AWS Welding Journal December 2013

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December 2013
WELDING JOURNAL VOLUME 92 NUMBER 12 DECEMBER 2013

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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CONTENTS
December 2013 Volume 92 Number 12
Features
26
26
Aluminum Weld-Quality Solutions Come in Threes

A trailer manufacturer finds ways to improve its aluminum
welds
F. Armao
30
Tips for Job Shops

Five suggestions are offered to job shops to be more
efficient and cost-effective
J. Leisner and D. Benson
34
Welding and Cutting Fair Attracts a Worldwide Audience

This every four-year event is still the gathering place to
display worldwide technology
A. Cullison
38
How Wire Diameter Affects Aluminum Welding

Find out how changing wire diameter might be the answer
to improving productivity
R. Krause
The American Welder
30
70
AWS Scholarships Proved a Channel to Success

Learn how successful professionals got a boost in their
careers with AWS scholarships
K. Campbell
74
Women Learn Welding Skills for New Careers

Women enter the workforce as welders through a special
program that helps the underprivileged
B. Atkinson and D. Flood
AWS website www.aws.org
Departments
Editorial ............................4
Washington Watchword ..........6
Press Time News ..................8
News of the Industry ............10
Aluminum Q&A ..................16
Brazing Q&A ......................20
Product & Print Spotlight ......22
Coming Events....................42
Certification Schedule ..........46
Society News ....................49
Tech Topics ......................50
Amendment Notice: D14.3:2010
Amendment Notice: D15.1:2012
Errata A5.16:2013
Guide to AWS Services ........67
Personnel ........................68
American Welder
Learning Track ..................79
Fact Sheet ......................82
Welding Journal Index ..........84
Classifieds ........................98
Advertiser Index ................100
Welding Research Supplement

347-s Spatter and Porosity in Gas-Metal Arc Welding of
Magnesium Alloys: Mechanisms and Elimination
The needs of the automotive industry have accelerated
research into welding magnesium alloys
D. C. Wagner et al.
38
363-s Effect of Adhesive Characteristics on the Weld Quality

in Weld-Bonding Multiple Steel Sheets
This hybrid joining process was investigated and suggested
guidelines for success are provided
Y. S. Zhang et al.
375-s Arc Characteristics of Ultrasonic Wave-Assisted GMAW
Experiments with this newly developed welding method produced
deep penetration and fine-grain crystallization
C. L. Fan et al.
381-s Sensing Dynamic Keyhole Behaviors in ControlledPulse Keyholing Plasma Arc Welding
New insight into the dynamics of keyhole behavior and its effect on
weld quality is revealed
Z. M. Liu et al.
390-s Heat Input Reduction in Fillet Welding Using Bypass
and Root Opening
The optimum root opening in a T-joint was sought that was
compatible with a submerged arc process using a double electrode
Y. Lu et al.
Welding Journal (ISSN 0043-2296) is published

monthly by the American Welding Society for
$120.00 per year in the United States and possessions, $160 per year in foreign countries: $7.50
per single issue for domestic AWS members and
$10.00 per single issue for nonmembers and
$14.00 single issue for international. American
Welding Society is located at 8669 NW 36th St.,
# 130, Miami, FL 33166-6672; telephone (305)
443-9353. Periodicals postage paid in Miami, Fla.,
and additional mailing offices. POSTMASTER: Send
address changes to Welding Journal, 8669 NW
36th St., # 130, Miami, FL 33166-6672. Canada
Post: Publications Mail Agreement #40612608
Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2,
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Readers of Welding Journal may make copies of
articles for personal, archival, educational or
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resale. Permission is granted to quote from articles, provided customary acknowledgment of
authors and sources is made. Starred (*) items
excluded from copyright.
On the cover: It is important for job shops to improve productivity, ensure the
best quality, and reduce costs to remain competitive. (Photo courtesy of Miller
Electric Mfg. Co., Appleton, Wis.)
WELDING JOURNAL
Editorial December 2013_Layout 1 11/14/13 2:53 PM Page 4
EDITORIAL
Its Been a Very Good Year

As 2013 draws to a close, I can assure you that it has been an important year for the
American Welding Society, for welding careers for women, and especially for me. Our
Society is healthy and growing both in the numbers of domestic and international members and with regard to its financial position. American Welding Online (awo.aws.org),
which is often referred to as AWO, is up and running with the CWI pre-seminar ready
and available as well as classes on safety, metallurgy, math, nondestructive testing, and
the Certified Welding Sales Representative program. Through AWO, you can access
information on the AWS SENSE program, podcasts, the AWS You Tube channel, and
blogs. The AWS believes everyone should have easy access to welding education and
knowledge anywhere and at any time, and AWO is one way to make that happen.
The AWS continues to offer new opportunities through membership, certifications,
and welding shows both in the United States and abroad. Its also now heavily involved
with the social media phenomenon. You can find AWS on Facebook, Twitter, and other
media that I must admit I dont quite understand, but my grandchildren and other members of our next generation certainly do.
As I have traveled the country throughout this year, I have encountered enthusiastic
District and Section leaders, people working in nearly every type of career in the welding industry, and excited students and teachers. I have enjoyed visiting companies making an interesting variety of products all requiring welding of some type and most in
need of additional welding professionals. It is my hope that through all of us working
together, these firms can soon find the skilled and educated welding professionals they
need.
As you may know, all year long I have emphasized the opportunities available for
women in welding and showcased some of the outstanding women already employed in
our industry. I have been pleased to see the interest employers have shown in hiring
more women. The jobs are there. We just need to interest women in these opportunities
and get them trained and educated so they can fill those positions and help our nation
prosper. Not many people, especially females, grow up thinking about a career in welding. We must change that mindset and update the welding image that is so limiting and
does not reflect the reality of the types of positions that need to be filled. Of course, the
jobs are not solely for females, but I believe women are a largely untapped resource for
industry and so have made that my focus this year.
On a personal note, I would like to thank everyone who came to see me and listen to
my talks, as well as all the manufacturers and schools that opened their doors to me. I
had the opportunity for some lively question-and-answer sessions with students, and had
the honor of hanging medals around the necks of the winners of the national welding
competition at SkillsUSA in Kansas City in June.
I was pleased to hear women say they were inspired by the females I featured, women
whom I think are excellent role models for others considering entering our industry. I
hope my presentations have made a difference to someone. I loved visiting schools and
manufacturing facilities and seeing the progress being made and the clean, well lit, and
safe environments in which our nations welding professionals are working. Jobs are
available for all aspects of welding, from welders as the base to technicians, engineers,
supervisors, salespeople, and Certified Welding Inspectors. Id like to thank the dedicated AWS staff who pull together the ideas and activities
of volunteers and produce and disseminate the knowledge in a financially responsible manner. I wish to
especially thank all of my hosts who have been invaluable in making my travels run so smoothly and be so
rewarding. As I said previously, its been an incredible
and, I believe, an important year.
Founded in 1919 to Advance the Science,

Technology and Application of Welding
Officers
President Nancy C. Cole
NCC Engineering
Vice President Dean R. Wilson
Well-Dean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
T. Anderson (At Large), ITW Global Welding Tech. Center
U. Aschemeier (Dist. 7), Miami Diver
J. R. Bray (Dist. 18), Affiliated Machinery, Inc.
R. E. Brenner (Dist. 10), CnD Industries, Inc.
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
D. A. Flood (At Large), Tri Tool, Inc.
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (Dist. 17), The Harris Products Group
W. A. Komlos (Dist. 20), ArcTech, LLC
T. J. Lienert (At Large), Los Alamos National Laboratory
J. Livesay (Dist. 8), Tennessee Technology Center
M. J. Lucas Jr. (At Large), Belcan Engineering
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
J. L. Mendoza (Past President), Lone Star Welding
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), KA Phy Services, Inc.
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
N. Saminich (Dist. 21), NS Inspection and Consulting
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), ACH Co.
J. A. Willard (Dist. 13), Kankakee Community College
M. R. Wiswesser (Dist. 3), Welder Training & Testing Institute
D. Wright (Dist. 16), Wright Welding Technologies
Nancy C. Cole
AWS President
DECEMBER 2013
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WASHINGTON
WATCHWORD
BY HUGH K. WEBSTER
AWS WASHINGTON GOVERNMENT AFFAIRS OFFICE
White House Manufacturing Board Revived

The White House has announced it will restart the former Advanced Manufacturing Partnership (AMP) under the new name,
Advanced Manufacturing Partnership Steering Committee 2.0.
The group disbanded last year after issuing a report, Capturing
Domestic Competitive Advantage in Advanced Manufacturing, in
which it advocated the following:
Sustaining U.S. investments in science, technology, and innovation; establishing the National Network of Manufacturing
Innovation Institutes a set of public-private partnerships to
build shared high-tech facilities and advance U.S. leadership in
emerging technologies;
Upgrading community-college workforce training programs
and deploying the talent of returning veterans to meet critical
manufacturing skills needs;
Improving the business climate for manufacturing investment through tax, regulatory, energy, and trade reform.
The new committee is expected to build on these three areas.
Members of the committee are leaders from manufacturing, academia, and labor.
Legislation Introduced to Reform Patent

Troll Litigation
The bipartisan Innovation Act (H.R. 3309), introduced in the
U.S. House of Representatives in late October, is intended to
eliminate certain practices considered by many to be abuses of
the U.S. patent system, discourage frivolous patent litigation,
and keep U.S. patent laws up to date.
A fee-shifting provision is probably the most impactful. Under
present law, a court may compel a losing plaintiff in a patent infringement case to pay the legal fees of the prevailing defendant,
though in practice this rarely occurs. The result is that defendant
companies are often compelled to settle claims rather than bear
the costs of defense, which typically range from $3 million to $10
million per patent case. Yet, litigation settlements only encourage more frivolous suits. This bill would compel a court to award
attorneys fees to a prevailing defendant in most cases.
Another reform is to strengthen the pleading requirements
for patent lawsuits. Under current law, a plaintiff may file a complaint with sparse allegations that fail to provide any notice as to
what products are being accused of being infringing and precisely
how they are alleged to infringe. The result is that so-called patent
assertion entities, or patent trolls, sue scores of defendants
who are left to guess as to what is being accused and why.
OSHA Publishes PEL Comparison Chart

The U.S. Occupational Safety and Health Administration has
developed a new chart of permissible exposure limits (PELs) that
compares those contained in the so-called Z-Tables in OSHA
regulations, 29 CFR 1910.1000, with the analogous restrictions
set by three other organizations, the California Division of Occupational Safety and Health PELs; National Institute for Occupational Safety and Health (NIOSH) Recommended Exposure
Limits; and the American Conference of Governmental Industrial Hygienists Threshold Limit Values and Biological Exposure
Indices. The new OSHA-annotated tables include a side-by-side
comparison of the OSHA PELs, Cal/OSHA PELs, NIOSH RELs,
and ACGIH TLVs. These new tables are informational only;
OSHAs mandatory PELs in the Z-Tables remain in effect.
DECEMBER 2013
NIST Sets Up Website for Manufacturing

Research and Reports
The Hollings Manufacturing Extension Partnership at the National Institute of Standards and Technology has a new website
that collects reports and studies on manufacturing policy and
practice. The site, www.nist.gov/mep/reports-102213.cfm, is intended to serve as a resource for the manufacturing community.
Bill Introduced to Facilitate Cross-Border

Energy Projects
The North American Energy Infrastructure Act (H.R. 3301)
is a bipartisan bill intended to create a more modern and efficient approval process for energy infrastructure projects that
cross the borders of the United States. Most importantly, this
legislation would consolidate and standardize the cross-border
approval process for oil pipelines, natural gas pipelines, and electric transmission lines, replacing and superseding the current
processes that have been created in an ad hoc fashion through
multiple executive orders. It would also require agencies to approve most cross-border applications within 120 days of
submission.
U.S. Implements First Export Control

Reform Measures
The first regulatory amendments implementing export control reforms took effect October 15. These amendments modify
the U.S. State Departments International Traffic in Arms Regulations (ITAR), which generally apply to military items, and the
U.S. Commerce Departments Export Administration Regulations (EAR), which generally apply to commercial dual-use items.
The amendments will transfer certain types of equipment and
software, mostly related to military aircraft and related components and technology, from the ITAR to the EAR.
While this step is limited, it is expected to be followed by additional reforms of export rules. The process has been slow; the
federal government announced its Export Control Reform Initiative over four years ago.
Water Infrastructure Legislation

Progressing
The U.S. House Committee on Transportation and Infrastructure has unanimously approved the Water Resources Reform and
Development Act (H.R. 3080), a bipartisan bill. The Senate
adopted its version of similar legislation in May (S. 601). The
House bill contains no earmarks and establishes a process for
project approval with congressional oversight. The focus is on
development, maintenance, and support of port and waterway
infrastructure. In the past, Congress approved water infrastructure legislation every two years; however, the last bill to be
adopted was in 2007.
Contact the AWS Washington Government Affairs Office at

1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail
hwebster@wc-b.com; FAX (202) 835-0243.
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PRESS TIME
NEWS
United Yacht Transport to Build Worlds Largest
Yacht Carrier
United Yacht Transport LLC, Fort Lauderdale, Fla., has committed to building a
semisubmersible vessel for servicing the yacht transportation industry. It is scheduled
for delivery in the second tax quarter of 2015.
The company believes that the conversion of a Panamax size bulk vessel will produce
the worlds largest yacht transport vessel with a cargo capacity exceeding 40,000 deadweight tonnage. Completed dimensions of this vessel will be 755 151 ft, allowing for
passage through the newly widened Panama Canal. Certain market conditions in the
dry bulk shipping industry have led to a reduction in the value of bulk vessels, creating
an opportunity for developing a lower-cost, semisubmersible vessel.
Andringa Inducted into Manufacturing Hall of Fame

Mary Vermeer Andringa, CEO, Vermeer Corp., Pella, Iowa,
has been inducted into the 2013 IndustryWeek Manufacturing
Hall of Fame class. Her citation reads, in part, With a track
record of 2350 kaizen (constant improvement) events since creating the Vermeer Lean Manufacturing Journey in 1997, Andringa has earned a seat at the lean guru table. Lean has been
employed across the entire organization translating into strong
financial results. Andringa and the other seven inductees were
cited as having integrity, passion, and a laser focus on serving
their customers, employees, and communities.
Mary Vermeer
Andringa
Backed by a $14.9 million, three-year grant from the U.S. Department of Labors
Trade Adjustment Assistance Community College and Career Training Grant awarded
to Wisconsins 16 technical colleges, Wisconsin Indianhead Technical College (WITC)
is able to better assist students entering the welding field.
The grant is a result of a state-wide collaboration between educational systems working with industry groups, workforce development boards, and more than 50 businesses.
Wisconsin technical colleges have committed to train more than 2500 individuals in the
next two years, in hopes of reducing the skills gap to meet employer manufacturing
needs.
According to Mary Ann Pebler, WITCs director of resource development, the grant
has provided funding to purchase a robotic welding machine and allowed expanding the
welding program by two sections.
WITC will use its grant portion to assist welding students entering the five Short
Term Embedded Technical Diploma pathways. The U.S. Department of Labors Employment and Training Administration has funded 55% of this project, equaling $605,450.
The intent of the welding career pathway is to provide students with options for
multiple entry and exit points that result in employment opportunities at each stage.
Students then have the option of coming back into the program should they choose to
complete the one-year technical diploma, said Cindy King, WITCs director of
curriculum.
Welders Sought in Western Canada

The need for welders in western Canada was recently called out in the Welders
Wanted in the West article by Virginia Galt for The Globe and Mail. As an example, in
Saskatchewan, Canada, when searching for the keyword welding on its governments
online job site at SaskJobs.ca, nearly 300 positions were available as of press time.
In addition, the article profiled Michael Reid who moved from Sarnia to Saskatchewan
and works as a welder for farm equipment manufacturer Morris Industries Ltd.
Its a challenge in Saskatchewan on the skilled labor side, said Don Henry, chief
operating officer of Morris Industries, Yorkton, Saskatchewan. I think our biggest
shortfall right now [at Morris] is welding.
DECEMBER 2013
Editorial
Editorial Director Andrew Cullison
Editor Mary Ruth Johnsen
Associate Editor Howard M. Woodward
Associate Editor Kristin Campbell
Editorial Asst./Peer Review Coordinator Melissa Gomez
Publisher Emeritus Jeff Weber
Design and Production
Production Manager Zaida Chavez
Senior Production Coordinator Brenda Flores
Manager of International Periodicals and
Electronic Media Carlos Guzman
Advertising
National Sales Director Rob Saltzstein
Advertising Sales Representative Lea Paneca
Advertising Sales Representative Sandra Jorgensen
Senior Advertising Production Manager Frank Wilson
Subscriptions
Subscriptions Representative Tabetha Moore
tmoore@aws.org
Grant Helps Wisconsin Indianhead Technical College

Move Welding Program Forward
Publisher Andrew Cullison

8669 NW 36 St., # 130, Miami, FL 33166-6672
(305) 443-9353 or (800) 443-9353
Publications, Expositions, Marketing Committee
D. L. Doench, Chair
Hobart Brothers Co.
S. Bartholomew, Vice Chair
ESAB Welding & Cutting Prod.
J. D. Weber, Secretary
D. Brown, Weiler Brush
T. Coco, Victor Technologies International
L. Davis, ORS Nasco
D. DeCorte, RoMan Mfg.
J. R. Franklin, Sellstrom Mfg. Co.
F. H. Kasnick, Praxair
D. Levin, Airgas
E. C. Lipphardt, Consultant
R. Madden, Hypertherm
D. Marquard, IBEDA Superflash
J. F. Saenger Jr., Consultant
S. Smith, Weld-Aid Products
D. Wilson, Well-Dean Enterprises
N. C. Cole, Ex Off., NCC Engineering
J. N. DuPont, Ex Off., Lehigh University
L. G. Kvidahl, Ex Off., Northrop Grumman Ship Systems
D. J. Landon, Ex Off., Vermeer Mfg.
S. P. Moran, Ex Off., Weir American Hydro
E. Norman, Ex Off., Southwest Area Career Center
R. G. Pali, Ex Off., J. P. Nissen Co.
N. Scotchmer, Ex Off., Huys Industries
R. W. Shook, Ex Off., American Welding Society
Copyright 2013 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or
opinion expressed herein. Data and information developed by the authors
of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the
part of potential users.
MEMBER
hodgson_FP_TEMP 11/13/13 7:49 AM Page 9
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NEWS OF THE
INDUSTRY
Alcoa, U.S. Army to Develop Worlds Largest Single-Piece Aluminum Hull
Alcoa, Pittsburgh, Pa., and the U.S. Army Research Laboratory, Washington, D.C., have launched a cooperative effort for developing an aluminum system to address a soldier safety threat
improvised explosive devices (IEDs). A single-piece aluminum
hull for ground combat vehicles would replace todays assembled
hulls.
For decades, the Army has recognized the survivability benefits of a single-piece hull due to its thickness, size, and shape for
ground combat vehicles, said Dr. Ernest Chin of the Army Research Laboratory. Our collaborative effort to develop continuous and seamless aluminum hull technology has the potential to
be a game changer for how combat vehicles are designed and made
to better protect our soldiers.
Alcoas single-piece aluminum hull would improve combat vehicle performance through improved blast protection, increased
damage resistance, efficient design, and cost savings.
Our experts are now developing the worlds largest, highstrength aluminum hull for combat vehicles to better defend Alcoa and the U.S. Army Research Laboratory have started a
against IEDs, the greatest threat our troops face in Afghanistan, cooperative effort to develop the worlds largest single-piece
while meeting the Armys affordability needs, said Ray Kilmer, aluminum hull for ground combat vehicles (as shown here in
a sketch).
Alcoa executive vice president and chief technology officer.
The Army Research Laboratory, in partnership with Alcoa
Defense, initiated the program after Alcoa modeled performance advantages of the single-piece hull.
In addition, Alcoa Defense, the Armys Research, Development and Engineering Command, and the Defense Advanced
Research Projects Agency will coordinate R&D efforts with scientists at the Alcoa Technical Center to refine the hull design
and develop alloy requirements. Alcoa Defense will then work with engineers at Alcoa Forgings and Extrusions in Cleveland
to produce 20- by 7-ft demonstrator hulls. These hulls will also be forged using Alcoa Clevelands 50,000-ton forging press.
Ironworkers Union in California to

Host Free Womens Welding Program
The Oakland San Francisco Bay Area Ironworkers Apprenticeship Program is planning another Womens Welder Program.
The 6-week, 150-h course will prepare up to 20 women for a 4year apprenticeship program as a Union Ironworker. There is
no cost for this training.
Women with prior welder training or experience are sought.
The Ironworker welders specialize in shielded metal arc and flux
cored arc welding processes and oxyfuel cutting. The program

will include an initial five days of training, then Friday night and
weekend classes during February and March, concluding in early
April.
Upon successful completion, these women will roll into the
four-year apprenticeship program and receive credit for classes
completed. Welding performed by Ironworkers is outdoors and
often at heights as they work on new construction of buildings,
stadiums, bridges, and industrial plants.
An orientation session is planned for January 6. To get an application and more information, visit universityofiron.org.
Ingalls Shipbuilding Starts Constructing

Sixth National Security Cutter
Attendees from the previous Ironworkers Womens Welder Program

are shown with their instructors.
10
DECEMBER 2013
Huntington Ingalls Industries Ingalls Shipbuilding division,

Pascagoula, Miss., has started fabricating the U.S. Coast Guards
sixth National Security Cutter (NSC), Munro (WMSL 755).
Our shipbuilders have a great jump start on the construction
of this ship as we have already cut and processed more than 400
tons of steel for NSC 6, said Jim French, Ingalls NSC program
manager.
Currently, Ingalls is building three NSCs and has delivered
three that are serving as the flagships of the Coast Guards cutter fleet. An electronics light-off milestone, where the ships electrical system is powered up for the first time, was recently achieved
on Ingalls fourth NSC, Hamilton (WMSL 753). Also, Ingalls
fifth NSC, James (WMSL 754), has more than 70% of its units
erected and will launch in the spring of 2014.
Designed to replace the 378-ft Hamilton-class high-endurance

cutters, the NSCs are 418 ft long with a 54-ft beam and displace
4500 tons with a full load. They have a top speed of 28 knots,
range of 12,000 miles, endurance of 60 days, and crew of 110.
Serving It Up Weld Done: High School

Students Create BBQ Smoker
After devoting nearly 300 h of their time, often early in the
morning and on weekends, Chris Crosslin and Jose Farias finished constructing Patriot a custom-made, 20-ft-long tandem
axle trailer with BBQ smoker. The recent high school graduates,
Gas metal arc welding was used during fabrication of a 20-ft-long

tandem axle trailer.
For info, go to www.aws.org/ad-index
TECHNOLOGY FOR THE WELDERS WORLD.
ABI-CLIP
MIG TORCH CABLE HOLSTER
Joined at the hip.

Abicor Binzel USA
Phone: 800.542.4867
Fax: 301.846.4497
customerservice@abicorusa.com
www.binzel-abicor.com
WELDING JOURNAL
11
GMAW. The means to purchase new materials came from selling the schools previous smoker along with metal roses and other
projects made by the welding students.
Compartments on its front and backside hold a refrigerator,
water heater, woodbox, holding tanks, two sinks, and storage
area. Bolts are in place for all metal parts to be removed.
As part of finishing, the trailer was disassembled for sandblasting followed by powder coating in the U.S. flag and high
school colors red, white, and blue. Now put back together, it can
be pulled by a truck. The smokers propane and water lines were
pressure tested, too. The finished trailer weighs 4200 lb and is
valued at around $30,000.
It has been a lot of work, but they have had a lot of fun doing
it, Kurpgeweit said.
Chris Crosslin (left) and Jose Farias pose in front of Patriot, the
trailer they finished featuring a BBQ smoker.
formerly part of the welding program at Eisenhower High School,
Yakima, Wash., received senior project guidance from their instructor, Gary Kurpgeweit, an American Welding Society member. They participated at the SkillsUSA national contest in Kansas
City, Mo., this past June and earned welding positions right after
high school.
The purpose of the smoker is a fundraiser for students,
Kurpgeweit said. Cookouts will take place to support field trips
and hotel/food costs during SkillsUSA competitions, plus help
with welding shop needs. We are able to take profits and put it
back into the program, he added.
The 7-ft-long smoker made out of 24-in.-diameter pipe, 14in. wall thickness, and a stainless steel tank was fabricated
using gas metal arc welding (GMAW). It can be fueled by propane
gas and heated wood. The trailer was also constructed using
mikeroweWORKS Foundation and Tulsa

Welding School Create Scholarships
The mikeroweWORKS Foundation (MRW) and Tulsa Welding School (TWS) recently formed the MRW/TWS Scholarship
Program for high school seniors. A total of 49 full-tuition paid
scholarships will be offered, a collective value of approximately
$800,000, across TWSs campuses in Tulsa, Okla., Jacksonville,
Fla., and its sister school, The Refrigeration School, Phoenix,
Ariz.
1.6 million dollars in mikeroweWORKS scholarships is a
pretty big deal, and Im hopeful more schools will follow...were
on our way to building an affiliation of excellent trade schools
that are not only determined to train the workers our country
needs, but reward the kind of work ethic we all want to encourage, said Mike Rowe, mikeroweWORKS CEO and Dirty Jobs
host.
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To qualify, applicants must be scheduled to graduate from
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Tri-County Technical College to Add

More Welding Booths, Equipment
A $250,000 grant from the Appalachian Regional Commission will add 24 new welding booths and equipment at Tri-County
Technical Colleges Industrial Technology Center (ITC), Sandy
Springs, S.C.
Our total enrollment for the welding program is 120 students
between day and evening, said Paul Phelps, welding program
coordinator. This grant will allow us to expand our program to
accept 48 more students and funding to purchase most of the
welding equipment needed for instruction. Matching funds will
supply the remainder of the welding equipment and all installation costs, including special ventilation and piping of the potentially hazardous gasses.
Until the ITC opened in spring of 2013, enrollment was limited to the number of welding booths at the Pendleton Campus
and students were not able to take classes that accommodated
Joe Finklea, a former student, gas tungsten arc welds in the 2G

position on 2-in., schedule 40 carbon steel pipe.
their varying schedules, he stated.
Also, one lab at the ITC will serve participants in SC Accelerate, a fast-track educational and career pathway for adults.
Two new companies, McLaughlin Body Works and SMF, recently located in this area, giving our graduates more job placement opportunities, Phelps added.
Victor TechnologiesTM Unveils Plasma

Design Center in West Lebanon, N.H.
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Industry Notes
Guilford Technical Community College, Jamestown, N.C.,
Victor TechnologiesTM CEO Martin Quinn uses a Victor Thermal Dynamics plasma system to cut a copper ribbon, officially
opening the companys new Design Center in West Lebanon, N.H.
cutting and arc welding technologies.
The center encompasses 50,000 sq ft and employs approximately 75 people. It is equipped with a plasma process research
and development laboratory, applications laboratory, classroom,
demonstration facility with cutting tables for hands-on training
of customers and employees, global technical support and service center, and pilot production lines for new products.
Our dedicated staff is focused on developing innovative solutions for our end-user customers and providing technical support and training for our distributor partners, said Victor Technologies CEO Martin Quinn, during the opening ceremony.
has bought a vacant property near its Jamestown Campus to

expand welding and transportation programs. The 37-acre
site includes a 253,000-sq-ft warehouse. The purchase cost
was $8.3 million.
UK-based Connor Solutions is investing nearly $6 million as
part of a three-year expansion plan for its manufacturing site
and increasing electronics production capabilities. Also, it
recently purchased Ersa Powerflow wave and Versaflow selective soldering lines from Blundell Production Equipment.
Palm Beach State College, Lake Worth, Fla., will enhance its
welding, information technology, and machining programs
using two grants totaling nearly $2.4 million awarded as part
of the federal Trade Adjustment Assistance Community College and Career Training grant program.
Applied Fusion, San Leandro, Calif., completed installing its
second 8-axis CNC large electron beam welding machine that
provides a larger working envelope due to a 125-ton, 64-cubicmeter vacuum chamber. A 65-in. tiltable rotary table with a
z-axis movement opens up a range of part options.
The Lincoln Electric Co., Cleveland, Ohio, has earned the
new Certified Robot Integrator designation from the Robotic
Industries Association.
RathGibson, Janesville, Wis., a manufacturer of welded tubing, has achieved the American Society of Mechanical Engineers BioProcessing Equipment certification.
14
DECEMBER 2013
continued on page 96
greiner_FP_TEMP 11/13/13 7:46 AM Page 15
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ALUMINUM Q AND A DECEMBER 2013_Layout 1 11/13/13 3:05 PM Page 16
ALUMINUM
Q&A
Following are the answers to the quiz
questions published in the October Aluminum Q&A column with a list of the ten
lucky winners.
1. What is the principal alloying element in the 8xxx series alloy group?
A Copper
B Lithium
C Zinc and Tin
D Other Element
D Other Element ANSI H35.1,
Alloy and Temper Designation System for
Aluminum, is clear in defining the 8xxx series alloys as being those with principal alloying elements other than the 1xxx through
7xxx series. The series consist of 1xxx Pure,
2xxx Copper, 3xxx Manganese, 4xxx Silicon,
5xxx Magnesium, 6xxx Magnesium and Silicon, and 7xxx Zinc. The 8xxx series alloys
are comprised of some aluminum/lithium
(Li) alloys that contain higher Li content
than copper (Cu), unlike the 2xxx series alloys that contain more Cu than Li. Also,
some aluminum/ferrite (Fe) alloys are included in the 8xxx series. The 8xxx series alloys are often described as the catch-all series since it contains any alloy that does not
fit the principal alloy category of the 1xxx
to 7xxx series.
2. What do the 2xxx, 6xxx, and 7xxx series alloys have in common?
A Heat Treatable
B Copper
C Nonheat Treatable
D Chemistry
A Heat Treatable 2xxx, 6xxx, and
7xxx are all heat-treatable alloys that are
strengthened through various types of
heat treatment. The initial strength of
these alloys is also produced by the addition of alloying elements to pure aluminum. These elements include copper
(2xxx series), magnesium and silicon,
which is able to form the compound magnesium silicide (6xxx series), and zinc
(7xxx series). When present in a given
alloy, singly or in various combinations,
these elements exhibit increasing solid solubility in aluminum as the temperature
increases. Because of this reaction, it is
possible to produce significant additional
strengthening to the heat-treatable alloys
by subjecting them to an elevated thermal
treatment, quenching, and, when applicable, precipitation heat treatment known
also as artificial aging.
Note: Because of additions of magnesium and/or copper, there are also a num16
DECEMBER 2013
BY TONY ANDERSON
ber of silicon (4xxx series) alloys that are
heat treatable.
In solution heat treatment, the material is typically heated to temperatures of
900 to 1050F, depending upon the alloy.
This causes the alloying elements within
the material to go into solution. Rapid
quenching, usually in water, which freezes
or traps the alloying elements in solution,
follows this process.
Precipitation heat treatment, or artificial aging, is used after solution heat-treatment. This involves heating the material for
a controlled time at a lower temperature
(around 250 to 400F). This process, used
after solution heat treatment, both increases strength and stabilizes the material.
3. Which of the following aluminum alloys has been solution heat treated and
naturally aged to a substantially stable
condition?
A 6061-T6
B 2014-T4
C 5052-H32
D 7075-T62
B 2014-T4 The -T4 indicates that
the alloy has been solution heat treated
and naturally aged to a substantially stable condition. The Temper Designation
System addresses the material conditions
called tempers. This is an extension of the
alloy numbering system and consists of a
series of letters and numbers that follow
the alloy designation number and are connected by a hyphen. Examples include
6061-T6, 6063-T4, 5052-H32, and 5083H112. The -T6 temper indicates solution
heat treated and artificially aged. The
-H32 and -H112 are strain-hardened tempers, that apply to nonheat-treatable alloys such as the 5xxx series, and the -T4
temper is heat treated and naturally aged.
4. When gas tungsten arc welding a
6xxx series aluminum base metal without
filler metal (autogenously), what type of
weld discontinuity would you most expect
to find in your weld?
A Porosity
B Incomplete Fusion
C Hot Cracking
D Undercut
C Hot Cracking The 6xxx series
base metals have chemical compositions
that are very susceptible to hot cracking.
If these alloys are not welded with a filler
metal of a different chemistry than that
of the base metal, they will invariably
crack during solidification. Either a 4xxx
or 5xxx series filler metal (4043, 4943,

4047, or 5356) is typically used to change
the composition of the resultant weld
metal to a chemistry different than that
of the base metal alone, thereby preventing hot cracking.
5. What is the most common reason,
when testing a weld made in 6061-T6 base
metal, for a transverse tension test to fail
in the heat-affected zone (HAZ) and not
meet the minimum tensile strength requirements of the welding code?
A Too Low Preheat

B Overheating Base Metal
C Porosity
D Hot Cracking
B Overheating Base Metal Porosity and hot cracking are not usually found
in the HAZ of aluminum welds, and a low
or no preheat will help to improve the
strength of the HAZ, not lower it. Overheating the base metal during welding,
from excessive preheating and/or high interpass temperature, is the most common
reason for reducing the strength of the
HAZ in the 6xxx series base metals. The
higher the preheat, interpass temperature, and heat input during welding
plus the longer the HAZ is held at high
temperature the greater the reduction
in strength of the HAZ. It is not uncommon for test samples to fail to meet the
minimum tensile strength because of overheating the base metal during welding.
6. What is the most suitable 5xxx filler
metal to be used for welding a structure
made from 5454 base metal and that is to
be exposed in service to temperatures
between 150 and 350F for prolonged
periods?
A ER5356
B ER5183
C ER5556
D ER5554
D ER5554 Stress corrosion cracking (SCC) in 5xxx series alloys, containing more than 3% magnesium, can be encountered when exposed to prolonged
time at temperatures between 150 and
350F. Base Alloy 5454 and filler Alloy
5554 both have magnesium content below
3%; therefore, both alloys are suitable for
elevated-temperature applications and
are not susceptible to SCC. Filler Alloys
5356, 5183, and 5556 all have more
than 3% magnesium and are not suitable
for prolonged elevated-temperature
applications.
7. What is the usual cause of porosity

in aluminum welds?
A Oxygen
B Silicon
C Hydrogen
D Nitrogen
C Hydrogen Hydrogen is the
usual cause of porosity in aluminum welds.
The solubility of hydrogen in aluminum
increases dramatically after the aluminum
reaches its liquid stage. When aluminum
is taken to temperatures above its melting point, it becomes very susceptible to
hydrogen absorption. The hydrogen can
then form bubbles in the molten aluminum as the aluminum solidifies, and
these bubbles are then trapped in the
metal, causing porosity.
The sources of hydrogen that create
porosity are as follows: hydrocarbons in the
form of contaminants such as paint, oil,
grease, cutting fluids, and lubricant; hydrated aluminum oxide, as aluminum oxide
can absorb moisture and become hydrated,
the hydrated oxide will release hydrogen
when subjected to the heat during welding;
and moisture (H2O), as moisture in the atmosphere can be a serious cause of porosity under certain circumstances (changes in
temperature and high humidity).

Moisture from other sources such as
compressed air, contaminated shielding
gas, or precleaning operations should also
be considered.
8. The electrolytic process used for
producing aluminum that was discovered
in 1886 and still used today is known by
what name?
A Davy Process
B Hall-Heroult Process
C Wohler Process
D Henri-Etienne Process
B Hall-Heroult Process In 1886,
by an amazing coincidence, two men (one
in France, and the other in the United
States of America) simultaneously discovered the electrolytic process for producing aluminum, and this process is still used
today. Charles Martin Hall was an Oberlin (Ohio) College student when he became interested in producing aluminum
inexpensively. He continued to use the
college laboratory after he graduated in
1885 and discovered his method eight
months later. He had developed a workable electrolytic process that formed
molten aluminum when purified alumina
was dissolved in a molten salt called cryolite and electrolyzed with direct current.
When Hall went to patent his process, he
discovered a French patent for essentially
the same process, discovered by Paul L.
T. Heroult. This process is now known as
the Hall-Heroult process. After several
unsuccessful attempts by Charles Martin
Hall to interest financial backers in promoting the discovery, he obtained the support of Alfred E. Hunt and a few of his
friends. Together, they formed the Pittsburgh Reduction Co. (later to become the
Aluminum Co. of America, Alcoa).
9. In accordance with the requirements
of AWS D1.2/D1.2M:2008, Structural Welding Code Aluminum, what is the maximum preheat temperature when welding
base metal 5052?
A 150F
B 250F
C 350F
D It does not give a max preheat for
this base metal.
D It does not give a max preheat
for this base metal. Section 4.8 of AWS
D1.2/D1.2M:2008, Structural Welding
Code Aluminum, Preheat and Interpass
WELDING JOURNAL
17
Temperatures, states the following:

When fabricating the heat-treatable aluminum alloys or the 5000-series aluminum-magnesium alloys containing
more than 3% magnesium, the preheat
and interpass temperatures shall not exceed 250F. Holding time at this temperature shall not exceed 15 min.
The 5052 base metal only has a maximum magnesium content of 2.8%; therefore, the code does not give a maximum
preheat for this base metal.
10. In accordance with the requirements
of AWS D1.2/D1.2M:2008, Structural Welding Code Aluminum, what is the minimum length of an intermittent fillet weld?
A 112 in.
B 212 in.
C 3 in.
D 312 in.
A 112 in. Section 2.4.2.4 clearly
states that the minimum length of an intermittent fillet weld shall be 112 in.
11. In accordance with the requirements of AWS D1.2/D1.2M:2008, Structural
Welding Code Aluminum, when testing
for a procedure qualification using a 5083H112 (1-in.-thick forging) base plate complete-joint-penetration groove weld, what
would be the minimum tensile strength required to pass the reduced section transverse tension tests?
A 36 ksi
B 38 ksi
C 39 ksi
D 40 ksi
B 38 ksi Table 3.2 of AWS D1.2
provides minimum tensile strengths for
5083-H112 in sheet, plate, extrusions, and
forgings. The 1-in.-thick forging has the
lowest tensile strength requirement at 38
ksi, with extrusions at 39 ksi, and sheet
and plate at 40 ksi.
12. In accordance with the requirements of AWS A5.10/A5.10M:2012, Welding Consumables Wire Electrodes,
Wires and Rods for Welding of Aluminum
and Aluminum-Alloys Classification,
the standard testing method for all ER
Classifications is chemical analysis plus
what other test?
A Tensile Tests
B Bead-on-Plate Test
C Radiographic Test
D Guided Bend Test
C Radiographic Test Table 2
of AWS A5.10 shows all classifications to
require chemical analysis, all R Classifications shall require a bead-on-plate test,
and all ER Classifications shall require radiographic testing.
Winners
I would like to thank all who participated 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
who indicated that responding to the quiz
was both educational and fun. What a
great combination!
The ten winners, selected at random
from all who sent me 100% correct answers,
are listed below in alphabetical order.
Wayne Abarca La Salle, Ill.
Robert Allan Ross-Shire, Scotland, UK
Steve Blevins Biloxi, Miss.
Yasser Elmasri New Westminster, B.C.,
Canada
Thomas Lienert Los Alamos, N.Mex.
Sylvain Pedneault Chicoutimi, Que,
Canada
Jonathan Roberts Mobile, Ala.
Kyle Savoie Larose, La.
John Speziale Canfield, Ohio
Rick Ward Manns Harbor, N.C.
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 committees. He is chairman of the Aluminum Association 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 36 St., # 130, Miami, FL
33166-6672, or via e-mail at tony.anderson@
millerwelds.com.
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BRAZING Q+A December_Layout 1 11/13/13 1:36 PM Page 20
BRAZING
Q&A
BY TIM P. HIRTHE
Q: We make connections between copper and steel tubing

on our assembly line using
manual torch brazing. We are
hand feeding a silver bearing
braze alloy (38% silver) and
using a white flux. After having
a high leak rate on these joints,
we identified significant differences between brazers in the
heating process. In order to
apply more consistent heating,
we have been trying induction
heating using a hand-held induction unit. The only other
variable we changed is that we
use a preform ring rather than
hand feeding brazing rod. The
leak rate has not dropped as
we anticipated. We obviously
are missing something. Can
you offer suggestions as to how
we can evaluate this?
training. On some joints, rather than battle the training issue it seems easier to
look at another process. Hand-held induction is a logical place to look. Figure
1 shows a typical setup and Fig. 2 shows a
close-up view of the tubular joint being
brazed.
If you are going to pursue this option,
you will be addressing the variable of
heating but, to make it work successfully,
you must make sure you address the others. The fact that you are brazing dissimilar metals (steel and copper) adds some
additional considerations. The variables
that need attention are:
A: Induction heating is a good choice for
7. Heating process
brazing as long as the joints you are making are of a consistent nature. It is a very
uniform and consistent heating method,
but it requires the parts being brazed to
be similarly uniform and consistent.
Manual torch brazing gets a bad rap
because of the difficulty in having it applied the same way by a group of operators, but it does have some benefits. Tubular joints like those found in refrigeration and air-conditioning systems feature
a great deal of variation. These are not
thought of as precision braze joints. In
addition to the wide variation in heating
you mention, joint clearances vary, joint
insertion depths vary, tube thickness
varies, and cleanliness is usually an issue
of some sort. Sometimes nitrogen is used
as a purge to keep interior surfaces oxide
free; sometimes a vapor flux is aspirated
into the fuel gas stream to help keep exterior surfaces clean along with myriad
methods to apply alloy and flux. A skilled
operator with a torch, properly set for gas
pressures and flame condition, can adjust
to the conditions presented and make a
good braze joint.
The word skilled is the issue. In previous columns weve addressed the issue of
20
DECEMBER 2013
1. Joint clearance
2. Joint depth
3. Cleanliness
4. Braze alloy and flux
5. Thermal conductivity
6. Thermal expansion
Take a look at Fig. 3. It shows a typical

tubing braze joint. It highlights what you
are facing. You can see that the joint clearance varies greatly. Typically, these types
of joints have a tremendous range of clearances. The maximum strength of a silver
brazed joint is achieved at a radial joint
clearance of 0.0015 in. (0.038 mm). This is

also a good clearance size for capillary
flow to pull the braze alloy into the joint.
Try to keep the radial clearance between
0.001 and 0.002 in. (0.0250.05mm).
The next thing to notice in Fig. 3 is the
joint depth. This example shows an extreme amount of overlap. It is common to
see this in production, and it is not normally controlled very well. As mentioned
in Octobers column, we usually recommend an overlap of 3T to 6T, where T is
the thickness of the thinner of the two
pieces. For practical purposes, a joint
depth of 0.200 in. on these types of joints
is all you need. This then needs to be controlled throughout the joining process.
Various types of end forms can be incorporated to help ensure the depth.
The problems with the condition
shown here start with the fact that it requires an excessive amount of braze alloy
to fill this joint. It is difficult to heat such
a deep joint and achieve proper capillary
flow throughout. It also takes longer to
heat because of the extra mass involved.
In short, it takes longer to make these
joints, requires more thermal energy,
and more braze alloy (in this case, more
silver).
The cleanliness of components required for induction brazing is the same
as for torch brazing. While a torch can be
adjusted to be oxidizing, neutral, or reducing in nature, an induction process
simply heats the parts. One feature that
induction offers is that you can flood the
Fig. 1 Tubular joint in a hand-held induction coil.
Fig. 2 Close-up view

of the joint.
BRAZING Q+A December_Layout 1 11/13/13 1:36 PM Page 21
and the steel will tend to hold the heat

while the copper will tend to draw it away.
With induction, a ferrous part will heat
faster than a nonferrous one. Since the
steel is the outer member of the joint,
when placed into the induction coil, the
steel will heat quickly. The inner copper
member will be heated mainly by conduction from the steel part. The power
supply will need to be adjusted to allow
the parts to heat uniformly. You will have
no problem getting the steel hot. You
need to be sure the copper is up to brazing temperature to ensure a good bond.
In addition, the induction coil will need
Fig. 3 Tubular joint in a hand-held induction coil.
joint during heating with an inert gas to

offer some protection from oxidation. In
both torch and induction heating, you can
protect the inside of the tubes by purging
with nitrogen.
The induction process allows you to
use a preform ring. It eliminates the overfeeding of braze alloy rod that normally
occurs during manual torch brazing. This
offers excellent control over the quantity
of braze alloy. There is a good option
available that incorporates the flux into
the braze ring. These come in a variety of
cross sections and flux contents. They are
available in the materials you are using.
The braze alloy conforms to AWS A5.8
BAg-34 and the flux conforms to AWS
A5.31 FB3A. In your application, you will
want the ring to be in good physical contact with the outside of the inner tube and
in contact with the edge of the outer tube
Fig. 2.
When heating this combination of
base metals, you will need to consider the
differences in materials. The main differences are in thermal expansion and thermal conductivity. Values for both materials, taken from the AWS Brazing Handbook, 5th Edition, are as follows: 1020
Steel coefficient of thermal expansion is
6.5 10 6 in./in./F (11.7 10 6
mm/mm/C). Copper coefficient of thermal expansion is 9.4 10 6 in./in./F
(17.0 10 6 mm/mm/C). 1020 Steel
thermal conductivity is 357 (Btu)(in./h)/(ft 2)(F) [51 W/mK]. Copper
thermal conductivity is 2689 (Btu)(in./h)/(ft2)(F) [388 W/mK].
It can be seen from these data, the
copper will expand more than the steel
to be placed so that the braze alloy is

drawn into the joint. Molten braze alloy
travels toward the hottest section of the
joint area, so place the coil accordingly.
Making the switch to induction heating can be achieved successfully, but it requires a strong attention to detail. As I
mentioned previously, manual torch
brazing gets a bad reputation because of
the difficulty in getting a group of operators on the same page. Likewise, induction brazing gets a bad reputation for its
lack of flexibility. To make it work, you
have to make sure you have all of the variables under control.
This column is written sequentially by TIM P. HIRTHE, ALEXANDER E.

SHAPIRO, and DAN KAY. Hirthe and Shapiro are members of and Kay is an advisor
to the C3 Committee on Brazing and Soldering. All three have contributed to the 5th
edition of AWS Brazing Handbook.
Hirthe (timhirthe@aol.com) currently serves as a vice chair of the Brazing & Soldering Manufacturers Committee (BSMC) and owns his own consulting business.
Shapiro (ashapiro@titanium-brazing.com) is brazing products manager at Titanium Brazing, Inc., Columbus, Ohio.
Kay (Dan@kaybrazing.com), with 40 years of experience in the industry, operates
his own brazing training and consulting business.
Readers are requested to post their questions for use in this column on the Brazing
Forum section of the BSMC Web site www.brazingandsoldering.com.
WELDING JOURNAL
21
P and P December 2013_Layout 1 11/13/13 1:42 PM Page 22
PRODUCT & PRINT

SPOTLIGHT
Focus on Aluminum and Job Shops
Machines with AC Pulsing Weld Thin Aluminum

A companys new line of Heliarc machines for AC/DC GTAW and
SMAW includes the 281i, a 280-A unit for single-phase 230 connections; the
283i, a 280-A unit for three-phase 460 connections; and the 353i, a 350-A,
three-phase 460 unit for more power when welding thicker materials. All
three use inverter technology and offer arc heat input and pulse current for
lower heat dissipation, better weld pool control, and less plate deformation.
DC pulsing with square wave cuts current peaks and provides symmetric
power, a stable arc, and good interfusion between the base and filler material. AC pulsing up to 2 Hz makes the products useful for welding thin aluminum. Five sections on the control panel allow choice of options and settings. The machines internal communication is digital. Buttons provide slope
down, pulse current, background current, pregas, postgas, pulse, and duty
options. Select between SMA, GTA 2- and 4-stroke mode (trigger latch),
GTA spot, and trigger-enabled peak to background current. In SMA mode,
the submenu allows for access to hot start and arc force settings. Additionally, the 281i and 283i are available as air- and water-cooled packages, while
the 353i is in a water-cooled package. All three include the power source,
25-ft torch, foot control, work cable, regulator flowmeter (ArCO2), and cart.
ESAB Welding & Cutting Products
www.esabna.com
(800) 372-2123
Vertical Machining Centers

Designed for Job Shops
4 + 1 machining (refering to the use of

four simultaneous axes plus one axis used
for positioning only). The GX 250 with
travels of 11.8 15.6 16.9 in. provides
fast rapid traverse of 1181 in./min on X,
Y, and Z axes. It features a 20-hp, 15,000rev/min, direct-drive spindle motor with
70.4 ft-lb of torque and 30-tool swing-arm
automatic tool changer. The larger GXR
320 with travels of 20 24 20 in. provides fast rapid traverse of 1693 in./min
on X and Y axes with 1417 in./min on the
Z axis. The machine features a 25-hp,
12,000-rev/min, direct-drive spindle with
86.3 ft-lb of torque and 48-tool swing-arm
automatic tool changer.
Hardinge, Inc.
www.hardinge.com
(800) 843-8801
Textbook Supplements
Welding Training Programs
Two Bridgeport five-face vertical machining centers are for job shop, OEM,
aerospace, automotive, power generation,
and other manufacturing industries. Two
machine sizes are available and come standard with a Fanuc Oi-Model D control for
22
DECEMBER 2013
The company has published Robotic

Welding Project-Based Lessons for use with
its robotic welding training systems. The
textbook includes lessons with an interactive approach to learning, emulating realworld use of robotics in production welding and provides exercises designed to develop problem-solving and decision-mak-
ing skills. Suitable for varying educational

needs, the book exposes students to various joint types and welding processes.
Lincoln Electric Automation
www.lincolnelectric.com
(888) 935-3878
Discs are Nonloading

on Aluminum
The Cotton Fiber Quick Change Discs
are rigid enough to reach into small corners, yet flexible for use on flat and contoured surfaces to remove small welds and
break edges. They are made from multiple layers of reinforced nonwoven cotton,
silicon carbide abrasives in seven different grain sizes and three different bonds.
Sensor Catalog Features

Technical Drawings
Rex-Cut Abrasives
www.rexcut.com
(800) 225-8182
CMM Meets Needs of

Job Shops
which are impregnated with abrasive

grains, then pressed/bonded together and
fitted with Type R- and Type S-style fasteners. Capable of grinding and finishing
in one step, the discs provide smooth
grinding action with no smearing on titanium and stainless steel. Also, they are
nonloading on aluminum, Kevlar, and
other composites. Designed for use with
right-angle grinders, they are available in
2- and 3-in. sizes with aluminum oxide and
The Ares XL coordinate measuring machine (CMM) is designed to meet the

needs of the typical
job shop. The CMM
is an ultrarigid alloy
platform with a silicon
carbide Z-axis column and an integral
dovetail X-axis machined directly into the
granite plate. The bridge beam is an FEAdesigned alloy extrusion, providing the optimum moment of inertia for minimum
deflection when operating at high accelerations. The machine has a 0.1-m resolution measuring scale that uses dynamic
signal processing to provide a low subdivisional error of better than 30 nm.
Coord3 Metrology
www.coord3-cmm.com
(248) 397-5490
The companys full-line object detection sensor catalog includes more than
1000 pages of new products, including
photoelectric, inductive, capacitive, and
magnetic cylinder sensors, along with accessories and cables. The catalog features
full-color photos and application images,
technical specs, accessories and recommended mating cables, technical drawings
and photos for every part number, selection guides in each section, and short
WELDING JOURNAL
23
order codes. It is available in print and

electronic formats.
Balluff
www.balluff.com
(800) 543-8390
Aluminum Weld Schedule

Improves Consistency
The aluminum adaptive weld schedule

controls weld quality by automatically
compensating for multiple sources of variations, such as material surface resistance,
geometry variations, and condition of the
electrodes. The multivariable adaptive
schedule reduces the incidence of bad
welds, increases the consistency of all
welds produced, and reduces or eliminates the manufacturers reliance on destructive testing.
WeldComputer Corp.
asymmetrical left and right composite

safety toes are nonconductive to temperature. Also, this boot is offered in 400-g
Keen.Warm insulation and soft toes.
www.weldcomputer.com
(800) 553-9353
Footwear Contains Cold

Weather Technology
The companys weld schedule for its

resistance welding Adaptive Control addresses aluminum welding challenges.
Keen, Inc.
Included in the companys fall 2013

collection is the Sheridan work boot. Designed to take on the challenge of cold and
wet working conditions, this insulated
model is the warmest company safety boot
to-date. The cold weather style features a
waterproof, full-grain leather upper with
Keen.Dry waterproof, breathable membrane and hydrophobic/hydrophilic twozone comfort liner to help keep the boot
ventilated and feet warm/dry. Lined with
600 g of Keen.Warm insulation and a thermal heat shield footbed, it delivers warmth
for cold climate projects. The companys
Honing Machine Drives

Diamond Abrasives
S
0%he U
10e in t
ad
SAVE MONEY
GET BETTER RESULTS
www.keenfootwear.com
(866) 676-5336
SuperFlash 2-Gas Adjustable Mixer

The SV-20 honing system is designed
for job-shop part production with a true
linear, vertical, servo-stroking system to
produce bore geometries on compressors,
oilfield components, automotive/truck
blocks, and similar parts. The machine
features a 760-mm X-axis, 1500-lb weight
capacity, and 508-mm stroke length for
large-part capacity. Equipped with a variable speed of 15550 rev/min, a 4.1-kW
spindle motor, metal bond, and diamond
abrasives, the system can be used to hone
bores with inside diameters measuring
from 19 to 200 mm.
Provides customized mixed gases for

welding machines and other operations
Available for all popular 2-gas mixtures
Fully adjustable, less than 1Ft3
in size, and very low maintenance
Call us or visit www.oxyfuelsafety.com
to see how much money you can save
vs. buying pre-mixed gases!
Sunnen Products Co.
Mixer model 0801-4410

for Ar/CO2
Superash Compressed Gas Equipment / IBEDA Inc.

