mar. 28 Seminar and exam are given at all sites listed under Certified
Chicago, IL Mar. 22–27 Mar. 28 Welding Inspector. Seminar attendees will not attend the Code
Dallas, TX Mar. 22–27 Mar. 28 Clinic portion of the seminar (usually the first two days).
Miami, FL Mar. 22–27 Mar. 28
Springfield, MO Mar. 22–27 Mar. 28
York, PA Exam only Mar. 28 Certified Welding Sales Representative (CWSR)
Las Vegas, NV Mar. 29–Apr. 3 Apr. 4 CWSR exams will be given at CWI exam sites.
Minneapolis, MN Mar. 29–Apr. 3 Apr. 4
Syracuse, NY Mar. 29–Apr. 3 Apr. 4 Certified Welding Supervisor (CWS)
St. Louis, MO Exam only Apr. 11 CWS exams are also given at all CWI exam sites.
Nashville, TN Apr. 12–17 Apr. 18
New Orleans, LA Apr. 12–17 Apr. 18 9­Year Recertification Seminar for CWI/SCWI
San Francisco, CA Apr. 12–17 Apr. 18 For current CWIs and SCWIs needing to meet education re-
Perrysburg, OH Exam only Apr. 18 quirements without taking the exam. The exam can be tak-
Miami, FL Exam only Apr. 23 en at any site listed under Certified Welding Inspector.
Corpus Christi, TX Apr. 26–May 1 May 2
Albuquerque, NM May 3–8 May 9 Certified Radiographic Interpreter (CRI)
Fresno, CA May 3–8 May 9 The CRI certification can be a stand-alone credential or can
Miami, FL May 3–8 May 9 exempt you from your next 9-Year Recertification.
Oklahoma City, OK May 3–8 May 9
Corpus Christi, TX Exam only May 16
Knoxville, TN Exam only May 23 Certified Robotic Arc Welding (CRAW)
Birmingham, AL May 31–June 5 June 6 ABB, Inc., Auburn Hills, MI; (248) 391–8421
Hutchinson, KS May 31–June 5 June 6 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
Spokane, WA May 31–June 5 June 6 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Bakersfield, CA June 7–12 June 13 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Beaumont, TX June 14–19 June 20 Wolf Robotics, Fort Collins, CO; (970) 225-7736
Hartford, CT June 14–19 June 20 On request at MATC, Milwaukee, WI; (414) 297-6996
Orlando, FL June 14–19 June 20
Memphis, TN June 14–19 June 20
Miami, FL Exam only June 25 IMPORTANT: This schedule is subject to change without notice. Please ver­
Corpus Christi, TX Exam only June 27 ify your event dates with the Certification Dept. to confirm your course sta­
tus before making travel plans. Applications are to be received at least six
Miami, FL Exam only July 16 weeks prior to the seminar/exam or exam. Applications received after that
Cleveland, OH July 12–17 July 18 time will be assessed a $250 Fast Track fee. Please verify application dead­
Jacksonville, FL July 12–17 July 18 line dates by visiting our website www.aws.org/certification/docs/sched­
Los Angeles, CA July 12–17 July 18 ules.html. For information on AWS seminars and certification programs, or
Louisville, KY July 12–17 July 18 to register online, visit www.aws.org/certification or call (800/305) 443­
9353, ext. 273, for Certification; or ext. 455 for Seminars.
Omaha, NE July 12–17 July 18

56 WELDING JOURNAL / DECEMBER 2014


For Info, go to www.aws.org/ad­index
BY HOWARD WOODWARD — woodward@aws.org
SOCIETY NEWS
AWS, Scouts, and Businesses Cooperate in Community Project
BY BILL ATKINSON AND DALE FLOOD

A major public sports complex lo-


cated in Folsom, Calif., needed to im-
prove access for the elderly and dis-
abled members of the community
who depend on the center for exercise
and recreation. The dynamic sports
complex boasts an indoor soccer field,
two basketball courts, three indoor
volleyball courts, four indoor batting
cages, and a pitching and hitting cage.
The scope of the required facility
improvements included a large Amer-
icans with Disabilities Act- (ADA-)
compliant concrete ramp and safety
handrails. The underlying question
was, who would “step up to the plate”
to meet this difficult challenge?
The answer was provided by caring From left, Kerry Shatell, AWS Dist. 22 Director, and Jerry Wentland, a Sacramento Val-
community Eagle Scouts, led by Con- ley Section officer, pose with the Eagle Scouts who worked on the construction project.
nor Stackhouse, who volunteered to
take this work on as a humanitarian
project. This was a noble commit- Chisea, and Nick Petrocelli. warding learning experience — and a
ment, but how could the Eagle Scouts Joining with the Section and sure-fire way to earn the Welding
organize such an effort that involved union workers, two local businesses Merit Badge.
digging foundations, building forms, agreed to support the project. Ken As the project progressed and the
and pouring a concrete ramp leading Morris from GNB, an advanced vacu- fabricated components neared com-
up to the bleachers? After that, stur- um chamber and valve manufacturer, pletion, they were transferred to the
dy metal handrails would need to be added the resources of his facility and Ironworkers Local 118 where many of
designed, welded, and installed. Fi- staff. From Sacramento-based Tri the final details were performed and
nally, all of this would have to meet Tool, Inc., a leading portable welding the components readied for transport
local construction codes for public equipment and machine tool manu- to the sports complex.
and disabled access in a community facturer, expert welder Jimmy Ray Finally, the installation work com-
area. Madrid and the Dale Flood, AWS vice menced, and while construction was
Obviously, this would require the president-elect, were eager to assist in progress inside, Kerry Shatell, AWS
talents of several skilled trades and with the project including material District 22 director, and Jerry Went-
leadership with the organizational fabrication and welding. land, a Sacramento Valley Section of-
skills to coordinate the entire project. The Eagle Scout idea snowballed ficer, and others, conducted hands-on
Stackhouse attempted to reach into reality as various labor union welding demonstrations designed to
out to the community, asking for help members organized the concrete foster welding education and arouse
for nearly 18 months. It was at that work, and concerned students and students’ interest about including
point he approached the American faculty members from Yuba and Sier- welding as their future occupation.
Welding Society’s Sacramento Valley ra regional community colleges and All in all, the project spanned more
Section for their assistance. Sacramento’s American River College than four weeks with on-site con-
Section Chair Jason Rafter recog- were recruited to study the local con- struction being completed to the sat-
nized this would be an excellent op- struction codes for compliance and isfaction of the city of Folsom’s Parks
portunity to improve the image of coordinate inspections and Building and Recreation Department and,
welding and promote the Society in Department approval of the plans. most importantly, by the appreciative
the community. He decided to help The valuable materials and steel elderly and disabled members of the
organize the project. Fortunately, were donated by GNB and Yuba Col- community who now have full access
Rafter is also the Ironworkers Ap- lege. Dan Turner from Yuba College to the sports complex.
prenticeship Coordinator for Local loaned a pipe bender for handrail
Union 118 and was very familiar with forming. Cutting, fabrication, and
BILL ATKINSON
this type of construction. The team welding on the guard and handrails (b.atkinson@tritool.com) is in the
he organized included the Sacramen- began during the evenings and week- Marketing Dept. and DALE FLOOD,
to Section Secretary Aleda Vaughn, ends at GNB with welding profession- AWS vice president-elect, is weld project
Ironworkers Ross Lundmark, Jim als working alongside the Eagle Scout manager at Tri Tool, Inc., Rancho
Martinez, Brad Gasaway, Justin Della members who viewed this as a re- Cordova, Calif.

DECEMBER 2014 / WELDING JOURNAL 59


SOCIETY NEWS
TECH TOPICS

D1 Committee on Structural Welding Convenes in Jackson, Wyoming

At right, D1 Committee leaders are


(from left) Todd Niemann (incoming first
vice chair), Dave McQuaid (AWS vice
president and a past D1 chair), Don
Rager (a past D1 chair), AWS President
Dean Wilson, Chair Duane Miller, and
Allen Sindel, incoming chair. Below, Todd
Niemann (center) receives his Silver
Member certificate for 25 years of serv-
ice to the Society from AWS President
Dean Wilson (left) and Dave McQuaid,
an AWS vice president.

A2 Committee on Definitions and Symbols Meets at EWI in Columbus, Ohio

Shown at the fall meeting, held Oct. 8, 9, are (from left) Chuck Ford, Ben Finney, Bill Beckman, Pat Newhouse, Chris Lander, John Gul-
lotti, Nancy Porter, Richard Holdren, Bryan Worley, David Beneteau, Steve Borrero, Johnny Dingler, Chair JP Christein, and Ben
Grimmett. The A2 Committee on Definitions and Symbols held its fall meeting Oct. 8, 9, at EWI in Columbus, Ohio. The committee is re-
sponsible for the oversight of the A2B Subcommittee on Definitions (AWS A3.0M/A3.0, Standard Welding Terms and Definitions) and
A2C Subcommittee on Symbols (AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination).

60 WELDING JOURNAL / DECEMBER 2014


SOCIETY NEWS
D10 Committee Meets at AWS World Headquarters in Miami

From left are Don Reis, Bill Newell, Jennifer Molin, Bill Kashin, Chair Mike Lang, John Hill, Chris Goocher, Danny Ciarlariello, Andy Mul-
roy, and John Hainsworth. At the meeting, John Hill received a certificate in appreciation for his 23 years of service to the committee.

STRENGTHENING AND REPAIR OF general instructions for the installa-


EXISTING STRUCTURES’ to ‘CLAUSE tion, operation, and maintenance of
7. FRICTION STIR WELDING’ common types of resistance welding
p. 174, Annex I: change page head- equipment. Generic preventative
er from ‘ANNEX K’ to ‘ANNEX I’ maintenance schedules and equip-
p. 176, Annex J: change page ment troubleshooting recommenda-
header from ‘ANNEX L’ to ‘ANNEX J’ tions are provided, as is an overview
of common weld qualification tech-
niques and how to correct common
Amendment Notice weld problems. Stakeholders: The re-
View and download the following sistance welding community. E.
and all AWS Amendments at www. Abrams, ext. 307, eabrams@aws.org.
aws.org/w/a/technical/amendments.

Standards Approved by ANSI


B5.1:2013 AMD1, Specification for B5.17-2014, Specification for the
Shown at the recent committee meet- the Qualification of Welding Inspec­ Qualification of Welding Fabricators.
ing in Miami, D10 Chair Mike Lang
tors Approved 9/12/2014.
(right) presents John Hill a certificate of
appreciation for his 23 years of service This Amendment adds AWS A2.4, B5.1-2013-AMD1-2013, Specifica-
on the committee. Standard Symbols for Welding, Brazing, tion for the Qualification of Welding In-
and Nondestructive Examination, and spectors. Approved 10/7/2014.
AWS A3.0, Standard Welding Terms
Errata and Definitions, to Annex A as refer-
D1.2/D1.2M:2014 ence documents applicable to AWI, Technical Committee Meetings
Structural Welding WI, SWI. Dec. 3, 4. Safety and Health Com-
Code — Aluminum mittee, Miami, Fla. S. Hedrick, ext.
Note: The following errata have 305, steveh@aws.org.
been identified and will be incorpo- New Standard Project Jan. 28. Committee on Personnel
rated into the next reprinting of this Development work has begun on & Facilities Qualification. Miami, Fla.
document. the following new standard. Affected S. Hedrick, ext. 305, steveh@aws.org.
p. xi, Table of Contents: delete line individuals are invited to contribute. April 7–10. D1 Committee and
‘Foreword …179’ Participation on all AWS Technical Subcommittees on Structural Weld-
p. 78, Figure 4.2: change ‘TABLE Committees is open to all persons. ing. Miami, Fla. B. McGrath, ext. 311,
4.6’ to ‘TABLE 5.3’ J1.2M/J1.2:201X, Guide to Instal- bmcgrath@aws.org.
pp. 106–111, Clause 7: change lation and Maintenance of Resistance
page header from ‘CLAUSE 7. Welding Machines. This guide provides

DECEMBER 2014 / WELDING JOURNAL 61


SOCIETY NEWS
NEW AWS SUPPORTERS
Sustaining Companies Global Mechanical Martin University
Applied Technical Services, Inc. 3494 Del Rio Ave.,Fracc Hacienda De 2171 Avondale Pl.
1049 Triad Ct., Marietta, GA 30062 Rio, Mexicali Bcn 21254, Mexico Indianapolis, IN 46218
Representative: Michael Murray
www.atslab.com Jenmar Specialty Products Maxine Waters Employment
Applied Technical Services (ATS) is a PO Box 270, Pounding Mill, VA 24609 Preparation Center
provider of consulting engineering, 10925 S. Central Ave.
testing, and inspection services. Since Lawrence Fabrication, Inc. Los Angeles, CA 90051
1967, it has established an excellent PO Box 8, Simpsonville, SC 29681
reputation with business, industry, and Middle East for Commercial Diving
the legal profession. Notably, ATS is Miller Welding & Fabrication, Inc. 3 Eskander Ibraheem St.
known for uncovering facts in metallur- 112 Little Tn School Rd. Miami, Alexandria, Egypt
gy, materials testing, chemical analysis, Maryville, TN 37801
nondestructive testing, calibrations, Rich Mountain Community College
fires, and explosions. Its quality assur- M. L. Ruberton Construction Co., Inc. 1100 College Dr., Mena, AR 71953
ance program meets ISO 9001, ISO PO Box 564, 1512 Mays Landing Rd.
17025, and Nuclear Requirements of 10 Folsom, NJ 08037 Southwest Texas Junior College
CFR 50 Appendix B, Part 21. 2401 Garner Field Rd.
Stoddard Silencers of Canada, Inc. Uvalde, TX 78801
Helical Pier Systems 491 Brimley Rd., Unit 1
Ste. 100, 103 Portage Close Toronto ON M1J 1A4, Canada
Sherwood Park, AB T8h2r5, Canada Supporting Companies
Representative: Shane Kasprick Strobel Manufacturing Envent Corp.
www.helicalpiersystems.com 105 S Green St., Clarks NE 68628 3220 E. 29 St.
Long Beach, CA 90806
Pemco of New Mexico, Inc. Tormex Industrias
POB 428, 2605 Lovington Hwy. San Pablo # 100-B Industrial, Mieleras Omega Natchiq, Inc.
Hobbs, NM 88241 Coahuila, Torreon 27400 4418 Pesson Rd.,
Representative: Garry Buie New Iberia, LA 70560
www.pemconm.com
Educational Institutions Uniarc Filler Metals, LLC
Cross Plains ISD 1102 Macy Dr.
Affiliate Companies 700 N. Main, Cross Plains, TX 76443 Roswell, GA 30076
Bae Industries
26020 Sherwood Ave. East Valley Institute of Technology
Warren, MI 48091 1601 W. Main St., Mesa, AZ 85201 Welding Distributers
ARC Enterprises, Inc.
Bridgehampton Steel & Welding, Inc. Greater Waco Advanced 27 Commercial Rd.
PO Box 19, #27 Foster Ave. Manufacturing Magnet Academy Kingfield, ME 04947
Bridgehampton, NY 11932 2401 JJ Flewellen Rd., Waco, TX 76704
BC Industrial Supply, Inc.
City Thermoplastic Engineering Sdn Hassan Abdul Karim Algahtani Sons Co. 3333 Lenox Ave.
Bhd., Lot 1, Jalan 7/3, Taman Industri Dammam-Khobar Hwy., near DHL of- Jacksonville, FL 32336
Selesa Jaya, Balakong Selangor 43300 fice, Al Nawawi St., Eastern Province
Malaysia Al Khobar 31942, Saudi Arabia Cargo Bed International, Inc.
2070-335 Wesley St.
Cogent Companies, Inc. Institute of International Recognized Nanaimo, BC V9R2T5, Canada
1550 Larkin Williams Rd. Qualifications (IIRQ), c/o Technology
Fenton, MO 63026 Innovation Center Tesco Engineers Co., Ltd.
Ste. #10, 237 Old Hope Rd. 39/13-16 Suanplu Corner Bldg. 3rd Fl.
Consorcio MMC Renter Kingston 6, Jamaica Soi. Suanplu, Sathorn, Thungmahamek,
Lope De Vega # 59, Plaza, Apt 15-C Sathorn, Bangkok 10120
Santo Domingo, Dominican Republic Kerrville ISD Thailand
1009 Barnett St., Kerrville, TX 78028
D/B Welding
4101 F M 113 N. Lubbock­Cooper ISD
Weatherford, TX 76088 16302 Loop 493, Lubbock, TX 79423

62 WELDING JOURNAL / DECEMBER 2014


SOCIETY NEWS
MEMBERSHIP ACTIVITIES

District Director Awards Member­Get­a­Member Update AWS Member Counts


Presented November 1, 2014
Listed are the members with points
The District Director Award pro- earned in the 2014 campaign. Five Sustaining.................................587
vides a means for District directors to points are awarded for each Individual Supporting .............................351
recognize individuals and local compa- Member and one point for each Stu- Educational...............................699
nies who have contributed their time dent Member recruited. See page 65 of Affiliate.....................................591
and effort to benefit the affairs of this Welding Journal for campaign Welding Distributor ...................54
their local Section and/or District. rules and prize list. Standings as of Total Corporate ......................2,282
Stewart Harris, Dist. 4 director, Oct. 21. Call the AWS Membership De- Individual ...........................59,845
nominated the following for this partment, (800/305) 443-9353, ext. Student + Transitional ...........10,453
award: 480, for more information. Total Members ..................70,298
Rich Husted, NE Carolina J. Morris, Mobile — 230
C. Wayne Hoose, Triangle M. Pelegrino, Chicago — 40
Greg Fredrick, Charlotte D. Saunders, Lakeshore — 33
Sergey Kobelev, Carolina R. Barber, East Texas — 30
Bill Rhodes, SW Virginia A. Stute, Madison-Beloit — 28 Nominate Your Candidate
Wayne Smith, Tidewater D. Ebenhoe, Kern — 25 for MIT Masubuchi Award
Wake Tech C. C. Student Chapter D. Mandina, New Orleans — 25
(Triangle Section) J. D. Mckenzie, Detroit — 25 The Prof. Koichi Masubuchi award,
Central Piedmont C. C. Student R. F Purvis, Sacramento — 25 with a $5000 honorarium, is presented
Chapter (Charlotte Section) E. Donaldson, Cumberland Valley — 24 to one person, 40 or younger, who has
York Technical College Student R. Richwine, Indiana — 24 made significant contributions to the
Chapter (Charlotte Section) A. Theriot, New Orleans — 24 advancement of materials joining
S. Miner, San Francisco — 22 through research and development.
D. Joshua Burgess, Dist. 8 director, R. Zabel, Southeast Nebraska — 22 Send a list of your candidate’s experi-
nominated the following for this J. Foley, Pittsburgh — 21 ence, publications, honors, awards, and
award: C. Bridwell, Ozark — 20 at least three letters of recommendation
Bradley Central High School Stu- D. Galigher, Detroit — 19 from fellow researchers to Prof. Todd
dent Chapter (Chattanooga) D. Lynnes, Northern Plains — 19 Palmer, tap103@psu.edu.
Gary Gammill, NE Mississippi R. Munns, Utah — 19 This award is sponsored annually by
Robbin Shull, NE Mississippi M. Haggard, Inland Empire — 19 the Massachusetts Institute of Technol-
Joe Smith, Greater Huntsville J. Kline, Northern New York — 18 ogy, Dept. of Ocean Engineering.
David Porter, Nashville G. Smith, Lehigh Valley — 17
G. Deem, Columbia — 15
John Stoll, District 18 director, nomi- R. Farquhar, Cleveland — 15
nated the following for this award: M. Trute, Atlanta — 15
Matt Richard, Corpus Christi J. Tso, LA/Inland Empire — 15
Ellery Francisco, Corpus Christi R. Eckstein, Northwest — 14
Brandy’s Landing, Houston C. Lariche, Cleveland — 14
Andre Horne, Houston R. Polito, Spokane — 14
Dan Jones, Houston J. Russell, Fox Valley — 14
Connie Rosbrough, Houston J. Carney, West Michigan — 13
Ron Theiss, Houston S. Robeson, Cumberland Valley — 13
Saty Segu, Houston C. Wolfman, Sacramento — 12
Scott Witkowski, Houston R. Bubb, Philadelphia — 11
Tom Holt, Sabine C. Ortega, North Texas — 11
Elaine Davis, San Antonio

DECEMBER 2014 / WELDING JOURNAL 63


SECTION NEWS

LONG ISLAND — From left are Tom Gartland, Jesse Provler, Chair Brian Cassidy, Deborah McInnis, Alex Duschere, Dist. 2 Director Har-
land Thompson, Ray O’Leary, and Barry McQuillan.

District 1
Thomas Ferri, director
(508) 527-1884
thomas_ferri@victortechnologies.com

BOSTON
September 19
Activity: The Section manned a booth
to promote the Society at a Steel Day
event hosted by Capone Iron Corp. in
Rowley, Mass. Tom Ferri, Dist. 1 di-
rector, and Dave Paquin were joined BOSTON — From left are Tom Ferri, Dist. 1 director; Dave Paquin; and Doug Desrochers
by Doug Desrochers representing the from the Central Mass./R.I. Section.
Central Mass./Rhode Island Section,
distributing literature and answering
questions for the high school stu-
dents and visitors.

District 2
Harland W. Thompson, director
(631) 546-2903
harland.w.thompson@us.ul.com

LONG ISLAND
October 9
Activity: The Section’s experts held a LEHIGH VALLEY — Mike Wiswesser, Dist. 3 director (standing, far right), is shown
group discussion on the relative mer- with attendees at the Lehigh Career and Technical Institute .
its of welding 1⁄4-in. plate using gas
metal arc vs. shielded metal arc LEHIGH VALLEY
processes. The winner was shielded District 3 August 6
metal arc. Participating were Chair Michael Wiswesser, director Activity: The first Section meeting of
Brian Cassidy, Jesse Provler, Deborah (610) 820-9551 the season was held at Lehigh Career
McInnis, Tom Gartland, Alex mike@welderinstitute.com and Technical Institute in Sch-
Duschere, Ray O’Leary, and Harland necksville, Pa. Mike Wiswesser, Dist.
Thompson, Dist. 2 director. 3 director, attended the program.

64 WELDING JOURNAL / DECEMBER 2014


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REV. 11/13
SECTION NEWS
District 4
Stewart A. Harris, director
(919) 824-0520
stewart.harris@altec.com

SOUTHWEST VIRGINIA
September 30
Activity: The Section members, Weld-
ing Instructor Chris Overfelt, and
Dist. 4 Director Stewart Harris con-
ducted a high school student weld-off
competition at A. R. Burton Technol-
ogy Center in Salem, Va. Hunter
Richard was the overall winner and
Rachel King took the top spot in the
girl’s division.

District 5
Carl Matricardi, director
(770) 356-2107
cmatricardi@aol.com
SOUTHWEST VIRGINIA — (Top photo) Attendees are shown at the September pro-
Aiken South Carolina gram. Above, at left, are Chris Overfelt (left), Hunter Richard (center), and Stewart Har-
Student Chapter ris, Dist. 4 director. At right, Rachel King displays her trophy.
October 16
Activity: The Student Chapter mem-
bers toured Praxair in Columbia, S.C.,
to study its gas cylinder filling opera-
tions.

FLORIDA WEST COAST


October 8
Speakers: Todd Faughn, Mike Vinson
Affiliation: 3M Personal Safety Div.
Topic: Controlling hazardous fumes in
the workplace
Activity: The event was held at Mimi’s
Café in Brandon, Fla.
FLORIDA WEST COAST — From left are Chair Charles Crumpton III and presenters
Todd Faughn and Mike Vinson.

AIKEN SOUTH CAROLINA STUDENT CHAPTER — From left are Jason Pfentner, Aaron Carter, Chandler Stokes, Brian Gore, Kevin
Rawlins, Joseph Long, Devon Rains, Lane Simmons, Robyn Westphas, Craig Miller, and Kevin Gratton.

DECEMBER 2014 / WELDING JOURNAL 67


SECTION NEWS

CHATTANOOGA — Attendees are shown at the Komatsu Manufacturing Operation in September.

District 6
Kenneth Phy, director
(315) 218-5297
kenneth.phy@gmail.com

NORTHERN NEW YORK


October 7
Activity: The members toured the
USS Slater moored in Albany, N.Y.
Doug Tanner, a USS Slater restoration
volunteer and a Section vice chair, PITTSBURGH — From left are Jody Dadum, Ken Broadbent, Section Chair George Kirk,
discussed the dry dock restorations Ron Delsandro, Lou Rudi, Matt Wilson, Treasurer Tom White, Past Chair John Menhart,
and conducted a tour of the ship. and Jack Trettle from Matheson Tri-Gas.

District 7
Uwe Aschemeier, director
(786) 473-9540
uwe@sgsdiving.com

COLUMBUS
September 23
Speaker: Melvin Pascall, professor
Affiliation: The Ohio State University
Topic: Food packaging nano technolo-
gy
Activity: The event was held at DNV
GL in Dublin, Ohio, for 37 attendees,
including members of local chapters
of SWE, ASME, ASM International,
and AIAA.
NORTHERN NEW YORK — Doug Tanner
is shown guiding the Section’s tour of the
October 15 USS Slater.
Speaker: Lee Kvidahl, AWS president
1993–1994
Affiliation: Ingalls Shipbuilding PITTSBURGH
Topic: Welding in shipbuilding Activity: Recently, more than 60 Sec-
Activity: Vice Chair Jim Worman re- tion members and welding students
ceived his Silver Member certificate toured Chapman Corp. in Washing-
for 25 years of service to the Society ton, Pa. Leading the program were
from Uwe Aschemeier, Dist. 7 direc- Ron Delsandro, Pipe Fabrication Shop
tor. Fifty people attended this pro- manager; Jody Dadum, general fore-
gram, including members of several man; Lou Rudi, QA manager; and COLUMBUS — (Top photo) Silver Mem-
local technical societies. The event Matt Wilson, foreman. Also attending ber Jim Worman (left) receives his certifi-
was held at La Scala Restaurant in were Ken Broadbent, business manag- cate from Uwe Aschemeier, Dist. 7 direc-
Columbus, Ohio. er, and workers from Steamfitters UA tor. (Above) Chair John Lawmon (left) is
Local #449 based in Pittsburgh, Pa. shown with speaker Lee Kvidahl.

68 WELDING JOURNAL / DECEMBER 2014


SECTION NEWS
Lusker, vice chair; Maurice Davis, pro- Kolasa, a welding school instructor at
District 8 gram chair; DeMarcus Gates, publicity Lincoln, chaired the program. The
D. Joshua Burgess, director chair; Rushton Syphurs, membership next Roundtable is scheduled for Dec.
(931) 260-7039 chair; Niya Jackson, secretary; and 6, 2014.
djoshuaburgess@gmail.com Jerome Ambers, treasurer.
CHATTANOOGA
September 11
Speaker: Bill Brooks, technical sales District 11
Affiliation: Holston Gases District 10 Robert P. Wilcox, director
Topic: Controlling fuel flashbacks Robert E. Brenner, director (734) 721-8272
Activity: The program was held at Ko- (330) 484-3650 rwilcox1@ford.com
matsu Manufacturing Operation.
DRAKE WELL Ferris State University
October 9 Student Chapter
NASHVILLE Activity: The Section held a planning September 30
October 16 and social meeting at The Commons Activity: The Chapter members, led
Speaker: Reid Laurens at Franklin in Franklin, Pa. by Advisor Jeff Carney, participated
Affiliation: Thermo Fisher Niton in a Michigan Dept. of Transportation
Topic: Positive material identification Adopt-a-Highway cleanup along a
Activity: The meeting was held at District 10 event two-mile section of highway in Big
World Testing, Inc., in Juliet, Tenn. September 27 Rapids, Mich.
Dist. Director Josh Burgess presented Activity: This year, the District hosted
the Section Meritorious Award to Jim its third annual series of Certified October 7
Kirby and the Section Dalton E. Welding Inspection (CWI) Roundta- Activity: The Student Chapter mem-
Hamilton Memorial CWI of the Year bles at The Lincoln Electric Co. in Eu- bers volunteered their maintenance
Award to Michael Morris of World clid, Ohio. Participating were 25 CWIs and cleanup services for the Big
Testing. The program was held at who discussed techniques for prepar- Rapids Riverwalk along the
World Testing, Inc., in Juliet, Tenn. ing for the CWI practical exam. Joe Muskegon River in Hemlock Park.

District 9
George Fairbanks Jr., director
(225) 473-6362
fits@bellsouth.net

Lawson State C. C.
Student Chapter
September 23
Activity: The Student Chapter held its
fall term election of officers at the
college in Birmingham, Ala. Elected LAWSON STATE C. C. STUDENT CHAPTER — From left are (seated) Niya Jackson,
were Ladarious Bledsoe, chair; Mason Chair Ladarious Bledsoe, and Mason Lusker; (standing) Maurice Davis, DeMarcus
Gates, Rushton Syphurs, and Jerome Ambers.

NASHVILLE — Members are shown at World Testing, Inc., in October.

DECEMBER 2014 / WELDING JOURNAL 69


SECTION NEWS

Ferris State University Student Chapter — Members are shown during their Adopt-a-Highway project in September.

District 12
Daniel J. Roland, director
(920) 241-1542
daniel.roland@airgas.com

District 13
John Willard, director
(815) 954-4838
kustom_bilt@msn.com

CHICAGO
October 15
Speaker: Stuart Kleven
Topic: Recovery and restoration of the
Huntley, a Confederate submarine
Activity: Attending were welding stu-
dents and members of the local chap-
ter of ASNT. The event was held at
Bohemian Crystal Restaurant in
DRAKE WELL — From left are (seated) Bob Fugate, Carol Miller, and Brenda Benyon;
Westmont, Ill., for 43 attendees. and (standing) Dan Bubenheim, Mike Owens, Ward Kiser, and Travis Crate.

CHATTANOOGA — Bill Brooks demon-


NASHVILLE — Josh Burgess (right in both photos) presents awards to Jim Kirby (left strated gas safety practices at Komatsu
photo) and Michael Morris. Manufacturing Operation.

70 WELDING JOURNAL / DECEMBER 2014


SECTION NEWS
search Center for Advanced Manufac- October 11, 12
District 14 turing at Southern Methodist Uni- Activity: The Tulsa Section hosted a
Robert L. Richwine, director versity (SMU) in Arlington, Tex. CWI exam. Officiating were test ad-
(765) 606-7970 Radovan Kovacevic, Research Center ministrators Chair Rich Howard and
rlrichwine2@aol.com director, demonstrated welding using Tim Jones; and Proctors Travis We-
high-power lasers and discussed fric- ber, Melissa Howard, and Jaimie Vera.
INDIANA tion stir welding process variations.
September 25
Activity: Twenty members and guests
toured the Endress+Hauser Flowtec EAST TEXAS District 18
automation and instrumentation June 14 John Stoll, director
plant in Greenwood, Ind. The speak- Activity: The Section hosted the Dis- (713) 724-2350
ers included Mike Moore, engineering trict 17 conference. John.Stoll@voestalpine.com
manager; Klaus Maier, industrial en-
gineering manager; Wally Wood, engi- September 18 HOUSTON
neering weld technician; and Robert Activity: The Section members toured September 17
Head, engineering staff member. the Norris Cylinder Co. in Longview, Speaker: Ben Pletcher, senior metal-
Tex. George Stevens, southeast region lurgist
September 25 sales manager, detailed the manufac- Affiliation: Select-Arc, Inc.®
Activity: The Indiana Section held its ture of seamless and welded industri- Topic: Innovations in metal cored
semiannual Certified Welding Inspec- al gas cylinders used for the storage, welding consumables
tor (CWI) seminar and testing pro- and dispensing of industrial gases. Activity: Jim Hansford, an education
gram for 35 applicants. The event was board member, discussed plans for
held at the Marriott Hotel in Indi- the seminar, “Welding Economics,”
anapolis, Ind. TULSA scheduled for Oct. 11 at NCI.
September 23
Speaker: Russel Fuchs October 3
ST. LOUIS Affiliation: voestalpine Böhler Weld- Activity: The Houston Section mem-
September 18 ing bers visited the Arc Specialities facili-
Activity: The Section members toured Topic: Cored welding wires ty in Houston, Tex. Dan Allford, own-
the Larry Jeffers Race Cars facility Activity: The event was held at Gold- er and CEO, and Richard Holdren,
and welding shop in House Springs, en Corral in Tulsa, Okla., for 41 atten- senior welding engineer, conducted
Mo. Larry Jeffers and David Zientara dees. the tour.
conducted the program.

District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com

District 16
Karl Fogleman, director
(402) 677-2490 HOUSTON — At left, Metallurgist Ben Pletcher (left) is shown with Vice Chair Grant
Peltier at the September program. At right, Arc Specialities owner Dan Allford (left)
fogleman3@cox.net chats with Chair Barney Burks.

District 17
Jerry Knapp, director
(918) 224-6455
jerry.knapp@gasandsupply.com

District 17 CWI Tour


October 9
Activity: The Certified Welding In-
spector 9-year recertification class,
headed by instructor Ron Theiss and
Ernest Levert, AWS president
2002–2003, featured a tour of the Re- TULSA — Officiating at the CWI exam are (from left) Travis Weber; Chair Rich Howard;
Melissa Howard; Tim Jones; and Jaimie Vera.

DECEMBER 2014 / WELDING JOURNAL 71


SECTION NEWS

CHICAGO — Attendees are shown at the October 15 meeting.

District 17 CWI Tour — Instructor Ron Theiss (third from the left) poses with his CWI class during their tour of SMU.

EAST TEXAS —At left, presenter George Stevens (left) is shown with J. Jones, AWS director-at-large. At right, attendees are shown at
the District 17 conference held June 14.

TULSA — Shown at the September pro-


gram are (from left) Chair Rich Howard,
speaker Russel Fuchs, and Wes Norton, ST. LOUIS — Jerry Simpson (center) is shown with presenters Larry Jeffers (left) and
vice chair. David Zientara during the race car factory tour.

72 WELDING JOURNAL / DECEMBER 2014


SECTION NEWS
October 3 Weber State University stitute of Technology in Mesa, Ariz.
Activity: Ron Theiss conducted the Student Chapter Attending were Chair Brent Boling,
15th annual nine-day CWI class and October 14 Gary Gardner, John Weber, Leon
exam for the United Brotherhood of Activity: Advisor Mark Baugh, An- Zamora, Buddy May, Jerry Siko, Paul
Carpenters and Joiners in Houston, drew Deceuster and Chapter mem- Moreno, Andrew Lamer, Nick Mar-
Tex, for 22 attendees. bers toured GSC Foundries, Inc., in tinez, and Fran Johnston.
Ogden, Utah, to study investment
casting of aluminum parts for Hellfire
LOS ANGELES/INLAND EMPIRE
District 19 missiles and fighter jet components.
October 10, 11
Ken Johnson, director Activity: The Section held its annual
(425) 957-3553 Welding Thunder team competition
kenneth.johnson@vigorindustrial.com District 21 for high school and college students,
Nanette Samanich, director at Santa Ana College.
PUGET SOUND OLYMPIC (702) 429-5017
October 2 nan07@aol.com October 16
Speaker: Sergio Vitomir, director
Speaker: Dean Wilson, AWS president
R&D ARIZONA Affiliation: Welldean Enterprises
Affiliation: Protocol Environmental June 25 Topic: The AWS Innovation Campaign
Solutions, Inc. Activity: The Section members toured Activity: The event was held at Green
Topic: Removing metal oxides the AWS Accredited Test Facility River Golf Club in Corona, Calif.
Activity: The program was held at (ATF) at Mohave College in Kingman,
Bellevue Coast Hotel in Bellevue, Ariz. Buddy May, a faculty member
Wash. and Section Student Affairs chair,
conducted the program. District 22
Kerry E. Shatell, director
SPOKANE October 6 (925) 866-5434
September 6 Activity: Arizona Section officers held kesi@pge.com
Activity: The annual golf outing was a planning meeting at East Valley In-
held at The Links Golf Course in Post
Falls, Idaho. Ten four-member teams
participated with funds and gifts do-
nated by local fabrication shops. The
winning team members were Doug
Owens, Kris Meeks, James Hill, and
Mark Hill.

October 15
Speaker: Phil Zammit, QA manager
Affiliation: Brooklyn Iron Works (ret.)
Topic: Reading welding symbols
Activity: The event was held at
Spokane Community College for 72 HOUSTON — Instructor Ron Theiss (wearing jacket) and CWI class members are shown
attendees. at United Brotherhood of Carpenters and Joiners of America.

District 20
Pierrette H. Gorman, director
(505) 284-9644
phgorma@sandia.gov

COLORADO
September 11
Activity: The Section visited Leed
Fabrication in Loveland, Colo., to
study the manufacture of pressure
vessels. Eric Warren made a presenta-
tion then conducted the tour of the
facility. ARIZONA — Shown at Mohave College
are (from left ) presenter Buddy May,
Fran Johnston, Leon Zamora, and Gary HOUSTON — Justin Gordy, a past chair,
Gardner. is shown during the Arc Specialities tour.

DECEMBER 2014 / WELDING JOURNAL 73


SECTION NEWS

COLORADO — Presenter Eric Warren (holding the Section banner) poses with Section members at Leed Fabrication.

Weber State University Student Chapter — Attendees are shown during their tour of GSC Foundries in Ogden, Utah.

PUGET SOUND OLYMPIC — From left


are Gary Marshall, speaker Sergio Vito-
mir, and Steve Pollard.

ARIZONA — Shown at the October meeting are from left (seated) John Weber, Buddy
May, Paul Moreno, and Chair Brent Boling; (standing) Gary Gardner, Leon Zamora, Jer-
ry Siko, Andrew Lamer, and Nick Martinez.

SPOKANE — From left are Doug Owens,


Kris Meeks, James Hill, and Mark Hill.

LA/INLAND EMPIRE — Chair George LA/INLAND EMPIRE — The top Welding Thunder team members are (from left) Ben
Rollo (left) is shown with Dean Wilson, Perez, Omar Andino, Alexandra Ruesga, Tyler Faust, Caleb Purdy, Michael Gilman, and
AWS president, in October. Joseph Brennan.

74 WELDING JOURNAL / DECEMBER 2014


Guide to American Welding Society® Services SOCIETY NEWS
American Welding Society® Operations Manager TECHNICAL SERVICES
8669 NW 36th St., #130 Natasha Alexis.. nalexis@aws.org . . . . . . . . . .(401) Dept. information . . . . . . . . . . . . . . . . . . . . . .(340)
Miami, FL 33166-6672 Managing Director
(800/305) 443-9353; Fax: (305) 443-7559 INTERNATIONAL SALES Technical Services Development & Systems
Phone extensions are in parentheses. Managing Director of North American Sales Andrew Davis.. adavis@aws.org . . . . . . . . . . .(466)
Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . . .(297) International Standards Activities, American
AWS PRESIDENT Council of the International Institute of Welding
Dean Wilson . . . deanwilsonaws@gmail.com Corporate Director, International Sales
Welldean Enterprises Jeff Kamentz..jkamentz@aws.org . . . . . . . . . .(233) Director, Operations
151 Oak Tree Cir., Glendora, CA 91741 Oversees international business activities; Annette Alonso.. aalonso@aws.org . . . . . . . . .(299)
certification, publications, and membership. Technical Committee Activities, Welding
ADMINISTRATION Qualification
Executive Director PUBLICATION SERVICES
Ray Shook.. rshook@aws.org . . . . . . . . . . . . . .(210) Dept. information . . . . . . . . . . . . . . . . . . . . . .(275) Manager, Safety and Health
Managing Director Stephen Hedrick.. steveh@aws.org . . . . . . . . .(305)
Sr. Associate Executive Director Andrew Cullison.. cullison@aws.org . . . . . . . .(249) Metric Practice, Safety and Health, Joining
Cassie Burrell.. cburrell@aws.org . . . . . . . . . . .(253) of Plastics and Composites, Personnel and Facili-
Welding Journal ties Qualification, Mechanical Testing of Welds
Chief Financial Officer Publisher
Gesana Villegas.. gvillegas@aws.org . . . . . . . .(252) Andrew Cullison.. cullison@aws.org . . . . . . . .(249) Program Managers II
Stephen Borrero... sborrero@aws.org . . . . . . .(334)
Chief Technology Officer Editor Brazing and Soldering, Brazing Filler Metals
Dennis Harwig..dharwig@aws.org . . . . . . . . .(213) Mary Ruth Johnsen.. mjohnsen@aws.org . . .(238) and Fluxes, Brazing Handbook, Soldering Hand-
book, Definitions and Symbols, Structural Sub-
National Sales Director
Chief Information Officer committees on Bridge Welding, Stainless Steel,
Rob Saltzstein.. salty@aws.org . . . . . . . . . . . .(243)
Emilio Del Riego..edelriego@aws.org . . . . . . .(247) and Reinforcing Steel
Society and Section News Editor
Associate Director of Board and Howard Woodward..woodward@aws.org . . . .(244) Rakesh Gupta.. gupta@aws.org . . . . . . . . . . .(301)
Executive Director Services Filler Metals and Allied Materials, Interna-
Alex Diaz.. adiaz@aws.org . . . . . . . . . . . . . . . .(294) Welding Handbook tional Filler Metals, UNS Numbers Assignment,
Editor Arc Welding and Cutting Processes, Computeri-
Administrative Services Annette O’Brien.. aobrien@aws.org . . . . . . . .(303) zation of Welding Information
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . . .(214) MARKETING COMMUNICATIONS Brian McGrath .... bmcgrath@aws.org . . . . . .(311)
Director Structural Welding, Welding in Marine Con-
Director Lorena Cora.. lcora@aws.org . . . . . . . . . . . . . .(417) struction
Hidail Nuñez..hidail@aws.org . . . . . . . . . . . . .(287)
Public Relations Manager Program Managers
HUMAN RESOURCES Cindy Weihl..cweihl@aws.org . . . . . . . . . . . . .(416) Efram Abrams.. eabrams@aws.org . . . . . . . . .(307)
Director Automotive, Resistance Welding, Machinery
Gricelda Manalich.. gricelda@aws.org . . . . . .(208) Webmaster and Equipment, Methods of Inspection
Jose Salgado..jsalgado@aws.org . . . . . . . . . . .(456)
Associate Director Chelsea Lewis.. clewis@aws.org . . . . . . . . . . . .(306)
Patrick Henry..phenry@aws.org . . . . . . . . . . .( 211) Section Web Editor Friction Welding, Oxyfuel Gas Welding and
Henry Chinea...hchinea@aws.org . . . . . . . . . .(452) Cutting, High-Energy Beam Welding, Robotics
INTERNATIONAL INSTITUTE OF WELDING Welding, Welding in Sanitary Applications, Addi-
Senior Coordinator MEMBER SERVICES tive Manufacturing
Sissibeth Lopez . . sissi@aws.org . . . . . . . . . . .(319) Dept. information . . . . . . . . . . . . . . . . . . . . . .(480)
Liaison services with other national and inter- Sr. Associate Executive Director Jennifer Molin.. jmolin@aws.org . . . . . . . . . .(304)
national societies and standards organizations. Cassie Burrell.. cburrell@aws.org . . . . . . . . . . .(253) Sheet Metal Welding, Welding and Brazing in
Aerospace, Ti and Zr Filler Metals, Joining of
GOVERNMENT LIAISON SERVICES Director Metals and Alloys, Piping and Tubing
Hugh Webster . . . . . . . . . . . . . .hwebster@wc-b.com Rhenda Kenny... rhenda@aws.org . . . . . . . . . .(260)
Webster, Chamberlain & Bean, Washington, D.C. Serves as a liaison between members and Jennifer Rosario.. jrosario@aws.org . . . . . . . .(308)
(202) 785-9500; F: (202) 835-0243. AWS headquarters. Railroad Welding, Thermal Spraying, Weld-
Monitors federal issues of importance to the ing Iron Castings, Welding Qualification
industry. CERTIFICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . .(273)
CONVENTION AND EXPOSITIONS Managing Director AWS FOUNDATION, INC.
Director, Convention and Meeting Services John Gayler.. gayler@aws.org . . . . . . . . . . . . .(472) www.aws.org/w/a/foundation
Matthew Rubin.....mrubin@aws.org . . . . . . . .(239) Oversees all certification activities. General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
ITSA — INTERNATIONAL THERMAL Director, Certification Operations Chairman, Board of Trustees
SPRAY ASSOCIATION Terry Perez..tperez@aws.org . . . . . . . . . . . . . .(470) Gerald Uttrachi
Senior Manager and Editor Application processing, renewals, and exams.
Kathy Dusa....kathydusa@thermalspray.org . .(232) Executive Director, Foundation
Director, Accreditation Programs Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
RWMA — RESISTANCE WELDING MANUFACTUR­ Linda Henderson..lindah@aws.org . . . . . . . . .(298)
ING ALLIANCE Oversees the development of new certifica- Corporate Director, Workforce Development
Management Specialist tion programs, as well as AWS-Accredited Test Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
Keila DeMoraes....kdemoraes@aws.org . . . . . .(444) Facilities, and AWS Certified Welding Fabrica-
tors. Associate Director of Scholarships
WEMCO — ASSOCIATION OF WELDING MANU­ Vicki Pinsky.. vpinsky@aws.org. . . . . . . . . . . . . . . . (212)
FACTURERS EDUCATION SERVICES
Management Specialist Director, Operations The AWS Foundation is a not-for-profit 501(c)(3)
Keila DeMoraes....kdemoraes@aws.org . . . . . .(444) Martica Ventura.. mventura@aws.org . . . . . .(224) charitable organization established to provide support for
the educational and scientific endeavors of the American
BRAZING AND SOLDERING Director, Development and Systems Welding Society. Promote the Foundation’s work with
MANUFACTURER’S COMMITTEE David Hernandez.. dhernandez@aws.org . . . .(219) your financial support.
Stephen Borrero..sborrero@aws.org . . . . . . . .(334)
AWS AWARDS, FELLOWS, COUNSELORS
GAWDA — GASES AND WELDING Senior Manager
DISTRIBUTORS ASSOCIATION Wendy Sue Reeve.. wreeve@aws.org . . . . . . . .(293)
Executive Director Coordinates AWS awards and Fellow and
John Ospina.. jospina@aws.org . . . . . . . . . . . .(462) Counselor nominations.

DECEMBER 2014 / WELDING JOURNAL 75


Where is the welding
industry headed?
The CEO of Lincoln knows. Economist Alan Beaulieu knows.

Head to WEMCO’s
annual meeting
or be left behind.
Non-member executives are encouraged to participate.
MEET THE SPEAKERS

An Association of Welding Manufacturers

2015 Annual Meeting


Feb. 25–27 Chris Mapes
Chairman, President, and CEO
Lincoln Electric

Vinoy Renaissance Resort & Golf Club Chris Mapes was appointed chairman of Lincoln Electric in
December 2013, and president and chief executive officer in
December 2012. Previously, Chris was Lincoln’s chief operating

St. Petersburg, Fla. officer, the position he was appointed to when he joined the
company in 2011. He was elected to the Lincoln Board in 2010
while serving as executive vice president of A.O. Smith Corporation
and president of its electrical products unit. Prior to his career at
Theme: Welding Industry A.O. Smith, Chris was president, motor sales and marketing of
Regal Beloit Corporation and had also served as president of the
Consolidation and Globalization Global OEM Business Group of Superior Essex, Inc.

Jack Keough
Contributing Editor and Associate Publisher
Industrial Distribution Magazine

T
he WEMCO Annual Meeting is filled with Jack Keough has been researching and writing about the
unparalleled networking opportunities and distribution/manufacturing sector for 30 years. He’s been serving
as contributing editor and associate publisher for Industrial
enlightening presentations. Renowned economist Distribution Magazine of Madison, Wis. for 26 of those years. Jack
is also the president of his own marketing and consulting firm,
Alan Beaulieu of the Institute for Trend Research will Keough Business Communications, and the contributing editor for
Electrical Distributor magazine and its website. He has written
again be our keynote speaker. Network with additional extensively about distribution management, sales and technology
issues that have changed industrial distribution in the past three
speakers such as Lincoln Electric CEO Chris Mapes decades.
and Industrial Distribution Magazine’s Jack Keough.
Non-members are welcome to attend and
experience the full benefits of networking
with your industry peers!

KEYNOTE SPEAKER
Alan Beaulieu
Economist and President
Institute for Trend Research
One of the country’s most informed economists, Alan Beaulieu is a
principal of ITR Economics, where he serves as president. He is
co-author of Make Your Move, a book on how to increase profits
through business cycle changes. Alan is also the senior economic
Registration opens mid-December. For more advisor to the NSW, chief forecaster for the European Power Train
Distributors Association, and the chief economist for HARDI.
information, please contact Keila DeMoraes at Pronouncements from the Institute for Trend Research and/or Mr.
Beaulieu have appeared in/on the Wall Street Journal, New York
kdemoraes@aws.org or 800-443-9353, ext. 444 Times, USA Today, Knight Ridder News Services, Business Week,
Associated Press, Washington Times, CBS Radio, CNN Radio, Sirius
talk radio, KABC, NPR affiliate WLRN, and numerous other outlets.
PERSONNEL

Cincinnati, Inc., Names social responsibility, from Barbara


President, CEO Couch, who will retain her roles as
board director, chair of the corporate
Cincinnati, Inc., social responsibility committee, and
Harrison, Ohio, a HOPE Foundation president.
build-to-order ma-
chine tool manufac-
turer, has selected Fronius Builds Its Sales Team
Carey Chen to
serve as president,
CEO, and a member
of the board of di- Glen Hicks Chris Mecleary
rectors beginning
early 2015. Chen Pa., has hired Glen Hicks and Chris
will succeed An- Mecleary to serve on its inside sales
Carey Chen drew Jamison who team. Hicks has extensive experience
will retire. Previ- in the metals industries where he has
ously, Chen served at Hypertherm, held sales positions at U.S. Metals,
Inc., concurrently as VP and general Inc., Tioga Pipe Supply Co., Inc., and
manager for light industrial business- most recently at MRC Global, Inc.
es, CFO, and chief information officer. A. Almaguer Jeffrey Iley Mecleary previously was a district
Earlier, he was VP finance at Wire- sales manager for the Mueller Indus-
mold/Legrand, Paris, and VP and CFO tries division, Precision Tool Co.
for Bayliner Marine Corp. Fronius USA, LLC, Portage, Ind.,
has promoted Angelica Almaguer to re-
gional marketing leader North Ameri- Chrysler Group Announces
Hypertherm to Make ca, and named Jeffrey Iley a sales/ap- Manufacturing Appointment
Management Changes plication engineer for its southeast lo-
cation. Almaguer previously served six Chrysler Group,
Hypertherm, Hanover, N.H., a sup- years as marketing director for the LLC, Auburn Hills,
plier of plasma, laser, and waterjet company’s two divisions in Mexico, Mich., has appoint-
cutting systems, announced succes- Perfect Welding and Solar Energy. Iley, ed Brian Harlow
sion plans to become effective Jan. 1. a graduate of the Hobart Institute of vice president,
Current President Evan Smith will as- Welding Technology, has experience in head of NAFTA
sume the role of CEO, succeeding the nuclear power and heavy industrial Manufacturing, re-
founder Dick Couch who will retain industries and the U.S. Navy. sponsible for all as-
the position of executive chairman of sembly, stamping,
the board and trustee of the compa- and powertrain
ny’s stock ownership plan. Concur- Laboratory Testing Adds Sales manufacturing op-
rently, Jenny Levy, director of corpo- Representatives erations in the
rate social responsibility, will assume Brian Harlow United States,
the role of vice president, corporate Laboratory Testing, Inc., Hatfield, Canada, and Mexi-
co, as well as implementation of the
World Class Manufacturing system at
all Chrysler Group manufacturing fa-
cilities. With the company since 1978,
Harlow most recently served as global
head of powertrain manufacturing en-
gineering and vice president and head
of NAFTA Powertrain Operations.

Camfil APC Makes Upper


Management Changes
Camfil Air Pollution Control (APC),
Jonesboro, Ark., has appointed Alan
O’Connell executive vice president in
charge of worldwide operations. He
succeeds Lee Morgan who will resign
For info, go to www.aws.org/ad­index

78 WELDING JOURNAL / DECEMBER 2014


as Camfil APC pres- then was named director of machine
ident at the end of and power tool products in 2011. CAN WE TALK?
this year to become
president of The The Welding Journal staff
encourages an exchange of ideas with
Systems Group, El Hobart Institute Hires you, our readers. If you’d like to ask a
Dorado, Ark., a di- Technical Trainer question, share an idea or voice an opin-
verse group of pri- ion, you can call, write, e-mail, or fax.
vately held compa- Hobart Institute Staff e-mail addresses are listed below,
nies engaged in of Welding Tech- along with a guide to help you interact
product and field nology, Troy, Ohio, with the right person.
installations for has named Ryan
steel mills, Freeze a technical Publisher
Alan O’Connell
foundries, and training instructor Andrew Cullison cullison@aws.org,
petrochemical for continuing edu- Ext. 249, Article Submissions
plants. O’Connell previously worked cation courses. A
for the parent company, Camfil Group, Editor
graduate of the In- Mary Ruth Johnsen mjohnsen@aws.org,
in Stockholm, Sweden, for more than stitute, and an Ext. 238, Feature Articles
30 years, including 12 years as presi- AWS Certified
dent and CEO. Welding Inspector, Associate Editor
Ryan Freeze Freeze has more Howard Woodward woodward@aws.org,
than 13 years’ ex- Ext. 244, Society News, Personnel
Marketing Manager Appointed perience in the field as an ironworker, Kristin Campbell kcampbell@aws.org,
at Solar Atmospheres bridge repair contractor, and most re- Ext. 257, New Products, News of the
cently as a project manager and esti- Industry
Solar Atmos- mator for a structural steel manufac-
pheres, Inc., Soud- turer. Production Manager
erton, Pa., a con- Zaida Chavez zaida@aws.org,
tract vacuum heat Ext. 265, Design and Production
treatment company Steel Recycling Institute
Senior Production Coordinator
and supplier of vac- Names VP
Brenda Flores bflores@aws.org,
uum furnaces, has
Ext. 330, Design and Production
hired Keith Reim as The Steel Market Development In-
corporate market- stitute (SMDI), Washington, D.C., a National Sales Director
ing manager. With business unit of the American Iron Rob Saltzstein salty@aws.org,
more than 19 years and Steel Institute, has named Mark Ext. 243, Advertising Sales
of experience in A. Thimons to succeed Gregory Craw-
Keith Reim marketing, Reim ford who has retired as vice president Sr. Advertising Sales Exec.
most recently of the Steel Recycling Institute. Thi- Sandra Jorgensen sjorgenen@aws.org
served as marketing manager for an mons, who joined SMDI in 2010 as di- Ext. 254, Advertising Sales
industrial automation company. rector of construction sustainability, Annette Delagrange adelagrange@aws.org
has 25 years of experience in steel Ext. 332, Advertising Sales
construction products and steel prod-
TRUMPF Appoints VP uct sustainability. Manager of Sales Operations
Technical Service Lea Garrigan Paneca lea@aws.org,
Ext. 220, Production and Promotion
James Rogowski Lockheed Martin Names VP
Advertising Sales Representative
has been promoted Sandra Jorgensen sjorgensen@aws.org
to vice president, Lockheed Martin, Bethesda, Md., Ext. 254, Advertising Sales
technical service of has appointed Greg Psihas vice presi-
TRUMPF, Inc., dent for corporate development, re- Sr. Advertising Production Manager
Farmington, Conn., sponsible for leading the corporation’s Frank Wilson fwilson@aws.org,
responsible for ac- mergers and acquisitions and integra- Ext. 465, Advertising Production
counts nationwide. tion activities, as well as technology
Rogowski began his commercialization and fund invest- Peer Review Coordinator
career with the ments. Psihas previously held various Melissa Gomez mgomez@aws.org,
company in 1998 positions at Eaton Corp. and Shell Oil Ext. 275, Peer Review of Research Papers
as a sheet metal ap- Co., and most recently served as corpo-
James Rogowski plications engineer, rate vice president of mergers and ac- Welding Journal Dept.
quisitions at Applied Materials, a semi- 8669 NW 36th St., #130
became managing
Miami, FL 33166
director TRUMPF Canada in 2008, conductor capital equipment company.
(800) 443-9353; FAX: (305) 443-7404

DECEMBER 2014 / WELDING JOURNAL 79


THE AMERICAN WELDER

Heat Tint Poses Corrosion


Hazard in Stainless Steel
Avoid time-consuming, difficult, and
expensive cleaning of heat tint by weld BY MICHAEL FLETCHER

purging during the welding process

W
e have all seen the effect of
welds carried out without ad-
equate gas coverage — the
hot metal simply oxidizes in contact
with air. The effect is noticeable with
stainless steels — Fig. 1. To some, this
is an inconvenient feature that can be
removed by grinding, but the cost of
doing so can be high, particularly if ac-
cess is difficult.
Even with reduced oxygen content
in the gas coverage, the effect can be
marked. It will come as a surprise to
most that oxygen contents as low as
60 ppm (0.006%) (Fig. 1B) can pro-
duce discoloration or “heat tint” in
stainless steels.
While for many applications this
discoloration may be acceptable cos-
metically, it is now apparent that it
presents a corrosion hazard (Refs.
1–7).
Fig. 1 — Photos showing oxidation of 316L stainless steel coupons welded using argon
purging gas: A — 12 ppm (ensures no heat tint occurs in stainless steel); B — 60 ppm (even
The Mechanism this relatively low oxygen content can lead to “heat tint”); C — 70 ppm; D — 200 ppm;
of Corrosion E — 250 ppm; F — 500 ppm (the result of poorly protected underbead in welded austenitic
stainless steel).

Stainless steels owe their resistance


to corrosion to the formation of a very fer sites for localized corrosion. Four might be weakened and it occurs in
thin (10–5 mm), transparent surface principal mechanisms are involved — stainless steels where oxidation has re-
layer of chromium oxide. This provides pitting corrosion, stress corrosion duced the passivity. Once the attack
a passive film that acts as a barrier to cracking, crevice corrosion, and micro- has started, the material can be com-
penetration by an invasive environ- biologically induced corrosion (MIC). pletely penetrated within a short time.
ment. When heated to a high tempera-
ture in the presence of oxygen, this Pitting Corrosion Stress Corrosion Cracking
film increases in thickness until it be-
comes visible; the color becomes dark- Pitting corrosion is a form of local- Stress corrosion cracking is charac-
er with increasing film thickness. ized corrosion. It produces attacks in terized by cracks propagating either
At a critical film thickness, the film the form of spots or pits. This type of transgranularly (through) or inter-
becomes unstable and begins to break corrosion attack most often takes granularly (along) grain boundaries. It
down. The fractured zones created of- place at points where the passive layer results from the combined action of

80 WELDING JOURNAL / DECEMBER 2014


THE AMERICAN WELDER

Fig. 2 — Schematic of a fully integrated, inflatable weld-purge system for use in pipe and tube fabrication. These devices are available for di-
ameters between 25 and 2400 mm.

tensile stresses in the material and the Removal of Heat Tint reliable and versatile — Fig. 2.
presence of a corrosive medium. It can Considerable design effort has been
be induced in some stainless steels by Light discoloration can be removed applied by the designers and manufac-
adverse heat treatments, such as those by bright annealing or acid pickling, turers of these products over the past
occurring in weld heat-affected zones. but heavier deposits may require ma- decade or so, and currently available
chining such as grinding and polish- systems address the problems of con-
Crevice Corrosion ing. Removal clearly requires access to trolled inert gas pressure and flow, the
the area in question, not only for need for easy and rapid deployment
treatment but also for debris removal. and removal to limit overall welding
Crevice corrosion is localized corro-
Even when access is available, none of time, thermal resistance, and leak-
sion of a metal surface that is attribut-
these treatments is easy and most can tight access for oxygen-monitoring
able to close proximity of another met-
be expensive. equipment. They also provide a large
al such as a weld. It is a locally acceler-
pipe contact area and therefore excel-
ated type of corrosion and is one of
lent and reliable sealing.
the major corrosion hazards in stain-
less steels.
Weld Purging Coupled with these advantages
comes flexibility to allow access and
The alternative to potentially time- removal through pipe bends, abrasion
Microbiologically consuming, difficult, and expensive resistance, and the use of materials
Induced Corrosion cleaning of heat tint is to avoid it dur- that meet food, semiconductor, and
ing the welding process. This can be nuclear compliance standards.
Microbiologically induced corrosion undertaken by protecting the joint The Argweld® systems are examples
(MIC) is promoted or caused by micro- from oxidation by using an inert gas of fully integrated, inflatable purge
organisms, typically in industries related such as argon. The upper side of the equipment that can accommodate
to food, beverage, and chemical process- joint is protected by the inert gas used tube and pipe diameters from 25 to
ing. It is common in welded sections. in the torch. The underside, known as 2400 mm (Ref. 8).
To avoid these forms of corrosion, it the underbead, needs separate treat- Clearly, a knowledge of the oxygen
is essential that heat tints are properly ment. This technique is referred to as level in the purge gas is essential, rec-
removed before the stainless steel weld purging. ognizing that a level as low as 12 ppm
equipment or piping is exposed to ag- Seals are inserted on either side of may be necessary — Fig. 1A. This can
gressive or aqueous environments. The the weld root and inert gas is admitted be accommodated with an oxygen
alternative is to prevent heat tinting to displace air in the space between monitor, and sensitive versions of
during the welding process by using an them. While a wide range of options these have been developed specifically
inert environment to protect the sur- for sealing are available, those based for the welding industry. Commercial-
face. on inflatable seals have been found be ly available weld-purge monitors can

DECEMBER 2014 / WELDING JOURNAL 81


THE AMERICAN WELDER

combine monitoring down to 10 ppm suming that stainless steels are totally 5. Henon, B. K. 2008. Considera-
with software for data recording, resistant to corrosion can be risky. WJ tions for orbital welding of corrosion
analysis, and quality control. resistant materials to the ASME Bio-
References processing Equipment Standard. Pre-
Conclusion 1. Titz, J. T. Microbiologically in-
sented at the Stainless Steel America
Conference 2008 and available at
fluenced corrosion of stainless steel. www.arcmachines.com/applications.
During the last few years, the semi- Proceedings of the 2nd Symposium 6. Netten, G. Necessity of
conductor, bioprocessing, food and On Orbital Welding In High Purity In- removal of heat tints on stainless
beverage, and petrochemical indus- dustries, La Baule, France. steel to avoid or minimize corrosion.
tries in particular have revised their 2. Ammann, T. 2010. Purging Vecon Netherlands Technical Bulletin
weld-acceptance standards upward in while Welding. BOC Australia July 2005.
striving to manufacture products with Document. 7. Taban, E., et al. 2014. Effect of
impurity levels measured in nanome- 3. Grant, A., Henon, B. K., and the purging gas on properties of 304H
ters. The welding accessory manufac- Mansfeld, F. 1997. Effects of purge GTA welds. Welding Journal 93(4):
turers have responded by developing gas purity and Chelant passivation on 124-s to 130-s.
equipment capable of meeting these the corrosion resistance of orbitally 8. Huntingdon Fusion
standards, but increased use of this welded 316L stainless steel tubing. Techniques, Ltd, UK.
equipment is vital in the pursuit of Pharmaceutical Engineering 17 (1): www.huntingdonfusion.com.
quality. 1–13, (2): 46–54.
Industry sectors with demanding 4. Purge welding stainless steel for
standards for weld quality need to be cleanability and corrosion resistance.
aware of the corrosion hazards arising Food Processing Online. May 20, 2010. Michael Fletcher is CEO of Delta
Consultants, UK.
from poor welding practice. Simply as- www.foodprocessing.com.au.

For info, go to www.aws.org/ad­index

82 WELDING JOURNAL / DECEMBER 2014


THE AMERICAN WELDER

Welding Program Revitalized


A long-dormant welding program is given
new life, and inner-city students are on BY ANDREW CULLISON

track for a future in welding

W
hen Joe Williams graduated Many school districts looked on weld- erment jobs, shipyards, and even on
from the welding class at ing as dirty, expensive, and not a very the production set of Avatar: The Last
Philadelphia’s A. Philip Ran- good career path. The program became Airbender. “I was always getting calls
dolph Career and Technical High dormant until 2012 when Williams for welding jobs,” he said. “One day, I
School in 1986, little did he think that was hired to revive it. thought ‘if there is this great need for
he would come back to his old class- welders, who is teaching all these
room and sit at his teacher’s desk, no Fateful Call welders who are needed?’” That
longer a student, but the instructor thought motivated him to call the
running the program. Like many weld- Since his graduation, Williams nev- Philadelphia school district and in-
ing programs in the last 20 years, it er had a hard time finding a welding quire whether there were any welding
fell into disfavor and faded away. job. He’s worked in oil refineries, gov- jobs open. He got a positive response

Fig. 1 — Instructor Joe Williams and his welding class.

84 WELDING JOURNAL / DECEMBER 2014


THE AMERICAN WELDER

Fig. 2 — A student welding an Amnesty Box for the Philadelphia school district.

and immediately sent in his résumé. Admission is competitive. a partnership with the school would be
Within 30 days, he was approved and “Initially, the welding program was a good fit to help fulfill the future
signed up as the instructor who would not very popular and was considered need for welders,” said Stark. “It also
give a rebirth to the welding program. by the students not to be as ‘glam- presented a good social outreach for us
orous’ as other programs,” said and its close proximity to our head-
Williams. He exposed those initial quarters were favorable factors, but
Diverse Student classes to the many opportunities that what sealed the deal was meeting Mr.
Population welding careers provide, but it was Williams,” said Stark. “He was enthusi-
hard to get them hooked when the astic and dedicated to the program.”
A. Philip Randolph Career and equipment they were using to practice The deal involved providing new
Technical High School is a city-wide their skills dated back to when equipment and accessories for the
school servicing a diverse group of stu- Williams was a student. That problem welding lab. Through a partnership
dents from across Philadelphia. “In ad- was solved when a helping hand was with Miller Electric Co., Appleton,
dition to core academics, it offers nine offered from Airgas, Radnor, Pa. Wis., Airgas was able to provide new
programs of study, one of which is Miller welding machines and related
welding,” said Williams. “My students products. “Now the students could
learn all facets of the welding trade Partnership Jump perfect their skills on state-of-the-art
from reading blueprints to processes Starts Program equipment,” said Williams. “With
like shielded metal arc, gas metal arc, these industry collaborations, word
and flux cored arc welding.” Ron Stark, senior vice president of quickly spread through the school and
Students who attend the high sales and marketing for Airgas, came the community, and the welding pro-
school have to apply for admission. It in contact with Darryl Overton, princi- gram became the school’s premier of-
is a magnet school that is not restrict- pal of A. Philip Randolph High School, fering,” he continued. “This year, our
ed by neighborhood boundaries and who was passionate about restarting enrollment in the welding class has
accepts students from across the city. the welding program. “Airgas thought doubled from last year.”

DECEMBER 2014 / WELDING JOURNAL 85


THE AMERICAN WELDER

More than Equipment


The industry collaboration with Air-
gas wasn’t limited to just providing
equipment. Dave Schaffer, a welding
process specialist, provided his expert-
ise to what was needed to get the pro-
gram into the 21st century. Dan Ske-
han, director of automation, was avail-
able to offer advice, and Eric Smith, a
district manager in Airgas East region,
has been involved since 2013, and sits
on the school’s Occupational Advisory
Committee. They provided additional
help by getting donations of scrap, pro-
viding setup and training on the new
equipment, and organizing field trips
to various industries. “Airgas personnel
remain active in helping the program.
Recently, the City of Philadelphia and
its school district, along with represen-
tatives from Airgas, held a celebration
in the welding work area. “Airgas pro-
vides not only resources, but also men-
torship,” said Williams. “Their people
always take time to speak to my stu-
dents, drop off products, and give
workshops,” he continued.

Student Interest Grows


Williams presently has 45 students
in his class — Fig. 1. “Many students
were initially enrolled in other pro-
grams before transferring over to the
welding program,” said Williams.
Fig. 3 — A finished Amnesty Box designed and fabricated by Williams’ students.
“However, they made sacrifices and
took risks to join my program and
learn unfamiliar skills about an unfa- ters from parents thanking me be- First Graduating Class
miliar trade and industry,” he contin- cause they no longer have problems
ued. “Many of my students also make getting their child to school. They This year will see the first graduat-
daily sacrifices to learn their craft, in- want to go to welding class,” said ing class for 11 seniors. Williams has
cluding staying after school and forgo- Williams. “I think I was meant to be a 100% placement for all the graduates.
ing their lunch to have extra time. teacher; it has changed my life.” They will be starting jobs with various
They understand the long-term bene- local industries earning $12–16 to be-
fits and give up much of their in- Recognition gin. Three of his students already had
school socializing to dedicate them- full-time jobs lined up with PTR Baler
selves to welding,” said Williams. Williams’ class has gained recogni- Compacter, where they had been serv-
Many students come from unstable tion through the local newspaper and ing internships. “I constantly receive
home environments. “If not for the TV media. Recently, his class was com- calls from companies in dire need of
school-provided breakfast, some may missioned by the School District of welders.” As long as Williams contin-
not eat on a regular basis,” said Philadelphia to design and fabricate ues to inspire his students to do their
Williams. “Welding helps them focus (Fig. 2) Amnesty Boxes. These all- best, he will be able to meet those
their energy and attention beyond welded boxes (Fig. 3) are located out- needs. WJ
their current situation and into the fu- side persistently dangerous schools for
ture. I am very proud of the growth students to anonymously dispose of il-
and pride my students have for their legal contraband, such as drugs and
craft, but most importantly in them- weapons, with no questions asked.
selves.” “My students and I are very proud
“I found out I am not just a teacher, to be part of this program to reduce vi- ANDREW CULLISON is publisher,
but a mentor,” he said. “I have had let- olence,” said Williams. Welding Journal

86 WELDING JOURNAL / DECEMBER 2014


MAY
MAY 5-7,
5-7, 2015
2015
Cintermex,
Cin Monterrey,
termex, Monterrey, México
México

EVENTS
THE 4 EVEN TS LEADING THE METAL
FABRICATION INDUSTRY IN MONTERREY

258,000+
SQUARE FEET
OF FLOOR SPACE

TALKS
AND WORKSHOPS
LIVE
DEMONSTRATIONS

550
EXHIBITORS

For more information about registering


to attend or reserving booth space, go to

ww
www.fabtechmexico.com
w.fabtechmexico.com
THE AMERICAN WELDER

Considerations for Selecting


Shop Grinders
Detailed are five grinder tool
power sources and the author’s BY ADRIAN H. KRIEG

recommendations to shop owners

G
rinding in metal fabrication is
one of the most expensive and
time-consuming operations.
There are, however, many ways that
the fabricator can save time, effort,
and money to reduce the prohibitive
cost of grinding. While there are alter-
native means to grinding, including
weld preparation bevelers, and other
tools, this article is strictly related to
grinding.
The first consideration of a fabrica-
tor who employs many people in
grinding operations is what sort of
power tool, i.e., grinder, should they
be using. The first considerations are
the volume of work and the number of
employees who use grinding. If the
shop has more than five grinding sta-
tions, considerable savings can be real-
ized. There are several decisions to be Other Cost Factors moved from job to job, and offer rela-
made. tively good power-to-weight ratio.
In grinding operations, the issues However, they have the highest main-
Grinder Power Sources of paramount importance are mainte- tenance costs, and are heavier than
nance costs, power-to-weight ratio, some other options.
The market in power tools is huge, horsepower, speed (rev/min), total The pneumatically driven motors
but for specialty applications it is tool weight, and noise. commonly used industrially tend to be
much smaller than the common tool All of these can impact operator fa- noisy, have poorer power-to-weight ra-
market. For powering grinders, there tigue, which in grinding is an impor- tios, are expensive in power consump-
are the following five types of motors tant factor. While the grinding wheel tion, require frequent service, and do
currently available: makeup, binder, and grit size are also not operate at constant speeds.
• Universal 110-V, 60-Hz, single- important, this article assumes all are The squirrel cage three-phase in-
phase electric motor optimized for the task in question. duction motors are heavy and more
• Pneumatic (air-driven) motor Each of the five motor types has difficult to handle.
• Three-phase (squirrel cage) induc- certain advantages and shortcomings Hydraulic motors, while excellent
tion motor as follows: for some power tool applications, are
• Hydraulic (oil-liquid-driven) The universal 110-V, 60-Hz electric not suited to grinding operations at
• High-frequency, 300- to 360-Hz motors have these advantages. They all.
electric squirrel cage motors. can be used most any place, are easily Since the high-frequency or high-

88 WELDING JOURNAL / DECEMBER 2014


THE AMERICAN WELDER

cycle tools are not commonly used, an explode. For this reason, all air motors

WORK
W ORK
explanation is required. The three- used in grinding applications have
phase, 60-Hz induction motors oper- built-in governors. Another drawback
ate at 3600 rev/min. This speed is not is air tools are very noisy. The motor
high enough for industrial grinding exhaust noise is often louder than the
operations, which normally require a grinding noise. Consider also that air
speed of 16,000 surface ft/min. Note:
This is the optimum speed of a grind-
ing wheel at the point of contact,
which is approximately the speed of a
22-caliber bullet. High-frequency tools
operate at multiples of the line fre-
motors have very poor power curves.
As the load increases, the rev/min rap-
idly fall. Bear in mind that if optimum
speed (rev/min) of the grinding wheel
is not maintained, the output falls.
And lastly, air tools are heavy and
SSMART
MART
RT
quency, which in the United States is clumsy compared to modern high-
60 Hz. The multiples of 60 Hz are 60, frequency tools.
120, 180, 240, 300, 360, etc. The 120 The high-frequency-powered tools
and 180 Hz are too low, resulting in are by far the most satisfactory for
motor speeds of only 7200 and 10,800 grinding operations. The reasons are
rev/min, respectively. The optimum as follows: They offer the best weight-
speed for such a motor is from 18,000 to-power output, lowest weight-to-
to 21,600 rev/min. All commercial air- power ratio, highest rev/min, and low-
craft engines use 400-Hz motors due est maintenance requirements. In ad-
to weight and the fact they are not tied dition, they offer the lowest noise out-
to a 60-Hz original power source, they put and most favorable operator ac-
operate at about 25,000 rev/min. Air- ceptance. In shipbuilding, foundries,
craft motor information is mentioned and heavy fabrication where more
here to provide proof that the power- than ten grinders are employed, the
to-weight ratios and reliability for cost reductions and improved work
high-frequency tools are far and away output can pay for the equipment in Model 200 Positioner
the best for all power tools. less than 12 months.
It may be worthwhile to investigate
Comparing Two Power the cost to upgrade the equipment in
your shop. Start by getting quotes
Sources for Best from the high-frequency tool manu-
Operation facturers, which include Bosch, Fein,
AEG, and CP. The frequency convert-
The two most desirable power tool ers are available from GE, Westing-
grinding methods therefore require house, and Himmelwerke. The
secondary power sources. Pneumatic switchgear products are sold by Square
tools require a compressor, in most D and most electrical switchgear man-
cases, a screw compressor; and high- ufacturers.
frequency tools require a frequency Because the grinding speed is close-
converter. In both cases, there is appli- ly related to wheel consumption it is Model 1200 Pipemate
cable electric switchgear in environ- important to keep the grinding edge of
mentally and economically sound ap- the wheel running at the optimum
plications. Note the star-delta motor 16,000 surface speed per second
starter switches use less power when (SFPS). To maintain this speed, the
starting. user should purchase grinders with
These two comparative means of different operating speeds. For exam-
driving the power tool in question re- ple, for angle grinders, the most com-
quires us to consider their individual monly used grinder, purchase tools
rated at 6000 and 8500 rev/min, and
For info, go to www.aws.org/ad­index

characteristics.
Air-driven tools have very poor 9-in.-diameter wheels. As the wheel
ability to maintain constant speed. Air wears down to under 7 in. in diameter,
tool manufacturers try to compensate switch to the higher speed grinder to
for this using a motor-speed governor, maintain 16,000 SFPS constant speed
which complicates the motor design, at point of contact and get the best
but is absolutely necessary from a possible output. WJ
safety perspective. Without a gover-
nor, an excessive increase in air-line DR. ADRIAN H. KRIEG, CMFGE
(adriankrieg@A2ZPublications.com) is an
pressure could cause the motor to spin AWS Life Member. He is with
too fast causing the grinding wheel to A2Z Publications LLC, Bradenton, Fla.

DECEMBER 2014 / WELDING JOURNAL 89


THE AMERICAN WELDER LEARNING TRACK

R & S Welding Mentors Offers Small Classes and


Personalized Instruction
Experienced instructors share their expertise to train BY HOWARD M. WOODWARD
students for good­paying jobs in the Pacific Northwest HOWARD M. WOODWARD
(woodward@aws.org) is associate editor of
the Welding Journal.

At R & S Welding Mentors LLC, Mission Statement al professional goals.


Salem, Ore., instruction is targeted to The facility is a Private Career
training students for good-paying jobs R & S Welding Mentors’ mission is School licensed by the Oregon’s Higher
in the structural steel, fabrication, and to deliver specialized training for indi- Education Coordination Commission.
production industries that are currently viduals eager to learn welding and fab- Students first complete safety training
available in the Pacific Northwest rication skills for the 21st century. Its then receive instruction on setting up
region. The school offers both hands-on goal is to help young people, displaced welding machines for various consum-
performance-based training and AWS workers, and others receive the best in ables and welding parameters. Stu-
welding certification training and class welding skills, knowledge, and dents have the opportunity to begin
testing with special stress on workplace workforce competencies, to enable welding on their first day.
safety, and the skills necessary for them to secure high-paying jobs and The standards of the American
developing teamwork, and good work add value to the organizations they Welding Society are referenced
ethics. work for, while achieving their person- throughout the course material and

R & S Welding Mentors LLC management and teaching staff members are (from left) CWI Tom Welch, Instructors Tony Kummer and Milan
Pond, Owner James Stanton, Business Manager Koneta Stanton, Administrator Collette Myers, and CWI BJ Hutchins. All photos by Barry
Hutchins Photography, Salem, Ore.

90 WELDING JOURNAL / DECEMBER 2014


THE AMERICAN WELDER

tional welding processes. charge to all students who have com-


School owner James W. Stanton pleted the 15-week program.
said, “We teach SMA, FCA, GMA, and
GTA welding processes on mild steel, Additional Services
stainless steel, and aluminum. In addi-
tion, students learn torch cutting, Stanton said, “While a majority of
plasma cutting, and carbon arc, includ- our students seek instruction to pur-
ing setting the parameters and safety sue a career in welding, we also wel-
aspect for each process. come students who want to weld for
“Our training is performance- hobby or home repairs. Private tutor-
based. Each student is enabled to ing is also offered. Occasionally, a
move forward at his or her own pace welder may purchase a machine for
determined by their ability to learn personal use then ask us to help set it
and to meet the welding standards. We up and show them how to make the
try to keep each student challenged best use of their new equipment. We
and excited about moving forward. We can provide an instructor to help them
also strive to help students under- correctly assemble and determine the
stand the value of good work ethics parameters for its proper use.
and the value of relating to coworkers
Peter Frey practices his weld tacking
and being a team player.” Enrollment
Stanton noted that he has received
technique under James Stanton’s watch­
ful eye. calls from a number of former stu- Welding can be a demanding trade,
dents telling him how they have pro- so before being accepted for training
gressed in their careers in the welding each student is interviewed to deter-
the certification process.
industry. Hearing from them as they mine whether this training would be
As part of the students’ training in
receive raises and promotions over the appropriate for them, and to deter-
proper welding procedures, their in-
years and become financially self-suffi- mine what level of training is needed.
structors supplement their educations
cient is very rewarding. Applicants must be at least 18 years
with their personal experiences in the
“We encourage previous students to old, pass a drug test, be healthy
field and pass on some tricks of the
schedule a day in the welding lab enough to work an 8-h shift in all
trade based on their real world knowl-
whenever they have an interview weather conditions, have the ability to
edge of a cross section of the welding
scheduled for a welding job,” he added. lift at least 45 lb, work at times with
industry.
They can spend a day refreshing their arms elevated, have 20/20 vision, and
Most beginning students practice
skills so they can be better prepared possess the spatial and mechanical
the shielded metal arc (SMA) welding
for taking an employer’s weld test. perceptions required to safely perform
process first before advancing to learn-
This opportunity is offered free of the work. This interview may also in-
ing the gas metal arc (GMA) and/or
flux core arc (FCA) welding processes.
Students then are offered the opportu-
nity to learn either or both gas tung-
sten arc (GTA) and pipe welding pre-
sented as advanced courses. Upon
completion of instruction in these
processes, students can schedule a cer-
tification test at the school with CWI
BJ Hutchins of IQA (Inspection Quali-
ty Assurance).