##-' +-/()! //
+++$,-*!()-$"/(!(
$,-*!()-$"
Toll Free: 1-888-327-7306

24
DECEMBER 2013
www.sunnen.com
(800) 325-3670
TY
FE
S SA
A
G
S
ARE XPERT
WE
E
Report Discusses Key

Brazing Market Vendors
The Global Brazing Materials Market
20122016 report has been prepared
based on an in-depth market analysis with

inputs from industry experts. The report
covers China and the ROW, plus the
global brazing materials market landscape
and its growth prospects. Also covered is
a discussion of the key vendors operating
in the market. The report includes information on the increasing demand for aluminum brazing alloys from the automotive industry, key market trends, challenges to market growth, and opportunities and threats faced by key vendors,
among other factors.
Robot Upgrade Allows

Handling of Larger Parts
Research and Markets Ltd.

www.researchandmarkets.com
(800) 526-8630
Aluminum Crane Controls

Load up to 2 Metric Tons
The top payload of the IRB 1600 has

increased from 8 to 10 kg, expanding the
robots performance to heavier part applications. The increased payload is in the
1.2- and 1.45-m reach variants, plus will
allow the robot to handle larger parts and
end-of-arm tools. The companys
patented, second-generation QuickMove motion control technology and
low friction spur gears allow speeding
up/slowing down fast while second-generation TrueMove technology ensures
maintaining the same path at all speeds.
ABB Robotics
www.abb.com/robotics
(248) 391-9000
Orbital Cutting Machine

Works in the Shop or Field
The XA Aluminum Workstation Crane

is lightweight yet strong enough to handle demanding production needs and can
control loads up to 2 metric tons. The system features a modular design intended
to reduce downtime during installation,
expansions, or upgrades. High structural
stiffness, small rolling resistance, and
quiet use make it useful for standard and
tailor-made lifting systems. The aluminum
construction has been designed to result
in a more ergonomic workflow. An anodized surface provides corrosion resistance. The crane has different profile sizes.
Customizable options include a motorized trolley with integrated frequency control, suspensions and power-feeding lines,
and a self-standing structure.
Konecranes, Inc.
www.konecranesamericas.com
(877) 363-1895
The Ultimate Split 1 is an orbital cutting machine designed for tube cutting in
a workshop or at a job site. The portable
machine can be fixed on a bench or
opened to handle tubular bundles. For
mounting, it fits onto the Ultimaster
bench unit system along with a 110- or 220V battery adaptor. The machines features
include self-centering, burr-free cuts, no
vibrations, no heat-affected zone, cordless drive, and a split-frame housing. It
can be used on mild and stainless steels,
Inconel, Hastelloy, duplex and superduplex steels, and other materials.
Ultimaster
www.ultimaster.com
49 (0) 7247 9393 - 0
WELDING JOURNAL
25
Armao Lincoln feature DECEMBER_Layout 1 11/11/13 3:05 PM Page 26
Aluminum Weld-Quality
Solutions Come in Threes
The right combination of consumable
chemistry, process, and equipment produces
high-quality, 53-ft-long welds at a
refrigerated-trailer manufacturing plant
BY FRANK ARMAO
FRANK ARMAO (www.lincolnelectric.com)
is director of aluminum technology, The
Lincoln Electric Co., Cleveland, Ohio.
luminum has become increasingly prevalent in manufacturing

as a lightweight alternative to
steel, because it delivers an improved
strength-to-weight ratio, corrosion resistance, and general, overall weldability.
But, as those in the welding industry
know, aluminum behaves much differently than steel in welding applications.
When it comes to welding performance, aluminum definitely is a different
breed. The typical characteristics and
performance one expects when welding
with steel dont necessarily apply. This
metal has high thermal conductivity and
a low melting point factors that can
combine to yield such defects as meltthrough and warping slowing production and impairing the ultimate weld
integrity.
The secret to success for an aluminum
welding job comes down to three key factors the right equipment, the right
waveform, and the right consumable
Fig. 1. These factors are especially important when it comes to production with
automation systems.
Properly Equipped and

Programmed
Trailer manufacturing is one industry
where the proper union of these variables
comes into crucial play. Manufacturers
in this segment commonly use aluminum
and, thus, require welding setups that deliver strong, attractive welds quickly and
efficiently. They seek fast travel speeds,
26
DECEMBER 2013
Fig. 1 A reel of welding wire engineered for use with aluminum alloys.
Fig. 2 A manual welder puts finishing touches on an aluminum panel.
clean welds, and consistent bead profiles.

At the recently constructed Great
Dane Trailers refrigerated trailer manufacturing facility, which opened in April
2012 in Statesboro, Ga., company executives sought to install the latest technology, including welding equipment. Consistent material flow and throughput is a
constant goal at the plant and this
holds true in the welding booths, as well
Fig. 2.
When we put in new welding equipment, we wanted consistency to be our
first priority, noted Kevin Black, Great
Danes plant manager. And, if in the
process, this equipment upgrade makes
us a little more efficient, then thats even
better.
Great Danes fabrication crew uses
Power Wave welding machines from
Lincoln Electric with pulse waveform
technology for automated welding on the
refrigerated trailers aluminum floors

a complex process that involves a continuous, 53-ft-long weld of 12-in. boards
across the entire trailer floor. The system features ten boom-mounted wire
feeders and fixed welding guns on an automated setup with a mechanical gantry
that rides up and down the floor on rails
Fig. 3.
Waveform Technology
Pulse waveforms typically deliver weld
penetration with low heat at fast travel
speeds, providing a stable and consistent
arc with few defects. Through the instantaneous feedback from the power source,
the automated system responds more
quickly to stickout changes and contamination in the weld.
Over the years, improvements in
waveform control technology have
helped operators gain fast arc response

and optimized performance in almost
any application. Welding equipment
manufacturers have improved the waveform technology to boost efficiency and
weld consistency. In the past, inverters
may have operated at 40, 60, or even 80
kHz, but the waveform control was only
10 kHz, so it only made decisions controlling the weld at that speed sacrificing the machines full power for the
sake of accurate waveform control.
Today, both the waveform control and
the latest inverters operate at 120 kHz,
with waveform capable of changing up to
every 8.3 s. Parts of the waveform can
be independently manipulated, including peak on time, peak current, background, and current and pulse frequency.
These are synergistically controlled when
the operator picks a wire feed speed, or
selects the nominal waveform for the
given wire and welds. If there are jobspecific parameters, these can be included in the setup.
This controllability makes a big difference. It allows modern advanced
process welding power sources to react
much faster to a higher level of detail and
regulate the process with more precision,
including both wire feed and travel
speeds. Operators have the ability to
maintain better control of the arc, which
can adapt not only to gaps but also to material and joint variations.
In automated systems, such as that
used at Great Dane, welds can be made
faster without inconsistencies and loss of
weld pool control, eliminating spatter,
incomplete fusion, and undercut, while
avoiding discontinuities in the weld and
reduced quality. With the delicate nature
of aluminum substrates, this is even more
important for achieving quality welds and
consistent throughput.
Consumables, Chemistry
Control, and Quality
The success of the latest welding
power source and waveform technology,
however, also depends on the type of consumable specified for the job, particularly in aluminum trailer fabrication
and on trailer floors because they are a
highly visible feature.
You want your floor to be sealed
tightly and not have any issues with moisture infiltration, which could compromise the integrity of the floor and the insulation underneath it, Black said. You
want to be sure you have good coverage
on your floor. You can achieve this with
WELDING JOURNAL
27
Fig. 3 Previously unobtainable technology makes possible high-quality, automated continuous welds, 53-ft-long, in aluminum
flooring for refrigerated trailers that are smooth and attractive.
a material that not only bonds as it

should, but that is easy for the operators
and welding equipment to deliver a nice,
smooth appearance. You want the floors
cosmetic qualities to go hand in hand
with the structural qualities.
Welders at Great Dane selected a consumable specifically designed for the
trailer manufacturing industry in this
case, SuperGlaze 5356TM GMA welding wire with chemistry developed by
Indalco Alloys, a division of Lincoln
Electric.
This aluminum alloy GMAW wire was
designed to provide weld pool clarity and
arc action, as well as wetting for both
semiautomatic and high-productivity automatic applications. Additionally, its
controlled chemistry contributes to a
consistent bead profile and appearance
for a smooth surface finish at high travel
speeds.
Chemistry control supports such factors as a consumables mechanical properties, flow, and operability, among others. Strict oversight of this chemistry
throughout the manufacturing process
28
DECEMBER 2013
can help eliminate troublesome variations and ensure consistent, performance, even on the most temperamental
substrates, including aluminum.
Chemistry control also ensures quality; quality more often than not equals
certifications. When choosing the right
consumable for any application, its also
a good idea to review each products specific certifications. Look for products certified to meet AWS minimums; however,
note that some manufacturers provide
mechanical properties beyond AWS minimums without sacrificing the operability advantages.
Visible Results
At Great Dane, using an appropriate,
automated power source with the proper
waveform control, and specifying a consumable designed specifically for aluminum welding and trailer fabrication
has delivered improved results both in
product quality and integrity, as well as
aesthetics on trailer floors.
Welding has been one of the toughest quality items for us to manage, and it
is an important one to manage, said
Alan Whiten, Great Danes director of
manufacturing engineering. Weve reduced pickups, which is huge. If a customer sees a pickup or a break in the
weld, they arent going to like it.
Black said the nature of the particular welding application requires starts
and stops, and, in the past, the appearance of welded trailer floors at any manufacturing facility, Great Dane and others, just looked bad. He added, This
is something the industry has just accepted, but were trying to take that out
of the equation and get rid of the blemishes in the trailer floors appearance. We
now have equipment that allows us to
control the welds more than we previously could. We can set the parameters
so we dont get oversized welds. We dont
even want our customers to know there
are welds there. We want material to run
into material, and we are achieving that.
Our first priority always is the quality of
the products we produce.
otc daihen_FP_TEMP 11/13/13 7:51 AM Page 29
Miller Feature December 2013_Layout 1 11/12/13 3:56 PM Page 30
Tips for Job Shops
Improving productivity, ensuring the best

quality, and reducing costs are all important
if job shops are to remain competitive as
well as provide the best, and most timely,
service and products to their customers.
30
DECEMBER 2013
Five methods are presented to

enhance your manufacturing
operations and decrease costs
he goal for any job is to complete

it correctly, on time, within
budget, and with the greatest
amount of efficiency and it is no different for welding applications in a job
shop.
Improving productivity, ensuring the
best quality, and reducing costs are all
important if job shops are to remain
competitive plus provide the best, and
most timely, service and products to their
customers.
There is more to meeting these goals,
however, than just having the fastest employees or a particular piece of equipment. Factors like proper product storage (particularly filler metals), welding
operator safety and training, and effective purchasing are also critical. As job
shops become more sophisticated, it is
also important to find the most efficient
ways of managing the quality- and productivity-enhancing aspects of the welding process.
Here are five key tips to help job shops
meet their goals, all while gaining that
competitive edge.
1. Offer Ongoing
Employee Training
Investing time and money into training can yield significant long-term benefits for a job shop. Welding operators
benefit individually from process and
equipment training, and in many cases,
it can also help them optimize the welding operation for greater efficiency.
Proper training can also give job shops a
competitive edge over those that have
less-skilled labor, and it promotes teamwork among employees.
Training opportunities are typically
available through equipment and filler
metal manufacturers or welding distributors. In some cases, working with a local
technical college can offer training for

specific applications.
Employee involvement and training
is based on the idea of continuous improvement. Better-trained welding operators are more involved in the process
and more invested in the job they do. It
empowers employees to have ownership
of their portion of the process.
Proper training takes a time and effort commitment, but the investment can
pay off in the long run by reducing downtime, inefficiencies, and lost productivity, along with improving the end product quality.
2. Instill Proper Safety

Measures
Controlling the fumes created by
welding processes creates a cleaner,
more productive job shop. Along with
making employee comfort a priority, controlling weld fumes also helps ensure
compliance with safety regulations.
There are many options for weldfume management, and selecting the best
system depends on cost, space, and the
specific welding applications conducted
in the job shop. Also, note that every
welding environment is different and
should be inspected by a qualified industrial hygienist to determine the appropriate course of action for fume controls.
Modifying the welding process can
help reduce weld fume. Changing base
material, wire, gas, process, and/or optimizing parameters are all options job
shops can utilize. Teaching employees
proper weld positioning to minimize exposure to the weld-fume path is also important. Welding operators should not
position themselves directly above the
weld and should never stand between a
fan and the weld.
Beyond welding process and behav-
BY JOHN LEISNER AND

DAVID BENSON
JOHN LEISNER is a senior product man
ager for Miller Electric Mfg. Co.
(www.millerwelds.com), Appleton,
Wis. DAVID BENSON is an applications
engineer for Hobart Brothers Co.
(www.hobartbrothers.com),Troy, Ohio.
ioral changes, the next step is to consider

engineering controls such as source capture systems. Source capture systems
draw weld fume away from the welding
operators breathing zone and keep the
facility cleaner. These systems, however,
can be difficult to position over large
weldments or obstructions in the weld
cell.
New advancements in source capture
technology are making that challenge
easier. These mobile fume-extraction systems increase the fume extraction area
to a greater width and distance up to
4 ft wide and 5 ft away Fig. 1. This
larger capture area reduces downtime
and pauses during welding that are spent
repositioning the capture arm. This extended capture system is the best choice
for any weldment or part more than 18
in. long. Other source capture options
are available, as well, depending on the
size and needs of individual job shops.
These include conventional, portable, or
mobile floor models, stationary/wallmounted models, fume guns, and centralized industrial systems (for larger
shops).
If the above measures are not enough
to address safety and compliance issues,
using personal protective equipment
such as powered air-purifying respirators, air supply helmets, and half-mask
respirators is the best option.
3. Establish Proper
Filler Metal Storage
and Handling Practices
Taking simple precautions to store
and handle filler metals correctly can
help job shops get the best performance
out of products and minimize costs.
Damaged filler metals, including covered
electrodes and solid or tubular wire, can
WELDING JOURNAL
31
Miller Feature December 2013_Layout 1 11/15/13 10:59 AM Page 32
Fig. 1 This mobile

fumeextraction system
is a good addition to
any job shop.
cause poor weld quality that ultimately

leads to expensive and time-consuming
rework. Also, if filler metals become wet
or pick up contaminants such as dirt, oil,
or grease, they should be replaced.
Filler metals are in sealed packaging
when they leave the factory. The first step
for keeping them in the best possible condition is to always use gloves when removing them from their original packaging or preparing them for welding, since
filler metals can easily pick up sweat from
bare hands.
Welding operators should keep filler
metals away from areas in the shop where
plasma or oxyfuel cutting takes place, as
the cutting dust from those processes can
accumulate on the surface of solid and tubular wires and cause poor wire feeding.
The dust also can clog the contact tip and
nozzle on the gas metal arc welding
(GMAW) gun, creating poor electrical
conductivity and an unstable or erratic arc.
In addition, filler metals should be kept
away from water, oil, and grease; these
contaminants can lead to poor weld quality, rework, or other performance issues.
Storing filler metals properly when
they are not in use is important. At a minimum, welding operators should cover
32
DECEMBER 2013
the welding wire spool with a plastic bag

if it is left on the feeder overnight. A better practice is to remove the spool from
the feeder, place it in a clean plastic bag,
and securely close it. Store it in a clean,
dry area until it is used again. Using an
enclosed wire feeder, when possible, is
another good way to protect the welding
wire from the environment.
Covered electrodes should be stored
in ovens according to the manufacturers
recommendation.
4. Implement Welding
Information
Management
Welding information management is
not new to the industry, but it is a technology that can positively contribute to
the efficiency of a job shop. In the past,
this technology delivered raw data, and
it was up to the user to take that data, interpret it, and convert it into actions for
meaningful, continuous improvement.
Often, the effort needed to convert the
data into actionable information was too
much especially for a smaller shop that
may have limited resources. Technology

has evolved to help bridge the gap between data and information, and it requires less manpower.
Welding equipment manufacturers
have embedded welding information
management capabilities directly into
power sources for simplified deployment
and management, or in some cases, have
made the power sources able to be easily retrofitted by adding a module. Welding information management systems
that are fully integrated into the power
source offer seamless integration and
minimal start-up time, and many feature
wireless capabilities, so the data is easily
uploaded into a computer program.
Newer welding information management
systems are cloud based, allowing job
shops to access information from the integrated power source or retrofitted
module by way of a standard Internet web
browser.
The primary categories of weld-data
monitoring are real-time weld/arc monitoring, which measures defined variables
like voltage, wire speed, and gas flow;
weld data acquisition, which measures,
displays, and stores defined variables
to evaluate specific arc characteristics;
and production data, which provides

various layers of productivity-related information, including overall equipment
effectiveness.
The real value of this technology
comes when the production output is
compared to acceptable limits or standards so the job shop can identify potential process variances and understand the
welding operations true cost.
Ultimately, job shops can use this information to increase productivity, improve quality and training, and lower operating costs. The data provide many opportunities for continuous improvement
and can help shops assess risks and set
goals.
5. Purchase Based on
Quality, Not Price
It is important to select the best filler
metal and equipment for the job, and
sometimes this means making a bigger
Es
investment. While the up-front cost savings are tempting, cheaper is not always
better because it can lead to problems
down the road such as poor weld quality
and more maintenance.
With regard to filler metals, it is not
uncommon to experience downtime associated with poor wire feeding, excessive spatter, or weld defects when using
lower-quality products. Workers may
also find themselves spending an excessive amount of time on activities that hinder productivity, such as applying antispatter and postweld grinding or rework.
It is important to look at the total cost of
using particular filler metals vs. the perunit cost. Higher-quality filler metals
can often minimize labor costs and provide better weld quality and greater
productivity.
The same considerations are true
when selecting power sources. Less expensive machines may not have the
longevity of more expensive, quality
equipment, which can result in higher
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ica
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and more frequent replacement costs for

job shop fleets. Cheaper machines may
also experience more breakdowns, which
means higher maintenance costs and lost
productivity. More expensive machines
also may offer a more intuitive product
interface and easier operation, simplifying operator training.
In Closing
These tips may involve an investment
of time, effort, and resources, but they
can pay off in productivity and quality
gains along with reduced costs in the long
run for job shops that use a variety of
welding processes and equipment.
The goal for any shop to remain competitive is to look for practical efficiencies that make it easier to manage its
filler metals and equipment, and get the
most out of these technologies. Having
well-trained, safe employees adds to that
goal, instilling a sense of ownership and
pride in having a well-run shop.
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WELDING JOURNAL
33
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Cullison 12-13_Layout 1 11/11/13 3:30 PM Page 34
Welding and Cutting Fair

Attracts a Worldwide Audience
BY ANDREW CULLISON
The event held every

four years in Essen,
Germany, again
proved to be the
biggest platform for
exhibiting welding
and cutting products
in the world
There was a convergence of all things welding and cutting this

past Sept. 1621 in the industrial city of Essen, Germany. Every
four years, this city hosts the Schweissen and Schneiden (Welding and Cutting) International Trade Fair. This event has become
a magnet for manufacturers and visitors from around the world
to come together and experience the vast technology available
around the globe. The 1017 exhibitors from 42 countries exposed
their wares to some 60,000 visitors. The exhibition complex consists of 12 halls and a Galleria comprising 110,000 sq m of display space. The Fair is organized by Messe Essen GmbH in cooperation with DVS, the German Welding Society.
ANDREW CULLISON (cullison@aws.org) is publisher of the Welding Journal.
34
DECEMBER 2013
Moving Forward
This year, eight different countries,
including the United States, had pavilions to exhibit products unique to their
countries. The U.S. pavilion, organized
by the American Welding Society, had 25
companies demonstrate their specific
technologies. The AWS was also active
in the pavilion, with an exhibition that
promoted publications, certifications,
and membership.
The last time the fair was held in 2009,
it operated under the pall of a world economic downturn. Not so this time. In
talking to manufacturers, there was an

indication that business is robust this
time around. Although there were some
who would like a little faster growth,
overall the response was positive, especially about the type of visitors who attended the fair. Many were ready to talk
business and make a deal.
Activity Preceding the

Fair
The International Institute of Welding held its 66th Annual Assembly prior
to the Welding and Cutting International
Fig. 1 Five wires are fed into a multiwire submerged arc system for narrow groove
welding.
Fig. 2 An all-aluminum hull provides a standard platform to boat construction.
Fair. This annual meeting was held Sept.

1117 at the Congress Center Essen. The
German Welding Society was the host organization for this event. In addition to
28 working units of IIW that were active
during the meeting, an international conference on Automation in Welding was
conducted Sept. 16 and 17.
Speakers from around the world gave
presentations on automation technology
that incorporates arc welding, lasers, friction stir welding, and resistance welding.
Products
A brief look at some of the technology that was on display is given below.
Wind tower technology is much in evidence in Europe as the land and
seascape are dotted with rotating turbines. Uhrhan-Schwill, Essen, Germany,
featured its multiple-wire narrow groove
submerged arc welding system (Fig. 1)
designed for joining the critical joints in
wind tower main columns. The company
is affiliated with Lincoln Electric and the
Power Wave AC/DC 1000 is used to
power the system. The weld head for this
particular system was set up with two twin
2.4-mm wires and one 4.0-mm wire. Deposition rates of 50 kg/h can be reached
and wall thicknesses up to 100 mm can
be joined. Wire locations are automatically adjusted as the joint is welded out.
The weld heads are designed to withstand
applications requiring up to 2000 A.
www.uhrhan-schwill.de
Ophardt Maritim, Duisberg, Germany, introduced a novel concept of
module construction for the hull of a
boat. The idea is similar to the auto industry where various different models
may share the same chassis. The OPSHIPP boat chassis (Fig. 2) can accommodate vessels 812 m long. The
boat manufacturer chooses whatever
prefabricated module is needed and then
uses it as a platform to fit out the superstructure to whatever design requirements the customer desires. The modules are all aluminum and are primarily
welded robotically. The concept has the
advantages of reducing costs, since standard and mass-produced parts can be
used; speeding production, with a typical module hull taking a week to produce,
while a conventional hull might take five
weeks; reducing distortion; and consistency of fabrication. www.ophardtmaritim.de
Messer Group, Bad Soden, Germany,
took this opportunity to introduce its
MegaPack cylinder holder (Fig. 3), which
takes the standard cylinder capacity from
WELDING JOURNAL
35
Fig. 4 Motofil is involved in all phases of welding and cutting, including its Motomig
solid welding wire.
Fig. 3 The reinforced frame holds four

to six 150-L cylinders.
50 to 150 L and bundles it in a four or six
pack. Targeted for laser applications, the
bundle is contained in a heavy-duty, impact-resistant frame that allows access
only to the necessary valves and connections. A roll bar incorporated into the
frame structure protects the cylinders
from accidental damage. The operating
panel is at a height for simple access, and
it has a gas level indicator that is large
enough to be read at a distance. Wide
color-coded strips on the corners of the
frame identify the gas contained in the
cylinder. www.messergroup.com
Motofil Group is a company from Portugal that sees much promise in the welding economy; enough to invest in a brandnew solid wire electrode manufacturing
facility with a 20,000 ton/year capacity,
which opened last July. The plant has the
latest technology for manufacturing
welding wire. Its Motomig wire is produced in 0.8, 0.9, 1.0, and 1.20 mm diameters, and they can be dispensed from a
250-kg bulk wire pack (Fig. 4) also manufactured by the company. Motofil is also
into design of systems for robotics, positioners/gantries, and thermal cutting with
working relationships with Fanuc, Binzel,
Kempii, and Miller among others. The
companys Feline cutting line utilizes
oxyfuel, plasma, and laser cutting technologies. The company has manufactur-
36
DECEMBER 2013
ing or distribution centers in Europe,

Africa, and South America and is looking to expand into the United States.
www.grupomotofil.com
The FabCOR F6 metal cored wire for
welding galvanized steel was introduced
at Essen by Hobart. With the push for
fuel economy in cars, the use of galvanized parts is on the upswing in the automotive industry. Zinc has always been
problematic to weld, but with some projecting a 70% increase in galvanized components in the next three years, Tier 1
suppliers are looking for reliable ways to
weld those parts. A manufacturer needed
2200 parts/day, but was only getting
1400/day with a 90% rework rate. When
this metal cored welding wire was used
in the application, it was claimed to have
improved production to 2500/day with
minimal rework. The wire is designed for
flat and horizontal welding using an
argon/CO2 shielding mixture. It operates
from 100 to 350 A depending on diameter. Available diameters are 0.35, 0.39,
and 0.045 in. Four Tier 1 automotive suppliers are presently using the wire.
www.hobartbrothers.com
Fronius introduced its AccuPocket
150/400 battery-powered power source
(Fig. 5). Intended for situations that require quick repair or remote operation
where the mains grid is inaccessible, the
unit is powered by a rechargeable
lithium-ion battery. When it has a full
charge, there is power enough to deposit
16 2.5-mm or 6 3.25-mm shielded metal
arc (SMA) electrodes. The power source

has capabilities up to 140 A for SMA
welding, and it can also be switched to
gas tungsten arc welding mode producing 150 A. A generator can be used to operate the unit. The weight is 11 kg, and
5.25 kg for its companion Active Charger.
www.fronius.com
Fig. 5 This power source runs on a

rechargeable lithium-ion battery.
Rapid arc welding (RAW) machines
for attaching studs and other types of anchors were promoted by Silicon. The
whole process is controlled by a series of
eight parameters programmed into the
power source. Stepper motors in the
welding gun access the computer in the
unit and check off each preset parameter from beginning to end of the weld,
making sure each step of the process is
controlled. The combination of welding
Fig. 6 Stepper motors in the gun react to

a series of preprogrammed parameters that
control the welding process.
Fig. 7 Modules for weld heads and pincers
can be combined in multiple configurations
for different applications.
Fig. 8 A new wire feeder with a four-roll
drive was introduced by EWM.
gun and power source provides (Fig. 6)
technology capable of welding up to a 46mm stud. The company custom makes
stud holders, ferrules, and ferrule plates
according to the type of anchor the customer needs. www.silicon.nu
The PECO newhorizon weld heads
and pincers from Miyachi Europe can be
configured to address a variety of resistance welding applications (Fig. 7). One
such application in automotive was the
attachment of LED headlights to their
support frame. A vibration problem was
causing the headlights to loosen, even in
flat terrain conditions. The problem was
addressed with the line of PECO modular resistance welding machines. Up to
24 basic modules of weld heads and pincers can be combined into hundreds of
different configurations to meet various
applications. www.miyachieurope.com
The new Multimatrix Wire Feeder 4x
was on display at EWM, Mundersbach,

Germany. The unit uses a four-roll drive
design (Fig. 8) for maximum wire contact.
The large diameter of the rollers places
extra pressure on the wire. The rollers
lock in place to minimize movement, and
no tools are required to change them.
The wire feeder weighs 13 kg and is configured to fit through tight openings. It
has automated wire inching to control
feeding, and it is mounted on a cast aluminum base. www.ewm-group.com
Among many technologies exhibited
by ESAB, the PowerCut 1300 plasma arc
cutting machine has the extra voltage capability to perform gouging. The operator can automatically switch to the gouging mode from cutting giving added
versatility. Certain design features, such
as suspending the internal electronics
from an aluminum frame, help minimize
shock and vibration that might be en-
countered in daily use. The switches are

also sealed to protect against dirt and
dust contamination. The unit cuts material up to 114 in. and severs up to 112 in.
www.esab.com
Designed for micro applications, the
MEBW-60 compact electron beam machine was exhibited by FOCUS. This unit
can weld similar, dissimilar, and refractory metals in thicknesses of 20 m to 12
mm. It has a maximum beam power of 2
kW. The standard model has a motorized
rotating chuck that can handle parts from
3 to 135 mm in diameter. An extended
version of the model has an x-y table and
can accept parts 300 250 200 mm.
There is an automatic push-button vacuum clearing system that attains 5 104
mbar in two minutes. The unit can also
be used for brazing, drilling, and surface
modification. www.focus-gmbh.com.
WELDING JOURNAL
37
Krause feature_Layout 1 11/11/13 3:36 PM Page 38
How Wire Diameter Affects

Aluminum Welding
Increasing wire diameter for aluminum GMAW
can boost productivity, but making this change
requires other procedure modifications
BY ROB KRAUSE
ROB KRAUSE (RKrause@alcotec.com)
is technical services manager,
AlcoTec Wire Corp., Traverse City, Mich.
ow many manufacturers would

not want to increase the number
of parts they could produce in a
given time? Obviously, not many, if any
at all. One factor rarely considered to increase productivity is to use a largerdiameter aluminum welding wire. Aluminum is specified because its high electrical and thermal conductivities make it
a much better candidate than other metals for some of the techniques discussed
in this article.
Effects of Wire Diameter

The advantages of increasing wire diameter include better fusion and penetration, increased travel speeds, higher
deposition rates, lower price/lb, and better feedability. However, it is important
to understand how a seemingly insignificant change in wire diameter can considerably affect the wire volume and other
welding parameters.
AWS A5.10/A5.10M:2012, Welding
Consumables Wire Electrodes, Wires
and Rods for Welding of Aluminum and
Aluminum Alloys Classification, specifies
a
diameter
tolerance
of
+0.001/0.002 in. for aluminum gas
metal arc welding (GMAW) wire. Although a difference of 0.003 in., the maximum tolerance range, may seem very
small, it actually results in a significant
volume change. Figure 1 shows the effect
diameter has on volume for several diameters as well as its impact on the welding machine settings.
38
DECEMBER 2013
A hard automated welding system is shown joining aluminum-alloy panels.
Fig. 1 The effects of welding wire diameter tolerance variations on deposited weld
metal, and the effect of electrode diameter on several welding parameters.
Fig. 2 Weld beads made with Alloy 5356 wires of different diameters deposited at
feed speeds adjusted to equalize the amount of weld metal deposited.
Now that we have a better understanding of how wire volume impacts

actual welding, lets look at some examples of how this can be used to your
advantage.
The goal for the first example was to
obtain a comparable bead size using different wire diameters. Considering an increased diameters effect on volume, the
travel speed must also be increased to
equalize the deposition rate. Due to
travel speed restrictions on the equipment we used, 0.094-in. (2.4-mm) wire
was used as the baseline. The parameters
for the other three welds were adjusted
to achieve a bead size as close as possible to the baseline. Figure 2 shows the
beads run using four different wire diameters (all Alloy 5356). The photo shows
very little difference in the beads appearance. Table 1 lists the travel speeds
used, percent-change between each wire
increment, as well as the increase if you
were to skip a level. The table also
shows the increase in amperage, which is
discussed more under the Limitations
heading.
When you dont need to weld faster,
but have an application where you need
a larger weld, you definitely do not want
to slow down. In this case, you could use
a larger-diameter wire to increase the
deposition rate (and possibly even pick
up a little speed). Table 2 illustrates how
increasing the wire diameter affects the
bead size when the travel speed remains
constant.
So, how does increasing the wire diameter improve penetration/fusion? The
simple answer is amperage = penetration. Therefore, as you increase the wire
diameter, the amperage (penetration)
automatically increases with it. However,
its not always that simple. As more wire
goes into the weld, you must be aware of
the increased chance of arcing off the
weld pool, which can have a negative impact on penetration. The key to preventing this is to ensure your wire is always
on the leading edge of the weld pool
Fig. 3. This can be done by increasing
travel speed, slightly increasing your push
angle, or by running your weld slightly
uphill (for flat, horizontal, and overhead
positions). The actual depths of penetration from the test samples are listed in
Table 3.
The last two advantages mentioned do
not require extensive explanation. Basically, since less work is necessary to produce the same alloy in a larger diameter,
the result is a lower price/lb. The increased diameter also improves feedability as the wire is more rigid, allowing for
WELDING JOURNAL
39
less deflection as it travels through the

drive rolls and liner. Anyone who has
used aluminum GMAW wire knows feedability can be a major issue with certain
alloys and diameters.
Limitations
There are always limitations or possible disadvantages when making changes.
Machine capacity will be the first point
of discussion. For this example, Alloy
5356 in 0.047-in.- (1.2-mm-) diameter
wire was used. For the lab tests being referenced, the average amperage with this
product was 220 A. For a weld of similar
size made using 0.062-in.- (1.6-mm-) diameter wire, the average amperage increased to 274 A. This would not pose a
problem for a 400-A machine, but a machine rated for 300 A at 100% duty cycle
may struggle to keep up. As a result of
the travel speed increase, the total heat
input did not significantly increase, but
greater machine capacity was required
for the increased amps.
Due to the higher amperages needed
for the larger wires, an air-cooled gun
may be unsatisfactory as the nozzle will
heat up much faster. This may not be a
problem if the average weld length is relatively short, but for most production applications, you may want to consider a
water-cooled welding gun if you are going
to use 0.062-in. wire or larger. Be aware
that most welding guns have their amperage ratings based on CO 2 or a mix containing CO 2. Since aluminum GMAW
applications will utilize either 100%
argon, or a mixture of argon and helium,
these amperage ratings must be reduced.
One manufacturer rates its welding gun
at 400 A with CO2 and only 260 A when
using argon.
Another potential limitation, albeit
less profound, is travel speed. If the goal
is to increase productivity by increasing
wire diameter, the travel speed must be
increased if the bead size is to remain
constant. This may not be difficult to do
in robotic or hard automation applications, but for manual operations, your
welders may require training to move
faster, possibly as much as 30% faster.
From a safety standpoint, the heat
generation at the welding gun should also
be considered. For robotic and automated systems, this will most likely not
pose a problem. For manual applications,
however, heat shields for your welders
gloves will be very important.
The last concern to consider is the actual weldment. The thickness of the material, the part geometry, and the assem40
DECEMBER 2013
Fig. 3 Shown is the proper position of the wire and the arc relative to the weld pool.
Table 1 Wire Diameter-Travel Speed Combinations to Obtain Same Weld Bead Size
Diameter (in.)
Amps (A)
Volts (V)
Wire Feed Speed (in./min)
Bead Width Target (in.)
Travel Speed (in./min)
% Increase in Travel Speed
0.047
223
22.5
523
0.45
26
0.062
274
23
366
0.45
35.8
37.7%
0.071
319
24
295
0.45
42
17.3%
61.5%
0.094
375
25
180
0.45
49
16.7%
36.9%
88.5%
Table 2 Wire Diameter vs. Weld Bead Width with Constant Travel Speed
Diameter (in.)
Amps (A)
Volts (V)
Wire Feed Speed (in./min)
Travel Speed (in./min)
Bead Width (in.)
% Increase in Bead Width
0.047
225
23
531
27
0.422
0.062
258
23
366
27
0.480
13.7%
0.071
264
23
271
27
0.582
21.3%
37.9%
0.094
375
26
180
27
0.688
18.1%
43.2%
62.9%
Table 3 Depths of Penetration for Four Wire Diameters Welded at the Same Travel Speed
Diameter (in.)
Amps (A)
Depth of Penetration
% Change in Penetration
0.047
225
0.111
bly sequence may simply not permit you

to increase the wire diameter and weld
amperage. However, if your machine has
pulse capabilities you may be able to reduce the average amperage and heat
input by welding using a pulse mode.
Summary
The use of aluminum is continually increasing, resulting in more companies
0.062
258
0.128
15.3%
0.071
264
0.179
39.8%
61.3%
0.094
375
0.191
6.7%
49.2%
72.1%
trying to compete for aluminum welding

business. To remain competitive, these
companies must always be looking for
ways to stay ahead of their competition.
The physical and mechanical properties
of aluminum make it a unique metal and
its differences can be used to your competitive advantage to improve performance and productivity. Increasing wire diameter can be a relatively simple way to
do this, but it is only one aspect of the
overall welding improvement process.
at&f_FP_TEMP 11/13/13 7:43 AM Page 41
x Coming Events Dec._Layout 1 11/12/13 3:50 PM Page 42
COMING
EVENTS
NOTE: A DIAMOND ( ) DENOTES AN AWS-SPONSORED EVENT.
CyberSE 2013, Intl Conf. on Cyber Science and Engineering.

Dec. 14, 15. Guangzhou, China. www.cyberse2013.org.
United States-European Welding Standards Conf. Jan. 27, 28.
American Welding Society World Headquarters, Miami, Fla.

Cosponsored by AWS and GSI (Gesellschaft fr Schwisstechnik,
Intl.). Topics to include welding standards covering structural
fabrication, pressure vessels, railway vehicles, and company certification. Contact P. Henry, phenry@aws.org; (800) 443-9353, ext.
215.
AERODEF Manufacturing. Feb. 2527. Long Beach Convention
Center, Long Beach, Calif. Society of Manufacturing Engineers.
(800) 733-4763; www.aerodefevent.com.
FABTECH Canada. March 1820. Toronto Congress Centre,
Toronto, Ont., Canada. www.fabtechcanada.com.
Metal & Steel Saudi Arabia 2014. April 710. Riyadh, Saudi Arabia. Visit www.metalsteelsaudi.com.
FABTECH India colocated with Weld India. April 1012. Pra-
gati Maidan Exhibition Complex, New Delhi, India. Concurrent

with the 2014 Intl Congress of the IIW. Cosponsored by AWS,
FMA, SME, PMA, CCAI, and India Institute of Welding.
www.fabtechexpoindia.com.
42
DECEMBER 2013
ITSA International Thermal Spray Assn. Annual Meeting.

April 2426. Savannah, Ga. Sponsored by ITSA, an AWS Standing Committee. itsa@thermalspray.org; www.thermalspray.org.
JOM, 18th Intl Conf. on Joining Materials. April 2629. Konventum LO-Skolen, Helsingr, Denmark. In association with the
Intl Institute of Welding, cosonsored by American Welding Society, Japan Welding Society, Welding Technology Institute of Australia, Brazilian Welding Society, and others. E-mail
jom_aws@post10.tele.dk; download brochure at www.aws.org/wj/
JOM-18-CallForPapers.pdf.
First Intl Symposium on Advances in Resistance Welding.

April 2830. Atlanta, Ga. Sponsored by AWS and the Resistance
Welding Manufacturing Alliance (RWMA), an AWS Standing
Commitee. Topics will include research results, projects, and industrial experiences that describe significant advances in resistance welding technology. Visit www.aws.org/rwma, or contact
Patrick Henry, phenry@aws.org; (800/305) 443-9353, ext. 215.
AWS Weldmex, FABTECH Mexico, METALFORM, Mexico.
May 68. Centro Banamex, Mexico City, Mexico. www.fabtechmexico.com.
JOIN-TRANS Third European Conf., Joining and Construction of Railway Vehicles. May 6, 7. An IIW associated event. Weld-
ing Training and Research Centre, SLV Halle GmbH, Halle

(Saale), Germany. www.jointrans.eu.
mfg4 colocated with MicroManufacturing Conf. and Exhibits.
May 68. Connecticut Convention Center, Hartford, Conn. The
Society of Manufacturing Engineers; (800) 733-4763;
www.mfg4event.com.
Intl Laser Technology Congress AKL 14 and Expo. May 79.
Aachen, Germany. Visit www.lasercongress.org/en/home/.
MMTS Montreal Mfg. Technology Show. May 1214. Place
Bonaventure, Montreal, Que., Canada. www.mmts.ca.
Composites Manufacturing. May 1315. Northern Kentucky
Convention Center, Covington, Ky. Society of Manufacturing Engineers. www.sme.org/composites.
Atlanta, Ga. This exhibition is the largest event in North America

dedicated to showcasing the full spectrum of metal forming, fabricating, tube and pipe, welding equipment, and myriad manufacturing technologies. American Welding Society. (800/305) 4439353, ext. 264; www.fabtechexpo.com.
FABTECH 2015. Nov. 912. McCormick Place, Chicago, Ill. This
exhibition is the largest event in North America dedicated to

showcasing the full spectrum of metal forming, fabricating, tube
and pipe, welding equipment, and myriad manufacturing technologies. American Welding Society. (800/305) 443-9353, ext. 264;
www.fabtechexpo.com.
Educational Opportunities
Metal & Steel Middle East 2014. May 1517. Cairo, Egypt. Visit
www.metalsteeleg.com.
Hypertherm Cutting Institute Online. Includes video tutorials,

interactive e-learning courses, discussion forums, and blogs. Visit
www.hyperthermcuttinginstitute.com.
THE BIG M including SME Annual Meeting, RAPID Conf. and

Expo, and North American Research Conf. June 912. Cobo Center, Detroit, Mich. Society of Manufacturing Engineers. www.thebigmevent.com.
INTEG Courses. Courses in NDE disciplines to meet certifications to Canadian General Standards Board or Canadian
Nuclear Safety Commission. The Canadian Welding Bureau;
(800) 844-6790; www.cwbgroup.org.
7th Offshore Energy Expo and Conf. Oct. 28, 29. Amsterdam RAI,
The Netherlands. Visit www.offshore-energy.biz.
Laser Safety Online Courses. Courses include Medical Laser

Safety Officer, Laser Safety Training for Physicians, Industrial
Laser Safety, and Laser Safety in Educational Institutions. Laser
Institute of America; (800) 345-3737; www.laserinstitute.org.
FABTECH 2014. Nov. 1113. Georgia World Congress Center,
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43
Laser Safety Training Courses. Courses based on ANSI Z136.1,

Safe Use of Lasers, Orlando, Fla., or customers site. Laser
Institute of America; (800) 345-3737; www.laserinstitute.org.
Laser U Online Education Portal. Offers practical information to use on the job. Topics range from 3D printing to drilling,
welding, wireless and optical product rquirements, and many
others. Visit website for complete information and to sign up for
modules. Laser Institute of America; www.lia.org/laseru.
Laser Vision Seminars. Two-day classes, offered monthly and on
request, include tutorials and practical training. Presented at
Servo-Robot, Inc., St. Bruno, QC, Canada. For schedule, cost,
and availability, send your request to info@servorobot.com.
Machine Safeguarding Seminars. Rockford Systems, Inc.; (800)
922-7533; visit www.rockfordsystems.com.
Machining and Grinding Courses. TechSolve, www.TechSolve.org.
NACE Intl Training and Certification Courses. National Assoc.
of Corrosion Engineers; (281) 228-6223; www.nace.org.
NDE and CWI/CWE Courses and Exams. Allentown, Pa., and
customers locations. Welder Training and Testing Institute, (800)
223-9884; www.wtti.edu.
NDT Courses and Exams. Brea, Calif., and customers locations.
Level I and II and refresher courses in PA, UT, MP, radiation
safety, radiography, visual, etc. Test NDT, LLC; (714) 255-1500;
www.testndt.com.
Online Education Courses. Topics include Introduction to Die

Casting ($99), Metal Melting and Handling ($99), Product
Design ($59), Energy Training ($19), Dross Training ($19),
Managing Dust Hazards ($19), Safety (free). North American
Die Casting Assn.; (847) 808-3161; www.diecasting.org/education/online.
Plastics Welding School. A two-day course for certification to
European plastics welding standards. Malcom Hot Air Systems;
www.plasticweldingtools.com.
Protective Coatings Training and Certification Courses. At various locations and online. The Society for Protective Coatings;
(877) 281-7772; www.sspc.org.
Robotics Operator Training. Presented by ABB University at 13
locations nationwide. For course titles and locations: (800) 4357365, opt. 2, opt. 4; www.abb.us/abbuniversity.
Safety Training Online. Unlimited training on myriad industrial
safety course titles for $45/employee/year. Visit website for complete information and previews of several courses;
www.safety99.com.
Service Manager Course. For sheet metal workers and HVAC
service shop owners. Various locations and dates. International
Training Institute, www.sheetmetal-iti.org; (703) 739-7200.
Servo-Robot Training Seminars. Two-day laser-vision seminars
held throughout the year at Servo-Robot, Inc., near Montreal,
Canada. Seminars include tutorials and hands-on practical train-
Weld Smarter With

Total Welding Management
Implementing the principles and
concepts in this book could save
you $15,000 to $25,000 annually
per welder.
Drawing on more than 50 years

of welding experience, author Jack
R. Barckhoff, P.E., gives you a solid
step-by-step plan to manage your
welding operations for maximum
productivity and cost efficiency.
Specific recommendations and
real-life production examples
illustrate how your welding team
can realize productivity gains of 20 percent to 50 percent.
Total Welding Management explains the management
principles, structure, and details you need to transform your
welding operations from a cost center into a profit center. A
must-read for supervisors, managers, and executives who
seek to make their welding operations more efficient and
more productive. 185 pages, 35 figure, 20 tables, hardbound.
Order yours today: 888-WELDING (935-3464).
Outside North America: 305-824-1177.
Online: www.aws.org/standards
Order code: AWS TWM, $49.50
American Welding Society 2006
44
DECEMBER 2013
WJS1235
ing. For seminar schedule and costs, e-mail request to info@

servorobot.com.
Shielded Metal Arc Welding of 2-in. Pipe in the 6G Position
Uphill. Troy, Ohio. Hobart Institute of Welding Technology;
(800) 332-9448; www.welding.org.
SSPC Training and Certification Courses. Courses in protective
coatings, abrasive blasting, paint inspector, bridge coatings
inspector, surface preparation, NAVSEA inspector, and many
others. The Society for Protective Coatings; www.sspc.org.
Thermadyne Distributor Training. Year-around training at
Denton, Tex.; West Lebanon, N.H.; Bowling Green, Ky.; and
Chino, Calif. Contact trainingteam@victortechnologies.com.
Welding Courses. A wide range of specialized courses presented

throughout the year. The Lincoln Electric Co.; (216) 486-1751;
www.lincolnelectric.com.
Welding Introduction for Robot Operators and Programmers.
This one-week course is presented in Troy, Ohio, or at customers
locations. Hobart Institute of Welding Technology; (800) 3329448, ext. 5603; www.welding.org.
Welding Skills Training Courses. Courses include weldability of
ferrous and nonferrous metals, arc welding inspection, quality
control, and preparation for recertification of CWIs. Hobart Institute of Welding Technology. (800) 332-9448; www.welding.org.
TIP TIG Manual and Automated Plate and Pipe Welding

Workshops. Held the third Thursday of every month. 1901 Kitty
Hawk Ave., Bldg. 68, Philadelphia Naval Shipyard, Philadelphia,
Pa.; (215) 389-7700; www.tiptigusa.com.
Tool and Die Welding Courses. Troy, Ohio. Hobart Institute of
Welding Technology; (800) 332-9448; www.welding.org.
Unitek Miyachi Corp. Training Services. Personalized training
services on resistance and laser beam welding and laser marking;
(626) 303-5676; www.unitekmiyachi.com.
Vibration Training Short Courses. Presented at locations nationwide, customers site, and by correspondence. Vibration
Institute; www.vibinst.org.
An Important Event
on Its Way?
Send information on upcoming events to the Welding
Journal Dept., 8669 NW 36th St., Miami, FL 33166.
Items can also be sent via FAX to (305) 443-7404 or
by e-mail to woodward@aws.org.
WELDING JOURNAL
45
Cert Schedule Dec_Layout 1 11/13/13 10:47 AM Page 46
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION
SEMINAR DATES
Charlotte, NC
Jan. 510
Miami, FL
Exam only
Beaumont, TX
Jan. 1217
Long Beach, CA
Jan. 1924
Denver, CO
Jan. 2631
Miami, FL
Jan. 2631
Pittsburgh, PA
Jan. 2631
Corpus Christi, TX
Exam only
New Orleans, LA
Feb. 914
Waco, TX
Feb. 914
Seattle, WA
Feb. 914
San Diego, CA
Feb. 2328
Atlanta, GA
Feb. 2328
Mobile, AL
Mar. 27
Kansas City, MO
Mar. 27
Houston, TX
Mar. 27
Norfolk, VA
Mar. 27
Milwaukee, WI
Mar. 27
Birmingham, AL
Mar. 914
Indianapolis, IN
Mar. 914
Boston, MA
Mar. 914
Portland, OR
Mar. 914
Rochester, NY
Exam only
York, PA
Exam only
Miami, FL
Mar. 2328
Chicago, IL
Mar. 2328
Springfield, MO
Mar. 2328
Dallas, TX
Mar. 2328
Minneapolis, MN
Mar. 30Apr. 4
Las Vegas, NV
Mar. 30Apr. 4
Syracuse, NY
Mar. 30Apr. 4
San Francisco, CA
Apr. 611
New Orleans, LA
Apr. 611
Nashville, TN
Apr. 611
Corpus Christi, TX
Exam only
Miami, FL
Exam only
St. Louis, MO
Exam only
Annapolis, MD
Apr. 27May 2
Detroit, MI
Apr. 27May 2
Corpus Christi, TX
Apr. 27May 2
Fresno, CA
May 49
Miami, FL
May 49
Albuquerque, NM
May 49
Oklahoma City, OK
May 49
Corpus Christi, TX
Exam only
Birmingham, AL
June 16
Hutchinson, KS
June 16
Spokane, WA
June 16
Bakersfield, CA
June 813
Pittsburgh, PA
June 813
Beaumont, TX
June 813
Miami, FL
Exam only
Certification Seminars, Code Clinics, and Examinations

EXAM DATE
Jan. 11
Jan. 16
Jan. 18
Jan. 25
Feb. 1
Feb. 1
Feb. 1
Feb. 1
Feb. 15
Feb. 15
Feb. 15
Mar. 1
Mar. 1
Mar. 8
Mar. 8
Mar. 8
Mar. 8
Mar. 8
Mar. 15
Mar. 15
Mar. 15
Mar. 15
Mar. 22
Mar. 22
Mar. 29
Mar. 29
Mar. 29
Mar. 29
Apr. 5
Apr. 5
Apr. 5
Apr. 12
Apr. 12
Apr. 12
Apr. 12
Apr. 17
Apr. 19
May 3
May 3
May 3
May 10
May 10
May 10
May 10
May 31
June 7
June 7
June 7
June 14
June 14
June 14
June 19
Certified Welding Educator (CWE)

Seminar and exam are given at all sites listed under Certified
Welding Inspector. Seminar attendees will not attend the Code
Clinic portion of the seminar (usually the first two days).
Certified Welding Sales Representative (CWSR)

CWSR exams will be given at CWI exam sites.
Certified Welding Supervisor (CWS)
LOCATION
SEMINAR DATES
Atlanta, GA
Jan. 610
New Orleans, LA
Mar. 31Apr. 4
Minneapolis, MN
July 1418
Miami, FL
Sept. 1519
Norfolk, VA
Oct. 1317
CWS exams are also given at all CWI exam sites.
EXAM DATE
Jan. 11
Apr. 5
July 19
Sept. 20
Oct. 18
9-Year Recertification Seminar for CWI/SCWI

(No exams given.)
For current CWIs and SCWIs needing to meet education requirements without taking the exam. The exam can be taken at any site
listed under Certified Welding Inspector.
LOCATION
SEMINAR DATES
New Orleans, LA
Jan. 510
Denver, CO
Feb. 914
Dallas, TX
Mar. 914
Miami, FL
Mar. 2328
Sacramento, CA
Apr. 27May 2
Boston, MA
Apr. 27May 2
Charlotte, NC
May 49
Pittsburgh, PA
June 16
Certified Radiographic Interpreter (CRI)
LOCATION
SEMINAR DATES
EXAM DATE
Seattle, WA
Feb. 2428
Mar. 1
Houston, TX
Mar. 31Apr. 4
Apr. 5
Las Vegas, NV
May 59
May 10
The CRI certification can be a stand-alone credential or can
exempt you from your next 9-Year Recertification.
Certified Robotic Arc Welding (CRAW)
The seminar dates (S:) are followed by the exam dates (E:)
S: Feb. 1013, E: Feb. 14; S: July 2831, E: Aug. 1; at
ABB, Inc., Auburn Hills, MI; (248) 3918421
S: Feb. 2426, E: Feb. 27, 28; S: Apr. 2123, E: Apr. 24, 25;
S: Oct. 2022, E: Oct. 23, 24 at:
OTC Daihen, Inc., Tipp City, OH; (937) 667-0800
S: Mar. 35, E: Mar. 6; S: Oct. 2022, E: Oct. 23; at
Lincoln Electric Co., Cleveland, OH; (216) 383-8542
S: Feb. 1720, E: Feb. 21; S: Apr. 710, E: Apr. 11;
S: Aug. 1114, E: Aug. 15; S: Oct. 1316, E: Oct. 17; at
Genesis-Systems Group, Davenport, IA; (563) 445-5688
S: Jan. 2022, E: Jan. 23, 24; S: Mar. 1719, E: Mar. 20, 21
S: May 1921, E: May 22, 23; S: July 2123, E: July 24, 25;
S: Sept. 2224, E: Sept. 25, 26; S: Nov. 1719, E: Nov. 20, 21; at
Wolf Robotics, Fort Collins, CO; (970) 225-7736
On request at
MATC, Milwaukee, WI; (414) 297-6996
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the seminar/exam or
exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website
www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept. to confirm your course status before making
travel plans. For information on AWS seminars and certification programs, or to register online, visit www.aws.org/certification or call (800/305)
443-9353, ext. 273, for Certification; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.
46
DECEMBER 2013
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Society News December_Layout 1 11/14/13 8:46 AM Page 49
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
The American Welding Society

Has Gone Social
BY ROQUE CORONA
Over the last year, the American Welding Societys presence across the social
media landscape has grown tremendously.
It started with just a few hundred Facebook
fans at the beginning of last year, and since
then has expanded to include tens of thousands of followers across multiple channels. Right now, the Society has a presence
on the following eight media, and you are
urged to check all of them out.
Facebook
Twitter
YouTube
Instagram
Tumblr
LinkedIn
Official Blog
Google+
The Society has joined the long list of

entities in the welding industry that have
made social media a priority in their efforts
to connect with customers and help bring
awareness to the welding industry. These
media pages offer visitors opportunities to
find answers to questions and engage in
conversations with peers on many topics.
The Societys social media presence offers visitors up-to-date news about the Society and the ability to share ideas with fellow welders, learn new things, and even
have some fun.
For example, the AWS Facebook page
presents polls every Tuesday to offer visitors
the opportunity to chime-in on topics like
describing their biggest welding milestone
or how they were inspired to get into the
welding industry. On Wednesdays, this page
features the Welding Wonder Wednesday
series that profiles interesting structures
made possible by welding. Every Monday,
visitors have a chance to be selected as the
Welder in the Spotlight by sending in a
photo showing them on the job.
In addition, the AWS Facebook page offers news about membership promotions,
conferences, contests, and giveaways. Currently, the page offers a free American
Welding Society membership to the person
submitting the winning entry in the photo
contest.
The AWS Google+ Community offers
a page to chat with fellow welders about
your projects and to offer and receive practical advice. Its a place where visitors can
even show off their favorite welds. Think
of this page as a club for welders.
The Instagram page offers behind-thescenes views of many welding-related pages
including the American Welding Societys
World Headquarters in Miami, Fla., and
the Careers in Welding Trailer.
The Societys YouTube channel currently offers 12 videos covering topics from
robotic welding to career opportunities for
women. One of these videos features a
guest appearance by late-night talk show
host Jay Leno.
In the near future, the Society plans to
host Google+ Hangouts that will give visitors the opportunity to join a live chat with
Society staff members. For example, it will
be possible to speak directly to a Certification Department representative to get detailed answers to questions about the certification process, or join a Hangout with
AWS President Nancy Cole to ask her questions about her experiences during her year
as president.
These descriptions are just the tip of the
iceberg of what is currently available and
coming soon across the American Welding
Societys social media presence.
The Societys online exposure is everevolving in an effort to provide interesting
social media pages where its members and
customers can meet in a global conversation about their industry.
The AWS Tumblr page has many interesting

photos including this cover of the first issue of
what became the Welding Journal. It also includes a link to download the PDF of the entire 62-page document.
ROQUE CORONA (rcorona@aws.org) is digital content manager, Marketing Dept., American Welding Society, Miami, Fla.
WELDING JOURNAL
49
Tech Topics
C4 Committee Meets at AWS World Headquarters
Shown (from left) are C4 Committee Vice Chair Duane Overvaag, Chair Mike Hogan, Jim
Papritan, Ben Johnson, A. Ted Sheppard, John Henderson, and Secretary Chelsea Lewis. The
C4 Committee on Oxyfuel Gas Welding and Cutting met Oct. 24 and 25, at AWS World Headquarters in Miami, Fla.
Errata
A5.16/A5.16M:2013
(ISO 24034-2010 MOD)
Specification for Titanium and TitaniumAlloy Welding Electrodes and Rods
The following errata have been identified and will be incorporated into the next
reprinting of this document.
Page 10, Table B.1:
Correct: Ti 6114 to Ti 6414
Amendment Notices
All Amendments may be viewed and
downloaded from the AWS Web site. Visit
www.aws.org/w/a/technical/amendments.
D14.3/D14.3M:2010-AMD1, Railroad
Welding Specification for Cars and Locomotives. The Amendment reflects numerical changes made to a group of prequalified weld joints within Annex A as well as
minor AWS document title updates, and
clause and table references within the
body of the document.
D15.1/D15.1M:2012, Railroad Welding
Specification for Cars and Locomotives.
The Amendment details revisions to Tables 10.1, 10.5, 11.3, and an errata list.
New Standards Projects
Development work has begun to revise
the following four standards. Affected individuals are invited to contribute to their
development. For information, e-mail the
Staff Secretary listed with the document.
D3.6M:201X, Underwater Welding
Code, covers the requirements for welding structures or components underwater
in both wet and dry environments. Stakeholders: Underwater welding industry associates. B. McGrath, bmcgrath@aws.org.
D16.1M/D16.1:201X, Specification for
50
DECEMBER 2013
Robotic Arc Welding Safety, sets safety requirements for the design, manufacture,
setup, maintenance, and operation of arc
welding robotic systems and ancillary
equipment. Stakeholders: Manufacturers. C. Lewis, clewis@aws.org.
D16.2M/D16.2:201X, Guide for Components of Robotic and Automatic Arc
Welding Installations, provides recommendations for evaluating components of a
typical robotic or automatic welding installation, with emphasis on the role of the
welding interface. A pin arrangement and
specific pin function for each location in
a standardized 37-pin connector are proposed. Stakeholders: Users of arc welding
robots. C. Lewis, clewis@aws.org.
D16.3M/D16.3:201X, Risk Assessment
Guide for Robotic Arc Welding, provides
guidelines for the safe application of robotic arc welding. Stakeholders: Any industry using robots for arc welding operations. C. Lewis, clewis@aws.org.
Standard Approved by ANSI
D15.1/D15.1M:2012-AMD1, Railroad
Welding Specification for Cars and Locomotives. Approved 8/30/13.
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute
(ANSI) in 1979. AWS rules, as approved
by ANSI, require that all standards be
open to public review for comment during the approval process. The amendment
standard listed above was approved by
ANSI effective on the date shown.
ISO Standards for Public Review
ISO/DIS 15614-7, Specification and
qualification of welding procedures for
metallic materials Welding procedure test
Part 7: Overlay welding
ISO/DIS 18278-1, Resistance welding
Weldability Part 1: Assessment of weld-
ability for resistance spot, seam and projection welding of metallic materials
Copies of these standards are available
for review and comment through your national standards body, which in the United
States is ANSI, 25 W. 43rd St., 4th Fl., New
York, NY, 10036; (212) 642-4900.
In the United States, if you wish to participate in the development of International
Standards for welding, contact A. Davis at
adavis@aws.org.
Standards for Public Review
A5.24/A5.24M:20XX, Specification for
Zirconium and Zirconium-Alloy Welding
Electrodes and Rods. $30.
G2.4/G2.4M 20XX, Guide for the Fusion
Welding of Titanium and Titanium Alloys.
$32.00.
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute
(ANSI) in 1979. AWS rules, as approved by
ANSI, require that all standards be open to
public review for comment during the approval process. The reviews for the above
two revised standards will expire Dec. 9.
Draft copies may be ordered from A. Diaz,
adiaz@aws.org.
Technical Committee Meetings
All AWS technical committee meetings
are open to the public. Persons wishing to
attend a meeting should e-mail the program
manager listed.
Dec. 4, 5, Safety and Health Committee. Miami, Fla. Contact S. Hedrick,
steveh@aws.org.
Jan. 29, 30, Technical Activities Committee. Miami, Fla. Contact A. Alonso,
aalonso@aws.org.
Jan. 29, 30, International Standards Activities Committee. Miami, Fla. Contact A.
Davis, adavis@aws.org.
Nominations Sought for MIT

Koichi Masubuchi Award
The Prof. Koichi Masubuchi Award is
presented each year to one person, 40
years old or younger, who has made significant contributions to the advancement of materials joining through research and development. E-mail your
nomination to Todd A. Palmer, assistant
professor, The Pennsylvania State University, tap103@psu.edu. Include candidates experience, list of publications,
honors, awards, and at least three letters
of recommendation from fellow researchers. The award, including a $5000
honorarium, is sponsored by the Massachusetts Institute of Technology Dept. of
Ocean Engineering.
Opportunities to Serve on AWS Technical Committees
Volunteers are sought to contribute to the following technical committees. Visit www.aws.org/technical/jointechcomm.html.
Methods of Weld Inspection, The B1
Committee seeks educators, general interest, and end users. E. Abrams,
eabrams@aws.org.
Safety and Health Committee seeks educators, users, general interest, and consultants. S. Hedrick, steveh@aws.org.
Oxyfuel gas welding and cutting, C4
Committee seeks educators, general interest, and end users. C. Lewis,
clewis@aws.org.
Friction welding, C6 Committee seeks
professionals. C. Lewis, clewis@aws.org.
High energy beam welding and cutting,
C7 Committee seeks professionals. C.
Lewis, clewis@aws.org.
Magnesium alloy filler metals, A5L
Subcommittee seeks professionals. R.
Gupta, gupta@aws.org.
Robotic and automatic welding, D16

Committee seeks general interest and educational members. B. McGrath, bmcgrath@aws.org.
Local heat treating of pipe, D10P Subcommittee seeks professionals. B. McGrath, bmcgrath@aws.org.
Mechanical testing of welds, B4 Committee seeks professionals. B. McGrath,
bmcgrath@aws.org.
Reactive Alloys, G2D Subcommittee
seeks volunteers. A. Diaz, adiaz@aws.org.
Titanium and zirconium filler metals,
A5K Subcommittee seeks professionals. A.
Diaz, adiaz@aws.org.
Welding qualifications, B2B Subcommittee seeks members. A. Diaz,
adiaz@aws.org.
Friction stir welding of aluminum alloys for aerospace applications, D17J Subcommittee seeks members. A. Diaz,
adiaz@aws.org.
Resistance welding equipment, J1 Committee seeks educators, general interest,
and users. E. Abrams, eabrams@aws.org.
Thermal spraying and automotive welding, The D8 and C2 Committees seek educators, general interest, and end users. E.
Abrams, eabrams@aws.org.
Machinery and equipment and Surfacing and reconditioning of industrial mill
rolls, D14 Committee and D14H Subcommittee seek professionals. E. Abrams,
eabrams@aws.org.
Membership Committee Members Meet at AWS Headquarters

AWS Membership Committee members
met Oct. 22 at AWS World Headquarters in
Miami, Fla. Shown enjoying lunch at a local
eatery are, clockwise from left, AWS Executive Director Ray Shook, Dist. 1 Director Tom
Ferri, Director-at-Large Dale Flood, Dist. 9
Director George Fairbanks, Senior Associate Executive Director Cassie Burrell, Director Member Services Rhenda Kenny, AWS
Past President Lee Kvidahl, Jim Appledorn,
and Dist. 22 Director Nanette Saminich.
Committee member David Trees, who took
this photo, also was presented his Silver
Member Certificate for 25 years of service to
the Society.
Finance Committee Members Convene in Islamorada

Following a Finance Committee meeting
in Islamorada, several of the volunteers enjoyed a fishing outing. Shown with their
catch after a successful venture on the high
seas are (from left) Leon Cole, Cary Chen,
AWS Treasurer and Finance Committee
Chair Bob Pali, Mark Elender, and Mike
Molinini.
Dist. 18 Awards Presented

John Bray, Dist. 18 Director, has nominated Weldinghouse, Corpus Christi Section, and Coastal Welding Supply, Sabine
Section, to receive this award.
The District Director Award provides
a means for District directors to recognize
corporations and individuals who have
contributed their time and effort to the affairs of a local Section and/or District.
WELDING JOURNAL
51
New AWS Supporters

Sustaining Member Companies
DIS-TRAN Steel, LLC.
529 Cenla Dr.
Pineville, LA 71360
Representative: Thomas S. Malo
www.distran.com
Crimmins Welding & Fabrication, Inc.

2125 Lainson Ave.
Fort Dodge, IA 50501
Eastern Iowa C. C. District

306 W. River Dr.
Davenport, IA 52801
Delta Stress
PO Box 874, Kenosha, WI 53141
EFS WEST
28472 Constellation Rd.
Valencia, CA 91355
Representative: John Neilan
www.efswest.com
DLT Manufacturing
4081 Shilling Way, Dallas, TX 75237
Industrial Training
Calle de Leibnitz #11, Despacho 204
Colonia Anzures, Delegacin
Miguel Hidalgo, DF 11590, Mexico
Midland Cogeneration Venture

100 Progress Pl.
Midland, MI 48640
Representative: Douglas W. Kee
www.midcogen.com
Quality Mechanicals, Inc.
1225 Streng St.
Cincinnati, OH 45223
Representative: Richard J. Doll
www.qualitymechanicals.com
Supporting Companies
Global Pipe Co.
Lot 2, Block 11, Section - K,
Secondary Industrial Park
Jubail 1, Eastren 31961
Saudi Arabia
Industrial Mechanical, Inc.
1241 Greensboro Hwy.
PO Box 537, Watkinsville, GA 30677
Affiliate Companies
Abasco Inc.
5225 Southwestern Blvd.
Hamburg, NY 14075
Fab Tech, Inc.

12 N. 25th St., Van Buren, AR 72956
KMA Manufacturing, LLC
101 Parliament Dr.
Moon Township, PA 15108
Kinkisharyo
20 Caven Point Ave.
Jersey City, NJ 07305
S & S Metal Fabrication
981 6th Ave. Dr., Kingsburg, CA 93631
Steel Clad, Inc.
27 Sulphur Springs Rd.
Greenville, SC 29671
Steves Welding Service
158 Shaw Rd., Bernardston, MA 01337
Educational Institutions
Bakersfield H. S.
1201 Hwy. O, PO Box 38
Bakersfield, MO 65609
Caddo Mills H. S.
2710 Gilmer St., Caddo Mills, TX 75135
Arkana
9737 NW 41 St., Ste. #242
Doral, FL 33178
Corporacion BGA-Tech, C.A.

Calle 23 Sur, Sector Pueblo Nuevo CC
Rui Oficina 15 Planta Alta
El Tigre, Anzoategui 6050, Venezuela
B & C Metal Works

7600 S. Santa Fe Dr., Bldg. I
Houston, TX 77061
Dobson H. S.
1501 W. Guadalupe Rd.
Mesa, AZ 85202
Louisiana Delta C. C.
West Monroe Campus
609 Vocational Pkwy.
West Monroe, LA 71292
Marine Infra School of NDT & Welding
Marine Mansion, #23-23-12,
Sivalayam Temple, Opp: Ore Berth
Main Gate, Beach, Visakapatnam,
Andhra Pradesh 530001, India
Mesa H. S.
1630 E. Southern Ave., Mesa, AZ 85204
Mountain View H. S.
2700 E. Brown Rd., Mesa, AZ 85213
NCK Tech
PO Box 507, 3033 US Hwy. 24
Beloit, KS 67420
New Boston ISD
1 W. Lion Dr., New Boston, TX 75570
Pewitt H.S.
1216 Hwy. 67 W., Omaha, TX 75571
Seneca Valley School District
126 Seneca School Rd.
Harmony, PA 16037
Summit College
965 S. Mt. Vernon, Colton, CA 92324
UDSS University
18501 Pines Blvd., Ste. 300
Pembroke Pines, FL 33029
Member-Get-A-Member Campaign
Listed are the members participating
in the June 1Dec. 31, 2013 campaign.
Members receive 5 points for each Indi-
vidual and 1 point for each Student Member recruited. Standings as of Oct. 21. See
page 65 of this Welding Journal for cam-
20+ Points
J. Compton, San Fernando Valley 85
J. Morris, Mobile 75
M. Box, Mobile 42
B. Scherer, Cincinnati 40
K. Rawlin, Columbia 31
M. Pelegrino, Chicago 30
S. Siviski, Maine 29
B. Trankler, West Tennessee 27
R. Richwine, Indiana 25
D. Wheeler, Oklahoma City 25
D. Saunders, Lakeshore 22
F. Babish, Lehigh Valley 20
52
DECEMBER 2013
1519 Points
Joseph Vincent, Kansas City 18
Paul Kreitman, Chicago 15
S. Schulte, Kansas City 15
J. Terry, Greater Huntsville 15
1014 Points
Rodney Riggs, Tulsa 14
paign rules and prize list or visit

www.aws.org/mgm. Call (800) 443-9353,
ext. 480, for more information.
J. Goodson, New Orleans 12
C. Becker, Cleveland 10
D. Hughes, Mahoning Valley 10
A. Kinsler, Arizona 10
C. Layton, Central Arkansas 10
J. Livesay, Nashville 10
J. Lopez, Kansas City 10
D. Nance, Iowa 10
K. Villarreal, Houston 10
K. Williams, Johnstown-Altoona 10
SECTIONNEWS
Shown during the Long Island Section tour are (from left) Guide Ed Scottie, Jesse Provler, Ray OLeary, Chair Brian Cassidy, Alex Duchere,
Gene Sanquini, Tom Gartland, and Harland Thompson, Dist. 2 director.
District 1
Thomas Ferri, director

(508) 527-1884
thomas_ferri@victortechnologies.com
District 2
Harland W. Thompson, director

(631) 546-2903
harland.w.thompson@us.ul.com
NEW JERSEY
OCTOBER 15
Speaker: Louis Thomas, account manager
Affiliation: ITW Welding, North America
Topic: Weld fume extraction
Activity: The program was held at Pantagis
in Fanwood, N.J.
LONG ISLAND
OCTOBER 16
Activity: The Section members toured
Sulzer Metco in Westbury, N.Y. Ed Scottie, manufacturing manager, conducted
the tour and described its thermal spraying, thin film coatings, and various surfaceenhancement services.
NEW YORK/PHILADELPHIA
SEPTEMBER 21, 22
Activity: The Sections participated at the
World Maker Faire in New York City. Attending were Dist. 2 Director Harland
Shown at the Careers in Welding Trailer at the World Maker Faire are (from left) Julie Nuccio; Harland Thompson, Dist. 2 director; Ouidad Kadri; and Ken Temme.
Thompson, Julie Nuccio, Ouidad Kadri,
Ken Temme, Mike Chomin, John X. Retrepo, David Ennis, Kendrick Cumberbatch, Bo Chan, Liliana Melo, and Jonny
Olarte.
AWS Member Counts

November 1, 2013
Sustaining ......................................603
Supporting .....................................345
Educational ...................................650
Affiliate..........................................537
Welding Distributor........................51
Total Corporate ..........................2,186
Individual .................................59,283
Student + Transitional .................9,162
Total Members .........................68,445
Speaker Louis Thomas (right) is shown with

Paul Lenox, New Jersey Section chair.
WELDING JOURNAL
53
Shown at the World Maker Faire are from left (front) Mike Chomin and John X. Retrepo,
and (back) David Ennis, Kendrick Cumberbatch, Bo Chan, Liliana Melo, Jonny Olarte,
and Harland Thompson, Dist. 2 director.
Shown at the SW Virginia Section weld off

are Taylor Reed (left) and David Owens.
PHILADELPHIA
SEPTEMBER 18
Speakers: Robert Bubb, executive director; Dave Poli, director of education
Affiliation: All-State Career Center
Topic: The need for welders to make critical infrastructure repairs
Activity: The event was held at the school
in Lester, Pa.
District 3
Long Island Section members are, from left, Jesse Provler, Tom Gartland, Alex Duschere,
Ray OLeary, Chair Brian Cassidy, Joe Kass, and Dist. 2 Director Harland Thompson.
Michael Wiswesser, director

(610) 820-9551
mike@wtti.com
READING
SEPTEMBER 11
Speaker: David Watson, sales engineer
Affiliation: The Lincoln Electric Co.
Topic: Mobile apps for manufacturing
Activity: Merilyn McLaughlin was cited
for her accomplishments as 2013 contest
chair. Watson was presented a certificate
of appreciation for contributing consumables for the Sections welding contests.
The event was held at Lebanon County Career & Technology Center in Lebanon, Pa.
Speaker Robert Bubb (left) is shown with
Bill Mowbray, Philadelphia Section chair.
Shown are Reading Section Chair Richard

Heisey (left), speaker David Watson, and
Merilyn McLaughlin.
OCTOBER 10
Activity: The Reading Section members
toured Reading Alloys, an AMETEK
Company, in Robesonia, Pa. Russ Relkin,
manufacturing manager, powder products,
made a presentation and guided the tour.
District 4
Stewart A. Harris, director

(919) 824-0520
stewart.harris@altec.com
SOUTHWEST VIRGINIA
Shown at the October Reading Section meeting are (from left) John Tobias, Jerry Cross,
Bob Wampler, Dave Hibshman, Merilyn McLaughlin, Tracy Davenport, tour guide Russ
Relkin, and Keeley Morris.
54
DECEMBER 2013
SEPTEMBER 25
Activity: The Section held a weld off at
Burton Technologies in Roanoke, Va.,
hosted by Chris Overfelt. The top contender was Taylor Reed from Burton Tech-
The participants in the Southwest Virginia Section weld off posed for a group shot.
Justin Stacey (left) receives a speaker award

from Carl Matricardi, Dist. 5 director, at the
Atlanta Section program.
Hostess Vickie Moody and Carl Matricardi,

Dist. 5 director, are shown at the Atlanta Section event.
Speaker Bill Hodges is shown with Robyn

Westphal, Columbia Section chair.
Dave Schaffer (right) is shown with Larry

Hidde, Northern New York Section chair.
Jesse Steffan (left) is shown with Fred

Schmidt, Niagara Frontier Section chair.
District 6
NORTHERN NEW YORK
nologies. The judges were Teddy Green

from Freight Car America, David Owens
from Altec Industries, and Mark Gilbert
from New River Community College.
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
ATLANTA
SEPTEMBER 19
Activity: The Section held a skeet shooting outing at Tom Lowe Shooting
Grounds.
OCTOBER 17
Speaker: Justin Stacey
Affiliation: Baja Racing Team
Topic: Failures in race car frames
Activity: Vickie Moody hosted this event
at Southern Polytechnic State University.
COLUMBIA
SEPTEMBER 18
Speaker: Bill Hodges, sales manager
Affiliation: Burny Kaliburn
Topic: Plasma cutting systems
Activity: The meeting was held at Lexington Career Center in Lexington, S.C.
Kenneth Phy, director

(315) 218-5297
kenneth.phy@gmail.com
NIAGARA FRONTIER
SEPTEMBER 26
Activity: The Section members visited
Race Visions Reborn shop to see demonstrations of welding used to make drag motorcycles. The presenters included Jesse
Steffan, Gordy Welfare, and Dave Zobel.
OCTOBER 1
Speaker: Dave Schaffer, welding process
specialist
Affiliation: Airgas
Topic: Gas tungsten arc welding aluminum
Activity: The program was held at Shaker
Ridge Country Club in Latham, N.Y.
District 7
Uwe Aschemeier, director

(786) 473-9540
uwe@miamidiver.com
WELDING JOURNAL
55
Shown at the Nashville Section tour are (from left) Billy Davis, Scott Bradley, David Porter, Mark Hartmann, Clif Coleman, Bob Williams,
Steve Jefsen, Sean Koontz, and Marion Brown.
Northeast Tennessee members and guests are shown at the October program.
Michael Patch (right) is shown with Thomas

Atkinson, Chattanooga Section chair.
The Birmingham Section members and guests are shown in the two photos above.
Stephen Liu (right) is shown with Roger

Miller, NE Tennessee Section vice chair.
56
DECEMBER 2013
Lawson State C. C. Student Chapter members are shown at the October event.
Shown at the Mobile Section program are (from left) Dale Box, Clint Brown, Dist. 9 Director George Fairbanks, Chair Michael Zoghby,
Philip Goudreault, and Mark Logan Murphy.
Shown at the Drake Well Section event are from left (front row) Mike Young, Travis Crate, and Robert Fugate, (middle row) Rolf Laemmer,
Dist. 10 director Bob Brenner, Carol Miller, Erik Speer, and Tom Kostreba, (back row) Ward Kiser, Mike Owens, and Jordan Thompson.
District 8
District 9
CHATTANOOGA
BIRMINGHAM/
Lawson State C. C.
Student Chapter
Joe Livesay, director

(931) 484-7502, ext. 143
joe.livesay@ttcc.edu
OCTOBER 17
Speaker: Michael Patch, project manager
Affiliation: Westinghouse BWR Service
Center, Chattanooga, Tenn.
Topic: Service-induced weld defects in nuclear power plants
Activity: The program was held at Alstom
Power in Chattanooga, Tenn.
NASHVILLE
SEPTEMBER 12
Activity: The Section toured Mid-South
Metallurgical in Murfreesboro, Tenn., to
study its heat treating operations. The presenters were Owner Clif Coleman and
Plant Superintendent Steve Jefsen.
NORTHEAST TENNESSEE
OCTOBER 3
Speaker: Stephen Liu, professor
Affiliation: Colorado School of Mines
Topic: Low transformation temperature
welding consumables
Activity: The event was held at Lakeside
Restaurant in Knoxville, Tenn.
George Fairbanks Jr., director

(225) 473-6362
fits@bellsouth.net
OCTOBER 8
Activity: The Section and Student Chapter members visited Oxylance Corp. for
demonstrations of its bore repair and welding equipment. The presenters were Greg
Cain and Frank Neeley. George Fairbanks,
Dist. 9 director, 39 members, and 21 students attended the event.
MOBILE
SEPTEMBER 12
Speaker: David Hernandez, director, education development
Affiliation: AWS Headquarters, staff
Topic: Educational programs
Activity: The program was held at The
Original Oyster House in Spanish Fort,
Ala., for 74 attendees.
District 10
Robert E. Brenner, director

(330) 484-3650
bobren28@yahoo.com
Keith Lloyd spoke at the Detroit Section tour.
DRAKE WELL
OCTOBER 10
Activity: The Section held a social event
at The Commons at Franklin in Franklin,
Pa. Bob Brenner, Dist. 10 director, spoke
on OSHA safety regulations, and Erik
Speer made a presentation on the history
of the American Welding Society and the
benefits of membership.
District 11
Robert P. Wilcox, director
(734) 721-8272
rmwilcox@wowway.com
DETROIT
OCTOBER 10
Speaker: Keith Lloyd, training specialist
Affiliation: ABB Robotics and Section certification chair
Topic: The AWS Certified Robotic Arc
WELDING JOURNAL
57
Ferris State University Student Chapter members are shown during their Adopt-A-Highway community service.
Elizabeth Rolston, representing the Ferris State University S.C., presents a check and food
donations to Robert Beaverson representing Our Brothers Keeper Shelter.
The Blackhawk Technical College S.C. members take a break while hauling in scrap metal to raise funds for needy seniors.
Welding (CRAW) program
Activity: Following the talk, the Detroit
Section attendees toured the ABB Robotics Auburn Hills, Mich., facility to study its
operations.
Ferris State University

Student Chapter
Speaker Tony Anderson (left) is shown with

Brian Strebe, Lakeshore Section vice chair.
SEPTEMBER 26
Activity: Continuing its eight-year AdoptA-Highway tradition, 17 students and
three faculty members removed debris
from a two-mile stretch of M-20 highway
in Stanwood, Mich., headed by Jeffrey
Carney, advisor.
SEPTEMBER 27
Activity: The Ferris State University hapter members collected and delivered more
than 240 food items plus a check for $250
to Robert Beaverson of Our Brothers
Keeper Shelter in Big Rapids, Mich. The
food and cash were donated by welding
students and faculty.
Speaker Stuart Kleven (left) is shown with

Pete Host at the joint Chicago Section and
ASNT meeting.
58
DECEMBER 2013
District 12
Daniel J. Roland, director

(715) 735-9341, ext. 6421
daniel.roland@us.fincantieri.com
Blackhawk Technical
College
Student Chapter
SEPTEMBER 28
Activity: The Chapter members participated in a metals drive to raise funds to
help low-income seniors in Rock County
get an air-conditioner. The activity was
headed by Advisor Dan Crifase, chairman
of the Racine-Kenosha Section.
LAKESHORE
OCTOBER 10
Speaker: Tony Anderson, director of aluminum technology
Affiliation: ITW Welding North America
Topic: MAXAL aluminum wires
Activity: The event was held at Machuts
Supper Club in Two Rivers, Wis.
MADISON-BELOIT
SEPTEMBER 13
Activity: The Section toured Truax Field,
home of the 115th Air National Guard in
Madison, Wis. Lt. Stephen Montgomery
conducted the program with Steve
Dempsey and Thomas Donnan showing
the fire department. Sgt. Tim Walter led
the tour of the Metals Shop, and Sgt. Andrew Brickl discussed the F15 aircraft.
The Madison-Beloit Section members are shown during their visit to Truax Field.
Chicago Section and ASNT Chapter members are shown at the October 16 program.
Shown at the Chicago board meeting are from left (standing) Pete Host and Cliff Iftimie
and (seated) Jeff Stanczak, Chair Eric Krauss, Bob Zimny, and Eric Purke.
District 13
District 14
CHICAGO
INDIANA
John Willard, director

(815) 954-4838
kustom_bilt@msn.com
OCTOBER 12
Activity: The Section held its board meeting at Hackneys in Palos Park, Ill. Attending were Chair Eric Krauss, Jeff Stanczak,
Bob Zimny, Eric Purke, Pete Host, and
Cliff Iftimie.
OCTOBER 16
Speaker: Stuart Kleven
Topic: New inspection methodology for industry
Activity: The Chicago Section met with
members of the local chapter of ASNT at
Bohemian Crystal Restaurant in Westmont, Ill.
Shown at the Indiana Section September

meeting are AWS Past President Dick Alley
(left) with Chair Bennie Flynn.
Robert L. Richwine, director

(765) 378-5378
bobrichwine@aol.com
SEPTEMBER 26
Activity: The Section held its annual planning meeting for the District, state, MidWest Team Welding Tournament, and professional welding competition in Chicago.
Attending were past AWS President Dick
Alley, Dist. 14 Director Bob Richwine,
Chair Bennie Flynn, Gary Dugger, Gary
Tucker, and Eric Cooper.
OCTOBER 11
Activity: Dist. 14 Director Bob Richwine
and Frank Blanchard, Ivy Tech C. C. program chair, presented Levi Crusmire the
Student Chapter Member Award for his
Levi Crusmire (center) receives the Student

Chapter Member Award from Dist. 14 Director Bob Richwine (left), and Frank Blanchard, Ivy Tech C. C. program chair.
outstanding academic and community
service achievements. Richwine is also advisor for the Student Chapter.
WELDING JOURNAL
59
The Nebraska Section members are shown at Metropolitan Community College in September.
Attendees are shown at the Louisville Section program.
Louisville Section Chair Bud Merrill (left)

is shown with presenter Ben Coons.
coln Electric VRTEX 360 virtual arc welding trainer. A welding contest using the
machine followed with the winner receiving a welding helmet.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
The Oklahoma City Section first-place sporting clay shooters are (from left) Mike Cook,
Dave Cook, Tony Hackney, Joe Hackney, and Shane Downs.
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
NEBRASKA
Guides (from left) John Kurek, Don Bough,

and Dwayne Harty led the Indiana Section
on a tour of the Local 440 Training Center.
Top sharp shooter Roger Hobrock (left) is

congratulated by Cary Reeves, Oklahoma
City Section chair.
OCTOBER 15
Activity: The Indiana Section and Ivy Tech
Student Chapter toured Plumbers &
Steamfitters Local 440 Training Center in
Indianapolis, Ind. John Kurek, Don
Bough, and Dwayne Harty led the tour.
Shown at the Oklahoma Technical College

Student Chapter program are (from left)
speaker Paul Wittenbach, Advisor Charles
Griffin, Instructor Rodney Riggs, and Chair
Heather Nance.
60
DECEMBER 2013
LOUISVILLE
SEPTEMBER 26
Activity: The Section members visited Jefferson Community and Technical College
in Louisville, Ky., for a presentation by Ben
Coons, sales manager, on use of the Lin-
SEPTEMBER 26
Activity: The Section members met at Metropolitan C. C. in Omaha, Neb., for a program on methods for extracting welding
fume presented by Mike Ellis.
District 17
J. Jones, director
(832) 506-5986
jjones6@lincolnelectric.com
OKLAHOMA CITY
OCTOBER 18
Activity: The Section hosted a clay-buster
event at Silverleaf Shotgun Sports in
Guthrie, Okla. Roger Hobrock scored
highest. The first-place team was Mike
Cook, Dave Cook, Tony Hackney, Joe
Hackney, and Shane Downs.
Tulsa Section CWI seminar attendees are shown Sept. 19 at Tulsa Technology Center in Tulsa, Okla.
Houston Section Chair Derek Stelly (left) is

shown with speaker Juvenal Calvo.
Shown at the Tulsa Section Sept. 24 program are (from left) Vice Chair Rich Howard,
speaker Barney Burks, and Jerry Knapp.
Oklahoma Technical
College
Student Chapter
SEPTEMBER 23
Speaker: Paul Wittenbach, metallurgist
Affiliation: Phillips 66, Refining and Research Dept.
Topic: Introduction to steel metallurgy
Activity: The meeting was conducted by
Advisor Charles Griffin and Chair
Heather Nance for 22 participants. Welding Instructor Rodney Riggs attended the
program. The Chapter is affiliated with the
Tulsa Section.
The top scorers in the Olympic golf tournament are (from left) Steve Wright, Joe Lynch,
Todd Hildebrand, and Lyle Proctor.
TULSA
District 18
District 19
HOUSTON
OLYMPIC
SEPTEMBER 19
Activity: The Section members conducted
a CWI preparatory class for 20 candidates.
The seminar was held at Tulsa Technology
Center in Tulsa, Okla. The facilitators were
Ray Wilsdorf and Ralph Johnson.
SEPTEMBER 24
Speaker: Barney Burks, sales engineer
Affiliation: Sowesco, Pinnacle Alloys
Topic: Maintaining welding equipment
Activity: This Tulsa Section program was
attended by 32 members and guests. Incoming Dist. 17 Director Jerry Knapp attended the meeting.
John Bray, director

(281) 997-7273
sales@affiliatedmachinery.com
OCTOBER 16
Speaker: Juvenal Calvo, process control
specialist
Affiliation: TIP TIG
Topic: The Evolution of Gas Tungsten Arc
Welding
Activity: Calvos presentation included a
demonstration of equipment using the TIP
TIG semiautomatic gas tungsten arc welding technology.
Ken Johnson, director

(425) 957-3553
kenneth.johnson@vigorshipyards.com
SEPTEMBER 8
Activity: The Section hosted its fourth annual golf outing at Northshore Golf
Course in Tacoma, Wash. The event raised
$3000 for the Sections scholarship fund,
including donations from its Gold Sponsors Airgas, ALT Welding Supplies, Central Welding Supply, CK Worldwide, Harris Products Group, Jesse Engineering,
Lincoln Electric Co., N.W. Welding and
WELDING JOURNAL
61
Olympic Section attendees pose for a group shot at the October program.
Everett C. C. Student Chapter members are (from left) Tadish Watson, Jason Speicher, Josh Anderson, John Holgren, Julie Burger, Advisor
Robert White, Robert Gonzales, Ian Frasher, and Max Hinricksen.
Raffle winners are shown at the joint Puget Sound Section/Everett C. C. Student Chapter event.
Speaker Philip Dovinh (right) is shown with

Jim Behee, Olympic Section program chair.
62
DECEMBER 2013
Don Sly (left) is shown with Ken Johnson,

Dist. 19 director, at the Puget Sound Section
program.
Shown at the Arizona section program are

(from left) Chair Brent Boling, speaker
Buddy May, and Jerry Siko, vice chair.
Sacramento Valley Section and Iron Workers Local 118 members are shown at the September program.
Gases, Praxair, and Weldors Equipment
Repair.
OCTOBER 15
Speaker: Philip Dovinh
Affiliation: Bates Technical College
Topic: Welding in confined spaces
Activity: About 30 Olympic Section members and college students attended this
program, held at Bates Technical College
in Tacoma, Wash.
PUGET SOUND/Everett C.C.

Student Chapter
OCTOBER 3
Speaker: Don Sly, marine chemist
Affiliation: Sound Testing, Inc.
Topic: Making emergency welding repairs
on marine vessels containing fuel
Activity: The program was held at Bellevue Coast Hotel in Bellevue, Wash.
Shown at the Sacramento Valley Section program are (from left) Instructor Carlos Shelton,
Publicity Chair Ken Morris, Apprenticeship Coordinator and Section Chair Jason Rafter,
and Instructors Brad Gasaway and Pat Linggi.
District 20
William A. Komlos, director

(801) 560-2353
bkoz@arctechllc.com
District 21
Nanette Samanich, director

(702) 429-5017
nan07@aol.com
District 21
ARIZONA
SEPTEMBER 10
Speaker: Buddy May, chair, SENSE and
Student Affairs Committee
Affiliation: Mohave C. C.
Shown at the L.A./Inland Empire Section program are (from left) Tim Chubbs, speaker
Ben Pletcher, and Chair George Rolla.
WELDING JOURNAL
63
Topic: How to implement the AWS

SENSE welding program in schools
Activity: This Arizona Section program
was hosted by the Maricopa Skill Center
in Phoenix, Ariz.
L.A./INLAND EMPIRE
OCTOBER 8
Speaker: Ben Pletcher
Affiliation: Select-Arc
Topic: The Secrets of Welding High-Performance Alloys
Activity: The program was held in Corona,
Calif.
Speaker Joe Langemeier (left) is shown with

Mike Zinser, San Francisco Section vice
chair.
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
SACRAMENTO VALLEY
SEPTEMBER 18
Activity: Iron Workers Local 118 hosted
this program at its Apprenticeship Training facility in Sacramento, Calif. Instructor Pat Linggi demonstrated welding following the seismic supplement to the AWS
D1.8 code. Others participating were Apprentice Coordinator and Section Chair
Jason Rafter and Instructors Carlos Shelton and Brad Gasaway, and Dist. 22 Director Kerry Shatell.
SAN FRANCISCO
OCTOBER 2
Speaker: Joe Langemeier, national marketing manager
Affiliation: AZZ, Inc., Ft. Worth, Tex.
Topic: Welding galvanized steel
Activity: Thirty-nine members and guests
attended the program, held at Spengers
Restaurant in Berkeley, Calif.
Name Your Candidates for These AWS Awards

The deadline for nominating candidates for the following awards is December 31 prior to the year of the awards presentations. Contact Wendy Sue Reeve, wreeve@aws.org; (800/305) 443-9353, ext. 293.
William Irrgang Memorial Award

This award is given to the individual who has done the
most over the past five years to enhance the Societys goal
of advancing the science and technology of welding. It includes a $2500 honorarium and a certificate.
Honorary Membership Award
This award acknowledges eminence in the welding profession, or one who is credited with exceptional accomplishments in the development of the welding art. Honorary Members have full rights of membership.
National Meritorious Certificate Award
This award recognizes the recipients counsel, loyalty,
and dedication to AWS affairs, assistance in promoting
cordial relations with industry and other organizations,

and for contributions of time and effort on behalf of the
Society.
George E. Willis Award
This award is given to an individual who promoted
the advancement of welding internationally by fostering cooperative participation in technology transfer,
standards rationalization, and promotion of industrial
goodwill. It includes a $2500 honorarium.
International Meritorious Certificate Award
This honor recognizes recipients significant contributions to the welding industry for service to the international
welding community in the broadest terms. The award consists of a certificate and a one-year AWS membership.
First Call for Papers

JOM-18
18th International Conference on Joining Materials
Institute for the Joining of Materials in association with the IIW
Helsingr, Denmark, April 2629, 2015
Download the brochure detailing topics, expenses, and registration form at:
www.aws.org/wj/JOM-18-CallForPapers.pdf
Review the brochure for conference topics. E-mail a title and short abstract of your paper before Nov. 2, 2014. You will receive
author guidelines for preparation of the full paper by Nov. 30. The full paper for publication in the Conference Proceedings must
be received by Jan. 15, 2015. E-mail to jom_aws@post10.tele.dk.
64
DECEMBER 2013
Guide to AWS Services

8669 NW 36th St., #130, Miami, FL 33166-6672
T: (800/305) 443-9353; F: (305) 443-7559
Staff phone extensions are shown in parentheses.
AWS PRESIDENT
Nancy C. Cole
nccengr@yahoo.com
NCC Engineering
2735 Robert Oliver Ave.
Fernandina Beach, FL 32034
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
INTERNATIONAL SALES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(340)

Managing Director
Technical Services Development & Systems
Andrew R. Davis.. adavis@aws.org . . . . . . .(466)
International Standards Activities, American Council of the International Institute of Welding (IIW)
PUBLICATION SERVICES
Director, Operations
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Technical Activities Committee

Managing Director
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Chief Financial Officer

Gesana Villegas.. gvillegas@aws.org . . . . . .(252)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Chief Technology Officer

Dennis Harwig..dharwig@aws.org . . . . . . . . .(213)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
Executive Assistant for Board Services

Gricelda Manalich.. gricelda@aws.org . . . . .(294)
National Sales Director

Rob Saltzstein.. salty@aws.org . . . . . . . . . . .(243)
Administrative Services
Society and News Editor

Howard Woodward..woodward@aws.org . .(244)
Managing Director
Jim Lankford.. jiml@aws.org . . . . . . . . . . . . .(214)
Director
Hidail Nuez..hidail@aws.org . . . . . . . . . . . .(287)
Welding Handbook
Editor
Annette OBrien.. aobrien@aws.org . . . . . . .(303)
Director of IT Operations
Natalia Swain..nswain@aws.org . . . . . . . . . .(245)
MARKETING COMMUNICATIONS
Human Resources
Director, Compensation and Benefits

Luisa Hernandez.. luisa@aws.org . . . . . . . . .(266)
Director, Human Resources
Dora A. Shade.. dshade@aws.org . . . . . . . . .(235)
International Institute of Welding
Director
Ross Hancock.. rhancock@aws.org . . . . . . .(226)
Public Relations Manager
Cindy Weihl..cweihl@aws.org . . . . . . . . . . . .(416)
Webmaster
Jose Salgado..jsalgado@aws.org . . . . . . . . .(456)
Senior Coordinator
Sissibeth Lopez . . sissi@aws.org . . . . . . . . .(319)
Liaison services with other national and international
societies and standards organizations.
Section Web Editor

Henry Chinea...hchinea@aws.org . . . . . . . . .(452)
GOVERNMENT LIAISON SERVICES

Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Hugh K. Webster . . . . . . . . .hwebster@wc-b.com

Webster, Chamberlain & Bean, Washington, D.C.,
(202) 785-9500; FAX (202) 835-0243. Monitors federal issues of importance to the industry.
CONVENTION and EXPOSITIONS
Director, Convention and Meeting Services

Matthew Rubin.....mrubin@aws.org . . . . . . .(239)
ITSA International Thermal

Spray Association
Senior Manager and Editor

Kathy Dusa.kathydusa@thermalspray.org . . .(232)
RWMA Resistance Welding

Manufacturing Alliance
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
Brazing and Soldering

Manufacturers Committee
Stephen Borrero..sborrero@aws.org . . . . . .(334)
GAWDA Gases and Welding

Distributors Association
Executive Director
John Ospina.. jospina@aws.org . . . . . . . . . .(462)
Operations Manager
Natasha Alexis.. nalexis@aws.org . . . . . . . . .(401)
TECHNICAL SERVICES
Managing Director, Global Exposition Sales

Joe Krall..jkrall@aws.org . . . . . . . . . . . . . . . .(297)
Corporate Director, International Sales
Jeff P. Kamentz..jkamentz@aws.org . . . . . . .(233)
Oversees international business activities involving
certification, publication, and membership.
MEMBER SERVICES
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between members and AWS headquarters.
CERTIFICATION SERVICES

Managing Director
John L. Gayler.. gayler@aws.org . . . . . . . . . .(472)
Oversees all certification activities including all international certification programs.
Director, Certification Operations
Terry Perez..tperez@aws.org . . . . . . . . . . . . .(470)
Oversees application processing, renewals, and exam
scoring.
Director, Accreditation Programs
Linda Henderson..lindah@aws.org . . . . . . .(298)
Oversees the development of new certification programs, as well as AWS-Accredited Test Facilities, and
AWS Certified Welding Fabricators.
EDUCATION SERVICES
Associate Director, Operations

Alex L. Diaz.... adiaz@aws.org . . . . . . . . . . . .(304)
Welding Qualification, Sheet Metal Welding, Aircraft and Aerospace, Joining of Metals and Alloys
Manager, Safety and Health
Stephen P. Hedrick.. steveh@aws.org . . . . . .(305)
Metric Practice, Safety and Health, Joining of Plastics and Composites, Personnel and Facilities Qualification, Mechanical Testing of Welds
Program Managers II
Stephen Borrero... sborrero@aws.org . . . . .(334)
Brazing and Soldering, Brazing Filler Metals and
Fluxes, Brazing Handbook, Soldering Handbook,
Definitions and Symbols, Structural Subcommittees on Bridge Welding, Stainless Steel, and Reinforcing Steel
Rakesh Gupta.. gupta@aws.org . . . . . . . . . .(301)
Filler Metals and Allied Materials, International
Filler Metals, UNS Numbers Assignment, Arc
Welding and Cutting Processes, Computerization
of Welding Information
Brian McGrath .... bmcgrath@aws.org . . . . .(311)
Structural Welding, Welding in Marine Construction, Piping and Tubing
Program Managers
Efram Abrams.. eabrams@aws.org . . . . . . . .(307)
Automotive, Resistance Welding, Machinery and
Equipment, Methods of Inspection
Chelsea Lewis.. clewis@aws.org . . . . . . . . . .(215)
Friction Welding, Oxyfuel Gas Welding and Cutting, High-Energy Beam Welding, Robotics Welding, Welding in Sanitary Applications
Jennifer Rosario.. jrosario@aws.org . . . . . .(308)
Railroad Welding, Thermal Spraying, Welding Iron
Castings, Welding Qualification
Note: Official interpretations of AWS standards

may be obtained only by sending a request in writing to Andrew R. Davis, managing director, Technical Services, adavis@aws.org. Oral opinions on
AWS standards may be rendered, however, oral
opinions do not constitute official or unofficial
opinions or interpretations of AWS. In addition,
oral opinions are informal and should not be used
as a substitute for an official interpretation.
AWS FOUNDATION, Inc.
www.aws.org/w/a/foundation
General Information
(800/305) 443-9353, ext. 212, vpinsky@aws.org
Chairman, Board of Trustees
Gerald D. Uttrachi
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
Executive Director, Foundation

Sam Gentry.. sgentry@aws.org. . . . . . . . . . . . . . . (331)
Director, Development and Systems

David Hernandez.. dhernandez@aws.org . . .(219)
Corporate Director, Workforce Development

Monica Pfarr.. mpfarr@aws.org. . . . . . . . . . . . . . . . (461)
AWS AWARDS, FELLOWS, COUNSELORS
Senior Manager
Wendy S. Reeve.. wreeve@aws.org . . . . . . . .(293)
Coordinates AWS awards and Fellow and Counselor nominations.
The AWS Foundation is a not-for-profit corporation

established to provide support for the educational
and scientific endeavors of the American Welding
Society. Promote the Foundations work with your financial support. For information, call Vicki Pinsky,
(800/305) 443-9353, ext. 212; e-mail vpinsky@aws.org.
WELDING JOURNAL
67
Personnel Dec._Layout 1 11/13/13 8:28 AM Page 68
PERSONNEL
Cyl-Tec Names Two VPs
Chris Colaw
Sandi Radtke
Cyl-Tec, Inc., Aurora, Ill., a supplier of

high-pressure steel, aluminum, acetylene,
and cryogenic cylinders, has named Chris
Colaw vice president of business development and Sandi Radtke vice president of
human resources. Previously, Colaw
worked for Praxair, Inc., for 13 years.
Radtke, prior to this promotion, served
more than five years as human resources
manager.
Solar Atmospheres
Appoints Sales Manager
Solar Atmospheres of Western Pennsylvania, Inc., Hermitage, Pa., a provider
of vacuum heat treating and brazing services, has named
Michael Paponetti
regional sales manager. With 18 years of
experience in the industry, Paponetti previously served as
president of Expert
Brazing and Heat
Treating, based in
Michael Paponetti Massillon, Ohio.
Camfil Names Top Official

Camfil Air Pollution Control, Jonesboro, Ark., has announced that its parent
company, Camfil (Stockholm, Sweden),

has appointed Magnus Yngen president
and CEO. He succeeds Alan OConnell
who held the post for the past 12 years.
Yngen has been a
member of the Camfil board for the past
year. Prior to joining
the company, he
worked for the Electrolux Group, responsible for its European operations,
and was later appointed CEO of the
Magnus Yngen
Husqvarna Group.
SME Elects Six to Its

College of Fellows
The Society of Manufacturing Engineers (SME), Dearborn, Mich., has
elected the following members to its 2013
Class of Fellows: M. Helmi Attia, Doug
Genord, John W. Gillespie Jr., Vincent W.
Howell Sr., Yeau-Ren Jeng, and Bert
Lauwers. Attia is with the National Research Council Canada and McGill University; Genord is chair of SMEs Product
& Process Design and Management Community; Gillespie is director, University
of Delaware Center for Composite Materials; Howell is manager, Information Security and Policy at Corning, Inc.; Jeng is
Endowed Chair Professor and executive
vice president, National Chung Cheng
University, Taiwan; and Lauwers is a professor, KU Leuven, Belgium.
Fronius Announces Area

Sales Managers
Fronius USA, LLC, Portage, Ind., a
supplier of welding technology, battery
charging systems, and solar electronics,
has named Brandon Beattie and Tim
Rowntree area sales managers for the
Northern and Southern California areas,
respectively. Beattie, an AWS CWI and
CWE, is vice chair of the Sacramento Valley Section. He previously worked as a
68
DECEMBER 2013
Brandon Beattie
Tim Rowntree
Personnel Dec._Layout 1 11/13/13 8:29 AM Page 69
Publish Your
Research in the
Member Milestone
Gerald D. Uttrachi
Gerald Uttrachi
Gerald D. Uttrachi has received international acclaim for his book, Advanced Automotive Welding, published by CarTech, Inc. His work earned the Bronze
Medal in the 22nd International Automotive Media
Award Competition, held under the auspices of the
International Council for Press and Broadcasting,
based in London, UK. Uttrachi is president of WA
Technology, chairman of the AWS Foundation board
of trustees, and a past AWS president. He said he intended the book to stimulate interest in the science of
welding and the possibility of the many young folks involved in the car hobby to consider welding as a profession. Jeff Weber, publisher emeritus, Welding Journal, wrote, The illustrations showing the step-by-step
procedures are excellent and really give a feel for what
the job requires. This book should be in the library of
every automotive enthusiast. Walter J. Sperkos extensive review of Uttrachis book appeared in the April
2013 Welding Journal. The 176-page volume contains
more than 450 pictures and offers some basic welding
metallurgy and arc physics written on a level easily understood by all welders from beginners to advanced.
Uttrachis medal
welder in the railroad industry. Rowntree

previously was a regional sales representative for Abicor Binzel USA, and earlier
owned a metal fabrication company.
SigmaTEK Fills Key Posts
Adept Technology
Names CFO
Adept Technology, Inc., Pleasanton,
Calif., a provider of intelligent robots and
autonomous mobile solutions, has named
Seth Halio CFO. Halio, with 30 years of
senior-level financial management experience, previously served as CFO at LED
Engin, Novariant, Diamond Foods, and
Spectra-Physics.
Materials Research Society

Elects Leaders
Kevin Ramirez
Steve Ties
SigmaTEK Systems, LLC, Cincinnati,

Ohio, a CAD/CAM nesting and manufacturing process automation company, has
appointed Kevin Ramirez vice president
of sales and Steve Ties regional sales manager. Ramirez previously served the company as a regional sales director for the
Latin American market. Ties will service
clients in the northern-United States region including Wisconsin, Minnesota, and
North and South Dakota. Previously, he
served as the companys regional sales
representative for the region.
Oliver Kraft
Sean Hearne
The Materials Research Society, Warrendale, Pa., has announced Oliver Kraft
will serve as vice president beginning Jan.
1 and will lead its board of directors as
continued on page 96
and Youll Get

Your research sent to more

than 68,000 American
Welding Society members
Your published paper

posted on the AWS Web
site for FREE access
worldwide
(www.aws.org/w/a/
research/index.html)
The most recent Impact

Factor of 1.00
No page charges
Your paper printed in

full color
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tracking through Editorial
Manager
(www.editorial
manager.com/wj)
Every research paper

published in the Welding
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available FREE on the
AWS Web site
(www.aws.org/wj/
supplement/supplementindex.html)
By far
far,, the most people, at the
least cost, will be exposed to
your research when you
publish in the world-respected
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elding Journal
WELDING JOURNAL
69
Campbell AW Feature December 2013_Layout 1 11/12/13 3:20 PM Page 70
THE AMERICAN WELDER
AWS Scholarships Proved

a Channel to Success
Three AWS board members share their educational
backgrounds, career highlights, and reasons why they
decided to give back to the Society whose scholarships
kick started their careers
Im sure there are many welding students out there

wondering how industry leaders got to be where they are
today. While studying and working hard were certainly fac
tors for achieving degrees and moving on up in the work
place, so were going the extra mile to contribute and ded
icate efforts to extracurricular activities.
70
DECEMBER 2013
KRISTIN CAMPBELL (kcampbell@aws.org)

is associate editor of the Welding Journal.
Presented in this article are the journeys of three

American Welding Society (AWS) board members. They
have come a long way from earning AWS college scholar
ships to achieving successful careers. They also relate how
being dedicated AWS volunteers has contributed to their
success and allowed them to help others.
J. Jones
J. Jones, Dist. 17 director
BY KRISTIN CAMPBELL
As a member of the Industrial Arts

Club in high school, J. Jones discovered
that he had a skill for building and working with equipment. Married and with a
new son, he decided to pursue the welding profession, determined to make a
good living.
I made my pickup truck into a welding rig and worked odd jobs so I could go
back to school. Most people in the welding industry at that time had no formal
education related to welding. Having the
education with the skill made me more
marketable and valuable, Jones said.
He has been an AWS member for
nearly 20 years.
Jones worked for Dawn Construction
Co., Dallas, Tex., as a construction superintendent while finishing Eastfield
College, Mesquite, Tex., in 1983 with an
associate degree in applied arts and sciences for welding technology. He went
on to hold positions for Pizza Inn, Inc.,
Dallas, Tex., as a construction superintendent/manager and Texas Instruments,
Inc., Dallas, Tex., as a welding technician.
He first learned about AWS scholar-
ship offerings at a North Texas Section

meeting. In 1995, while working as an
operations foreman for Smiths Welding
Works, Garland, Tex., he earned a North
Texas Section Scholarship for $100 followed by District 17 Scholarships for
$1000 in 1997 and $2500 in 1998. The
assistance provided him the opportunity
to continue his education and was beneficial because to teach high school, Jones
needed a Texas Teaching Certificate,
which required going back to college.
He took an offer in 1996 from
Garland Independent School District,
Garland, Tex., to serve as the welding
and transportation instructor, thereby
keeping that program open. While there,
he started its AWS Student Chapter.
I chose to accept the challenge of
teaching high school because I had been
an adjunct welding professor at Eastfield
Community College, Mesquite, Tex.,
teaching welding for the past 12 years,
Jones said.
In 2000, he earned a bachelor of science degree in instructional training/
design from Texas A&M UniversityCommerce, Commerce, Tex.
He then pursued other opportunities.
THE AMERICAN WELDER
J. Jones, a district sales manager for the Harris Products Group, Mason, Ohio, performs oxy
fuel cutting. He also has experience in many other welding and cutting processes.
This led to being a training specialist for
Victor Equipment Co., Denton, Tex.;
applications specialist for Thermadyne
Industries, St. Louis, Mo.; and district
sales manager for Victor Technologies,
St. Louis, Mo.
Today, Jones is a district sales manager for the Harris Products Group, Mason,
Ohio. He acts as a liaison and conducts
product knowledge training for distributors and end users, plus builds company
brand recognition in the territory.
Through the years, his AWS involvement has evolved, too. Being a member
has exposed me to individuals in the
industry who have assisted me in my
career and have become life friends,
Jones said.
He currently is the AWS District 17
director, East Texas Section program
chair, and a Houston Section membership committee member. Also, he is on
the AWS Districts Council, Education
Committee, Communications Council,
Thomas J. Lienert
Thomas J. Lienert, directoratlarge
Thomas J. Lienert wholeheartedly believes that through District scholarships

and graduate fellowships, AWS helped
support his education and development.
He has been a member of the organization for almost 25 years.
In 1981, Lienert earned an associate
of applied science degree in materials
technology from Erie Community College, Williamsville, N.Y.
However, it was not until the late 1980s
while working at Sandia National Laboratories, Albuquerque, N.Mex., that he
knew he wanted to pursue a career in the
welding industry.
Lienert discovered financial assistance
opportunities through the Welding Journal. He received two District 7 scholarships while attending The Ohio State University (OSU), Columbus, Ohio, for the
school years 19901991 and 19911992
and National Nominating Committee.