Small Class Sizes


Students benefit from the school’s
small class sizes featuring a 6-to-1
student-instructor ratio. This provides
each student a lot of one-on-one at-
tention and enables trainees with no
previous welding experience to achieve
in just 15 weeks all the skills and con-
fidence necessary to succeed in an
entry-level position.
Graduates of the basic courses may
choose to continue their studies to be- James Stanton (left) and CWI BJ Hutchins prepare an outdoor welding project to give
come more proficient and learn addi- the students some simulated field experience.

DECEMBER 2014 / WELDING JOURNAL 91


THE AMERICAN WELDER

effectively shares his enthusiasm for


the welding trades with his classes.

Community Impact
Mari McGovern, a job developer
and training specialist at Careers NW,
said, “As a job developer for the Ore-
gon Vocational Rehabilitation Services
program, I have seen several of my
clients successfully complete welding
certificates of every kind at R&S Weld-
ing Mentors. Because my clients face
serious barriers to employment, from
physical and learning disabilities to
homelessness and felonies, just to
name a few, James Stanton and Busi-
ness Manager Koneta Stanton mentor
far beyond simply teaching them weld-
ing skills. They use a nonjudgmental,
gentle yet firm approach with them,
taking into consideration the welding
Practicing some team cooperation are (from left) Instructor Milan Pond, student Travis student’s underlying struggles and
Suek, and CWI BJ Hutchins. background to teach them both the
vocational and life skills necessary to
clude a skill assessment should the ap- school, continued welding training become a successful, contributing
plicant have welding experience. through high school, and graduated team member. As a result, many of the
Stanton said, “We strive to help with the skills to secure a journeyman companies I work with recruit their
each student set appropriate goals for welder position. He worked in many welding candidates directly through
their long-term career plans. Under- different aspects of the industry in- R&S.”
standing each student’s goals in the cluding production welding, as a jour- Graduate welding student Heather
welding industry helps us tailor their neyman shipwright, manufacturing, Clark agreed the instructors are help-
training on an individual basis. This crane operator/certified welder in ful, encouraging, and consistent every
enables each student to be more suc- bridge construction, and underground day. Their interaction with students is
cessful in his or her pursuit of employ- boring including pipe welding. During with the utmost respect and patience.
ment in the welding industry. his work in the industry, Stanton en- She especially liked the emphasis on
joyed teaching coworkers the art of time allocated to welding in the booth,
The Facility welding and fabrication. He is passion- which for her was the best way to de-
ate about teaching and helping stu- velop the skills she needed to acquire
The R & S Welding Mentors facility dents overcome barriers while devel- the various certifications. WJ
is equipped with 14 individual welding oping their strengths. “Welding,” he
booths with the latest state-of-the-art said, “is in my genes, being that I am
equipment. In addition, a number of the great-grandson of the famous R & S Welding Mentors LLC
older welding machines is maintained blacksmith Walter Stanton of the Contact
on site to familiarize students with the Charles Goodnight Ranch.” Koneta Stanton
earlier technology they may encounter Tom Welch, a Senior Certified Business Manager
while working in the field. The equip- Welding Inspector (SCWI) and a con- 1750 Oxford St. SE, Salem, OR 97302
ment training is occasionally supple- sultant for IMR KHA Portland Test Phone: (503) 884-3277
mented by demonstrations presented Labs and Steel Quality Specialists, e-mail; jwsteam@clear.net
by Ron Gross, district manager for shares his extensive experience and www.weldingmentors.com
Miller Electric who details the Dynasty knowledge of the welding industry to
350, and Les Nelson, district business students in his classes.
manager for Victor Technologies, who Milan Pond, a full time instructor,
displays the newest products in the is passionate about teaching and help-
Tweeco line. ing students overcome barriers while
developing their strengths. Pond is ex-
The Instructors perienced in the building construction,
automotive welding, fabrication, and
School owner James W. Stanton has ornamental ironwork industries.
an extensive background in the weld- Tony Kummer recently joined the
ing industry. He discovered his pas- staff as a part-time instructor. Kum-
sion for welding during junior high mer is a highly skilled GTA welder who

92 WELDING JOURNAL / DECEMBER 2014


THE AMERICAN WELDER FACT SHEET

Quality Considerations for Submerged Arc Welding

High-quality welds with fewer weld defects than other Incomplete Fusion
processes can be produced with submerged arc welding
(SAW) because of the excellent protection of the weld metal Incomplete fusion can occur at any depth of the weld. It
by the blanket of molten slag. As in other processes, howev- can occur between either the present or previous beads or
er, the problems of porosity, slag inclusions, incomplete fu- the bead and the bevel or groove faces. Specific conditions,
sion, and cracking occur in SAW. Following are some causes most of which inhibit the melting and the fusible contact
and remedies for the problems. between surfaces, may foster incomplete fusion. These con-
ditions include the following:
Porosity 1) Incorrect joint preparation or procedure
2) Presence of slag or oxide residue
Weld metal deposited with the SAW process is usually clean 3) Arc instability
and free of harmful porosity, but when porosity does occur, it 4) High travel speeds
may be found on the weld bead surface or beneath a sound 5) Insufficient heat input
surface. As with other welding processes, the base metal and 6) Improper displacement, angle, or position of the weld-
electrode must be clean and dry in SAW. High travel speeds ing head.
and associated fast weld metal solidification do not provide
time for gas to escape from the molten weld metal. The travel Cracking
speed can be reduced, but other solutions should be investigat-
ed to avoid higher welding costs. Porosity from covered elec- Weldment cracking is considered the most serious of dis-
trode tack welds can be avoided by using electrodes that leave continuities because of the potential for catastrophic service
no porosity-causing residue. Recommended tack weld elec- failure and the often-experienced difficulty in radiographic
trodes are E6010, E6011, E7015, E7016, and E7018. inspection. Cracking can be categorized according to several
criteria, including location [weld metal, heat-affected zone,
Inclusions or base metal cracking (hot or cold cracking)], but it is gen-
erally assumed to have two causes — an imposed strain and
An inclusion in a weld is defined as the entrapment of an inability to accommodate that strain.
solid foreign material such as slag, flux, or oxide. If not
properly applied, SAW is not immune to slag inclusions. In- Hot and Cold Cracking
clusions are primarily found in the root overlap or between
previous passes, and generally near bevel faces or groove The types of hot cracking include solidification, liquation,
faces. The risk of inclusions is greater under the following and stress-relief cracking. This discontinuity is usually asso-
conditions: ciated with the weld metal. Several conditions associated
1) In downhill orientations, which may allow the molten with strains and the ability to accommodate them, predomi-
flux to race ahead of the weld pool and then roll under to be- nantly of cross-sectional geometry and chemistry, follow:
come entrapped during solidification; 1) Excess depth-to-width ratio
2) In grooves along the edges of previously deposited 2) Excessive concavity (inability to accommodate strains),
beads, especially if they are convex; especially with fillet welds
3) If there is undercut along the edges of the weld bead; 3) Inadequate fill at weld bead stopping points (decreases
4) When arc destabilization inhibits the slag from rising ability to accommodate strain), which can cause crater
to the top of the solidifying weld pool; cracks
5) When a flux too high in viscosity is used, impeding the 4) Chemical contamination, especially from sulfur or
solidification of the weld pool; hydrocarbon-bearing compounds.
6) When a clean prior bead surface is not maintained; Excessive heat input may decrease the cooling rate and
7) In the case of improper welding head displacement, increase the time for metallurgical reactions in a crack-
particularly in the downhill orientation; susceptible temperature range.
8) In the case of reduced penetration due to reduced heat Like hot cracking, cold cracking manifests itself in a num-
input, supplemental wires or powders, increased electrode ber of ways. These include hydrogen-induced cracking or
extension, excessive travel speed, or reduced arc density; stress-corrosion cracking. Most cold cracking is associated
9) In the case of excessive travel speed, which causes with the heat-affected zone, base metal, or weld metal. WJ
faster cooling and may inhibit the slag from rising to the top
of the weld pool.

Excerpted from the Welding Handbook, 9th Edition, Volume 2, Welding Processes, Part 1.

94 WELDING JOURNAL / DECEMBER 2014


DISSIMILAR
DISSIM
IM
MILAR MATERIAL
MILAR MA
ATTERIAL
TER WELDING /
JOIN
OININ WORKSHOP
JOINING
American Welding
Welding Society ®
JANUARY
JA
JANUARRY 26,
2 2015
www
www.aws.org
.aws.org The Blackwell Inn and Conference Center at
at
State University
The Ohio State University,, Columbus, OH
The jjoiningg oof dissimilar ma materials
terials can present manmanyy challenges across a
number of induind
industr
industryy sectors inc luding automotive, petrochemical, power
including power
gen
eneratio
tion, medical products and microelectronics. This workshop is designed
generation, nedd to
descr
scrib
ribe the st
describe ate-of-the art in dissimilar join
state-of-the ing and will bring together exp
joining xpperts
pe
experts
in the fieldd to
t sshare their insight and experience. Topics Toopics will include
include process
proc
ocess
technolog
technology, y, ma aterials, design, and modeling. In addition to technical
materials, al
presentations
presenta ations byb experts
ex from academia and industr industry,
y, the works
workshop
rkshop will fea
feature
ature
a panel discussion that
sion thaat will provide aattendees
ttendeess the opportunity experts
nity to ask the exp
about their dissimilar
similar joining
joini
ning
ng problems.
problems The workshop will wi also feature
w feature a tour of
the welding labora tories aatt Ohio
laboratories hio Sta te University
State sity and
nd Edison W elding Institute.
Welding

Time
Tiime Event/Speaker Subject

7:45-8:30 Registration
Registration & Continental
Contin
Co tine Breakfast
Breakfast
8:30-8:45 old
John Lippold Introduct
Introductions
The Ohio State
io Sta
S te University
8:45-9:30 Johhhnn DuPont
John Tempera
eem ture Failure
High Temperature Failure of Austenitic to Ferritic
Ferritic
Lehigh
Le University Welds: Causes and Cures
Dissimilar Metal Welds:
9:30-10:15 Alexandrov
Boian Alexandrov Dissimilar Metal Overlays for Oil and Gas
State University
The Ohio State sityy AApplication
pplication
10:15-10
-10:30
10:15-10:30 Break
Break
100:30-11:15
10:3
0
10:30-11:15 McCracken
Steve McCracken Dissimila
laar Metal Joining in the PPower
Dissimilar ower Genera
ation
Generation
Electric PPower
ower Research Institute Industr
Industryy
11:15-12:00
11:15-12:0
2:00 Antonio Rameriz Joining Dissimilar e-based and Ni-based
lar FFe-based
State University
The Ohio State Materials by FSW
Materials
12:00-1:00 Lunch
Lunch
1:00-1:45 Jerr
erry Gould
Jerry Application
ion of Dissimilar Metals
Application Metal
tals Joining in the
Edison Welding
on Weelding Institute Automotive Industry
Industry
1:45-2:30 Daeh
ehn
Glenn Daehn Welding Technologies
Impact Welding Teechnologies for Dissimilar
Dissim
ssim
State Universi
The Ohio State sityy
University Ma terials
Materials
2:30-3:15 Tim Frech
Tim Frech materials joining in the
Dissimilar materials
Edison Weelding Institute
Welding tute medical and electronic industries
3:15-3:30 Break
Break
3:30-4:15 Wei Zhang
Wei Dissimilar Metal Joint of Titanium
Titanium to Stainless
State University
The Ohio State Literature Assessment and Numerical
Steel – Literature
Modeling
4:15-5:15 John Lippold Panel Discussion
Panel
State University
The Ohio State
WELDING JOURNAL INDEX

Part 1 — WELDING JOURNAL


SUBJECT INDEX
VOLUME 93

5, 4, 3, 2, 1...Getting the New Year’s Eve Ball Done! — K. Corrosion Hazard in Stainless Steel, Heat Tint Poses — M.
Campbell, (March) 90 Fletcher, (Dec) 80
A Must in Today’s Workplace: Weld-Quality Monitoring — DC Pulse Welding Machine, The Control System for a — H.
M. Albright, (Dec) 48 Zheng-Xiang, Y. Yan-Yan, X. Guo-Jian, and Z. Jing-Quan,
A Technology to Increase SAW Productivity — H. Raudsepp, (July) 36
(Dec) 46 Digital Systems Deliver Orbital Welding Consistency — S.
Abrasive Flap Disc, Tips for Selecting an — T. Hufford, Cole and K. Beardsley, (Sept) 50
(July) 32 Dispelling Automation Myths — D. Postlethwaite, (June) 68
Additive Manufacturing of Titanium, Exploring Arc Welding Dissimilar Metals, Explosion Welding of — D. J. Butler and
for — N. Kapustka and I. D. Harris, (March) 32 D. G. Brasher, (Nov) 40
Agents Gather, AWS International — K. Campbell, (May) 59 Dissimilar Welding Utilizing Nickel-Based Filler Metals — B.
Aluminum Brazing, What Matters Most in Vacuum — C. Gaal, M. Caruso, and S. Kiser, (Nov) 50
Moller and J. Grann, (Feb) 50 Education, The Future of Welding — W. R. Polanin, (April)
Analyzing the Physical Stress Welding Guns Create — C. Pe- 38
termann, K. Krüger, F. C. Mooren, and E. Schubert, (Aug) Effects of Buttering on High-Carbon Equivalent In-Service
50 Pipe — M. Dull and K. Forest, (Sept) 48
Anniversary Special: AWS at 95 — A. Cullison, M. R. Engineers, Meeting the Demand for Welding — D. Phillips,
Johnsen, H. Woodward, K. Campbell, and M. Gomez, A. Benatar, and J. C. Lippold, (Oct) 52
(June) 60 Equipment for Comfort and Efficiency, Selecting GMAW —
Army Offers Uncommon Career Path — (March) 96 J. Wells, (June) 122
Art of Upcycling: Welding Trash into Treasure, The — M. European Way, Welding Personnel Qualification the — L.
Gomez, (March) 86 Quintino, (April) 51
Automated Pipe Cutting, Making the Switch from Manual to Exploring Arc Welding for Additive Manufacturing of Tita-
— J. Henderson, (Sept) 40 nium — N. Kapustka and I. D. Harris, (March) 32
Automating a Wheel Manufacturing Operation — J. C. Explosion Welding of Dissimilar Metals — D. J. Butler and
Dutra, N. G. Bonacorso, D. Erdmann Dos Santos, M. H. D. G. Brasher, (Nov) 40
Hemmer, and R. H. Gonçalves E Silva, (June) 76 FABTECH 2013 — A. Cullison, K. Campbell, and M. R.
Automation Myths, Dispelling — D. Postlethwaite, (June) Johnsen, (Jan) 44
68 FABTECH Canada Shows Growth — A. Cullison, (June) 86
AWS International Agents Gather — K. Campbell, (May) 59 Fume Control, Questions You Need to Ask about — C. Brod-
Brazing a Honeycomb in Turbine Engines, Selecting Materi- nick and J. Lange, (Aug) 56
als for — D. Sporer and D. Fortuna, (Feb) 44 Fume Management in Your Shop, Weld — A. Felicijan and S.
Brazing Best Practices: 12 Tips for HVAC Technicians — C. Lowney, (Aug) 46
Cordia and G. Mitchell, (Nov) 62 Galvanized Steel with Metal-Cored Wire, Pairing — A.
Brazing Brightens Surface Finish, Controlled-Atmosphere D’Arcy, (Oct) 44
Induction — K. K. Kuhn and R. Detty, (Nov) 58 Genealogy, Tracing Our Welding — A. F. Manz, (June) 72
Brazing Ceramics to Titanium Using Amorphous Filler GMAW Efficiency through Shielding Gases, Improving — D.
Metal — Y. H. Liu, J. D. Hu, Z. X. Guo, and J. C. Li, (Nov) Sarma, (Dec) 40
66 Going beyond the Arc: Welding Program Teaches Teamwork
Business Briefs Profile: John Stropki — (Feb) 38 — B. Wehrman, (April) 48
Business Software Benefits — S. Leavitt, (Aug) 62 Grinders, Considerations for Selecting Shop — A. H. Krieg,
Buttering on High-Carbon Equivalent In-Service Pipe, (Dec) 88
Effects of — M. Dull and K. Forest, (Sept) 48 Grinding Pointers for a Safer Workplace — (July) 40
Canada, There’s More to See and Do at FABTECH — H. M. Guns Create, Analyzing the Physical Stress Welding — C. Pe-
Woodward, (March) 46 termann, K. Krüger, F. C. Mooren, and E. Schubert, (Aug)
Canada Shows Growth, FABTECH — A. Cullison, (June) 86 50
Ceramics to Titanium Using Amorphous Filler Metal, Braz- Hazard Communication, Changes Are Coming to — (Oct) 48
ing — Y. H. Liu, J. D. Hu, Z. X. Guo, and J. C. Li, (Nov) 66 Heat Tint Poses Corrosion Hazard in Stainless Steel — M.
Changes Are Coming to Hazard Communication — (Oct) 48 Fletcher, (Dec) 80
Career Path, Army Offers Uncommon — (March) 96 High-Carbon Equivalent In-Service Pipe, Effects of Butter-
Codes and Standards that Deal with Stainless Steels — R. ing on — M. Dull and K. Forest, (Sept) 48
Campbell, L. Sturgill, and W. Roth, (May) 44 High-Purity Welding for Hygienic Applications — W. Roth,
Considerations for Selecting Shop Grinders — A. H. Krieg, R. Campbell, B. Henon, and D. Avery, (Nov) 54
(Dec) 88 High-Purity Welding in the Biotechnology and Pharmaceuti-
Controlled-Atmosphere Induction Brazing Brightens cal Industries — R. Campbell, J. Dvorscek, C. Elkins, and
Surface Finish — K. K. Kuhn and R. Detty, (Nov) 58 W. Roth, (Nov) 44

96 WELDING JOURNAL / DECEMBER 2014


Hollywood Spotlight Shines on Welding — K. Campbell, Robotic Welding Supervisors, Tips for — R. Lizotte, (June)
(April) 32 126
HVAC Technicians, Brazing Best Practices: 12 Tips for — C. Rolling Induction Technology Provides Steady Heating — J.
Cordia and G. Mitchell, (Nov) 62 Ryan, (Sept) 44
Hygienic Applications, High-Purity Welding for — W. Roth, Rust on Stainless Steel Pipes, Preventing — W. C. LaPlante,
R. Campbell, B. Henon, and D. Avery, (Nov) 54 (Sept) 100
Improving GMAW Efficiency through Shielding Gases — D. Safer Workplace, Grinding Pointers for a — (July) 40
Sarma, (Dec) 40 Safety, Improving Welder — D. Thornton, (March) 36
Improving Welder Safety — D. Thornton, (March) 36 Safety, The Basics of Thermal Spray — D. Hayden, (July) 29
Induction Technology Provides Steady Heating, Rolling — J. SAW Productivity, A Technology to Increase — H.
Ryan, (Sept) 44 Raudsepp, (Dec) 46
In-Line Inspection of Resistance Spot Welds for Sheet Metal Selecting GMAW Equipment for Comfort and Efficiency —
Assembly — R. Gr. Maev, A. M. Chertov, W. Perez Regal- J. Wells, (June) 122
ado, A. Karloff, A. Tchipilko, P. Lichaa, D. Clement, and T. Selecting Materials for Brazing a Honeycomb in Turbine En-
Phan, (Jan) 58 gines — D. Sporer and D. Fortuna, (Feb) 44
John Stropki, Business Briefs Profile: — (Feb) 34 Sheet Metal Assembly, In-Line Inspection of Resistance Spot
Lights, Camera...Welding — S. Skrjanc and G. Coleman, Welds for — R. Gr. Maev, A. M. Chertov, W. Perez Regal-
(April) 42 ado, A. Karloff, A. Tchipilko, P. Lichaa, D. Clement, and T.
Making Sense of Welding Procedure Qualification — R. L. Phan, (Jan) 58
Holdren, (May) 50 Sheet Metal Grades and Gauges, Spot Welding Different —
Making the Switch from Manual to Automated Pipe Cutting E. Biro, L. Cretteur, and T. Dupuy, (Jan) 38
— J. Henderson, (Sept) 40 Shielding Gases, Improving GMAW Efficiency through — D.
Manganese Exposure Means to You, What the Recent Sarma, (Dec) 40
Recommendation on — D. Clark, (Aug) 36 Software Benefits, Business — S. Leavitt, (Aug) 62
Manufacturing, Taking the Next Step in Additive — R. Mar- Software is Best for Your Business?, Which Nesting — D.
tukanitz and J. Hollingsworth, (March) 40 Wood, (Aug) 42
Meeting the Demand for Welding Engineers — D. Phillips, Spot Welding Different Sheet Metal Grades and Gauges —
A. Benatar, and J. C. Lippold, (Oct) 52 E. Biro, L. Cretteur, and T. Dupuy, (Jan) 38
Monitoring, A Must in Today’s Workplace: Weld-Quality — Stainless Steel, Heat Tint Poses Corrosion Hazard in — M.
M. Albright, (Dec) 48 Fletcher, (Dec) 80
NASA, Welding Technology Takes Flight with — C. Russell, Stainless Steel Pipes, Preventing Rust on — W. C. LaPlante,
J. Ding, A. Nunes, and K. Lawless, (May) 38 (Sept) 100
New Year’s Eve Ball Done!, 5, 4, 3, 2, 1... Getting the — K. Stainless Steel to Carbon Steel, Tips for Successfully Welding
Campbell, (March) 90 — D. Benson, (May) 54
Nickel-Based Filler Metals, Dissimilar Welding Utilizing — Stainless Steels, Codes and Standards that Deal with — R.
B. Gaal, M. Caruso, and S. Kiser, (Nov) 50 Campbell, L. Sturgill, and W. Roth, (May) 44
Orbital Welding Consistency, Digital Systems Deliver — S. Standards that Deal with Stainless Steels, Codes and — R.
Cole and K. Beardsley, (Sept) 50 Campbell, L. Sturgill, and W. Roth, (May) 44
Pairing Galvanized Steel with Metal-Cored Wire — A. Study of Underwater Friction Welding Technology — G.
D’Arcy, (Oct) 44 Hui, J. Xiang-Dong, X. Ya-Guo, and Z. Can-Feng, (Sept)
Pharmaceutical Industries, High-Purity Welding in the 54
Biotechnology and — R. Campbell, J. Dvorscek, C. Elkins, Taking the Next Step in Additive Manufacturing — R. Mar-
and W. Roth, (Nov) 44 tukanitz and J. Hollingsworth, (March) 40
Pipe Cutting, Making the Switch from Manual to Automated Teaches Teamwork, Going beyond the Arc: Welding Program
— J. Henderson, (Sept) 40 — B. Wehrman, (April) 48
Positioner, Tips for Selecting a — C. White, (Feb) 34 The Art of Upcycling: Welding Trash into Treasure — M.
Positioner Do for You?, What Can a Welding — Ditteinrich Gomez, (March) 86
II, (Feb) 42 The Basics of Thermal Spray Safety — D. Hayden, (July) 29
Preheating 4130?, What is the Best Method for — J. Walker, The Control System for a DC Pulse Welding Machine — H.
D. Hebble, and R. Holdren, (Jan) 52 Zheng-Xiang, Y. Yan-Yan, X. Guo-Jian, and Z. Jing-Quan,
Preventing Rust on Stainless Steel Pipes — W. C. LaPlante, (July) 36
(Sept) 100 The Future of Welding Education — W. R. Polanin, (April) 38
Procedure Qualification, Making Sense of Welding — R. L. There’s More to See and Do at FABTECH Canada — H. M.
Holdren, (May) 50 Woodward, (March) 46
Qualification the European Way, Welding Personnel — L. Thermal Spray Safety, The Basics of — D. Hayden, (July) 29
Quintino, (April) 51 Tips for HVAC Technicians, Brazing Best Practices: 12 — C.
Questions You Need to Ask about Fume Control — C. Brod- Cordia and G. Mitchell, (Nov) 62
nick and J. Lange, (Aug) 56 Tips for Robotic Welding Supervisors — R. Lizotte, (June)
Repair Historic Navy Ship, Volunteers — M. Gomez, (Sept) 126
96 Tips for Selecting a Positioner — C. White, (Feb) 34
Resistance Spot Welds for Sheet Metal Assembly, In-Line In- Tips for Selecting an Abrasive Flap Disc — T. Hufford, (July)
spection of — R. Gr. Maev, A. M. Chertov, W. Perez Regal- 32
ado, A. Karloff, A. Tchipilko, P. Lichaa, D. Clement, and T. Tips for Successfully Welding Stainless Steel to Carbon Steel
Phan, (Jan) 58 — D. Benson, (May) 54

DECEMBER 2014 / WELDING JOURNAL 97


Titanium, Exploring Arc Welding for Additive Manufactur- Quintino, (April) 51
ing of — N. Kapustka and I. D. Harris, (March) 32 Welding Program Revitalized — A. Cullison, (Dec) 84
Titanium Using Amorphous Filler Metal, Brazing Ceramics What Can a Welding Positioner Do for You? — D. Heinrich
to — Y. H. Liu, J. D. Hu, Z. X. Guo, and J. C. Li, (Nov) 66 II, (Feb) 42
Tracing Our Welding Genealogy — A. F. Manz, (June) 72 Welding Technology Takes Flight with NASA — C. Russell, J.
Turbine Engines, Selecting Materials for Brazing a Ding, A. Nunes, and K. Lawless, (May) 38
Honeycomb in — D. Sporer and D. Fortuna, (Feb) 44 What Is the Best Method for Preheating 4130? — J. Walker,
Underwater Friction Welding Technology, Study of — G. D. Hebble, and R. Holdren, (Jan) 52
Hui, J. Xiang-Dong, X. Ya-Guo, and Z. Can-Feng, (Sept) What Matters Most in Vacuum Aluminum Brazing — C.
54 Moller and J. Grann, (Feb) 50
Volunteers Repair Historic Navy Ship — M. Gomez, (Sept) What the Recent Recommendation on Manganese Exposure
96 Means to You — D. Clark, (Aug) 36
Weld Fume Management in Your Shop — A. Felicijan and S. Wheel Manufacturing Operation, Automating a — J. C.
Lowney, (Aug) 46 Dutra, N. G. Bonacorso, D. Erdmann Dos Santos, M. H.
Welding for Unique Industries — M. R. Johnsen and K. Hemmer, and R. H. Gonçalves E Silva, (June) 76
Campbell, (July) 44 Which Nesting Software is Best for Your Business? — D.
Welding Personnel Qualification the European Way — L. Wood, (Aug) 42

AUTHORS FOR FEATURE ARTICLES

Albright, M. — A Must in Today’s Workplace: Weld-Quality Study of Underwater Friction Welding Technology, (Sept)
Monitoring, (Dec) 48 54
Avery, D., Roth, W., Campbell, R., and Henon, B. — High- Caruso, M., Kiser, S., and Gaal, B. — Dissimilar Welding Uti-
Purity Welding for Hygienic Applications, (Nov) 54 lizing Nickel-Based Filler Metals, (Nov) 50
Beardsley, K., and Cole, S. — Digital Systems Deliver Orbital Chertov, A. M., Perez Regalado, W., Karloff, A., Tchipilko, A.,
Welding Consistency, (Sept) 50 Lichaa, P., Clement, D., Phan, T., and Maev, R. Gr. — In-
Benatar, A., Lippold, J. C., and Phillips, D. — Meeting the De- Line Inspection of Resistance Spot Welds for Sheet Metal
mand for Welding Engineers, (Oct) 52 Assembly, (Jan) 58
Benson, D. — Tips for Successfully Welding Stainless Steel to Clark, D. — What the Recent Recommendation on
Carbon Steel, (May) 54 Manganese Exposure Means to You, (Aug) 36
Biro, E., Cretteur, L., and Dupuy, T. — Spot Welding Clement, D., Phan, T., Maev, R. Gr., Chertov, A. M., Perez Re-
Different Sheet Metal Grades and Gauges, (Jan) 38 galado, W., Karloff, A., Tchipilko, A., and Lichaa, P. — In-
Bonacorso, N. G., Erdmann Dos Santos, D., Hemmer, M. H., Line Inspection of Resistance Spot Welds for Sheet Metal
Gonçalves E Silva, R. H., and Dutra, J. C. — Automating a Assembly, (Jan) 58
Wheel Manufacturing Operation, (June) 76 Cole, S., and Beardsley, K. — Digital Systems Deliver Orbital
Brasher, D. G., and Butler, D. J. — Explosion Welding of Dis- Welding Consistency, (Sept) 50
similar Metals, (Nov) 40 Coleman, G., and Skrjanc, S. — Lights, Camera...Welding,
Brodnick, C., and Lange, J. — Questions You Need to Ask (April) 38
about Fume Control, (Aug) 56 Cordia, C., and Mitchell, G. — Brazing Best Practices: 12 Tips
Butler, D. J., and Brasher, D. G. — Explosion Welding of Dis- for HVAC Technicians, (Nov) 62
similar Metals, (Nov) 40 Cretteur, L., Dupuy, T., and Biro, E. — Spot Welding
Campbell, K. — 5, 4, 3, 2, 1...Getting the New Year’s Eve Ball Different Sheet Metal Grades and Gauges, (Jan) 38
Done!, (March) 90 Cullison, A. — FABTECH Canada Shows Growth, (June) 86
Campbell, K. — AWS International Agents Gather, (May) 59 Cullison, A. — Welding Program Revitalized, (Dec) 84
Campbell, K. — Hollywood Spotlight Shines on Welding, Cullison, A., Johnsen, M. R., Woodward, H., Campbell, K.,
(April) 32 and Gomez, M. — Anniversary Special: AWS at 95, (June)
Campbell, K., Gomez, M., Cullison, A., Johnsen, M. R., and 60
Woodward, H. — Anniversary Special: AWS at 95, (June) Cullison, A., Campbell, K., and Johnsen, M. R. — FABTECH
60 2013, (Jan) 44
Campbell, K., and Johnsen, M. R. — Welding for Unique In- D’Arcy, A. — Pairing Galvanized Steel with Metal-Cored
dustries, (July) 44 Wire, (Oct) 44
Campbell, K., Johnsen, M. R., and Cullison, A. — FABTECH Detty, R., and Kuhn, K. K. — Controlled-Atmosphere Induc-
2013, (Jan) 44 tion Brazing Brightens Surface Finish, (Nov) 58
Campbell, R., Sturgill, L., and Roth, W. — Codes and Ding, J., Nunes, A., Lawless, K., and Russell, C. — Welding
Standards that Deal with Stainless Steels, (May) 44 Technology Takes Flight with NASA, (May) 38
Campbell, R., Henon, B., Avery, D., and Roth, W. — High- Dull, M., and Forest, K. — Effects of Buttering on High-
Purity Welding for Hygienic Applications, (Nov) 54 Carbon-Equivalent In-Service Pipe, (Sept) 48
Campbell, R., Dvorscek, J., Elkins, C., and Roth, W. — High- Dupuy, T., Biro, E., and Cretteur, L. — Spot Welding
Purity Welding in the Biotechnology and Pharmaceutical Different Sheet Metal Grades and Gauges, (Jan) 38
Industries, (Nov) 44 Dutra, J. C., Bonacorso, N. G., Erdmann Dos Santos, D.,
Can-Feng, Z., Hui, G., Xiang-Dong, J., and Ya-Guo, X. — Hemmer, M. H., and Gonçalves E Silva, R. H. — Automat-

98 WELDING JOURNAL / DECEMBER 2014


ing a Wheel Manufacturing Operation, (June) 76 Study of Underwater Friction Welding Technology, (Sept)
Dvorscek, J., Elkins, C., Roth, W., and Campbell, R. — High- 54
Purity Welding in the Biotechnology and Pharmaceutical Jing-Quan, Z., Zheng-Xiang, H., Yan-Yan, Y., and Guo-Jian,
Industries, (Nov) 44 X. — The Control System for a DC Pulse Welding
Elkins, C., Roth, W., Campbell, R., and Dvorscek, J. — High- Machine, (July) 36
Purity Welding in the Biotechnology and Pharmaceutical Johnsen, M. R., Woodward, H., Campbell, K., Gomez, M.,
Industries, (Nov) 44 and Cullison, A. — Anniversary Special: AWS at 95,
Erdmann Dos Santos, D., Hemmer, M. H., Gonçalves E Silva, (June) 60
R. H., Dutra, J. C., and Bonacorso, N. G. — Automating a Johnsen, M. R., Cullison, A., and Campbell, K. — FABTECH
Wheel Manufacturing Operation, (June) 76 2013, (Jan) 44
Felicijan, A., and Lowney, S. — Weld Fume Management in Johnsen, M. R., and Campbell, K. — Welding for Unique In-
Your Shop, (Aug) 46 dustries, (July) 44
Fletcher, M. — Heat Tint Poses Corrosion Hazard in Stain- Kapustka, N., and Harris, I. D. — Exploring Arc Welding for
less Steel, (Dec) 80 Additive Manufacturing of Titanium, (March) 32
Forest, K., and Dull, M. — Effects of Buttering on High- Karloff, A., Tchipilko, A., Lichaa, P., Clement, D., Phan, T.,
Carbon-Equivalent In-Service Pipe, (Sept) 48 Maev, R. Gr., Chertov, A. M., and Perez Regalado, W. —
Fortuna, D., and Sporer, D. — Selecting Materials for Braz- In-Line Inspection of Resistance Spot Welds for Sheet
ing a Honeycomb in Turbine Engines, (Feb) 44 Metal Assembly, (Jan) 58
Gaal, B., Caruso, M., and Kiser, S. — Dissimilar Welding Uti- Kiser, S., Gaal, B., and Caruso, M. — Dissimilar Welding Uti-
lizing Nickel-Based Filler Metals, (Nov) 50 lizing Nickel-Based Filler Metals, (Nov) 50
Gomez, M., Cullison, A., Johnsen, M. R., Woodward, H., and Krieg, A. H. — Considerations for Selecting Shop Grinders,
Campbell, K. — Anniversary Special: AWS at 95, (June) (Dec) 88
60 Krüger, K., Mooren, F. C., Schubert, E., and Petermann, C.
Gomez, M. — The Art of Upcycling: Welding Trash into — Analyzing the Physical Stress Welding Guns Create,
Treasure, (March) 86 (Aug) 50
Gomez, M. — Volunteers Repair Historic Navy Warship, Kuhn, K. K., and Detty, R. — Controlled-Atmosphere Induc-
(Sept) 96 tion Brazing Brightens Surface Finish, (Nov) 58
Gonçalves E Silva, R. H., Dutra, J. C., Bonacorso, N. G., Erd- Lange, J., and Brodnick, C. — Questions You Need to Ask
mann Dos Santos, D., and Hemmer, M. H. — Automating about Fume Control, (Aug) 56
a Wheel Manufacturing Operation, (June) 76 LaPlante, W. C. — Preventing Rust on Stainless Steel Pipes,
Grann, J., and Moller, C. — What Matters Most in Vacuum (Sept) 100
Aluminum Brazing, (Feb) 50 Lawless, K., Russell, C., Ding, J., and Nunes, A. — Welding
Guo-Jian, X., Jing-Quan, Z., Zheng-Xiang, H., and Yan-Yan, Technology Takes Flight with NASA, (May) 38
Y. — The Control System for a DC Pulse Welding Leavitt, S. — Business Software Benefits, (Aug) 62
Machine, (July) 36 Li, J. C., Liu, Y. H., Hu, J. D., and Guo, Z. X. — Brazing
Guo, Z. X., Li, J. C., Liu, Y. H., and Hu, J. D. — Brazing Ceramics to Titanium Using Amorphous Filler Metal,
Ceramics to Titanium Using Amorphous Filler Metal, (Nov) 66
(Nov) 66 Lichaa, P., Clement, D., Phan, T., Maev, R. Gr., Chertov, A.
Harris, I. D., and Kapustka, N. — Exploring Arc Welding for M., Perez Regalado, W., Karloff, A., and Tchipilko, A. —
Additive Manufacturing of Titanium, (March) 32 In-Line Inspection of Resistance Spot Welds for Sheet
Hayden, D. — The Basics of Thermal Spray Safety, (July) 29 Metal Assembly, (Jan) 58
Hebble, D., Holdren, R., and Walker, J. — What is the Best Lippold, J. C., Phillips, D., and Benatar, A. — Meeting the
Method for Preheating 4130?, (Jan) 52 Demand for Welding Engineers, (Oct) 52
Heinrich II, D. — What Can a Welding Positioner Do for Liu, Y. H., Hu, J. D., Guo, Z. X., and Li, J. C. — Brazing
You?, (Feb) 42 Ceramics to Titanium Using Amorphous Filler Metal,
Hemmer, M. H., Gonçalves E Silva, R. H., Dutra, J. C., Bona- (Nov) 66
corso, N. G., and Erdmann Dos Santos, D. — Automating Lizotte, R. — Tips for Robotic Welding Supervisors, (June)
a Wheel Manufacturing Operation, (June) 76 126
Henderson, J. — Making the Switch from Manual to Auto- Lowney, S., and Felicijan, A. — Weld Fume Management in
mated Pipe Cutting, (Sept) 40 Your Shop, (Aug) 46
Henon, B., Avery, D., Roth, W., and Campbell, R. — High- Maev, R. Gr., Chertov, A. M., Perez Regalado, W., Karloff, A.,
Purity Welding for Hygienic Applications, (Nov) 54 Tchipilko, A., Lichaa, P., Clement, D., and Phan, T. — In-
Holdren, R. L. — Making Sense of Welding Procedure Quali- Line Inspection of Resistance Spot Welds for Sheet Metal
fication, (May) 50 Assembly, (Jan) 58
Holdren, R., Walker, J., and Hebble, D. — What is the Best Manz, A. F. — Tracing Our Welding Genealogy, (June) 72
Method for Preheating 4130?, (Jan) 52 Martukanitz, R., and Hollingsworth, J. — Taking the Next
Hollingsworth, J., and Martukanitz, R. — Taking the Next Step in Additive Manufacturing, (March) 40
Step in Additive Manufacturing, (March) 40 Mitchell, G., and Cordia, C. — Brazing Best Practices: 12
Hu, J. D., Guo, Z. X., Li, J. C., and Liu, Y. H. — Brazing Tips for HVAC Technicians, (Nov) 62
Ceramics to Titanium Using Amorphous Filler Metal, Moller, C., and Grann, J. — What Matters Most in Vacuum
(Nov) 66 Aluminum Brazing, (Feb) 50
Hufford, T. — Tips for Selecting an Abrasive Flap Disc, Mooren, F. C., Schubert, E., Petermann, C., and Krüger, K.
(July) 32 — Analyzing the Physical Stress Welding Guns Create,
Hui, G., Xiang-Dong, J., Ya-Guo, X., and Can-Feng, Z. — (Aug) 50