Among his activities are serving on
seven college advisory committees and
as a Boy Scouts of America Welding
Merit Badge contributor.
Its important to give back because
that is what continues the success of
AWS, Jones said. By helping others
you help yourself.
Joness awards include the AWS
National Private Sector Instructor
(20042005) and District Educator
(19992005), the Garland Independent
Schools Regular Educator of the Year
(19981999), and Eastfield Community
College
Continuing
Education
Instructor of the Year (1993).
In addition, he contributed to the
oxyfuel welding portion of the Welding
Handbook 9th Edition; written articles
for the Welding Journal, Scrap Magazine,
and The World of Welding; worked on
Instructors Guides for Welding Processes
by Delmar-Thomson Publishing; and
provided technical contributions to all
editions of Welding Principles and
Applications by Larry Jeffus.
Jones wants to continue serving on
the AWS board and perhaps run for
AWS president one day. I also intend to
continue working with students, the Boy
Scouts, and others promoting welding
and the AWS, he added.
totaling $20003000. In addition, he received three graduate fellowships for the

period of 19941997 at $20,000 each.
The financial support provided by the
scholarships permitted me to focus on my
education rather than having to divert
time to a job to meet basic needs like rent
and food, Lienert said. I did work at the
Edison Welding Institute during my undergrad years, but my schedule was flexible. The focus on education was important at that time since I had already decided to attend graduate school.
His degrees from OSU include a bachelor of science in welding engineering
(1992), master of science in materials science and engineering (1995), and PhD in
materials science and engineering (1998).
Presently, Lienert is an R&D engineer
IV in the welding and joining team at Los
Alamos National Laboratory, Los
Alamos, N.Mex. He has worked there for
more than 11 years and supports laser
WELDING JOURNAL
71
THE AMERICAN WELDER

welding manufacturing activities.
Prior positions include working as an
assistant professor in the Department of
Mechanical Engineering at the University
of South Carolina and senior research engineer at the Edison Welding Institute,
Columbus, Ohio.
Over the years, Lienert has been AWS
District 20 deputy director, chair and vice
chair of the Albuquerque Section, and
vice chair of the Columbus Section.
It is important to pay back AWS for
its investment in my education by supporting the future of the Society and the
welding industry, Lienert said.
Currently, he is an AWS Fellow, direc-
tor-at-large, and board of directors member. He also serves on the AWS Education Scholarship Committee, of which he
formerly was the vice chair; Welding Research & Development Committee; vice
chair of the Education Committee;
Higher Education Subcommittee chair;
Technical Activities Committee; and he
chairs the AWS C6 Committee on Friction Welding.
When asked how he has been able to
accomplish so much for AWS, Lienert
replied, I dont know. I guess I have a
passion for doing so, and maybe I am well
organized.
In addition, he is a lead principal re-
Sean P. Moran
Sean P. Moran, directoratlarge
72
DECEMBER 2013
Sean P. Moran had no idea that

receiving an AWS membership nearly 30
years ago thanks to winning a pretrial
event for the Professional Welders
Competition (organized by the North
Texas Section and sponsored by a local
independent welding supply company) at
the 1984 AWS Welding Show in Dallas,
Tex. would still impact him today.
But even back then, he realized AWS
was seen as weldings professional entity,
and wanted be part of that. He also completed a six-month welder training program prior to that show at the Industrial
Trade School in Dallas, Tex.
That beginning, which began as path
to get a job and a paycheck, turned into
a true passion and a never-ending desire
to learn more of the science, technology,
and application of welding, Moran said.
In 1986, he earned an associate of
applied science degree in welding technology from Mountain View College,
Dallas, Tex.
Through involvements in the North
Texas Section, for which he later became
an officer, Moran heard about AWS
scholarships. The first he received,
awarded after presenting a videotape of
himself explaining his devotion to welding, came from District 17 in 1995 for
$1000.
He completed the requirements for a
Trade and Industrial Secondary
Education Certificate at the University
of North Texas, Denton, Tex., in 1996.
While attending The Ohio State
viewer for the Welding Journal Research

Supplements; vice chair of the Technical
Papers Committee; session chair at the
Professional Program Sessions; chair of
the Welding Handbooks chapters on friction stir welding (9th Edition, Vol. 3) and
stainless and heat-resisting steels (9th
Edition, Vol. 4); and a Certified Welding
Inspector.
AWS has also provided me with conduits for publishing and presenting my research and with networking opportunities
for continued professional development,
Lienert added.
In fact, he would like to eventually become AWS president.
University, Moran achieved three scholarships through District 7 in 1996 for

$1000, in 1997 for $1500, and in 1998 for
$1500. In addition, he earned the
Donald F. Hastings Scholarship in 1997
for $2500. He received a bachelor of science degree from OSU in 1999 where he
majored in welding engineering.
Also, he received the Hypertherm
International
HyTech
Leadership
Scholarship for $2500 in 2002 while
studying for a master of science degree in
engineering management from the
Milwaukee School of Engineering,
Milwaukee, Wis., which he earned in
2004.
Being a scholarship recipient meant
multiple aspects to me personally,
Moran said. Of course, there are the
monetary benefits. However, more
important was the aspect of being recognized by peers in the industry. Along
with this recognition was the trust shown
by looking to invest in me to complete
my education goals and be a contributing
factor to the welding industry.
Throughout Morans long career, he
has progressed from a journeyman pipe
welder, high school shop class educator,
and Edison Welding Institute research
technician while earning an engineering
degree to becoming a welding engineer
and product manager in product and
process development for Illinois Tool
Works, welding engineer with PDM
Bridge, and ESAB product manager for
solid wire consumables with bachelors
and masters degrees.
Currently, he is a welding engineer at
THE AMERICAN WELDER
Sean P. Moran (left), a welding engineer at Weir American Hydro, York, Pa., assists
welder Lonnie Dietz while on the job to fabricate a former that will be used for forging
the blades of a hydro turbine.
Weir American Hydro, York, Pa.,
responsible for all welding applications,
process development, equipment and
consumables, procedures, qualifications,
and planning.
Morans current AWS leadership
roles include the following: a board of

director member; director-at-large; chair
of the Education Scholarship and
Product Development Committees;
Welding Handbook Committee member;
Skill Competition Committee member;
and D1 Committee on Structural

Welding where he is a member of the
D1Q Subcommittee on Steel Structures,
Task Group 5 on Stud Welding, and Task
Group 6 on Prequalification.
In todays environment, we are
always challenged to do more with less
while obtaining the most amount of
value for ones time, Moran said.
He believes his AWS involvement
allows him to see how the organization
can be the most beneficial to its individual and corporate members. He added
that important benefits include the
opportunity to work with a vast member
base for developing what can be of the
most value while promoting growth in
the welding industry. He enjoys paying it
forward as well.
As I have learned and developed in
my career, I want to put forth aspects
that will bring benefit to the industry
while also bringing the next generation
of welders, technicians, and engineers to
continue building the prosperity that the
industry provides to both individuals and
the economy, Moran said.
WELDING JOURNAL
73
Atkinson/Flood AmWeld Dec 2013_Layout 1 11/11/13 3:45 PM Page 74
THE AMERICAN WELDER
Women Learn Welding

Skills for New Careers
Women welders key to workforce
augmentation success in the Philippines
ith todays worldwide communication capabilities, and the

ease of traveling to any part of
the world, initiatives started at a grassroots level can take on a global significance.
In 1995, a faith-based organization
was formed in Bulacan, Philippines, with
the goal of helping the underprivileged
break the cycle of poverty through education and technical training. The organization was named AMG Skilled Hands
Technology College (ASHTEC), and
Fransisco Pascual was chosen as its president. ASHTEC is a project of AMG
International, Chattanooga, Tenn., with
project funding by Woord en Daad (Word
and Deed) in The Netherlands.
Over the years, ASHTECs primary
mission has grown to offer students a
complete curriculum in information and
communication technologies, electronics,
welding technology, and entrepreneurship. The organization now provides
effective on-the-job training and occupational placement with leading companies
throughout the world.
the most need of help, in areas where

there were many underprivileged.
The Filipino population contains a
huge potential workforce. An effective
occupational training and placement program could result in tremendous financial
benefit to the people at large, and even
more significantly, to the underprivileged
who had few real possibilities for good
jobs.
Many of the Filipino men who are
trained in various trades find employment
in positions all over the world that pay
BY BILL ATKINSON AND

DALE FLOOD
BILL ATKINSON (b.atkinson@tritool. com)
is with the Marketing Dept. and DALE
FLOOD (d.flood@tritool.com) is project
manager, R&D, Tri Tool, Inc., Rancho
Cordova, Calif.
higher than the prevailing wage at home.

Oddly enough, this results in a shortage
of welders in their native land.
This is where the concept of training
women welders took on special importance. Women had proven less likely to
pursue jobs outside of the Philippines, so
if the local welding workforce could be
augmented through an increased effort to
train women welders at the school, this
would effectively ensure that enough permanent resident welders were available
to satisfy local labor requirements.
The Welding Workforce

One project with particular interest to
the welding profession was a welder
workforce initiative in the Philippines.
True to the mission of the school, Pascual
worked with local town officials in
Bulacan to identify families who were in
74
DECEMBER 2013
Fig. 1 Some of the women students in the ASHTEC training program.
THE AMERICAN WELDER

Finding Partners
Fig. 2 These female students are inspecting weld beads on pipe coupons under
the watchful eye of Edwin Fernandez, DMI service engineer.
Fig. 3 The EEI modular training facility at Bulacan, Philippines, boasts a nonfunctioning mini-refinery containing all of the full-sized pipe, fittings, and safety elements that the companys trainees and the schools students could experience on
the job.
Women in the program have demonstrated that they possess excellent skills
and proficiency with all of the required
aspects of modern welding procedures
Figs. 1, 2.
ASHTEC students both male and
female are required to sign a contract
and live on campus for the entire school
term. They participate in a full education-
al curriculum and are taught the many

aspects of a technical trade. In addition,
they attend special classes covering such
topics as etiquette and religion. The
school offers training in a wide array of
technical trades; however, due to the
worldwide demand for knowledgeable
welders, welding is one of the more popular and sought-after trades.
While Pascual recognized the potential for finding employment for the students, he also understood the realities of
the organizations limited funding. To
overcome this obstacle, he sought help
from area businesses. He acquired the
support of Deutsche Machine, Inc.
(DMI), a leading regional distributor of
industrial and welding equipment that
had provided most of the welding
machines, grinders, and other items used
at the school. With DMIs involvement,
the project was moving in the right direction but Pascual knew he also needed
the support of the areas industrial
contractors.
He contacted Frank M. Ventanilla,
manager of the Welding, Technical and
Craft Services Group within the
Construction Division of EEI Corp. As a
leading industrial contractor in the
Philippines, EEI could directly benefit
from a cooperative project with a technical trade education program.
Ventanilla turned out to be instrumental in developing the cooperative program
between EEI and ASHTEC, and early on
was able to acquire steel plate and pipe
for training and weld testing at the school.
At the schools facility in Bulacan, EEI
has made a major commitment to welding
education by providing facilities and a
unique mini refinery that, while nonfunctional, contains all of the full-scale
valves, flanges, pipes, and fittings that
would be encountered in a full-size refinery Fig. 3. In addition to piping system
components, students get to learn welding in an environment with industry standard scaffolding, flooring, and many
other structural elements of an industrial
workplace in order to build familiarity
and maximize operator safety.
At this location, EEI trains many
women welders who come from EEIsponsored welding schools throughout
the Philippines. The welders are sent to
the EEI training facility located inside the
ASHTEC campus before being sent to
the companys local projects as well as
ones in Saudi Arabia, Caledonia,
Singapore, and Malaysia. Beside its own
trainees, through its close cooperation
with the school, EEI also accepts some
qualified ASHTEC students and graduates for employment. Thus far,
ASHTECs educational program has
WELDING JOURNAL
75
THE AMERICAN WELDER

placed more than 1000 students with EEI.
Another important element in the
programs success is the excellent instruction provided to the EEI trainees by
Primitivo Guevarra and to the ASHTEC
students by Benjie Mantawil. As they
taught welding technology and techniques, the two instructors noticed
female students often quickly learned gas
tungsten arc welding (GTAW) and produced high-quality results.
Building Support
To build additional funding and commercial support for the welder training
program, the organization recently held
an open house during which officials from
numerous industrial companies toured
the facility, watched demonstrations of
welding procedures, asked questions, and
were introduced to the important educational benefits the schools operation provides Fig. 4.
As part of the event, representatives
from Tri Tool, Inc., Rancho Cordova,
Calif., demonstrated precision portable
weld preparation equipment as well as a
complete AdaptARC orbital welding
system.
EEI had consulted with DMI on welding equipment that would optimally suit
its business requirements. Arnel Samonte
of DMI had traveled to California to see
a demonstration of the Tri Tool mechanized, multiprocess welding equipment
and evaluate it for use with EEIs piping
projects. Samonte was shown the systems
reconfigurability for producing gas tungsten arc welding, short circuit and pulsed
spray gas metal arc welding, and flux
Fig. 4 Shown during the open house are (front row) Primitivo Guevarra, EEI facility
welding supervisor, and Dale Flood, Tri Tool, Inc., along with a group of the schools
students.
cored arc welding. EEI had expressed a
need to decrease the time and costs associated with major welding projects and to
increase productivity for welding operations. Now that a ready source of qualified welders was at hand, the contractor
recognized that the welding equipment
utilized on its job sites would be an
important factor in attaining greater
speed. The orbital welding system was
suited for high productivity by a young
workforce that is fully trained but has limited field experience.
76
DECEMBER 2013
As well as demonstrating the equipment Dale, Flood, Tri Tool welding project manager and an AWS Director-atLarge, presented the benefits of AWS
membership to students, faculty, and
guests. Many of the people in attendance
were unaware of AWS educational products, certifications, and services provided
to those in the welding industry.
Summary
The coalition between the contractor,
the school, the welding distributor, and
the students has proved beneficial to all
concerned. EEIs leading role in training
women welders with ASHTEC as its partner through use of the ASHTEC campus
has allowed the mission and goals of
Pascual and the organizations founders
to be fulfilled. DMI is in position for the
ongoing supply of welding equipment not
only for the school, but to satisfy the
increased welding capacity of the regions
industry.
Most important of all, the newly
trained Filipino students achieve financial security and a higher standard of
living through careers in the welding
industry.
educ (euro standards conf)_FP_TEMP 11/11/13 2:26 PM Page 77
www.aws.org
32102/.-,+*,)(-,'&%-$-#"!- 202//--2(-/2
Learn from the experts why thousands of European

manufacturers have implemented ISO 3834 to improve
productivity, quality, competitiveness, and trade.
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/-2-www.aws.org/conferences
educ (energy conf)_FP_TEMP 11/14/13 11:11 AM Page 78
AWS Conference on
Energy

The demand for new and improved welding technology from expanding and established
energy marketsis
tsis starting to pay of
off
ff in the development of superior hybrid welding processes,
new filler metals, and cladding procedures. The technologies are showing up in nuclear power
plants, in coal-fired utilities, renewable sources, and especially in the new 1,700-mile-long
pipelines designed to bring oil and natural gas to world markets.
Earn PDHs toward your A

AWS
WS recertification when you attend the conference
conference..
For the latest conference information and registration, visit our web site
at www.aws.org/conferences
www.aws.org/conferences or call (800) 443-9353, ext. 223.
Thielsch Welding School_Layout 1 11/13/13 8:55 AM Page 79
THE AMERICAN WELDER

LEARNING TRACK
Thielsch Welding School Offers Its New
Advanced Welder Training Program
As a special perk, graduate students are welcome
to return to the school for a day of refresher
training prior to going on a job interview
Thielsch Welding School, located in

Cranston, R.I., offers hands-on training,
one-on-one instruction, and all the skills
necessary for students to succeed in this
high-demand field, said Norm King,
welding school administrator and instructor. King, an experienced professional in
the metal fabrication industry, is certified
in various welding processes in both structural and pipe materials. His expertise includes nondestructive testing, magnetic
particle, visual testing, liquid dye penetrant, and ultrasonic testing. He holds an
associates degree in business administration, a bachelors in industrial management, and a masters in industrial technology/psychology.
King noted Thielsch Engineering is

the only American Welding Society-Accredited Test Facility (ATF) in the state of
Rhode Island. This distinction, he said,
offers our students the opportunity to become AWS-certified if they continue
through the testing program with the
schools in-house Certified Welding Inspectors.
The Hands-on Training

The 210-hour Welding Training and
Technology course prepares students to
understand the theory and develop their
practical skills in the following four welding processes.
BY HOWARD M. WOODWARD
HOWARD M. WOODWARD
(woodward@aws.org) is associate editor
of the Welding Journal.
Shielded metal arc welding (SMAW) is

the most versatile process for welding ferrous and several nonferrous base metals
using coated electrodes. Students master
this manual process working in all
positions.
Students also learn to use the gas metal
arc welding (GMAW) process with the
filler metal wire fed using hand-held semiautomated equipment. The automated
process is most widely used for production
applications.
The flux core arc welding (FCAW)
process is taught in all positions for manufacturing a variety of components and assemblies. This process is similar to
GMAW, the main difference is the filler
A recent Thielsch Engineering Welding School class includes (from left) Instructors Norm King and Mike Galdonik, Zakiry Lussier,
Jesus Salamaca, Sean Graham, Dave Gracia, Chase Henebury, Ronald Gizzareli, Richard Daigneault, and Instructor Bob Wright.
WELDING JOURNAL
79
Thielsch Welding School_Layout 1 11/13/13 8:55 AM Page 80
THE AMERICAN WELDER

LEARNING TRACK
Kelly Brown gets some pointers on the SMAW 4G position welding

from Mike Galdonik.
metal wire has a core filled with a flux that

provides the shielding gas during welding.
Students also learn the gas tungsten arc
welding (GTAW) technique. This process
is useful for joining aluminum, stainless
steel, and other alloys, and is commonly
used for welding piping systems and lightgauge metals.
The welding program also gives students experience using the tools and other
skills associated with welding, including
techniques for using acetylene torches for
welding and cutting.
The Classroom Studies

In the classroom, students learn the
AWS welding symbols, nondestructive inspection techniques, and basic welding
metallurgy. Another important part of the
classroom studies is the inclusion
of the OSHA 10 Program. This Occupational Safety and Health Administration
course stresses a comprehensive understanding of how to stay safe in various industrial environments. The ten-hour
course is divided into 12 individual lessons
with an exam at the end of each lesson and
a final exam at the end of the course.
OSHA 10 training is a requirement for
employment at many companies.
The Teaching Staff

The Thielsch instructing staff includes
Norm King, Bob Wright, and Mike Galdonik.
Bob Wright is an experienced journeyman welder skilled in the GTAW process
who specializes in pipe details, exotic metals, and alloys. Wright has 30 years of ex80
DECEMBER 2013
Student Henry De La Cruz (right) and Instructor Norm King, discuss changing the roller size on a wire feeder.
perience in the shipbuilding industry, and

is certified in the GTAW, GMAW, SMAW,
FCAW, pulsed, short circuiting, and submerged arc welding (SAW) processes.
Mike Galdonik, a technical school
graduate in the Metal Fabrication Industry, is certified in the GMA, SMA, and
FCA welding processes. He holds a
Rhode Island Electrical License. His
background is a big asset in teaching students details of the various welding power
sources. Galdonik specializes in teaching
welding theory as well as the practical
welding based on the American Welding
Society standards.
Workshop Facilities
The hands-on training facility has ten
welding booths fitted with Lincoln Electric and Miller Electric welding machines
equipped for the various welding
processes. The facility is approved as a
welder training provider by the state of
Rhode Island Department of Labor and
Training.
Graduates Prospects
King noted, With state-of-the-art
equipment and our knowledgeable instructors, Thielsch Welding School provides the training necessary for our graduates to succeed in a welding career.
Following graduation, there are interesting prospects for employment nearby.
Rhode Island is home to numerous major
companies that employ welders, including
General Dynamics, Electric Boat Div.,
Raytheon, and Textron.
Student Services
The schools Human Resources Dept.
is available to assist prospective students
on available grants and other financial-assistance opportunities and tuition payment plans. The department also helps
students prepare their rsums.
And, as a special service, graduates of
the program are invited to return to the
school for a day of refresher training in a
weld process prior to going for a job interview or skill-level evaluation.
Thielsch Welding School

www.thielsch.com
195 Frances Ave.
Cranston, RI 02910
(401) 467-6454
Contact:
Norm King
Welding School Administrator
nking@thielsch.com
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Fact Sheet AmWeld Dec 2013_Layout 1 11/13/13 3:34 PM Page 82
THE AMERICAN WELDER

JUST THE FACTS
Protecting Personnel and the Work Area
Welding equipment, machines, cable,
and other apparatus need to be located so
that they do not present a hazard to personnel. Maintain good housekeeping; for
example, locations such as passageways,
ladders, or stairways should be kept clear
and precautionary information should be
posted when circumstances present additional hazards.
Post signs designating welding areas,
and indicating that eye protection and
other applicable protective devices are to
be worn.
Protective Screens. Workers or other
persons adjacent to the welding areas shall
be protected from the radiant energy and
spatter of welding and cutting by noncombustible or flame-resistant screens or
shields, or shall be required to wear eye and
face protection, and protective clothing.
Radiation-protective, semitransparent
materials are permissible. Screens should
permit circulation of air at floor level as
well as above the screen.
Reflectivity. Where arc welding is regularly carried out, adjacent walls and other
surfaces shall have low reflectivity to ultraviolet radiation.
Finishes formulated with pigments
such as titanium dioxide or zinc oxide have
low reflectivity to ultraviolet radiation.
Color pigments may be added if they do
not increase reflectivity. Lamp black has
been recommended as a paint additive in
the past, but it reduces visible light and is
accordingly less desirable in view of the
need for good lighting as well as ultraviolet radiation absorption. Pigments based
on powdered or flaked metals are not recommended because of their high reflectivity of ultraviolet radiation. Welding curtains are another means of reducing
reflectivity.
Welding Booths. Where operations
permit, welding stations are to be separated by noncombustible screens or
shields with characteristics as described
previously.
Protective Clothing
Select clothing to minimize the potential for ignition, burning, trapping hot
sparks, or electric shock.
Heavier materials such as woolen
clothing or heavy cotton are preferable to
lighter materials because they are more
difficult to ignite. Cotton clothing, if used
for protection, should be chemically

treated to reduce its combustibility. Clothing treated with flame-resistant materials
may lose some of its protective characteristics after repeated washing or cleaning.
Clothing made from materials that can
melt and cause severe burns should not be
worn when welding or cutting.
Sparks may lodge in rolled-up sleeves,
pockets of clothing, or cuffs of overalls or
trousers. It is recommended that sleeves
and collars be kept buttoned and pockets
be eliminated from the front of clothing.
When pockets are present, they should be
emptied of flammable or readily combustible materials. Trousers or overalls
should not have cuffs and should not be
turned up on the outside. Trousers should
overlap shoe tops to prevent spatter from
getting into shoes.
Frayed clothing is particularly susceptible to ignition and burning and should
not be worn when welding or cutting.
Appropriate protective clothing for
any welding and cutting operation will
vary with the size, nature, and location of
the work to be performed. Clothing
should be kept clean, as oil and grease can
reduce its protective qualities.
Selection. Clothing shall provide sufficient coverage, and be made of suitable
materials, to minimize skin burns caused
by sparks, spatter, or radiation.
Gloves. All welders and cutters must
wear protective flame-resistant gloves. All
gloves should be in good repair, dry, and
capable of providing protection from electric shock by the welding equipment.
Gloves made of leather, rubber, or
other suitable materials are recommended. Insulated linings should be used
to protect areas exposed to high radiant
energy.
Leggings. For heavy work, use flameresistant leggings or other equivalent
means to give added protection to the legs,
when necessary.
In production work, a sheet metal
screen in front of the workers legs can
provide further protection against sparks
and molten metal in cutting operations.
Capes and Sleeves. Wear cape sleeves
or shoulder covers with bibs made of
leather or other flame-resistant material
during overhead welding, cutting, or other
operations, when necessary.
Properly fitted flame-resistant plugs in
the ear canals, or equivalent protection,
Excerpted from ANSI Z49.1:2012, Safety in Welding, Cutting, and Allied Processes.
82
DECEMBER 2013
shall be used where hazards to the ear

canals exist.
Wear caps made from flame-resistant
material under helmets, when necessary,
to prevent head burns.
Noise Control. When feasible, control
noise at the source. When control methods fail to bring noise exposure within allowable limits, use personal protective devices such as ear muffs or ear plugs.
In welding, cutting, and allied operations, noise results from the process and
from the equipment. Processes that may
produce high noise levels are air carbon
arc cutting and gouging, and plasma arc
cutting and gouging, plus some oxyfuel
processes and equipment, and support
equipment.
Engine-driven generators sometimes
have a high noise level. Other equipment
and processes, such as chipping and grinding, may produce hazardous noise exposure, depending on specific circumstances.
Respiratory Protective Equipment.
When controls such as ventilation fail to
reduce air contaminants to allowable levels or when the implementation of such
controls is not feasible, respiratory protective equipment shall be used to protect
personnel from hazardous concentrations
of airborne contaminants.
Approvals of respiratory equipment
are issued by the National Institute for Occupational Safety and Health (NIOSH) or
the Mine Safety and Health Administration (MSHA).
Only approved respiratory protective
equipment is to be used, and whenever the
use of respirators is required, a program to
establish its proper selection and use shall
be implemented.
Federal regulations for respirator use
dictate that respirators not be passed from
one employee to another without being
sanitized per OSHA 29 CFR, Section
1910.134, Respiratory Protection Standard.
Compressed air for air-supplied respirators or other breathing equipment
should at least meet the Grade D requirements of the Compressed Gas Association
ANSI/CGA G-7.1, Commodity Specification for Air.
Training. Persons (workers and their
immediate supervisors) exposed to welding hazards shall be trained in the use of,
and understand the reasons for, protective
clothing and equipment.
general coporate_FP_TEMP 11/11/13 9:38 AM Page 83
WJ Index 2013-R[1]_WJ Index 2006 11/14/13 8:25 AM Page 84
WELDING JOURNAL
INDEX
Part 1 WELDING JOURNAL
SUBJECT INDEX
VOLUME 92
A History of the Oxyacetylene and Plasma Cutting Processes

J. Henderson and N. Hussary, (Oct) 44
A New Development in Aluminum Welding Wire: Alloy 4943
T. Anderson, (July) 32
A Perspective on Welding Engineering Education Confessions of a PhD Who Can Actually Weld Y. Adonyi,
(April) 48
Aerospace Brazing, Whats Happening with T. Sandin,
(Oct) 56
Alabama Center Preps Trainees for Shipbuilding Jobs M.
R. Johnsen, (Nov) 52
Alabama Trains Workers at World-Class Robotics Center
M. R. Johnsen, (April) 38
Aluminum Weld-Quality Solutions Come in Threes F.
Armao, (Dec) 26
Aluminum Welding, How Wire Diameter Affects R.
Krause, (Dec) 38
Aluminum Welding Safety Tips T. Pfaller, (Sept) 34
Aluminum Welding Wire: Alloy 4943, A New Development in
T. Anderson, (July) 32
Amtrak Unveils Next Era of Locomotives (Aug) 38
Automated Welding Applied in Deep-Water Pipelines J.
Xiang-Dong, Z. Can-Feng, C. Jia-Qing, J. Weng-Gang, L.
Zhi-Gang, Z. Dong-Yan, and C. Jun, (July) 48
Automobile Manufacturing Using Laser Beam Welding N.
Cavusoglu and H. zden, (Feb) 32
Automotive Industry, Benefits of Remote Laser Welding in
the T. Ryba, D. Havrilla, and A. Andreev, (Jan) 48
Automotive Structures, Improving Aluminum Resistance
Spot Welding in D. R. Sigler, B. E. Carlson, and P. Janiak, (June) 64
AWS Scholarships Proved a Channel to Success K. Campbell, (Dec) 70
Basics of Brazing with Induction Heating B. Daly, (Oct) 52
Benefits of Remote Laser Welding in the Automotive Industry T. Ryba, D. Havrilla, and A. Andreev, (Jan) 48
Bevels with Plasma, Producing Better M. Avila, (Oct) 38
Boot Woes, Solving the Winter Work M. Reilly, (Sept) 78
Brazing of Aluminum Heat Exchangers, Controlled Atmosphere H. Zhao, S. Elbel, and P. Hrnjak, (Feb) 44
Business Shines in Sunny Florida, Family M. R. Johnsen,
(March) 80
Cladding Faces the Challenges of Oil and Natural Gas Drilling
WM. J. Hoffart, (June) 54
Cold Cutting: A Clean and Repeatable Technology M.
Leska, (Oct) 26
Consumables for Nuclear Work, Tips for Purchasing Welding
W. J. Sperko, (Nov) 56
Control Technology Helps Reduce Fall Hazards, Remote J.
Ryan, (Sept) 42
Controlled Atmosphere Brazing of Aluminum Heat Exchangers H. Zhao, S. Elbel, and P. Hrnjak, (Feb) 44
Controlling Hydrogen-Induced Cracking B. Guy, (Sept) 82
Controlling SMA Welding Fumes in the Mining Industry K.
Sham and S. Liu, (Nov) 46
Cutting: A Clean and Repeatable Technology, Cold M.
Leska, (Oct) 26
Cutting Fair Attracts a Worldwide Audience, Welding and
A. Cullison, (Dec) 34
84
DECEMBER 2013
Dissimilar Metals, Friction Stud Welding of G. Zhang, W.

Jiao, J. Zhao, and J. Zhang, (Jan) 54
Diver and Weld Underwater, How to Become a Commercial
T. M. Brown, (March) 76
Droplets during Gas Metal Arc Welding, Exploring the Forces
that Shape A. Yelistratov, (May) 48
Education Confessions of a PhD Who Can Actually Weld,
A Perspective on Welding Engineering Y. Adonyi,
(April) 48
Effect of Tool Angle on Friction Stir Weldability of AISI 430
M. B. Bilgin, C. Meran, and O. E. Canyurt, (Jan) 42
Evaluating SMAW Electrode Fume Formation Rates K.
Sham and S. Liu, (Sept) 38
Exploring the Forces that Shape Droplets during Gas Metal
Arc Welding A. Yelistratov, (May) 48
FABTECH (Nov) 60
FABTECH 2012 A. Cullison, K. Campbell, C. Guzman, and
M. R. Johnsen, (Jan) 28
Family Business Shines in Sunny Florida M. R. Johnsen,
(March) 80
Friction Stir Weldability of AISI 430, Effect of Tool Angle on
M. B. Bilgin, C. Meran, and O. E. Canyurt, (Jan) 42
Friction Stud Welding of Dissimilar Metals G. Zhang, W.
Fume Extraction Guns: Understanding the Basics D.
Weimer, (April) 51
Fume Formation Rates, Evaluating SMAW Electrode K.
Sham and S. Liu, (Sept) 38
Fumes in the Mining Industry, Controlling SMA Welding
K. Sham and S. Liu, (Nov) 46
Fusion Welding Success, The Secret to W. C. LaPlante,
(June) 120
Gas Blends Suited for Different Metals, Shielding (Aug) 34
GMA Gun, How to Maintain Your R. Fleischmann, (April)
44
Gun for GMAW, Selecting the Right B. Thayer, (April) 34
Guns: Understanding the Basics, Fume Extraction D.
Weimer, (April) 51
Heat Exchanger Resurgence, Technology Drives U.S. M.
Leska, (June) 58
How to Become a Commercial Diver and Weld Underwater
T. M. Brown, (March) 76
How to Get Paid for Jobs Youve Completed D. Sadler,
(Aug) 51
How to Improve GTAW Performance M. Franklin, (July)
38
How to Maintain Your GMA Gun R. Fleischmann, (April)
44
How Wire Diameter Affects Aluminum Welding R. Krause,
(Dec) 38
Hull 15 m below the Waterline, Repair of a U. Aschemeier
and K. Peters, (March) 32
Hybrid Laser Arc Welding, What You Should Know about
P. Denney, (Jan) 38
Hydrogen-Induced Cracking, Controlling B. Guy, (Sept) 82
Improving Aluminum Resistance Spot Welding in Automotive
Structures D. R. Sigler, B. E. Carlson, and P. Janiak,
(June) 64
Improving Surfacing Performance with GMAW J. C. Dutra,
E. B. Puhl, N. G. Bonacorso, and R. H. Goncalves E Silva,

(May) 42
Induction Heating, Basics of Brazing with B. Daly, (Oct) 52
Induction Heating for Stress Relieving Shortens Lead Times
J. Ryan, (July) 44
International Trade Fair and IIW Set to Dazzle Next Month
H. M. Woodward, (Aug) 46
Inverters Improve Control for AC Gas Tungsten Arc Welding
R. L. Bitzky and J. Garraux, (July) 28
Ladder Safety: Staying Steady D. Francis, (June) 116
Laser Arc Welding, What You Should Know about Hybrid
(Jan) 38
Laser Beam Welding, Automobile Manufacturing Using N.
Cavusoglu and H. zden, (Feb) 32
Laser Welded Steel Wheel Rims, Mechanical and Technological Properties of A. . na and H. zden, (Feb) 38
Laser Welding in the Automotive Industry, Benefits of Remote T. Ryba, D. Havrilla, and A. Andreev, (Jan) 48
Locomotives, Amtrak Unveils Next Era of (Aug) 38
Maximizing Pipeline Welding Efficiency J. Nelson, (June) 74
Mechanical and Technological Properties of Laser Welded
Steel Wheel Rims A. . na and H. zden, (Feb) 38
Minimizing Risk in Offshore Submerged Arc Welding B.
Schaeffer and T. Melfi, (March) 40
Navigating Welding Standards M. J. Skinkle, (March) 88
NO-Doped Shielding Gases Benefit Stainless Steel Welding
J. Berkmanns, (Aug) 42
Not Your Fathers Gas Shielded Flux Cored Electrodes T.
Myers, (May) 30
Nuclear Work, Tips for Purchasing Welding Consumables for
Offshore Submerged Arc Welding, Minimizing Risk in B.
Schaeffer and T. Melfi, (March) 40
Oil and Natural Gas Drilling, Cladding Faces the Challenges
of WM. J. Hoffart, (June) 54
Operational Changes = A Saved Business, Welding Ingenuity
+ K. Campbell, (Nov) 40
Origins of Gas Tungsten Arc Welding A. F. Manz, (Sept) 86
Oxyacetylene and Plasma Cutting Processes, A History of the
Paid for Jobs Youve Completed, How to Get D. Sadler,
(Aug) 51
Pipeline Welding Efficiency, Maximizing J. Nelson, (June)
74
Pipelines, Automated Welding Applied in Deep-Water J.
Xiang-Dong, Z. Can-Feng, C. Jia-Qing, J. Weng-Gang, L.
Zhi-Gang, Z. Dong-Yan, and C. Jun, (July) 48
Plasma Cutting Processes, A History of the Oxyacetylene and
Producing Better Bevels with Plasma M. Avila, (Oct) 38
Reflow of AuSn Solder Creates Strong Joints I. Golosker
and J. Florando, (Feb) 48
Remote Control Technology Helps Reduce Fall Hazards J.
Ryan, (Sept) 42
Repair of a Hull 15 m below the Waterline U. Aschemeier
and K. Peters, (March) 32
Resistance Spot Welding in Automotive Structures, Improving
Aluminum D. R. Sigler, B. E. Carlson, and P. Janiak,
(June) 64
Resources for When Youre on the Go, Welding H. Woodward, M. R. Johnsen, C. Guzman, and K. Campbell, (May)
36
Robotics Center, Alabama Trains Workers at World-Class
M. R. Johnsen, (April) 38
Safety Tips, Aluminum Welding T. Pfaller, (Sept) 34
Scholarships Proved a Channel to Success, AWS K. Campbell, (Dec) 70
Sculptures Roaring to Life, Welding Students Bring Steel

K. Campbell, (March) 92
Selecting the Right Gun for GMAW B. Thayer, (April) 34
Shielded Flux Cored Electrodes, Not Your Fathers Gas T.
Myers (May) 30
Shielded Gas Blends Suited for Different Metals (Aug) 34
Shielding Gases Benefit Stainless Steel Welding, NO-Doped
Shipbuilding Jobs, Alabama Center Preps Trainees for M.
R. Johnsen, (Nov) 52
Should You Add Thermal Spray to Your Welding Course?
R. S. Brunhouse, P. Foy, and D. Moody, (April) 54
Skills for New Careers, Women Learn Welding B. Atkinson
and D. Flood, (Dec) 74
Solder Creates Strong Joints, Reflow of AuSn I. Golosker
and J. Florando, (Feb) 48
Solutions Come in Threes, Aluminum Weld-Quality F.
Armao, (Dec) 26
Solving the Winter Work Boot Woes M. Reilly, (Sept) 78
Spray to Your Welding Course?, Should You Add Thermal
R. S. Brunhouse, P. Foy, and D. Moody, (April) 54
Stainless Steel Welding, NO-Doped Shielding Gases Benefit
Stress Relieving Shortens Lead Times, Induction Heating for
J. Ryan, (July) 44
Stud Welding of Dissimilar Metals, Friction G. Zhang, W.
Students Bring Steel Sculptures Roaring to Life, Welding
Surfacing Performance with GMAW, Improving J. C.
Dutra, E. B. Puhl, N. G. Bonacorso, and R. H. Goncalves E
Silva, (May) 42
Technology Drives U.S. Heat Exchanger Resurgence M.
Leska, (June) 58
The Secret to Fusion Welding Success W. C. LaPlante,
(June) 120
The Three Rs of Welded Art H. Woodward, K. Campbell,
and M. R. Johnsen, (Oct) 30
Tips for Job Shops J. Leisner and D. Benson, (Dec) 30
Tips for Purchasing Welding Consumables for Nuclear Work
Trade Fair and IIW Set to Dazzle Next Month, International
H. M. Woodward, (Aug) 46
Tungsten Arc Welding, Inverters Improve Control for AC Gas
R. L. Bitzky and J. Garraux, (July) 28
Tungsten Arc Welding, Origins of Gas A. F. Manz, (Sept)
86
Welding and Cutting Fair Attracts a Worldwide Audience
Welding Ingenuity + Operational Changes = A Saved Business K. Campbell, (Nov) 40
Welding Resources for When Youre on the Go H. Woodward, M. R. Johnsen, C. Guzman, and K. Campbell, (May)
36
Welding Students Bring Steel Sculptures Roaring to Life
What You Should Know about Hybrid Laser Arc Welding
P. Denney, (Jan) 38
Whats Happening with Aerospace Brazing T. Sandin, (Oct)
56
Wheel Rims, Mechanical and Technological Properties of
Laser Welded Steel A. . na and H. zden, (Feb) 38
Women Learn Welding Skills for New Careers B. Atkinson
and D. Flood, (Dec) 74
Worldwide Audience, Welding and Cutting Fair Attracts a
WELDING JOURNAL
85
AUTHORS FOR FEATURE ARTICLES

Adonyi, Y. A Perspective on Welding Engineering Education Confessions of a PhD Who Can Actually Weld,
(April) 48
Anderson, T. A New Development in Aluminum Welding
Wire: Alloy 4943, (July) 32
Andreev, A., Ryba, T., and Havrilla, D. Benefits of Remote
Laser Welding in the Automotive Industry, (Jan) 48
Armao, F. Aluminum Weld-Quality Solutions Come in
Threes, (Dec) 26
Aschemeier, U., and Peters, K. Repair of a Hull 15 m below
the Waterline, (March) 32
Atkinson, B., and Flood, D. Women Learn Welding Skills
for New Careers, (Dec) 74
Avila, M. Producing Better Bevels with Plasma, (Oct) 38
Benson, D., and Leisner, J. Tips for Job Shops, (Dec) 30
Berkmanns, J. NO-Doped Shielding Gases Benefit Stainless
Steel Welding, (Aug) 42
Bilgin, M. B., Meran, C., and Canyurt, O. E. Effect of Tool
Angle on Friction Stir Weldability of AISI 430, (Jan) 42
Bitzy, R. L., and Garraux, J. Inverters Improve Control for
AC Gas Tungsten Arc Welding, (July) 28
Bonacorso, N. G., Goncalves E Silva, R. H., Dutra, J. C., and
Puhl, E. B. Improving Surfacing Performance with
GMAW, (May) 42
Brown, T. M. How to Become a Commercial Diver and Weld
Underwater, (March) 76
Brunhouse, R. S., Foy, P., and Moody, D. Should You Add
Thermal Spray to Your Welding Course?, (April) 54
Campbell, K. AWS Scholarships Proved a Channel to Success, (Dec) 70
Campbell, K. Welding Ingenuity + Operational Changes =
A Saved Business, (Nov) 40
Campbell, K. Welding Students Bring Steel Sculptures
Roaring to Life, (March) 92
Campbell, K., Guzman, C., Johnsen, M. R., and Cullison, A.
FABTECH 2012 (Jan) 28
Campbell, K., Johnsen, M. R., and Woodward, H. The
Three Rs of Welded Art, (Oct) 30
Campbell, K., Woodward, H., Johnsen, M. R., and Guzman, C.
Welding Resources for When Youre on the Go, (May)
36
Can-Feng, Z., Jia-Qing, C., Weng-Gang, J., Zhi-Gang, L.,
Dong-Yan, Z., Jun, C., and Xiang-Dong, J. Automated
Welding Applied in Deep-Water Pipelines, (July) 48
Canyurt, O. E., Bilgin, M. B., and Meran, C. Effect of Tool
Carlson, B. E., Janiak, P., and Sigler, D. R. Improving Aluminum Resistance Spot Welding in Automotive Structures,
(June) 64
Cavusoglu, N. and zden, H. Automobile Manufacturing
Using Laser Beam Welding, (Feb) 32
Cullison, A. Welding and Cutting Fair Attracts a Worldwide
Audience, (Dec) 34
Cullison, A., Campbell, K., Guzman, C., and Johnsen, M. R.
FABTECH 2012, (Jan) 28
Daly, B. Basics of Brazing with Induction Heating, (Oct) 52
Denney, P., What You Should Know about Hybrid Laser Arc
Welding, (Jan) 38
Dong-Yan, Z., Jun, C., Xiang-Dong, J., Can-Feng, Z., Jia-Qing,
C., Weng-Gang, J., and Zhi-Gang, L. Automated Welding Applied in Deep-Water Pipelines, (July) 48
Dutra, J. C., Puhl, E. B., Bonacorso, N. G., and Goncalves E
Silva, R. H. Improving Surfacing Performance with
GMAW, (May) 42
Elbel, S., Hrnjak, P., and Zhao, H. Controlled Atmosphere
Brazing of Aluminum Heat Exchangers, (Feb) 44
86
DECEMBER 2013
Fleischmann, R. How to Maintain Your GMA Gun, (April)

44
Flood, D., and Atkinson, B. Women Learn Welding Skills
for New Careers, (Dec) 74
Florando, J., and Golosker, I. Reflow of AuSn Solder Creates Strong Joints, (Feb) 48
Foy, P., Moody, D., and Brunhouse, R. S. Should You Add
Francis, D. Ladder Safety: Staying Steady, (June) 116
Franklin, M. How to Improve GTAW Performance, (July)
38
Garraux, J., and Bitzky, R. L. Inverters Improve Control for
AC Gas Tungsten Arc Welding, (July) 28
Golosker, I., and Florando, J. Reflow of AuSn Solder Creates Strong Joints, (Feb) 48
Goncalves E Silva, R. H., Dutra, J. C., Puhl, E. B., and Bonacorso, N. G. Improving Surfacing Performance with
GMAW, (May) 42
Guy, B. Controlling Hydrogen-Induced Cracking, (Sept) 82
Guzman, C., Johnsen, M. R., Cullison, A., and Campbell, K.
Guzman, C., Campbell, K., Woodward, H., and Johnsen, M. R.
Welding Resources for When Youre on the Go, (May) 36
Havrilla, D., Andreev, A., and Ryba, T. Benefits of Remote
Henderson, J., and Hussary, N. A History of the Oxyacetylene and Plasma Cutting Processes, (Oct) 44
Hoffart, WM. J. Cladding Faces the Challenges of Oil and
Natural Gas Drilling, (June) 54
Hrnjak, P., Zhao, H., and Elbel, S. Controlled Atmosphere
Hussary, N., and Henderson, J. A History of the Oxyacetylene and Plasma Cutting Processes, (Oct) 44
Janiak, P., Sigler, D. R., and Carlson, B. Improving Aluminum Resistance Spot Welding in Automotive Structures,
(June) 64
Jia-Qing, C., Weng-Gang, J., Zhi-Gang, L., Dong-Yan, Z., Jun,
C., Xiang-Dong, J., and Can-Feng, Z. Automated Welding Applied in Deep-Water Pipelines, (July) 48
Jiao, W., Zhao, J., Zhang, J., and Zhang, G. Friction Stud
Welding of Dissmilar Metals, (Jan) 54
Johnsen, M. R. Alabama Center Preps Trainees for Shipbuilding Jobs, (Nov) 52
Johnsen, M. R. Alabama Trains Workers at World-Class Robotics Center, (April) 38
Johnsen, M. R. Family Business Shines in Sunny Florida,
(March) 80
Johnsen, M. R., Cullison, A., Campbell, K., and Guzman, C.
Johnsen, M. R., Woodward, H., Campbell, K. The Three Rs
of Welded Art, (Oct) 30
Johnsen, M. R., Guzman, C., Campbell, K., and Woodward, H.
36
Jun, C., Xiang-Dong, J., Can-Feng, Z., Jia-Qing, C., WengGang, J., Zhi-Gang, L., and Dong-Yan, Z. Automated
Krause, R. How Wire Diameter Affects Aluminum Welding, (Dec) 38
LaPlante, W. C. The Secret to Fusion Welding Success,
(June) 120
Leisner, J., and Benson, D. Tips for Job Shops, (Dec) 30
Leska, M. Cold Cutting: A Clean and Repeatable Technology, (Oct) 26
Leska, M. Technology Drives U.S. Heat Exchanger Resurgence, (June) 58
Liu, S., and Sham, K. Controlling SMA Welding Fumes in

the Mining Industry, (Nov) 46
Liu, S., and Sham, K. Evaluating SMAW Electrode Fume
Formation Rates, (Sept) 38
Manz, A. F. Origins of Gas Tungsten Arc Welding, (Sept) 86
Melfi, T., and Schaeffer, B. Minimizing Risk in Offshore
Submerged Arc Welding, (March) 40
Meran, C., Canyurt, O. E., and Bilgin, M. B. Effect of Tool
Moody, D., Brunhouse, R. S., and Foy, P. Should You Add
Myers, T. Not Your Fathers Gas Shielded Flux Cored Electrodes, (May) 30
Nelson, J. Maximizing Pipeline Welding Efficiency, (June)
74
na, A. ., and zden, H. Mechanical and Technological
Properties of Laser Welded Steel Wheel Rims, (Feb) 38
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Using Laser Beam Welding, (Feb) 32
zden, H., and na , A. . Mechanical and Technological
Properties of Laser Welded Steel Wheel Rims, (Feb) 38
Peters, K., and Aschemeier, U. Repair of a Hull 15 m below
the Waterline, (March) 32
Pfaller, T. Aluminum Welding Safety Tips, (Sept) 34
Puhl, E. B., Bonacorso, N. G., Goncalves E Silva, R. H., and
Dutra, J. C. Improving Surfacing Performance with
GMAW, (May) 42
Reilly, M. Solving the Winter Work Boot Woes, (Sept) 78
Ryan, J. Induction Heating for Stress Relieving Shortens
Lead Times, (July) 44
Ryan, J. Remote Control Technology Helps Reduce Fall
Hazards, (Sept) 42
Ryba, T., Havrilla, D., and Andreev, A. Benefits of Remote
Sadler, D. How to Get Paid for Jobs Youve Completed,
(Aug) 51
Sandin, T. Whats Happening with Aerospace Brazing, (Oct)
56
Schaeffer, B., and Melfi, T. Minimizing Risk in Offshore
Submerged Arc Welding, (March) 40
Sham, K., and Liu, S. Controlling SMA Welding Fumes in

the Mining Industry, (Nov) 46
Sham, K., and Liu, S. Evaluating SMAW Electrode Fume
Formation Rates, (Sept) 38
Sigler, D. R., Carlson, B. E., and Janiak, P. Improving Aluminum Resistance Spot Welding in Automotive Structures,
(June) 64
Skinkle, M. J. Navigating Welding Standards, (March) 88
Sperko, W. J. Tips for Purchasing Welding Consumables for
Nuclear Work, (Nov) 56
Thayer, B. Selecting the Right Gun for GMAW, (April) 34
Weimer, D. Fume Extraction Guns: Understanding the Basics, (April) 51
Weng-Gang, J., Zhi-Gang, L., Dong-Yan, Z., Jun, C., XiangDong, J., Can-Feng, Z., and Jia-Qing, C. Automated
Woodward, H. International Trade Fair and IIW Set to Dazzle Next Month, (Aug) 46
Woodward, H., Campbell, K., and Johnsen, M. R. The
Three Rs of Welded Art, (Oct) 30
Woodward, H., Johnsen, M. R., Guzman, C., and Campbell, K.
36
Xiang-Dong, J., Can-Feng, Z., Jia-Qing, C., Weng-Gang, J.,
Zhi-Gang, L., Dong-Yan, Z., and Jun, C. Automated
Yelistratov, A. Exploring the Forces that Shape Droplets
during Gas Metal Arc Welding, (May) 48
Zhang, G., Jiao, W., Zhao, J., and Zhang, J. Friction Stud
Zhang, J., Zhang, G., Jiao, W., and Zhao, J. Friction Stud
Zhao, H., Elbel, S., and Hrnjak, P. Controlled Atmosphere
Zhao, J., Zhang, J., Zhang, G., and Jiao, W. Friction Stud
Zhi-Gang, L., Dong-Yan, Z., Jun, C., Xiang-Dong, J., CanFeng, Z., Jia-Qing, C., and Weng-Gang, J. Automated
Part 2 RESEARCH
SUPPLEMENT SUBJECT INDEX
VOLUME 92
Active Droplet Oscillation Excited by Optimized Waveform J.
Xiao, G. J. Zhang, S. J. Chen, L. Wu, and Y. M. Zhang, (July)
205-s
Adhesive Characteristics on the Weld Quality in Weld-Bonding
Multiple Steel Sheets, Effect of Y. S. Zhang, J. Shen, Y. Y.
Zhao, P. C. Wang, and B. Carlson (Dec) 363-s
Application of Friction Stir Processing as a Pretreatment to Fusion Welding J. R. Rule, J. M. Rodelas, and J. C. Lippold,
(Oct) 283-s
Arc Characteristics of Ultrasonic Wave-Assisted GMAW C. L.
Fan, C. L. Yang, S. B. Lin, and Y. Y. Fan, (Dec) 375-s
Brazed Sapphire to Inconel 600 Using Porous Interlayer, Microstructure Analysis of T. Zaharinie, F. Yusof, M. Hamdi,
T. Ariga, and M. Fadzil, (Nov) 332-s
Brazing of Stainless Steel 304, Transient Liquid Phase Diffusion
M. Mazar Atabaki, J. Noor Wati, and J. Idris, (March)
57-s
Brazing of Titanium and Titanium/Stainless Steel Joints, Preliminary Investigation on Ultrasonic-Assisted A. Elrefaey, L.
Wojarski, J. Pfeiffer, and W. Tillman, (May) 148-s

Claddings and Coextruded Coatings, High-Temperature Corrosion Behavior of Alloy 600 and 622 Weld J. N. DuPont, A.
W. Stockdale, A. Caizza, and A. Esposito, (July) 218-s
Contribution of Phosphorus and Sulfur on Hot Cracking Susceptibility for Extra-High-Purity 25Cr-35Ni Stainless Steels
K. Saida, Y. Nishijima, K. Nishimoto, K. Kiuchi, and J.
Nakayama, (Nov) 322-s
Corrosion Behavior of Alloy 600 and 622 Weld Claddings and
Coextruded Coatings, High-Temperature J. N. DuPont, A.
Cr-Plated Sheet, Influences of Laser Spot on High-Speed Welding for J. Zhan and M. J. Yang, (Oct) 291-s
Cracking in High-Strength Naval Steels, Quantifying Heat-Affected Zone Hydrogen-Induced X. Yue, X. L. Feng, and J.
C. Lippold, (Sept) 265-s
Cracking of Laser Welded IN738LC Superalloy, Heat Input and
the Liquation M. Montazeri, F. Malek Ghaini, and O. A.
Ojo, (Sept) 258-s
WELDING JOURNAL
87
Cracking Susceptibility of Naval Steels, The Weld Heat-Affected

Zone Liquation J. L. Caron, S. S. Babu, and J. C. Lippold,
(April) 110-s
Design Effects for FSW of AA7039, Tool D. Venkateswarlu,
N. R. Mandal, M. M. Mahapatra, and S. P. Harsh, (Feb) 41-s
Diode Laser Brazed AZ31B Magnesium to Steel Sheet Using a
Nickel Interlayer, Interfacial Microstructure of A. M.
Nasiri, D. C. Weckman, and Y. Zhou, (Jan) 1-s
Dissimilar Alloys, Fabrication and Characterization of Graded
Transition Joints for Welding G. J. Brentrup and J. N.
DuPont, (March) 72-s
Droplet Oscillation Excited by Optimized Waveform, Active
J. Xiao, G. J. Zhang, S. J. Chen, L. Wu, and Y. M. Zhang, (July)
205-s
Dual-Phase Steel, Magnetically Assisted Resistance Spot Welding of Y. B. Li, Y. T. Li, Q. Shen, and Z. Q. Lin, (April)
124-s
Dynamic Control of the GTAW Process Using a Human Welder
Response Model W. J. Zhang and Y. M. Zhang, (May)
154-s
Effect of Adhesive Characteristics on the Weld Quality in WeldBonding Multiple Steel Sheets Y. S. Zhang, J. Shen, Y. Y.
Zhao, P. C. Wang, and Carlson, B., (Dec) 363-s
Effect of Postweld Heat Treatment on the Toughness of Heat-Affected Zone for Grade 91 Steel B. Silwal, L. Li, A. Deceuster, and B. Griffiths, (March) 80-s
Effect of Tempering Pass on HSLA-80 Steel HAZ Microstructures A. Cruz-Crespo, D. Bezerra de Araujo, and A. Scotti,
(Oct) 304-s
Embrittlement in Type 316FR Weld Metal, Prediction of -Phase
E. J. Chun, H. Baba, K. Terashima, K. Nishimoto, and K.
Saida, (May) 133-s
Estimation of Weld Joint Penetration under Varying GTA Pools
Y. K. Liu, W. J. Zhang, and Y. M. Zhang, (Nov) 313-s
Evaluation of Heat-Affected Zone Hydrogen-Induced Cracking
in Navy Steels X. Yue and J. C. Lippold, (Jan) 20-s
Evaluation of Susceptibility of Alloy IN740 to HAZ Stress-Relaxation Cracking J. E. Ramirez, (April) 89-s
Eye Protection by Welders, New Optical Filter Plate for Use as
A. Langa-Moraga, C. Bonnin-Arias, E. Chamorro, J. PrezCarrasco, and C. Snchez-Ramos, (Feb) 36-s
Fabrication and Characterization of Graded Transition Joints for
Welding Dissimilar Alloys G. J. Brentrup and J. N. DuPont,
(March) 72-s
Feasibility of Cold-Metal-Transfer Welding Magnesium AZ31 to
Galvanized Mild Steel R. Cao, J. Y. Yu, J. H. Chen, and P.
C. Wang, (Sept) 274-s
Ferrite Number Predictions vs. Measurements, Sources of Variation in D. J. Kotecki and Z. Zhang, (June) 175-s
Fiber Laser Welding, Neural Network Model for Recognizing
Joint Offset during X. D. Gao, L. Mo, Q. Wen, and S.
Katayama, (Sept) 251-s
Fillet Welding Using Bypass and Root Opening, Heat Input Reduction in Y. Lu, Y. M. Zhang, and L. Kvidahl, (Dec)
390-s
Friction Stir Processing as a Pretreatment to Fusion Welding, Application of J. R. Rule, J. M. Rodelas, and J. C. Lippold,
(Oct) 283-s
Friction Stir Weld Stir Zone, Processing Effects on the J.
Schneider, R. Stromberg, P. Schilling, B. Cao, W. Zhou, J.
Morfa, and O. Myers, (Jan) 11-s
Full Reality vs. Integrated Virtual Reality Training in Welding
R. T. Stone, E. McLaurin, P. Zhong, and K. Watts, (June)
167-s
Galvannealed Interstitial-Free Steel, GMA Brazing of S.
Basak, T. K. Pal, M. Shome, and J. Maity, (Feb) 29-s
GMA Brazing of Galvannealed Interstitial-Free Steel S.
Basak, T. K. Pal, M. Shome, and J. Maity, (Feb) 29-s
Grade 91 Steel, Effect of Postweld Heat Treatment on the Toughness of Heat-Affected Zone for B. Silwal, L. Li, A. De88
DECEMBER 2013
ceuster, and B. Griffiths, (March) 80-s

GTAW Process Using a Human Welder Response Model, Dynamic Control of the W. J. Zhang and Y. M. Zhang, (May)
154-s
Hardfacing Layer, Microstructure and Wear Properties of Fe-2
wt-% Cr-X wt-% W-0.67 wt-% C J. Yang, Y. Yang, Y. Zhou,
X. Qi, Y. Gao, X. Ren, and Q. Yang, (Aug) 225-s
HAZ Hardness, Simplified Mathematical Modeling of Implant
Limit Stress and Maximum A. Fotouh, M. El-Shennawy,
and R. El-Hebeary, (Nov) 337-s
HAZ Microstructures, Effect of Tempering Pass on HSLA-80
Steel A. Cruz-Crespo, D. Bezerra de Araujo, and A. Scotti,
(Oct) 304-s
HAZ Stress-Relaxation Cracking, Evaluation of Susceptibility of
Alloy IN740 to J. E. Ramirez, (April) 89-s
Heat-Affected Zone Hydrogen-Induced Cracking in Navy Steels,
Evaluation of X. Yue and J. C. Lippold, (Jan) 20-s
Heat-Affected Zones in an Iron-Copper Based Multicomponent
Steel, Microstructural Evolution and Mechanical Properties
of Simulated J. D. Farren, A. H. Hunter, J. N. DuPont, C.
V. Robino, E. Kozeschnik, and D. N. Seidman, (May) 140-s
Heat Input and the Liquation Cracking of Laser Welded
IN738LC Superalloy M. Montazeri, F. Malek Ghaini, and
O. A. Ojo, (Sept) 258-s
Heat Input Reduction in Fillet Welding Using Bypass and Root
Opening Y. Lu, Y. M. Zhang, and L. Kvidahl, (Dec) 390-s
High-Temperature Corrosion Behavior of Alloy 600 and 622
Weld Claddings and Coextruded Coatings J. N. DuPont, A.
Hot Cracking Susceptibility for Extra-High-Purity 25Cr-35Ni
Stainless Steels, Contribution of Phosphorus and Sulfur on
K. Saida, Y. Nishijima, K. Nishimoto, K. Kiuchi, and J.
Human Welder Response Model, Dynamic Control of the
GTAW Process Using a W. J. Zhang and Y. M. Zhang,
(May) 154-s
Hybrid Laser Arc Welded Al-Zn-Mg-Cu Alloy with Synchrotron
Radiation Analysis, Porosity, Element Loss, and Strength
Model on Softening Behavior of S. C. Wu, X. Yu, R. Z. Zuo,
W. H. Zhang, H. L. Xie, and J. Z. Jiang, (March) 64-s
Hydrogen-Induced Cracking in High-Strength Naval Steels,
Quantifying Heat-Affected Zone X. Yue, X. L. Feng, and
J. C. Lippold, (Sept) 265-s
Hydrogen-Induced Cracking in Navy Steels, Evaluation of HeatAffected Zone X. Yue and J. C. Lippold, (Jan) 20-s
Inconel 600 Using Porous Interlayer, Microstructure Analysis
of Brazed Sapphire to T. Zaharinie, F. Yusof, M. Hamdi, T.
Ariga, and M. Fadzil, (Nov) 332-s
Influences of Laser Spot on High-Speed Welding for Cr-Plated
Sheet J. Zhan and M. J. Yang, (Oct) 291-s
Interfacial Microstructure of Diode Laser Brazed AZ31B Magnesium to Steel Sheet Using a Nickel Interlayer A. M.
Keyhole Behaviors in Controlled-Pulse Keyholing Plasma Arc
Welding, Sensing Dynamic Z. M. Liu, C. S. Wu, and J.
Chen, (Dec) 381-s
Laser Spot on High-Speed Welding for Cr-Plated Sheet, Influences of J. Zhan and M. J. Yang, (Oct) 291-s
Laser Welded IN738LC Superalloy, Heat Input and the Liquation Cracking of M. Montazeri, F. Malek Ghaini, and O. A.
Ojo, (Sept) 258-s
Laser Welding, Reducing the Porosity in Die-Cast Magnesium
Alloys during J. Zhang, J. G. Shan, J. L. Ren, and P. Wen,
(April) 101-s
Laser Welding of Zinc-Coated Steels in a Gap-Free Lap Joint
Configuration, Vacuum-Assisted S. Yang, J. Wang, B. E.
Carlson, and J. Zhang, (July) 197-s
Magnesium Alloys during Laser Welding, Reducing the Porosity
in Die-Cast J. Zhang, J. G. Shan, J. L. Ren, and P. Wen,
(April) 101-s
Magnesium Alloys: Mechanisms and Elimination, Spatter and

Porosity in Gas-Metal Arc Welding of D. C. Wagner, Y. K.
Yang, and S. Kou, (Dec) 347-s
Magnesium AZ31 to Galvanized Mild Steel, Feasibility of ColdMetal-Transfer Welding R. Cao, J. Y. Yu, J. H. Chen, and
P. C. Wang, (Sept) 274-s
Magnesium to Steel Sheet Using a Nickel Interlayer, Interfacial
Microstructure of Diode Laser Brazed AZ31B A. M.
Magnetically Assisted Resistance Spot Welding of Dual-Phase
Steel Y. B. Li, Y. T. Li, Q. Shen, and Z. Q. Lin, (April)
124-s
Microstructural Evolution and Mechanical Properties of Simulated Heat-Affected Zones in an Iron-Copper Based Multicomponent Steel J. D. Farren, A. H. Hunter, J. N. DuPont,
C. V. Robino, E. Kozeschnik, and D. N. Seidman, (May)
140-s
Microstructure Analysis of Brazed Sapphire to Inconel 600
Using Porous Interlayer T. Zaharinie, F. Yusof, M. Hamdi,
T. Ariga, and M. Fadzil, (Nov) 332-s
Microstructure and Wear Properties of Fe-2 wt-% Cr-X wt-% W0.67 wt-% C Hardfacing Layer J. Yang, Y. Yang, Y. Zhou,
X. Qi, Y. Gao, X. Ren, and Q. Yang, (Aug) 225-s
Model for Recognizing Joint Offset during Fiber Laser Welding,
Neural Network X. D. Gao, L. Mo, Q. Wen, and S.
Modeling of Implant Limit Stress and Maximum HAZ Hardness, Simplified Mathematical A. Fotouh, M. El-Shennawy,
Monitoring and Control in Submerged Arc Welding, Penetration
Depth X. R. Li, Y. M. Zhang, and L. Kvidahl, (Feb) 48-s
Monitoring and Control of Penetration in GTAW and Pipe Welding X. R. Li, Z. Shao, Y. M. Zhang, and L. Kvidahl, (June)
190-s
Naval Steels, The Weld Heat-Affected Zone Liquation Cracking
Susceptibility of J. L. Caron, S. S. Babu, and J. C. Lippold,
(April) 110-s
Naval Steels, Quantifying Heat-Affected Zone Hydrogen-Induced Cracking in High-Strength X. Yue, X. L. Feng, and
J. C. Lippold, (Sept) 265-s
Navy Steels, Evaluation of Heat-Affected Zone Hydrogen-Induced Cracking in Navy Steels X. Yue and J. C. Lippold,
(Jan) 20-s
Neural Network Model for Recognizing Joint Offset during
Fiber Laser Welding X. D. Gao, L. Mo, Q. Wen, and S.
New Optical Filter Plate for Use as Eye Protection by Welders
Nickel Interlayer, Interfacial Microstructure of Diode Laser
Brazed AZ31B Magnesium to Steel Sheet Using a A. M.
Optical Filter Plate for Use as Eye Protection by Welders, New
Penetration Depth Monitoring and Control in Submerged Arc
Welding X. R. Li, Y. M. Zhang, and L. Kvidahl, (Feb) 48-s
Penetration in GTAW and Pipe Welding, Monitoring and Control of X. R. Li, Z. Shao, Y. M. Zhang, and L. Kvidahl,
(June) 190-s
Penetration under Varying GTA Pools, Estimation of Weld Joint
Y. K. Liu, W. J. Zhang, and Y. M. Zhang, (Nov) 313-s
Pipe Welding, Monitoring and Control of Penetration in GTAW
and X. R. Li, Z. Shao, Y. M. Zhang, and L. Kvidahl, (June)
190-s
Plasma Arc Welding, Sensing Dynamic Keyhole Behaviors in
Controlled-Pulse Keyholing Z. M. Liu, C. S. Wu, and J.
Chen, (Dec) 381-s
Porosity, Element Loss, and Strength Model on Softening Behavior of Hybrid Laser Arc Welded Al-Zn-Mg-Cu Alloy with
Synchrotron Radiation Analysis S. C. Wu, X. Yu, R. Z. Zuo,

Porosity in Die-Cast Magnesium Alloys during Laser Welding,
Reducing the J. Zhang, J. G. Shan, J. L. Ren, and P. Wen,
(April) 101-s
Porosity in Gas-Metal Arc Welding of Magnesium Alloys: Mechanisms and Elimination, Spatter and D. C. Wagner, Y. K.
Yang, and S. Kou, (Dec) PAGE
Postweld Heat Treatment on the Toughness of Heat-Affected
Zone for Grade 91 Steel B. Silwal, L. Li, A. Deceuster, and
B. Griffiths, (March) 80-s
Prediction of -Phase Embrittlement in Type 316FR Weld Metal
E. J. Chun, H. Baba, K. Terashima, K. Nishimoto, and K.
Saida, (May) 133-s
Preliminary Investigation on Ultrasonic-Assisted Brazing of Titanium and Titanium/Stainless Steel Joints A. Elrefaey, L.
Processing Effects of Friction Stir Weld Stir Zone J. Schneider, R. Stromberg, P. Schilling, B. Cao, W. Zhou, J. Morfa, and
O. Myers, (Jan) 11-s
Quantifying Heat-Affected Zone Hydrogen-Induced Cracking in
High-Strength Naval Steels X. Yue, X. L. Feng, and J. C.
Lippold, (Sept) 265-s
Radiation Analysis, Porosity, Element Loss, and Strength Model
on Softening Behavior of Hybrid Laser Arc Welded Al-ZnMg-Cu Alloy with Synchrotron S. C. Wu, X. Yu, R. Z. Zuo,
Reality vs. Integrated Virtual Reality Training in Welding, Full
R. T. Stone, E. McLaurin, P. Zhong, and K. Watts, (June)
167-s
Reducing the Porosity in Die-Cast Magnesium Alloys during
Laser Welding J. Zhang, J. G. Shan, J. L. Ren, and P. Wen,
(April) 101-s
Resistance Spot Welding of Dual-Phase Steel, Magnetically Assisted Y. B. Li, Y. T. Li, Q. Shen, and Z. Q. Lin, (April)
124-s
Resistance Spot Welding Steels Part 1: Experimental Study,
Shunting Effect in B. Wang, M. Lou, Q. Shen, Y. B. Li, and
H. Zhang, (June) 182-s
Resistance Spot Welding Steels Part 2: Theoretical Analysis,
Shunting Effect in Y. B. Li, B. Wang, Q. Shen, M. Lou, and
H. Zhang, (Aug) 231-s
Sensing Dynamic Keyhole Behaviors in Controlled-Pulse Keyholing Plasma Arc Welding Z. M. Liu, C. S. Wu, and J.
Chen, (Dec) 381-s
Shielding Gas and Postweld Heat Treatment, Supermartensitic
Stainless Steel Deposits: Effects of S. Zappa, H. G. Svoboda, and E. S. Surian, (Oct) 297-s
Shunting Effect in Resistance Spot Welding Steels Part 1: Experimental Study B. Wang, M. Lou, Q. Shen, Y. B. Li, and
H. Zhang, (June) 182-s
Shunting Effect in Resistance Spot Welding Steels Part 2: Theoretical Analysis Y. B. Li, B. Wang, Q. Shen, M. Lou, and
H. Zhang, (Aug) 231-s
Simplified Mathematical Modeling of Implant Limit Stress and
Maximum HAZ Hardness A. Fotouh, M. El-Shennawy,
Sources of Variation in Ferrite Number Predictions vs. Measurements D. J. Kotecki and Z. Zhang, (June) 175-s
Spatter and Porosity in Gas-Metal Arc Welding of Magnesium
Alloys: Mechanisms and Elimination D. C. Wagner, Y. K.
Yang, and S. Kou, (Dec) 347-s
Stainless Steel 304, Transient Liquid Phase Diffusion Brazing of
57-s
Stainless Steel Deposits: Effects of Shielding Gas and Postweld
Heat Treatment, Supermartensitic S. Zappa, H. G. Svoboda, and E. S. Surian, (Oct) 297-s
Stainless Steels, Contribution of Phosphorus and Sulfur on Hot
Cracking Susceptibility for Extra-High-Purity 25Cr-35Ni K.
WELDING JOURNAL
89
Saida, Y. Nishijima, K. Nishimoto, K. Kiuchi, and J.

Submerged Arc Welding, Penetration Depth Monitoring and Control in X. R. Li, Y. M. Zhang, and L. Kvidahl, (Feb) 48-s
Supermartensitic Stainless Steel Deposits: Effects of Shielding
Gas and Postweld Heat Treatment S. Zappa, H. G. Svoboda, and E. S. Surian, (Oct) 297-s
Susceptibility of Alloy IN740 to HAZ Stress-Relaxation Cracking J. E. Ramirez, (April) 89-s
Tempering Pass on HSLA-80 Steel HAZ Microstructures, Effect
of A. Cruz-Crespo, D. Bezerra de Araujo, and A. Scotti,
(Oct) 304-s
The Weld Heat-Affected Zone Liquation Cracking Susceptibility of Naval Steels J. L. Caron, S. S. Babu, and J. C. Lippold,
(April) 110-s
Three-Dimensional Simulation of Underwater Welding and Investigation of Effective Parameters P. Ghadimi, H. Ghassemi, M. Ghassabzadeh, and Z. Kiaei, (Aug) 239-s
Titanium and Titanium/Stainless Steel Joints, Preliminary Investigation on Ultrasonic-Assisted Brazing of A. Elrefaey, L.
Tool Design Effects for FSW of AA7039 D. Venkateswarlu, N.
R. Mandal, M. M. Mahapatra, and S. P. Harsh, (Feb) 41-s
Toughness of Heat-Affected Zone for Grade 91 Steel, Effect of
Postweld Heat Treatment on the B. Silwal, L. Li, A. Deceuster, and B. Griffiths, (March) 80-s
Training in Welding, Full Reality vs. Integrated Virtual Reality
R. T. Stone, E. McLaurin, P. Zhong, and K. Watts, (June) 167-s
Transfer Welding Magnesium AZ31 to Galvanized Mild Steel,

Feasibility of Cold-Metal- R. Cao, J. Y. Yu, J. H. Chen, and
P. C. Wang, (Sept) 274-s
Transient Liquid Phase Diffusion Brazing of Stainless Steel 304
57-s
Ultrasonic-Assisted Brazing of Titanium and Titanium/Stainless
Steel Joints, Preliminary Investigation on A. Elrefaey, L.
Ultrasonic Wave-Assisted GMAW, Arc Characteristics of C.
L. Fan, C. L. Yang, S. B. Lin, and Y. Y. Fan, (Dec) 375-s
Underwater Welding and Investigation of Effective Parameters,
Three-Dimensional Simulation of P. Ghadimi, H. Ghassemi, M. Ghassabzadeh, and Z. Kiaei, (Aug) 239-s
Vacuum-Assisted Laser Welding of Zinc-Coated Steels in a GapFree Lap Joint Configuration S. Yang, J. Wang, B. E. Carlson, and J. Zhang, (July) 197-s
Wear Properties of Fe-2 wt-% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, Microstructure and J. Yang, Y. Yang, Y.
Zhou, X. Qi, Y. Gao, X. Ren, and Q. Yang, (Aug) 225-s
Weld-Bonding Multiple Steel Sheets, Effect of Adhesive Characteristics on the Weld Quality in Y. S. Zhang, J. Shen, Y.
Y. Zhao, P. C. Wang, and B. Carlson, (Dec) 363-s
Zinc-Coated Steels in a Gap-Free Lap Joint Configuration, Vacuum-Assisted Laser Welding of S. Yang, J. Wang, B. E. Carlson, and J. Zhang, (July) 197-s
AUTHORS FOR RESEARCH SUPPLEMENT

Ariga, T., Fadzil, M., Zaharinie, T., Yusof, F., and Hamdi, M.
Microstructure Analysis of Brazed Sapphire to Inconel
600 Using Porous Interlayer, (Nov) 332-s
Atabaki, M., Noor Wati, J., and Idris, J. Transient Liquid
Phase Diffusion Brazing of Stainless Steel 304, (March)
57-s
Baba, H., Terashima, K., Nishimoto, K., Saida, K., and Chun,
E. J. Prediction of the -Phase Embrittlement in Type
316FR Weld Metal, (May) 133-s
Babu, S. S., Lippold, J. C., and Caron, J. L. The Weld HeatAffected Zone Liquation Cracking Susceptibility of Naval
Steels, (April) 110-s
Basak, S., Pal, T. K., Shome, M., and Maity, J. GMA Brazing of Galvannealed Interstitial-Free Steel, (Feb) 29-s
Bezerra de Araujo, D., Scotti, A., and Cruz-Crespo, A. Effect of Tempering Pass on HSLA-80 Steel HAZ Microstructures, (Oct) 304-s
Bonnin-Arias, C., Chamorro, E., Prez-Carrasco, J., SnchezRamos, C., and Langa-Moraga, A. New Optical Filter
Plate for Use as Eye Protection by Welders, (Feb) 36-s
Brentrup, G. J., and DuPont, J. N. Fabrication and Characterization of Graded Transition Joints for Welding Dissimilar Alloys, (March) 72-s
Caizza, A., Esposito, A., DuPont, J. N., and Stockdale, A.
Weld Claddings and Coextruded Coatings, (July) 218-s
Cao, B., Zhou,W., Morfa, J., Myers. O., Schneider, J.,
Stromberg, R., and Schilling, P. Processing Effects on the
Friction Stir Weld Stir Zone, (Jan) 11-s
Cao, R., Yu, J. Y., Chen, J. H., and Wang, P. C. Feasibility
of Cold-Metal-Transfer Welding Magnesium AZ31 to
Galvinized Mild Steel, (Sept) 274-s
Carlson, B., Zhang, Y. S., Shen, J., Zhao, Y. Y., and Wang, P.
90
DECEMBER 2013
C. Effect of Adhesive Characteristics on the Weld Quality in Weld-Bonding Multiple Steel Sheets, (Dec) 363-s
Carlson, B. E., Zhang, J., Yang, S., and Wang, J. VacuumAssisted Laser Welding of Zinc-Coated Steels in a Gap-Free
Lap Joint Configuration, (July) 197-s
Caron, J. L., Babu, S. S., and Lippold, J. C. The Weld HeatAffected Zone Liquation Cracking Susceptibility of Naval
Chamorro, E., Prez-Carrasco, J., Snchez-Ramos, C., LangaMoraga, A., and Bonnin-Arias, C. New Optical Filter
Chen, J., Liu, Z. M., and Wu, C. S. Sensing Dynamic Keyhole Behaviors in Controlled-Pulse Keyholing Plasma Arc
Welding, (Dec) 381-s
Chen, J. H., Wang, P. C., Cao, R., and Yu, J. Y. Feasibility
Chen, S. J., Wu, L., Zhang, Y. M., Xiao, J., and Zhang, G. J.
Active Droplet Oscillation Excited by Optimized Waveform,
(July) 205-s
Chun, E. J., Baba, H., Terashima, K., Nishimoto, K., and Saida,
K. Prediction of the -Phase Embrittlement in Type
Cruz-Crespo, A., Bezerra de Araujo, D., and Scotti, A. Effect of Tempering Pass on HSLA-80 Steel HAZ Microstructures, (Oct) 304-s
Deceuster, A., Griffiths, B., Silwal, B., and Li, L. Effect of
Postweld Heat Treatment on the Toughness of HeatAffected Zone for Grade 91 Steel, (March) 80-s
DuPont, J. N., and Brentrup, G. J. Fabrication and Characterization of Graded Transition Joints for Welding Dissimilar Alloys, (March) 72-s
DuPont, J. N., Stockdale, A. W., Caizza, A., and Esposito, A.
High-Temperature Corrosion Behavior of Alloy 600 and

622 Weld Claddings and Coextruded Coatings, (July) 218-s
DuPont, J. N., Robino, C. V., Kozeschnik, E., Seidman, D. N.,
Farren, J. D., and Hunter, A. H. Microstructural Evolution and Mechanical Properties of Simulated Heat-Affected
Zones in an Iron-Copper Based Multicomponent Steel,
(May) 140-s
El-Hebeary, R., Fotouh, A., and El-Shennawy, M. Simplified Mathematical Modeling of Implant Limit Stress and
Maximum HAZ Hardness, (Nov) 336-s
El-Shennawy, M., El-Hebeary, R., and Fotouh, A. Simplified Mathematical Modeling of Implant Limit Stress and
Esposito, A., DuPont, J. N., Stockdale, A., and Caizza, A.
Weld Claddings and Coextruded Coatings, (July) 218-s
Fadzil, M., Zaharinie, T., Yusof, F., Hamdi, M., and Ariga, T.
Fan, C. L., Yang, C. L., Lin, S. B., and Fan, Y. Y. Arc Characteristics of Ultrasonic Wave-Assisted GMAW, (Dec)
375-s
Fan, Y. Y., Fan, C. L., Yang, C. L., and Lin, S. B. Arc Characteristics of Ultrasonic Wave-Assisted GMAW, (Dec)
375-s
Farren, J.D., Hunter, A. H., DuPont, J. N., Robino, C. V.,
Kozeschnik, E., and Seidman, D. N. Microstructural Evolution and Mechanical Properties of Simulated HeatAffected Zones in an Iron-Copper Based Multicomponent
Steel, (May) 140-s
Feng, X. L., Lippold, J. C., and Yue, X. Quantifying HeatAffected Zone Hydrogen-Induced Cracking in HighStrength Naval Steels, (Sept) 265-s
Fotouh, A., El-Shennawy, M., and El-Hebeary, R. Simplified Mathematical Modeling of Implant Limit Stress and
Gao, Y., Ren, X., Yang, Q., Yang, J., Yang, Y., Zhou, Y., and
Qi, X. Microstructure and Wear Properties of Fe-2 wt-%
Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug) 225-s
Gao, X. D., Mo, L., Wen, Q., and Katayama, S. Neural Network Model for Recognizing Joint Offset during Fiber Laser
Welding, (Sept) 251-s
Ghadimi, P., Ghassemi, H., Ghassabzadeh, M., and Kiaei, Z.
Three-Dimensional Simulation of Underwater Welding and
Investigation of Effective Parameters, (Aug) 239-s
Ghassabzadeh, M., Kiaei, Z., Ghadimi, P., and Ghassemi, M.
Three-Dimensional Simulation of Underwater Welding
and Investigation of Effective Parameters, (Aug) 239-s
Ghassemi, H., Ghassabzadeh, M., Kiaei, Z., and Ghadimi, P.
Three-Dimensional Simulation of Underwater Welding and
Investigation of Effective Parameters, (Aug) 239-s
Griffiths, B., Silwal, B., Li, L., and Deceuster, A. Effect of
Hamdi, M., Ariga, T., Fadzil, M., Zaharinie, T., and Yusof, F.
Harsh, S. P., Venkateswarlu, D., Mandal, N. R., and Mahapatra, M. M. Tool Design Effects for FSW of AA7039, (Feb)
41-s
Hunter, A. H., DuPont, J. N., Robino, C. V., Kozeschnik, E.,
Seidman, D. N., and Farren, J. D. Microstructural Evolution and Mechanical Properties of Simulated HeatAffected Zones in an Iron-Copper Based Multicomponent
Steel, (May) 140-s
Idris, J., Mazar Atabaki, M., and Noor Wati, J. Transient
Liquid Phase Diffusion Brazing of Stainless Steel 304,
(March) 57-s
Jiang, J. Z., Wu, S. C., Yu, X., Zuo, R. Z., Zhang, W. H., and
Xie, H. L. Porosity, Element Loss, and Strength Model
on Softening Behavior of Hybrid Laser Arc Welded Al-ZnMg-Cu Alloy with Synchrotron Radiation Analysis, (March)
64-s
Katayama, S., Gao, X. D., Mo, L., and Wen, Q. Neural Network Model for Recognizing Joint Offset during Fiber Laser
Kiaei, Z., Ghadimi, P., Ghassemi, M., and Ghassabzadeh, M.
Three-Dimensional Simulation of Underwater Welding
and Investigation of Effective Parameters, (Aug) 239-s
Kiuchi, K., Nakayama, J., Saida, K., Nishijima, Y., and Nishimoto, K. Contribution of Phosphorus and Sulfur on Hot
Cracking Susceptibility for Extra-High-Purity 25Cr-35Ni
Stainless Steels, (Nov) 322-s
Kotecki, D. J., and Zhang, Z. Sources of Variation in Ferrite Number Predictions vs. Measurements, (June) 175-s
Kou, S., Wagner, D. C., and Yang, Y. K. Spatter and Porosity in Gas-Metal Arc Welding of Magnesium Alloys: Mechanisms and Elimination, (Dec) 347-s
Kozeschnik, E., Seidman, D. N., Farren, J. D., Hunter, A. H.,
DuPont, J. N., and Robino, C. V. Microstructural Evolution and Mechanical Properties of Simulated Heat-Affected
(May) 140-s
Kvidahl, L., Lu, Y., and Zhang, Y. M. Heat Input Reduction in Fillet Welding Using Bypass and Root Opening,
(Dec) 390-s
Kvidahl, L., Li, X. R., Shao, Z., and Zhang, Y. M. Monitoring and Control of Penetration in GTAW and Pipe Welding,
(June) 190-s
Kvidahl, L., Li, X. R., and Zhang, Y. M. Penetration Depth
Monitoring and Control in Submerged Arc Welding, (Feb)
48-s
Langa-Moraga, A., Bonnin-Arias, C., Chamorro, E., PrezCarrasco, J., and Snchez-Ramos, C. New Optical Filter
Li, L., Deceuster, A., Griffiths, B., and Silwal, B. Effect of
Li, X. R., Shao, Z., Zhang, Y. M., and Kvidahl, L. Monitoring and Control of Penetration in GTAW and Pipe Welding,
(June) 190-s
Li, X. R., Zhang, Y. M., and Kvidahl, L. Penetration Depth
48-s
Li, Y. B., Li, Y. T., Shen, Q., and Lin, Z. Q. Magnetically Assisted Resistance Spot Welding of Dual-Phase Steel, (April)
124-s
Li, Y. B., Zhang, H., Wang, B., Lou, M., and Shen, Q. Shunting Effect in Resistance Spot Welding Steels Part 1: Experimental Study, (June) 182-s
Li, Y. B., Wang, B., Shen, Q., Lou, M., and Zhang, H. Shunting Effect in Resistance Spot Welding Steels Part 2: Theoretical Analysis, (Aug) 231-s
Li, Y. T., Shen, Q., Lin, Z. Q., and Li, Y. B. Magnetically Assisted Resistance Spot Welding of Dual-Phase Steel, (April)
124-s
Lin, S. B., Fan, Y. Y., Fan, C. L., and Yang, C. L. Arc Characteristics of Ultrasonic Wave-Assisted GMAW, (Dec)
375-s
Lin, Z. Q., Li, Y. B., Li, Y. T., and Shen, Q. Magnetically Assisted Resistance Spot Welding of Dual-Phase Steel, (April)
124-s
Lippold, J. C., Rule, J. R., and Rodelas, J. M. Application
of Friction Stir Processing as a Pretreatment to Fusion Welding, (Oct) 283-s
Lippold, J. C., and Yue, X. Evaluation of Heat-Affected
Zone Hydrogen-Induced Cracking in Navy Steels, (Jan)
20-s
Lippold, J. C., Caron, J. L., and Babu, S., S. The Weld HeatAffected Zone Liquation Cracking Susceptibility of Naval
WELDING JOURNAL
91

Lippold, J. C., Yue, X., and Feng, X. L. Quantifying HeatAffected Zone Hydrogen-Induced Cracking in HighStrength Naval Steels, (Sept) 265-s
Liu, Y. K., Zhang, W. J., and Zhang, Y. M. Estimation of
Weld Joint Penetration under Varying GTA Pools, (Nov)
313-s
Liu, Z. M., Wu, C. S., and Chen, J. Sensing Dynamic Keyhole Behaviors in Controlled-Pulse Keyholing Plasma Arc
Lou, M., Shen, Q., Li, Y. B., Zhang, H., and Wang, B. Shunting Effect in Resistance Spot Welding Steels Part 1: Experimental Study, (June) 182-s
Lou, M., Zhang, H., Li, Y. B., Wang, B., and Shen, Q. Shunting Effect in Resistance Spot Welding Steels Part 2: Theoretical Analysis, (Aug) 231-s
Lu, Y., Zhang, Y. M., and Kvidahl, L. Heat Input Reduction in Fillet Welding Using Bypass and Root Opening,
(Dec) 390-s
Maity, J., Basak, S., Pal, T. K., and Shome, M. GMA Brazing of Galvannealed Interstitial-Free Steel, (Feb) 29-s
Mahapatra, M. M., Harsh, S. P., Venkateswarlu, D., and Mandal, N. R. Tool Design Effects for FSW of AA7039, (Feb)
41-s
Malek Ghaini, F., Ojo, O. A., and Montazeri, M. Heat Input
and the Liquation Cracking of Laser Welded IN738LC Superalloy, (Sept) 258-s
Mandal, N. R., Mahapatra, M. M., Harsh, S. P., and
Venkateswarlu, D. Tool Design Effects for FSW of
AA7039, (Feb) 41-s
McLaurin, E., Zhong, P., Watts, K., and Stone, R. T. Full Virtual Reality vs. Integrated Virtual Reality Training in Welding, (June) 167-s
Mo, L., Wen, Q., Katayama, S., and Gao, X. D. Neural Network Model for Recognizing Joint Offset during Fiber Laser
Montazeri, M., Malek Ghaini, F., and Ojo, O. A. Heat Input
Morfa, J., Myers, O., Schneider, J., Stromberg, R., Schilling, P.,
Cao, B., and Zhou, W. Processing Effects on the Friction
Stir Weld Stir Zone, (Jan) 11-s
Myers, O., Schneider, J., Stromberg, R., Schilling, P., Cao, B.,
Zhou, W., and Morfa, J. Processing Effects on the Friction Stir Weld Stir Zone, (Jan) 11-s
Nakayama, J., Saida, K., Nishijima, Y., Nishimoto, K., and Kiuchi, K. Contribution of Phosphorus and Sulfur on Hot
Nasiri, A. M., Weckman, D. C., and Zhou, Y. Interfacial Microstructure of Diode Laser Brazed AZ31B Magnesium to
Steel Sheet Using a Nickel Interlayer, (Jan) 1-s
Nishijima, Y., Nishimoto, K., Kiuchi, K., Nakayama, J., and
Saida, K. Contribution of Phosphorus and Sulfur on Hot
Nishimoto, K., Kiuchi, K., Nakayama, J., Saida, K., and Nishijima, Y. Contribution of Phosphorus and Sulfur on Hot
Nishimoto, K., Saida, K., Chun, E. J., Baba, H., and Terashima,
Noor Wati, J., Idris, J., and Mazar Atabaki, M. Transient
Liquid Phase Diffusion Brazing of Stainless Steel 304,
(March) 57-s
Ojo, O. A., Montazeri, M., and Malek Ghaini, F. Heat Input
Pal, T. K., Shome, M., Maity, J., and Basak, S. GMA Braz92
DECEMBER 2013
ing of Galvannealed Interstitial-Free Steel, (Feb) 29-s

Prez-Carrasco, J., Snchez-Ramos, C., Langa-Moraga, A.,
Bonnin-Arias, C., and Chamorro, E. New Optical Filter
Qi, X., Gao, Y., Ren, X., Yang, Q., Yang, J., Yang, Y., and
Zhou, Y. Microstructure and Wear Properties of Fe-2 wt% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug)
225-s
Ramirez, J. E. Evaluation of Susceptibility of Alloy IN740
to HAZ Stress-Relaxation Cracking, (April) 89-s
Ren, J. L., Wen, P., Zhang, J., and Shan, J. G. Reducing the
Porosity in Die-Cast Magnesium Alloys during Laser Welding, (April) 101-s
Ren, X., Yang, Q., Yang, J., Yang, Y., Zhou, Y., Qi, X., and
Gao, Y. Microstructure and Wear Properties of Fe-2 wt% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug)
225-s
Robino, C. V., Kozeschnik, E., Seidman, D. N., Farren, J. D.,
Hunter, A. H., and DuPont, J. N. Microstructural Evolution and Mechanical Properties of Simulated Heat-Affected
(May) 140-s
Rodelas, J. M., Lippold, J. C., and Rule, J. R. Application
Rule, J. R., Rodelas, J. M., and Lippold, J. C. Application
Saida, K., Nishijima, Y., Nishimoto, K., Kiuchi, K., and
Nakayama, J. Contribution of Phosphorus and Sulfur on
Hot Cracking Susceptibility for Extra-High-Purity 25Cr35Ni Stainless Steels, (Nov) 322-s
Saida, K., Chun, E. J., Baba, H., Terashima, K., and Nishimoto,
Snchez-Ramos, C., Langa-Moraga, A., Bonnin-Arias, C.,
Chamorro, E., and Prez-Carrasco, J. New Optical Filter
Schilling, P., Cao, B., Zhou,W., Morfa, J., Myers, O., Schneider, J., and Stromberg, R. Processing Effects on the Friction Stir Weld Stir Zone, (Jan) 11-s
Schneider, J., Stromberg, R., Schilling, P., Cao, B., Zhou,W.,
Morfa, J., and Myers, O. Processing Effects on the Friction Stir Weld Stir Zone, (Jan) 11-s
Scotti, A., Cruz-Crespo, A., and Bezerra de Araujo, D. Effect of Tempering Pass on HSLA-80 Steel HAZ Microstructures, (Oct) 304-s
Seidman, D. N., Farren, J. D., Hunter, A. H., DuPont, J. N.,
Robino, C. V., and Kozeschnik, E. Microstructural Evolution and Mechanical Properties of Simulated HeatAffected Zones in an Iron-Copper Based Multicomponent
Steel, (May) 140-s
Shan, S., Ren, J. L., Wen, P., and Zhang, J. Reducing the
Shao, Z., Zhang, Y. M., Kvidahl, L., and Li, X. R. Monitoring and Control of Penetration in GTAW and Pipe Welding,
(June) 190-s
Shen, J., Zhao, Y. Y., Wang, P. C., Carlson, B., and Zhang, Y.
S. Effect of Adhesive Characteristics on the Weld Quality in Weld-Bonding Multiple Steel Sheets, (Dec) 363-s
Shen, Q., Lin, Z. Q., Li, Y. B., and Li, Y. T. Magnetically Assisted Resistance Spot Welding of Dual-Phase Steel, (April)
124-s
Shen, Q., Li, Y. B., Zhang, H., Wang, B., and Lou, M. Shunting Effect in Resistance Spot Welding Steels Part 1: Experimental Study, (June) 182-s
Shen, Q., Lou, M., Zhang, H., Li, Y. B., and Wang, B. Shunting Effect in Resistance Spot Welding Steels Part 2: Theoretical Analysis, (Aug) 231-s
Shome, M., Maity, J., Basak, S., and Pal, T. K. GMA Brazing of Galvannealed Interstitial-Free Steel, (Feb) 29-s
Silwal, B., Li, L., Deceuster, A., and Griffiths, B. Effect of
Stockdale, A. W., Caizza, A., Esposito, A., and DuPont, J. N.
High-Temperature Corrosion Behavior of Alloy 600 and
622 Weld Claddings and Coextruded Coatings, (July) 218-s
Stromberg, R., Schilling, P., Cao, B., Zhou,W., Morfa, J.,
Myers, O., and Schneider, J. Processing Effects on the
Friction Stir Weld Stir Zone, (Jan) 11-s
Stone, R. T., McLaurin, E., Zhong, P., and Watts, K. Full Virtual Reality vs. Integrated Virtual Reality Training in Welding, (June) 167-s
Surian, E. S., Zappa, S., and Svoboda, H. G. Supermartensitic Stainless Steel Deposits: Effects of Shielding Gas and
Postweld Heat Treatment, (Oct) 297-s
Svoboda, H. G., Surian, E. S., and Zappa, S. Supermartensitic Stainless Steel Deposits: Effects of Shielding Gas and
Terashima, K., Nishimoto, K., Saida, K., Chun, E. J., and Baba,
H. Prediction of the -Phase Embrittlement in Type
Venkateswarlu, D., Mandal, N. R., Mahapatra, M. M., and
Harsh, S. P. Tool Design Effects for FSW of AA7039,
(Feb) 41-s
Wagner, D. C., Yang, Y. K., and Kou, S. Spatter and Porosity in Gas-Metal Arc Welding of Magnesium Alloys: Mechanisms and Elimination, (Dec) 347-s
Wang, B., Lou, M., Shen, Q., Li, Y. B., and Zhang, H. Shunting Effect in Resistance Spot Welding Steels Part 1: Experimental Study, (June) 182-s
Wang, B., Shen, Q., Lou, M., Zhang, H., and Li, Y. B. Shunting Effect in Resistance Spot Welding Steels Part 2: Theoretical Analysis, (Aug) 231-s
Wang, J., Carlson, B. E., Zhang, J., and Yang, S. VacuumAssisted Laser Welding of Zinc-Coated Steels in a Gap-Free
Wang, P. C., Carlson, B., Zhang, Y. S., Shen, J., and Zhao, Y.
Y. Effect of Adhesive Characteristics on the Weld Quality in Weld-Bonding Multiple Steel Sheets, (Dec) 363-s
Wang, P. C., Cao, R., Yu, J. Y., and Chen, J. H. Feasibility
Watts, K., Stone, R. T., McLaurin, E., and Zhong, P. Full Virtual Reality vs. Integrated Virtual Reality Training in Welding, (June) 167-s
Weckman, D. C., Zhou, Y., and Nasiri, A. M. Interfacial Microstructure of Diode Laser Brazed AZ31B Magnesium to
Wen, P., Zhang, J., Shan, J. G., and Ren, J. L. Reducing the
Wen, Q., Katayama, S., Gao, X. D., and Mo, L. Neural Network Model for Recognizing Joint Offset during Fiber Laser
Wu, C. S., Chen, J., and Liu, Z. M. Sensing Dynamic Keyhole Behaviors in Controlled-Pulse Keyholing Plasma Arc
Wu, L., Zhang, Y. M., Xiao, J., Zhang, G. J., and Chen, S. J.
(July) 205-s
Wu, S. C., Yu, X., Zuo, R. Z., Zhang, W. H., Xie, H. L., and
Jiang, J. Z. Porosity, Element Loss, and Strength Model
on Softening Behavior of Hybrid Laser Arc Welded Al-ZnMg-Cu Alloy with Synchrotron Radiation Analysis, (March)
64-s
Xiao, J., Zhang, G. J., Chen, S. J., Wu, L., and Zhang, Y. M.
(July) 205-s
Xie, H. L., Jiang, J. Z., Wu, S. C., Yu, X., Zuo, R. Z., and
Zhang, W. H. Porosity, Element Loss, and Strength
Model on Softening Behavior of Hybrid Laser Arc Welded
Al-Zn-Mg-Cu Alloy with Synchrotron Radiation Analysis,
(March) 64-s
Yang, C. L., Lin, S. B., Fan, Y. Y., and Fan, C. L. Arc Characteristics of Ultrasonic Wave-Assisted GMAW, (Dec)
375-s
Yang, J., Yang, Y., Zhou, Y., Qi, X., Gao, Y., Ren, X., and
Yang, Q. Microstructure and Wear Properties of Fe-2 wt% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug)
225-s
Yang, M. J. and Zhan, J. Influences of Laser Spot on HighSpeed Welding for Cr-Plated Sheet, (Oct) 291-s
Yang, Q., Yang, J., Yang, Y., Zhou, Y., Qi, X., Gao, Y., and
Ren, X. Microstructure and Wear Properties of Fe-2 wt% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug)
225-s
Yang, S., Wang, J., Carlson, B. E., and Zhang, J. VacuumAssisted Laser Welding of Zinc-Coated Steels in a Gap-Free
Yang, Y., Zhou, Y., Qi, X., Gao, Y., Ren, X., Yang, Q., and
Yang, J. Microstructure and Wear Properties of Fe-2 wt% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug)
225-s
Yang, Y. K., Kou, S., and Wagner, D. C. Spatter and Porosity in Gas-Metal Arc Welding of Magnesium Alloys: Mechanisms and Elimination, (Dec) 347-s
Yu, J. Y., Chen, J. H., Wang, P. C., and Cao, R. Feasibility
Yu, X., Zuo, R. Z., Zhang, W. H., Xie, H. L., Jiang, J. Z., and
Wu, S. C. Porosity, Element Loss, and Strength Model on
Softening Behavior of Hybrid Laser Arc Welded Al-Zn-MgCu Alloy with Synchrotron Radiation Analysis, (March)
64-s
Yue, X. and Lippold, J. C. Evaluation of Heat-Affected
Zone Hydrogen-Induced Cracking in Navy Steels, (Jan)
20-s
Yue, X., Feng, X. L., and Lippold, J. C. Quantifying HeatAffected Zone Hydrogen-Induced Cracking in HighStrength Naval Steels, (Sept) 265-s
Yusof, F., Hamdi, M., Ariga, T., Fadzil, M., and Zaharinie, T.
Zaharinie, T., Yusof, F., Hamdi, M., Ariga, T., and Fadzil, M.
Zappa, S., Svoboda, H. G., and Surian, E. S. Supermartensitic Stainless Steel Deposits: Effects of Shielding Gas and
Zhan, J., and Yang, M. J. Influences of Laser Spot on HighSpeed Welding for Cr-Plated Sheet, (Oct) 291-s
Zhang, G. J., Chen, S. J., Wu, L., Zhang, Y. M., and Xiao, J.
(July) 205-s
Zhang, H., Wang, B., Lou, M., Shen, Q., and Zhang, H.
Shunting Effect in Resistance Spot Welding Steels Part 1:
Experimental Study, (June) 182-s
Zhang, H., Li, Y. B., Wang, B., Shen, Q., and Lou, M. Shunting Effect in Resistance Spot Welding Steels Part 2: Theoretical Analysis, (Aug) 231-s
Zhang, J., Shan, J. G., Ren, J. L., and Wen, P. Reducing the
Zhang, J., Yang, S., Wang, J., and Carlson, B. E. VacuumAssisted Laser Welding of Zinc-Coated Steels in a Gap-Free
Zhang, W. H., Xie, H. L., Jiang, J. Z., Wu, S. C., Yu, X., and Zuo,
R. Z. Porosity, Element Loss, and Strength Model on SoftWELDING JOURNAL
93
ening Behavior of Hybrid Laser Arc Welded Al-Zn-Mg-Cu

Alloy with Synchrotron Radiation Analysis, (March) 64-s
Zhang, W. J. and Zhang, Y. M. Dynamic Control of the
GTAW Process Using a Human Welder Response Model,
(May) 154-s
Zhang, W. J., Zhang, Y. M., and Liu, Y. K. Estimation of
313-s
Zhang, Y. M., Xiao, J., Zhang, G. J., Chen, S. J., and Wu, L.
(July) 205-s
Zhang, Y. M., and Zhang, W. J. Dynamic Control of the
GTAW Process Using a Human Welder Response Model,
(May) 154-s
Zhang, Y. M., Liu, Y. K., and Zhang, W. J. Estimation of
313-s
Zhang, Y. M., Kvidahl, L., and Lu, Y. Heat Input Reduction in Fillet Welding Using Bypass and Root Opening,
(Dec) 390-s
Zhang, Y. M., Kvidahl, L., Li, X. R., and Shao, Z. Monitoring and Control of Penetration in GTAW and Pipe Welding,
(June) 190-s
Zhang, Y. M., Kvidahl, L., and Li, X. R. Penetration Depth
48-s
Zhang, Y. S., Shen, J., Zhao, Y. Y., Wang, P. C., and Carlson,
B. Effect of Adhesive Characteristics on the Weld Quality in Weld-Bonding Multiple Steel Sheets, (Dec) 363-s
Zhang, Z., and Kotecki, D. J. Sources of Variation in Ferrite Number Predictions vs. Measurements, (June) 175-s
Zhao, Y. Y., Wang, P. C., Carlson, B., Zhang, Y. S., and Shen,
J. Effect of Adhesive Characteristics on the Weld Quality in Weld-Bonding Multiple Steel Sheets, (Dec) 363-s
Zhong, P., Watts, K., Stone, R. T., and McLaurin, E. Full Virtual Reality vs. Integrated Virtual Reality Training in Welding, (June) 167-s
Zhou,W., Morfa, J., Myers, O., Schneider, J., Stromberg, R.,
Schilling, P., and Cao, B. Processing Effects on the Friction Stir Weld Stir Zone, (Jan) 11-s
Zhou, Y., Nasiri, A. M., and Weckman, D. C. Interfacial Microstructure of Diode Laser Brazed AZ31B Magnesium to
Zhou, Y., Qi, X., Gao, Y., Ren, X., Yang, Q., Yang, J., and
Yang, Y. Microstructure and Wear Properties of Fe-2 wt% Cr-X wt-% W-0.67 wt-% C Hardfacing Layer, (Aug)
225-s
Zuo, R. Z., Zhang, W. H., Xie, H. L., Jiang, J. Z., Wu, S. C., and
Yu, X. Porosity, Element Loss, and Strength Model on
Softening Behavior of Hybrid Laser Arc Welded Al-Zn-MgCu Alloy with Synchrotron Radiation Analysis, (March) 64-s
AWS PROFESSIONAL PROGRAM

ABSTRACT SUBMITTAL
AT FABTECH 2014
Atlanta Nov. 11-13, 2014
Submission deadline: Mar. 29, 2014
The AWS Professional Program is an annual three-day program of sessions
on technical topics featuring the most recent welding research and best practices
in manufacturing and construction from around the world.
Submit your Professional Program abstract online by March 28 at
http://awo.aws.org/professional-program-abstract-form
or contact Martica Ventura at (800) 443-9353 ext 224 (mventura@aws.org)
94
DECEMBER 2013
educ (pipeline conf)_FP_TEMP 11/11/13 2:26 PM Page 95
Pipelines Conference
Mar
W

back to the days when hand-held oxyacetylene torches wer
r
re pipeline welding trends will be
AWS-sponsored confer
Highlights
Learn about the progress of new and innovative developments
in pipeline welding.

business growth.
AWS Conference attendees are awarded 1 PDH (Professional
Development Hour) for each hour of conference attendance.

and renewals.
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 223.
Personnel Dec._Layout 1 11/13/13 4:04 PM Page 96
NEWS OF THE INDUSTRY

continued from page 14
Laurus Technical Institute, Atlanta, Ga., launched a Welding
Technology program that combines 25% classroom theory with

75% practical exercises. Students learn shielded metal arc, gas
metal arc, flux core, and gas tungsten arc welding.
Adept Technology, Inc., a provider of robots and autonomous
mobile systems, opened its east coast application and demo
center within the companys Amherst, N.H., facility.
Flight safety eyewear from Gateway Safety, Cleveland, Ohio,
won the top spot in Industrial Safety & Hygiene News first Readers Choice Awards contest.
Weld Plus, Inc., Cincinnati, Ohio, has been named the exclusive distributor of Watts Specialties products, which include
pipe fabricating and cutting systems, in Ohio, Kentucky, Pennsylvania, West Virginia, Indiana, and Michigan.
Central Carolina Community College in North Carolina has
launched a new, four-semester Diploma in Welding Technology program. It offers 128 h of instructional time in gas metal
arc/flux core welding and 128 h in gas tungsten arc welding.
Miyachi Unitek Corp., a Monrovia, Calif., manufacturer of
welding equipment and laser processing systems, is now Miyachi America Corp. However, the company will continue to use
the Miyachi Unitek brand name.
Climax Portable Machining & Welding Systems, Newberg, Ore.,
finished its acquisition of privately held Calder Testers, an
equipment provider for testing industrial valves and more.
John Deere Ottumwa Works, Iowa, recently donated five welding machines, 150 pairs of welding gloves, eight autodarkening
PERSONNEL
continued from page 69
president in 2015. Sean Hearne was reelected secretary for a second three-year
term. Kraft is director at the Institute for
Applied Materials and is also Robert
Bosch Professor for Nanostructured
Functional Materials at Karlsruhe Institute of Technology in Germany. Hearne
is manager of the Grid Electrical Energy
Storage department at Sandia National
Laboratories (SNL). Incoming board
members include Alexandra Boltasseva,
Perdue University; C. Jeffrey Brinker,
SNL and University of New Mexico;
Hideo Hosono, Tokyo Institute of Technology; Kornelius Nielsch, University of
Hamburg; and Loucas Tsakalakos, General Electric Global Research Center.
ASM Names Eisenman