DECEMBER 2014 / WELDING JOURNAL 99


Nunes, A., Lawless, K., Russell, C., and Ding, J. — Welding (Aug) 50
Technology Takes Flight with NASA, (May) 38 Skrjanc, S., and Coleman, G. — Lights, Camera...Welding,
Perez Regalado, W., Karloff, A., Tchipilko, A., Lichaa, P., (April) 42
Clement, D., Phan, T., Maev, R. Gr., and Chertov, A. M. — Sporer, D., and Fortuna, D. — Selecting Materials for Braz-
In-Line Inspection of Resistance Spot Welds for Sheet ing a Honeycomb in Turbine Engines, (Feb) 44
Metal Assembly, (Jan) 58 Sturgill, L., Roth, W., and Campbell, R. — Codes and
Pettermann, C., Krüger, K., Mooren, F. C., and Schubert, E. Standards that Deal with Stainless Steels, (May) 44
— Analyzing the Physical Stress Welding Guns Create, Tchipilko, A., Lichaa, P., Clement, D., Phan, T., Maev, R. Gr.,
(Aug) 50 Chertov, A. M., Perez Regalado, W., and Karloff, A. — In-
Phan, T., Maev, R. Gr., Chertov, A. M., Perez Regalado, W., Line Inspection of Resistance Spot Welds for Sheet Metal
Karloff, A., Tchipilko, A., Lichaa, P., and Clement, D. — Assembly, (Jan) 58
In-Line Inspection of Resistance Spot Welds for Sheet Thornton, D. — Improving Welder Safety, (March) 36
Metal Assembly, (Jan) 58 Walker, J., Hebble, D., and Holdren, R. — What is the Best
Phillips, D., Benatar, A., and Lippold, J. C. — Meeting the Method for Preheating 4130?, (Jan) 52
Demand for Welding Engineers, (Oct) 52 Wehrman, B. — Going beyond the Arc: Welding Program
Polanin, W. R. — The Future of Welding Education, (April) Teaches Teamwork, (April) 48
38 Wells, J. — Selecting GMAW Equipment for Comfort and
Postlethwaite, D. — Dispelling Automation Myths, (June) Efficiency, (June) 122
68 White, C. — Tips for Selecting a Positioner, (Feb) 34
Quintino, L. — Welding Personnel Qualification the Wood, D. — Which Nesting Software Is Best for Your Busi-
European Way, (April) 51 ness?, (Aug) 42
Raudsepp, H. — A Technology to Increase SAW Productiv- Woodward, H., Campbell, K., Gomez, M., Cullison, A., and
ity, (Dec) 46 Johnsen, M. R. — Anniversary Special: AWS at 95, (June)
Roth, W., Campbell, R., and Sturgill, L. — Codes and 60
Standards that Deal with Stainless Steels, (May) 44 Woodward, H. M. — There’s More to See and Do at
Roth, W., Campbell, R., Henon, B., and Avery D. — High-Pu- FABTECH Canada, (March) 46
rity Welding for Hygienic Applications, (Nov) 54 Xiang-Dong, J., Ya-Guo, X., Can-Feng, Z., and Hui, G. —
Roth, W., Campbell, R., Dvorscek, J., and Elkins, C. — High- Study of Underwater Friction Welding Technology, (Sept)
Purity Welding in the Biotechnology and Pharmaceutical 54
Industries, (Nov) 44 Ya-Guo, X., Can-Feng, Z., Hui, G., and Xiang-Dong, J. —
Russell, C., Ding, J., Nunes, A., and Lawless, K. — Welding Study of Underwater Friction Welding Technology, (Sept)
Technology Takes Flight with NASA, (May) 38 54
Ryan, J. — Rolling Induction Technology Provides Steady Yan-Yan, Y., Guo-Jian, X., Jing-Quan, Z., and Zheng-Xiang,
Heating, (Sept) 44 H. — The Control System for a DC Pulse Welding
Sarma, D. — Improving GMAW Efficiency through Machine, (July) 36
Shielding Gases, (Dec) 40 Zheng-Xiang, H., Yan-Yan, Y., Guo-Jian, X., and Jing-Quan,
Schubert, E., Petermann, C., Krüger, K., and Mooren, F. C. Z. — The Control System for a DC Pulse Welding
— Analyzing the Physical Stress Welding Guns Create, Machine, (July) 36

Part 2 – RESEARCH
SUPPLEMENT SUBJECT INDEX
VOLUME 93

A Study on the Surface Depression of the Molten Pool with Aluminum Weld Metal: Part 1 — Grain Morphology Depend-
Pulsed Welding — M. Yang, Z. Yang, B. Cong, and B. Qi, ent upon Alloy Composition and Grain Refiner Content, So-
(Aug) 312-s lidification of GTA — P. Schempp, C. E. Cross, A. Pittner, G.
Active Metal Transfer Control by Utilizing Enhanced Droplet Oder, R. S. Neumann, H. Rooch, I. Dörfel, W. Österle, and
Oscillation Part 1: Experimental Study — J. Xiao, G. J. M. Rethmeier, (Feb) 53-s
Zhang, W. J. Zhang, and Y. M. Zhang, (Aug) 292-s Aluminum Weld Metal: Part 2 — Thermal Conditions and
Active Metal Transfer Control by Utilizing Enhanced Droplet Model for Columnar-to-Equiaxed Transition, Solidification
Oscillation Part II: Modeling and Analysis — J. Xiao, G. J. of GTA — P. Schempp, C. E. Cross, A. Pittner, and M. Reth-
Zhang, W. J. Zhang, and Y. M. Zhang, (Sept) 321-s meier, (March) 69-s
Aluminum Alloy 2-mm-Thick Sheets Using Ultrasonic Spot Analysis of the Local Stresses at Laser-Welded Lap Joints —
Welding, Joining 5754 Automotive — C. Y. Zhang, D. L. K. D. Lee, K. I. Ho, and K. Y. Park, (Sept) 351-s
Chen, and A. A. Luo, (April) 131-s Arcs by the Schlieren Measuring Technique, Visualization of
Aluminum to Magnesium with Zn-Coated Steel Interlayers, Gas Flows in Welding — E. Siewert, G. Wilhelm, M. Hässler,
Dissimilar Resistance Spot Welding of — P. Penner, L. Liu, J. Schein, T. Hanson, M. Schnick, and U. Füssel, (Jan) 1-s
A. Gerlich, and Y. Zhou, (June) 225-s Barium Titanate Ceramics, Wettability by Liquid Metals, Met-
Aluminum to Steel, Pulsed Double-Electrode GMAW-Brazing alization, and Brazing of — T. V. Sydorenko and Yu. V.
for Joining of — Y. Shi, G. Zhang, Y. Huang, L. Lu, J. Naidich, (Jan) 6-s
Huang, and Y. Shao, (June) 216-s Boron Steels with Various Coatings, Weldability of CMT Join-

100 WELDING JOURNAL / DECEMBER 2014


ing of AA6061-T6 to — R. Cao, J. H. Sun, J. H. Chen, and Zhang, (July) 253-s
P.-C. Wang, (June) 193-s Cutting Discs, Evaluation of Triangular, Engineered-Shape
Brazing for Joining of Aluminum to Steel, Pulsed Double- Ceramic Abrasive in — J. Badger, (April) 107-s
Electrode GMAW- — Y. Shi, G. Zhang, Y. Huang, L. Lu, J. Development of High-Cr, Ni-Based Filler Metals Using Com-
Huang, and Y. Shao, (June) 216-s bined Computational and Experimental Techniques — E.
Brazing Joints, The Microstructure and Strength of Copper W. Fusner, A. T. Hope, and J. C. Lippold, (May) 171-s
Alloy — A. Hasap, N. Noraphaiphipaksa, and C. Diffusion Brazing Metallurgy of IN718/Ni-Cr-Si-B-Fe/IN718
Kanchanomai, (April) 116-s — M. Pouranvari, A. Ekrami, and A. H. Kokabi, (Feb) 60-s
Brazing of Barium Titanate Ceramics, Wettability by Liquid Dissimilar Resistance Spot Welding of Aluminum to Magne-
Metals, Metalization, and — T. V. Sydorenko and Yu. V. sium with Zn-Coated Steel Interlayers — P. Penner, L. Liu,
Naidich, (Jan) 6-s A. Gerlich, and Y. Zhou, (June) 225-s
Brazing of CMSX-4 with a Boron- and Silicon-Free Ni-Co-Zr- Distortion, Material Strength Effect on Weld Shrinkage and
Hf-Cr-Ti-Al Brazing Alloy — X. Huang, (July) 233-s — Y. P. Yang, R. Dull, H. Castner, T. D. Huang, and D. Fan-
Brazing Metallurgy of IN718/Ni-Cr-Si-B-Fe/IN718, Diffusion guy, (Nov) 421-s
— M. Pouranvari, A. Ekrami, and A. H. Kokabi, (Feb) 60-s Double-Electrode GMAW-Brazing for Joining of Aluminum to
Carbon Steel-Duplex Stainless Steel GTA Weld Pool, Modeling Steel, Pulsed — Y. Shi, G. Zhang, Y. Huang, L. Lu, J. Huang,
of — A. Bahrami and D. K. Aidun, (July) 262-s and Y. Shao, (June) 216-s
Ceramic Abrasive in Cutting Discs, Evaluation of Triangular, Duplex Stainless Steel GTA Weld Pool, Modeling of Carbon
Engineered-Shape — J. Badger, (April) 107-s Steel- — A. Bahrami and D. K. Aidun, (July) 262-s
Ceramics, Wettability by Liquid Metals, Metalization, and Effect of Inserted Strips on Electrode Degradation in Resist-
Brazing of Barium Titanate — T. V. Sydorenko and Yu. V. ance Spot Welding — Y. Y. Zhao, Y. S. Zhang, X. M. Lai, and
Naidich, (Jan) 6-s P.-C. Wang, (Nov) 411-s
Characterization of CSC-GMAW Titanium-Rich Weld Effect of the Purging Gas on Properties of 304H GTA Welds
Overlays — J. E. Ramirez, (Sept) 338-s — E. Taban, E. Kaluc, and T. S. Aykan, (April) 124-s
Characterization of High-Strength Weld Metal Containing Effect of Welding Parameters on the Heat-Affected Zone Hy-
Mg-Bearing Inclusions — A. P. Gerlich, H. Izadi, J. Bundy, drogen-Induced Cracking Tendency of a Blast-Resistant
and P. F. Mendez, (Jan) 15-s Steel — X. Yue, X.-L. Feng, and J. C. Lippold, (March) 98-s
Characterization of Multilayered Multipass Friction Stir Weld Electrode Degradation in Resistance Spot Welding, Effect of
on ASTM A572 G50 Steel — Y. C. Lim, S. Sanderson, M. Inserted Strips on — Y. Y. Zhao, Y. S. Zhang, X. M. Lai, and
Mahoney, X. Yu, D. Qiao, Y. Wang, W. Zhang, and Z. Feng, P.-C. Wang, (Nov) 411-s
(Dec) 443-s Electrode GMAW-Brazing for Joining of Aluminum to Steel,
Coatings, Weldability of CMT Joining of AA6061-T6 to Boron Pulsed Double- — Y. Shi, G. Zhang, Y. Huang, L. Lu, J.
Steels with Various — R. Cao, J. H. Sun, J. H. Chen, and P.- Huang, and Y. Shao, (June) 216-s
C. Wang, (June) 193-s Energy Applications, Welding of Nickel-Based Alloys for — J.
Compressive Residual Stresses, Low Transformation Welding N. DuPont, (Feb) 31-s
Consumables for Residual Stress Management: A Numeri- Evaluation of Triangular, Engineered-Shape Ceramic Abrasive
cal Model for the Prediction of Phase Transformation- in Cutting Discs — J. Badger, (April) 107-s
Induced — T. Alghamdi and S. Liu, (Dec) 458-s Fatigue Performance of Spot Welds in Advanced High-
Consumable Electrode of High-Nickel Alloys, Flux-Coating Strength Steels, Improving — S. K. Vanimisetti and D. R.
Development for SMAW — K. Sham and S. Liu, (Aug) Sigler, (May) 153-s
271-s Filler Metals Using Combined Computational and Experimen-
Consumables for Residual Stress Management: Consumables tal Techniques, Development of High-Cr, Ni-Based — E. W.
Development and Testing Qualification, Low-Transforma- Fusner, A. T. Hope, and J. C. Lippold, (May) 171-s
tion-Temperature (LTT) Welding — T. Alghamdi and S. Liu, Flux-Assisted Gas Tungsten Arc and Laser Welding of
(July) 243-s Titanium with Cryolite-Containing Fluxes: Arc
Convection on Weld Pool Formation in Laser Cladding, Influ- Spectroscopy and Corrosion Resistance Studies — T.
ence of Fluid — Y. S. Lee, M. Nordin, S. S. Babu, and D. F. AlSabti, A. AlShawaf, and S. Liu, (Oct) 379-s
Farson, (Aug) 292-s Flux-Coating Development for SMAW Consumable Electrode
Copper Alloy Brazing Joints, The Microstructure and of High-Nickel Alloys — K. Sham and S. Liu, (Aug) 271-s
Strength of — A. Hasap, N. Noraphaiphipaksa, and C. Kan- Friction Stir Weld on ASTM A572 G50 Steel, Characterization
chanomai, (April) 116-s of Multilayered Multipass — Y. C. Lim, S. Sanderson, M.
Corrosion Resistance Studies, Flux-Assisted Gas Tungsten Arc Mahoney, X. Yu, D. Qiao, Y. Wang, W. Zhang, and Z. Feng,
and Laser Welding of Titanium with Cryolite-Containing (Dec) 443-s
Fluxes: Arc Spectroscopy and — T. AlSabti, A. AlShawaf, Friction Stir Welding of Extruded Powder Metallurgy Al Alloy
and S. Liu, (Oct) 379-s — A. Elrefaey, K. Anders, H. Kilian, F. Ellermann, and W.
Cracking in Pulsed-Tandem Gas Metal Arc Welding of Naval Kühlein, (Dec) 451-s
Steels, Weld-End Solidification — Z. Sterjovski, C. Bayley, Galvanized DP780 Steel, Improvement of Process Robustness
J. Donato, N. Lane, and D. Lang, (May) 145-s in Weld Bonding of — Y. S. Zhang, H. T. Sun, P.-C. Wang,
Cracking Tendency of a Blast-Resistant Steel, Effect of Weld- and G. L. Chen, (Dec) 472-s
ing Parameters on the Heat-Affected Zone Hydrogen- Gas Flows in Welding Arcs by the Schlieren Measuring Tech-
Induced — X. Yue, X.-L. Feng, and J. C. Lippold, (March) nique, Visualization of — E. Siewert, G. Wilhelm, M.
98-s Hässler, J. Schein, T. Hanson, M. Schnick, and U. Füssel,
Current in Electrical Arc — An Initial Study, Separation of Arc (Jan) 1-s
Plasma and — S. J. Chen, F. Jiang, Y. S. Lu, and Y. M. Gas Metal Arc Welding Enhanced by Using a Pulsed Laser —

DECEMBER 2014 / WELDING JOURNAL 101


Y. Shao and Y. M. Zhang, (June) 205-s Bahrami, D. K. Aidun, and D. T. Valentine, (April) 139-s
Gravity Forces in Spot GTA Weld Pool, Interaction of — A. Joining 5754 Automotive Aluminum Alloy 2-mm-Thick
Bahrami, D. K. Aidun, and D. T. Valentine, (April) 139-s Sheets Using Ultrasonic Spot Welding — C. Y. Zhang, D. L.
GTA Weld Pool, Modeling of Carbon Steel-Duplex Stainless Chen, and A. A. Luo, (April) 131-s
Steel — A. Bahrami and D. K. Aidun, (July) 262-s Joining of Aluminum to Steel, Pulsed Double-Electrode
GTAW Process, The Effect of Materials on Radiation GMAW-Brazing for — Y. Shi, G. Zhang, Y. Huang, L. Lu, J.
Exposure during the — A. Gursel and A. Kurt, (Nov) 439-s Huang, and Y. Shao, (June) 216-s
Hardness-Tensile Property Relationships for HAZ in 6061- Laser Cladding, Influence of Fluid Convection on Weld Pool
T651 Aluminum — P. A. Stathers, A. K. Hellier, R. P. Harri- Formation in — Y. S. Lee, M. Nordin, S. S. Babu, and D. F.
son, M. I. Ripley, and J. Norrish, (Aug) 301-s Farson, (Aug) 292-s
HAZ in 6061-T651 Aluminum, Hardness-Tensile Property Re- Laser Welded-Brazed Mg Alloy-Stainless Steel Joint,
lationships for — P. A. Stathers, A. K. Hellier, R. P. Microstructural Characteristics and Mechanical Properties
Harrison, M. I. Ripley, and J. Norrish, (Aug) 301-s of Fiber — C. W. Tan, L. Q. Li, Y. B. Chen, A. M. Nasiri, and
Heat-Affected Zone Hydrogen-Induced Cracking Tendency of Y. Zhou, (Oct) 399-s
a Blast-Resistant Steel, Effect of Welding Parameters on Laser-Welded Lap Joints, Analysis of the Local Stresses at —
the — X. Yue, X.-L. Feng, and J. C. Lippold, (March) 98-s K. D. Lee, K. I. Ho, and K. Y. Park, (Sept) 351-s
Heat Source Modeling and Analysis of Submerged Arc Weld- Laser Welding of a Maraging Steel, Heat Treatment and Yb-
ing — D. Podder, N. R. Mandal, and S. Das, (May) 183-s Fiber — L. Fanton, A. J. Abdalla, and M. S. Fernandes de
Heat Treatment and Yb-Fiber Laser Welding of a Maraging Lima, (Sept) 362-s
Steel — L. Fanton, A. J. Abdalla, and M. S. Fernandes de Laser Welding of Titanium with Cryolite-Containing Fluxes:
Lima, (Sept) 362-s Arc Spectroscopy and Corrosion Resistance Studies, Flux-
High-Cr, Ni-Based Filler Metals Using Combined Assisted Gas Tungsten Arc and — T. AlSabti, A. AlShawaf,
Computational and Experimental Techniques, and S. Liu, (Oct) 379-s
Development of — E. W. Fusner, A. T. Hope, and J. C. Lip- Laser Welding of Zinc-Coated Steels in a Zero Root Opening,
pold, (May) 171-s Lap-Joint Configuration, Semi-Cutting-Assisted — S.
High-Nickel Alloys, Flux-Coating Development for SMAW Yang, Z. Chen, W. Tao, C. Wang, J. Wang, and B. E. Carlson,
Consumable Electrode of — K. Sham and S. Liu, (Aug) (Sept) 331-s
271-s Learning Human Welder Movement in Pipe GTAW: A Virtual-
High-Strength Steel for Pipelines, Weldability of Niobium- ized Welding Approach — Y. K. Liu, Z. Shao, and Y. M.
Containing — I. I. Frantov, A. A. Velichko, A. N. Bortsov, Zhang, (Oct) 388-s
and I. Y. Utkin, (Jan) 23-s Low-Transformation-Temperature (LTT) Welding
High-Strength Steels, Improving Fatigue Performance of Spot Consumables for Residual Stress Management:
Welds in Advanced — S. K. Vanimisetti and D. R. Sigler, Consumables Development and Testing Qualification — T.
(May) 153-s Alghamdi and S. Liu, (July) 243-s
High-Strength Weld Metal Containing Mg-Bearing Low Transformation Temperature Welding Consumables for
Inclusions, Characterization of — A. P. Gerlich, H. Izadi, J. Residual Stress Management: A Numerical Model for the
Bundy, and P. F. Mendez, (Jan) 15-s Prediction of Phase Transformation-Induced Compressive
Human Welder Intelligence Modeling and Control: Part 1 — Residual Stresses — T. Alghamdi and S. Liu, (Dec) 458-s
Modeling, Skilled — Y. K. Liu, Y. M. Zhang, and L. Kvidahl, Magnesium with Zn-Coated Steel Interlayers, Dissimilar Re-
(Feb) 46-s sistance Spot Welding of Aluminum to — P. Penner, L. Liu,
Human Welder Intelligence Modeling and Control: Part II — A. Gerlich, and Y. Zhou, (June) 225-s
Analysis and Control Applications, Skilled — Y. K. Liu, Y. Maraging Steel, Heat Treatment and Yb-Fiber Laser Welding
M. Zhang, and L. Kvidahl, (May) 162-s of a — L. Fanton, A. J. Abdalla, and M. S. Fernandes de
Imperfections in GMAW, Quality Level Assessment for — G. Lima, (Sept) 362-s
Senthil Kumar, U. Natarajan, T. Veerarajan, and S. S. Anan- Material Strength Effect on Weld Shrinkage and Distortion
than, (March) 85-s — Y. P. Yang, R. Dull, H. Castner, T. D. Huang, and D. Fan-
Improvement of Process Robustness in Weld Bonding of Gal- guy, (Nov) 421-s
vanized DP780 Steel — Y. S. Zhang, H. T. Sun, P.-C. Wang, Mechanical Behavior of Titanium-Clad Steel Welded Joints —
and G. L. Chen, (Dec) 472-s J. E. Ramirez, (Oct) 369-s
Improvement of Weldability of 1 GPa Grade Twin-Induced Metal Transfer with Force Analysis in Consumable and Non-
Plasticity Steel — J. Yu, D. Choi, and S. Rhee, (March) 78-s consumable Indirect Arc Welding Process — J. Wang, Y.
Improving Fatigue Performance of Spot Welds in Advanced Huang, J. Xiao, J. Feng, C. Y. Tian, and J. Wang, (Nov)
High-Strength Steels — S. K. Vanimisetti and D. R. Sigler, 431-s
(May) 153-s Metallurgy Al Alloy, Friction Stir Welding of Extruded Powder
Inclusions, Characterization of High-Strength Weld Metal — A. Elrefaey, K. Anders, H. Kilian, F. Ellermann, and W.
Containing Mg-Bearing — A. P. Gerlich, H. Izadi, J. Bundy, Kühlein, (Dec) 451-s
and P. F. Mendez, (Jan) 15-s Microstructural Characteristics and Mechanical Properties of
Influence of Fluid Convection on Weld Pool Formation in Fiber Laser Welded-Brazed Mg Alloy-Stainless Steel Joint
Laser Cladding — Y. S. Lee, M. Nordin, S. S. Babu, and D. F. — C. W. Tan, L. Q. Li, Y. B. Chen, A. M. Nasiri, and Y. Zhou,
Farson, (Aug) 292-s (Oct) 399-s
Intelligence Modeling and Control: Part II — Analysis and Modeling and Analysis of Submerged Arc Welding, Heat
Control Applications, Skilled Human Welder — Y. K. Liu, Source — D. Podder, N. R. Mandal, and S. Das, (May) 183-s
Y. M. Zhang, and L. Kvidahl, (May) 162-s Modeling of Carbon Steel-Duplex Stainless Steel GTA Weld
Interaction of Gravity Forces in Spot GTA Weld Pool — A. Pool — A. Bahrami and D. K. Aidun, (July) 262-s

102 WELDING JOURNAL / DECEMBER 2014


Morphology Dependent upon Alloy Composition and Grain — Y. P. Yang, R. Dull, H. Castner, T. D. Huang, and D. Fan-
Refiner Content, Solidification of GTA Aluminum Weld guy, (Nov) 421-s
Metal: Part 1 — Grain — P. Schempp, C. E. Cross, A. Silicon-Free Ni-Co-Zr-Hf-Cr-Ti-Al Brazing Alloy, Brazing of
Pittner, G. Oder, R. S. Neumann, H. Rooch, I. Dörfel, W. CMSX-4 with a Boron- and — X. Huang, (July) 233-s
Österle, and M. Rethmeier, (Feb) 53-s Skilled Human Welder Intelligence Modeling and Control:
Multilayered Multipass Friction Stir Weld on ASTM A572 Part 1 — Modeling — Y. K. Liu, Y. M. Zhang, and L.
G50 Steel, Characterization of — Y. C. Lim, S. Sanderson, Kvidahl, (Feb) 46-s
M. Mahoney, X. Yu, D. Qiao, Y. Wang, W. Zhang, and Z. Skilled Human Welder Intelligence Modeling and Control:
Feng, (Dec) 443-s Part II — Analysis and Control Applications — Y. K. Liu,
Naval Steels, Weld-End Solidification Cracking in Pulsed- Y. M. Zhang, and L. Kvidahl, (May) 162-s
Tandem Gas Metal Arc Welding of — Z. Sterjovski, C. Solidification of GTA Aluminum Weld Metal: Part 1 — Grain
Bayley, J. Donato, N. Lane, and D. Lang, (May) 145-s Morphology Dependent upon Alloy Composition and
Nickel-Based Alloys for Energy Applications, Welding of — Grain Refiner Content — P. Schempp, C. E. Cross, A.
J. N. DuPont, (Feb) 31-s Pittner, G. Oder, R. S. Neumann, H. Rooch, I. Dörfel, W.
Niobium-Containing High-Strength Steel for Pipelines, Weld- Österle, and M. Rethmeier, (Feb) 53-s
ability of — I. I. Frantov, A. A. Velichko, A. N. Bortsov, and Solidification of GTA Aluminum Weld Metal: Part 2 — Ther-
I. Y. Utkin, (Jan) 23-s mal Conditions and Model for Columnar-to-Equiaxed
Oscillation Part 1: Experimental Study, Active Metal Transfer Transition — P. Schempp, C. E. Cross, A. Pittner, and M.
Control by Utilizing Enhanced Droplet — J. Xiao, G. J. Rethmeier, (March) 69-s
Zhang, W. J. Zhang, and Y. M. Zhang, (Aug) 292-s Spot GTA Weld Pool, Interaction of Gravity Forces in — A.
Oscillation Part II: Modeling and Analysis, Active Metal Bahrami, D. K. Aidun, and D. T. Valentine, (April) 139-s
Transfer Control by Utilizing Enhanced Droplet — J. Xiao, Spot Welding of Aluminum to Magnesium with Zn-Coated
G. J. Zhang, W. J. Zhang, and Y. M. Zhang, (Sept) 321-s Steel Interlayers, Dissimilar Resistance — P. Penner, L. Liu,
Overlays, Characterization of CSC-GMAW Titanium-Rich A. Gerlich, and Y. Zhou, (June) 225-s
Weld — J. E. Ramirez, (Sept) 338-s Spot Welds in Advanced High-Strength Steels, Improving Fa-
Pipe GTAW: A Virtualized Welding Approach, Learning tigue Performance of — S. K. Vanimisetti and D. R. Sigler,
Human Welder Movement in — Y. K. Liu, Z. Shao, and (May) 153-s
Y. M. Zhang, (Oct) 388-s Stainless Steel Joint, Microstructural Characteristics and Me-
Pipelines, Weldability of Niobium-Containing High-Strength chanical Properties of Fiber Laser Welded-Brazed Mg
Steel for — I. I. Frantov, A. A. Velichko, A. N. Bortsov, and Alloy- — C. W. Tan, L. Q. Li, Y. B. Chen, A. M. Nasiri, and Y.
I. Y. Utkin, (Jan) 23-s Zhou, (Oct) 399-s
Plasma and Current in Electrical Arc — An Initial Study, Sepa- Stress Management: Consumables Development and Testing
ration of Arc — S. J. Chen, F. Jiang, Y. S. Lu, and Y. M. Qualification, Low-Transformation-Temperature (LTT)
Zhang, (July) 253-s Welding Consumables for Residual — T. Alghamdi and S.
Plasticity Steel, Improvement of Weldability of 1 GPa Grade Liu, (July) 243-s
Twin-Induced — J. Yu, D. Choi, and S. Rhee, (March) 78-s Stress Management: A Numerical Model for the Prediction of
Pulsed Double-Electrode GMAW-Brazing for Joining of Alu- Phase Transformation-Induced Compressive Residual
minum to Steel — Y. Shi, G. Zhang, Y. Huang, L. Lu, J. Stresses, Low Transformation Temperature Welding Con-
Huang, and Y. Shao, (June) 216-s sumables for Residual — T. Alghamdi and S. Liu, (Dec)
Pulsed Laser, Gas Metal Arc Welding Enhanced by Using a — 458-s
Y. Shao and Y. M. Zhang, (June) 205-s Submerged Arc Welding, Heat Source Modeling and Analysis
Pulsed-Tandem Gas Metal Arc Welding of Naval Steels, Weld- of — D. Podder, N. R. Mandal, and S. Das, (May) 183-s
End Solidification Cracking in — Z. Sterjovski, C. Bayley, J. Surface Depression of the Molten Pool with Pulsed Welding,
Donato, N. Lane, and D. Lang, (May) 145-s A Study on the — M. Yang, Z. Yang, B. Cong, and B. Qi,
Pulsed Welding, A Study on the Molten Pool with — M. Yang, (Aug) 312-s
Z. Yang, B. Cong, and B. Qi, (Aug) 312-s The Effect of Materials on Radiation Exposure during the
Purging Gas on Properties of 304H GTA Welds, Effect of the GTAW Process — A. Gursel and A. Kurt, (Nov) 439-s
— E. Taban, E. Kaluc, and T. S. Aykan, (April) 124-s The Microstructure and Strength of Copper Alloy Brazing
Quality Level Assessment for Imperfections in GMAW — G. Joints — A. Hasap, N. Noraphaiphipaksa, and C.
Senthil Kumar, U. Natarajan, T. Veerarajan, and S. S. Anan- Kanchanomai, (April) 116-s
than, (March) 85-s Thermal Conditions and Model for Columnar-to-Equiaxed
Radiation Exposure during the GTAW Process, The Effect of Transition, Solidification of GTA Aluminum Weld Metal:
Materials on — A. Gursel and A. Kurt, (Nov) 439-s Part 2 — P. Schempp, C. E. Cross, A. Pittner, and M. Reth-
Resistance Spot Welding, Effect of Inserted Strips on meier, (March) 69-s
Electrode Degradation in — Y. Y. Zhao, Y. S. Zhang, X. M. Titanium-Clad Steel Welded Joints, Mechanical Behavior of
Lai, and P.-C. Wang, (Nov) 411-s — J. E. Ramirez, (Oct) 369-s
Semi-Cutting-Assisted Laser Welding of Zinc-Coated Steels in Titanium-Rich Weld Overlays, Characterization of CSC-
a Zero Root Opening, Lap-Joint Configuration — S. Yang, GMAW — J. E. Ramirez, (Sept) 338-s
Z. Chen, W. Tao, C. Wang, J. Wang, and B. E. Carlson, Transfer Control by Utilizing Enhanced Droplet Oscillation
(Sept) 331-s Part 1: Experimental Study, Active Metal — J. Xiao, G. J.
Separation of Arc Plasma and Current in Electrical Arc — An Zhang, W. J. Zhang, and Y. M. Zhang, (Aug) 292-s
Initial Study — S. J. Chen, F. Jiang, Y. S. Lu, and Y. M. Transfer Control by Utilizing Enhanced Droplet Oscillation
Zhang, (July) 253-s Part II: Modeling and Analysis, Active Metal — J. Xiao, G.
Shrinkage and Distortion, Material Strength Effect on Weld J. Zhang, W. J. Zhang, and Y. M. Zhang, (Sept) 321-s

DECEMBER 2014 / WELDING JOURNAL 103


Transfer with Force Analysis in Consumable and Nonconsum- Weldability of 1 GPa Grade Twin-Induced Plasticity Steel, Im-
able Indirect Arc Welding Process, Metal — J. Wang, Y. provement of — J. Yu, D. Choi, and S. Rhee, (March) 78-s
Huang, J. Xiao, J. Feng, C. Y. Tian, and J. Wang, (Nov) Weldability of CMT Joining of AA6061-T6 to Boron Steels
431-s with Various Coatings — R. Cao, J. H. Sun, J. H. Chen, and
Tungsten Arc and Laser Welding of Titanium with Cryolite- P.-C. Wang, (June) 193-s
Containing Fluxes: Arc Spectroscopy and Corrosion Resist- Weldability of Niobium-Containing High-Strength Steel for
ance Studies, Flux-Assisted Gas — T. AlSabti, A. AlShawaf, Pipelines — I. I. Frantov, A. A. Velichko, A. N. Bortsov, and
and S. Liu, (Oct) 379-s I. Y. Utkin, (Jan) 23-s
Ultrasonic Spot Welding, Joining 5754 Automotive Welding of Nickel-Based Alloys for Energy Applications —
Aluminum Alloy 2-mm-Thick Sheets Using — C. Y. Zhang, J. N. DuPont, (Feb) 31-s
D. L. Chen, and A. A. Luo, (April) 131-s Wettability by Liquid Metals, Metalization, and Brazing of
Virtualized Welding Approach, Learning Human Welder Barium Titanate Ceramics — T. V. Sydorenko and Yu. V.
Movement in Pipe GTAW: A — Y. K. Liu, Z. Shao, and Y. M. Naidich, (Jan) 6-s
Zhang, (Oct) 388-s Zinc-Coated Steels in a Zero Root Opening, Lap-Joint Config-
Visualization of Gas Flows in Welding Arcs by the Schlieren uration, Semi-Cutting-Assisted Laser Welding of — S.
Measuring Technique — E. Siewert, G. Wilhelm, M. Yang, Z. Chen, W. Tao, C. Wang, J. Wang, and B. E. Carlson,
Hässler, J. Schein, T. Hanson, M. Schnick, and U. Füssel, (Sept) 331-s
(Jan) 1-s Zn-Coated Steel Interlayers, Dissimilar Resistance Spot Weld-
Weld-End Solidification Cracking in Pulsed-Tandem Gas ing of Aluminum to Magnesium with — P. Penner, L. Liu,
Metal Arc Welding of Naval Steels — Z. Sterjovski, C. Bay- A. Gerlich, and Y. Zhou, (June) 225-s
ley, J. Donato, N. Lane, and D. Lang, (May) 145-s

AUTHORS FOR RESEARCH SUPPLEMENT


Abdalla, A. J., Fernandes de Lima, M. S., and Fanton, L. — Duplex Stainless Steel GTA Weld Pool, (July) 262-s
Heat Treatment and Yb-Fiber Laser Welding of a Maraging Bayley, C., Donato, J., Lane, N., Lang, D., and Sterjovski, Z. —
Steel, (Sept) 362-s Weld-End Solidification Cracking in Pulsed-Tandem Gas
Aidun, D. K., Valentine, D. T., and Bahrami, A. — Interaction of Metal Arc Welding of Naval Steels, (May) 145-s
Gravity Forces in Spot GTA Weld Pool, (April) 139-s Bortsov, A. N., Utkin, I. Y., Frantov, I. I., and Velichko, A. A. —
Aidun, D. K., and Bahrami, A. — Modeling of Carbon Steel- Weldability of Niobium-Containing High-Strength Steel for
Duplex Stainless Steel GTA Weld Pool, (July) 262-s Pipelines, (Jan) 23-s
Alghamdi, T., and Liu, S. — Low-Transformation-Temperature Bundy, J., Mendez, P. F., Gerlich, A. P., and Izadi, H. — Charac-
(LTT) Welding Consumables Development and Testing terization of High-Strength Weld Metal Containing Mg-
Qualification, (July) 243-s Bearing Inclusions, (Jan) 15-s
Alghamdi, T., and Liu, S. — Low Transformation Temperature Cao, R., Sun, J. H., Chen, J. H., and Wang, P.-C. — Weldability
Welding Consumables for Residual Stress Management: A of CMT Joining of AA6061-T6 to Boron Steels with Various
Numerical Model for the Prediction of Phase Coatings, (June) 193-s
Transformation-Induced Compressive Residual Stresses, Carlson, B. E., Yang, S., Chen, Z., Tao, W., Wang, C., and Wang,
(Dec) 458-s J. — Semi-Cutting-Assisted Laser Welding of Zinc-Coated
AlSabti, T., AlShawaf, A., and Liu, S. — Flux-Assisted Gas Tung- Steels in a Zero Root Opening, Lap-Joint Configuration,
sten Arc and Laser Welding of Titanium with Cryolite- (Sept) 331-s
Containing Fluxes: Arc Spectroscopy and Corrosion Resist- Castner, H., Huang, T. D., Fanguy, D., Yang, Y. P., and Dull, R. —
ance Studies, (Oct) 379-s Material Strength Effect on Weld Shrinkage and Distortion,
AlShawaf, A., Liu, S., and AlSabti, T. — Flux-Assisted Gas Tung- (Nov) 421-s
sten Arc and Laser Welding of Titanium with Cryolite- Chen, D. L., Luo, A. A., and Zhang, C. Y. — Joining 5754 Auto-
Containing Fluxes: Arc Spectroscopy and Corrosion Resist- motive Aluminum Alloy 2-mm-Thick Sheets Using
ance Studies, (Oct) 379-s Ultrasonic Spot Welding, (April) 131-s
Ananthan, S. S., Senthil Kumar, G., Natarajan, U., and Veerara- Chen, G. L., Zhang, Y. S., Sun, H. T., and Wang, P.-C. —
jan, T. — Quality Level Assessment for Imperfections in Improvement of Process Robustness in Weld Bonding of
GMAW, (March) 85-s Galvanized DP780 Steel, (Dec) 472-s
Anders, K., Kilian, H., Ellermann, F., Kühlein, W., and Elrefaey, Chen, J. H., Wang, P.-C., Cao, R., and Sun, J. H. — Weldability
A. — Friction Stir Welding of Extruded Powder Metallurgy of CMT Joining of AA6061-T6 to Boron Steels with Various
Al Alloy, (Dec) 451-s Coatings, (June) 193-s
Aykan, T. S., Taban, E., and Kaluc, E. — Effect of the Purging Chen, S. J., Jiang, F., Lu, Y. S., and Zhang, Y. M. — Separation
Gas on Properties of 304H GTA Welds, (April) 124-s of Arc Plasma and Current in Electrical Arc — An Initial
Babu, S. S., Farson, D. F., Lee, Y. S., and Nordin, M. — Influence Study, (July) 253-s
of Fluid Convection on Weld Pool Formation in Laser Chen, Y. B., Nasiri, A. M., Zhou, Y., Tan, C. W., and Li, L. Q. —
Cladding, (Aug) 292-s Microstructural Characteristics and Mechanical Properties
Badger, J. — Evaluation of Triangular, Engineered-Shape of Fiber Laser Welded-Brazed Mg Alloy-Stainless Steel Joint,
Ceramic Abrasive in Cutting Discs, (April) 107-s (Oct) 399-s
Bahrami, A., Aidun, D. K., and Valentine, D. T. — Interaction of Chen, Z., Tao, W., Wang, C., Wang, J., Carlson, B. E., and Yang,
Gravity Forces in Spot GTA Weld Pool, (April) 139-s S. — Semi-Cutting-Assisted Laser Welding of Zinc-Coated
Bahrami, A., and Aidun, D. K. — Modeling of Carbon Steel- Steels in a Zero Root Opening, Lap-Joint Configuration,