Award Winner
ASM International, Materials Park,
Ohio, has presented the 2013 William
Hunt Eisenman Award to Mark L. Robinson, vice president of technology (ret.),
Hamilton Precision Metals, Lancaster, Pa.
Robinson was cited for sustained contributions in cast, powder metallurgy,
96
DECEMBER 2013
welding helmets, welding wire, and about 45,000-lb of scrap

metal to Ottumwa High Schools welding program.
Hgans, an iron and metal powders producer, inaugurated a
production plant with its brazing facility in Ath, Belgium. At
the ribbon cutting were Marc Duvivier, Aths mayor, and Kjell
Paulsson, former company operations director, region Europe.
Over the past three years, JLB Welding, McCook, Neb., owned
by Jeremy and Laura Bain has expanded from a one-man, sideline business to a multipurpose firm with a new 4000-sq-ft shop
and eight full-time employees. Among its services are performing repair and fabrication work, plus making steel benches.
Fox Valley Technical College implemented eight robotic welding machines at its Oshkosh, Wis., Advanced Manufacturing
Technology Center. Governor Scott Walker also visited.
Industrial Scientific, Pittsburgh, Pa., has been named Advanced
Manufacturing Company of the Year in the Pittsburgh Technology Councils Tech 50 Awards. Also, it recently broke ground
for the construction of a 200,000-sq-ft building to serve as its
global headquarters near Pittsburgh in Robinson Township.
US Fab, Vigor Industrials fabrication and shipbuilding subsidiary, is now Vigor Fab. Additionally, Alaska Ship and Drydock, which operates the Ketchikan shipyard in Alaska, is now
Vigor Alaska.
SAIT Polytechnic, Calgary, Alberta, Canada, has achieved two
LEED gold certifications and one silver recognition for the
Trades and Technology Complex. Green features include 95%
of the building material waste being recyclable.
Mercer Abrasives, a manufacturer of industrial products, has
moved its corporate headquarters to Ronkonkoma, N.Y. It is
now in a building that has twice the capacity of its previous N.Y.
facility.
and wrought products over a career in

industrial product
development, and
technical leadership
in industrial research
and development.
Established in 1960,
the Eisenman award
recognizes achieveMark Robinson ments in the practical
application of materials science and engineering.
Titan Aerospace
Announces CEO
Founded in 2012, Titan Aerospace,
Moriarty, N.Mex., a producer of solarpowered atmospheric satellites, has
named Vern Raburn chairman and CEO.
Raburn previously served as CEO of
Eclipse Aviation, a company he founded.
Ingalls Employees Receive

STEM Recognition
Eleven Huntington Ingalls Industries
employees have been recognized for
achievements in the fields of science, technology, engineering, and math (STEM).
Ivette Nuez, a systems engineer at the

companys Ingalls Shipbuilding division,
Pascagoula, Miss., was honored at the
annual Hispanic Engineer National
Achievement Awards Corp. Conference
in October. Recognized at the 18th annual Women of Color STEM Conference
were Newport News, Va., Shipbuilding division, personnel Dorothy Shaw, Lakela
Lofton, Cynthia Bowles, Cynthia Griffin,
Arlene Grimme, Deborah Stanton, Debbie Braudis, Chara Clancy, Veronica
Nance-Crossley, and Danyelle Saunders.
Obituary
Michael Eugene Stoops
Michael Eugene Stoops, 55, died July
21 in Ames, Iowa, where he lived his entire life. He served as
the north-central regional manager for
Wolf Robotics, selling robots for more
than 14 years. He was
a member of the
American Welding
Society from 1999 to
2005, associated with
Michael Stoops the Iowa Section.
educ (stainless conf)_FP_TEMP 11/11/13 2:42 PM Page 97
DEC 2013 WJ CLASSIFIEDS_Classified Template 11/14/13 3:12 PM Page 98
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WELDING JOURNAL
99
ADVERTISER
INDEX
Abicor Binzel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
www.binzel-abicor.com . . . . . . . . . . . . . . . . . .(800) 542-4867
Industrial Quality Services, LLC . . . . . . . . . . . . . . . . . . . .45

www.iqsllc.com . . . . . . . . . . . . . . . . . . . . . . . .(330) 559-4542
American Torch Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

www.americantorchtip.com . . . . . . . . . . . . . .(800) 342-8477
Intercon Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .14

www.intercononline.com . . . . . . . . . . . . . . . . .(800) 665-6655
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC

www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460
Kimberly Clark Professional . . . . . . . . . . . . . . . . . . . . . . .13

www.kcprofessional.com/BalderPromo . . . .(800) 241-3146
AT&F Headquarters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

www.atfco.com . . . . . . . . . . . . . . . . . . . . . . . . .(216) 252-1500
K.I.W.O.T.O., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

www.rodguard.net . . . . . . . . . . . . . . . . . . . . . .(269) 944-1552
Atlas Welding Accessories, Inc. . . . . . . . . . . . . . . . . . . . . .68

www.atlaswelding.com . . . . . . . . . . . . . . . . . .(800) 962-9353
KMT Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

www.kmtsaw.com . . . . . . . . . . . . . . . . . . . . . . .(269) 321-8860
AWS Education Services . . . . . . . . . . . . . . .77, 78, 94, 95, 97

www.aws.org/education/ . . . . . . . . . .(800) 443-9353, ext. 455
Lincoln Electric Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC

www.lincolnelectric.com . . . . . . . . . . . . . . . . .(216) 481-8100
AWS Membership Services . . . . . . . . . . . . . . . . . . . . . .48, 83

www.aws.org/membership/ . . . . . . .(800) 443-9353, ext. 480
Mathey Dearman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
www.matheycnc.com . . . . . . . . . . . . . . . . . . . .(918) 447-1288
AWS Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44, 69

www.aws.org/standards/ . . . . . . . . . . . . . . . . .(888) 935-3464
OTC Daihen, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

www.daihen-usa.com . . . . . . . . . . . . . . . . . . .(888) 682-7626
Camfil Air Pollution Control . . . . . . . . . . . . . . . . . . . . . . . .2

www.camfilapc.com . . . . . . . . . . . . . . . . . . . . .(800) 479-6801
RWMA/Resistance Welding Mfg. Alliance . . . . . . . . . . . .18

www.aws.org/rwma . . . . . . . . . . . . . .(800) 443-9353, ext. 444
Champion Welding Alloys . . . . . . . . . . . . . . . . . . . . . . . . . .76

www.championwelding.com . . . . . . . . . . . . . .(800) 321-9353
Schaefer Ventilation Equipment . . . . . . . . . . . . . . . . . . . .43

www.schaeferfan.com . . . . . . . . . . . . . . . . . . .(800) 779-3267
Commercial Diving Academy . . . . . . . . . . . . . . . . . . . . . . .21

www.commercialdivingacademy.com . . . . . .(888) 974-2232
Select Arc, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFC

www.select-arc.com . . . . . . . . . . . . . . . . . . . . .(937) 295-5215
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
www.cor-met.com . . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
Superflash Compressed Gas Equipment/IBEDA, Inc. . .24

www.oxyfuelsafety.com . . . . . . . . . . . . . . . . . .(888) 327-7306
Diamond Ground Products, Inc. . . . . . . . . . . . . . . . . . . . .23

www.diamondground.com . . . . . . . . . . . . . . .(805) 498-3837
TEKA North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

www.teka-direct.com . . . . . . . . . . . . . . . . . . . .(816) 842-1773
Flexovit USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

www.flexovitabrasives.com . . . . . . . . . . . . . . .(800) 689-3539
Triangle Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . .43

www.trieng.com . . . . . . . . . . . . . . . . . . . . . . . .(781) 878-1500
Fronius USA, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

www.fronius-usa.com . . . . . . . . . . . . . . . . . . .(877) 376-6487
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
www.us.trumpf.com . . . . . . . . . . . . . . . . . . .web contact only
Gedik Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

www.gedikwelding.com . . . . . . . . . . . . . . .+90 216 378 50 00
voestalpine Bhler Welding . . . . . . . . . . . . . . . . . . . . . . . .81

www.voestalpine.com/welding . . . . . . . . . . . .(800) 527-0791
Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

www.greinerindustries.com . . . . . . . . . . . . . .(800) 782-2110
Weld Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

www.weldaid.com . . . . . . . . . . . . . . . . . . . . . .(800) 935-3243
Hobart Institute of Welding Technology . . . . . . . . . . . . . .42

www.welding.org . . . . . . . . . . . . . . . . . . . . . . .(800) 332-9448
Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
www.weldengineering.com . . . . . . . . . . . . . . .(508) 842-2224
Hodgson Custom Rolling, Inc. . . . . . . . . . . . . . . . . . . . . . . .9

www.hcrsteel.com . . . . . . . . . . . . . . . . . . . . . .(800) 263-2547
WEMCO/An Association of Welding Manufacturers . . . .73

www.aws.org/wemco . . . . . . . . . . . . .(800) 443-9353, ext. 444
Hypertherm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
www.hypertherm.com . . . . . . . . . . . . . . . . . . .(800) 643-0030
IFC = Inside Front Cover

IBC = Inside Back Cover
OBC = Outside Back Cover
IMPACT (Ironworkers) . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

www.ironworkers.org . . . . . . . . . . . . . . . . . . .(800) 545-4921
100 DECEMBER 2013
Visit the AWS Interactive Ad Index: www.aws.org/ad-index
Wagner 12-13_Layout 1 11/14/13 3:57 PM Page 347
SUPPLEMENT TO THE WELDING JOURNAL, DECEMBER 2013

Sponsored by the American Welding Society and the Welding Research Council
Spatter and Porosity in Gas-Metal Arc

Welding of Magnesium
Alloys: Mechanisms and Elimination
The mechanisms were established, the elimination was demonstrated, and
the recommendations for porosity prevention are made
to filler metal manufacturers and users
ABSTRACT
Recently, there has been a rapid increase in the use of Mg alloys for weight reduction,
in an effort to improve fuel economy in the automotive industry. A versatile process for
welding Mg alloys is needed. Gas metal arc welding (GMAW), though widely used for
welding Al alloys, is still not used much for Mg alloys. The present study focuses on 1)
spatter, which can cause 50% or more loss of the filler metal and which has long hindered
the use of GMAW for Mg alloys, and 2) gas porosity, which has hardly been studied in
GMAW of Mg alloys. The widely used AZ31 Mg (~ Mg-3Al-1Zn) sheets were welded
with its recommended AZ61 Mg (~ Mg-6Al-1Zn) welding wire. Spatter was very severe
with conventional Mg GMAW as expected. The mechanism for spatter was established.
In order to suppress spatter, the use of CSC-GMAW for welding Mg alloys was explored,
which is an advanced GMAW process with controlled short circuiting (CSC). Spatter was
eliminated and the reason explained. However, with either process severe gas porosity was
encountered, much worse than that in Al GMAW. The porosity-formation mechanism
was established. Porosity was eliminated either by cleaning the welding wire with sandpaper before welding or baking the welding wire before welding. The much more severe
gas porosity in Mg GMAW than Al GMAW was explained. Recommendations for preventing gas porosity in Mg GMAW based on the present study were made to both the
manufacturers and users of Mg welding wires.
Introduction
In order to reduce fuel consumption and
emissions, the automotive industry has been
reducing vehicle weight by using lighter
structural materials including magnesium
alloys (Refs. 1, 2). Magnesium (Mg) is the
lightest metallic structural material and its
specific strength (that is, the strength/density ratio) is excellent (Ref. 3). Recently, the
use of Mg alloys has been increasing rapidly
worldwide (Refs. 13), and the cost of Mg
per kg has decreased below that of Al since
2004 (Ref. 3). The research interest in Mg
welding has grown rapidly recently, with
more than 100 publications in the past few
years. Reviews on recent Mg welding reD. C. WAGNER, former graduate student, is now
with Miller Electric Mfg. Co., Appleton, Wis. Y. K.
YANG was postdoctorate and S. KOU is Professor, Department of Materials Science and Engineering, the University of Wisconsin, Madison,
Wis.
search are available (Refs. 47).

Gas metal arc welding (GMAW) is not
used much for Mg alloys. In general,
GMAW is a very widely used process for
welding common materials such as Al alloys, steels, and stainless steels. It has both
good weld quality and high production
rate, and it is easily automated. Unfortunately, Mg GMAW can suffer from severe
spatter. Spatter is the expelling of filler
metal (i.e., welding wire) droplets from
KEYWORDS
Automotive
Gas Metal Arc
Porosity
Magnesium Alloys
Short Circuiting
Spatter
the arc during welding. Severe spatter can

make the weld messy and irregular in
shape. The weld width and penetration
depth can vary significantly along the weld,
which may not be straight. Additionally, a
significant amount of the welding wire can
be wasted. Losses of 50% or more of the
Mg filler metal from spatter has been reported (Refs. 5, 8).
Lockwood pioneered the early work on
GMAW of Mg alloys in 1963 (Ref. 9) and
1970 (Ref. 10). He welded AZ31 Mg with
an AZ61 welding wire. He tried various
levels of wire feed rate, and hence welding
current, from spray transfer at high currents to globular transfer at intermediate
currents and short circuiting transfer at
low currents (Ref. 9). The transfer of
molten filler metal to the weld pool was
stable except for globular transfer, which
was unstable and caused spatter. Spray
transfer could not be established without
using very high welding currents, much
higher than those for GMAW of Al. Thus,
spray transfer worked only for thick sheets
(> 4.8 mm or 316 in.), and short circuiting
transfer was used for thinner sheets (1.0
3.2 mm or 0.040.125 in.). In order to improve the bead contours and penetration
over those with short circuiting transfer,
he welded AZ31 Mg sheets 1.66.4 mm
(0.063 0.250 in.) by pulsed-spray transfer
at intermediate currents. That is, filler
metal transfer was no longer globular but
became stable with one small droplet
transferred per pulse. After that, investigation of Mg GMAW seemed to stop.
Recently, the study of GMAW of Mg alloys has resumed. In 2004, in Germany,
Rethmeier et al. (Ref. 8) used short circuit
GMAW (GMAW-S) to weld AZ31 Mg and
AZ61 Mg 1.352.5 mm (0.0530.098 in.) in
thickness with an AZ61 welding wire. Spatter was eliminated. In the same year in
Japan, Ueyama et al. (Ref. 11) maintained
a stable droplet transfer by using pulsed
WELDING JOURNAL 347-s
WELDING RESEARCH
BY D. C. WAGNER, Y. K. YANG, AND S. KOU
WELDING RESEARCH
Fig. 1 Top views of bead-on-plate welds in the as-welded condition, that

is, before removing vapor deposit and spatter. A Conventional GMAW
showing spatter; B CSC-GMAW showing no spatter.
GMAW (GMAW-P). In 2010, in China,

Song et al. (Ref. 12) used AC GMAW-P to
weld AZ31 Mg 3.0 mm (1.18 in.) in thickness with an extruded AZ31 Mg wire as the
filler metal. It was reported in both studies
that spatter was effectively reduced or eliminated. In 2012, in China, Zhang et al. (Ref.
13) reported significant spatter reduction in
conventional GMAW of 6-mm-thick AZ61
Mg plates by precoating the workpiece surface with a KCl flux. The authors are unaware of any new published reports on
GMAW of Mg alloys conducted in the
United States since 1970.
Unlike spatter, gas porosity in GMAW
of Mg alloys has hardly been studied at all.
Lockwood (Ref. 9) reported gas porosity
caused by welding Mg without first degreasing the workpiece surface.
Both laser beam welding (LBW) and
electron beam welding (EBW) have been
used to weld Mg alloys. Deinzer et al. (Ref.
5) pointed out that a major limitation of
LBW and EBW is that the equipment is expensive and not readily available. Also, gas
porosity has been observed in LBW (Refs.
348-s DECEMBER 2013, VOL. 92
14, 15) and EBW

(Refs. 16, 17) of Mg
alloys. In either
case, the high welding speed and
deep/narrow weld
pool impede gas Fig. 2 Conventional GMAW of Mg alloy showing that a large globule, bebubbles from escap- cause of low Mg density, can be light and thus easily pushed away from the weld
ing from the weld pool by the arc. A nearly horizontal globule can grow much larger before touchpool before solidifi- ing the weld pool to short circuit than a vertical one. Frame rate: 4000 f/s. Weldcation. The problem ing conditions: those of weld 54.
is exacerbated when
welding as-cast Mg
tion. An Ar/H2 shielding gas was used in
alloys due to preexisting gas pores. In LBW
GTAW of AZ80 Mg without a filler metal,
of die-cast AM60 Mg, preexisting pores coand gas porosity was observed (Ref. 18).
alesced into large pores in the fusion zone
Friction stir welding (FSW) can be used
(Ref. 14). In LBW of thixomolded Mg alto weld Mg alloys successfully (Refs. 1921).
loys, the air entrapped during the mold-fillAccording to The Welding Institute (where
ing process caused severe gas porosity (Ref.
FSW was invented), the workpiece must be
15).
rigidly clamped, a backing bar is required,
Gas tungsten arc welding (GTAW) can
and joints that require metal deposition
be used to weld Mg alloys successfully
cannot be made (Ref. 22). In the construc(Ref. 4). However, GTAW in general has a
tion of vehicle space frames, there can be
low production rate and requires a high
many T-joints requiring metal deposition,
level of welding skill, thus is often more
which are very easy for GMAW. Deinzer et
suitable for repairing than mass producal. (Ref. 5) pointed out that a limitation of
position is Mg-3Al-1Zn by wt-%. The

sheet was 203 mm long, 76 mm wide, and
1.6 mm thick (8 3 116 in.), and was beadon-plate welded along the centerline in the
length and rolling direction. Before welding, the workpiece was degreased with acetone, the oxide film was removed in the
area intended for welding with a stainless
steel brush, and cleaned with acetone
again. It was found that in butt joint welding of Mg alloys, the faying surfaces and
the root opening between them can affect
the porosity in the resultant weld. Therefore, to keep them from affecting gas
porosity, it was decided to do bead-onplate instead of butt joint welding in the
present study.
Two AZ61A Mg welding wires with 1.2
mm (363 in.) diameter, filler metals A and
B, were purchased from two different Mg
welding wire suppliers. The nominal composition of AZ61 Mg is Mg-6Al-1Zn by
wt-%. AZ61A Mg is the recommended
welding wire for welding AZ31 Mg alloy
(Ref. 23). Filler metal A, which was purchased first, needed to be cleaned by the
supplier before shipping. Filler metal B,
on the other hand, was brand new and
thus required no cleaning.
Conventional GMAW
Fig. 3 Conventional GMAW of Mg alloy showing a nearly horizontal globule growing very large before short circuiting, and its subsequent expulsion to cause severe spatter. Frame rate: 4000 f/s. Welding conditions: those of weld 54.
FSW is that the best use is with long and

straight welds.
In summary, a versatile welding process
is needed for Mg alloys in order to accelerate their use as a light structural material.
GMAW, which has been widely used for Al
alloys, steels, and stainless steels, has the potential to be such a welding process, but its
application to Mg alloys is still very limited.
Severe spatter has been the most frequently
mentioned problem hindering Mg GMAW.
It is very likely that severe gas porosity in
Mg GMAW, though not reported so far, has
been encountered in practice, and thus further discourages the use of GMAW for Mg
alloys.
The present study deals with spatter and
porosity in GMAW of Mg alloys. The mechanisms of the formation of spatter and

porosity were established and their elimination demonstrated. Both a conventional
GMAW and an advanced GMAW process
were used and the resultant welds compared. The goal was to make GMAW a versatile process for welding Mg alloys in order
to help accelerate the use of Mg alloys.
Experimental Procedure
Materials
AZ31B-H24 Mg alloy sheets were

welded. This is the most widely used
wrought Mg alloy, and its nominal com-
Conventional GMAW was conducted

using the Invision 456 power source and
the XR-M wire feeder from Miller Electric Mfg. Co., in Appleton, Wisc. The
welding conditions were as follows: Unless
otherwise stated, the wire feed rate was
122 mm/s (288 in./min), the travel speed
7.6 mm/s (18 in./min), the voltage 19 V,
and the contact-tube-to-workpiece distance 12.7 mm (0.5 in.). The shielding gas
was pure Ar at the flow rate of 275 cm3/s
(35 ft3/h).
The workpiece was held down by steel
clamps to prevent movement during welding. Two steel rectangular bars were
placed between the workpiece and the
clamps, one on each side of the area intended for welding. Consequently, deposition of Mg vapor (and perhaps some Zn
vapor as well) occurred on the workpiece
surface only in the area between the bars.
CSC-GMAW
A controlled short circuit (CSC) version of the GMAW process was used. It is
referred to as CSC-MIG in Ref. 24. There
are other controlled short circuit GMAW
processes, for instance, CMT (cold-metal
transfer) (Ref. 25) and STT (surface tension transfer) (Ref. 26). The reasons for
selecting CSC-GMAW were as follows:
First, it was available in the welding lab at
UW-Madison. Second, little, if any, research on it has been published. It has not
been used for welding Mg alloys.
In CSC-GMAW, the process controller
WELDING RESEARCH
and arc voltage were recorded using a

computer data-acquisition system together
with LabView software. The data-sampling rate for each signal was 15,000 Hz.
High-Speed Photography
A high-speed camera was used to record

the arc and filler metal transfer during both
conventional GMAW and CSC GMAW.
The camera used, Memrecam HX-3, was
manufactured by NAC Image Technology.
The frame speed used was 4000 f/s. A closeup lens, along with two neutral density filters, was mounted on the camera. Four
250-W Lowel VIP System Pro lamps were
used to illuminate the area outside the arc.
Examination of Welds
WELDING RESEARCH
The top surfaces of the resultant welds

and the workpiece were examined visually
before and after cleaning with acetone.
The welds were then cut in the longitudinal direction along the weld centerline,
polished and etched with a solution consisting of 5 mL of acetic acid, 2.1 g of picric
acid, 5 mL of distilled water, and 35 mL of
ethanol for 2 s. The welds were then examined under an optical microscope to
check for porosity inside.
X-Ray Diffraction
Fig. 4 Power surge in conventional GMAW causing arc expansion to expel globule and cause spatter. A Top view of weld; B waveforms of current and voltage.
coordinates the feeding and speed of the

wire electrode with the level of welding current delivered by the power source (Ref.
24). Briefly, the welding process has two primary phases: the arc phase during which
heat is generated to melt the base metal,
and the short circuiting phase during which
the filler metal droplet is deposited when
the welding wire makes contact with the
weld pool (Ref. 24). The controller monitors the voltage between the electrode and
the workpiece to determine which phase the
process is in at any given time. The controller clears the short by retracting the wire
to the preset arc length level. Once the arc
is established again, the controller begins
feeding the wire toward the weld pool, and
the cycle repeats.
The waveforms of the welding current
in CSC-GMAW can be tailored in great
detail in order to optimize the welding
process and reduce spatter. Examples of
the details that can be specified include: 1)
current levels and durations (for the start
and mid periods) of the arc phase and

those of the short circuiting phase; 2) the
wire down speed, the delay before wire
down, the wire up speed, and the delay before wire up; 3) the arc length; and 4) the
penetration delay.
The travel speed was 7.6 mm/s, the
contact tube-to-workpiece distance was
12.7 mm, and the shielding was pure Ar at
the flow rate of 275 cm3/s (35 ft3/h). The
same Invision 456 power source used for
conventional GMAW was used. All that
was needed was to connect the power
source to the process controller and a
welding gun with a wire-drive assembly
dedicated to CSC-GMAW. The process
controller used in the present study was
originally developed by the Miller Electric
Mfg. Co. and was manufactured by Jetline
Engineering, Irvine, Calif.
Data Acquisition
The waveforms of the welding current
To identify any compounds on the

welding wire surface that may have contributed to gas porosity in the welds, powder was removed from the welding wire
surface with a sharp blade for x-ray diffraction (XRD). For this purpose the
Rigaku RAPID II curved detector XRD
system in the Geoscience Department at
UW-Madison was used. One significant
advantage of this system is that the
amount of powder available can be very
small. Conventional X-ray diffraction machines, such as the Hi-Star 2-D XRD system with an area detector and a FTIR
system in the Materials Science Center
(MSC) of UW-Madison, did not work.
Results and Discussion

Spatter and Its Elimination
As expected, severe spatter was encountered in welding AZ31 Mg by conventional GMAW. Figure 1A shows the
top view of a weld made by conventional
GMAW in the as-welded condition. As
shown, the weld and its surrounding area
between the steel clamping bars were covered with deposited vapor and spatter.
The wire feed rate was 93 mm/s (220
in./min), the travel speed 8.5 mm/s (20
in./min), and the voltage 19 V. Unlike conventional GMAW, welds made by CSCGMAW were essentially spatter free.
Figure 1B shows the top view of a weld
made by CSC-GMAW in the as-welded

condition.
The very low density of Mg reduces the

energy required to heat up and melt the
Mg welding wire. For comparison, the
heat of fusion and specific heat of Al are
respectively 398 J/g and 0.91 J/(g K). Multiplying them by the density of Al (2.7
g/cm3) yields a 1075 J/cm3 volumetric heat
of fusion and a 2.46 J/(cm3 K) volumetric
specific heat of Al. As for Mg, the heat of
fusion and specific heat are respectively
368 J/g and 1.05 J/(g K), which are close to
those of Al. However, the density of Mg,
1.7 g/cm3, is about one-third lower than
that of Al, 2.7 g/cm3 (Ref. 27). Upon multiplication by the density of Mg, the volumetric heat of fusion of Mg becomes 626
J/cm3 and the volumetric specific heat 1.79
J/(cm3 K), which are significantly lower
than those of Al. Thus, because of the significantly lower density of Mg, the energy
required to heat up the same volume of
welding wire is 27% less for Mg than for
Al, and the energy required to melt the
same volume of welding wire is 42% less
for Mg than for Al.
The very low density of Mg, though
highly desirable for vehicle weight reduction, can cause significant problems for
GMAW. First, the globule can grow very
fast because the Mg welding wire melts
very easily. Second, the welding wire globule is light and difficult to detach from the
welding wire tip by gravity. Thus, the globule can keep on growing until it becomes
very large and touches the weld pool to
cause short circuiting, and hence spatter.
This explains why, in conventional
GMAW of Mg, a very high current is
needed to pinch off the molten filler metal
by the Lorentz force and establish spray
transfer. Unfortunately, the high current
produces too much heat input for welding
Mg sheets (thinner than 4.8 mm) (Ref. 9).
In conventional GMAW of steel with a
shielding gas such as pure Ar or Ar containing CO2, the Lorentz force can push
the globule upward if the anode spot at the
globule bottom is small such that the current in the globule converges toward it before entering the arc (Refs. 28, 29). In
conventional GMAW of steel with 100%
CO2 gas shielding, according to Kim et al.
(Ref. 29), the globule is pushed upward by
a strong cathode jet and can continue to
grow very large in size.
Two phenomena that prolong globule
growth in conventional GMAW of Mg alloys before short circuiting have been revealed by the high-speed videos. The
globule is pushed forward and upward
away from the weld pool by the arc and is
allowed to grow very large before it
WELDING RESEARCH
Excessive Growth of Globule in

Conventional GMAW
Fig. 4 Power surge in conventional GMAW causing arc expansion to expel globule and cause spatter. C current surge enlarged; D short-circuit voltage enlarged; E corresponding power surge.
Photos from Fig. 3 are positioned in D using the shorting-circuiting period as reference for time.
touches the weld pool to cause short circuiting, as shown in Fig. 2. The reason the
globule is easy to push is because it is light
due to the low Mg density. The evidence
of droplet motion can be seen clearly in a
series of video frames (one frame in each
0.25 ms). Each photo in Fig. 2 is representative and illustrates one frame, in a series
of frames, during each stage of droplet
motion.
The first phenomenon is the arc pushing the globule forward in the welding direction (from right to left in Fig. 2A, B). A
nearly horizontal globule can grow much
larger before touching the workpiece to
cause short circuiting than a vertical one.
The globule shape is pear-like instead of
either ball-like or irregular (distorted by
the cathode jet) as in conventional
GMAW of steel with 100% CO2 shielding

(Ref. 29). The arc moves slightly backward
(from left to right) from the vertical position to become more or less normal to the
inclined pool surface, that is, to follow the
shortest path between the wire tip and the
pool surface. The arc could not have been
deflected backward by the so-called arc
blow, which represents an unbalanced
condition in the magnetic field surrounding the arc (Ref. 30). This is because the
ground cable (far back into the paper) and
the video camera (far out of the paper)
were on the opposite sides of the weld, and
the line connecting them is more or less
normal to the weld. Thus, if arc blow had
occurred, it would have deflected the arc
toward the camera instead of in the opposite direction of welding (Ref. 30). When
proached (Ref. 31). More than one force

might be acting on the globule.
As mentioned previously, Zhang et al.
(Ref. 13) used conventional GMAW to weld
AZ61 Mg plates 6 mm in thickness (with a
1.6-mm welding wire extruded from AZ61
Mg) with and without a flux. Without the
flux, the large globule was also nearly horizontal. However, instead of being pushed
forward in the welding direction, it was observed to swing back and forth around the
wire. The welding current was much higher
(~ 185 A vs. 40 A as is shown in Fig. 4C in
the absence of short circuiting), the arc voltage was significantly higher (23 V vs. 19 V
here), and the wire diameter was significantly larger (1.6- mm AZ61 Mg vs. 1.2-mm
AZ31 Mg here). It is possible that one or
more of the aforementioned pushing forces
became so much stronger as to make the
globule swing back and forth around the
wire. The higher voltage and hence larger
arc gap could also decrease the chance for
the drag force to keep the globule forward
pointing.
WELDING RESEARCH
Mechanisms of Spatter Formation and

Elimination
Fig. 5 Mechanisms of spatter formation and elimination in GMAW of Mg alloys. A Spatter in

conventional GMAW; B no spatter in CSC-GMAW.
the welding direction was reversed without reversing the location of the ground
cable with respect to the workpiece, the
arc was still more or less normal to the inclined pool surface and the globule was
still pushed forward in the welding direction (now from left to right).
The second phenomenon prolonging
globule growth before short circuiting is
the arcing at the bottom of the globule
(Fig. 2C, D) to push it upward (Fig.
2EH). The videos show that this can
occur multiple times in a row. The globule
is light and thus thrown upward easily by
the arc, and the arc immediately switches
back to between the wire tip and the inclined pool surface (Fig. 2E, F). The light
globule keeps on rising (Fig. 2G, H) before it can descend to make another attempt for short circuiting. During this
period of bouncing up and down, the globule continues to grow larger.
Possible candidates for the force pushing the globule forward and upward (Fig.
2) are considered as follows: As mentioned previously, the Lorentz force can
push the globule upward if the anode spot
is small. However, it is not clear if the
anode spot can switch back and forth between the wire tip and the globule bottom
to make the arc switch back and forth. As
mentioned previously, the globule can be
pushed upward (but not forward) by a
strong cathode jet in conventional GMAW
of steel with 100% CO2 shielding. It is not

clear if a strong enough cathode jet can
exist in conventional GMAW of Mg with
Ar shielding while switching back and
forth between the wire tip and the globule
bottom. In view of the high vapor pressure
of Mg, another possibility is the recoil
force induced by rapid Mg evaporation
from the globule surface. Rapid Mg evaporation may occur at the backside of the
globule, which is heated by the arc. However, the bottom of the globule is levitated
even though no arc heating is present
there to cause rapid evaporation (Fig. 2A).
Still another possibility is the pushing
force caused by the fast gas flow through
the arc (the gas being ionic within the arc
core). Because of the inclined pool surface, the Lorentz-force-driven gas flow
through the arc goes around and below the
globule to push it forward and levitate it
Fig. 2B. In the so-called static force balance theory (Ref. 29), the gas flow through
the arc is said to exert a downward drag
force on a vertical globule. The fact that
the shape of the nearly horizontal globule
is pear-like instead of ball-like or irregular
(Fig. 2A) seems consistent with the gas
flow dragging the globule forward. In the
absence of an inclined pool surface and a
globule, the flow pattern is downward
along the arc axis (and the maximum velocity can be on the order of 100 m/s) and
outward as the workpiece surface is ap-
The mechanism of spatter in conventional GMAW was established based on

both the transfer of the filler metal and the
waveforms of the current and voltage
recorded during welding. In fact, unlike
previous studies, the waveform of power
was also shown to further explain the spatter mechanism.
The high-speed videos of spatter indicate that severe spatter occurs mainly because of excessive globule growth before
short circuiting, that is, to provide a very
large globule for the arc to expel and cause
spatter. As explained previously, the excessive growth is caused by the very low
Mg density. Figure 3 shows a series of photos taken from a video. As mentioned previously, the globule is pushed forward by
the arc to nearly horizontal Fig. 3A.
Unlike the vertical position, the horizontal position provides unlimited space for
the globule to grow longer. As can be expected, as the globule grows longer, it also
grows fatter to approach the workpiece
Fig. 3B. Short circuiting occurs when the
globule touches the weld pool or the workpiece Fig. 3C. The arc reinitiation (Fig.
3D) after short circuiting is followed immediately by a sudden arc expansion (Fig.
3E) to expel the globule Fig. 3F.
Sometimes spatter was significantly less
than expected in spite of the very large globule formed during welding. A nearly horizontal globule could grow so far ahead of
the weld pool as to land on the solid workpiece instead of the weld pool. The globule,
being farther away from the arc heat, and
hence cooler, could solidify quickly upon
contact with the solid workpiece before arc
expansion. Since the solidified globule was

elongated and in line with the welding direction, it was subsequently remelted completely by the advancing weld pool. This
made the weld bead nonuniform, that is,
higher and wider than average where this
occurred, and lower and narrower than average just before it.
The current and voltage waveforms indicate a current surge during short circuiting, which is typical of GMAW in the
constant-voltage mode. Figure 4 shows a
weld made by conventional GMAW and
the waveforms recorded under welding
conditions identical to those in Fig. 3. The
spatter has been removed from the workpiece surface to show the weld Fig. 4A.
Each large spike in the current waveform
represents a current surge caused by short
circuiting Fig. 4B. The current and voltage waveforms associated with the first
large spike in the figure are enlarged
Fig. 4C. Video recording of the globule/arc
was not synchronized with that of the
waveforms. Thus, the photos in Fig. 3 are
positioned in the enlarged voltage waveform using the short circuiting period as
the reference for time.
A current surge occurs (Fig. 4C) when
the voltage drops suddenly during short circuiting (Fig. 4D), which is typical of conventional GMAW in the widely used
constant-voltage mode. This mode is set up
to rapidly change the welding current in
order to maintain a constant voltage and
hence arc length during welding. When the
arc length, and hence arc voltage decrease
suddenly, the current will spontaneously increase sharply to instantaneously melt back
the welding wire, and quickly bring the arc
length back to normal (Ref. 32). When the
globule touches the pool surface and the
voltage drops suddenly to nearly zero (Fig.
4D), the current rises sharply to about 300 A
(Fig. 4C) to induce a Lorentz force to almost completely pinch off the liquid bridge
between the globule and the pool surface
(at either the droplet bottom or neck), the
remaining material becomes too thin to sustain the current density. This material is
then vaporized and the arc is reinitiated.
Unlike in previous studies (Refs. 3336),
the waveform of the power (power = current voltage) is also presented, and it
shows a power surge immediately following
arc reinitiation Fig. 4E. This is because
the voltage has recovered and, in fact, overshot somewhat (Fig. 4D), but the current is
still very high though falling Fig. 4C. This
power surge heats up the arc plasma, which
is a gas containing ionic as well as neutral
species. Since gas expands upon heating, the
arc expands suddenly, causing expulsion of
the globule and hence spatter (Refs. 37, 38).
The short-circuiting time (~ 2 ms) is too
short for the large light globule to enter the
weld pool before arc expansion
Thus, based on the videos of filler metal
Fig. 6 CSC-GMAW of Mg alloy showing absence of excessive globule growth, sudden arc
expansion, globule expulsion, and hence spattering. Frame rate: 4000 f/s. Welding conditions:
those of weld 50.
transfer and the waveforms of current and

voltage recorded during welding, the mechanism of spatter formation in conventional
GMAW of Mg alloys can be summarized
with the help of Fig. 5A. Essentially, the
very low density of Mg makes it very easy
for the welding wire to melt and for the melt
to keep hanging onto the wire tip as a globule. Consequently, the globule can become
excessively large by the time it touches the
weld pool to short circuit. The sudden arc
expansion immediately following arc reinitiation from the short circuit expels the large
globule into severe spatter.
Before leaving the subject of spatter,
the high vapor pressure of Mg is discussed
further. It has been pointed out that 1) the
vapor pressure of Mg is about three orders
of magnitude higher than that of Al in the
temperature interval relevant to arc welding, 2) the energy input into the welding
wire has to be regulated in such a way that
the wire will melt but not vaporize, and 3)
severe spatter loss (> 50%) can occur if
the temperature of the filler metal exceeds
~ 900C (Refs. 5, 8). It is likely that the
power surge (Fig. 4E) can cause a sudden
rapid Mg evaporation from the globule
and that this may induce a recoil force.
However, it is not clear if the recoil force
can be large enough to cause the expulsion
or explosion of the globule and hence
spatter. Also, Figure 3 shows no inflight
explosion caused by an internal vapor
burst like that in spray transfer GMAW of
Al alloys containing high-vapor pressure
elements such as Zn and Mg (Ref. 39).
Video recording during CSC-GMAW

shows no evidence of excessive globule
growth, sudden arc expansion, globule expulsion, and hence spatter, as shown by
Fig. 6. As in conventional GMAW, the
globule is pushed forward by the arc (Fig.
6A, B), and it touches the weld pool to
cause short circuiting Fig. 6C. However,
the globule is smaller, the period of short
circuiting is much longer (~ 18 ms), and
the globule has much more time to enter
the weld pool before arc reinitiation
Fig. 6D. Furthermore, the arc expansion is
more gradual and more restricted Fig.
6E, F. Consequently, there is no expulsion
of the globule to cause spatter.
The waveform of the welding current in
CSC-GMAW shows no large periodic
spikes like those in conventional GMAW.
Unlike the constant voltage mode, the CSC
mode of GMAW is set up to control the current rather than voltage. Figure 7 shows a
CSC-GMAW weld and the waveforms
recorded under welding conditions identical to those in Fig. 6. There is no spatter
Fig. 7A. The short-circuiting phase and the
arc phase are both visible in the current and
voltage waveforms Fig. 7B. The voltage
during the short-circuit ing phase is essentially zero, but the current is still under control. There are current spikes when the
voltage drops, but the height and width of
the spike are much less than those in conventional GMAW Fig. 4B. When the arc
reinitiates after short circuiting (red line in
Fig. 7C), the voltage rises but the current
falls and, consequently, the power waveWELDING JOURNAL 353-s
WELDING RESEARCH
WELDING RESEARCH
Fig. 7 CSC-GMAW showing no power surge to cause arc expansion and hence spatter. A Top
view of weld; B waveforms of current and voltage.
form (Fig. 7D) does not show power surges

like those in conventional GMAW (Fig. 4E)
to cause sudden arc expansion and expulsion of the globule.
Thus, based on the videos of filler metal
transfer and the waveforms of current and
voltage recorded during welding, the mechanism of spatter elimination by CSCGMAW can be summarized with the help
of Fig. 5B. As shown, the current is under
tight control even during short circuiting
and immediately after arc reinitiation.
There is neither a huge globule to expel nor
a sudden arc expansion to do it. It is worth
mentioning that the welding wire can be
pushed down to cause short circuiting and
pulled back to reestablish the arc (Ref. 24).
Although a conventional GMAW machine
can also be operated in the short-circuiting
mode (where the voltage is no longer constant), the welding wire is only pushed down
and not pulled back.
It should be mentioned that, for the purpose of comparison, the weld in Fig. 7 made
by CSC-GMAW and that in Fig. 4 made by
conventional GMAW had similar heat inputs per unit length of the weld. They are
126.3 J/mm (3209 J/in.) for the CSC-GMA
weld and 125.4 J/mm (3184 J/in.) for the
conventional GMA weld. The heat input
per unit length of the weld Q was calculated
using the following equation:
t
Q = ( I E )" dt / ( t U )
0
(1)
where I is the current, E is the voltage, t is

the welding time, and U is the travel speed.
Porosity Caused by Welding Wire A and
Its Elimination
Severe gas porosity was observed in
welds made with as-received welding wire

A, by both conventional GMAW and CSCGMAW. Figure 8 shows the porosity in a
weld made by conventional GMAW with
welding wire A. Some pores tend to have
large openings at the weld surface Fig.
8A. Small openings of pores are visible inside the large opening Fig. 8B. Porosity
exists throughout the weld metal, that is, in
the fusion zone Fig. 8C. During cutting
of the weld for metallography, roofs of some
large holes broke off, leaving behind large
open pits on the weld surface.
As shown in Fig. 9, porosity also exists
throughout the weld made by CSCGMAW with welding wire A. The weld is
irregular in shape. In fact, some spatter
can be seen, even though it is supposed to
be eliminated by CSC-GMAW. The coexistence of porosity and spatter seems to
suggest that the conditions causing severe
porosity may also make the arc erratic to
cause spatter. It can be seen in Figs. 8C
and 9B that the pores tend to grow upward
and forward (in the welding direction),
that is, essentially normal to the solidification front during welding.
With both spatter and porosity being
severe, it is not difficult to imagine why
GMAW has not been used much for welding Mg alloys. The level of gas porosity in
the welds is far beyond that encountered
in normal GMAW of common Al alloys.
Examination of welding wire A reveals
dark areas on the wire surface as shown in
Fig. 10, where the wire segment is rotated
to show how the dark areas vary on the
surface. The 90- and 270-deg angles correspond to the inward- and outward-facing surfaces of the wire segment
respectively before it was cut and removed
from the spool for photography. The partially dark surface of welding wire A indicates its supplier did not or could not clean
it thoroughly before shipping.
To determine whether the dark areas
on the surface of welding wire A were responsible for causing severe gas porosity,
the areas were removed by polishing the
wire surface with sandpaper followed by
acetone cleaning. The cleaned wire is
shiny, as shown at the bottom of Fig. 10.
Removing the dark areas from the surface of welding wire A eliminated porosity
from Mg welds made by both conventional
GMAW and CSC-GMAW. Figure 11 shows
a weld made by conventional GMAW with
welding wire A cleaned with sandpaper before welding. This weld, in fact, is the same
weld shown previously in Fig. 4A. The weld
is essentially free of porosity. Figure 12
shows a porosity-free weld made by CSCGMAW with welding wire A cleaned with
sandpaper before welding.
It is clear that the dark areas on the
welding wire surface caused severe gas
porosity in welds made by both conventional GMAW and CSC-GMAW. The au-
thors have used various commercial welding wires for GMAW, including Al alloys,
steels, and stainless steels, and have not
experienced any problems caused by not
cleaning the welding wire before welding.
Thus, Mg welding wires are an exception.
Surprisingly, the dark surfaces of the
AZ61 Mg sheets did not cause severe gas
porosity, at least the sheets used in the
present study. A CSC-GMA weld was
made under welding conditions identical
to those for the porosity-free weld in Fig.
12, except the workpiece surface was degreased by acetone alone, without removing the oxide film with a stainless steel
brush before welding. The resultant weld
has hardly any porosity as shown in Fig. 13.
Baking welding wire A at a sufficiently
high temperature also eliminated gas porosity. Since a spool of welding wire is very
long, it is much easier to bake the whole
spool of wire in a furnace than to polish it
manually. Welding wire A was baked in air
at 300C for 24 h before welding, and porosity was reduced but not eliminated. Baking
at 324C for 2 h was also tried, but again
porosity was reduced, but not eliminated.
However, baking at 380C for 11 min eliminated porosity as shown in Fig. 14.
Porosity Caused by Welding Wire B and Its
Elimination
In view of the porosity caused by the

partially dark surface of welding wire A, a
brand-new spool of welding wire with a
shiny surface was used and the welds were
porosity free as shown by the CSC-GMA
weld in Fig. 15. This wire, called welding
wire B hereinafter, was a 1.2-mm AZ61A
welding wire ordered from a different supplier. The as-received welding wire was
clean, free of any dark surface.
However, welds made after welding
wire B had been exposed to air for a few
months show considerable porosity, as can
be seen in Fig. 16. Examination of welding
wire B, as shown in Fig. 17, indicated that
dark areas had formed on the wire surface.
Again, the 90- and 270-deg angles correspond to the inward- and outward-facing
surfaces of the wire segment, respectively,
before it was cut and removed from the
spool for photography. The outward-facing surface of the wire appears darker because it was exposed to air and hence
subjected to atmospheric corrosion.
Removal of the dark areas from the
surface of welding wire B eliminated
porosity from welds. The cleaned wire surface was shiny and free of dark areas as
shown at the bottom of Fig. 17. Baking
welding wire B at 380C for 11 min eliminated porosity as well, as shown in Fig. 18.
Mechanism of Porosity Formation
The mechanism for the formation of
Fig. 7 CSC-GMAW showing no power surge to cause arc expansion and hence spatter. C enlarged
waveforms; D corresponding power waveform. Photos refer to those in Fig. 6. Current levels during
start, mid, and end periods of short-circuiting phase and arc phase are indicated.
gas porosity in GMAW of Mg alloys is proposed in Fig. 19A. As shown, hydrogen

can come from three different places: the
welding wire surface, the workpiece surface, and the workpiece interior. Firstly, if
the welding wire is covered with hydrogencontaining compounds, the compounds
can decompose upon heating by the arc
and release hydrogen into the arc. This hydrogen can dissolve in both the welding
wire droplets and the weld pool. Hydrogen
dissolved in metal is denoted as H. Since
the surface area per unit volume of Mg is
much larger with the welding wire than
with the workpiece, the welding wire can
easily be the primary source of hydrogen
porosity if it is indeed covered with hydrogen-containing compounds. Secondly, if
the workpiece is covered with hydrogencontaining compounds (such as grease,
moisture, etc.), hydrogen can enter the
weld pool. Lastly, if pores preexist inside
the workpiece (such as air bubbles trapped
in liquid Mg during mold filling in die casting), they can enter the weld pool as bub-
bles upon melting the workpiece during

welding. Unlike in laser or electron beam
welding, the weld pool in GMAW is relatively big and slow freezing. Consequently,
hydrogen bubbles from either the workpiece surface or interior may have a fairly
good chance to escape.
When the weld pool solidifies, the H rejected by the weld metal into the weld pool
forms a H-rich layer at the solidification
front, causing the reaction 2H H2 (g)
to occur, and hence hydrogen bubbles to
nucleate at the solidification front Fig.
19A. The H rejection is caused by the sudden solubility drop upon solidification, as
shown by the hydrogen-solubility curve in
Fig. 19B (Ref. 40). The drop indicates that
at the melting point, Tm, Mg(S) can accommodate less H than Mg(L) and thus
has to reject H into Mg(L). Since diffusion
is slow and fluid flow diminishes near the
solidification front, a H-rich layer exists in
the weld pool at the solidification front,
providing highly concentrated H to cause
2H H2 (g) at the solidification front. As
WELDING RESEARCH
WELDING RESEARCH
Fig. 9 Porosity in CSC-GMAW made with as-received welding wire A. A

Top view; B longitudinal cross section.
begin to form. However, if the solidification front happens to

be nearly vertical at
the pool surface, solidification may continue
in the horizontal direction and hence cause a
long and nearly horizontal pore Fig.
16B.
As mentioned previously, in GTAW of
Fig. 8 Porosity in weld made by conventional GMAW with as-received AZ80 Mg without a
welding wire A. A Top view; B close-up view; C longitudinal cross- welding wire, an
section (roof of pore opening broke off during cutting).
Ar/H2 shielding gas
caused porosity (Ref.
known from fluid mechanics, fluid flow is
18). This is consistent with the proposed
slowed down near a solid wall (Ref. 41).
mechanism (Fig. 19A), but not sufficient
This is true even when the solid wall conto verify it because in the present study the
tains some liquid, such as the dendritic soshielding gas was pure Ar instead of an
lidification front of the weld metal.
Ar/H2 mixture.
The bubbles at the solidification front, if
The proposed mechanism was verified by
they fail to rise and escape in time, can be
the identification of Mg(OH)2 on the Mg
engulfed by the advancing solidification
welding wire. The result of X-ray diffracfront as gas pores in the weld metal. Since
tion (XRD) in Fig. 20A shows Mg(OH)2
solidification of the weld metal is essentially
was present in the dark areas. Since the
normal to the solidification front (Ref. 42),
amount of dark material that could be rethe pores also grow essentially normal to the
moved from the wire surface is very small,
solidification front as illustrated in Fig. 19A
the peaks corresponding to Mg(OH)2 are
and observed in Figs. 8C, 9B, and 16B.
very small, though still clear for its identifiThere is little porosity at the fusion boundcation. Fortunately, the Rigaku RAPID II
ary, where the growth rate, and hence H recurved detector XRD system worked even
jection, are essentially zero (Ref. 42). Near
with a very small amount of powder. The
the top of the weld, the pores are mostly
Mg peaks are much larger because for each
small because solidification of the weld
tiny area on the wire surface removed,
metal is already near the end when pores
much more material underneath was re356-s DECEMBER 2013, VOL. 92
moved along with it.

Mg can corrode by reacting with moisture in the air to form Mg(OH)2 (Refs. 43,
44). Mg(OH)2 decomposes upon heating
as follows: Mg(OH)2(s) MgO(s) +
H2O(g) (Refs. 45, 46). The H2O(g) enters
the welding arc, wherein it decomposes to
release hydrogen. This hydrogen can dissolve in the filler metal droplets and the
weld pool.
The workpiece surface, which was dark
everywhere (Fig. 13A), was identified by
XRD as MgO as shown in Fig. 20B. Removing powder from the workpiece was
much easier than from the wire surface. A
sharp peak of MgO exists at about 20 deg.
The fact that the workpiece surface was
covered with MgO instead of Mg(OH)2
explains the essentially porosity-free weld
made with the welding wire that was sandpaper cleaned before welding and the uncleaned workpiece Fig. 13. It is not
clear why the MgO on the workpiece did
not change to Mg(OH)2 by reacting with
moisture in the air.
The mechanism of porosity elimination
by baking the Mg welding wire before welding is proposed as follows: When the welding wire is baked at 380C for 11 minutes,
the reaction Mg(OH)2(s) MgO(s) +
H2O(g) occurs and the wire surface is no
longer covered with a hydrogen-containing
compound to cause porosity. Thermogravimetric analysis of Mg(OH)2 powder has
shown that 90% of Mg(OH)2 can decompose in air in about 80 min at 350C, 10 min
at 400C, and 5 min at 450C (Ref. 46).
Porosity Formation in Mg GMAW vs.

Al GMAW
The mechanism of gas porosity formation in GMAW of Al alloys can be expected to be similar to that in GMAW of
Mg alloys, though the presence of
Al(OH)3 on the surface of the Al welding
wire has not been verified yet. The similarity is based on the following facts. First,
Al reacts with moisture in the air to form
Al(OH)3 on the surface, and Al(OH)3 decomposes upon heating by 2Al(OH)3
Al2O3 + 3H2O (Ref. 45). These reactions
are similar to those of Mg mentioned previously. Second, as in Mg welding, H2 (or
H2O) has been added to the shielding gas
and porosity was observed (Refs. 4749).
The Mg welds made by GMAW in the
present study show that gas porosity can
be much more severe in Mg GMAW than
in Al GMAW. The difference between the
two cases can be explained as follows
based on three factors: 1) the tendency for
metal hydroxide to form, 2) the hydrogen
solubility as a function of temperature,
and 3) the density of the liquid metal.
First, Mg(OH)2 forms much more easily
on the Mg welding wire than Al(OH)3 can
on the Al welding wire. This means much
more hydrogen can be supplied to the Mg
weld pool to cause porosity. Figure 21 shows
two wire spools. The 5356 Al (~ Al-5Mg)
spool (Fig. 21A) has been exposed to air for
14 years, and the AZ61B Mg spool (Fig.
21B) 3 years. As shown, the Mg welding
wire turns dark, but the Al welding wire remains as shiny as brand new.
Second, the hydrogen solubility is much
higher in Mg(L) than in Al(L) as shown in
Fig. 22 (Ref. 50). For instance, the hydrogen
solubility at the melting point is about 60
times higher in Mg(L) than in Al(L) (1.0
103 vs. 1.6 105). This

means much more hydrogen, if supplied, can
enter the Mg weld pool Fig. 11 Porosity-free weld made by conventional GMAW with welding
than the Al one. Fur- wire A cleaned with sandpaper before welding. A Top view; B longithermore, the hydro- tudinal cross section.
gen-solubility
drop
upon freezing is about
low cooling rate (low travel speed and high
twenty times higher with Mg(L) than with
heat input), on the other hand, most gas
Al (L) (3.6 104 vs. 1.5 105). Thus, much
bubbles can escape easily.
more H is rejected by the weld metal into
the weld pool at the solidification front to
Butt and Lap Joint Welding by CSC-GMAW
trigger the reaction 2H H2(g) and cause
porosity.
It is worth mentioning that butt and lap
Third, as mentioned previously, the
joint welds have been made by welding
density of Mg (1.7 g/cm3) is about oneAZ31 Mg with an AZ61 welding wire by
third lower than that of Al (2.7 g/cm3).
CSC-GMAW. The welds were straight,
Consequently, in view of Stokess law
smooth, and free of spatter and porosity.
(Ref. 41), hydrogen bubbles can be exThe results will be published elsewhere,
pected to rise more slowly in a Mg weld
including the effect of porosity on the weld
pool to escape than in an Al weld pool.
mechanical properties. Here, the effect is
Thus, all three factors favor the formation
only illustrated by the tensile testing reof more gas porosity in Mg GMAW than
sults of two specimens as shown in Fig. 23.
in Al GMAW.
The specimens were taken from a butt
joint weld made with as-received wire A at
Effect of Welding Conditions on Porosity
two different locations with different
porosity levels. The specimen with more
It is worth mentioning that the welding
porosity is weaker and much less ductile.
conditions can affect gas porosity in
Thus, it is essential to prevent porosity in
GMAW of Mg alloys, though this is beMg welds.
yond the scope of the present study. The
welding wire feed rate can affect the rate
Recommendations to Manufacturers and
at which hydrogen is released into the arc.
Users of Mg Welding Wires
Also, the cooling rate can affect the
growth of bubbles by H diffusion to bubTo prevent gas porosity in GMAW of
bles or by coalescence of smaller bubbles.
Mg alloys, the following things are recomIt can also affect the escape of bubbles
mended to the manufacturers and users of
from the weld pool. A maximum porosity
Mg welding wires:
has been observed at an intermediate
1) The manufacturers can at least vaccooling rate in Al GMAW (Ref. 47). At a
uum seal the Mg welding wire spool in a
very high cooling rate (high travel speed
plastic bag soon after the wire is manufacand low heat input), the gas bubbles nutured, which was not the case when the aucleated have little time to grow. At a very
thors purchased their Mg welding wires.
WELDING RESEARCH
Fig. 10 As-received welding wire A (AZ61A Mg 1.2 mm in diameter)

shown at different angles to reveal dark areas (arrows) on the surface and
right after cleaning with sandpaper (bottom).
WELDING RESEARCH
Fig. 12 Porosity-free weld made by CSC-GMAW with welding wire A

cleaned with sandpaper before welding. A Top view; B longitudinal
cross section.
This can help prevent atmospheric corrosion before the bag is opened for use.
Coating the wire with a thin layer of a
metal that resists atmospheric corrosion
better than Mg while causing no additional
welding problems may be worth considering though the cost may be a concern.
2) The manufacturers can also consider
allowing the users to bake the wire-reel assembly. A plastic reel such as that shown
in Fig. 21B cannot be baked at temperatures near 350C. A reel made of welded
steel or stainless steel wires may be one
possibility if galvanic corrosion does not
become too much of a problem.
3) For users that consume a large volume of welding wires routinely, such as the
automotive industry, the welding wires will
be used up before any atmospheric corrosion can occur. For small-volume users,
however, the protection against atmospheric corrosion may be needed if the leftover wire is not to be used again soon. One
possibility is to store the welding wire
spool in a commercially available storage
or in a rebaking oven, for either flux cored
wires or covered electrodes, at a temperature that is high enough to keep atmospheric corrosion from occurring. This
temperature needs to be determined. Another possibility is to vacuum seal the
welding wire spool in a plastic bag until it
is to be used again. There might be other
ways as well. Any extra efforts taken to
avoid atmospheric corrosion may be
Fig. 13 Essentially porosity-free weld made by CSC-GMAW with welding

wire A cleaned with sandpaper before welding. A Top view; B longitudinal cross section. Workpiece: degreased with acetone but not cleaned with a
stainless steel brush.
worthwhile because Mg welding wires are

expensive.
4) The Mg welding wire users can inspect it before welding. If the wire surface
is already partially dark, porosity is likely
to occur. If the welds to be made are relatively short and small in number, the wire
can be cleaned. Polishing the wire surface
with sandpaper is one possibility. Otherwise, baking the welding wire spool can be
considered.
Conclusions
The present study on GMAW of Mgalloy sheets aims to both establish the fundamental mechanisms of spatter and
porosity formation and offer practical solutions to eliminate them. This will help
make GMAW a versatile process for welding Mg alloys, which is still not available in
spite of the rapidly increasing use of Mg
alloys for weight reduction. The conclusions are as follows:
1) Exploration of the use of CSCGMAW for welding of Mg sheets has shown
that spatter, which is often severe with conventional GMAW, can be eliminated.
2) Based on both the high-speed videos
(at 4000 f/s) of molten-metal transfer from
the welding wire tip to the weld pool and
the detailed waveforms of current and
voltage recorded during welding, the
mechanism of spatter has been established
and the elimination of spatter by CSC-
GMAW has been explained.

3) The mechanism of spatter formation
in conventional GMAW of Mg alloys is as
follows: The low density of Mg is good for
vehicle weight reduction but, unfortunately,
bad for GMAW. Because of the very low Mg
density, the welding wire melts easily and
the melt keeps hanging onto the wire tip to
grow into an excessively large globule by the
time it touches the weld pool to short circuit. This provides considerable amounts of
molten filler metal to be expelled as severe
spatter by the sudden arc expansion immediately following arc reinitiation from the
short circuit.
4) Because of the very low density of Mg
(about one-third less than that of Al), the
energy required for melting the Mg welding
wire is very low (42% less than that for melting an Al welding wire of the same diameter) and the globule is light and thus difficult
to detach by gravity. Consequently, the
globule can be expected to form easily and
keep on growing until it touches the weld
pool to cause short circuiting.
5) To make matters worse, the low Mg
density allows the light globule to be
pushed away easily from the weld pool and
thus continue to grow until it becomes excessively large. Without being pushed
away, the globule can only grow vertically
down to the size limited by the distance
between the wire tip and the pool surface.
6) Conclusions 4 and 5 explain the very
high current needed to pinch off the
Fig. 14 Porosity-free weld made by CSC-GMAW with welding wire A

baked at 380C for 11 min before welding. A Top view; B longitudinal
cross section.
Fig. 15 Porosity-free weld made by CSC-GMAW with welding wire B

when it was still clean. A Top view; B longitudinal cross section.
Fig. 17 Welding wire B (AZ61A Mg 1.2 mm in diameter) after being exposed to air for months, shown at different angles to reveal dark areas (arrows) on the surface and right after cleaning with sandpaper (bottom).
show a large current

surge during short cirFig. 16 Porosity in CSC-GMA weld made with welding wire B after ex- cuiting, typical of conposure to air for months before welding. A Top view; B longitudinal ventional
GMAW
cross section.
designed to spontaneously increase the
molten filler metal by the Lorentz force
current sharply to instantaneously melt back
and establish spray transfer in conventhe welding wire, which quickly brings the
tional GMAW of Mg, which unfortunately
arc length back to normal automatically and
provides too much heat for welding Mg
thus makes manual GMAW easy (much
sheets (Ref. 9).
easier than manual GTAW). Unlike in pre7) The current and voltage waveforms
vious studies, however, the waveform of
power (= current voltage) is also presented, and it reveals a power surge immediately after arc reinitiation, when the
voltage has already recovered but the current, though falling, is still very high.
8) The power surge heats up the arc
plasma instantaneously and causes a sudden arc expansion to expel the globule.
The short-circuiting time (~ 2 ms) is too
short for the large light globule to enter
the weld pool before arc expansion.
9) Unlike the constant voltage mode,
WELDING RESEARCH
WELDING RESEARCH
Fig. 18 Porosity-free weld made by CSC-GMAW with welding wire B

baked at 380C for 11 min after exposure to air for months. A Top view;
B longitudinal cross section.
the CSC mode of GMAW is set up to control the current instead of voltage. The
globule is smaller, and the much longer
short-circuiting time (~ 18 ms) allows the
globule to enter the pool. More importantly, the large current surge upon short
circuiting can be limited, thus eliminating
the power surge and hence spattering. In
CSC-GMAW, the waveform of the welding current can be tailored in great detail
to optimize the welding process.
10) Unlike in Al GMAW, severe gas
porosity can occur in Mg GMAW, either
conventional GMAW or CSC-GMAW, if
the welding wire has been exposed to open
air for an extended period of time.
11) Based on X-ray diffraction of the
surface layer removed from the welding
wire and the solubility of hydrogen in Mg
as a function of temperature, the mechanism of porosity formation has been established.
12) The mechanism of porosity formation in GMAW of Mg alloys is as follows:
With its large surface area per unit volume,
a welding wire covered with Mg(OH)2 can
carry a significant amount of Mg(OH)2 into
the arc, where it decomposes by Mg(OH)2
MgO + H2O. The H2O further decomposes to hydrogen to dissolve in Mg(L) as
atomic hydrogen H. Since Mg(S) can dissolve much less H than Mg(L), it rejects H
to form a H-rich liquid layer at the solidification front, where the high H concentration can push the reaction 2H H2(g) to
the right and form hydrogen porosity.
13) Mg(OH)2 has been identified on
the surfaces of the

welding wires that
caused severe gas
porosity, by using a
special X-ray difFig. 19 Mechanism of gas-porosity formation in GMAW of Mg alloys. A
fraction system that Mechanism; B hydrogen solubility in Mg (Ref. 40).
works even with a
very small amount
in air at 380C for 11 min before welding
of powder removed from the wire surface.
can eliminate gas porosity by making the
The surface appears dark where Mg(OH)2
reaction Mg(OH)2 MgO + H2O
exists. Mg welding wires can react with
occur before, instead of during, welding.
moisture in the air to form Mg(OH)2, that
16) Recommendations for porosity
is, atmospheric corrosion.
prevention in GMAW of Mg alloys have
14) The much more severe gas porosbeen made, based on the results of the
ity in Mg GMAW than in Al GMAW is
present study, to both the manufacturers
caused by: 1) much more hydrogen is
and users of Mg welding wires.
available to dissolve in the Mg weld pool
because Mg(OH)2 forms much more easAcknowledgments
ily on a Mg welding wire than Al(OH) 3
does on an Al welding wire, 2) much
This work was supported by the National
more hydrogen can actually dissolve in
Science Foundation under Grant No. IIPthe Mg weld pool because of the much
1034695 and the University of Wisconsin
higher hydrogen solubility in Mg(L) than
Foundation through the Industry/University
Al(L) (by about 60 times at the melting
Collaborative Research Center (I/UCRC)
point), 3) much greater hydrogen-solufor Integrated Materials Joining Science for
bility drop occurs upon solidification of
Energy Applications.
Mg (L) than Al (L) (by about 20 times),
The authors would like to thank Bruce
causing much more H rejection into the
Albrecht, Todd Holverson, Rick Hutchison,
liquid at the solidification front to trigand Joe Fink of Miller Electric Mfg. Co. and
ger the reaction 2H H2(g), and (4)
ITW Global Welding Technology Center,
H2(g) bubbles rise to escape from a Mg
both located in Appleton, Wis. for donating
weld pool more slowly than an Al weld
the CSC process controller and drive aspool because of the lower density of Mg.
sembly, Invision 456 power source, XR15) Cleaning the Mg welding wire
M wire feeder, and welding gun used in the
with sandpaper before welding can elimpresent study. They would like to give speinate gas porosity by eliminating
cial thanks to Rick Hutchison and Joe Fink
Mg(OH)2. Baking the Mg welding wire
Fig. 21 Welding wires on spools after extended exposure to air. A Surface

of 5356 Al (~Al-5Mg) welding wire still shiny after 14 years; B surface of
AZ61 Mg (~Mg-6Al-1Zn) welding wire very dark after 3 years.
Dr. Hiromi Konishi

of the Geoscience
Department at the
University of Wisconsin for assistance
in X-ray diffraction,
and
Alexandra
Padilla-Vega of the
University of Puerto
Rico at Mayagez
for reviewing the revised manuscript.
References
Fig. 20 X-ray diffraction of powder removed from the dark surfaces. A AZ61
Mg welding wire A, showing match between peaks and characteristic diffraction
angles of Mg(OH)2 (blue lines); B AZ31 Mg sheet, showing match between
peaks and characteristic diffraction angles of MgO.
for setting up the CSC-GMAW system at

UW-Madison and providing technical assistance during the present study. They would
also like to thank Kent Peterson of NAC
Image Technique, Simi Valley, Calif., for
high-speed video recording during welding,
1. Watarai, H.
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Zhang et al Supplement December 2013_Layout 1 11/14/13 3:05 PM Page 363
Effect of Adhesive Characteristics on the

Weld Quality in Weld Bonding
Multiple Steel Sheets
Guidelines are presented for weld bonding multiple
stacks of steel sheets for vehicle manufacturing
ABSTRACT
The use of weld bonding (i.e., a combination of resistance spot welding and adhesive bonding) as a structural fastener is increasing in the automotive industry.
However, a series of issues needs to be addressed such as the influence of adhesive characteristics (e.g., adhesive properties and bondline thickness) in the weldbonding application to enhance the knowledge of this technology and reinforce
its use. As part of the development and implementation of weld bonding, the present study was undertaken to experimentally evaluate the effects of the adhesive
characteristics on the weld quality of weld-bonded multiple steel sheets.
The weld quality in terms of the weld size, weld expulsion, and weld strength in
weld bonding multiple stacks of steel sheets composed of 0.8-mm-thick SAE1004,
1.4-mm-thick DP600, and 1.8-mm-thick DP780 with different epoxy adhesives (i.e.,
A2 and A1) and bondline thicknesses (0.2~1.4 mm) are investigated in this study. It
was found that while the viscosity of the adhesive significantly affects the static contact and dynamic resistances between the steel sheets, the uncured adhesive bondline thickness has little impact upon the contact and dynamic resistances. Consequently, the weld size and weld expulsion in weld-bonding multiple steel sheets
increased with an increase in viscosity of the adhesive and exhibited little effect by
the bondline thickness. The lap-shear strength of weld-bonded multiple steel sheets
was increased significantly by the presence of the cured adhesive but was not affected
by the applied, uncured adhesive bondline thickness. Finally, the placement of an adhesive between the thin external and thicker middle sheet to improve the weld size
and penetration into the thin external sheet could be a feasible solution to resolve
undersized welds in the resistance welding of multiple steel sheets. This study provides guidelines to the application of adhesive in weld bonding multiple stacks of steel
sheets for vehicle manufacturing.
Introduction
In mass producing automotive lightweight body frames, the application of hybrid joining techniques is increasing in importance. The weld bonding process,
Y. S. ZHANG (zhangyansong@sjtu.edu.cn),
J. SHEN, and Y. Y. ZHAO are with the Shanghai
Key Laboratory of Digital Manufacture for Thinwalled Structures, Shanghai Jiao Tong University,
Shanghai, China. PEI-CHUNG WANG and B.
CARLSON are with the Manufacturing Systems
Research Lab, General Motors Research & Development Center, Warren, Mich.
Paper presented at the AWS Detroit Sections
Sheet Metal Welding Conference XV, Livonia,
Mich., October 25, 2012.
shown in Fig. 1 as a combination of resistance spot welding (RSW) and adhesive

bonding, provides a more desirable joint
performance compared to either RSW or
adhesive bonding alone (Refs. 13). It not
only improves the crashworthiness, stiff-
KEYWORDS
Weld Bonding
Multiple Steel Sheets
Weld Quality
Bondline Thickness
ness, fatigue behavior, and corrosion resistance (Refs. 4, 5), but also potentially
enables a reduction in the number of
welds in vehicle structures. Therefore, the
technology is state of the art in many
branches of joining metal sheets, especially for newly developed advanced highstrength steels (AHSS).
However, a series of issues needs to be
addressed such as the influence of adhesive property and location in weld bonding
multiple metal sheets to enhance the
knowledge of this technology and reinforce its use. The variety of adhesive
strengths and moduli leads to potentially
different bonding conditions, changes the
contact state of the steel sheets after being
squeezed out by the electrode force, and
consequently influences the weld quality
in weld bonding steel sheets. Many studies
concerning weld bonding two steel sheets
have shown that the adhesive increased
the weld size and strength in the weldbonded joints compared to resistance spot
welds under the same welding parameters
(Refs. 68). Furthermore, the effect of the
adhesive on the weld size is closely related
to the increase of the contact resistance
between the steel sheets, which influences
the current density pattern and temperature field via the joule heating effect (Refs.
912). The temperature field then influences the mechanical pressure distribution through thermal deformation of the
workpieces. Therefore, the formation of
the weld is indeed dependent upon the
contact phenomena at the faying interfaces. In weld bonding multiple stacks of
steel sheets, the contact states between the
steel sheets are more complex than for the
traditional two-sheet stackup. Therefore,
it is essential that an understanding of the
effect of adhesive characteristics on weld
bonding multiple-sheet stackups of steel
sheets be obtained.
The present study was undertaken to
WELDING RESEARCH
BY Y. S. ZHANG, J. SHEN, Y. Y. ZHAO, PEI-CHUNG WANG, AND B. CARLSON
Fig. 1 Procedure of the weld-bonding process. A Apply adhesive and assemble; B spot welding; and C adhesive cure in the paint shop oven.
WELDING RESEARCH
experimentally evaluate the effect of the

adhesive characteristics on the weld quality in weld bonding multiple stacks of steel
sheets. There are three main parts in this
study; the first presents the experimental
procedure, including material, experimental setup, sample fabrication, weld expulsion and weld nugget size measurements, plus mechanical test. In the
following section, the static contact resistance during the squeeze cycle and dynamic resistance during the weld cycle
were measured and analyzed to investigate the weld formation mechanism in
weld bonding multiple steel sheets. Finally, the effects of adhesive type and
bondline thickness on the weld quality in
terms of the weld expulsion, weld size, and
joint strength were experimentally studied. This study provides valuable guidelines to the application of adhesive in weld
bonding multiple stacks of steel sheets for
vehicle manufacturing.
Sample Fabrication
In this study, the

weld-bonding process
was realized through
use of a servo gun
welding system having a medium-frequency direct current
(MFDC) welding machine. The multiple
stacks of three steel
sheets was composed
of
0.8-mm-thick
SAE1004 as top
sheet, 1.4-mm-thick
DP600 as middle
sheet, and 1.8-mm- Fig. 2 A Weld configuration in weld bonding three steel sheets; B
thick DP780 as bot- shims used to maintain the bondline thickness.
tom sheet (Fig. 2A).
The adhesive bead
(i.e., A1 or A2) was
by the steel shims that were removed prior
manually applied onto the steel sheets by
to welding.
a glue gun and then the steel sheets with
adhesive were stacked together prior to
Measurement of Contact Resistance
resistance welding. The welding current is
applied through the adhesive and steels to
To investigate the adhesives effect on
get a final weld-bonded joint.
the contact resistance between the steel
A Class II copper alloy with chromium
sheets, both static contact resistance (Ref.
and zirconium electrode (Cr: >0.4%, Zr:
12) and dynamic resistance (Refs. 1417)
0.30.15) was used in the experiment, and
have been measured in this study. The
the welding parameters are listed in Table
measurement principle, presented in Fig.
3 (Ref. 13). To show the weld nugget for3A, is based upon RM, which is the total
mation, various welding times were used
resistance between two fixtures. These fixand metallographic cross-section examitures are installed 40 mm from the centernations of the weld-bonded joints were
line of the electrode and enables RM
performed to measure the weld nugget
(where RM = 2RS + RC) to be directly
sizes. To ensure that the contact resistance
measured by the system. When a conmeasurement was consistent, a set of steel
trolled current is passed through the elecshims were used in this study to maintain
trodes, the voltage between the fixtures,
a consistent bondline thickness. Figure 2B
i.e., contacts shown as arrows in Fig. 3A,
shows the bondline thickness maintained
Experimental Procedure
Materials
To investigate weld bonding multiple

stacks of steel sheets, 0.8-mm-thick hotdipped galvanized (HDG) low-carbon steel
SAE1004, 1.4-mm-thick (HDG) DP600,
and 1.8-mm-thick (HDG) DP780 steels
were used in this study. All steel sheets had
a coating thickness of 60 g/m2. The chemical composition and mechanical properties
of these steels were measured and listed in
Table 1. Two one-component hot-cured
epoxy resin-based adhesives (i.e., A1 and
A2) were used in this study. Per the manufacturers data sheet, Table 2 lists the material properties of A1 and A2 adhesives.
Table 1 Chemical Composition and Mechanical Properties of Various Steels
Chemical Composition (%)
Mechanical Properties
Steel
SAE1004
DP600
DP780
Mn
0.037
0.08
0.15
0.21
1.74
1.80
P
0.01
0.012
0.004
Si
0.02
0.003
0.016
0.018
0.016
0.010
Al
0.04
0.041
0.048
Yield
Strength
(MPa)
Tensile
Strength
(MPa)
Elongation
(%)
152
316
508
278
607
834
66
29
26
Fig. 3 Experimental schematic for measurement between the steel sheets and adhesive in weld bonding multiple steel sheets. A Static contact; B
dynamic resistances.
Spatter
Paper
Magnet
Tansparent box
1 cm
25 cm
Fig. 4 A Setup for collecting the weld expulsion; B weld spatter collected
by a magnet.
can be measured and is denoted by RM.

However, this also represents the voltage
across the top sheet through the adhesive
and to the bottom sheet.
Furthermore, the contacts are sufficiently far from the electrodes to avoid
shunting of the current. Since RS is the
bulk resistivity of the steel sheets from the
contact region to the fixture, and is a
known constant value at ambient temperatures than RC, the static contact resistance between the steel sheets can be calculated using the following relationship:
(RM = 2RS + RC). Figure 3B is a
schematic of the measurement method
where R1 is the dynamic resistance between the top and middle sheets, and R2 is
the dynamic resistance between the middle and bottom sheets. Measurements of
dynamic resistance appear to be one of the
most widely accepted procedures to assess
weld quality. In general, to directly inspect
the heat to generate the nugget, tip voltage and current measurements at the secondary side of the transformer are used to
calculate dynamic resistance. A Miyachi
Weld Checker, including the toroidal coil
and voltage detection cord, were used to
directly measure the tip voltage and welding current in secondary circuit. The resistance can be calculated accurately using
the current, where di/dt = 0, and the volt-
Fig. 5 A Schematic view of tensile-shear sample (dimensions in mm);

B sample between the testing grips.
age at that moment. Five replicates were

performed for each type of weld bonding,
and the average dynamic resistances were
reported. A detailed description can be
found in Ref. 14.
Measurement of Weld Expulsion
One attribute of weld quality in resistance spot welding is the amount of weld
expulsion. Although weld expulsion is an
important indicator of weld quality, there
are few references regarding quantification or measurement of weld expulsion. To
generate weld expulsion, the process parameters listed in Table 3 were kept unchanged except that the welding current
was increased to 10.0 kA and the bondline
thickness was fixed at 0.4 mm. Five replicates were performed, and the weld spatter was collected and weighed.
To capture the weld expulsion in this
study, the welding process was conducted
in a 1-m3 box made of transparent resin;
refer to Fig. 4A. The weld spatter material
was collected using a magnet shown in Fig.
4B. To separate the collected spatter from
the magnet more easily, the magnet was
Table 2 Material Properties for A1 and A2 Adhesives

Adhesive
Specific Gravity
Viscosity
@50oC (Pas)
Tensile Strength
(MPa)
Elongation at Break
(%)
A1
A2
1.03
1.05~1.20
2040
3050
37
30
6.2
10
Table 3 Welding Parameters

Cap (Class II)
Face Diameter
(mm)
Electrode
Force
(kN)
Welding
Current
(kA)
Squeezing
5.0
5.5
8.5
200
Time (ms)
Welding
420
Hold
100
WELDING RESEARCH
Servo gun
Workpiece
Fig. 6 Effect of the adhesive on the static contact resistance between the following: A 0.8-mm-thick SAE1004 and 1.4-mm-thick DP600; B 1.4-mmthick DP600 and 1.8-mm-thick DP780 steel.
WELDING RESEARCH
Fig. 7 Effect of the bondline thickness of A2 on the static contact resistance between the following: A 0.8-mm-thick SAE1004 steel and 1.4-mm-thick
DP600 steel; B 1.4-mm-thick DP600 steel and 1.8-mm-thick DP780 steel.
wrapped in a clean paper. Using this magnet to scan everywhere within the box, the
spatter would jump onto the paper due to
the magnetic force. To generate the weld
expulsion, the welding current was increased to 10.0 kA while other parameters
were kept constant as shown in Table 3.
4% etch applied after mechanical grinding

and polishing. Five replicates were prepared for the metallographic tests. The
thicknesses of the top and middle sheets
are 0.8 and 1.4 mm, respectively, the minimum dimension for weld size d is set at 4.0
mm (Ref. 13). Furthermore, the desired
minimum weld size D is 5.0 mm.
shear tests were performed at a crosshead

speed of 5 mm/min with a SUNS universal
testing machine. Five replicates were
tested in this study.
Results
Static Resistance during Squeeze Cycle
Weld Characterization
Mechanical Test
Because of the complexity of the joint

stackup, the traditional weld dimension
(diameter in the center of the weld) cannot clearly characterize the quality and
shape of the weld in weld bonding three
sheets. Hence, a new weld configuration
with a typical dimensional parameter for
joints having multiple sheets is presented
in Fig. 2. There are two critical dimensions
of the weld weld sizes d and D. Weld
size d can represent the joint quality between the top and middle sheets. Weld
size D represents the connection between
the middle and bottom sheets. These two
weld sizes can be measured from the micrographs of the joint cross section, which
is prepared for measurement using Nital
Beside the weld nugget size, weld

strength is also an important indicator of
weld quality. Since the sheet combination
used in this study involves three steel
sheets, there are two welds at two faying
interfaces. To simplify the mechanical test
specimen grip design, we measured only
the strength of the weld between the middle and bottom sheets. Figure 5A shows a
schematic of the specimen configuration
and gripping arrangement. To minimize
bending stresses inherent in the testing of
lap shear specimens, filler plates used to
accommodate the sample offset as can be
seen in Fig. 5B were attached to both ends
of the sample using masking tape. Lap-
Figure 6A and B present the effect of the

adhesive on the static contact resistance between the top and middle workpieces, and
middle and bottom workpieces, respectively. The static contact resistance for all
cases decreases with an increasing level of
applied electrode force, and for the case
where adhesive is present, the resistance
drops precipitately at low levels of applied
electrode force and then exhibits a knee in
the data and the resistance levels off to similar levels as for the case with no adhesive
present and the applied electrode force continues to increase. As the electrode force increases, the difference in static contact resistance between the steel sheets for the
joints made with and without adhesive
decreases.
Fig. 8 Effect of the adhesive on the dynamic resistance between the following: A 0.8-mm-thick SAE1004 and 1.4-mm-thick DP600; B 1.4-mm-thick
DP600 and 1.8-mm-thick DP780 steels.
Fig. 9 Effect of the bondline thickness of A2 on the dynamic resistance between the following: A 0.8-mm-thick SAE1004 and 1.4-mm-thick DP600;
B 1.4-mm-thick DP600 and 1.8-mm-thick DP780 steels.
For those situations without adhesive,

the static contact resistance for both configurations is fairly stable below a value of
2.0 m for the range of applied electrode
forces, 0.56.0 kN. However, the static
contact resistance between the middle and
bottom sheets, i.e., 1.4-mm DP600/1.8mm DP780, does rise slightly for electrode
forces below 2.0 kN whereas the same resistance for the top and middle sheets, i.e.,
0.8-mm, SAE1004/1.4-mm DP600, does
not. The application of adhesive increases
the contact resistance for all levels of electrode force but significantly more so for
adhesive A2 than adhesive A1 at lower
levels of electrode force. In particular, the
contact resistance between the top and
middle sheets, i.e., the 0.8-mm SAE1004/
1.4-mm DP600 interface, with adhesive
rises significantly below an electrode force
of 2.0 and 4.0 kN for adhesives A1 and A2,
respectively, whereas the contact resist-
ances for the middle and bottom sheets,

i.e., 1.4-mm DP600/1.8-mm DP780 interface, rise significantly below electrode levels of 3.0 and 4.0 kN for adhesives A1 and
A2, respectively.
Effect of Bondline Thickness on Static

Contact Resistance
Beside the effect of the adhesive, the

uncured bondline thickness between the
substrates is another variable that may af-
Table 4 Adhesive Combinations with A1 and A2

Adhesive
Combinations
Adhesive Applied at the Interface

between
Top and Middle Sheets
Adhesive Applied at the Interface

between
Middle and Bottom Sheets
No adhesive
No adhesive + A1
No adhesive + A2
A1 + No adhesive
A1 + A1
A1 + A2
A2 + No adhesive
A2 + A1
A2 + A2
No adhesive
No adhesive
No adhesive
A1
A1
A1
A2
A2
A2
No adhesive
A1
A2
No adhesive
A1
A2
No adhesive
A1
A2
WELDING RESEARCH
WELDING RESEARCH
Fig. 10 Effects of the adhesive properties on weld formation in the following: A Weld bonding
with A1; B A2 adhesive; and C resistance spot welding of 0.8-mm-thick SAE1004, 1.4-mmthick DP600, and 1.8-mm-thick DP780 steel.
Table 5 Factors and Levels
Variable
X1
X2
Adhesive Location
No Adhesive
Value
A1
A2
0
0
-1
-1
1
1
Top and middle faying interface

Middle and bottom faying interface
fect weld bonding multiple steel sheets. To

address this variable, the bondline thickness was varied from 0 to 1.4 mm. Figure
7 presents the effect of the bondline thickness on the static contact resistances between the steel sheets. As shown in Fig.
7A, the effect of the bondline thickness on
the static contact resistance is insignificant
between the top and middle steel sheets at
low electrode force. Similar results were
observed in Fig. 7B about the contact resistance between the middle and bottom
sheets except that a larger electrode force
is required to squeeze out the adhesive between the workpieces.
(i.e., 1.4-mm-thick DP600 and 1.8-mmthick DP780) are higher than that without
adhesive during the first and second stages
of the weld-bonding process. Adhesive A2
exhibited the greatest dynamic resistance
followed by adhesive A1 and finally steel
without adhesive for any welding time in
the period between 50 and 150 msec. The
dynamic resistance for all conditions eventually leveled out to approximately the
same value at a welding time of 300 msec.
No significant effect of the applied bondline thickness on the dynamic resistance
between the multiple steel sheets can be
made (refer to the results presented in
Fig. 9).
Dynamic Resistance during Weld Cycle

Weld Size
To investigate the effect of the adhesive

on the dynamic resistance during the weld
cycle, weld bonding multiple steel sheets
(i.e., 0.8-mm-thick SAE1004, 1.4-mmthick DP600 and 1.8-mm-thick DP780
steel) with A1 and A2 adhesives was conducted with the welding parameters listed
in Table 3, and the results shown in Fig. 8.
It can be seen from the results that the dynamic resistances at faying interfaces between the top and middle sheets (i.e., 0.8mm-thick SAE1004 and 1.4-mm-thick
DP600) and the middle and bottom sheets
Since the contact resistances during the

squeeze and weld cycles of weld bonding
multiple stacks of steel sheets were significantly affected by the presence of the adhesive, it is necessary to study the effect of the
adhesive characteristics on the weld nugget
sizes as defined in Fig. 2A. Figure 10A and
B are typical metallographic cross sections
of the weld formation in weld bonding multiple steel sheets with the adhesives A1 and
A2, respectively. For the purpose of comparison, resistance spot welded joints are
also included in Fig. 10C. Two general observations can be made longer welding
times resulted in increased weld nugget diameters, and the presence of adhesive, either A1 or A2, resulted in greater weld
nugget diameters, d and D in reference to
Fig. 2A, compared to the same stackup
without adhesive for a given weld schedule.
Furthermore, the results show that the weld
bonding nugget diameter with A2 adhesive
was consistently larger than that with the A1
adhesive.
To thoroughly assess the effect of the adhesive on the weld size in weld bonding,
tests with various adhesive combinations
shown in Table 4 were also conducted. Five
replicates were tested for each adhesive
combination using the welding parameters
listed in Table 3, and the results are presented in Fig. 11. The presence of the adhesive between the workpieces regardless of
the bondline thickness in the range that was
studied increased both weld sizes d and D.
However, the extent of that increase in weld
size varies widely for different adhesive
types and combinations.
Tests were also conducted to study the
effect of the bondline thickness of A2 adhesive on the weld size in weld bonding
multiple stacks of steel sheets. Figure 12
presents the test results that show the adhesive bondline thickness had no statistical effect upon the weld sizes d and D in
weld bonding multiple steel sheets in this
study. These results are consistent with the
measurements of the static and dynamic
resistances shown in Figs. 7 and 9.
Weld Expulsion
Since weld expulsion is an important

weld quality attribute, the effect of the adhesive combinations shown in Table 4 on
the weld expulsion was investigated in this
study. The weld spatter results for various
combinations of weld bonding with adhesive A1 and A2 are presented in Fig. 13.
As would be expected, the amount of weld
spatter increased with the presence of the
adhesive where A2 generated a greater
amount as compared to A1. As shown in
Fig. 14, as the bondline thickness increased from 0.2 to 1.2 mm, the weld spatter decreased from 1.30 to 0.88 g. Figure
15 shows the SEM photos of the broken
faying interface with various adhesive
bondline thicknesses.
Weld Strength
To assess the effect of adhesive combination on the weld strength of weldbonded multiple steel sheets, lap-shear
tests were performed prior to the adhesive
curing. Figure 16 has the test results. As
shown, the presence of the uncured adhesive significantly improved the force displacement of weld-bonded multiple steel
sheets. Tests were also performed to measure the effect of the adhesive bondline
thickness on the strength of weld-bonded
multiple steel sheets, and the results are
shown in Fig. 17. The uncured adhesive
bondline thickness had no significant effect upon the strength of weld-bonded
multiple steel sheets.
Discussion
Static Contact Resistance
The static contact resistances shown in

Fig. 6A and B between the middle and bottom sheets, i.e., 1.4-mm DP600/1.8-mm
DP780, are greater than the resistance for
the top and middle sheets, i.e., 0.8-mm
SAE1004/1.4-mm DP600 for a given electrode force. This is attributed to the fact
that the thinner and less-stiff top sheet deforms upon application of the electrode
force and thereby wraps around the electrode tip to a greater extent than the
thicker and stiffer bottom sheet. This creates a greater interfacial area and hence,
increases the static contact resistance for a
given applied electrode force.
The static contact resistances between
the steel sheets with adhesive A1 were
smaller than that with adhesive A2 during
the squeeze stage. This difference is attributed to the fact that the viscosity of A1
is less than that of A2 (refer to Table 2),
which translates to the adhesive A1 being
spread thinner upon application of the
electrode force and thereby posing a lower
static resistance. Subsequently, following
this logic, one can observe that without
any adhesive the static resistance value is
lowest. It can also be observed from Fig. 6
that there is a drop in contact resistance
with increasing electrode force and that
there is a knee in the data above which the
resistance becomes increasingly independent of electrode force. This knee for
the contact resistances between the

top and middle steels
with adhesive occurs
at approximately 1
and 3 kN for adhesives A1 and A2, respectively, while it
occurs at higher values, 2.5 and 4 kN for
adhesives A1 and A2,
respectively, for the
contact resistance
between the middle
and bottom sheets
with adhesive. The
greater force levels to
achieve a lower contact resistance is attributed to a greater
Fig. 12 Effect of the bondline thickness on the weld size in weld bonding
stiffness of the joint 0.8-mm-thick SAE1004, 1.4-mm-thick DP600, and 1.8-mm-thick DP780
between the middle steel with A2 adhesive.
and bottom sheets,
which in turn is a result of greater sheet
properties and electrode force in weld
thicknesses and strengths as compared to
bonding. Therefore, the bondline thickthe top and middle sheet combination.
ness had little effect on the contact resistance between the steel sheets under inEffect of Bondline Thickness on Static
dustrially relevant electrode force levels.
Contact Resistance
Similar results were observed in Fig. 7B
about the contact resistance between the
As shown in Fig. 7A, the effect of the
middle and bottom sheets except that a
bondline thickness on the static contact relarger electrode force is required to
sistance is insignificant between the top
squeeze out the adhesive between the
and middle steel sheets at low electrode
workpieces, which is attributed to the midforce. As the electrode force increases, the
dle and bottom sheets having greater
bondline thickness has no influence for an
thickness and able to carry a greater load
electrode force up to approximately 3 kN.
than the thinner top and middle sheets.
This is likely due to the fact that the exFinally, there is a significant increase of
cessive adhesive, regardless of the bondresistance with decreasing adhesive bondline thicknesses in this study, was
line thickness at the lowest electrode force
squeezed out of the steel sheets by the
levels. The reason for this is unclear and
large electrode force. The results shown in
will require further study. However, the
Figs. 6 and 7 suggest that the contact reelectrode force levels at this level are not
sistance between the substrates with adheindustrially relevant.
sive is primarily influenced by the adhesive
WELDING RESEARCH
Fig. 11 Effect of different adhesive combinations on the following: A Weld size d; B weld size D in weld bonding 0.8-mm-thick SAE1004, 1.4-mm-thick
DP600, and 1.8-mm-thick DP780 steel.
WELDING RESEARCH
Fig. 13 Effect of the adhesive combination on the weld spatter of five specimens in weld bonding 0.8-mm-thick SAE1004, 1.4-mm-thick DP600, and
1.8-mm-thick DP780 steel.
Fig. 14 Effect of the uncured adhesive bondline thickness of adhesive A2

on amount of the weld spatter of five specimens in weld bonding 0.8-mmthick SAE1004, 1.4-mm-thick DP600, and 1.8-mm-thick DP780 steel.
Fig. 15 Retained weld spatter at the faying interface for a bondline thickness. A 0.2; B 0.4; C 0.8; D 1.2 mm.
Dynamic Resistance during Weld Cycle
The initial increase in dynamic resistance during the first stage in weld bonding
compared to that without adhesive is attributed mainly to the influence of the adhesive on the static contact resistance between the substrates. However, as the
temperature of the substrates increased,
i.e., 50 to 200 or 300 ms in reference to Fig.
8A and B, respectively, this effect was diminished by the thermal degradation and
decomposition of the adhesive.
The joule heat generation during the
first stage enhanced the increase of the
bulk resistivity of the steel sheets as the
temperature increased (Ref. 15). Therefore, the total dynamic resistance of the
weld bonded steel sheets during the second stage was greater than that without
adhesive. The dynamic resistance of the

joint with A1 adhesive was located in between that with A2 adhesive and without
adhesive in Fig. 8. This was a result of less
joule heat generation at the faying interfaces for the joint made with A1 because
of the smaller contact resistance between
the substrates as compared to that with the
A2 adhesive.
Finally, the dynamic resistances shown
in Fig. 8 also indicate that there is a major
difference in the time to initiate a weld
nugget between resistance spot welding
and weld bonding. The details of the weld
initiation and growth in weld bonding are
discussed later.
The effect of the applied bondline thickness on the dynamic resistance between the
multiple steel sheets was examined, and the
results are presented in Fig. 9. It can be seen
from the results that the effect of the bondline thickness on the dynamic resistance is
insignificant. This is likely attributed to the
adhesive being squeezed out of the faying
interfaces under the applied electrode
force, and the variation in the amount of adhesive remaining as a function of applied
bondline thickness is insignificant to generate any sizable differences in joule heating
or other effect. Therefore, it can be concluded that the bondline thickness has little
effect upon the weld formation and size in
weld bonding multiple steel sheets.
Weld Size
The results in Figs. 10AC and 11A, B

exhibit a greater weld bonding nugget size
with the A2 adhesive as compared to the
A1 adhesive. Since the A2 adhesive is as-
Fig. 16 Effects of adhesive properties on the interface between the middle and bottom sheets for weld-bonded 0.8-mm-thick SAE1004, 1.4-mm-thick DP600,
and 1.8-mm-thick DP780 steel. A Load displacement; B joint strength.
Fig. 17 Effects of uncured adhesive bondline thickness A2 on the interface between the middle and bottom sheets. A Load displacement; B joint strength.
sociated with a greater static and dynamic

contact resistance compared to the adhesive A1 (refer to Figs. 6 and 8), it is hypothesized that the greater resistance results in more joule heat generation, which
assists the weld nugget initiation and
growth of the molten weld nugget during
welding that would increase the final weld
sizes (i.e., d and D). Furthermore, the
weld sizes d and D with either A1 or A2
adhesive were larger than the joints made
without adhesive. A similar argument can
be made for the presence of adhesive having greater levels of resistance as compared to joints without adhesive leading to
greater weld nugget sizes, d and D.
As shown in Fig. 11, the placement of the
adhesive has a direct correlation to which
weld nugget diameter attribute, d or D, will
exhibit a statistical increase. The adhesive
placed only between the top and middle
steel sheets (A1 + No, A2 + No) increased
the weld size d more than weld size D. Similarly, the placement of the adhesive between the middle and bottom steels (No +
A1, No + A2) increased the weld size D
more than weld size d. This is a function of
the adhesive increasing the contact resistance resulting in relatively greater joule
heating at that interface. These results
Fig. 18 Retained spatter particles within the adhesive in weld bonding 0.8-mm-thick SAE1004, 1.4mm-thick DP600, and 1.8-mm-thick DP780 steel. A A1; B A2 adhesive.
agree well with the results on the static contact resistance and dynamic resistance
shown in Figs. 6 and 8. Because the placement of the adhesive between the top and
middle sheets generated a significantly
greater weld size d, this could be a potential
solution to resolve the issue of undersized
weld nuggets as seen in Fig. 10C.

To summarize the effects of the adhesive and location on the weld sizes in weld
bonding 0.8-mm-thick SAE1004, 1.4-mmthick DP600, and 1.8-mm-thick DP780
steel, the empirical equations for the weld
sizes d and D were derived based on the
WELDING RESEARCH
WELDING RESEARCH
Fig. 19 SEM observation and EDS analysis of retained spatter with the
following adhesives: A A1; B A2; C erupted weld spatter with adhesive A1; D erupted weld spatter with adhesive A2; E erupted spatter
particles of resistance spot welding.
test results, and are presented as follows:

d = 4.90 (1 + 0.0765X1+ 0.0408X2
+ 0.0276X12 + 0.0204X22 0.0367X1X2)
with correlation coefficient R2 = 0.9218
D = 6.87 (1 + 0.0339X1 + 0.1053X2
0.0047X12 0.0323X22 0.0338X1X2)
with correlation coefficient R2 = 0.9236
where the values for X1 and X2 are described in Table 5. For example, if the adhesives A1 and A2 are placed at the interfaces
between the middle and bottom sheets, and
middle and bottom sheets, respectively, the
weld size D is approximately 7.05 mm (i.e.,
X1 = 1 and X2 = 1).
Weld Expulsion
Weld expulsion occurs when the pressure from the liquid molten pool against
the solid containment equals or exceeds
the applied electrode pressure. Since adhesive A2 generates a greater amount of
joule heating followed by earlier weld
nugget melt initiation and growth, com372-s DECEMBER 2013, VOL. 92
pared to adhesive
A1, it might be expected that there
would be a corresponding
greater
molten pool pressure
buildup as well.
Therefore, the argument can be extended that a greater
amount of weld spatter is to be anticipated with the presence of adhesive A2
compared to adhesive A1 or no adhesive
at all. This line of reasoning is supported
by the data presented in Fig. 13.
Experimental observations showed
that most of the weld spatter erupted from
the interfaces between the sheets instead
of the sheet surface and that the adhesive
surrounding the molten weld pool decomposed because of the elevated temperatures. Because of the relatively high current levels, weld spatter erupting at the
faying interface was forced to pass through
the remains of the adhesive layer. However, a small portion of the erupted liquid
metal was retained by the remains of the

adhesive layer and solidified in place as
verified by experimental observations,
refer to Fig. 18.
SEM and EDS analyses of the retained
weld spatter particles from stackups using
adhesives A1 and A2 are shown in Fig.
19A and B, respectively. Similarly,
erupted weld spatter particles from weld
bonding with adhesives A1 and A2 were
analyzed, and the results are presented in
Fig. 19C and D, respectively. For the purpose of the comparison, the weld spatter
from resistance spot welding with no adhesive was also analyzed, and the result is
Weld Strength
The presence of the uncured adhesive

significantly improved the force-displacement behavior of weld-bonded multiple
steel sheets; refer to Fig. 16A and B. Since
the tests were performed prior to adhesive
curing, these results suggest that the increase of the force displacement is primarily attributed to the increased weld
nugget size resulting from the extra joule
heat introduced by the presence of the adhesive at the faying interfaces. This is supported by the good correlation coefficient,
R2 = 0.97287, of the peak load (as a measure of weld strength) vs. weld nugget size
(D) data, refer to Fig. 20.
Tests to measure the effect of the adhesive bondline thickness on the strength
of weld-bonded multiple steel sheets show
(refer to Fig. 17A and B) that the uncured
adhesive bondline thickness had no significant effect upon the strength of weldbonded multiple steel sheets. This is con-
Fig. 20 Correlation between the peak load and weld size for weld bonding 0.8-mm-thick SAE1004,
1.4-mm-thick DP600, and 1.8-mm-thick DP780 steel joints made based on Table 4.
sistent with the earlier data showing that

the bondline thickness exhibited no significant relationship to static resistance or
weld nugget size.
Conclusions
The measurements of the static and dynamic contact resistances, welding experiments, metallography analyses, and mechanical tests conducted on weld bonding
multiple steel sheets (i.e., 0.8-mm-thick
SAE1004, 1.4-mm-thick DP600, and 1.8mm-thick DP780) with epoxy adhesives
(i.e., A1 and A2) concluded the following:
1. The presence of adhesive between
steel sheets during resistance spot welding
results in a comparatively greater static
and dynamic contact resistance leading to
greater joule heating, earlier weld nugget
melt initiation, and greater growth leading
to a larger weld nugget diameter as compared to a joint without adhesive.
2. The viscosity of the adhesive significantly affects the static contact and dynamic resistances between the steel
sheets. A more viscous adhesive requires
a greater applied electrode force to
squeeze out the adhesive from bondline
and results in a relatively higher contact
resistance.
3. The uncured adhesive bondline
thickness in the range of 0.21.2 mm exhibits no statistical correlation to the contact and dynamic resistances.
4. The presence of adhesive is correlated to a relatively greater amount of
weld spatter generation compared to a
joint without adhesive. This is attributed
to the elevated contact resistance resulting
from the presence of the adhesive leading
to relatively greater joule heating and a
larger molten weld nugget pool, which in

turn, leads to greater pressure buildup and
resultant weld spatter.
5. Weld spatter from weld bonding has
been found to be both retained within the
bondline adhesive as well as erupted from
the bondline, which poses a potential of
contamination of the weld assembly
fixtures.
6. The amount of erupted weld spatter
collected outside of the weld coupon decreases with increasing bondline thickness
in the range from 0.2 to 1.2 mm. This is attributed to a greater proportion of retained weld spatter being captured within
the bondline thickness vs. having a greater
proportion of the adhesive burning and
thereby allowing the weld spatter to erupt
from between the steel sheets.
7. The strength of weld-bonded multiple steel sheets was increased significantly
by the presence of the adhesive but was
not affected by the uncured adhesive
bondline thickness.
8. The placement of the adhesive between the thin external and relatively
thicker middle sheet to improve the weld
size could be a feasible solution to resolve
the issue of undersized welds in resistance
welding of multiple steel sheets.
Acknowledgments
This research was supported by the
General Motors Collaborative Research
Laboratory at Shanghai Jiao Tong University. The authors gratefully acknowledge
the financial and technical support provided by GM-Research and Development
to carry out the present work. Also, this research was supported by National Natural
Science Foundation of China (No.
WELDING RESEARCH
presented in Fig. 19E. It can be concluded

from the EDS analyses that both the retained and erupted spatter produced from
weld bonding multiple steel sheets contained silicon and calcium, which are inherent ingredients of the uncured adhesive and not the base metal. These results
suggest that uncured adhesive in erupted
weld spatter from weld bonding could potentially contaminate the tooling and
fixturing.
Although the results shown in Figs. 7,
9, and 12 indicate that the bondline thickness exhibited little influence on the contact resistance and weld nugget size, there
is a significant correlation to the amount
of weld spatter. As shown in Fig. 14, as the
bondline thickness increased from 0.2 to
1.2 mm, the weld spatter decreased from
1.30 to 0.88 g. This decrease is attributed
to the fact that an elevated amount of the
weld spatter was retained by the increased
bondline thickness. Figure 15 shows the
SEM photos of the broken faying interface
with various adhesive bondline thicknesses. As can be seen, the amount of retained weld spatter (in dark color) increased with increased adhesive bondline
thickness.
In addition, although a reduction of the
erupted spatter collected outside of the
bondline was observed with thickening of
the bondline, the amount of spatter with
adhesive was still significantly higher than
that without adhesive. This phenomenon
also resulted from the growth in contact
resistance and heat generation brought
about by the adhesive layer. More metal
was molten during welding and resulted in
higher pressure from the liquid metal to
the solid containment, thus weld expulsion
would be easier to occur under the effect
of the adhesive layer.
50905111, No. 51275304) and Shanghai

Rising-Star Program (No. 11QA1403600).
References
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mechanism and properties of weld bonded joints.
Sheet Metal Industries 72(9): 30, 31.
2. Chang, B. H., Shi, Y. W., and Dong, S. J.
1999. Study on the role of adhesives in weldbonded joints. Welding Journal 78(8): 275-s to
279-s.
3. Darwish, S. M. H., and Ghanya, A. 2000.
Critical assessment of weld-bonded technologies.
Journal of Materials Processing Technology 105:
221229.
4. Wang, P. C., Chisholm, S. K., Banas, G., and
Lawrence, F. V. Jr. 1995. Role of failure mode, resistance spot weld and adhesive on the fatigue behavior of weld-bonded aluminum. Welding Journal 74(2): 41-s to 47-s.
5. Darwish, S. M. H. 2003. Weld-bonding
strengthens and balances the stresses in spotwelded dissimilar thickness joints. Journal of
Materials Processing Technology 134(3):
352362.
6. Goncalves, V. M., and Martins, P. A. F. 2006.
Static and fatigue performance of weld-bonded
stainless steel joints. Materials and Manufacturing
Processes 21: 774778.
7. Long, X., and Khanna, S. K. 2008. Fatigue
performance of spot welded and weld bonded advanced high-strength steel sheets. Science and
Technology of Welding and Joining 13(3): 241247.
8. Sam, S., and Shome, M. 2010. Static and fatigue performance of weld bonded dual phase
steel sheets. Science and Technology of Welding
and Joining 15(3): 242247.
9. Vogler, M., and Sheppard, S. 1993. Electrical contact resistance under high loads and
elevated temperatures. Welding Journal 72:
231-s to 298-s.
10. Thornton, P. H., Krause, A. R., and
Davies, R. G. 1996. Contact resistances in spot
welding. Welding Journal 75(12): 402-s to 412-s.
11. Song, Q., Zhang, W., and Bay, N. 2005. An
experimental study determines the electrical contact resistance in resistance welding. Welding
Journal 84(5): 73-s to 76-s.
12. Rogeona, P., Carrea, P., Costaa, J., Sibilia,
G., and Saindrenanb, G. 2008. Characterization
of electrical contact conditions in spot welding assemblies. Journal of Materials Processing Technology 195: 117124.
13. American Welding Society. 1997. Recommended Practices for Test Methods for Evaluating
the Resistance Spot Welding Behavior of Automotive Sheet Steel Materials, ANSI/AWS/SAE/D8.9
97.
14. Shen, J., Zhang, Y. S., Lai, X. M., and
Wang, Pei-Chung. 2012. Adhesive placement in
weld-bonding multiple stacks of steel sheets.
15. Garza, F., and Das, M. 2001. On real- time
monitoring and control of resistance spot welds
using dynamic resistance signatures. Midwest
Symposium on Circuits and Systems 1: 4144.
16. Cho, Y., and Rhee, S. 2002. Primary circuit dynamic resistance monitoring and its application to quality estimation during resistance
spot welding. Welding Journal 81(6): 104-s to 111s.
17. Ma, C., Bhole, S. D., Chen, D. L., Lee, A.,
Biro, E., and Boudreau, G. 2006. Expulsion monitoring in spot welded advanced highstrength
automotive steels. Science and Technology of
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Fan Supplement December 2013_Layout 1 11/14/13 4:06 PM Page 375
Arc Characteristics of Ultrasonic

Wave-Assisted GMAW
The arc characteristics vary when an ultrasonic wave is added to the
gas metal arc welding process
ABSTRACT
Ultrasonic wave-assisted gas metal arc welding (U-GMAW) is a newly developed welding method. Under the action of the ultrasonic wave, the characteristics of the welding arc make an obvious change. Compared with the conventional
GMAW arc, the U-GMAW arc is more contracted and becomes brighter, and its
length is decreased. The arc length varies wavelike with the height of the ultrasonic radiator. The reason is that the amplitude of the stationary ultrasonic wave
pressure varies with the phase difference between the incident wave and the reflected wave. Under the same conditions, the ultrasonic energy and the contraction degree of the arc are enhanced with the increase in the diameter of the ultrasonic radiator and the ultrasonic vibration amplitude. In addition, the arc
length in both GMAW and U-GMAW increases with increasing voltage. But at
the same voltage, the arc length in U-GMAW is shorter than with GMAW, and
the difference increases with the increasing voltage. For U-GMAW, the unit increase in arc length with increased voltage is only about one-third that of conventional GMAW.
Introduction
Gas metal arc welding (GMAW) has
been widely employed in manufacturing,
and has attracted extensive attention due
to its advantages, which include high efficiency, high flexibility, and adaptability for
welding most metals (Ref. 1). The stability
and quality of GMAW is highly related to
metal transfer, which is affected by many
factors (Refs. 2, 3). Therefore, controlling
and getting the ideal metal transfer is still
a challenge. Many researchers have done
some distinctive work in this field. In Ref.
4, a new method to employ the melting
rate, heat input, and detaching droplet diameter as controlled variables to control
heat and mass transfer was proposed. The
Trifarc method used an extra wire with reversed electric current, which was inserted
between the electrodes of the standard to
control the molten droplet and pool (Ref.
5). In Ref. 6, the researchers struck an additional arc on the droplet, which served as
the cathode to regulate the current distribution and metal transfer. Y. M. Zhang
C. L. FAN (fclwh@hit.edu.cn), C. L. YANG,
and S. B. LIN (sblin@hit.edu.cn) are with the
Stake Key Laboratory of Advanced Welding and
Joining, Harbin Institute of Technology, Harbin,
China. Y. Y. FAN is with Dongfang Electric Machinery Co., Ltd., Deyang, China.
and others (Refs. 710) decoupled the undesired dependence of the metal transfer
on the welding current and used a laser to
facilitate droplet detachment from the
wire tip. In addition plasma diagnostics
(Ref. 11), arc light and spectrum (Refs. 12,
13), magnetic field (Ref. 14), mechanical
vibration (Refs. 15, 16), and arc sound
(Refs. 17, 18) also have been used to control the metal transfer process.
In Refs. 19 and 20, the authors proposed a new hybrid welding method, ultrasonic wave-assisted gas metal arc welding (U-GMAW). During the U-GMAW
process, ultrasonic radiation force was
used to control the metal transfer. The experimental results showed the dimension
of the droplet decreased and the transfer
frequency increased, which led to deeper
welding penetration and finer grain crystallization. The welding arc has important
influences on the metal transfer process;
however, the characteristics of the welding
arc in the novel U-GMAW process have
KEYWORDS
Gas Metal Arc Welding
Arc Characteristics
Ultrasonic Wave
not been systematically studied and

discussed.
It is well known that the arc is the ultimate source of the welding process and
has the decisive influence on metal transfer as well as fusion of the base metal. During this research, it was also found that the
ultrasonic wave not only had an obvious
effect on the metal transfer but also on the
welding arc. Under the action of the ultrasonic wave, it was obvious that the arc
contracted and its energy density increased. The purpose of this study is to reveal the relationship and the action mechanism of the main ultrasonic parameters
on the welding arc, such as the distance between the ultrasonic radiator and the
workpiece, the ultrasonic vibration amplitude, and the action area of the ultrasonic
radiator. The results are helpful in comprehensively understanding the UGMAW method.
Experimental Setup and

Parameters
Experimental Setup
The U-GMAW system includes three

components, i.e., an ultrasonic power
source, a welding power source, and a hybrid welding torch, as shown in Fig. 1 (Ref.
19). The main body of the torch can be divided into two parts, i.e., the ultrasonic
transducer and the ultrasonic horn. The
ultrasonic transducer transforms electric
energy into ultrasonic vibration, and then
the vibration is amplified by the ultrasonic
horn. The ultrasonic wave radiates out
from the end of the ultrasonic horn (ultrasonic radiator in Fig. 1). The welding wire
is fed through the axial hole of the transducer and the horn, and the arc is ignited
between the wire tip and the workpiece.
Since the wire does not contact any vibrating component, no vibration is conducted directly from the wire to the arc.
In order to conveniently observe the
arc, bead-on-plate welding experiments
were conducted. During welding, the
workpiece also acts as the ultrasonic reflector. Since the dimension of the workpiece is much larger than the ultrasonic radiator, the workpiece can be regarded as
WELDING RESEARCH
BY C. L. FAN, C. L. YANG, S. B. LIN, AND Y. Y. FAN
Fig. 1 Schematic of U-GMAW (Ref. 19).
Fig. 2 Schematic diagram of the experiment system.
WELDING RESEARCH
Fig. 4 Parameters of the arc shape.
Fig. 3 Parameters of the ultrasonic system.
an ideal infinite reflector. With the reflection, a stable interference acoustic field is
formed between the radiator and the
workpiece, and the arc is burning inside
this acoustic field.
The ultrasonic power source was a
CSHJ-1000 with the output power of 1000
W. A digital control, constant voltage
power supply (Kemppi, Promig 500) was
employed, and the welding process was
performed under the direct current electrode positive (DCEP) condition. During
the experiments, the welding torch was
fixed and the workpiece was moved at a
constant speed. The base metal was mild
steel, and 1.2-mm-diameter ER70S-6 wire
was chosen as the electrode. Pure argon
was used as the shielding

gas. The other welding parameters are shown in
Table 1.
High-speed photography and a laser shadowing
method were used to investigate the welding arc,
as shown in Fig. 2. The camera was an Optronis CamRecord D50002. The wavelength of the laser beam used as the back
light is 808 nm, and a bandpass filter with
the same wavelength was mounted in front
of the lens to strain off the arc light. With
a shutter speed of 20 s, the cameras
frame rate is 3000 f/s at an image resolution of 512 512 pixels.
Experimental Parameters
There are four main ultrasonic parameters related to the experiments, i.e., f (ultrasonic frequency), H (distance between the
ultrasonic radiator and the workpiece),
(ultrasonic vibration amplitude), and D (diameter of the ultrasonic radiator), as shown

in Fig. 3. In this study, according to the frequency of the ultrasonic piezoelectric transducer, f was fixed at 20 kHz. The working
voltage and current of the ultrasonic power
were 220 V and 0.5 A, respectively. Of all
these parameters, f and are mainly concerned with the state of the incident wave.
The characteristic parameters of the
arc shape are L (arc length), Dp (projected
diameter), and DR (root diameter) (Ref.
21), as shown in Fig. 4. During the GMAW
process, because of the interference of the
metal transfer, the arc shape is not invariable. Many factors, such as the form and
transition of the droplet, have influence
on it. By long-term observation, it was
found that during a droplet transition period, Dp and DR were changed violently
while the variation of L was very slight.
Therefore, in the following study, L is selected as the main characteristic parameter to indicate constriction of the arc.
Table 1 Experimental Parameters

Wire Feed
Speed
(wfs, m/min)
Welding
Voltage
(V)
Welding
Speed
(mm/min)
Flow Rate of the

Shielding Gas
(L/min)
Distance from the Contact

Tube to the Workpiece
(mm)
Distance from the Nozzle

to the Workpiece
(mm)
3.5
27
300
25
24
11
Fig. 7 Ultrasonic horns with different end diameters.
Fig. 6 Relationship between H and L.