104 WELDING JOURNAL / DECEMBER 2014


(Sept) 331-s Fusner, E. W., Hope, A. T., and Lippold, J. C. — Development
Choi, D., Rhee, S., and Yu, J. — Improvement of Weldability of of High-Cr, Ni-Based Filler Metals Using Combined Compu-
1 GPa Grade Twin-Induced Plasticity Steel, (March) 78-s tational and Experimental Techniques, (May) 171-s
Cong, B., Qi, B., Yang, M., and Yang, Z. — A Study on the Sur- Füssel, U., Siewert, E., Wilhelm, G., Hässler, M., Schein, J.,
face Depression of the Molten Pool with Pulsed Welding, Hanson, T., and Schnick, M. — Visualization of Gas Flows
(Aug) 312-s in Welding Arcs by the Schlieren Measuring Technique,
Cross, C. E., Pittner, A., Oder, G., Neumann, R. S., Rooch, H., (Jan) 1-s
Dörfel, I., Österle, W., Rethmeier, M., and Schempp, P. — Gerlich, A. P., Izadi, H., Bundy, J., and Mendez, P. F. — Charac-
Solidification of GTA Aluminum Weld Metal: Part 1 — terization of High-Strength Weld Metal Containing Mg-
Grain Morphology Dependent upon Alloy Composition and Bearing Inclusions, (Jan) 15-s
Grain Refiner Content, (Feb) 53-s Gerlich, A., Zhou, Y., Penner, P., and Liu, L. — Dissimilar
Cross, C. E., Pittner, A., Rethmeier, M., and Schempp, P. — So- Resistance Spot Welding of Aluminum to Magnesium with
lidification of GTA Aluminum Weld Metal: Part 2 — Ther- Zn-Coated Steel Interlayers, (June) 225-s
mal Conditions and Model for Columnar-to-Equiaxed Tran- Gursel, A., and Kurt, A. — The Effect of Materials on
sition, (March) 69-s Radiation Exposure during the GTAW Process, (Nov) 439-s
Das, S., Podder, D., and N. R. Mandal — Heat Source Modeling Hanson, T., Schnick, M., Füssel, U., Siewert, E., Wilhelm, G.,
and Analysis of Submerged Arc Welding, (May) 183-s Hässler, M., and Schein, J. — Visualization of Gas Flows in
Donato, J., Lane, N., Lang, D., Sterjovski, Z., and Bayley, C. — Welding Arcs by the Schlieren Measuring Technique, (Jan)
Weld-End Solidification Cracking in Pulsed-Tandem Gas 1-s
Metal Arc Welding of Naval Steels, (May) 145-s Harrison, R. P., Ripley, M. I., Norrish, J., Stathers, P. A., and
Dörfel, I., Österle, W., Rethmeier, M., Schempp, P., Cross, C. E., Hellier, A. K. — Hardness-Tensile Property Relationships
Pittner, A., Oder, G., Neumann, R. S., and Rooch, H. — So- for HAZ in 6061-T651 Aluminum, (Aug) 301-s
lidification of GTA Aluminum Weld Metal: Part 1 — Grain Hasap, A., Noraphaiphipaksa, N., and Kanchanomai, C. — The
Morphology Dependent upon Alloy Composition and Grain Microstructure and Strength of Copper Alloy Brazing
Refiner Content, (Feb) 53-s Joints, (April) 116-s
Dull, R., Castner, H., Huang, T. D., Fanguy, D., and Yang, Y. P. Hässler, M., Schein, J., Hanson, T., Schnick, M., Füssel, U.,
— Material Strength Effect on Weld Shrinkage and Distor- Siewert, E., and Wilhelm, G. — Visualization of Gas Flows
tion, (Nov) 421-s in Welding Arcs by the Schlieren Measuring Technique,
DuPont, J. N. — Welding of Nickel-Based Alloys for Energy (Jan) 1-s
Applications, (Feb) 31-s Hellier, A. K., Harrison, R. P., Ripley, M. I., Norrish, J., and
Ekrami, A., Kokabi, A. H., and Pouranvari, M. — Diffusion Stathers, P. A. — Hardness-Tensile Property Relationships
Brazing Metallurgy of IN718/Ni-Cr-Si-B-Fe/IN718, (Feb) for HAZ in 6061-T651 Aluminum, (Aug) 301-s
60-s Ho, K. I., Park, K. Y., and Lee, K. D. — Analysis of the Local
Ellermann, F., Kühlein, W., Elrefaey, A., Anders, K., and Kilian, Stresses at Laser-Welded Lap Joints, (Sept) 351-s
H. — Friction Stir Welding of Extruded Powder Metallurgy Hope, A. T., Lippold, J. C., and Fussner, E. W. — Development
Al Alloy, (Dec) 451-s of High-Cr, Ni-Based Filler Metals Using Combined Compu-
Elrefaey, A., Anders, K., Kilian, H., Ellermann, F., and Kühlein, tational and Experimental Techniques, (May) 171-s
W. — Friction Stir Welding of Extruded Powder Metallurgy Huang, J., Shao, Y., Shi, Y., Zhang, G., Huang, Y., and Lu, L. —
Al Alloy, (Dec) 451-s Pulsed Double-Electrode GMAW-Brazing for Joining of Alu-
Fanguy, D., Yang, Y. P., Dull, R., Castner, H., and Huang, T. D. minum to Steel, (June) 216-s
— Material Strength Effect on Weld Shrinkage and Distor- Huang, T. D., Fanguy, D., Yang, Y. P., Dull, R., and Castner, H.
tion, (Nov) 421-s — Material Strength Effect on Weld Shrinkage and Distor-
Fanton, L., Abdalla, A. J., and Fernandes de Lima, M. S. — tion, (Nov) 421-s
Heat Treatment and Yb-Fiber Laser Welding of a Maraging Huang, X. — Brazing of CMSX-4 with a Boron- and Silicon-
Steel, (Sept) 362-s Free Ni-Co-Zr-Hf-Cr-Ti-Al Brazing Alloy, (July) 233-s
Farson, D. F., Lee, Y. S., Nordin, M., and Babu, S. S. — Huang, Y., Xiao, J., Feng, J., Tian, C. Y., Wang, J., and Wang, J.
Influence of Fluid Convection on Weld Pool Formation in — Metal Transfer with Force Analysis in Consumable and
Laser Cladding, (Aug) 292-s Nonconsumable Indirect Arc Welding Process, (Nov) 431-s
Feng, J., Tian, C. Y., Wang, J., Wang, J., Huang, Y., and Xiao, J. Huang, Y., Lu, L., Huang, J., Shao, Y., Shi, Y., and Zhang, G. —
— Metal Transfer with Force Analysis in Consumable and Pulsed Double-Electrode GMAW-Brazing for Joining of Alu-
Nonconsumable Indirect Arc Welding Process, (Nov) 431-s minum to Steel, (June) 216-s
Feng, X.-L., Lippold, J. C., and Yue, X. — Effect of Welding Pa- Izadi, H., Bundy, J., Mendez, P. F.,and Gerlich, A. P. — Charac-
rameters on the Heat-Affected Zone Hydrogen-Induced terization of High-Strength Weld Metal Containing Mg-
Cracking Tendency of a Blast-Resistant Steel, (March) 98-s Bearing Inclusions, (Jan) 15-s
Feng, Z., Lim, Y. C., Sanderson, S., Mahoney, M., Yu, X., Qiao, Jiang, F., Lu, Y. S., Zhang, Y. M., and Chen, S. J. — Separation
D., Wang, Y., and Zhang, W. — Characterization of of Arc Plasma and Current in Electrical Arc — An Initial
Multilayered Multipass Friction Stir Weld on ASTM A572 Study, (July) 253-s
G50 Steel, (Dec) 443-s Kaluc, E., Aykan, T. S., and Taban, E. — Effect of the Purging
Fernandes de Lima, M. S., Fanton, L., and Abdalla, A. J. — Gas on Properties of 304H GTA Welds, (April) 124-s
Heat Treatment and Yb-Fiber Laser Welding of a Maraging Kanchanomai, C., Hasap, A., and Noraphaiphipaksa, N. — The
Steel, (Sept) 362-s Microstructure and Strength of Copper Alloy Brazing
Frantov, I. I., Velichko, A. A., Bortsov, A. N., and Utkin, I. Y. — Joints, (April) 116-s
Weldability of Niobium-Containing High-Strength Steel for Kilian, H., Ellermann, F., Kühlein, W., Elrefaey, A., and Anders,
Pipelines, (Jan) 23-s K. — Friction Stir Welding of Extruded Powder Metallurgy

DECEMBER 2014 / WELDING JOURNAL 105


Al Alloy, (Dec) 451-s Welder Intelligence Modeling and Control: Part 1 — Model-
Kokabi, A. H., Pouranvari, M., and Ekrami, A. — Diffusion ing, (Feb) 46-s
Brazing Metallurgy of IN718/Ni-Cr-Si-B-Fe/IN718, (Feb) Liu, Y. K., Zhang, Y. M., and Kvidahl, L. — Skilled Human
60-s Welder Intelligence Modeling and Control: Part II — Analy-
Kühlein, W., Elrefaey, A., Anders, K., Kilian, H., and Ellermann, sis and Control Applications, (May) 162-s
F. — Friction Stir Welding of Extruded Powder Metallurgy Lu, L., Huang, J., Shao, Y., Shi, Y., Zhang, G., and Huang, Y. —
Al Alloy, (Dec) 451-s Pulsed Double-Electrode GMAW-Brazing for Joining of Alu-
Kurt, A., and Gursel, A. — The Effect of Materials on minum to Steel, (June) 216-s
Radiation Exposure during the GTAW Process, (Nov) 439-s Lu, Y. S., Zhang, Y. M., Chen, S. J., and Jiang, F. — Separation
Kvidahl, L., Liu, Y. K., and Zhang, Y. M. — Skilled Human of Arc Plasma and Current in Electrical Arc — An Initial
Welder Intelligence Modeling and Control: Part 1 — Model- Study, (July) 253-s
ing, (Feb) 46-s Luo, A. A., Zhang, C. Y., and Chen, D. L. — Joining 5754 Auto-
Kvidahl, L., Liu, Y. K., and Zhang, Y. M. — Skilled Human motive Aluminum Alloy 2-mm-Thick Sheets Using
Welder Intelligence Modeling and Control: Part II — Analy- Ultrasonic Spot Welding, (April) 131-s
sis and Control Applications, (May) 162-s Mahoney, M., Yu, X., Qiao, D., Wang, Y., Zhang, W., Feng, Z.,
Lai, X. M., Wang, P.-C., Zhao, Y. Y., and Zhang, Y. S. — Effect of Lim, Y. C., and Sanderson, S. — Characterization of Multi-
Inserted Strips on Electrode Degradation in Resistance Spot layered Multipass Friction Stir Weld on ASTM A572 G50
Welding, (Nov) 411-s Steel, (Dec) 443-s
Lane, N., Lang, D., Sterjovski, Z., Bayley, C., and Donato, J. — Mandal, N. R., Das, S., and Podder, D. — Heat Source Model-
Weld-End Solidification Cracking in Pulsed-Tandem Gas ing and Analysis of Submerged Arc Welding, (May) 183-s
Metal Arc Welding of Naval Steels, (May) 145-s Mendez, P. F., Gerlich, A. P., Izadi, H., and Bundy, J. — Charac-
Lang, D., Sterjovski, Z., Bayley, C., Donato, J., and Lane, N. — terization of High-Strength Weld Metal Containing Mg-
Weld-End Solidification Cracking in Pulsed-Tandem Gas Bearing Inclusions, (Jan) 15-s
Metal Arc Welding of Naval Steels, (May) 145-s Naidich, Yu. V., and Sydorenko, T. V. — Wettability by Liquid
Lee, K. D., Ho, K. I., and Park, K. Y. — Analysis of the Local Metals, Metalization, and Brazing of Barium Titanate
Stresses at Laser-Welded Lap Joints, (Sept) 351-s Ceramics, (Jan) 6-s
Lee, Y. S., Nordin, M., Babu, S. S., and Farson, D. F. — Nasiri, A. M., Zhou, Y., Tan, C. W., Li, L. Q., and Chen, Y. B. —
Influence of Fluid Convection on Weld Pool Formation in Microstructural Characteristics and Mechanical Properties
Laser Cladding, (Aug) 292-s of Fiber Laser Welded-Brazed Mg Alloy-Stainless Steel
Li, L. Q., Chen, Y. B., Nasiri, A. M., Zhou, Y., and Tan, C. W. — Joint, (Oct) 399-s
Microstructural Characteristics and Mechanical Properties Natarajan, U., Veerarajan, T., Ananthan, S. S., and Senthil
of Fiber Laser Welded-Brazed Mg Alloy-Stainless Steel Kumar, G. — Quality Level Assessment for Imperfections
Joint, (Oct) 399-s in GMAW, (March) 85-s
Lim, Y. C., Sanderson, S., Mahoney, M., Yu, X., Qiao, D., Wang, Neumann, R. S., Rooch, H., Dörfel, I., Österle, W., Rethmeier,
Y., Zhang, W., and Feng, Z. — Characterization of Multilay- M., Schempp, P., Cross, C. E., Pittner, A., and Oder, G. —
ered Multipass Friction Stir Weld on ASTM A572 G50 Steel, Solidification of GTA Aluminum Weld Metal: Part 1 —
(Dec) 443-s Grain Morphology Dependent upon Alloy Composition and
Lippold, J. C., Fussner, E. W., and Hope, A. T. — Development Grain Refiner Content, (Feb) 53-s
of High-Cr, Ni-Based Filler Metals Using Combined Compu- Noraphaiphipaksa, N., Kanchanomai, C., and Hasap, A. — The
tational and Experimental Techniques, (May) 171-s Microstructure and Strength of Copper Alloy Brazing
Lippold, J. C., Yue, X., and Feng, X.-L. — Effect of Welding Pa- Joints, (April) 116-s
rameters on the Heat-Affected Zone Hydrogen-Induced Nordin, M., Babu, S. S., Farson, D. F., and Lee, Y. S. —
Cracking Tendency of a Blast-Resistant Steel, (March) 98-s Influence of Fluid Convection on Weld Pool Formation in
Liu, L., Gerlich, A., Zhou, Y., and Penner, P. — Dissimilar Laser Cladding, (Aug) 292-s
Resistance Spot Welding of Aluminum to Magnesium with Norrish, J., Stathers, P. A., Hellier, A. K., Harrison, R. P., and
Zn-Coated Steel Interlayers, (June) 225-s Ripley, M. I. — Hardness-Tensile Property Relationships for
Liu, S., AlSabti, T., and AlShawaf, A. — Flux-Assisted Gas HAZ in 6061-T651 Aluminum, (Aug) 301-s
Tungsten Arc and Laser Welding of Titanium with Cryolite- Oder, G., Neumann, R. S., Rooch, H., Dörfel, I., Österle, W.,
Containing Fluxes: Arc Spectroscopy and Corrosion Resist- Rethmeier, M., Schempp, P., Cross, C. E., and Pittner, A. —
ance Studies, (Oct) 379-s Solidification of GTA Aluminum Weld Metal: Part 1 —
Liu, S., and Sham, K. — Flux-Coating Development for SMAW Grain Morphology Dependent upon Alloy Composition and
Consumable Electrode of High-Nickel Alloys, (Aug) 271-s Grain Refiner Content, (Feb) 53-s
Liu, S., and Alghamdi, T. — Low-Transformation-Temperature Österle, W., Rethmeier, M., Schempp, P., Cross, C. E., Pittner,
(LTT) Welding Consumables Development and Testing A., Oder, G., Neumann, R. S., Rooch, H., and Dörfel, I. —
Qualification, (July) 243-s Solidification of GTA Aluminum Weld Metal: Part 1 —
Liu, S., and Alghamdi, T. — Low Transformation Temperature Grain Morphology Dependent upon Alloy Composition and
Welding Consumables for Residual Stress Management: A Grain Refiner Content, (Feb) 53-s
Numerical Model for the Prediction of Phase Park, K. Y., Lee, K. D., and Ho, K. I. — Analysis of the Local
Transformation-Induced Compressive Residual Stresses, Stresses at Laser-Welded Lap Joints, (Sept) 351-s
(Dec) 458-s Penner, P., Liu, L., Gerlich, A., and Zhou, Y. — Dissimilar
Liu, Y. K., Shao, Z., and Zhang, Y. M. — Learning Human Resistance Spot Welding of Aluminum to Magnesium with
Welder Movement in Pipe GTAW: A Virtualized Welding Zn-Coated Steel Interlayers, (June) 225-s
Approach, (Oct) 388-s Pittner, A., Oder, G., Neumann, R. S., Rooch, H., Dörfel, I.,
Liu, Y. K., Zhang, Y. M., and Kvidahl, L. — Skilled Human Österle, W., Rethmeier, M., Schempp, P., and Cross, C. E. —

106 WELDING JOURNAL / DECEMBER 2014


Solidification of GTA Aluminum Weld Metal: Part 1 — Senthil Kumar, G., Natarajan, U., Veerarajan, T., and Anan-
Grain Morphology Dependent upon Alloy Composition and than, S. S. — Quality Level Assessment for Imperfections
Grain Refiner Content, (Feb) 53-s in GMAW, (March) 85-s
Pittner, A., Rethmeier, M., Schempp, P., and Cross, C. E. — So- Sham, K., and Liu, S. — Flux-Coating Development for SMAW
lidification of GTA Aluminum Weld Metal: Part 2 — Ther- Consumable Electrode of High-Nickel Alloys, (Aug) 271-s
mal Conditions and Model for Columnar-to-Equiaxed Tran- Shao, Y., and Zhang, Y. M. — Gas Metal Arc Welding Enhanced
sition, (March) 69-s by Using a Pulsed Laser, (June) 205-s
Podder, D., Mandal, N. R., and Das, S. — Heat Source Model- Shao, Y., Shi, Y., Zhang, G., Huang, Y., Lu, L., and Huang, J. —
ing and Analysis of Submerged Arc Welding, (May) 183-s Pulsed Double-Electrode GMAW-Brazing for Joining of Alu-
Pouranvari, M., Ekrami, A., and Kokabi, A. H. — Diffusion minum to Steel, (June) 216-s
Brazing Metallurgy of IN718/Ni-Cr-Si-B-Fe/IN718, (Feb) Shao, Z., Zhang, Y. M., and Liu, Y. K. — Learning Human
60-s Welder Movement in Pipe GTAW: A Virtualized Welding
Qi, B., Yang, M., Yang, Z., and Cong, B. — A Study on the Sur- Approach, (Oct) 388-s
face Depression of the Molten Pool with Pulsed Welding, Shi, Y., Zhang, G., Huang, Y., Lu, L., Huang, J., and Shao, Y. —
(Aug) 312-s Pulsed Double-Electrode GMAW-Brazing for Joining of Alu-
Qiao, D., Wang, Y., Zhang, W., Feng, Z., Lim, Y. C., Sanderson, minum to Steel, (June) 216-s
S., Mahoney, M., and Yu, X. — Characterization of Siewert, E., Wilhelm, G., Hässler, M., Schein, J., Hanson, T.,
Multilayered Multipass Friction Stir Weld on ASTM A572 Schnick, M., and Füssel, U. — Visualization of Gas Flows in
G50 Steel, (Dec) 443-s Welding Arcs by the Schlieren Measuring Technique, (Jan)
Ramirez, J. E. — Characterization of CSW-GMAW Titanium- 1-s
Rich Weld Overlays, (Sept) 338-s Sigler, D. R., and Vanimisetti, S. K. — Improving Fatigue Per-
Ramirez, J. E. — Mechanical Behavior of Titanium-Clad Steel formance of Spot Welds in Advanced High-Strength Steels,
Welded Joints, (Oct) 369-s (May) 153-s
Rethmeier, M., Schempp, P., Cross, C. E., Pittner, A., Oder, G., Stathers, P. A., Hellier, A. K., Harrison, R. P., Ripley, M. I., and
Neumann, R. S., Rooch, H., Dörfel, I., and Österle, W. — So- Norrish, J. — Hardness-Tensile Property Relationships for
lidification of GTA Aluminum Weld Metal: Part 1 — Grain HAZ in 6061-T651 Aluminum, (Aug) 301-s
Morphology Dependent upon Alloy Composition and Grain Sterjovski, Z., Bayley, C., Donato, J., Lane, N., and Lang, D. —
Refiner Content, (Feb) 53-s Weld-End Solidification Cracking in Pulsed-Tandem Gas
Rethmeier, M., Schempp, P., Cross, C. E., and Pittner, A. — So- Metal Arc Welding of Naval Steels, (May) 145-s
lidification of GTA Aluminum Weld Metal: Part 2 — Ther- Sun, H. T., Wang, P.-C., Chen, G. L., and Zhang, Y. S. —
mal Conditions and Model for Columnar-to-Equiaxed Tran- Improvement of Process Robustness in Weld Bonding of
sition, (March) 69-s Galvanized DP780 Steel, (Dec) 472-s
Rhee, S., Yu, J., and Choi, D. — Improvement of Weldability of Sun, J. H., Chen, J. H., Wang, P.-C., and Cao, R. — Weldability
1 GPa Grade Twin-Induced Plasticity Steel, (March) 78-s of CMT Joining of AA6061-T6 to Boron Steels with Various
Ripley, M. I., Norrish, J., Stathers, P. A., Hellier, A. K., and Coatings, (June) 193-s
Harrison, R. P. — Hardness-Tensile Property Sydorenko, T. V., and Naidich, Yu. V. — Wettability by Liquid
Relationships for HAZ in 6061-T651 Aluminum, (Aug) Metals, Metalization, and Brazing of Barium Titanate
301-s Ceramics, (Jan) 6-s
Rooch, H., Dörfel, I., Österle, W., Rethmeier, M., Schempp, P., Taban, E., Kaluc, E., and Aykan, T. S. — Effect of the Purging
Cross, C. E., Pittner, A., Oder, G., and Neumann, R. S. — So- Gas on Properties of 304H GTA Welds, (April) 124-s
lidification of GTA Aluminum Weld Metal: Part 1 — Grain Tan, C. W., Li, L. Q., Chen, Y. B., Nasiri, A. M., and Zhou, Y. —
Morphology Dependent upon Alloy Composition and Grain Microstructural Characteristics and Mechanical Properties
Refiner Content, (Feb) 53-s of Fiber Laser Welded-Brazed Mg Alloy-Stainless Steel
Sanderson, S., Mahoney, M., Yu, X., Qiao, D., Wang, Y., Joint, (Oct) 399-s
Zhang, W., Feng, Z., and Lim, Y. C. — Characterization of Tao, W., Wang, C., Wang, J., Carlson, B. E., Yang, S., and Chen,
Multilayered Multipass Friction Stir Weld on ASTM A572 Z. — Semi-Cutting-Assisted Laser Welding of Zinc-Coated
G50 Steel, (Dec) 443-s Steels in a Zero Root Opening, Lap-Joint Configuration,
Schein, J., Hanson, T., Schnick, M., Füssel, U., Siewert, E., (Sept) 331-s
Wilhelm, G., and Hässler, M. — Visualization of Gas Tian, C. Y., Wang, J., Wang, J., Huang, Y., Xiao, J., and Feng, J.
Flows in Welding Arcs by the Schlieren Measuring Tech- — Metal Transfer with Force Analysis in Consumable and
nique, (Jan) 1-s Nonconsumable Indirect Arc Welding Process, (Nov) 431-s
Schempp, P., Cross, C. E., Pittner, A., Oder, G., Neumann, R. Utkin, I. Y., Frantov, I. I., Velichko, A. A., and Bortsov, A. N. —
S., Rooch, H., Dörfel, I., Österle, W., and Rethmeier, M. — Weldability of Niobium-Containing High-Strength Steel for
Solidification of GTA Aluminum Weld Metal: Part 1 — Pipelines, (Jan) 23-s
Grain Morphology Dependent upon Alloy Composition Valentine, D. T., Bahrami, A., and Aidun, D. K. — Interaction
and Grain Refiner Content, (Feb) 53-s of Gravity Forces in Spot GTA Weld Pool, (April) 139-s
Schempp, P., Cross, C. E., Pittner, A., and Rethmeier, M. — So- Vanimisetti, S. K., and Sigler, D. R. — Improving Fatigue Per-
lidification of GTA Aluminum Weld Metal: Part 2 — Ther- formance of Spot Welds in Advanced High-Strength Steels,
mal Conditions and Model for Columnar-to-Equiaxed Tran- (May) 153-s
sition, (March) 69-s Veerarajan, T., Ananthan, S. S., Senthil Kumar, G., and Natara-
Schnick, M., Füssel, U., Siewert, E., Wilhelm, G., Hässler, M., jan, U. — Quality Level Assessment for Imperfections in
Schein, J., and Hanson, T. — Visualization of Gas Flows GMAW, (March) 85-s
in Welding Arcs by the Schlieren Measuring Technique, Velichko, A. A., Bortsov, A. N., Utkin, I. Y., and Frantov, I. I. —
(Jan) 1-s Weldability of Niobium-Containing High-Strength Steel for

DECEMBER 2014 / WELDING JOURNAL 107


Pipelines, (Jan) 23-s Zhang, C. Y., Chen, D. L., and Luo, A. A. — Joining 5754 Au-
Wang, C., Wang, J., Carlson, B. E., Yang, S., Chen, Z., and Tao, tomotive Aluminum Alloy 2-mm-Thick Sheets Using Ul-
W. — Semi-Cutting-Assisted Laser Welding of Zinc-Coated trasonic Spot Welding, (April) 131-s
Steels in a Zero Root Opening, Lap-Joint Configuration, Zhang, G., Huang, Y., Lu, L., Huang, J., Shao, Y., and Shi, Y.
(Sept) 331-s — Pulsed Double-Electrode GMAW-Brazing for Joining
Wang, J., Huang, Y., Xiao, J., Feng, J., Tian, C. Y., and Wang, J. of Aluminum to Steel, (June) 216-s
— Metal Transfer with Force Analysis in Consumable and Zhang, G. J., Zhang, W. J., Zhang, Y. M., and Xiao, J. — Ac-
Nonconsumable Indirect Arc Welding Process, (Nov) 431-s tive Metal Transfer Control by Utilizing Enhanced
Wang, J., Wang, J., Huang, Y., Xiao, J., Feng, J., and Tian, C. Y. Droplet Oscillation Part I: Experimental Study, (Aug)
— Metal Transfer with Force Analysis in Consumable and 282-s
Nonconsumable Indirect Arc Welding Process, (Nov) 431-s Zhang, G. J., Zhang, W. J., Zhang, Y. M., and Xiao, J. — Ac-
Wang, J., Carlson, B. E., Yang, S., Chen, Z., Tao, W., and Wang, tive Metal Transfer Control by Utilizing Enhanced
C. — Semi-Cutting-Assisted Laser Welding of Zinc-Coated Droplet Oscillation Part II: Modeling and Analysis, (Sept)
Steels in a Zero Root Opening, Lap-Joint Configuration, 321-s
(Sept) 331-s Zhang, W., Feng, Z., Lim, Y. C., Sanderson, S., Mahoney, M.,
Wang, P.-C., Cao, R., Sun, J. H., and Chen, J. H. — Weldability Yu, X., Qiao, D., and Wang, Y. — Characterization of Mul-
of CMT Joining of AA6061-T6 to Boron Steels with Various tilayered Multipass Friction Stir Weld on ASTM A572
Coatings, (June) 193-s G50 Steel, (Dec) 443-s
Wang, P.-C., Chen, G. L., Zhang, Y. S., and Sun, H. T. — Zhang, W. J., Zhang, Y. M., Xiao, J., and Zhang, G. J. — Ac-
Improvement of Process Robustness in Weld Bonding of tive Metal Transfer Control by Utilizing Enhanced
Galvanized DP780 Steel, (Dec) 472-s Droplet Oscillation Part I: Experimental Study, (Aug)
Wang, P.-C., Zhao, Y. Y., Zhang, Y. S., and Lai, X. M. — Effect of 282-s
Inserted Strips on Electrode Degradation in Resistance Spot Zhang, W. J., Zhang, Y. M., Xiao, J., and Zhang, G. J. — Ac-
Welding, (Nov) 411-s tive Metal Transfer Control by Utilizing Enhanced
Wang, Y., Zhang, W., Feng, Z., Lim, Y. C., Sanderson, S., Droplet Oscillation Part II: Modeling and Analysis, (Sept)
Mahoney, M., Yu, X., and Qiao, D. — Characterization of 321-s
Multilayered Multipass Friction Stir Weld on ASTM A572 Zhang, Y. M., Xiao, J., Zhang, G. J., and Zhang, W. J. — Ac-
G50 Steel, (Dec) 443-s tive Metal Transfer Control by Utilizing Enhanced
Wilhelm, G., Hässler, M., Schein, J., Hanson, T., Schnick, M., Droplet Oscillation Part I: Experimental Study, (Aug)
Füssel, U., and Siewert, E. — Visualization of Gas Flows 282-s
in Welding Arcs by the Schlieren Measuring Technique, Zhang, Y. M., Xiao, J., Zhang, G. J., and Zhang, W. J. — Ac-
(Jan) 1-s tive Metal Transfer Control by Utilizing Enhanced
Xiao, J., Zhang, G. J., Zhang, W. J., and Zhang, Y. M. — Ac- Droplet Oscillation Part II: Modeling and Analysis, (Sept)
tive Metal Transfer Control by Utilizing Enhanced 321-s
Droplet Oscillation Part I: Experimental Study, (Aug) Zhang, Y. M., and Shao, Y. — Gas Metal Arc Welding
282-s Enhanced by Using a Pulsed Laser, (June) 205-s
Xiao, J., Zhang, G. J., Zhang, W. J., and Zhang, Y. M. — Active Zhang, Y. M., Liu, Y. K., and Shao, Z. — Learning Human
Metal Transfer Control by Utilizing Enhanced Droplet Os- Welder Movement in Pipe GTAW: A Virtualized Welding
cillation Part II: Modeling and Analysis, (Sept) 321-s Approach, (Oct) 388-s
Xiao, J., Feng, J., Tian, C. Y., Wang, J., Wang, J., and Huang, Y. Zhang, Y. M., Chen, S. J., Jiang, F., and Lu, Y. S. —
— Metal Transfer with Force Analysis in Consumable and Separation of Arc Plasma and Current in Electrical Arc —
Nonconsumable Indirect Arc Welding Process, (Nov) 431-s An Initial Study, (July) 253-s
Yang, M., Yang, Z., Cong, B., and Qi, B. — A Study on the Sur- Zhang, Y. M., Kvidahl, L., and Liu, Y. K. — Skilled Human
face Depression of the Molten Pool with Pulsed Welding, Welder Intelligence Modeling and Control: Part 1 —
(Aug) 312-s Modeling, (Feb) 46-s
Yang, S., Chen, Z., Tao, W., Wang, C., Wang, J., and Carlson, B. Zhang, Y. M., Kvidahl, L., and Liu, Y. K. — Skilled Human
E. — Semi-Cutting-Assisted Laser Welding of Zinc-Coated Welder Intelligence Modeling and Control: Part II —
Steels in a Zero Root Opening, Lap-Joint Configuration, Analysis and Control Applications, (May) 162-s
(Sept) 331-s Zhang, Y. S., Lai, X. M., Wang, P.-C., and Zhao, Y. Y. — Effect
Yang, Y. P., Dull, R., Castner, H., Huang, T. D., and Fanguy, D. of Inserted Strips on Electrode Degradation in Resistance
— Material Strength Effect on Weld Shrinkage and Distor- Spot Welding, (Nov) 411-s
tion, (Nov) 421-s Zhang, Y. S., Sun, H. T., Wang, P.-C., and Chen, G. L. — Im-
Yang, Z., Cong, B., Qi, B., and Yang, M. — A Study on the Sur- provement of Process Robustness in Weld Bonding of
face Depression of the Molten Pool with Pulsed Welding, Galvanized DP780 Steel, (Dec) 472-s
(Aug) 312-s Zhao, Y. Y., Zhang, Y. S., Lai, X. M., and Wang, P.-C. — Effect
Yu, J., Choi, D., and Rhee, S. — Improvement of Weldability of of Inserted Strips on Electrode Degradation in Resistance
1 GPa Grade Twin-Induced Plasticity Steel, (March) 78-s Spot Welding, (Nov) 411-s
Yu, X., Qiao, D., Wang, Y., Zhang, W., Feng, Z., Lim, Y. C., Zhou, Y., Penner, P., Liu, L, and Gerlich, A. — Dissimilar Re-
Sanderson, S., and Mahoney, M. — Characterization of sistance Spot Welding of Aluminum to Magnesium with
Multilayered Multipass Friction Stir Weld on ASTM A572 Zn-Coated Steel Interlayers, (June) 225-s
G50 Steel, (Dec) 443-s Zhou, Y., Tan, C. W., Li, L. Q., Chen, Y. B., and Nasiri, A. M.
Yue, X., Feng, X.-L., and Lippold, J. C. — Effect of Welding Pa- — Microstructural Characteristics and Mechanical Prop-
rameters on the Heat-Affected Zone Hydrogen-Induced erties of Fiber Laser Welded-Brazed Mg Alloy-Stainless
Cracking Tendency of a Blast-Resistant Steel, (March) 98-s Steel Joint, (Oct) 399-s

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Gullco International, Inc. ­ U.S.A. 19 Weld Engineering 7


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Harris Products Group 57 WEMCO/An Association of Welding Manufacturers 76­77


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Hobart Inst. of Welding Technology 36


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114 WELDING JOURNAL / DECEMBER 2014


WELDING RESEARCH
SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 2014
Sponsored by the American Welding Society and the Welding Research Council

Characterization of Multilayered Multipass Friction


Stir Weld on ASTM A572 G50 Steel
Multilayered multipass friction stir welding was made on A572 G50 steel, resulting in
improvement of mechanical properties and grain refinement in the stir zone

BY Y. C. LIM, S. SANDERSON, M. MAHONEY, X. YU, D. QIAO, Y. WANG, W. ZHANG, AND Z. FENG,

C) steels evaluating mechanical prop-


erties and weld nugget morphologies.
ABSTRACT Similarly, Lienert and coworkers (Ref.
A multilayered multipass friction stir weld (MM­FSW) on ASTM A572 Grade 50 1) studied the joining of hot-rolled
steel was characterized to understand its potential application for thick­section struc­ AISI 1018 mild steel (0.18% C) using
tures. The 15­mm­thick section was fabricated by stacking three steel plates and then FSW. Both researchers identified grain
friction stir welding the plates together in a total of five passes. The unique butt/lap refinement in the stir zone (SZ) and
joint configuration encountered in the multilayer weld was examined to understand improved weld mechanical properties
the effect of tool rotation direction on the joint quality, especially the formation of as compared to parent steels (i.e., base
hooking defect. Charpy V­notch impact toughness tests showed generally higher im­ metals). Furthermore, Fujii and col-
pact toughness energy for the stir zone than the base metal with a ductile fracture leagues (Ref. 9) researched the me-
mode. The microhardness value was measured from 195 to 220 HV in the stir zone, chanical properties and
while the base metal showed an average value of 170 HV. The microstructure in the
stir zone and the adjacent heat­affected zone was quantified using optical and scan­
microstructural evolution of friction
ning electron microscopy (SEM) including electron backscatter diffraction (EBSD). The stir welds in three carbon steels with
increased toughness and hardness were correlated with the refined microstructure in different carbon contents (i.e., ul-
the stir zone, resulting from severe plastic deformation and subsequent dynamic re­ tralow carbon, 0.12% C, and 0.34% C
crystallization during friction stir welding. steels) using different welding condi-
tions. Both alloy composition and
temperature resulting from different
welding conditions significantly af-
fected the microstructure and me-
KEYWORDS chanical properties in this study.
Khodri et al. (Ref. 10) also evaluated
•Friction Stir Welding • Multilayer • High­Strength Low­Alloy Steel microstructures and mechanical prop-
•Mechanical Properties • Microstructure
erties of a high-carbon steel (0.95% C)
with different FSW parameters. Differ-
ent process parameters were shown to
Introduction With the rapid development of new affect the evolution of microstruc-
tool materials, such as polycrystalline tures, resulting in different microhard-
cubic boron nitride (PCBN) and tung- ness values and fracture modes.
Due to its advantages over conven- sten-based alloys (Ref. 6), FSW has
tional fusion welding, including low Finally, Taendl et al. (Ref. 11) studied
been recently applied to high- FSW of a multilayered steel sheet com-
distortion and improved mechanical strength, high-temperature (or hard)
properties (Ref. 1), friction stir weld- posed of 15 alternating layers of
materials, such as steel and Ti alloys austenitic stainless steel and a marten-
ing (FSW), a solid-state joining (Refs. 1, 7–9). Thomas et al. (Ref. 8)
process, has experienced increasingly sitic stainless steel roll-bonded to a
were among the first to investigate the total thickness of 1.2 mm. The soften-
broad applications in relatively soft feasibility of FSW of both 12%
materials such as aluminum, magne- ing of martensitic layers after welding
chromium alloy and low-carbon (0.1% was alleviated by postweld heat treat-
sium, and copper alloys (Refs. 2–5).

Y. C. LIM, X. YU, D. QIAO, Y. WANG, W. ZHANG, and Z. FENG (fengz@ornl.gov) are with Materials Science & Technology Division, Oak Ridge National Laboratory,
Oak Ridge, Tenn. S. SANDERSON is with MegaStir Technologies LLC, Provo, Utah. M. MAHONEY is a consultant, Midway, Utah.

DECEMBER 2014 / WELDING JOURNAL 443-s


WELDING RESEARCH

A B buildup approach to produce a thick


structure with a conventional pin
length.
In the present study, a friction stir
welded multilayer structure of A572
Grade 50 steel, previously fabricated
(Ref. 14), was characterized to under-
stand its potential application for
thick-section structures. In particular,
the multilayered structure used corner
joints; a unique joint configuration
having both butt and lap features. Dif-
C ferent tool rotation directions on the
Fig. 1 — A — Optical image showing mi­ butt and lap joint configuration were
crostructures of the BM, consisting of applied and compared to understand
ferrite (white) and pearlite (dark); B — the effect on friction stir weld quality
magnified scanning electron microscope especially the formation of hooking
(SEM) image; C — magnified SEM image
defect at the joint interface. Also, MM-
illustrating the pearlite structure, con­
sisting of lamellar cementite, and ferrite FSW sample was characterized to un-
in the BM (F: ferrite, P: pearlite). derstand the correlation between
microstructure and mechanical prop-
erties. Specifically, optical and electron
microscopy were used to understand
A the microstructural evolution in both
the stir zone (SZ) and heat-affected
zone (HAZ). Different regions in the
friction stir welds were studied by elec-
B tron backscatter diffraction (EBSD) for
microstructural analysis and by micro-
indentation test for hardness distribu-
tion. Charpy V-notch impact tests
C were performed in the SZ, HAZ, and
base metal (BM) as a function of tem-
perature. Fracture surfaces from the
impact tests were evaluated by scan-
ning electron microscopy (SEM) to as-
D sess the failure mode.

Experimental Methods
Fig. 2 — Cross sections showing A — Premachined A572 Grade 50 plate for MM­FSW; B Friction Stir Welding Procedure
— butt­joint weld for the bottom layer; C — insertion and FSW of the first weld plate
above the root weld; D — insertion and FSW of the second weld plate above the first Detailed procedures for MM-FSW
weld plate and the final welded structure. Thickness of both top and middle layers was can be found in the authors’ recent
4.6 mm and the bottom layer was 6.1 mm. The total thickness of the MM­FSW structure publication (Ref. 14). To provide the
was 15.2 mm. The combination of tool rotation direction (counter clockwise) and tool necessary background for the detailed
travel direction puts the advancing side of the weld at the lap interface. characterization results (e.g., hooking
defect and toughness) presented later,
ment to achieve 95% joint efficiency. difficult to make thick structures with salient features of MM-FSW are de-
One shortcoming of FSW is the a thickness greater than 15 mm. To scribed in the following:
thickness of the workpiece that can be overcome this limitation, a new A three-layered structure, with five
joined, especially for hard materials method of FSW that can be applied to multipass friction stir welds, was made
such as steels. That is, the length of a thick section is needed. using flat plates of high-strength low-
the pin limits the thickness of material A thick-section steel structure, fab- alloy (HSLA) steel (ASTM A572 Grade
that can be friction stir welded. Only a ricated by a novel multilayer and mul- 50; chemistry: 0.23C-1.35Mn-0.04P-
few studies have reported FSW of steel tipass FSW (MM-FSW) method, was 0.05S-0.3Si-0.2Cu in wt-%) resulting
plates thicker than 10 mm (Refs. 8, demonstrated in the authors’ recent in a total thickness of 15.2 mm. As
12). Although double-sided welding work (Refs. 13, 14). Unlike the tradi- shown in Fig. 1A, the base metal con-
has been attempted to make thick tional multipass FSW (Ref. 15), the tains mainly equiaxed ferrite (F) and a
welds (up to 12 mm thick), it is still MM-FSW is based on a layer-by-layer small amount of pearlite (P). The mag-

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WELDING RESEARCH

Fig. 3 — Convex scroll shoulder step spiral pin (CS4


tool design) MS80 tool. The shoulder diameter was
36.8 mm with pin height and radius of 5.94 and
3.79 mm, respectively. Fig. 4 — Notch location and dimensions of specimen for Charpy impact test.

nified SEM image in Fig. 1B also indi- ishing of the mounted samples. A 5% at the Laboratory Testing Industry
cates distinct ferrite and pearlite mi- Nital solution was used to etch the (LTI) facility. After Charpy impact
crostructures in the BM. Figure 1C samples. An optical microscope (Nikon tests, the fracture surfaces were stud-
shows the pearlite microstructure il- Epiphot) and field emission scanning ied by SEM imaging.
lustrating a lamellar structure consist- electron microscope (FE-SEM) (Hi-
ing of alternate layers of ferrite and tachi S4800) were used to characterize Results and Discussion
cementite. The width of the cementite microstructures of the weld samples.
lamellar layer was measured to be ap- To characterize the original mi-
proximately 100 nm with a uniform crostructure of the steel and the mi- Characterization of MM­FSW
spacing of slightly more than 100 nm. crostructural evolution in the SZ and Structure
A brief description of each step for HAZ, a JEOL 6500 scanning electron
MM-FSW is illustrated in Fig. 2. A microscope equipped with an EBSD One characteristic of MM-FSW is a
stepped assembly was machined to ac- camera was used. This microscope has combination of butt and lab joint con-
commodate MM-FSW. To avoid over- an accelerating voltage of 20 kV and a figurations that involved inserting a
lapping with weld(s) in the previous spot diameter of 5 nm with a scanning metal plate to stack up the next layer.
layer, friction stir welds in the subse- step size of 0.1 mm. EBSD maps were For this reason, it is referred to as a
quent layer were offset transversely by analyzed using OIM analysis software. “butt/lap” joint. Such a butt/lap joint
a distance of 38.1 mm. For FSW, a tool Vickers hardness of each welded feature is likely to incur the interface
with a convex scroll shoulder step spi- sample was measured by a Leco micro- defect called “hooking.” This defect is
ral pin (CS4 tool design) was used and hardness tester (LM 100AT) with 200 typically formed at a lap joint due to
was fabricated from an MS80 grade of mm spacing, 200 g of load, and 13 s of upward bending or flow of the metal
PCBN, as shown in Fig. 3. MS80 grade dwell time. The measured hardness horizontal interface when the tool
is a PCBN material made of Al-based data were transferred to Origin® soft- penetrates into the bottom layer (Refs.
ceramic binder phases with 80 vol-% ware (Origin Pro 8.1) for visualizing 16–19). Figure 5 shows optical images
of the ultrahard CBN phase. For FSW, hardness maps. at a butt/lap joint interface with two
the plunge was performed at 1100 Charpy V-notch (CVN) impact different process conditions. The first
rev/min followed by a 6-s dwell at 250 toughness tests were conducted per condition was with the FSW tool posi-
rev/min. Following the dwell, the tool ASTM E23 to study the fracture tioned on the retreating side of the lap
rotation rate was maintained at 250 toughness of the SZ, HAZ, and BM at interface, as shown in Fig. 5A. The lat-
rev/min and the tool travel speed was each of the three layers. Due to the dif- ter condition positioned the FSW tool
1.27 mm·s–1. The FSW was performed ferent thicknesses at each layer, sub- on the advancing side of the lap inter-
using load control with normal loads sized samples were prepared for face, as depicted in Fig. 5C. In the first
ranging from 32 to 35.6 kN. impact testing with the following di- condition, uplift of the interface oc-
mensions (10 ¥ 4 ¥ 55 mm) with the curred even though the weld nugget
Metallography and Hardness notch tip oriented parallel to the weld- was free from volumetric defects, as
Testing ing (or longitudinal) direction, as shown in Fig. 5B. Conversely, Fig. 5D
shown in Fig. 4. Charpy tests were per- displays the top layer weld where in-
To reveal the microstructure at the formed at six different temperatures terfacing hooking was minimized.
weld zone for each layer, multilayered for the SZ, i.e., –50°, –30°, –20°, –10°, That is, hooking was minimized by po-
samples were cut and mounted for 0°, and 20°C. Similarly, samples lo- sitioning the tool advancing side on
metallography. Diamond solutions (6, cated in the HAZ and BM were tested the lap interface side of the corner
3, and 1 mm) were used for final pol- at –50°, 0°, and 20°C. Triplicate sam- joint. The difference in results is due
ples were tested at each temperature to the difference in material flow

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A B test results for each zone, with differ-


ent layers at different test tempera-
tures, are summarized in Fig. 6. For
example, the average absorbed energy
of the BM at the bottom layer (butt
joint) was found to be 15.8 J at –50°C.
The average impact toughness of the
SZ at the bottom layer at –50°C was
87.7 J, i.e., almost 5.5 times higher
than the BM. Toughness of the SZ at
the bottom layer and the top layer was
much higher than the BM at all tested
C D temperatures. However, the absorbed
energy of the SZ at the middle layer
was higher for all temperatures up to
0°C but was lower at 20°C. One possi-
ble explanation is that the welds were
not fully consolidated at this location,
i.e., small voids and defects were ob-
served in the SZ at the middle layer
potentially lowering the impact tough-
ness. In addition, the SZ at the top,
middle, and bottom layers showed an
Fig. 5 – A — When the FSW tool was positioned with the retreating side located on the
average of 79.1, 74.1, and 81% shear
lap interface; B — optical image showing hooking defect at the lap interface (red color fracture area. Next, the toughness of
arrows); C — a corner weld with the FSW tool advancing side positioned on the lap inter­ the HAZ at the bottom layer was 61.9
face; D — optical image showing minimal (or no) uplift of the lap interface. (Note: Adv is J, again considerably higher than the
advancing side and Ret is retreating side.) base metal at –50°C. The toughness of
the HAZ at the top and middle layer
was higher than the BM up to 0°C. The
HAZ at top, middle, and bottom layers
showed an average of 68.9, 68.9, and
78.3% shear fracture area. Konkol and
Mruczek studied the toughness of fric-
tion stir welded HSLA-65 steel using
subsized Charpy specimens (Ref. 22).
They also found the toughness for the
SZ and HAZ to be higher than the BM.
Similar observations were obtained for
aluminum alloys in previously re-
ported studies (Refs. 23, 24). This sub-
stantial increase in the absorbed
impact energy can be related to the
fine grain size of the SZ and HAZ. The
grain size of each zone is discussed
Fig. 6 — Charpy V­notch impact test results for each layer at different temperatures (Ref. 14). below with the microstructure images.
For comparison, the BM showed an
average of 20, 72, and 80% shear frac-
caused by the different combinations zontal metal flow, there is expected to ture area at –50°, 0°, and 20°C test
of tool rotation direction and tool be little uplift of the lap interface, thus temperatures, respectively.
travel direction. The uplift of the lap minimizing hooking. This different ap- The SEM images, which illustrate
interface in a corner joint is undesir- proach is beyond the scope of work for fracture surfaces from the impact
able because it can result in a decrease the present paper. toughness tests for each zone at the
in strength and potentially premature bottom layer, are shown in Fig. 7. For
failure (Ref. 20). An alternative way to Charpy Impact Toughness Test the SZ, the failure mode at all temper-
prevent a hooking defect is to use a Result atures was found to be ductile fracture
specially designed lap joint tool, which with the presence of dimples at the
has a feature at the tool tip that cre- Impact toughness of the SZ, HAZ, fracture surface — Fig. 7A–C. Simi-
ates horizontal metal flow (Ref. 21), and BM of each layer was studied by larly, the fracture mode was ductile for
as opposed to threads or the step spi- Charpy V-notch impact tests at differ- the HAZ with dimples at the fracture
ral that create vertical flow. With hori- ent temperatures. The Charpy impact surface at all temperatures. Finally, the

446-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


WELDING RESEARCH

BM shows two different failure modes


as a function of temperature. At 20°C
test temperatures, the fracture mode A B C
was found to be ductile with the pres-
ence of dimples at the fracture surface
— Fig 7G. Mostly ductile with small
brittle fracture surface was found at
0°C test temperature — Fig 7H. A brit-
tle failure mode was found at –50°C
where a cleavage fracture surface was D E F
identified, as shown in Fig. 7I.

Microhardness and
Metallography

Microhardness of each weld at the G H I


bottom, middle, and top layer was
measured to correlate with the
strength of each weld zone. Figure 8A
illustrates the hardness distribution
for the friction stir weld region at the
bottom layer, where the x direction is
transverse to the weld direction. The
hardness profiles along the two Fig. 7 — SEM images showing fracture surfaces after Charpy V­notch impact toughness
dashed lines in Fig. 8A are further testing (SZ, HAZ, and BM samples at the bottom layer) at different temperatures.
plotted in Fig. 8B. The average meas-
ured hardness of the BM was approxi-
mately 170 HV. For the HAZ, the
measured Vickers hardness value
ranged from 175 to 185 HV. In the SZ,
the highest hardness ranges from 195
to 220 HV. Similar hardness values
were measured at the middle and top
layer. Based on the hardness values in
the SZ, it is expected that a bainitic
microstructure formed upon cooling.
Variations in hardness results are
likely due to differences in the grain
size and microstructures sampled by
indentation grids. The hardness varia-
tion is fairly small between the differ-
ent weld zones in MM-FSW when
compared to a multipass flux cored arc
welded pipe steel (X-80) where hard-
ness variations up to 200 HV are com-
mon (Ref. 25). Moon et al. (Ref. 26)
also used multipass gas metal arc
welding (GMAW) on HSLA-100 steel
with various heat inputs ranging from
1200 to 4300 kJ·m–1. They found the Fig. 8 — A — Mapped Vickers microhardness values for the bottom layer (butt joint)
weld area; B — cross­sectional hardness plots at the height of 4 and 5 mm locations
hardness of the weldment varied from [dashed line in A). (Adv: advancing side, Ret: retreating side) (Ref. 14).
199 to 400 HV and was greatly de-
pendent on heat input and cooling
rate. size using optical microscopy and sec- (Fig. 9C) shows large polygonal ferrite
One of the advantages of FSW is ondary electron microscopy. The cur- with small islands of pearlite similar to
achieving high strength in the weld rent study applied EBSD to study the that shown in Fig. 1. Significant grain
through grain refinement in the stir microstructures and grains of the fric- refinement was found in the SZ (Fig.
zone. However, due to the complexity tion stir welds. EBSD maps for the SZ, 9A), as compared with the BM — Fig.
of refined ferrite grains in the stir re- HAZ and unaffected BM are shown in 9C. Grain refinement has been ob-
gion, it is difficult to quantify grain Fig. 8. The base metal orientation map served previously in the SZ due to dy-

DECEMBER 2014 / WELDING JOURNAL 447-s


WELDING RESEARCH

Fig. 10 — Grain size distribution of all three regions (SZ, HAZ, and BM).

TCFE database (Ref. 31). Therefore,


α for the stir zone, it is expected that the
T ⎡ ω ⎤ 2
=K⎢ 4 ⎥
base metal mixture of ferrite and
Tm ⎣ V ⋅ 10 ⎦ pearlite transforms to single-phase
(1) austenite during the heating cycle.
where T is the temperature Furthermore, the estimated peak tem-
during welding (°C), Tm is perature in the SZ supports the postu-
C lated peak temperature in the
the liquidus temperature of
the alloy (°C),  is the tool intercritical temperature range experi-
rotational rate, V is the enced by the HAZ.
weld travel speed,  (range The highest temperature, which is
of 0.04–0.06) and K (range estimated about 1100°C based on the
of 0.65–0.75) are two em- above calculation, can be used to ex-
pirical material constants, plain the two distinct regions ob-
respectively. The liquidus served in the HAZ, i.e., the
of A572 Grade 50 steel is intercritical HAZ (ICHAZ) and the
Fig. 9 — EBSD maps of different weld zones. A — Stir about 1504°C (2740°F) and fine-grained HAZ (FGHAZ) shown in
zone (some bainite plates were pointed out); B — the transverse tool speed Fig. 9B.
heat­affected zone [Note: fine­grained heat­affected used in the experiment was In the ICHAZ, there coexists fine
zone (FGHAZ) and intercritical heat­affected zone 1.27 ¥ 10–3 m·s–1. The tool and coarse ferrite grains. The peak
(ICHAZ); C — unaffected base metal. rotation speed was 250 temperature experienced by this re-
rev/min (26.18 radian·s–1). gion during welding is between A1 and
namic recrystallization and severe Based on different combi- A3. As a result, the ferrite to austenite
plastic deformation during FSW (Ref. nations of  and K values, the esti- transformation during heating is in-
1). In the SZ, the grains are not mated peak temperature ranged from complete due to the low peak tempera-
equiaxed. Wedge-shaped plate fea- 1147° to 1433°C, which is lower than ture, producing fragmented and thus
tures, which are an indication of a the liquidus temperature of steel. smaller austenite grains mixed with
bainitic microstructure, were also ob- When  and K are 0.04 and 0.65, re- original ferrite grains. Upon cooling,
served (Ref. 27). The hardness meas- spectively, the calculated peak temper- the austenite transforms back into fer-
ured in the SZ ranged from 195 to 220 ature is 1133°C. This estimated peak rite, resulting in a microstructure in
HVN, showing agreement with the mi- temperature is in reasonable agree- this region that is composed of newly
crostructure observations. ment with the peak temperature formed fine ferrite surrounded by un-
During FSW, heat generation is in- (ranged from 1000° to 1200°C) re- transformed ferrite (Ref. 32).
fluenced by the tool rotation rate and ported by previous researchers (Refs. On the other hand, the FGHAZ ex-
weld travel speed as well as material 1, 8). Similarly, Ghosh et al. (Refs. 29, periences a local peak temperature
properties. Due to the difficulty of 30) used Equation 1 to estimate the that is above A3, thus producing a full
temperature measurements in the SZ, peak temperature (calculated ranged austenite microstructure albeit with
the empirical expression developed by from 1030° to 1090°C) at the weld smaller grain size than the parent fer-
Arbegast (Ref. 28) is used to estimate nugget for friction stir welded M190 rite upon heating (Ref. 27). However,
the peak temperature in the weld steel. This estimated peak temperature as the highest temperature in the en-
nugget. in the SZ was well above the A3 tem- tire weld is capped at 1100°C, the
perature of the steel, 824°C, which was austenite grain growth was limited in
calculated using Thermo-Calc® and the FGHAZ. The small austenite trans-

448-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


WELDING RESEARCH

forms back into ferrite during cooling, age vessels. Multilayer pressure vessels 2. Dawes, C. J., and Thomas, W. M.
resulting in a final microstructure that or storages are often preferred over 1996. Friction stir process welds alu-
is composed of fine ferrite grains. In heavy thick single-wall structures due minum alloys. Welding Journal 75(3): 41-s
addition, the kernel average misorien- to lower cost and manufacturing effi- to 45-s.
3. Yu, Z. Z., Zhang, W., Choo, H., and
tation (KAM), a parameter that is used ciency (Refs. 37, 38).
Feng, Z. 2012. Transient heat and material
to evaluate the strain or the stored en- flow modeling of friction stir processing of
ergy for a given point (Refs. 33–35), Conclusion magnesium alloy using threaded tool. Met-
shows a very small value and no signif- allurgical and Materials Transactions A:
icant preferred orientation for regions In conclusion, the use of MM-FSW Physical Metallurgy and Materials Science
in Fig. 9B. Therefore, it is believed that enables fabrication of thick structures 43A (2): 724 to 737.
this region is not significantly influ- 4. Woo, W., Balogh, L., Ungar, T., Choo,
in high-strength low-alloy steel. This
enced by the mechanical deformation H., and Feng, Z. 2008. Grain structure and
technique can be potentially used for dislocation density measurements in a fric-
common to the thermal mechanically multilayer high-pressure storage/
affected zone. tion-stir welded aluminum alloy using X-
vessel applications. Strengths in the ray peak profile analysis. Materials Science
Figure 10 shows the grain size dis- SZ and HAZ were higher than the BM and Engineering A- Structural Materials
tribution in the SZ, HAZ (both FGHAZ based on microhardness measure- Properties Microstructures and Processing
and ICHAZ) and BM from EBSD data ments. Also, CVN results indicate that 498(1–2): 308 to 313.
for the bottom layer. The average grain impact toughness in the SZ and HAZ 5. Park, H. S., Kimura, T., Murakami, T.,
sizes of the FGHAZ and ICHAZ are are generally higher than BM. Both the Nagano, Y., Nakata, K., and Ushio, M.
slightly lower than that of SZ, both of SZ and HAZ have fine-grained mi- 2004. Microstructures and mechanical
which are less than 10 m. As a result, crostructures, although the mecha- properties of friction stir welds of 60% Cu-
the peak temperature of the FGHAZ 40% Zn copper alloy. Materials Science and
nism for it is expected to be different Engineering A- Structural Materials Proper-
observed in the current EBSD study is for the SZ (i.e., dynamic recrystalliza-
expected to be lower than 1000°C (Ref. ties Microstructures and Processing
tion) vs. the HAZ (i.e., intercritical 371 (1–2): 160 to 169.
36). Conversely, the BM has the temperature). Taken together, with all 6. Rai, R., De, A., Bhadeshia, H. K. D.
largest grain size, i.e., ~30 m. Similar the mechanical tests and hardness H., and DebRoy, T. 2011. Review: friction
grain sizes and microstructures were measurements, the present work indi- stir welding tools. Science and Technology of
found in the SZ, HAZ, and BM for the cates that the overall mechanical Welding and Joining 16(4): 325 to 342.
middle and top layers. For brevity, strength of the MM-FSW steel sam- 7. Park, S. H. C., Sato, Y. S., Kokawa, H.,
those microstructures are not re- ples were comparable or superior to Okamoto, K., Hirano, S., and Inagaki, M.
peated in the current paper. 2003. Rapid formation of the sigma phase
the base metal. For future work, hook-
Finally, the grain size was different in 304 stainless steel during friction stir
ing that occurs due to the butt/lap welding. Scripta Materialia 49(12): 1175 to
in the SZ, HAZ, and BM with the joint configuration should be avoided
smallest grain size found in the HAZ. 1180.
by either using a special tool to pro- 8. Thomas, W. M., Threadgill, P. L., and
If average grain diameters (9 m for duce horizontal metal flow or by using Nicholas, E. D. 1999. Feasibility of friction
the HAZ, 10 m for the SZ and 28 m an alternate joint design. stir welding steel. Science and Technology of
for the BM) were plugged into the fol- Welding and Joining 4(6): 365 to 372.
lowing Hall-Petch relationship, 9. Fujii, J., Cui, L., Tsuji, N., Maeda, M.,
Acknowledgments Nakata, K., and Nogi, K. 2006. Friction stir
g = KyD–1/2 (2) welding of carbon steels. Materials Science
and Engineering A- Structural Materials
where Ky is 0.363 MPa m1/2 (Ref. 36), Properties Microstructures and Processing
The authors would like to acknowl-
g is the strength contribution from edge the financial support of the U.S.
429(1-2): 50 to 57.
grain boundaries, and D is average 10. Khodir, S. A., Morisada, Y., Ueji, R.,
Department of Energy Office of En- and Fujii, H. 2012. Microstructures and
grain diameter. The estimated ergy Efficiency and Renewable Energy, mechanical properties evolution during
strength contribution from grain Fuel Cell Technologies Office and Ad- friction stir welding of SK4 high carbon
boundaries for the SZ, HAZ, and BM vanced Manufacturing Office. Oak steel alloy. Materials Science and Engineer-
are 114.8, 121, and 68.6 MPa, respec- Ridge National Laboratory (ORNL) is ing A- Structural Materials Properties Mi-
tively. Since bainite, which has more managed by UT-Battelle, LLC, for the crostructures and Processing. 558: 572 to
dislocations than ferrite, is also ob- U.S. Department of Energy under Con- 578.
served in the SZ, additional strength 11. Taendl, J., Nambu, S., Inoue, J., En-
tract DE-AC05-00OR22725.
in the SZ is expected. Nevertheless, zinger, N., and Koseki, T. 2012. Friction
the grain boundary strengthening has stir welding of multilayered steel. Science
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minum alloy. International Journal of Ma- Research. Eds. DebRoy, T., S. A. David, J. N. 35. Badji, R., Chauveau, T., and Bacroix,
chine Tools & Manufacture 49(2): 142 to 148. Koseki, and H. K. Bhadeshia. pp. 461–468. B. 2013. Texture, misorientation and me-
17. Ericsson, M., Jin, L. Z., and Sand- ASM International. chanical anisotropy in a deformed dual
strom, R. 2007. Fatigue properties of fric- 26. Moon, D. W., Fonda, R. W., Spanos, phase stainless steel weld joint. Materials
tion stir overlap welds. International G. 2000. Microhardness variations in Science and Engineering A- Structural Mate-
Journal of Fatigue 29(1): 57 to 68. HSLA-100 welds fabricated with new ultra- rials Properties Microstructures and Process-
18. Badarinarayan, H., Shi, Y., Li, X., low-carbon weld consumables. Welding ing 515: 94 to 103.
and Okamoto, K. 2009. Effect of tool Journal 79(10): 278-s to 285-s. 36. Yu, X., Caron, J. L., Babu, S. S., Lip-
geometry on hook formation and static 27. Bhadeshia, H. K. D. H. 2001. Bainite pold, J. C., Isheim, D., and Seidman, D. N.
strength of friction stir spot welded alu- in Steels: Transformations, Microstructures 2010. Characterization of microstructural
minum 5754-O sheets. International Jour- and Properties, IOM Communication Ltd., strengthening in the heat-affected zone of
nal of Machine Tools & Manufacture 49(11): London, pp.19. a blast-resistant naval steel. Acta Materialia
814 to 823. 28. Arbegast, W. J., in: Z. Jin, A. Beau- 58 (17): 5596 to 5609.
19. Yin, Y. H., Sun, N., North, T. H., and doin, T. A. Bieler, B. Radhakrishiman 37. Zhen, L., Jiang, N., and Liu, S. J.
Hu, S. S. 2010. Influence of tool design on (Eds.), Hot Deformation of Aluminum Alloys 2011. Experimental study of integrated
mechanical properties of AZ31 friction stir III, TMS, San Diego, Calif., 2003, pp. multilayer clamping high pressure vessel.
spot welds. Science and Technology of Weld- 313–327. Journal of Pressure Vessel Technology-Trans-
ing and Joining 15(1): 81 to 86. 29. Ghosh, M., Kumar, K., and Mishra, actions of the ASME 133(6): 061206-1 to
20. Yadava, M. K., Mishra, R. S., Chen, R. S. 2010. Analysis of microstructural 061206-6.
Y. L., Carlson, B., and Grant, G. J. 2010. evolution during friction stir welding of ul- 38. Zhang, W., Ren, F., Feng, Z., Wang,
Study of friction stir joining of thin alu- trahigh-strength steel. Scripta Materialia J.-A., Jawad, M., Kelly, M., and Vossoughi,
minum sheets in lap joint configuration. 63(8): 851 to 854. F. 2012. Design analysis of steel concrete
Science and Technology of Welding and Join- 30. Ghosh, M., Kumar, K., and Mishra, composite vessel for stationary storage of
ing. 15(1): 70 to 75. R. S. 2011. Friction stir lap welded ad- high-pressure hydrogen. International Hy-
21. Fuller, C. B., Mahoney, M. W., and vanced high strength steels: Microstruc- drogen Conference: Hydrogen-Materials In-
Bingel, W. H. 2005. Friction Stir Weld Tool ture and mechanical properties. Materials teractions. Eds. B. P. Somerday and P.
and Method. U.S Patent 20050121497 A1. Science and Engineering A- Structural Mate- Sofronis, pp. 479–488. ASME.

Call for Presentations


National Robotic Arc Welding Conference
The National Robotic Arc Welding Conference will take your presentation title, short paragraph discussing what it
place June 1–3, 2015, in Milwaukee, Wis. This year’s theme is about, and who will give the 30-min talk to j.noruk@ser-
is “Future Tools — Future Workforce” in recognition of the vorobot.com. Deadline for consideration is December 31,
fact that new technology will not work well without trained 2014.
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We are looking for speakers who have addressed robotic John Hinrichs, who passed away in 2012, started it with the
and automatic arc welding-related challenges and succeeded purpose of helping the fledgling robotic welding industry
through innovation in part design, tooling, process opti- grow by sharing new technology and ideas. Proceeds from
mization, workforce training, or other means. Submissions the conference will go to the John Hinrichs Memorial En-
are welcomed from end users, equipment suppliers, or a dowment, which is currently funded in an amount to pro-
combination of both. If you are interested, please submit vide more than $10,000 annually in scholarships.

450-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


WELDING RESEARCH

Friction Stir Welding of Extruded Powder


Metallurgy Al Alloy
Friction stir welding was used successfully to join an extruded powder metallurgy Al alloy
without discontinuities, voids, or defects

BY A. ELREFAEY, K. ANDERS, H. KILIAN, F. ELLERMANN, AND W. KÜHLEIN

minum and aluminum alloys. For ex-


ABSTRACT ample, liquid phase processes such as
conventional casting are cost effective
Friction stir welding (FSW) of an extruded powder metallurgy (PM) but cannot be used to make compo-
aluminum alloy was performed to produce a rotary engine housing. The mi­ nents for critical applications since low
crostructure, phase constituents, and mechanical properties of FSW joints mechanical property levels can be ob-
were studied by metallography, tensile, and fatigue tests. The results indicated tained as a result of coarser mi-
the process achieved sound joints without voids or discontinuities. The mi­ crostructural features commonly asso-
crostructure of welded area (stir zone) was finer and more homogeneous than ciated with conventionally cast materi-
the base metal, while the average yield strength value was 2.3% higher than als. Alloys produced by atomization
the base metal. Meanwhile, the average tensile strength was 95% that of the followed by powder metallurgy (PM)
base metal. Furthermore, statistical evaluation at 10, 50, and 90% probabilities consolidation and extrusion to the fi-
of survival of the fatigue test stresses were calculated as 81.94, 81.01, and nal shape overcome the formation of
80.09 MPa, respectively, at room temperature. Meanwhile, the fatigue limit coarse grains, coarse constituents, and
decreased approximately 25% due to raising the temperature to 240°C. macrosegregation because of the high
cooling rates. Therefore, these PM al-
loys are characterized by very fine, ho-
mogeneous, and segregation-free mi-
KEYWORDS crostructures combined with a fine
distribution of intermetallic particles.
• Friction Stir Welding (FSW) • Aluminum • Microstructure • Tension
Powder metallurgy alloys are now a
• Fatigue • Powder Metallurgy (PM)
potential alloy for the Wankel rotary
engine housing and the single rotary
piston to reduce weight of these com-
Introduction To comply with all of the previously ponents compared with the heavier
mentioned changes, automotive man- conventional quench and tempered
As the automotive industry ad- ufacturers worldwide are exploring al- steel. Reducing the weight of these
dresses environmental concerns, the ternative lightweight materials such as components would, in turn, reduce the
problems of fuel consumption and aluminum. amount of necessary counterweight,
weight reduction have come to the Aluminum alloys are not only light- and therefore reduce acceleration loss-
fore. Reducing the weight of automo- weight materials, but they also have es (Refs. 1, 2).
biles is one of the primary means by excellent corrosion resistance, high The PM alloys help to realize supe-
which their fuel consumption is low- workability, good thermal conductivi- rior properties but have limitations re-
ered. In addition to saving fuel, weight ty, and highly recyclable properties. lated to the dimensions of the compo-
reduction is a very effective way to im- For these reasons, aluminum is ex- nent and, in addition, involve high
prove the car’s driving and drifting pected to replace many parts in the au- costs (Refs. 3–7). As the component
abilities. It improves just about every- tomotive industry. The processing and size increases, the extrusion process
thing a car has to offer: acceleration, manufacturing process plays a vital becomes difficult to perform, the pow-
braking, handling, and CO2 emission. role in the final properties of alu- er needed is proportionally increased,

A. ELREFAEY (ahmed.elrefaei@ait.ac.at), K. ANDERS, and H. KILIAN are with Mobility Dept., LKR Leichtmetallkompetenzzentrum, Ranshofen GmbH (Light
Metals Technologies Ranshofen), Austrian Institute of Technology, Ranshofen, Austria. F. ELLERMANN and W. KÜHLEIN are with Hammerer Aluminium Indus­
tries Extrusion GmbH, Ranshofen, Austria.

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Fig. 1 — Samples of extruded sections and the joint configuration before welding.

al, a microstructure homogenization given in Table 1. Two 20-mm-thick ex-


process is also required. The unique ad- truded sections were assembled by tack
vantages of FSW, in respect to welding welding before FSW to produce the ro-
and microstructure homogenization, tary engine housing. Figure 1 shows a
can easily overcome the limitations of sample of the extruded sections and the
welded PM aluminum alloys and en- configuration of the joint before
hances their mechanical properties welding.
(Refs. 8, 10–13).
In recent years, several studies have FSW Process
been concentrated on friction stir pro-
cessing of aluminum alloys, PM alloys, The workpiece was placed on a
and composites to homogenize and re- backup plate and the whole geometry
fine the microstructure (Refs. 13–16). was rigidly clamped with a jig to pre-
Fig. 2 — The workpiece clamped in the However, as far as we know, little or vent lateral movements during FSW.
jig before FSW. no studies have been reported on PM Figure 2 shows the workpiece clamped
aluminum alloys after final forming by in the jig before the FSW process.
and the cost becomes unaffordable. the extrusion process. In this study, a A welding tool having a 16-mm pin
Therefore, a need for a joining process eutectic PM Al-Si alloy after extrusion diameter made from tool steel was
to assemble different extruded parts is has been welded by the FSW process. used. The tool axis was tilted by 2 deg
necessary. Therefore, this research has been with respect to the vertical axis of the
Friction stir welding has the poten- aimed at investigating the microstruc- plate surface. The applied rotation
tial to join PM Al alloys since it has been tural features, phase analysis, and me- speed was 500 rev/min, with a travel-
systematically developed for joining alu- chanical properties of the joints. ing speed of 200 mm/min, and a com-
minum alloys. It is proving to be far pressive force of 35 kN. The FSW tool,
more forgiving to use than arc welding Experimental Work fixed in the holder, was slowly pushed
techniques and can consistently pro- into the PM Al plate and then forcibly
duce long welds, especially between ex- Material traversed along the joint until the end
trusions of high quality, low cost, and of the weld was reached. The welding
with very low distortion since the weld The starting material was an air- tool was then retracted while the tool
is made in the solid phase (Refs. 8, 9). atomized powder aluminum alloy sieved continued to turn.
Additionally, PM processed aluminum to <150 m (Mepura Metallpulverge-
alloys suffer from three major mi- sellschaft m.b.H, Austria) with a density Microstructure and Mechanical
crostructural problems that limit their of 2.775 g/cm3. Consolidation was done Testing
full potential: prior-particle boundaries by cold compaction using an external
with an aluminum oxide film, mi- pressure of 200 MPa. The bulk material, The cross sections of the joints
crostructural inhomogeneity, and rem- having 300 mm diameter and 750 mm were prepared for metallographic
nant porosity. These microstructural length, was hot extruded into two half analysis with standard grinding and
features particularly hamper the ductili- sections with a reduction ratio of 9:1 af- polishing techniques. Selected samples
ty in very high-strength aluminum al- ter holding for 12 h at 450°C. None of were subsequently etched for 30 s with
loys and impede the welding process as the extruded bars showed blistering or a solution comprised of 50% water,
well. Therefore, in addition to the need cracking on the surface. The chemical 15% HCl, 25% HNO3, and 10% HF.
for a welding process to join the materi- analysis of the alloy after extrusion is The microstructure of the joints was

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WELDING RESEARCH

examined with a light optical micro-


scope and grain size measurements B
A
were performed with digital image
analysis software. A scanning electron
microscope (SEM), equipped with an
energy-dispersive X-ray (EDX), was
used for chemical analysis.
For the tensile tests, 140-mm-long
flat samples and 115-mm-long round
samples were prepared in accordance
with DIN 50125 at room temperature
(Ref. 17). The weld was centered in the
gauge section and the loading axis,
normal to the welding direction, was
applied. Sixteen round and flat sam- C D
ples were used to calculate the average
yield strength, tensile strength, and
ductility of the joints. Tensile strength
was determined by dividing the maxi-
mum load required during testing by
the cross-sectional area. It is worth
noting that transverse weld specimens
normally provide a measure of joint ef-
ficiency in terms of strength, but do
not provide a good ductility measure-
ment of the weld.
Since engineered parts are frequently
subjected to stress by dynamic forces,
especially alternating or cyclic loads, Fig. 3 — A — Microstructure of the extruded alloy; EDX mapping of, respectively,
which act periodically in the same man- B — Al; C — Si; D — Fe.
ner on the structural part, it is neces-
sary to evaluate the behavior of a mate-
rial under such loads by fatigue tests up chine at 0.1-kgf loads and an indenta- ture, these elements usually constitute
to very high load-cycle rates. The results tion time of 25 s. precipitation of Si, Mn, and Fe, and
are presented in what are known as forms an Al12(Fe,Mn)3Si phase. The
Wöhler diagrams or an S-N curve ob- Results and Discussion wide variety of intermetallic phases in
tained by plotting the applied stress (S) aluminum alloys occurs because alu-
against the number of cycles to failure Microstructure of Joints minum is highly electronegative and
(N). The fatigue strength or endurance trivalent, which has been the subject
limit is defined as the stress level a sam- The microstructure of the extruded of several studies (Refs. 21–23).
ple can withstand for at least 107 cycles. alloy is shown in Fig. 3A. The PM Al-Si Therefore, very fine precipitation was
The high cycle fatigue specimens alloys presented a fragmented eutectic scattered in the aluminum matrix. Fig-
were tested using a sinusoidal wave (a-aluminum + silicon) microstruc- ure 3B–D shows EDX mapping of Al,
form in accordance with DIN 50100 ture. Owing to the processing history Si, and Fe, respectively, in the Al alloy.
(Ref. 18) in air at room temperature and of the alloy, the microstructure is com- It is obvious that aluminum constitut-
240°C on a RUMUL AG Testronic 100- posed of very fine silicon particles ed the matrix and disappeared at the
kN tester. A test frequency between 70 scattered in the a-Al matrix. The pres- presence of Si particles. Owing to the
and 90 Hz and a load ratio of –1 were ence of these phases is in accordance low Si measuring sensitivity in the
used. The stress concentration factor is with the equilibrium microstructural case of very fine particles, concentra-
equal to 1, and the tests were terminat- phases predicted by the binary Al-Si tion of silicon seemed depleted (see
ed at 107 cycles. Fatigue tests were com- phase diagram (Ref. 20). The average fine green area at the microstructure,
paratively and statistically evaluated ac- Si size in the extruded section is 2.9 Fig. 3C) at the regions where fine par-
cording to the arcsin √p-method (Ref. mm. This structure is necessary to ticles were formed. Iron was detected
19). Using this method, the fracture achieve good mechanical performance with less concentration at random
probabilities of 10, 50, and 90% were of the consolidated material. Further- places throughout the microstructure,
estimated. The fatigue crack initiation more, the Al-Si alloy has some other as shown in Fig. 3D.
site and crack propagation mechanisms coexisting elements such as iron, cop- The macrostructure of the joint af-
were examined on the fracture surfaces per, magnesium, manganese, and zinc. ter FSW is shown in Fig. 4A. The flash
of failed samples via SEM. Hardness The solubility of these elements in alu- is only released on the retreating side,
measurement was performed with the minum usually increases with increas- where the direction of the tool rota-
help of a Vickers hardness testing ma- ing temperature. At room tempera- tion moves in the opposite direction to

DECEMBER 2014 / WELDING JOURNAL 453-s


WELDING RESEARCH

area of the weld, close to the advanc-


ing side. Previous studies reported the
presence of this onion ring in the
whole weld nugget and clear thermo-
mechanically affected zone (TMAZ) at
both sides of the joint on FSW of alu-
minum alloys (Refs. 24–26).
The microstructure of the joint stir
zone (area I in Fig. 5A) was character-
ized by the silicon particles in the a-Al
matrix — Fig. 5B. As clearly shown
A B from the microstructure without etch-
ing at the top right of Fig. 5A, F, the
Fig. 4 — A — Macrostructure of the joint after FSW; B — geometry of rotary engine structure of the stir zone is finer and
housing after grinding and cleaning. more homogeneous than the structure
of the base metal. The Si particles
showed an average grain size of 2.1 mm,
which is approximately 28% finer than
the base metal. This is partially due to
the amount of plastic strain caused by
the FSW pin and shoulder, which leads
to more disruption of the silicon and
consequently smaller grain size (Refs.
27–30). There was a very smooth tran-
sition area in between the stir zone and
the adjacent regions at both sides of the
A B joints. Figure 5C shows this area at the
advancing side, which is hard to detect;
therefore, a dashed white line was
drawn to distinguish this area. A TMAZ
with a slightly deformed structure was
observed beside this area at both sides
of the joints. Furthermore, adjacent to
the TMAZ, a HAZ characterized by a
microstructure similar to the base metal
was formed, as shown in Fig. 5D.
As mentioned previously, an onion
C D ring pattern was observed at the top
area of the weld close to the advancing
side. Figure 5E shows the microstruc-
ture of this zone. It is generally known
that the onion ring pattern results
from the interaction between the ma-
terial flow driven by the rotating pin
and the shoulder-driven flow. This in-
teraction is observed by the deforma-
tion of the onion rings in the advanc-
ing side of the weld. Several studies
E have focused on the formation of
F these patterns. However, detailed ex-
planations and discussions of this phe-
Fig. 5 — Characteristic microstructure of the joint: A — Cross­section macrostructure; B — nomenon is out of the scope of the
microstructure of the stir zone I; C — microstructure at the stir zone/HAZ interface II; D — present study. Furthermore, there has
microstructure of the HAZ III; E — microstructure of the onion ring zone IV; F — microstruc­
been no reported correlation between
ture of base metal V.
the phenomenon and the resulting
quality of the weld nugget (Ref. 8).
the travel direction. The geometry of 5A. It is worth noting that there are Figure 6 shows SEM micrographs of
the rotary engine housing after grind- no pores or unbounded areas, and a the base metal (A) and the stir zone
ing and cleaning is shown in Fig. 4B. sound weld was achieved. One of the (B). In addition to the finer and more
Macrostructures of the traverse sec- main joint features is the observed homogeneous distribution of silicon in
tions of the joints are shown in Fig. small onion ring structure at the top the stir zone, fragmented particles of

454-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


WELDING RESEARCH

eutectic were crushed in the matrix of


the stir zone as clearly shown by ar-
rows at the top right of Fig. 6B. There
was almost no difference in chemical
compositions between the compo-
nents of microstructure of stir zone
and base metal.

Mechanical Properties
The mechanical properties of the A B
FSW joints and the base metal are given
in Table 2. Surprisingly, the offset yield Fig. 6 — SEM micrographs of the following: A — Base metal; B — stir zone.
point (Rp0.2) of welded joints is 2.3%
higher than the base metal. Meanwhile,
the average maximum tensile strength
of the welded joints is 95% that of the
base metal. The reason for the improved
mechanical properties of the welded
joints is the severe plastic deformation
offered by the FSW process in addition
to the grain size refinement in the weld
metal area. These strengthening mecha-
nisms hinder dislocation motion and
render the material stronger than it was
previously (Refs. 31, 32). The reduction Fig. 7 — Macrograph of fractured samples in tensile and fatigue tests.
in area of the welded joints was almost
half of the values reported for the base
metal, and all welded samples showed
failure outside the welded region, which
is an indication of defect-free joints.
Figure 7 shows a tension sample after
testing in addition to a fatigue test sam-
ple that will be discussed later. Further
investigations were performed by ana-
lyzing the fracture surface of the sam- A B C
ples. Figure 8A shows a general view of
the tensile fracture surface whose frac- Fig. 8 — SEM of fracture tension sample: A — General view of the surface; B — magni­
ture featured a lot of tears, ridges, and a fied view of the propagated crack; C — dimple­like fracture surface.
few cracks at different areas. The rough
topography is due to the macroscopic Statistical evaluation of the fatigue ples, at room temperature, are quite
fracture process occurring on a plane test stresses for 10, 50, and 90% proba- similar to base metals, which is an indi-
that is at some angles to the applied bilities of survival was estimated at cation of sound welded joints.
stress direction in the tensile specimen. room temperature and also at 240°C. Figure 10A shows the postfatigued
A closer observation of the rectangular Figure 9 shows the plotted SN curves. fracture surface of sample failed after
area in Fig. 8A is shown in Fig. 8B. A The obtained data for the fatigue limit 877706 cycles under a stress of 81.25
dimple-like structure is prominent in are listed in the graph. Fatigue test MPa and at room temperature. Crack
the morphology. However, some Si par- stresses at room temperature for 10, 50 initiation sites were at or near the sur-
ticles and voids originated by the unat- and 90% probabilities of survival were face as shown by arrows in Fig. 10A, D.
tached silicon were clearly observed in calculated as 81.94, 81.01, and 80.09 Since the silicon particles are stiffer
the second close-up view in Fig. 8C. The MPa, respectively. All samples were frac- than the matrix, the stress concentra-
Si particles, confirmed by EDX analyses, tured outside the joined area as shown tion created in this area is enough to
and corresponding voids are indicated in Fig 7. The fatigue limit decreased ap- cause microslips in the matrix close to
by black and light arrows, respectively. proximately 25% due to raising the tem- the silicon particles, which leads to the
The presence of these areas close to the perature to 240°C. Additionally, the particle debonding and then crack ini-
crack is an indication of the initiation of base metal fatigue test stresses at room tiation (Ref. 34). Under a condition of
the crack owing to the Si particles. It is temperature for 10, 50, and 90% proba- relatively high stress levels, especially
reported that damage and failure of Al- bilities of survival were 82.32, 81.27, in aluminum alloys, quite large num-
Si alloys is generally associated with ini- and 79.92 MPa, respectively. It is also bers of microcracks were formed (Refs.
tiation and growth of cracks in the Si noted that (not included in Fig. 9) the 33, 35). At a later stage, linking up of
particles (Refs. 27, 33). fatigue characteristics of welded sam- these cracks occurred to form one sin-

DECEMBER 2014 / WELDING JOURNAL 455-s


WELDING RESEARCH

A B C

D E F
Fig. 9 — SN curves for the fatigue samples at room tempera­
ture and 240°C. Fig. 10 — Postfatigued fracture surface: A — Overview of the frac­
ture surface of sample tested at room temperature; B — magnified
view of one of the crack­initiation areas and the propagation direc­
tion at room temperature; C — magnified view of the flat and tear
areas at room temperature; D — overview of the fracture surface of
the sample tested at 240°C; E — magnified view of one of the crack­
initiation areas and the propagation direction tested at 240°C; F —
magnified view of the tear area tested at 240°C.

The microhard- join the extruded PM Al alloy without


ness distributions discontinuities, voids, or defects. Com-
across the welded pared to the base metal microstruc-
joint including the ture, fine and more homogeneously
base metal, HAZ, distributed structures were detected
Fig. 11 — Microhardness distributions at the top, middle, and
TMAZ, and stir after joining. The microstructure of
bottom of the FSW joint.
zone are shown in the welded joint at all regions was
Fig. 11. The differ- composed of very fine silicon particles
gle larger crack. A flat fracture surface ence in hardness values at the top, scattered in the a-Al matrix.
is observed at some parts; meanwhile, middle, and bottom of the joint is very 2) The achieved yield point of the
the main fracture area was fairly duc- small. The HAZ and TMAZ areas at welded joints is 2.3% higher than the
tile. Figure 10B shows a magnified both the advancing and retreating base metal, while the maximum ten-
view of one of the crack-initiation ar- sides of the joints were found to have sile strength is 95% that of the base
eas and the propagation direction. the minimum hardness compared to metal. Additionally, the fatigue limit
Meanwhile, Fig. 10C shows both flat the other regions of the weld. Probably decreased approximately 25% due to
and tear areas at high magnification. It this is caused by the annealing effect raising the temperature from room
is also worth noting that striation fea- during processing (Refs. 36, 37). Also, temperature to 240°C. Fracture of
tures were not detected at the fracture the highest hardness values were joints after tensile and fatigue tests
surface probably because of the very achieved in the stir zone because of was always in the base metal.
fine microstructure. the fine grain size and the severe plas- 3) Failure of Al-Si alloys was associ-
At high temperature, voids were ob- tic deformation at these areas (Refs. ated with initiation and growth of
served at the sample edges that are be- 37, 38). The average hardness value of cracks at the Si particles. The mor-
lieved to be the origin of the crack ini- stir zone, HAZ, and base metal were phology of the fracture was mainly
tiation. The formation mechanism of 89, 74, and 79 HV0.1, respectively. ductile after tension and fatigue tests.
these voids is not clear but it could be 4) The maximum hardness of the
the result of interactions of very small
silicon particles, which act as micro-
Conclusions joint was observed in the stir zone be-
cause of its fine grain size. Meanwhile,
notches with cyclic stress. Figure 10D the HAZ and TMAZ areas achieved the
shows these voids at the edges of the A 20-mm-thick PM aluminum alloy lowest hardness level in the joint.
fracture surface area, which initiated has been welded by FSW to produce a
the cracks. The crack propagation di- rotary engine housing after the extru-
rection at high magnification is clearly sion process. Detailed characteristic Acknowledgments
observed in Fig. 10E, meanwhile, the microstructure and mechanical inves-
rest of the fracture surface is com- tigation were evaluated. The following The authors would like to thank Aus-
posed of the dimple-like structure and conclusions were reached: trian Research Promotion Agency (FFG)
tear areas as shown in Fig. 10F. 1) FSW was successfully used to and the Federal Ministry for Transport,

456-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


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Innovation and Technology (bmvit) for 235–242. new-typed lap-butt joint of dissimilar Al
financial support in the framework of 12. Jata, K.V. 2003. Friction Stir Welding alloys. Materials and Design 34: 725–731.
A3plus from the program IV2Splus and Processing II. Warrendale, Pa.: TMS - 27. Tutunchilar, S., Besharati Givi, M.
(Project 824182, “Hybrid Rotary Engine The Minerals, Metals & Materials Society. K., Haghpanahi, M., and Asadi, P. 2012.
pp. 234–252. Eutectic Al-Si piston alloy surface trans-
Components in Aluminium Alloy”). Ad-
13. Mishra, R. S., and Ma, Z. Y. 2005. formed to modified hypereutectic alloy via
ditionally, the authors would like to ex- Review Article: Friction stir welding and FSP. Materials Science and Engineering A
press their appreciation to the project processing. Materials Science and Engineer- 534: 557–567.
partners AVL List GmbH, Mepura Met- ing R 50: 1–78. 28. Asadi, P., Mahdavinejad, R. A., and
allpulvergesellschaft m.b.H., Rübig 14. Wang, W., Shi, Q., Liu, P., Li, H., and Tutunchilar, S. 2011. Eutectic Al-Si piston
GmbH & Co KG. Li, T. 2009. A novel way to produce bulk alloy surface transformed to modified hy-
SiCp reinforced aluminum metal matrix pereutectic alloy via FSP simulation and
composites by friction stir processing. experimental investigation of FSP of AZ91
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Minerals, Metals & Materials Society, pp. ty research on friction stir welding of a

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WELDING RESEARCH

Low Transformation Temperature Welding


Consumables for Residual Stress Management:
A Numerical Model for the Prediction of Phase
Transformation­Induced Compressive
Residual Stresses
Using a finite element software, numerical analysis of gas metal arc welding with
developed low­transformation temperature welding wires was performed

BY T. ALGHAMDI AND S. LIU

Introduction
ABSTRACT
During the fabrication of steel
Harmful tensile residual stresses are observed in structural steel weld structures such as bridges, platforms,
joints as a result of the thermal strains between the solidified weld metal and ships, welding is the most essen-
and surrounding base material. These harmful stresses, superimposed on tial joining process. Upon completion
external stresses, make the welded joints more prone to fatigue failures.
Thus, the presence of compressive residual stresses, instead of the typical of solidification and after the weld is
tensile residual stresses, improves the fatigue resistance of the structural cooled to room temperature, nonuni-
welded joint. In this research work, numerical analysis of gas metal arc weld- form strain distribution and tensile
ing (GMAW) with developed low transformation temperature welding residual stresses often result. Distor-
(LTTW) wires was performed using Sysweld. Simulation of all-around fillet tion may also occur in welded structur-
welds on a structural steel plate clearly estimated the effects of the different al components. As tensile residual
experimentally developed LTTW wires on residual stress generation and stresses are deleterious to the integri-
welding distortion control. Alloys with higher chromium equivalent promot- ty of the weld joint (Refs. 1–3), it is
ed greater control on out-of-plane distortion. Their effect on compressive important to be able to model and pre-
residual stress generation around the weld toes was not as evident and de- dict the residual stress distribution in
serves further investigation. Simulation results agreed reasonably well with
the experimentally determined results. The weld made using the higher the weld toe region. Methods that can
chromium equivalent welding wire showed the maximum induced compres- reverse the residual stresses from ten-
sive residual stress in and around the weld joint (at the order of 600 MPa) sion to compression, and enhance fa-
with relatively low transverse distortion values compared to the other welds. tigue performance of welded compo-
Stress evolution with time plots from Sysweld simulation were able to show nents, are also important.
the interaction between thermal contraction and phase transformation- Postweld heat treatment (PWHT)
induced expansion, and also the amount of martensite required to promote and peening are known to reduce the
overall residual compressive stresses in the fillet weld joint. tensile residual stresses and possibly
induce a compressive stress state in a
weld joint. However, both methods are
costly and time consuming. A more at-
KEYWORDS tractive approach is to use a welding
consumable that can produce a com-
• Low Transformation Temperature Welding Consumables • Martensitic pressive residual stress state in the
Transformation • Phase­Induced Volumetric Expansion • Residual Stress weld joint during welding. These are
Management • Compressive Residual Stress • Numerical Analysis • Residual the low transformation temperature
Stress Evolution with Time welding consumables (Refs. 2–6).
When martensite transformation ini-
tiates at a low temperature and finish-

T. ALGHAMDI is with the Consulting Services Department­Saudi Aramco, Kingdom of Saudi Arabia. S. LIU (sliu@mines.edu) is with the
Center for Welding, Joining, and Coatings Research, Department of Metallurgical & Materials Engineering, Colorado School of Mines,
Golden, Colo.

458-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


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A B

Fig. 1 — Isothermal contour map for the


martensitic transformation temperature
as a function of Cr and Ni equivalents.
The Nieq­Creq field shown corresponds to
the martensite field in the Schaeffler
constitution diagram (Refs. 19, 20).

es just above room temperature, the


shrinkage due to thermal contraction D
C
can be counteracted and “neutralized”
by the volume expansion caused by
austenite-to-martensite transforma-
tion in the weld metal (Refs. 7–10). If
the magnitude of expansion is greater Fig. 2 — Dilatometric curves of the welds made using the recently developed LTTW
than that of thermal contraction, net wires with a cooling rate (CR) of 120°C/s. A — SO­200A; B — SO­200B; C — SO­350A;
residual compressive stresses result D — SO­350B.
(Refs. 11–20). In case that the marten-
site transformation ends much below
velopment and distortion control in welded joints. Since cost and produc-
room temperature, the martensite
the weld (Ref. 24). tivity was the main target, PWHT was
transformation would be incomplete
The main objective of this study is not the focus of this study. Anticipated
resulting in a reduced total fraction of
to develop welding consumables that applications of the low transformation
martensite.
would reduce the tensile residual temperature welding consumables can
Eckerlid et al. (Ref. 4) and Darcis et
stresses around the weld toe region be in steel structures such as bridges
al. (Ref. 5) showed that fatigue proper-
rather than the deleterious tensile and ships. The scale of these welded
ties are enhanced with these specially
residual stresses of the structural components may make PWHT unfeasi-
designed consumables. Welding
process characteristics, e.g., multiple
pass sequence and interpass tempera- Table 1 — Chemical Composition (in wt­%) of the Base Metal, Welding Wires, and As­Welded Metal
ture, can affect the effectiveness of
these consumables (Ref. 21). Shirzadi, C Mn Cr Ni Si Mo
Bhadeshia, and colleagues (Ref. 22) ex- Base Metal
A­36 Structural Steel 0.11 0.80 0.15 0.11 0.06 0.02
tended the concept developed by Ohta
et al. (Refs. 7–10, 12) by investigating SO­200A Wire 0.1 1.0 1.0 10.0 0.10 2.0
other stainless steel compositions that As­welded 0.11 1.07 0.97 5.83 0.26 2.11
would produce similar effects on resid-
ual stresses. Yamamoto et al. (Ref. 23) SO­200B Wire 0.04 1.25 10.0 4.0 0.15 0.5
also reported on the effects of marten- As­welded 0.11 1.09 9.04 2.98 0.29 0.50
sitic transformation on weld residual
SO­350A Wire 0.10 1.0 1.0 2.0 0.1 2.0
stress and distortion mitigation.
In summary, martensite transfor- As­welded 0.08 1.28 1.12 1.92 0.25 1.74
mation start (Ms) and finish (Mf) tem-
SO­350B Wire 0.05 1.0 4.0 0.50 0.10 2.0
peratures are essential parameters in
structural steel welding because of As­welded 0.06 1.19 3.57 0.45 0.24 1.79
their influences on residual stress de- ER70S­3 0.09 1.02 0.05 0.03 0.41 <0.01

DECEMBER 2014 / WELDING JOURNAL 459-s


WELDING RESEARCH

Fig. 3 — The out­of­plane distortions of ½­in.­thick bar­panel


assembly following single pass fillet welding using convention­
al welding wires, ER70S­3. Fig. 4 — Different transverse displacement (distortion) produced by
various LTT welding consumables and the commercial welding wire.

structural steel show the Ms temperature ranges of the


plates were welded two pairs of experimental alloys iden-
with four developed tified by the four circles (with x’s). The
welding wires (des- chemical compositions of the major al-
ignated as SO- loying elements for the experimental
200A, SO-200B, welding wires, conventional consum-
SO-350A, and SO- able, and base metal used in this work
350B) with low are listed in Table 1.
martensitic trans- Four sets of welding experiments
Fig. 5 — The dimensions of the T­joint welded structure in inch­
es (in.) of an all­around welded panel­bar assembly. formation tempera- were conducted. The first was in the
tures (LTT) using bead-on-plate configuration to meas-
semiautomatic gas ure angular distortion and extract
ble for stress relief or attainment of metal arc welding dilatometric specimens. The second
ductility. Therefore, the development (GMAW). The compositions of the one produced V-grooved butt welds
of welding wires that transform to welding wires were selected from a siz- from which mechanical testing speci-
martensite close to room temperature able matrix that spanned across the mens were extracted. Multipass weld
with maximum weld expansion and entire martensite field on the Schaef- pads were also produced to extract
eventually compressive residual stress- fler constitution diagram (Ref. 18) as dilatometric specimens for Ms deter-
es is highly desirable. Experimental shown in Fig. 1 where the Ms isotherm mination.
measurement and welding simulation contours were mapped according to Further distortion measurements
using finite element code Sysweld were the Self and Olson equation (Ref. 25). were conducted by fabricating double-
conducted to determine martensitic In Fig. 1, it can be easily recognized sided single pass fillet welds in the
transformation temperatures and bet- that different alloy compositions may form of bar-panel assemblies on A36
ter characterize the effects of phase exhibit similar Ms temperature indi- structural carbon-steel base materials
transformation on the evolution of cating that Ms temperature may not be using GMAW. The vertical bar was
residual stresses in structural welded the only indicator that may quantify first tack welded onto the panel plate
joints. the resulting compressive residual with zero root opening. No clamping
stresses. The first set of the designed was used during welding; the heat in-
filler metals have been selected along put was 25 kJ/in. and shielding gas
Experimental Procedure the 200°C isotherm line, and the other was Ar + 25%CO2.
and Results set was selected along the isotherm of The fillet weld described in the last
350°C on the contour map. The four paragraph was an all-around weld that
For the experiments, ASTM A36 green lines were added to more easily wrapped around the joint between the
vertical bar and flat panel. The weld
can be denoted weld 1 and weld 2 by
Table 2 — The Experimental Ms Temperatures Compared with the Predicted Calculations their order of deposition. Thus, the
heat from weld 2 would reheat weld 1.
Welding Wire Self and Olson Ghosh and Olson Eichelmann and Hull Experimental The increase in temperature would re-
Designation Methodology Equation Ms Temperature duce the cooling rate and amount of
(°C) (°C) (°C) (°C)
compressive stresses in fillet weld 1.
SO­200A 200 163 446 155 Measurements of distortion and calcu-
SO­200B 200 219 528 160 lation of residual stresses would, how-
SO­350A 350 157 935 370
SO­350B 350 177 985 400
ever, be conducted for weld 2.
To ensure that filler metal was the

460-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


WELDING RESEARCH

only variable in the welding experi-


ments, the welds were produced under
approximately identical conditions. The
bars and plates were cut to size and
ground flat for zero joint opening and
degreased prior to welding. The average
heat input was maintained constant
throughout the welding experiments,
and the welding sequence and direction
were also kept constant.
Standard metallographic techniques
were used to prepare the weld samples
for microscopy examination. The weld
microstructure was revealed using
Kallings No. 1 reagent. All experimental
welds exhibited martensitic microstruc-
ture (Refs. 19, 20, 36-38). The reference
ER70-S3 weld was predominantly ferrit-
ic (Refs. 19, 20, 36-38).
Tensile testing on the specimens
extracted from the welds (in the weld
length direction) collected the yield
and ultimate tensile strengths as well
as elongation data needed for the Fig. 6 — Solid T­joint finite element (Sysweld) model. Fine meshes near to heat flux
Sysweld finite element code. In the boundary and expanding away from it.
case of SO-200B wire, the room tem-
perature yield and ultimate tensile
strengths are 60 and 95 ksi, respec- tures between 155° and 160°C — Fig. Table 2 shows the Ms temperatures
tively (Refs. 20, 38). 2A, B. However, the largest amount of experimentally determined compared
Using a Gleeble 3500 thermome- expansion (+27 m) was exhibited by with the estimated values using Self
chanical simulation system, dilatomet- the specimen SO-200B as shown in Fig. and Olson (SO) and Eichelmann and
ric measurements were conducted to 2B. These results suggest that the maxi- Hull (EH) equations as well as the
experimentally measure the marten- mum expected compressive residual Ghosh and Olson (GO) methodology
sitic start temperature (Ms) of the de- stresses induced in the vicinity of the (Refs. 25–28, 38). With these specific
signed alloys, SO-200A, SO-200B, SO- weld metal would likely occur in a weld- chemical compositions, the SO equa-
350A, and SO-350B. Solid cylindrical ed joint with SO-200B welding wire. tion appeared to better predict the Ms
samples of 6.0 mm diameter and 80 The other samples made by the welding temperatures for the experimental al-
mm length were extracted from multi- wires, SO-200A, SO-350A, and SO- loys than EH and GO equations. De-
pass bead-on-plate welds deposited on 350B, revealed expansive elongations of tails of the calculations have been re-
ASTM A36 grade structural steel. The +20, +13, and +5 m, respectively. ported in another publication.
weld metal specimens were subjected These findings again suggest that all the The cumulative deflection for each
to thermal cycles that mimicked the experimental welding wires can produce experimental fillet weld was measured
cooling behavior experienced by the compressive residual stresses around and compiled with an uncertainty of
welds. All specimens were austenitized the weld toe. ±0.004 in. (±0.1 mm). Despite the fact
at 1100°C for 8 s, followed by cooling
at a constant rate of 120°C.s–1 to ambi-
ent temperature. The heating rate was Table 3 — The Measurements Taken for Transverse Displacements (Distortion) of Double­Sided Fillet
80°C.s–1. The heating and austenitiza- Welded Structures
tion process was conducted under vac- Wire Item Measurement Average by Unit Displacement Δ =
uum, and the cooling was achieved us- Average(in.) Conversion (mm) Thickness­ Height (mm)
ing a helium gas jet.
SO­200A Thickness 0.500±0.004 12.66 2.42
This test identifies the martensitic Height 0.590±0.008 15.08
start transformation temperature (Ms)
as the temperature at which the slope SO­200B Thickness 0.500±0.008 12.57 2.38
Height 0.590±0.008 14.95
changes from positive to negative dur-
ing cooling on an elongation-tempera- SO­350A Thickness 0.490±0.008 12.53 2.55
ture graph as shown in Fig. 2. This test Height 0.590±0.008 15.08
shows that martensitic transformation SO­350B Thickness 0.500±0.008 12.60 2.50
occurred in all four developed LTT weld- Height 0.590±0.008 15.10
ing wires. Samples SO-200A and SO- ER70S­3 Thickness 0.500±0.008 12.62 3.33
200B exhibited the lowest Ms tempera- Height 0.630±0.008 15.94

DECEMBER 2014 / WELDING JOURNAL 461-s


WELDING RESEARCH

Fig. 8 — Illustration of the groups necessary to define the weld path


(Ref. 34).

ble of reducing the distor- the data bank of mechanical and ther-
tion in the final weld. mophysical properties for a sizable
Taking into account materials specification, it allows the
the larger atomic radius of user to upload all possible experimen-
chromium, 128 pm as com- tal properties from the tested materi-
Fig. 7 — Goldak double ellipsoid heat source model.
The arrow points to the welding direction (Refs. 26,
pared with 126 pm (Fe) and als such as welding parameters, travel-
27). 124 pm (Ni), alloys with ing speed, elongations, Ms tempera-
higher chromium equiva- tures, etc. In this work, numerical
lent would promote greater analysis was considered for single bead
that all welding and structural param- expansive strains and likely higher T-joint weld, i.e., a continuous fillet
eters such as heat input, joint design, compressive residual stresses around weld around a bar member, on an
welding sequence and direction, weld the weld toe than the higher nickel ASTM A36 grade structural carbon
start and stop, and weld length were equivalent alloys for a similar Ms tem- steel plate. The dimensions of the T-
kept relatively unchanged, the welded perature. Moreover, a SO-200B weld joint are illustrated in Fig. 5.
joints using the different LTT welding joint in particular presented the mini- As with any finite element model,
consumables showed different trans- mum cumulative transverse distor- the first step in a weld analysis is the
verse, out-of-plane distortions with re- tion, which implied the maximum creation of an assembly and finite ele-
spect to the conventional wire such as compressive residual stresses of the ment mesh. Because of the high peak
ER70S-3. The thickness of the plate four welds. It is obvious that atomic temperature and large temperature
and the elevation of the plate from the radii difference should not be the only gradient and fluctuations imposed by
table were measured using a pair of factor considered in determining the the weld heat source, it is important to
calipers. To calculate the cumulative sign and magnitude of the resulting have fine meshing around the weld
displacement of the T-joint, the thick- residual stresses, bonding characteris- joint, i.e., very small element size, and
ness of the welded plate (H) is sub- tics (electronic interaction) between consistent time steps. The fine mesh
tracted from the total height from the chromium and iron, and nickel and helps to capture thermal gradient in
top surface of the workpiece to the flat iron should be examined more in de- small time steps to resolve the large
ground surface. The averages of three tail in the future to provide greater in- temperature variation for a given
measurements for the T-joint displace- sight. Preliminary ABINIT calculations mesh for the purpose of detailed and
ment are plotted and compared. showed that chromium additions in an accurate analysis in and near the weld
Figure 3 shows the out-of-plane iron lattice caused changes to the com- interfaces. Coarser meshes expanding
displacement of the T-joint fillet weld pressibility and bulk modulus of the away from the boundary of the heat
made by the conventional wire, crystal lattice (Refs. 39, 40). flux can be applied to obtain good ac-
ER70S-3. The out-of-plane distortions curacy with reasonable computation
would then be converted to angles us- Welding Simulation Using time.
ing trigonometric relationships. While Sysweld Code Figure 6 shows the finite element
the measurements were made in inch- model and mesh established for the sol-
es, the displacement values were ex- Sysweld is a finite element software id T-joint investigated. After the mesh is
pressed in millimeters. dedicated for thermal analysis and created, it is necessary to apply the ma-
Both Table 3 and Fig. 4 show that welding activities. Sysweld simulates terial properties (material database) and
the SO-200B weld metal exhibits the all common welding processes. It has apply thermal and mechanical bound-
minimum cumulative transverse (out- an excellent set of tools enabling re- ary conditions. Next are the heat source
of-plane) distortion compared to the searchers to control and optimize heat parameters and molten pool dimen-
other experimental wires, indicating treatment and welding by taking into sions (length, width, and depth). Other
possibly higher compressive residual consideration all aspects of material parameters such as the clamping condi-
stresses around the weld toe. The behavior, design, and process. It mini- tion, external loading, and heat transfer
transformation plasticity associated mizes the requirements for physical behavior can be entered through the
with the formation of martensite has prototypes with a reduction in cost welding advisor module before compu-
been shown experimentally to be capa- and lead time (Ref. 23). In addition to tation is initiated.

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Fig. 9 — A close­up view the first bead of the T­joint showing the
weld path, weld line (trajectory), reference line, and start nodes.

Fig. 10 — Concept of reduction of welding distortion by using


a low­transformation welding wire (Ref. 35).
A B
be easily changed to width and the distance behind the
model different source equal to two times the weld
welding processes width (Ref. 31).
and weld character- The heat source is applied along all
C D istics, e.g., shallower elements and can be extended to cover
or deeper penetra- the whole structure. The weld path in-
tion. Heat flux dis- cludes the trajectory and reference
Fig. 11 — The transverse distortion (in mm) for the structural
tribution is Gauss- lines, start and end nodes, plus the
welded joint made using LTTW wire. A — SO­200A; B — SO­
200B; C — SO­350A; D — SO­350B. ian along the longi- start element as shown in Fig. 8. The
tudinal weld direc- trajectory line is the line that includes
tion axis. If the cross all information to define the move-
For modeling of the heat source, section of the molten zone is known ment of the welding heat source in
Sysweld utilizes the three-dimensional from the experiment, this information space and describes the path of the
double ellipsoid model for the welding can be used to set the heat source di- center of the power source (the local Y-
arc proposed by Goldak et al. (Ref. 30) mensions. If precise data do not exist, axis coincident with the weld line ele-
and shown in Fig. 7. The double ellip- Goldak et al. suggest that it is reason- ment direction). This line is placed on
soid geometry is used because the size able to take the distance in front of the skin of the joint and not in the
and the shape of the heat source can the source equal to one-half the weld root. The reference line is another

Table 4 — Thermo­Physical Material Properties for Welding Simulation

Weld Base Weld Base Weld Base


Temperature Young’s Modulus Specific heat Conductivity (W/(m.°K))
(°C) (GPa) (kJ/(kg.°K)) Martensite Austenite Martensite Austenite
Phase Phase Phase Phase
20 195 200 0.494 0.486 51.90 14.88 51.90 15.00
100 188 198 0.520 0.486 51.20 16.50 51.20 u.a.
200 182 196 0.548 0.532 49.00 18.00 49.00 u.a.
300 175 178 0.562 0.574 46.00 19.50 46.00 u.a.
400 169 163 0.578 0.630 42.70 21.00 42.70 u.a.
500 160 u.a. 0.590 0.705 39.40 22.10 39.40 u.a.
600 150 83 0.599 0.800 35.60 23.00 35.60 u.a.
700 138 u.a. 0.607 1.432 31.80 25.00 31.80 u.a.
800 125 37 0.613 0.556 26.10 26.50 26.10 u.a.
900 114 u.a. u.a. 0.565 26.60 27.69 26.60 25.00
1000 99 14 u.a. u.a. 27.20 29.25 27.20 u.a.
1100 87 13 u.a. u.a. 28.50 30.29 28.50 u.a.
1200 72 11 u.a. u.a. 29.80 31.85 29.80 u.a.
1300 7 5 0.690 u.a. 33.10 33.20 33.10 u.a.
1400 1 1 0.800 0.620 33.00 28.00 33.00 32.00

u.a.–unavailable.

DECEMBER 2014 / WELDING JOURNAL 463-s


WELDING RESEARCH

A B

C D

E F

Fig. 12 — Cross­sectional view for all­around fillet welded joint using the SO­200A electrode showing the stresses. A — Along X­axis; C
— along Y­axis; and E — along Z­axis. Residual stress distribution (along the white dotted line on the contour map) is along the follow­
ing: B — X­axis of the weld; D — Y­axis of the weld; and F — Z­axis of the weld.

group of one-dimensional finite ele- trajectory. The start node is only one these parameters along the weld path
ments parallel to the welding trajecto- node that defines the starting point of is illustrated in Fig. 9.
ry. It is similar to the welding line used the trajectory. The temperature-dependent values
to determine the normal to the trajec- In case the reference line is applied, of thermal conductivity, specific heat
tory and must have the same number another node should be set as the capacity, and Young’s modulus are
of elements as the weld line. The pa- starting point of the reference and summarized in Table 4. Density was
rameters that should be entered in both nodes must be the first nodes in assumed to be 7850 kg.m–3 at room
this group are identical to the parame- this group (the starting side of the temperature and 7290 kg.m–3 at
ters of the trajectory, i.e., start and weld). On the other hand, the end 1400°C. The Poisson’s ratio was as-
end nodes plus a start element. If no nodes are the nodes defining the end- sumed to be 0.29 for the weld metal
reference data are entered, the source ing points of the trajectory and refer- and 0.26 for the base metal, independ-
must be axial-symmetric around the ence line (Ref. 29). A close-up view for ent of temperature. The thermal ex-

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WELDING RESEARCH

A B

C D Fig. 14 — Schematic drawing shows


where the through­thickness stresses
are measured along the dotted line.

Fig. 13 — Transverse residual stress distribution across the second bead of the fillet
weld. A — SO­200A; B — SO­200B; C — SO­350A; D — SO­350B.

pansion values were not listed in Table ciated with the martensitic transfor-
4. The individual values of thermal ex- mation can cancel the thermal shrink-
Fig. 15 — Stress distribution through
pansion coefficient, when needed for age of the weld and even create com- the thickness of the panel plate.
computation, are calculated for the pressive residual stresses as proven by
given T in Table 4, and the elonga- many researchers and explained earlier
tion of the deposited welds as plotted as shown in Fig. 10. Welding distor- larger expansion due to martensitic
in Fig. 2. tion is also expected to be reduced by transformation that offsets the ther-
In this analysis, the latent heat of this mechanism. mal contraction during cooling.
fusion was not considered. The yield Despite the heat input and geome- Stress was also calculated using the
strength is also defined as a tempera- try of the experimental welds were Sysweld code, taking into considera-
ture-dependent parameter as listed in similar, various out-of-plane distor- tion phase transformations. Sysweld
Table 5 for the weld and base metal, tion values were measured on plates simulation results agreed reasonably
respectively. The yield strength at welded with single pass fillet weld on well with the experimental analysis as
room temperature was taken from the both sides of the vertical plates as il- shown in Fig. 11, particularly regard-
experimental tensile testing results. lustrated in Table 3 and Figs. 3 and 4. ing the comparison between high-
However, the yield strengths at higher The actual magnitude of the expan- chromium equivalent and high-nickel
temperatures were defined from the sion varied with the composition of equivalent welds. The weld produced
literature for similar materials for the different alloying elements. This using SO-200B wire, which has higher
both the martensite and austenite behavior is illustrated by the different chromium equivalent, resulted in
phases. The thermal strains and Ms deflection angles or displacements of smaller out-of-plane distortion of 1.48
temperatures were input based on the the welded plates. Despite similar Ms mm as compared with the 1.58 mm for
dilatometric results obtained for each temperatures, e.g., SO-200B and SO- the SO-200A weld. The same explana-
individual welding wire. 200A, the two welds exhibited differ- tion is for SO-350A and SO-350B as
ent transverse distortions indicating shown in Fig. 11C and D where the Ms
Results and Discussion different residual stresses induced temperature is 350°C. The displace-
around the welded joints. Smaller dis- ments in this case were 1.40 and 1.38
Using the LTT welding wires with tortion, i.e., smaller deflection angle mm, respectively. In this case, the dis-
the delayed austenite decomposition, or smaller displacement in a unit tortions were quite similar, suggesting
volume expansion of weld metal asso- length of thickness, would imply in that higher martensite start tempera-

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welds shown in Figs. 3 and 4 were cu-


A B mulative that included the effects of
heat input, fillet weld design, welding
sequence and direction, plus weld start
and stop. Since not all these effects
could be incorporated into Sysweld,
some discrepancy of prediction is ex-
pected. Additionally, the numerical
model shows the nodal and not bulk
values, whether distortion or residual
stresses distribution, some discrepan-
cy from the experimentally measured
(bulk) values can be expected.
Figure 12A, C, and E show the
cross-sectional views of the fillet weld
joints made using the SO-200A elec-
C trode and with the stresses along the
X-, Y-, and Z-axis, respectively. The
right-side weld specifies the first bead
made, and the left-side weld is the sec-
ond part of the weld, in agreement
with the weld path of the all-around
fillet starting on the right side. These
two separate beads make one single
pass all-around fillet weld, and each
bead is modeled separately with 3 min
break-up time, i.e., 3 min between the
end of the first bead and the start of
the second bead. The effect of reheat-
ing on residual stress distribution can
Fig. 16 — Base metal­weld nodal stress evolution with respect to time for the SO­200B be easily observed in Fig. 12. Reheat-
weld. A — Along the X­axis; B — along the Z­axis; C — along the Y­axis (weld direction). ing relieved the induced compressive
Residual stress is represented by the solid line and martensite fraction, the dashed line. residual stress in the first weld.
Figure 12B, D, and F show the
stress distribution along the X-, Y-,
Table 5 — Yield Strength Dependency on Temperature for the Weld and Base Metals for the Welding and Z-axis, respectively, as a function
Simulation of particular locations in and around
the weld calculated with the considera-
Weld Base tion of phase transformations taking
Temperature (°C) Yield Strength, MPa Yield Strength, MPa place. The plotting axis is along the
(N/mm2) (N/mm2)
Martensite Austenite Martensite Austenite top of the base plate as indicated by
Phase Phase Phase Phase the white dashed lines on the contour
plots. This axis starts from the left end
20 450 172 500 183
100 450 148 500 173 of the dotted line (white line) crossing
200 450 123 500 157 the two beads of the fillet weld. For all
300 428 107 475 130 the three stress components, the weld
400 360 102 400 102 stresses were more compressive than
500 270 98 300 80
600 203 94 225 59
the weld-to-base plate interface where
700 90 88 100 33 the stress plots were created. Similar
800 45 75 50 24 findings were observed in the welds
900 23 55 25 18 made using the developed SO-200B,
1000 23 30 25 16 SO-350A, and SO-350B wires.
1100 23 19 25 14
1200 8 11 9 9 The residual stresses tend to be
1300 5 7 5 5 compressive at the weld toe in the de-
1400 5 5 4 3 veloped welded joints. Figure 13A–D
explains the stress distribution around
the T-weld joint toes. These stresses
ture was less effective in distortion distortions experienced by the SO200 are calculated along the X- and Z-axes
control. series welds. However, it is important of the second bead of the all-around
Sysweld simulation, nonetheless, to point out that the measured distor- single fillet weld starting from the
was unable to corroborate the smaller tions of the bar-panel assembly fillet weld toes. The trends of these plots

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WELDING RESEARCH

show how far compressive residual


stress exists around the welds in both A B
sides of the second bead of the T-joints
made using the developed welding
wires. It is clear that in the SO-200A
and SO-200B welds, the compressive
residual stresses exist for almost 3 mm
around the welds distributed along the
X- and Z-axes (across the weld bead).
However, compressive residual stress-
es extended only to approximately 2.0
mm around the welds made by SO-
350A and SO-350B.
Through-thickness stress distribu-
tion was also evaluated using Sysweld
for all experimental welds deposited
on 12.5-mm-thick panel plates as ex- C
plained in Fig. 14. The through-thick-
ness stresses were found to be com-
pressive almost half way through the
plate and were tensile in the remaining
thickness of the plate. According to
Fig. 15, compressive residual stresses
for SO-200A and SO-200B welds are
observed within 5.25 to 6.25 mm from
the welded surface. In comparison,
compressive stress state is present
within 7.5 to 8.0 mm from the weld
surface for SO-350A and SO-350B
welds.
Fig. 17 — Base metal­weld nodal stress evolution with respect to time for the SO­350A
weld. A — Along the X­axis; B — along the Z­axis; C — along the Y­axis (weld direction).
Residual Stresses Evolve
with Time
Table 6 — Nodal Stresses Observed on the Base Metal­Weld Interfaces of the T­Joint and Along the
The basic reason for occurrence of Weld Centerline
residual stresses in a welded compo-
nent is thermal strain caused by heat- Wire Stress along Stress along Stress along the weld
ing and cooling. This thermal strain X­axis (MPa) Z­axis (MPa) direction (MPa)
causes internal constraint within the SO­200A –140 –250 –610
SO­200B –150 –275 –650
welded workpiece. Immediately after SO­350A –80 –205 –150
the end of the welding process, cooling SO­350B –90 –180 –250
initiates the shrinkage stresses be-
tween a weld metal and the surround-
ing material because of thermal con- (nodal transverse stresses) and along of martensite) during cooling, immedi-
traction. During the heating and cool- the centerline of the weld in the Y direc- ate reduction in stresses occur then de-
ing process, the weld and the area near tion (nodal longitudinal stresses). The veloping into compressive residual
to the heat flux boundary go through time of 210 s, which is measured from stresses. The two dashed red lines cross
expansion and contraction against the the start of the first bead, corresponds at the time when tension residual stress
surrounding material undergoing com- to the start time of the second bead. reverses to compression.
pression and tension. This phenome- This figure shows how the stresses Knowing that the weld pool solidi-
non has been observed in all welding evolve with respect to time until room fies by epitaxy from both sides of the
simulation analysis and in all direc- temperature. At high temperature and weld joint and toward the weld center-
tions, i.e., stress on the weld toes or before approaching Ms temperature, line, the nodal tensile stresses in the
along the welding direction evolves tensile residual stresses tend to form base metal-weld interfaces (i.e., along
with time throughout the weld length. along the centerline of the weld and in the X- and Z-axes) reach the maximum
Figure 16 is an example that explains the weld toes. However, taking marten- point earlier than the nodal stresses
the nodal stress evolution with time for sitic transformation into account (de- along the center of the weld (Y-direc-
welds made using the developed SO- noted by dotted lines), it can be seen tion) before approaching the Ms tem-
200B wire. These nodal stresses (denot- that as the Ms temperature is reached peratures. Another observation is that
ed by solid lines) were computed on the and past (with the beginning of marten- the weld made using the higher
weld toes along the X- and Z-axes site formation and increasing amount chromium equivalent LTT welding

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WELDING RESEARCH

Fig. 18 — The nodal stress drops in the base metal­weld inter­ Fig. 19 — The nodal stress drops in the base metal­weld in­
face along the X­axis for the SO­200B weld. terface along the X­axis for the SO­350A weld.

wires generally showed higher induced workpiece dropped the stress to ap- the exact temperatures at which the
compressive residual stresses in and proximately 100 MPa at 273 s. different phase transformations oc-
around the weld joint as listed in Table The decrease in tensile stress had a curs should be better determined, the
6. Note that these stresses are nodal distinct behavior between 1600° and sequence of phase transformation is
stresses that do not necessarily repre- 1080°C. Several slope changes within credible and the residual stresses evo-
sent the bulk stresses of the weld this temperature range were observed lution as a function of martensite as
joint. However, the higher compres- with time. It is entirely likely that outlined is conceivable. In situ syn-
sive residual stresses reduced the cu- these slope changes are related to the chrotron X-ray diffraction appears to
mulative distortion as shown in Fig. several phases that formed during be the right technique to be consid-
11. transformation. For example, -ferrite ered with the experimental validation
When the transformation com- appeared to have begun to form be- of the observation extracted from
pletes at temperature higher than the tween 1600°–1510°C in about 1.2 s. Sysweld analysis.
ambient temperature, subsequent According to this simulation, solidifi- On the other hand, the tensile
thermal contraction continues, but cation would have completed by about stress drop prior to reaching Ms tem-
with no further associated volume ex- 1510°C and -ferrite remained the perature (Ms = 380°C) in the SO-350A
pansion. This thermal shrinkage after predominating phase between weld was quite different as shown in
Mf temperature tends to increase the 1510°–1250°C for about 1.2 s. Austen- Fig. 19. Nonetheless, at 241 s, the
tensile residual stresses in the weld ite appeared around 1250°C to coexist martensite started to form at 380°C
joint or reduce the compressive stress- with δ-ferrite between 1250°–1120°C where the residual stress was still al-
es as shown in Fig. 17 for the weld for approximately 1s. The wide tem- most 200 MPa in tension. After only
made using the SO-350B wire. perature range of δ-ferrite is possibly 0.8 s, the stress dropped to zero at
Using, as an example, the nodal associated to the high content of Cr in 355°C. Since martensite transforma-
stress of the base metal-weld interface the SO-200B welding wire (10 wt-%). tion completed quickly in this weld,
along the X-axis for the SO-200B weld Finally, austenite remained stable un- the compressive stress state originated
as shown in Fig. 16A to study the til the martensite start temperature of via phase transformation became less
stress evolution with time, a close-up 190°C at 273 s. The austenite-to- effective in counteracting the effects
view between 228 to 295 s shows that martensite transformation is associat- of contraction upon further cooling.
stress dropped in this region even ed with volume expansion leading to For the sake of evaluating the influ-
though the temperature had not further drop in the tensile residual ence of residual stress on weld distor-
reached the Ms temperature as shown stress. The drop took almost 14 s to tion, the SO-200B weld was selected for
in Fig. 18. This decreasing tensile reach zero residual tensile stress, at further simulation studies, with and
stress is conceivable due to simultane- 287 s. The zero residual stress was without taking into account the phase
ous accumulation of shrinkage and ex- achieved with approximately 32% of transformation effect. That is, the resid-
pansion in the surrounding of the martensite in the weld joint. As the ual stresses and distortion were com-
weld. The weld upon cooling under- fraction of the martensite continued puted with and without considering
goes shrinkage while the adjacent base to increase in the weld, the magnitude martensitic transformation. Without
metal expands because of the heat of the compressive stresses also in- the effect of solid-state phase transfor-
transferred from the heat source. creased to further counteract the ef- mation, no expansive strain due to the
These counteracting actions of the fect of contraction by cooling. While volume change would occur along the

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WELDING RESEARCH

Fig. 20 — The longitudinal stresses (in the direction of the Fig. 21 — The effect of martensite proportion in the weld made
weld) on the weld made using a SO­200B wire with and with­ using the SO­200B wire on the residual stresses
out considering the effect of phase transformation. distribution.

thermal strain and, thereby, resulting in metal is a function of design (struc- and at a predetermined depth and
tensile residuals stresses along the weld ture), material, and fabrication. How- width from the weld toe. Finally, the
and around the weld toe. This behavior ever, keeping the above parameters effect of martensitic transformation
would be equivalent to a non-LTTW unchanged, the magnitude of the volu- temperatures below 200°C need to be
consumable such as ER70S-3. These metric expansion in the weld and heat- further investigated. Concerns about
tensile residual stresses would have re- affected zone (HAZ) and, accordingly, incomplete martensitic transforma-
sulted in a weld distortion at the order the amount of residual stresses in and tion at room temperature must be
of 1.92 mm based on Sysweld calcula- around the welded joint, will depend clarified such that a reduction in
tion. On the other hand, simulation on the volume fraction of martensite martensite fraction in the weld does
work showed that the compressive that formed in the weld. not also result in reduced advanta-
residual stresses induced in the welded Using Sysweld as a predictive tool, geous compressive residual stress cre-
joint, when taking the phase transfor- Fig. 21 shows that when welding with ated around the weld toe.
mation into consideration, would have the SO-200B welding wire, which con-
reduced the transverse displacement to tained 10 wt-% chromium and 4 wt-% Conclusions
1.47 mm along the Z-axis. nickel (10.7 Creq and 5.8 Nieq), approxi-
As expected, the induced residual mately 40% of martensite would be Some major reflections and con-
stresses were found sensitive to mi- present at the reversal of tensile to clusions achieved in this work are as
crostructural evolution. For a weld ma- compressive residual stresses in the follows:
terial consisted of almost a 100% fer- vicinity of the weld. As the martensite • Despite similar heat input used
rite/pearlite microstructure, the ten- fraction increased, the compressive to weld with the newly developed LTT
sile residual stress state would have residual stresses also increased along welding wires, the welded joints
developed in the weld in the presence all three axes. Nevertheless, the signif- showed different transverse, out-of-
of thermal contraction alone. icance of the amount of martensite at plane distortions with respect to a
Figure 20 shows the two residual the tension-compression reversion for conventional welding wire, ER70S-3.
stress modes in the weld made using a particular welding consumable The LTTW consumables controlled
the SO-200B wire along the weld direc- should be examined more carefully. invariably better weld distortion.
tion. These (nodal) stresses were cal- Based on the findings in this work, • Keeping all structural and weld-
culated with and without considering it is recommended that martensitic ing parameters unchanged, the cumu-
the martensitic transformation. With transformation start temperature be lative distortion was found to be
martensitic transformation, a residual limited to below 350°C. A higher Ms strongly affected by the Ms tempera-
compressive stress (in the longitudinal temperature than 350°C may lead to ture and the content of the alloying
direction) at the order of 650 MPa tensile residual stresses due to the elements in the welding filler metal.
would have resulted instead of the 250 thermal contraction of the weld after • Alloys with similar Ms tempera-
MPa tensile residual stress when the completion of martensitic trans- ture exhibited different experimental
martensitic transformation is ignored. formation. By following this method- cumulative distortion and predicted
Several factors contribute to the ology, it is possible, in principle, to de- compressive residual stresses. This
formation of residuals stresses and de- sign cost-effective LTTW electrodes to observation points out that the Ms is
formation. The plastic deformation meet pre-established levels of com- not a unique indicator for the predic-
produced in the base metal and weld pressive residual stress requirements tion of the resulting transformation-

DECEMBER 2014 / WELDING JOURNAL 469-s


WELDING RESEARCH

induced compressive residual stresses. to, J., Hiraoka, K., Morikage, Y., Kubo, T., steel plate using low-transformation-tem-
• Alloys with higher chromium equiv- Yasuda, K., and Amano, K. 2007. Develop- perature welding wire. Welding Journal
alent seemed to promote greater com- ment of new low transformation tempera- 82(4): 78-s to 83-s.
pressive residual stresses around the ture welding consumable to prevent cold 13. Suzuki, N., Ohta, A., and Maeda, Y.
cracking in high strength steel welds. Sci- 2004. Repair of fatigue cracks initiated
weld toe as compared to the higher
ence and Technology of Welding and Joining around box welds using low transforma-
nickel equivalent alloys for similar Ms 12(6): 516–522. tion temperature welding material. Welding
temperatures. The SO-200B weld joint, 3. Zenitani, S., Hayakawa, N., Ya- International: 112–117.
in particular, presented the minimum mamoto, J., Hiraoka, K., Shiga, C., Morik- 14. Krauss, G. 1989. Steels: Heat Treat-
cumulative transverse distortion that age, Y., Kubo, T., and Yasuda, K. 2002. ment and Processing Principles. ASM Inter-
indicated the maximum compressive Prevention of cold cracking in high national. pp. 43–87.
residual stress. However, the effects of strength steel welds by applying newly de- 15. Martínez Díez, F. 2004. Develop-
chromium equivalent and nickel equiva- veloped low transformation-temperature ment of compressive residual stress in
lent on distortion as well as residual welding consumables. 6th International structural steel weld toes by means of weld
stresses should be further investigated. Trends in Welding. metal phase transformations. PhD thesis,
4. Eckerlid, J., Nilsson, T., and Karlsson, Colorado School of Mines.
• The expansive strain measured for
L. 2003. Fatigue properties of longitudinal 16. Martínez Díez, F., and Liu, S. 2007.
all designed welding wires in the attachments welded using low transforma- Compositional boundary between primary
dilatometric testing led to compressive tion temperature filler. Science and Technol- austenitic and ferritic Mn-Cr and Ni-Cr
residual stresses (the highest modal ogy of Welding and Joining 8: 353–359. steel weld metals. Materials Science and En-
value at the order to 600 MPa) in the 5. Darcis, Ph.P., Katsumoto, H., Pa- gineering: 452–453.
vicinity of the welds as predicted by yares-Asprino, M. C., Liu, S., and Siewert, 17. Payares-Asprino, M. C., Katsumoto,
Sysweld. T. A. November 2007. Cruciform fillet H., and Liu, S. 2008. Effect of martensite
• The stress evolution with time welded joint fatigue strength improve- start and finish temperature on residual
study showed that increasing marten- ments by weld metal phase transforma- stress development in structural steel
sitic fraction can reverse tensile resid- tions. Intl. Journal of Fatigue and Fracture of welds. Welding Journal 87(11): 279-s to
Engineering Materials and Structures 31: 289-s.
ual stresses to compressive stresses at
125–136. DOI: 10.1111/j.1460- 18. Schaeffler, A. L. 1949. Constitution
temperatures around and below the Ms 2695.2007.01205.x. diagram for stainless steel weld metal. Met-
temperature. 6. Martinez, F., and Liu, S. May 16–20, al Progress 56(11): 680–688.
• Results of the Sysweld simulation 2005. Development of compressive resid- 19. Alghamdi, T., and Liu, S. 2010.
also showed that leaner and more eco- ual stress in structural steel weld toes by Low transformation temperature (LTT)
nomical welding wires, i.e., with tai- means of weld metal phase transforma- welding consumable: Different methods
lored martensite faction in the weld tions. Proceedings of the 7th International for calculating martensitic transforma-
metal, can be designed to promote ad- Conference on Trends in Welding Research. tion start temperature. Material Science
equate compressive residual stresses 7. Ohta, A., Watanabe, O., Matsuoka, and Technology Conference, Houston, Tex.
in welded structures. K., Siga, C., and Nishijima, S. 1999. Fatigue 20. Alghamdi, T., and Liu, S. 2012.
strength improvement by using newly de- Newly developed low transformation tem-
veloped low transformation temperature perature (LTT) welding consumables. Pa-
Acknowledgments welding material. Welding in the World per presented at the 14th Middle East Cor-
43(6). rosion Conference (05-MS-01), Bahrain.
8. Ohta, A., Watanabe, O., Matsuoka, 21. Ramjaun, T., Stone, H. J., Karlsson,
The authors would like to acknowl- K., Maeda, Y., Suzuki, N., and Kubo, T. L., Kelleher, J., Moat, R. J., Kornmeier, J.
edge the support of Saudi Aramco, Con- 2000. Fatigue strength improvement of R., Dalaei, K., and Bhadeshia, H. K. D. H.
sulting Service Department (CSD) for box welds by low transformation tempera- 2014. Effect of interpass temperature on
the conduction of this research pro- ture welding wire and PWHT. Welding in residual stresses in multipass welds pro-
gram. The authors would also like to ex- the World 44. duced using low transformation tempera-
press their appreciation to Harald 9. Ohta, A., Suzuki, N., and Maeda, Y. ture filler alloy. Science and Technology of
2001. Superior fatigue strength of welded Welding and Joining 19: 44–51.
Porzner and Brian Shula of ESI America
joints made with low transformation tem- 22. Shirzadi, A., Bhadeshia, H. K. D. H.,
for their collaboration and great assis- perature welding material. National Insti- Karlsson, L., and Withers, P. J. 2009. Stain-
tance in the numerical modeling of the tute for Materials Science, Japan. less steel weld metal designed to mitigate
LTTW weld behavior using Sysweld. Fi- 10. Ohta, A., Maeda, Y., Suzuki, N., residual stresses. Science and Technology of
nally, the authors appreciate the sup- Watanabe, O., Kubo, T., and Matsuoka, K. Welding and Joining 14: 559–565.
port received from the NSF-CIMJSEA 2002. Fatigue strength improvement of 23. Yamamoto, J., Hiraoka, K., and
(Center for Integrative Materials Join- box welds using low transformation tem- Mochizuki, M. 2010. Analysis of marten-
ing Sciences for Energy Applications). perature welding material. tripled fatigue site transformation behaviour in welded
strength by post weld heat treatment. joint using low transformation tempera-
Welding International 16(1): 44–47. ture welding wire. Science and Technology of
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tion. Acta. Metall. Mater. 42(10): North America, Inc., 32605 W. 12 Mile, Ste. 39. Thomas, S. H. 2013. Analysis of low
3371–3379. 350, Farmington Hills, Mich., 48334-3379. transformation temperature welding
28. Ghosh, G., and Olson, G. B. 2003. 35. Yasumasa, N., et al. 2005. Welding (LTTW) consumables — Distortion control
The kinetics of lath martensitic transfor- distortion behavior of steel welds with and evolution of residual stresses. M.S.
mation. Journal De Physique IV, France 112. low-temperature transformation welding thesis, Colorado School of Mines.
29. Sysweld Reference Manual. 2011. ESI wire. International Institute of Welding, 40. Thomas, S. H., and Liu, S. May
Group. ESI US, Inc. & ESI North America, IIW-Doc. XV-119-05, Prague. 2014. Analysis of low transformation tem-
Inc., 32605 W. 12 Mile, Ste. 350, Farming- 36. AlGhamdi, T., Liu, S., and Al-Ab- perature welding (LTTW) consumables—
ton Hills, Mich., 48334-3379. bas, F. 2012. Newly developed low trans- Distortion control and evolution of stress-
30. Goldak, J., Chakravarti, A., and formation temperature (LTT) welding es. Journal of Science and Technology of
Bibby, M. 1984. A new finite element consumables. Proceedings of the 14th Mid- Welding and Joining 19(5): 392–401. Pub-
model for welding heat sources. Metallur- dle East Corrosion Conference & Exhibition, lished online: DOI
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31. Francis, J. D. 2002. Welding simula- MS-01-MECC, Manama, Kingdom of
tion of aluminum alloy joints by finite ele- Bahrain.

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DECEMBER 2014 / WELDING JOURNAL 471-s


WELDING RESEARCH

Improvement of Process Robustness in


Weld Bonding of Galvanized DP780 Steel
A method based on variable electrode force was developed to widen the welding lobe in
weld bonding of advanced high­strength steels using a servo gun

BY Y. S. ZHANG, H. T. SUN, PEI-CHUNG WANG, AND G. L. CHEN

ticity and strength (Refs. 12, 13).


ABSTRACT However, weld bonding of advanced
high-strength steel with epoxy-based
The development of the weld bonding process for lighter, stronger, and adhesives is prone to exhibit weld ex-
more cost-effective vehicle structures requires a detailed understanding of pulsion as well as a narrow welding
the process robustness (i.e., welding lobe, which is defined as the range of lobe (Refs. 14, 15), which is defined as
the welding current and time under a given electrode force in which an
acceptable weld is produced) in weld bonding of steels. In this study, a vari- the range of the welding current and
able electrode force and an orthogonal design-of-experiment approach were time under a given electrode force.
employed to widen the welding lobe in weld bonding of 1.6-mm-thick galva- Figure 1 shows the weld lobe diagram
nized DP780 steel. It was found that the optimized variable electrode force for producing an acceptable weld un-
not only significantly widened the weld lobe but minimized the weld expul- der a constant electrode force of 4.3
sion. With application of a servo weld gun, weld bonding with a variable kN in resistance spot welding 1.6-mm-
electrode force can be readily applied to vehicle assembly. thick hot-dipped galvanized (i.e.,
HDG60) DP780 steel. As shown in Fig.
1, the left boundary of the welding
lobe is determined by the combination
KEYWORDS of the lowest weld current for a given
weld time required to produce the
• Weld Bonding • Welding Lobe • Variable Electrode Force • Weld Expulsion minimum weld size (Ref. 16) while the
• Galvanized Steel right boundary is determined by the
combination of the lowest weld cur-
rent for a given weld time for which
Introduction Therefore, this joining method has
weld expulsion occurs. The range of
been widely applied in vehicle body
the weld current (i.e., lobe width) un-
The drive for increased fuel econo- structures such as front longitudinal
der a given weld time and an electrode
my and mechanical performance re- rails, A, B, and C pillars, and the bulk-
force provides an indication of the ro-
quirements in the automotive indus- head to inner wing. To facilitate the
bustness of the weld schedule. In gen-
try make the higher strength and stiff- use of weld bonding for lighter,
eral, the acceptable lobe width is 2 kA
ness steel associated with weld bond- stronger, and more cost-effective vehi-
according to the specification of Amer-
ing (i.e., a combination of resistance cle structures, process guidelines for
ican Iron and Steel Institute (Ref. 16).
spot welding (RSW) and adhesive weld bonding of structures are re-
If the welding lobe is too narrow, it
bonding) an attractive joining method quired (Refs. 9–11). The development
may result in a discrepant weld due to
(Refs. 1, 2). It produces more desirable of these guidelines requires not only a
typical process variations such as weld
joint performance when compared to detailed understanding of the mechan-
current fluctuation or electrode cap
either spot welding or adhesive bond- ical performance but also the manu-
wear. Therefore, it is important to
ing (Ref. 3). It not only improves the facturing process of weld-bonded
have a wide welding lobe.
stiffness (Refs. 4, 5), crashworthiness joints. Epoxy-based structural adhe-
To improve the process robustness,
(Refs. 6, 7), and fatigue behavior (Ref. sives have been widely employed for
the weld current range can be widened
8), but enables a reduction in the num- automotive applications because they
by extending the welding time (Ref.
ber of welds used in vehicle structures. have a relatively high modulus of elas-
17) or increasing the electrode force in

Y. S. ZHANG(zhangyansong@sjtu.edu.cn), H. T. SUN, and G. L.CHEN are with Shanghai Key Laboratory of Digital Manufacture for Thin­Walled Structures,
Shanghai Jiao Tong University, Shanghai, PR China. Pei Chung WANG is with Manufacturing Systems Research Lab, General Motors Research & Development
Center, Warren, Mich.

472-s WELDING JOURNAL / DECEMBER 2014, VOL. 93


WELDING RESEARCH

Fig. 2 — Lap­shear specimen configuration (dimensions in mm).

process robustness in weld Experimental Procedure


Fig. 1 — Typical welding lobe of resistance spot weld­ bonding of steel sheets.
ing under a given electrode force. The present study was
undertaken to apply a vari-
Materials
resistance spot welding of steel sheets able electrode force to
Hot-dipped galvanized (i.e.,
(Ref. 18). However, in the case of weld widen the welding lobe in weld bond-
HDG60) DP780 steel with 1.6 mm
bonding, increasing the welding time ing of 1.6-mm-thick galvanized DP780
thickness was used in this study. The
leads to excessive heat input because steel. There are three main parts in
chemical compositions and mechanical
of the presence of the adhesive layer, this study; the first presents the ex-
properties per our experimental meas-
i.e., greater faying interface resistance, perimental procedure including mate-
urements are listed in Table 1. A one-
and consequently has little effect upon rials, sample fabrication, measurment
component, hot-cured, toughened-
widening of the welding lobe. Further- of dynamic resistance, mechanical
epoxy resin-based adhesive (Ref. 21),
more, the width of the welding lobe testing, and design of experiment. In
was used in this study. Per the manu-
exhibited little improvement by in- the following section, the welding
facturer’s data sheet, Table 2 lists the
creasing the electrode force (Ref. 19). lobes of resistance spot welding and
material properties of the toughened-
Experimental observations indicated weld bonding of 1.6-mm-thick galva-
epoxy adhesive.
that variable electrode force had an in- nized DP780 steel under a constant
fluence on the adhesive flow and thus electrode force were developed and a
method to optimize the variable elec- Specimen Fabrication
the contact resistance at the faying in-
terfaces during the weld formation trode force that is used to widen the
welding lobe was proposed. Finally, The weld-bonded specimen config-
process (Refs. 20, 21). Therefore, the uration shown in Fig. 2 was selected in
use of variable electrode force may in- the effects of the optimized variable
electrode force on the dynamic resist- this study. The specimens were fabri-
hibit weld expulsion and consequently cated from 38 × 100 × 1.6-mm galva-
move the expulsion boundary to high- ance and process window were experi-
mentally studied. This study provides nized DP780 steel sheets. To simulate
er current levels. With the increased resistance welding and weld bonding
application of servo welding guns in valuable guidelines to the application
of weld bonding to join the advanced on a vehicle body, an overlap area of
the automotive body assembly 38 × 38 mm was selected. A spot weld
process, it may be feasible to apply high-strength steels for vehicle manu-
facturing. was centered on a 38-mm overlap re-
variable electrode force to improve the gion for the spot-welded and weld-
bonded specimens (Refs. 15, 22).
Table 1 — Chemical Compositions and Mechanical Properties of DP780 Steels The weld bonding processes were
realized by use of a welding system
Chemical Composition (%) Mechanical Properties having an alternating current welding
Steel Yield Tensile Elongation machine. A Class II copper alloy with a
C Mn P S Si Al Strength Strength (%) chromium and zirconium electrode
(MPa) (MPa) (Cr: >0.4%, Zr: 0.3–0.15%) was used in
DP780 0.15 1.8 0.004 0.016 0.010 0.048 508 834 26 the experiment. A fixture was used to
ensure consistent weld placement. The
weld nugget was measured from but-
Table 2 — Material Properties of Toughened­Epoxy Adhesive (Ref. 22) tons remaining on the specimens that
were peel tested in a vise. In this
Adhesive Specific Viscosity Tensile Strength Elongation at Break study, the target weld button diameter
Gravity @50C (Pa∙s) (MPa) (%) was fabricated based on AWS recom-
Toughened­Epoxy mended practice (Ref. 22).
Adhesive 1.05~1.20 30–50 >30 >10 The weld-bonded specimens were

DECEMBER 2014 / WELDING JOURNAL 473-s


WELDING RESEARCH

prepared as shown in Fig. 3 as follows:


A B
1) Apply the adhesive through a
hand-held injection gun, on one of the
two contact surfaces. Bring the two
sheets together with an overlap dis-
tance of 38 mm and gap distance (i.e.,
adhesive layer thickness) of 0.3 mm
defined by a thickness gauge (illustrat-
ed in Fig. 3A);
2) After removing the gauge, the
specimens were spot welded using the
welding schedule recommended by the C
weld specification (Ref. 22); and
3) The specimens were then cured
in an oven for 30 min at 180°C per
manufacturer’s recommended proce-
dures. Fig. 3 — Procedure of weld­bonding: A
All finished specimens were exam- — Apply adhesive and assemble; B —
ined for the presence of any defects. spot weld; C — curing the samples in
Here it should be noted that step 3 the oven.
was skipped in order to investigate the
mechanical properties of the weld-
bonded nugget (Refs. 15, 23).
Figure 4 shows the weld schedule
with three heat pulses under a constant
electrode force of 4.3 kN. Each pulse is
composed of a weld current of 8.5 kA
for the duration of 7 cycles (1 cycle = 20
ms) and a cool time of 1 cycle.

Measurement of Dynamic
Resistance
In order to investigate the effect of
adhesive on the resistance between
the steel sheets, dynamic resistance
was measured in this study (Refs. 24,
25). Figure 5A is a photo of the experi-
mental setup used to measure the dy- Fig. 4 — Weld schedule for resistance welding and weld bonding of 1.6­mm­thick galva­
namic resistance. The weld current nized DP780 steel.
and voltage data between the steel
sheets were collected using the weld-
ing monitor (MM-370A) made by MIY- Table 3 — The Orthogonal Experiment Levels and Factors for Tests of Variable Electrode Force Shown
ACHI. Figure 5B is a schematic of the in Fig. 9
measurement method where RD is the
dynamic resistance between the top Control Factors Levels
I II III
and bottom sheets. Five replicates
were performed for each type of weld Weld force during the first half of the weld cycle, FW1 (kN) 3.5 3.9 4.3
bonding, and the average dynamic re- Weld force during the second half of the weld cycle, FW2 (kN) 4.3 4.7 5.1
Forging force during the hold cycle, Ff (kN) 4.3 4.7 5.1
sistances were reported. A detailed de-
scription can be found in Ref. 15.

Mechanical Testing
mens, shims were attached to both [called lap-shear strength (Ref. 27)]
Quasi-static tests were performed ends of the specimen using masking were recorded. Postfailure analysis was
by loading each specimen to failure in tape to accommodate the specimen performed using optical microscopy to
a tensile tester according to the stan- offset, as shown in Fig. 2. Load vs. dis- study the failure mechanisms. During
dard ASTM D1002-01 (Ref. 26) for de- placement curves were obtained as the the metallographic analysis, the pol-
termination of the joint strength. To specimens were loaded at a stroke rate ished specimens were etched with a
minimize the bending stresses inher- of 2 mm/min. Five replicates were per- 4% Nital reagent and the weld nuggets
ent in the testing of lap shear speci- formed, and the average peak loads were examined by optical microscopy.

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WELDING RESEARCH

A B

Fig. 5 — Experimental schematic for measurement of the following: A — Test setup; B — dynamic resistance between the steel and adhesive in
weld bonding of 1.6­mm­thick galvanized DP780 steel.

A B

Fig. 6 — Comparison of resistance welding and weld bonding of 1.6­mm­thick galvanized DP780 steel: A — Process window; B — lobe
width (i.e., weld current range for an acceptable weld).

Design of Experiment Results and Discussion at the faying interfaces acted as a bar-
rier for conducting the welding cur-
A design of experiment on the vari- Welding Lobe rent, and consequently more joule
able electrode force was performed to heat was generated in WB compared
obtain the maximum weld strength and Tests were conducted to determine to that of RSW. The excessive heat in-
least weld expulsion. The Taguchi ap- the welding lobe (i.e., welding current put during welding caused both the
proach incorporating orthogonal arrays and welding time under a constant minimum nugget boundary and the
was used to perform the systematic electrode force) for weld bonding expulsion boundary to move to lower
evaluation of the variable electrode (WB) of 1.6-mm-thick galvanized current levels. Moreover, the expul-
force (Ref. 28). Table 3 shows the or- DP780 steel. For the purpose of com- sion limit had a more remarkable
thogonal array with regard to three fac- parison, resistance spot welding trend toward lower current levels
tors and three levels L9, where the sub- (RSW) of 1.6-mm-thick galvanized than the minimum nugget boundary
script 9 denotes the number of experi- DP780 steel under the same electrode resulting in an overall narrower weld-
ments to be performed. Based on the force was also performed and the re- ing lobe for weld bonding.
output response (i.e., the peak load in sults are shown in Fig. 6A, B. The re- The WB lobe width is less than the
all nine investigated cases), optimiza- sults show the overall welding lobe acceptable lobe width of 2 kA (Ref.
tion of the variable electrode force for weld bonding was smaller than 16). These results indicate a fluctua-
would be achieved by Taguchi experi- that for resistance spot welding and tion in welding current or weld cap
mental design. The design of orthogo- the minimum current level for an ac- wear may cause discrepant welds in
nal techniques, which can greatly reduce ceptable weld at a given time occurred production. Therefore, a method to
the time and increase the accuracy of at lower current levels for weld bond- widen the welding lobe for WB of 1.6-
prediction, have been widely used in the ing vs. resistance spot welding. This mm-thick galvanized steels is needed
optimization of welding parameters difference is primarily attributed to and will be presented in the following
(Refs. 29–31). the fact that the insulating adhesive section.

DECEMBER 2014 / WELDING JOURNAL 475-s


WELDING RESEARCH

Fig. 7 — Schematic of the effect of welding time on the weld expansion Fig. 8 — Schematic of the variable electrode force in weld
force resulting from the molten liquid under a given electrode force. bonding of 1.6­mm­thick galvanized DP780 steel.

Fig. 9 — Schematic of the variable force vs. time for the weld bonding Fig. 10 — The effect of variable electrode force on the peak
process. load of weld bonded 1.6­mm­thick galvanized DP780 steel.

Widening of the Welding Lobe Weld expulsion occurs when the the first half of the weld cycle, FW2; 3)
electrode force is less than the expan- weld force during the second half of
In regard to widening the welding sion force resulting from the weld ini- the weld cycle, FW2; and 4) forging
lobe, a key question is how to move tiation and growth of the molten liq- force, Ff . The effects of variable force
the expulsion boundary to the right. uid (Ref. 32). To avoid weld expulsion, and weld time on the weld initiation
Figure 7 shows a schematic of the ex- the electrode force needs to exceed the and growth are described below.
pansion force from the metal due to weld expansion force. Based on this As presented in Fig. 8, to start the
joule heating as a function of welding hypothesis, a variable electrode force weld bonding process a squeeze force
time under a given weld current in re- was adopted as a means to contain the (FS) is applied to the workpieces. This
sistance spot welding. As shown, the weld expulsion in WB of 1.6-mm-thick electrode force thins out the adhesive
expansion force increases with the galvanized DP780 steel. bondline thickness between the work-
welding time. In the early stage of the Figure 8 presents a schematic of the pieces, thereby enhancing the intimate
welding cycle, joule heat is generated variable electrode force in weld bond- contact of the workpieces at the faying
at the faying interface. As the welding ing of the steels. Experimental obser- interface. Once the workpieces are in in-
time is increased, the molten metal vations showed the weld bonding timate contact, the electrode force is
initiates and grows, and as a result, process generally can be divided into lowered to FW1 prior to conducting the
the expansion force from molten weld four stages: 1) adhesive squeeze-out; weld current. This decrease in electrode
metal increases. As the welding 2) weld nugget initiation; 3) weld force would result in an increased con-
process continues, a free volume ex- nugget growth; and 4) quenching of tact resistance at the faying interface.
pansion of the molten weld nugget is the molten weld pool. Corresponding Then, an electrical current is applied
constrained by the surrounding solid to these stages, the electrode force can through the electrodes and flows
metal, and consequently, the growth be also divided into four stages: 1) through the workpieces. As a conse-
of the weld nugget slows down. squeeze force, FS; 2) weld force during quence of the current flow, the temper-

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Fig. 11 — Effect of electrode forces at each stage on the peak B


load of weld bonded 1.6­mm­thick galvanized DP780 steel.

ature of the workpieces increases due to ty (Ref. 32).


the joule heating. To ensure the inti- Based on the
mate contact at the faying interface above analyses, the
generates sufficient joule heating, it electrode force may
may be necessary for the squeeze force be effective in en-
(FS) to be greater than the force (FW1). hancing the process
Once a weld nugget is initiated, it con- robustness in the
tinues to grow in volume with addition- weld bonding
al weld cycles. If the molten weld nugget process. In the first
becomes too large relative to the contact half of the weld cy-
area of the workpieces, which is deter- cle, the decrease in
mined by the electrode diameter and electrode force
applied force, weld expulsion would oc- would increase the
cur. Therefore, to avoid weld expulsion dynamic resist-
the electrode force (FW2) is increased af- ance, and conse- Fig.12 — Effect of an optimized variable electrode force on dynamic
ter the onset of weld initiation. FW2 is quently the joule resistance in weld bonding of 1.6­mm­thick galvanized DP780 steel
generally greater than FW1. As the weld- heat. The increase under the following weld currents: A — 9 kA; B — 10 kA.
ing process continues, the weld nugget in joule heat
grows to reach the desired size and then would result in
the current is shut off to start the hold the minimum boundary of the weld occurrence of weld expulsion. There-
cycle. A high electrode force, Ff, during lobe shifting to the left. Similarly, an fore, to widen the welding lobe in WB,
weld cooling is desirable to reduce weld increase in electrode force in the first the electrode force at each stage
discrepancies such as cracks and porosi- half of the weld cycle would inhibit the should satisfy the following inequality:

Ff and FW2 > FS > FW1 (1)


Table 4 — The Orthogonal Layout for the Variable Electrode Force in Weld Bonding of 1.6­mm­thick
Galvanized DP780 steel
Optimization of Variable
Electrode Force Failure Loads Weld Expulsion Electrode Force
(kN) (kN)
Specimen # FW1 FW2 Ff FT Yes or Little To describe the optimization of the
1 3.5 4.3 5.1 20.100 Yes
variable electrode force, a schematic of
2 3.9 4.3 4.3 18.822 Yes the variable force vs. time is presented
3 4.3 4.3 4.7 18.021 Yes in Fig. 9. As shown, the welding elec-
4 3.5 4.7 4.7 19.017 Little trode forces FW1, FW2, and Ff corre-
5 3.9 4.7 5.1 18.560 Little spond to time intervals, tW1, tW2, and tf,
6 4.3 4.7 4.3 19.634 Little
7 3.5 5.1 4.3 19.111 Little respectively. Table 4 lists the orthogo-
8 3.9 5.1 4.7 17.771 Little nal layout for the variable electrode
9 4.3 5.1 5.1 18.143 Little force, FW1, FW2, and Ff . Weld bonding
Optimized parameter I II I 21.162 Little 1.6-mm-thick galvanized DP780 steel

DECEMBER 2014 / WELDING JOURNAL 477-s


WELDING RESEARCH

Fig. 13 — Effect of an optimized variable electrode force on: A — Process window; B — lobe width (i.e., weld current range) in weld bond­
ing of 1.6­mm­thick galvanized DP780 steel.

A B

C D

Fig. 14 — Effect of variable electrode force and weld current on the weld quality of the weld bonded 1.6­mm­thick galvanized DP780
steel: A — 9 kA; B — 10 kA under constant electrode force; C — 9 kA; D — 10 kA under variable electrode force.

was conducted with a welding current


Table 5 — Analysis of the Peak Load of the Weld­Bonded 1.6­mm­thick Galvanized DP780 Steel
of 8.5 kA, a welding time of 7 cycles (1
cycle = 20ms), and a cooling time of 1
Factor kT1, (kN) kT2, (kN) kT3, (kN)
cycle for 3 pulses, as shown in Fig. 4. It
should be noted that the time of FW1 58.228 55.153 55.798
changing electrode force at each stage FW2 56.943 57.211 55.025
Ff 57.568 54.809 56.802
was set as 1 cycle. Figure 10 presents
the effect of variable electrode force
on the peak load for weld bonding of nation of peak load and minimal weld pressed as kTi, (i = 1,2,3). The relation-
1.6-mm-thick galvanized DP 780 steel. expulsion. For each factor (i.e., elec- ship between each factor and peak
The welded specimens were then me- trode force at each stage), the sum of load is illustrated in Table 5 and Fig.
chanically tested. Referring to Table 4 the peak load results of each corre- 11. Based on the results shown in Fig.
and Fig. 10, specimen #6 had a combi- sponding level was calculated, ex- 11, the optimized variable electrode

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Fig. 15 — Effect of variable electrode force on the force dis­


placement of weld bonded 1.6­mm­thick galvanized DP780
steel with various welding currents. Fig. 16 — Effect of electrode force on the failure mode of the
weld bonded 1.6­mm­thick galvanized DP780 steel with a
weld current of 9 kA under: A — Constant; B —variable elec­
force is composed of FW1 = 3.5 kN, FW2 the weld time was trode force.
= 4.7 kN, and Ff = 4.3 kN. increased up to 1 cy-
The results presented previously in- cle, the dynamic re-
dicate control of the electrode force is sistance dropped drastically and then the optimized variable electrode force.
critical to change the expulsion bound- started to increase. These results sug- Similar results for a welding current of
ary and thus widen the welding lobe. gest the resistance at the faying inter- 10 kA are shown in Fig. 12B.
The electrode force at the various
stages plays a different role in nugget face dropped quickly and the bulk steel
formation. In regard to this, it is criti- resistivity became dominant because Lobe Width
cal to decide a proper FW1 in terms of of joule heat generation. As a result of
high contact resistance. On the other joule heating, the weld nugget initiat- The effect of the optimized variable
hand, determining a proper FW2 is crit- ed and grew. As the weld time was in- electrode force on the welding lobe in
ical for balancing the quick nugget ex- creased to 12 cycles, the dynamic re- weld bonding of 1.6-mm-thick galva-
pansion in terms of inhibiting weld sistance under the optimized variable nized DP780 steel is presented in Fig.
expulsion. force started to drop to a greater de- 13. While the welding lobe under an
gree than that under a constant elec- optimized variable electrode force was
Effect of Optimized Variable trode force. This is primarily attrib- shifted to higher welding currents, the
uted to an increase in electrode force. total welding current range for a given
Electrode Force weld time was significantly increased.
Furthermore, the dynamic resistance
gradually decreased during the weld This is primarily attributed to the re-
To understand the effect of the op- formation indicating the successive sult of low FW1 and high FW2 electrode
timized variable force on the dynamic weld growth occurred with a lower forces. While low electrode force (FW1)
resistances and lobe width in weld propensity for weld expulsion. This is resulted in early weld nugget initiation
bonding of 1.6-mm-thick galvanized primarily because variation of dynam- and growth, high electrode force (FW2)
DP780 steel, test results conducted ic resistance is closely related to weld contained the molten pool while
under variable force (i.e., FS = 4.3 kN, initiation and growth. Since the resist- reaching the desired weld size. As
FW1 = 3.5 kN, FW2 = 4.7 kN, and Ff = 4.3 ance of the molten steel increased shown in Fig. 13, a higher weld current
kN) were compared with those of con- with the temperature, a sudden de- is required under a given weld time
stant electrode force (i.e., FS = Fw1 = Fw2 crease in dynamic resistance toward when using the variable electrode
= Ff = 4.3 kN). the end of welding indicates signifi- force. The average weld current range
cant molten metal (i.e., weld expul- (Iexpulsion – Imin.weld) is increased by about
Dynamic Resistance sion) was expelled. By varying the elec- 50% (from 1.5 to 2.3 kA) when com-
trode force, the joule heat can be prop- pared to the results under a given weld
Figure 12A, B presents the dynamic erly controlled, and consequently min- time and a constant electrode force of
resistance measurements taken during imize weld expulsion. The aforemen- 4.3 kN. These results indicate the
weld bonding of 1.6-mm-thick galva- tioned results indicate the weld nugget process window meets the criteria
nized DP780 steel for the welding cur- initiated early and the molten pool [i.e., weld current range >2 kA (Ref.
rents of 9 and 10 kA, respectively. As was contained by the increased elec- 16)] for resistance spot welding.
shown in Fig. 12A, the initial dynamic trode force toward the later stage of The results found in this study are
resistance under the optimized vari- the weld bonding process. As a result, of particular importance in regard to
able electrode force is greater than the desired weld nugget and minimal the process robustness for weld bond-
that of the constant electrode force. As weld expulsion were obtained under ing of steels. To obtain the acceptable

DECEMBER 2014 / WELDING JOURNAL 479-s


WELDING RESEARCH

process window, the application of weld bonded 1.6-mm-thick galva- of 1.6-mm-thick galvanized DP780
variable electrode force is recommend- nized DP780 steel. steel was developed. The variable elec-
ed. The comparative results made with trode force was composed of a squeeze
variable and constant electrode force Weld Strength force of 4.3 kN, the electrode forces of
proved that variable electrode force 3.5 and 4.7 kN for the first and second
has a satisfactory effectiveness for im- To examine the effect of variable halves of the weld cycles, respectively,
proving process robustness. With the electrode force on the strength of the and a hold force of 4.3 kN.
application of the servo gun, weld weld bonded specimens, quasi-static
bonding with a variable electrode force tests were conducted and the results
can be applied readily to the vehicle as- are shown in Fig. 15. As shown, the Acknowledgments
sembly. However, the potential nega- use of variable electrode force in-
tive influences of variable electrode creased slightly the force displacement This research was supported by the
force on other aspects of the weld of the weld bonded DP780 steel General Motors Collaborative Re-
bonded nugget deserve careful study sheets. To further understand the qua- search Laboratory at Shanghai Jiao
such as nugget thickness and indenta- si-static characteristics of the speci- Tong University and by National Natu-
tion on the surface of the sheet metal. mens, the failure modes of the tested ral Science Foundation of China (No.
spot-welded and weld-bonded speci- 50905111, No. 51275304).
Weld Quality mens made with a welding current of 9
kA were examined and the results are
Figure 14 shows the effects of shown in Fig. 16. As shown, the speci- References
welding current and variable elec- mens made with constant and variable
trode force on the weld quality of the electrode forces had the weld button-
weld bonded specimens. As shown in pullout (Ref. 33). Since both speci- 1. Messler, R. W. 2002. Weld-bonding:
Fig. 14A, B, the weld size increased mens had similar failure modes, the The best or worst of two processes. Indus-
from 6.90 to 7.03 mm as the welding increase in weld strength shown in trial Robot 29(2): 138–148.
Fig. 15 was likely related to the in- 2. Chang, B. H., Shi, Y. W., and Dong, S.
current increased from 9 to 10 kA for J. 1999. A study on the role of adhesives in
the specimens made with constant creased weld size resulting from the weld-bonded joints. Welding Journal 78(8):
electrode force. While the weld size extra joule heat introduced by the 275-s to 279-s.
increased, severe weld expulsion oc- presence of the small electrode force at 3. Darwish, S. M. 2003. Characteristics
curred for the welding current of 10 the first stage of the weld cycles. of weld-bonded commercial aluminum
kA. On the other hand, the weld size It is emphasized that the results sheets (B.S.1050). International Journal of
increased with an increase of the presented in this study only illustrate Adhesion and Adhesives 23(3): 169–176.
welding current from 9 to 10 kA, but the improvement of process robust- 4. Goncalves, V. M., and Martins, P. A. F.
little weld expulsion was observed for ness (i.e., weld lobe width) for weld 2006. Joining stainless steel parts by
the specimens made with variable bonding of 1.6-mm-thick galvanized means of weld bonding. International Jour-
DP780 steel by applying the variable nal of Mechanics and Materials in Design 3:
electrode force. Comparing the re- 91–101.
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in Fig. 14C, D revealed the specimens tions and alignment, and metal fitup Veldt, T. 2013. Structural performance of
made with variable electrode force reported here are not indicative of the adhesive and weld-bonded joints. Welding
had slightly larger weld sizes than production environment in a vehicle in the World 57: 147–156.
those made with constant force (i.e., body shop. Nevertheless, the present 6. Xia, Y., Zhou, Q., Wang, P. C., John-
about 5 and 8% increase for the weld- results showed process robustness in son, N. L., Gayden, X. Q., and Fickes, J. D.
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tively). Furthermore, little weld ex- can be improved significantly. With modeling technique for weld-bonded steel
pulsion was observed at a welding the current servo gun technology, the in vehicle structures, Part I. Static Experi-
variable electrode force method can be ments and Simulation. International Jour-
current of 10 kA with variable elec- nal of Adhesion & Adhesives 29: 414–426.
trode force. Careful examination of readily implemented. 7. Xia, Y., Zhou, Q., Wang, P. C., Johnson,
the test results indicated the reduc- N. L., Gayden, X. Q., and Fickes, J. D. 2009.
tion in weld expulsion was primarily Conclusions Development of a high-efficiency modeling
attributed to the increase in electrode technique for weld-bonded steel in vehicle
force that contained the molten steel 1. Variable electrode force was adopt- structures - Part II; Dynamic experiments
during the welding process. Further- ed to improve the process robustness and simulations. International Journal of Ad-
more, as shown in Fig. 14, the weld (i.e., widening the weld lobe) in weld hesion & Adhesives 29: 427–433.
microstructure and indentation (or bonding of 1.6-mm-thick galvanized 8. Long, X., and Khanna, S. K. 2008. Fa-
metal thinning) of the welds made tigue performance of spot welded and weld
DP780 steel. It not only widened the
bonded advanced high strength steel
with variable electrode force were weld current range by approximately sheets. Science and Technology of Welding
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Practices for Test Methods for Evaluating the Research in the
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Durability of adhesively-bonded single lap- Sibilia, G., and Saindrenanb, G. 2008. % Your research sent to more
shear joints in accelerated hygrothermal Characterization of electrical contact con- than 69,000 American
exposure for automotive applications, In- ditions in spot welding assemblies. Journal
ternational Journal of Adhesion and Adhe- of Materials Processing Technology 195: Welding Society members
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13. Morin, D., Haugou, G., Bennani, B., 25. Cho, Y., and Rhee, S. 2002. Primary % Your published paper
and Lauro, F. 2011. Experimental charac- circuit dynamic resistance monitoring and posted on the AWS Web
terization of a toughened epoxy adhesive its application to quality estimation during site for FREE access
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of Adhesion Science and Technology 25(13): 81(6): 104-s to 111-s. worldwide
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to 132-s. Bonded Metal Specimens by Tension Loading
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adhesive characteristics on the weld quali- Ilhan, E., and Demir, Z. 2007. Effect of % No page charges
ty in weld bonding multiple steel sheets. welding current on mechanical properties
Welding Journal 92(12): 363-s to 374-s. of galvanized chromided steel sheets in % Your paper printed in
16. Tawade, G., and Boudreau, G. 2004. electrical resistance spot welding. Materials
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coated high-strength automotive steels. 28. Roy, R. 1990. Designs with Interac-
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