The Effect of the Ultrasonic Parameters
The Distance between the Ultrasonic Radiator
and the Workpiece
Figure 5 shows the differences between

the conventional GMAW arc and the UGMAW arc. From the figures, it can be
seen that compared with conventional
GMAW, the U-GMAW arc is contracted
and becomes brighter. The relationship
between L and H is shown in Fig. 6, and
the fitting curve is wavelike rather than
linear, which typically represents the influence of the acoustic field. It can also be
seen that the contraction degree of the UGMAW arc varies with H. Under the H of
20 and 30 mm, the arc is shorter than that
under the other H values.
The incident ultrasonic emitted from
the radiator can be expressed as wave
Equation 1 (Ref. 22):
pi = pAcos(t 1)
(1)
where pi is the ultrasonic pressure, pA is

the amplitude of pi, is the angular fre-
quency, t is time, and 1 refers

to the initial phase of the ultrasonic wave.
When the incident ultrasonic
wave hits the reflector (the
workpiece) surface, the reflected wave is generated. If
neglecting the attenuation of
the ultrasonic wave, the reflected wave can
be expressed as Equation 2, where pr is the
reflected wave pressure, 2 is the phase of
the reflected ultrasonic wave, and 2 = 1
+ . is the phase difference between the
incident wave and reflected wave.
pr = pAcos(t + 2)
(2)
The virtual ultrasonic field between the

ultrasonic radiator and the workpiece is
the interfered result of the incident ultrasonic wave and the reflected ultrasonic
wave, which can be called the stationary
acoustic field. This field is given in Equations 3 and 4, where pC is the amplitude of
the stationary ultrasonic wave pressure,
and refers to the phase of the stationary
ultrasonic wave.
p = pi + pr = pCcos(t )
pC2 = 2pA2 + 2pA2cos()
= arctan
sin1 + sin 2
cos1 + cos 2
(3)
(4)
From the equations, it can be seen that

the stationary ultrasonic wave is still an ul-
trasonic wave with the same vibration frequency as the incident ultrasonic wave.
The amplitude of the stationary ultrasonic
wave depends on the phase difference ()
between the incident wave and the reflected wave, instead of the algebraic sum
of their absolute values.
The most important influence factor of
is the distance between the radiator and
the workpiece, i.e., H. Under some specific H values, is even multiple times of
. The incident ultrasonic wave and the reflected wave reach the peak value simultaneously, and the stationary ultrasonic
wave has double amplitude of the incident
ultrasonic wave where the stationary
acoustic field is a syntonic field with the
maximum energy density. While under
some other specific H values, is odd multiple times of , the incident ultrasonic
wave and the reflected wave canceled out,
which means the amplitude of the stationary wave is zero and the ultrasonic field
energy density is minimum.
The particles inside the normal arc,
such as the electrons and ions, are moved
by the drive of the electric field between
the anode and cathode. But the situation
changed inside the U-GMAW arc; the additional ultrasonic wave will influence the
motion state of the particles. Beside the
motion caused by the electric field, the
particles are forced to oscillate around
their equilibrium position 20,000 times
per second. This vibration increases the
instantaneous velocity and the collision
WELDING RESEARCH
Fig. 5 Comparison of conventional GMAW and U-GMAW arcs. A Conventional GMAW arc; B U-GMAW arc.
Fig. 8 Relationship between D and L.
Fig. 9 Relationship between and L.
WELDING RESEARCH
wave and the reflected wave resonated, and the stationary

acoustic
field reaches to the
maximum energy
density, thus the
constriction degree
of the arc reaches to
the peak value.
From Fig. 6, it can
be seen that when
the H value equals
20 or 30 mm, the
contraction degree
of the arc reaches
maximum, and the
Fig. 10 Schematic of the comparative experiment.
arc length is only
about 4348% of
that of the convenprobability of the particles, which will
tional GMAW arc (Fig. 5A), respectively,
surely increase their thermal conductivity.
and the variation curve of the L-H reaches
In other words, more heat will be transthe trough area.
ferred to the workpiece, and this will break
Though the degree of arc contraction is
the equilibrium of the general heat promaximized under the condition of H = 20
duction and dissipation. According to the
or 30 mm (a little bit weaker when H = 30
principle of minimum voltage (Ref. 2), the
mm), but from the welding point, H = 30
arc has to constrict to reduce the heat loss.
mm is much better. Thats because during
On the other side, the arc must increase
the GMAW process, spatter is unavoidthe electric field strength to remain the inable, and if spatter attaches on the radiacreasing particle collision probability and
tor surface, it would affect the emission of
generate more heat to compensate for the
the ultrasonic wave, so a higher H value is
heat loss. The increasing electric field
more reasonable. Otherwise, a smaller H
strength leads to the increasing power
means the horn is closer to the arc and the
density along the arc, and that is why the
temperature of the horn is higher, which
U-GMAW arc is brighter than the GMAW
will weaken the stability and efficiency of
arc. A similar phenomenon has also been
the ultrasonic radiation.
observed during ultrasonic-assisted gas
Diameter of the Ultrasonic Radiator
tungsten arc welding (U-GTAW) (Ref.
23). However, the arc length in the GTAW
In order to test the influence of the ulprocess is stable between the nonconsumtrasonic radiator dimension on the arc,
able electrode and the workpiece. This is
five horns with different end diameters
different from the U-GMAW process.
(D) were machined, as shown in Fig. 7. For
If the H value is changed continuously,
the limit of the spray nozzle dimension,
as shown in Fig. 6, will vary synchrothe largest D was 28 mm. The test results
nously, which causes continuous variation
are showed in Fig. 8.
of the stationary acoustic field energy denIn Fig. 8, the arc length reduced mosity. Under some certain H values (e.g., H
notonously with the increase in D. Higher
= 20 or 30 mm), the incident ultrasonic
D means a larger radiation area, which

surely would improve the ultrasonic energy density and the degree of arc contraction. In addition, the degree of arc
contraction was greater when D changed
from 24 to 28 mm than when it changed
from 20 to 24 mm. Thats because when D
was at a higher level, the increase in the
annular radiation area caused by the same
increasing diameter was higher.
The Ultrasonic Vibration Amplitude
The ultrasonic system has three levels

of vibration amplitudes, i.e., = 25, 28,
and 30 m. Figure 9 shows the influence of
the vibration amplitudes on the welding
arc. The degree of arc contraction increased with the increasing vibration amplitude, but compared with H and D, the
effect of the ultrasonic vibration amplitude was not very strong.
The level of the ultrasonic vibration
amplitude indicates the degree that the
particles are forced to oscillate around
their equilibrium position, so it is not difficult to understand that greater causes
higher arc contraction.
The Effect of the Arc Voltage
In order to find out the influence of the

arc voltage, a series of experiments was
done based on the conditions of H = 30
mm, D = 28 mm, and = 30 m. In order
to ensure the same conditions for GMAW
and U-GMAW, the test was taken on the
same workpiece, as shown in Fig. 10. At
the middle of the process, the ultrasonic
wave was applied.
The arcs of conventional GMAW and
U-GMAW at different welding voltages
are showed in Fig. 11, and their differences are summarized as follows:
1. At the same voltage, the arc of UGMAW is invariably shorter than that of
GMAW, and the difference in length increases with the increasing voltage. In addition, the U-GMAW arc is distinctly
WELDING RESEARCH
Fig. 11 Arc shape at different welding voltages (wire feed speed (wfs) = 4.5 m/min; C stands for conventional GMAW; U stands for U-GMAW). A 21 V; B 22 V; C 23 V; D 24 V; E 25 V;
F 26 V; G 27 V; H 28 V; I 29 V; J 30 V; K 31 V; L 32 V; M 33 V.
K
brighter and more stable.
2. Arc length for both conventional
GMAW and U-GMAW increased with the
increasing welding voltage, but the growth
rate of the conventional GMAW arc
length is much higher than that of the UGMAW arc. When the welding voltage
reached 28 V, the conventional GMAW
arc approached the nozzle (Fig. 11H). If
the voltage increased continuously, the arc
would retreat into the nozzle and damage
the welding torch. In contrast, the UGMAW arc remained a reasonable length
within a large voltage range, even when
the voltage reached 33 V. This is why only
U-GMAW arc pictures were given when
the voltage went beyond 28 V.
WELDING RESEARCH
brighter and its length is

decreased. The arc
length varies wavelike
with the height of the radiator, but enhances with
the increasing diameter
of the radiator and the
ultrasonic vibration amplitude monotonously.
2. The amplitude of the
stationary ultrasonic
wave pressure is associated with the phase difference () of the incident wave and the
reflected wave. Sometimes when is even
multiple times of , the
Fig. 12 Relationship between welding voltage (U) and L.
contraction degree of
the arc reaches maximum; when is odd
multiple times of , the
Figure 12 reveals the relationship becontraction degree of the arc is negligible.
tween the arc length and the welding volt3. The arc length of both conventional
age. Both the fitting curves of convenGMAW and U-GMAW increases with intional GMAW and U-GMAW are linear.
creasing voltage. At the same voltage, the
The fitting curve equations presented in
arc length of U-GMAW is invariably
the figure show that for conventional
shorter than that of GMAW, and the difGMAW, the unit increase of the arc length
ference increases with the increasing voltis about 0.99 mm/V, while for U-GMAW,
age. For U-GMAW, the unit increase of
it is about 0.35 mm/V, which is only about
the arc length to the voltage is only about
one-third that of the former. Also, it can
one-third that of conventional GMAW.
be deduced that the sum of cathode and
anode fall voltages in U-GMAW is about
Acknowledgments
4.3 V less than that in the GMAW process.
In the experimental conditions, the
This work was financially supported by
welding material and the plate material
the National Natural Science Foundation
are both low-carbon steel, which is a coldof China under grant No. 51275134 and
cathode material. So, the electrical parti50975063.
cle emission mechanisms are mainly elecReferences
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Liu (201321) December 2013_Layout 1 11/14/13 3:40 PM Page 381
Sensing Dynamic Keyhole Behaviors in

Controlled-Pulse Keyholing
Plasma Arc Welding
The keyhole evolution and its deviation distance vs. time are experimentally
determined per pulse in controlled-pulse keyholing plasma arc welding
ABSTRACT
A controlled-pulse keyholing plasma arc welding (PAW) system is developed to
implement the active control of keyhole dynamics and to ensure complete joint penetration and defect-free welds. To deeply understand the dynamic keyhole behaviors,
a cost-effective vision system is employed to monitor and detect the transient keyhole status from the backside of the workpiece in the controlled-pulse keyholing PAW
process. From sequential images of the keyhole exit, both the keyhole dimensions
and its positions relative to the torch axis are determined at different moments in
each pulse cycle. The keyholing process, including keyhole establishment, expansion,
contraction, and closure in each pulse cycle, is observed, and the dynamic variation
of the keyhole size and its position inside the weld pool is analyzed. The inclination
of the front keyhole wall and its relation to the keyhole evolution are investigated.
The effects of the slopes of the current falling edges on the keyhole dynamic behaviors are examined, and the underlying mechanisms of keyhole evolution are discussed. The research results lay a solid foundation for implementing process optimization in controlled-pulse keyholing PAW.
Introduction
Plasma arc welding (PAW), laser beam
welding (LBW), and electron beam welding (EBW) can operate in keyhole mode,
which is the primary attribute of such highpower-density welding processes (Ref. 1).
During such processes, a keyhole is
formed inside the weld pool, and the heat
is deposited along the thickness direction,
so that deep penetration is achieved and
thicker plates are welded with a single pass
(Ref. 2). Compared to LBW and EBW,
keyhole PAW, as a variant of gas tungsten
arc welding, is more cost effective and
more tolerant of joint preparation (Refs.
3, 4). Thus, keyhole PAW has found wide
application in industry (Refs. 3, 5, 6).
However, the keyhole stability, which depends on the physical characteristics of the
material to be welded and the welding parameters to be used, is a critical issue in applying PAW (Refs. 7, 8). In conventional
keyhole PAW, slight variations in the heat
Z. M. LIU, C. S. WU (wucs@sdu.edu.cn), and
J. CHEN are with MOE Key Lab for Liquid-Solid
Structure Evolution and Materials Processing, Institute of Materials Joining, Shandong University,
Jinan, China.
input may cause keyhole closure or weld

pool collapse (Ref. 9)so that incomplete
penetration or melt-through occur easily.
To widen the applicable welding process
parameter window in the keyhole PAW
process, the controlled-pulse keyholing
PAW system was developed (Ref. 10),
which is based on the specially designed
welding current waveform as shown in Fig.
1. At the falling stage of the welding current from the peak level to the base level,
two substages of the current falling with
different slopes of K1 and K2 are added.
When the peak current IP is applied, the
system keeps detecting the signal characterizing the keyhole status. As soon as the
keyhole signal reaches a certain magnitude (associated with the establishment of
an open keyhole penetrating through the
KEYWORDS
Dynamic Keyhole Behaviors
Vision-Based Observation
Keyhole Exit Image
Controlled-Pulse Keyholing
Plasma Arc Welding
workpiece), the welding current starts to

decrease with a falling slope K1. Because
of thermal inertia, the keyhole volume remains to expand slowly even though both
heat input and arc force associated with
the welding current start to fall during this
stage. When the keyhole size reaches the
preset value to meet the desired practical
requirements of the weld quality, the
welding current decreases at a steeper
slope K2 (|K2|>|K1|), then the keyhole
stops expansion but starts to contract. At
instant t1, the open keyhole is completely
closed, and a blind keyhole may exist.
After the base current IB is applied for a
preselected period TB, the current is
switched to the peak level IP again to begin
a new cycle, and at instant t2, the open keyhole starts to form again. In this way, the
keyhole status is actively controlled with
specially designed pulse waveform of the
welding current in each pulse cycle.
Therefore, the controlled pulse keyholing
PAW system can ensure the open keyhole
and complete joint penetration but avoid
melt-through defects. Such novel process
and system have great potential application in industry.
However, the controlled-pulse keyholing strategy involves an increased number
of process parameters. To optimize the
welding process, it is essential to get deep
insight into the dynamic behaviors of the
keyhole and its effect on the welding
process and weld quality. Thus, it is of critical significance to conduct experimental
sensing and observation of the keyhole behaviors in the controlled-pulse keyholing
PAW process.
A few sensing methods, such as the
electrical potential of the efflux plasma
from the keyhole exit (Refs. 10, 11), the
acoustic signal (Ref. 12), the plasma arc
light (Ref. 13), the plasma cloud (Ref. 14),
and the plasma reflection (Ref. 15), have
been tried to sense and monitor the keyhole status in conventional PAW. However, all these sensing approaches are indirect, which just indicate if an open
keyhole is formed or not, but do not quanWELDING JOURNAL 381-s
WELDING RESEARCH
BY Z. M. LIU, C. S. WU, AND J. CHEN
Fig. 1 The welding current waveform in controlled-pulse keyholing PAW.
Fig. 2 Schematic of the controlled-pulse keyholing PAW system.
WELDING RESEARCH
Fig. 3 The efflux plasma and the electrical signals in controlled-pulse keyholing PAW. A The image of the plasma arc and efflux plasma; B the
detected welding current and efflux plasma voltage.
titatively characterize the shape and size

of an open keyhole. Vision-based sensing
provides more direct information, and
thus has been used to monitor the weld
pool in various arc welding processes
(Refs. 1618). The keyhole or weld pool in
laser welding has been observed by vision
sensors (Refs. 1922). But the underlying
mechanism of keyhole formation and sustainment in PAW is different from that in
LBW, and the keyhole size in PAW is much
larger than that in LBW (Ref. 5). Because
of the relatively larger PAW torch body
and its short distance to the workpiece,
there is a very narrow viewing angle of the
camera for observing the keyhole and/or
weld pool from the front side of the workpiece when a camera device is employed in
the PAW process. An ultrahigh shutter
speed vision system was used to simulta382-s DECEMBER 2013, VOL. 92
neously image the

keyhole and the
weld pool from the
backside of the
workpiece (Ref. 7).
But such laserStrobe system is complicated and very expensive in practical applications since the vision system consists
of a strobe-illumination unit (pulse laser),
camera head, and system controller. In a
previous study, a low-cost visual sensor
was developed to observe the keyhole
from the backside of the workpiece in the
conventional PAW process (Refs. 23, 24).
Up to now, the dynamic behaviors of the
keyhole in the controlled-pulse keyholing
PAW process has not yet been monitored
and visualized.
In this study, a cost-effective vision system was employed to monitor and detect
the dynamic keyhole status from the backside of the workpiece in the controlledpulse keyholing PAW process. The keyholing process, including keyhole
establishment, expansion, contraction,
and closure in each pulse cycle, was observed. The dynamic variation of the keyhole size and its position inside the weld
pool were analyzed. The inclination of the
front keyhole wall and its relation with the
keyhole evolution was investigated. The
observation results lay a solid foundation
for implementing process optimization in
controlled-pulse keyholing PAW.
Experimental Setup
Figure 2 shows the developed controlled-pulse keyholing PAW system. The
PAW machine consists of a digital power
source, a plasma generator, and a plasma
torch. A piece of mild-steel bar (the measuring bar) is mounted underneath the
workpiece to be welded and kept insulated
electrically. If an open keyhole is established, the plasma jet must exit through
the keyhole channel to form the efflux
plasma at the backside of the workpiece,
as shown in Fig. 3A. The efflux plasma will
establish an electrical potential between
Fig. 4 The captured image of the keyhole exit. A Raw image; B the extracted boundary.
Fig. 5 The sampled electrical signals and the sequential images of the keyhole in two consecutive pulses. A The detected welding current and efflux plasma
voltage; B the sequential images of the keyhole.
the workpiece and the measuring bar due

to the phenomenon of plasma space
charge. If an open keyhole is not established (blind keyhole), there will be no efflux plasma between the workpiece and
the measuring bar and thus no electrical
potential exists. A simple sensor consisting of a resistor R and a capacitor C is used
to detect the electrical potential or the
voltage between the workpiece and the
measuring bar. The larger the keyhole
size, the higher the intensity of the efflux
plasma, and the larger the efflux plasma
voltage (VE). There is a correlation of the
keyhole diameter at the backside with the
measured efflux plasma voltage signal
(Ref. 9). Both the transient signals of the
welding current and the efflux plasma
voltage are sampled in-process via the
input/output interfaces (PCI8613 and
ROB5000). The computer controls the
waveform of the welding current and adjusts it in real time according to the feedback keyhole signal represented by the efflux plasma voltage (VE). Figure 3B shows
the measured welding current and efflux
plasma voltage signals during the controlled-pulse keyholing PAW process.
As shown in Fig. 2, a CCD camera is

aimed at the weld pool from the backside
of the workpiece to capture the keyhole exit
images during the controlled-pulse keyholing PAW process. For the experimental system, both the PAW torch and the CCD
camera are stationary, while the workpiece
travels at the welding speed, which is controlled by the computer. The CCD camera
(Model AM1101A manufactured by Beijing JoinHope Image Technology Ltd.) is
equipped with a narrow-band filter (central
wavelength is 655 nm, bandwidth is 40 nm,
and transparency is 85%) and a neutral filter. The trigger circuit makes image capturing and electrical signal sampling kept
synchronously. If the workpiece is completely penetrated and an open keyhole is
formed, the keyhole exit image is captured
by the CCD. The captured keyhole images
are digitized through the image grabber
(OK-M10A). In this study, the observation
is toward the rear of the weld pool, as
shown in Fig. 2, and the viewing angle is set
at 70 deg. The distance from the camera
lens to the object plane is around 150 mm.
By using the algorithms of the developed
image processing and calibration (Ref. 24),
the shape and size of the keyhole exit are

obtained. Figure 4 illustrates the keyhole
image and the extracted boundary from
which the keyhole dimension is
determined.

Keyhole Sizes and Position Deviations
By using the developed controlledpulse keyholing PAW system, bead-onplate welding tests were conducted on 8mm-thick, Type 304 stainless steel
workpieces. The torch orifice diameter
was 2.8 mm, the throat length was 3 mm,
and the tungsten electrode setback was 2.0
mm. The torch orifice standoff from the
workpiece was 5.0 mm. Both the plasma
gas and shielding gas were pure argon, and
their flow rates were 3.0 L min1 and 20 L
min1, respectively. The welding speed was
120 mm/min.
For the study case, the waveform parameters of the welding current, as defined in Fig. 1, are as follows:
Ip = 185 A, IB = 82 A, TP = 300 ms, TB =
100 ms, TK1 = 225 ms, and TK2 = 100 ms.
WELDING RESEARCH
Fig. 6 The measured width and length of keyhole exit vs. the current pulse.
WELDING RESEARCH
Figure 5 shows the in-process measuring

results of the welding current, the efflux
plasma voltage, and the keyhole images in
two consecutive pulse cycles. Both the efflux plasma voltage and the keyhole image
are related to the shape and size of the
keyhole exit at backside of the workpiece,
so they both vary dynamically with the
welding current in each pulse cycle. Figure
5A demonstrates that each pulse produces
one completely penetrated (open) keyhole. Figure 5B gives the sequential images of the keyhole in two pulse cycles. It
is clear that in a pulse cycle from 30.2 to
30.75 s (the first pulse in Fig. 5A), after the
pulse current is exerted for some time, an
open keyhole is established at instant
30.313 s, and then both its shape and position change. To control the keyhole size
actively, the pulse current starts to decrease at instant 30.39 s when the detected
efflux plasma voltage exceeds a certain
value. When the keyhole size reaches the
preset value to meet the desired practical
requirements of the weld quality, the current decreases at a steeper slope, so that
the keyhole stops expansion but starts to
close. At a certain instant (30.58 s), the
open keyhole is completely closed. For the
next pulse, at instant 30.875 s, an open keyhole appears again, and a similar process
repeats. In this way, it can ensure the keyhole establishment and complete joint
penetration but avoid melt-through defects. Figure 5B demonstrates the full
cycle for a keyhole in each pulse period,
i.e., keyhole establishment, expansion,
contraction, and closure.
Based on the sequential images of the
keyhole in Fig. 5B, the keyhole exit sizes can
be determined. Figure 6 shows the dynamic
variation of the width and length of the keyhole exit in two pulse cycles. For each pulse
cycle, at the start of keyhole establishment,
the keyhole exit looks like an oval, i.e., its
length (along the welding direction) is
longer than its width (perpendicular to the
welding direction).
However, it immediately changes its
shape from oval to Fig. 7 Schematic of the deviation distance of the keyhole exit.
oblate roundness,
i.e., its length is a little bit less than its
From the sequential images in Fig. 5B,
width. The keyhole exit takes such a shape
the deviation distance of the keyhole exit
of oblate round for almost the whole pulse
is obtained. Figure 8 shows that at the becycle, as the sequential images of the keyginning of open keyhole establishment,
hole demonstrate in Fig. 5B. This phenomthe deviation distance of the keyhole exit
enon, i.e., the keyhole exit shape is oblate
is largest. As time goes on, its value dealong the welding direction, was also obcreases in a pulse cycle. This means that
served in conventional PAW process (Ref.
when an open keyhole is just formed, it lo23). However, during the controlled-pulse
cates farthest away from the torch axis, but
keyholing PAW process, the keyhole exit in
it continuously moves forward as time
each pulse cycle has the similar oblate
goes on. At the end of each pulse cycle,
geometry, i.e., its length along the welding
there is the least deviation distance just
line is a little bit less than its width perpenbefore the open keyhole closes.
dicular to the welding direction, except for
the very beginning stage of open keyhole
The Mechanism of the Deviation Distance
formation. For welding workpieces with
of the Keyhole Exit
medium thickness, the moving plasma arc
exerts more energy and pressure along the
As shown in Fig. 7, the open keyhole
welding direction to produce an open keyhas an entrance aperture at topside and an
hole, so that the keyhole exit looks oblate.
exit aperture at backside, respectively.
Of course, this is just a preliminary explaSince the keyhole is unsymmetrical and
nation, and further investigation is
noncoaxial with the PAW torch, the keyrequired.
hole channel is curved, and bending of the
Figure 5B illustrates that the position
keyhole axis occurs. The keyhole exit is
of the keyhole exit is not stationary in a
displaced in the direction opposite to the
pulse cycle. The up and down displacewelding direction, as illustrated in Fig. 7.
ment of the keyhole images corresponds
The deviation of the keyhole exit from the
to the forward and backward movement of
torch axis is due to the motion of the
the keyhole exit inside the weld pool at the
plasma arc along the welding direction.
underside along the welding direction, beBecause of the relative motion between
cause the torch and the camera are fixed
the plasma torch and the workpiece, the
while the workpiece is traveling. This
thermal field on the workpiece is dismeans that there is a deviation of the keytorted, and the weld pool becomes unsymhole exit from the torch axis. Figure 7
metrical with respect to the torch axis.
shows the schematic of the deviation disTaking the torch axis as a reference, the
tance and its definition. In this study, the
shape of the weld pool looks like a double
difference between the centerpoint of the
half-ellipsoid, and its front part is less
keyhole exit and the PAW torch axis along
while its rear part is much larger, which is
the welding direction (x-coordinate) is decaused by the distortion of the thermal
fined as the deviation distance of the keyfield due to the motion of the heat source
hole exit.
represented by the plasma arc. Therefore,
Fig. 8 The measured deviation distance of keyhole exit vs. the current pulse.
The Correlation of the Deviation and the

Inclination of Keyhole Front Wall
For the stainless steel workpieces, the

inclination of the front keyhole wall (and
Table 1 The Combinations of TK1 and TK2

Test
TK1 / TK2
TK1(ms)
TK2 (ms)
K1 (A s 1)
K2 (A s1)
Averaged
Current (A)
Test 1
Test 2
Test 3
Test 4
Test 5
20:80
40:60
50:50
60:40
70:30
70
140
175
210
245
280
210
175
140
105
428
214
171
143
122
143
190
229
286
381
133.8
134.8
136.1
137.3
138.6
associated deviation distance of the keyhole exit) is mainly affected by the welding
process parameters. To demonstrate the
effect of the current waveform on the inclination of the front keyhole wall, special
experiments were conducted. The controlled-pulse waveform of the welding current in Fig. 10A was used. The peak current Ip = 180 A, the base current Ib = 60
A, the plasma gas flow rate 2.8 L min1,
and the other parameters and conditions
are as aforementioned. The controlledpulse keyholing PAW test was repeated a
few times, and the welding processes were
suddenly stopped at different instants
(T1T5) in a pulse cycle. Sudden stopping
of the welding process remain the most
part of the keyhole at that moment, although the bottom part of the keyhole may
be refilled by some molten metal. After
welding, the weld samples were cut along
the welding direction, and longitudinal
sections of the weld end were obtained.
Figure 10B is the macrograph of the
longitudinal section weld stopped suddenly at instant T1. In pulse (n), an open
keyhole was established at instant T1 after
the peak current was acted for the period
300 ms. The front keyhole wall (almost the
same as the melting line) is from point A
to point B in Fig. 10B. The projection
length L of the curve AB along the longitudinal direction (welding direction) is
4.96 mm. At instant T2, the welding current had been lowered by 30% from the
peak value, but an open keyhole still ex-
isted at this moment, and the thermal accumulation from higher heat input causes
melting at the front keyhole wall. When
the welding process was suddenly stopped
at instant T2, the macrograph of the longitudinal section of the weld was obtained,
as shown in Fig. 10C. The front keyhole
wall is almost an inclined plane with the
projection length L of 3.22 mm. At instant
T3, the welding current had been lowered
by 70% from the peak value, and the open
keyhole was closed at the bottom before
this moment. When the welding process
was suddenly stopped at instant T3, the remaining macrograph of the longitudinal
section of the weld is given in Fig. 10D.
Due to a blind keyhole existing at instant
T3, the plasma arc deposits more heat at
the upper part of the keyhole cavity, and
the upper front keyhole wall becomes a little bit curved, so that the projection length
L of the melting line is about 4.24 mm. The
instant T4 is the end of the base duration,
the bottom of the blind keyhole gets much
less heat from the plasma arc, and the
melting line is curved backward at the bottom Fig. 10E. The projection length L
of the melting line is about 4.73 mm at instant T4. The instant T5 is within the initial
stage of the next pulse period, more heat
reaches the bottom of the blind keyhole,
but no open keyhole forms. The projection line length L of the melting line is
about 5.13 mm at instant T5, as shown in
Fig. 10F. It can be seen that so long as the
open keyhole is closed and a blind keyhole
WELDING RESEARCH
the plasma arc is mainly deposited at the

front part, most of the molten metal is
pushed toward the rear part of the weld
pool, and the liquid layer at the front wall
of the keyhole is very thin, as schematically
shown in Fig. 7. A previous experiment
proved that the molten layer at the front
keyhole wall has a thickness of about 100
microns (Ref. 25). It can be imaged that
the liquid metal layer enveloping the keyhole varies its thickness circumferentially,
and the front keyhole wall is nearly the
same as the front edge of the weld pool
(melting line). As shown in Fig. 9, when
the plasma jet strikes the nearly solid front
wall of the keyhole, the minor part of the
plasma jet (part A) will be reflected by the
wall, flow along the rear wall of the keyhole, and finally may get out through the
keyhole entrance aperture, while most of
the plasma jet (part B) will be bent by the
inclined front wall of the keyhole toward
the rear part of the weld pool, and finally
flow out through the keyhole exit. The
bent plasma jet (part B) gives pressure to
the rear keyhole wall and holds the weld
pool; on the other hand, it heats and melts
the keyhole wall. If the heat input from the
plasma jet is high enough, the front wall
will be completely molten, and produces a
shorter melting line; while if the current is
lower, the heat input to the solid keyhole
wall decreases and the melting line extends longer. As the liquid layer on the
front keyhole wall is very thin, the front
point of the keyhole exit closely sticks to
the relevant point of the melting line.
Hence the keyhole exit deviation distance
is directly determined by the slope of the
keyhole front wall or the melting line. This
point is discussed in more detail in next
subsection.
Fig. 9 The schematic of interaction between the plasma arc and front keyhole wall.
WELDING RESEARCH
Fig. 10 The evolution of the front keyhole wall in a pulse cycle. A The waveform of the welding current used in the sudden stop test; B the macrograph
of the longitudinal section of the weld at instant T1; C the macrograph of the longitudinal section of the weld at instant T2; D the macrograph of the longitudinal section of the weld at instant T3; E the macrograph of the longitudinal section of the weld at instant T4; F the macrograph of longitudinal section weld at instant T5.
is formed, the bottom part of the workpiece stops melting forward, the melting
line near the bottom surface is curved toward the rear part of the weld pool, and
the projection length of the front melting
line increases. As the plasma arc heats the
workpiece during the pulse period, melting occurs forward, the curved extent of
the melting line at the bottom is lowered,
and the projection length of the melting
line decreases. It can be concluded that at
the moment just before the open keyhole
is established during the pulse period

(such as T5), there is the longest melting
line, while the melting line has the shortest length at the moment just before the
open keyhole is closed (such as T2).
The longer the projection length of the
melting line, the more severe is the melting
lines incline. As mentioned previously, the
liquid layer on the front keyhole wall is very
thin, the front point of the keyhole exit
nearly coincides with the bottom end of the
melting line. Hence the keyhole exit devia-
tion distance is directly determined by the

slope of the keyhole front wall or the length
of the melting line. As shown in Fig. 8, when
the open keyhole is just established (at instant T5 in Fig. 10A, corresponding to the
most severe incline of the melting line),
there is a large deviation distance of about
2.75 mm, while the deviation distance gets
its minimum (about 0.75 mm) just before
the blind keyhole is formed (at instant T2 in
Fig. 10A, corresponding to the least incline
of the melting line).
The Keyholing Process in a Pulse Cycle
Comparing Fig. 6 with Fig. 8, one can

see that in a pulse cycle the variation scope
of the keyhole length and width is around
0.30.6 mm except for the moment when
the open keyhole is just formed, while the
deviation distance of the keyhole exit
varies with a maximum of around 2.0 mm.
Thus, the deviation distance of the keyhole exit describes the keyhole dynamic
behaviors more markedly than the keyhole size in a pulse cycle. The dominating
force to maintain an open keyhole is the
plasma arc pressure. The surface tension
and hydrostatic head are the main forces
to close an open keyhole. Due to the inclination of the front keyhole wall, the heat
and force of the plasma arc mainly act on
the front keyhole wall with a very thin
layer of molten metal. The variation of the
plasma arc force is not so much larger at
the keyhole exit, so the dimension of the
keyhole exit changes within a lesser range
in a pulse cycle. But the inclination of the
front keyhole wall is sensitive to the variation of the welding current in a pulse, as
demonstrated in Fig. 10. There is a larger
variation extent for the deviation distance
of keyhole exit in a pulse cycle. Therefore,
the variation of the deviation distance of
keyhole exit is more dynamic than the keyhole size in a pulse cycle.
In a pulse cycle, the heat and pressure
effects on the keyhole inside the weld pool
are different at different moments. Thus,
the keyhole presents different opening
and closing behaviors. As shown in Fig.
11, the keyholing process may be divided
into four stages in each pulse. These include prekeyholing, keyhole expansion,
keyhole contraction, and blind keyhole.
During the prekeyholing substage, the
plasma arc heats and melts the workpiece,
and the weld pool expands. The continued
deposition of heat and pressure causes
Fig. 12 The pulse waveform with variable TK1 and TK.
greater depression of the molten metal,

and eventually the cavity (blind keyhole)
transforms into an open keyhole penetrating through the workpiece thickness. As
soon as the open keyhole forms, the keyhole exit at bottom has a larger deviation
away from the torch axis, and it continues
to grow in volume. At this substage of keyhole expansion, the deviation distance of
the keyhole exit continuously decreases.
When the welding current falls to some extent, the open keyhole closes at the bottom, and a blind status emerges again. The
same keyholing process repeats again in
the next pulse cycle.
The Effect of the Current Falling Slopes
on the Keyhole Dynamics
As mentioned previously, the controlled-pulse waveform of welding current

as shown in Fig. 1 is able to control the
opening and closing of the keyhole actively in a pulse cycle. To examine the effect of the slopes at the falling edge of a
pulse waveform on the keyholing process,
a group of bead-on-plate welding tests was
conducted using different combinations of
the two slopes K1 and K2. If the first and
second falling stages of the welding current take different duration periods TK1
and TK2, then two slopes K1 and K2 will
change correspondingly. As illustrated in
Fig. 12, the pulse current (IP = 160 A) and
base current (IB = 60 A) periods were 500
and 100 ms, respectively. The total time
TK1 + TK2 was constant (350 ms), but they
took different values so that different
combinations are listed in Table 1.
From Test 1 to Test 5, different combinations of TK1 and TK2 were used. As the
period TK1 lasts longer, the averaged current in a pulse cycle increases a little bit
since the period TK1 corresponds to a
higher level of welding current. During the
controlled-pulse keyholing PAW process,
the keyhole exit images were captured.

After image processing and calibration,
the keyhole sizes and deviation distance
were determined. Figure 13 shows the
measured keyhole width, length, and deviation distance of the keyhole exit at different test conditions. For these five test
cases, the keyhole size changes very little
since the averaged current varies within a
range of about 5 A. However, the sustaining period of keyhole in each pulse
changes obviously because of the variation
of both TK1 and TK2. As the period TK1 increases, the slope K1 decreases, and the
sustaining period of the keyhole in each
pulse becomes longer. The variation trend
of the deviation distance is almost the
same for five tests, and it gets the maximum and minimum when the open keyhole is established and closed, respectively. As the period TK1 increases, the
deviation distance decreases, as shown in
Fig. 13E. Although the averaged current
does not change much (just 5 A from Test
1 to 5), the deviation distance of the keyhole exit varies visibly. Thereby, active adjusting of the falling slopes of the welding
current is able to control the keyhole dynamic behaviors.
Conclusion
A controlled-pulse keyholing system
was developed to implement active control
of the keyhole PAW process and achieve
the ideal mode of one open keyhole per
pulse. By using the specially designed waveform with two substages of current decreasing at the falling edge in a pulse, the
keyholing dynamic behaviors are intentionally adjusted to ensure complete joint penetration and defect-free welds. A costeffective vision system was developed to
observe the images of keyhole exit at the
backside of the workpiece in controlledpulse keyholing PAW. Sequential images of
WELDING RESEARCH
Fig. 11 The substages in the keyholing process.
WELDING RESEARCH
A1
A2
B1
B2
C1
C2
Fig. 13 The measured keyhole sizes and positions. A Test 1; B Test 2; C Test 3.
the keyhole exit were captured to characterize the dynamic variation in each pulse
cycle. It was found that the keyholing
process may be divided into the following
stages per pulse: prekey-holing, keyhole expansion, keyhole contraction, and blind
keyhole. The keyhole exit shape during
each pulse has an oblate geometry, i.e., its
length along the welding line is a little bit
less than its width perpendicular to the
welding direction, except for the very beginning stage of open keyhole formation.
The position of the keyhole exit is not stationary in a pulse cycle, and there is a deviation of the keyhole exit away from the
torch axis. Under the welding conditions
used in this study, the variation scope of the
keyhole length and width is around 0.30.6
mm except for the moment when the open

keyhole is just formed, while the deviation
distance of the keyhole exit varies with a
maximum of around 2.0 mm in each pulse
cycle. The deviation distance takes its maximum when the open keyhole is just established and its minimum when the open keyhole is just closed, respectively. As the
welding current varies within a single pulse,
the heating and melting conditions at the
melting-line of the weld pool results in the
change of the inclination extent of the front
keyhole wall, which determines the deviation distance of the keyhole exit. Different
combinations of the two substages of the
current decreasing at the pulse edge are
used to check out the effect of the current
falling slopes on the keyhole dynamics.
These observations lay the foundation for

better understanding of the dynamic
processes occurring in controlled-pulse
PAW.
Acknowledgment
The authors are grateful for the financial support for this research from the National Natural Science Foundation of
China (Key Program Grant No.
50936003).
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Lu 12-13_Layout 1 11/14/13 3:12 PM Page 390
Heat Input Reduction in Fillet Welding Using

Bypass and Root Opening
Experiments were conducted to find the optimum combination of root opening in a
T-joint and travel speed using the double-electrode submerged arc process
BY Y. LU, Y. M. ZHANG, AND L. KVIDAHL
ABSTRACT
WELDING RESEARCH
Submerged arc welding (SAW) of fillet welds is one of the major applications in
the shipbuilding industry. Due to the requirement for the weld size, a sufficient
amount of metal must be deposited. In a conventional SAW process, the heat input
is proportional to the amount of metal melted and is thus determined by the required weld size. To meet this requirement, an excessive amount of heat is applied
causing large distortions in the welded structures whose follow-up straightening is
very costly. In order to reduce the needed heat input, double-electrode technology
has been previously practiced creating the double-electrode SAW (DE-SAW)
method for fillet welds. However, the reduction in the heat input also reduces the
penetration capability. The ability to produce required weld beads is compromised.
In this study, the authors propose to introduce a root opening in a T-joint between
the flat and perpendicular panels forming a modified fillet weld design. Experimental results verified that the use of a root opening improves the ability of DESAW to produce the required weld beads at reduced heat input and penetration
capability. Major parameters including the root opening, travel speed, and heat
input have been selected/optimized/minimized to produce required fillet weld beads
with a minimized heat input based on qualitative and quantitative analyses.
Introduction
Submerged arc welding (SAW) is a
widely used process. Similar to conventional gas metal arc welding (GMAW)
(Refs. 1, 2) and flux cored arc welding
(FCAW) (Refs. 3, 4), it melts a continuously fed consumable solid or flux cored
electrode wire (Refs. 57) to deposit metal
into the workpiece. In the SAW process,
however, the consumable wire and the arc
are shielded from atmospheric contamination by being submerged under a blanket of granular, fusible flux (Ref. 8).
Submerged arc welding has significant advantages (Refs. 69) over GMAW and
FCAW including higher productivity,
more stable arc, spatter-free, and harmful
ultraviolet radiation-free. Moreover, the
molten metal is effectively protected by a
layer of flux. SAW is thus the most commonly used process for flat and horizontal
welding in the shipbuilding industry, espeY. LU and Y. M. ZHANG (ymzhang@
uky.edu) are with Adaptive Intelligent Systems
LLC, and University of Kentucky, Department of
Electrical and Computer Engineering and Institute
for Sustainable Manufacturing, College of Engineering, Lexington, Ky. L. KVIDAHL is with
Huntington Ingalls Industries, Pascagoula, Miss.
cially in joining plates for ship shells,

decks, and bulkheads (Ref. 10). In a typical 150,000 DWT (deadweight tonnage)
tanker, the length of a horizontal fillet
weld can reach more than 70% of the
whole welding length of the bottom shell
block at the assembly stage (Ref. 11).
Due to the requirement of the weld
size in fillet welding, a sufficient amount
of metal must be melted. In conventional
SAW, the heat input is proportional to the
amount of metal melted and deposited in
the process. As a result, a large heat input
causes unwanted distortion in the welded
structures whose follow-up straightening
is very costly. While the cost for correction
of welding-related distortion varies with
ship size and structure and thus is difficult
to accurately determine, it is generally
considered to be higher than the cost
KEYWORDS
Submerged Arc Welding (SAW)
Fillet Weld
Double-Electrode (DE)
Root Opening
Heat Input
needed to make the welds. In addition,

distortion correction involves the use of
flame and water, causing adverse effects
on the working environment.
In order to reduce the excessive heat
input in fillet welding, a double-electrode
SAW (DE-SAW) process was practiced in
the laboratory of Adaptive Intelligent Systems LLC (AIS) in which the total welding current is divided into the base metal
current and bypass current after it melts
the main wire. Since part of the current is
bypassed without flowing into the workpiece, the heat input into the workpiece is
reduced. When the metal from the bypass
wire melted by the bypass arc is added into
the workpiece, the reduced heat input is
added back but the metal deposition is increased. The DE-SAW process is therefore capable of depositing the same
amount of metal at reduced heat input or
depositing more metal at the same heat
input similarly as its original variant, i.e.,
double-electrode gas metal arc welding
(DE-GMAW) (Refs. 1219).
However, after having the heat input reduced greatly in the fillet welds by using the
DE-SAW process, the penetration capability is also reduced due to the reduction in
the base metal current. The weld beads produced become convex, causing the reentrant angle to be undesirably reduced.
Decreasing the penetration capability required for producing desirable welds is thus
an issue that needs to be resolved in order to
effectively utilize the ability of DE-SAW in
reducing the heat input to produce a desirable fillet weld bead.
In this paper, the authors first propose
to intentionally introduce a root opening
in a T-joint between the perpendicular and
flat plates to modify the joint design as
shown in Fig. 1. After the effectiveness
was verified, the welding parameters were
optimized so that a complete solution for
DE-SAW can be provided to produce the
required fillet weld at reduced heat input.
Experimental System and

Conditions
Double-electrode submerged arc weld-
Lu 12-13_Layout 1 11/14/13 3:12 PM Page 391
Fig. 2 Diagram of DE-SAW experimental platform.
established based on a
conventional
SAW
process by adding a
GMAW weld head
next to the SAW head
of the Lincoln LT-7
tractor (Ref. 20) to
provide a second/bypass loop for the welding current. The main
wire feeder is combined with the tractor,
but the bypass wire
needs an external wire
feeder.
The relationship of
Fig. 3 Current relationships in the DE-SAW process.
the welding currents
in
the
DE-SAW
process can be explained by Fig. 3. The
ing is considered a variant of DE-GMAW
main loop represents the path through
that was previously developed at the Uniwhich the base metal current (I1) flows,
versity of Kentucky (Ref. 12). Except for
and the bypass loop is the path through
changing from gas shielding to flux shieldwhich the bypass current (I2) flows. The
ing so as to take advantage of the desirable
positive terminals of the two power supcharacteristics associated with the SAW
plies (both of them are working in conprocess mentioned previously, the princistant-voltage mode (CV)) are connected
ple of the electrical circuit remains
together as a common positive terminal.
unchanged.
The main SAW head is connected to the
common positive terminal, and the workExperimental Systems
piece (or base metal) is connected with the
negative terminal of the main power supFigure 2 shows the experimental platply. This kind of connection is based on
form of the DE-SAW process. It has been
the direct current electrode positive

(DCEP) polarity mode. For most of the
applications, DCEP mode is used because
of its benefits to the arc stability, metal
transfer, and deep penetration (Ref. 21).
The bypass GMAW head is connected to
the negative terminal of the bypass power
supply. After the power supplies are
turned on, the main arc is established between the tip of the electrode of the main
welding head and the surface of the workpiece, and the bypass arc is established between the tip of the main electrode and
the tip of the bypass electrode.
As shown by the arrows in Fig. 3, the
base metal current (I1) flows from the
main electrode to the workpiece, and the
bypass current (I2) flows from the main
electrode to the bypass electrode. Because
both the base metal current and the bypass
current flow through the main wire electrode, the current inside the electrode of
the main submerged arc weld head equals
the total welding current (I). This fundamental relationship can be expressed by
Equation 1.
I = I1 + I2
(1)
where, I is the total welding current; I1 is

the base metal current that flows through
the workpiece, and I2 is the bypass current
that flows through the bypass wire.
Experimental Conditions
Table 1 Experimental Conditions

Model Number
Perpendicular Plate
C1018 Cold-Rolled Steel Plate
Flat Plate
C1018 Cold-Rolled Steel Plate
Main Wire
Bypass Wire
Flux Powder
Lincoln Weld L-61

Kobelco MG-51T
Lincoln Weld 882
Size
Thickness: 316 in. (4.763 mm)
Width: 1 in. (25.4 mm)
Thickness: 316 in. (4.763 mm)
Width: 4 in. (101.6 mm)
Diameter: 332 in. (2.381 mm)
Diameter: 0.045 in. (1.14 mm)
N/A
The experimental conditions here refer

primarily to the materials of the wire electrodes, the steel plates used for the T-joint,
and the model number of the flux powder.
The specifications of experimental conditions are listed in Table 1. All the experiments in this paper were conducted under
these conditions. C1018 cold-rolled steel
was used because it is commercially available for various thicknesses and dimenWELDING JOURNAL 391-s
WELDING RESEARCH
Fig 1 Modified fillet joint design with a root opening.
Lu 12-13_Layout 1 11/14/13 3:12 PM Page 392
sions and it is in the same category of DH

36 (the most widely used steel in ship
structures) such that the procedures developed for C1018 can be directly used for
DH 36 without requalification.
Root Opening Effect and Selection
WELDING RESEARCH
With the purpose of illustrating the effect of the root opening, the different root
sizes tested were no root opening, small
root opening, and large root opening. In
order to decouple from the effect of the
mass, all the experiments were conducted
using open-loop controls, i.e., using constant wire feed speeds without feedback
control, which would adjust the wire feed
speeds such that the mass would change
also. Because the major concern was
whether the root opening would reduce
the convexity and increase the reentrant
angle, analysis was first done in this section qualitatively without exact readings/measurements of the reentrant angles
or leg sizes. The reentrant angle was a concern because shipyard visual acceptance
criteria typically require the reentrant
angle to be no less than 90 deg to reduce
possible stress concentration, which would
reduce the fatigue life.
Fig. 4 Currents and wire speeds plot in the no root opening experiment.
No Root Opening Experiment
In the no root opening experiment, the

T-joint was prepared without an intentional root opening. This experiment
served as a reference to illustrate the effect of the root opening in later experiments with root openings. The welding
parameters used in the no root opening as
well as the experiments with root openings
are listed in Table 2.
Figure 4 shows the welding currents
and wire feed speeds recorded from the
data-acquisition (DAQ) system. In the legend of the plots, I1 and I2 represent the
base metal and bypass currents and W1
and W2 stand for the main and bypass wire
feed speeds, hereafter. As can be seen
from the experimental data, after the
process reaches its steady-state, the average base metal current is approximately
262 A, and the average bypass current is
around 154 A. Hence, the average total
welding current within the steady-state period was 416 A. Because the perpendicular
and flat plates are relatively straight, the
welding process was relatively stable although no feedback control was used.
Figure 5 shows the photo of the weld
bead in the no root opening experiment.
Figure 6 shows a typical cross section of
the welded joint. It can be seen that the
weld bead is convex (shown with the
dashed lines in Fig. 6). Also, the reentrant
angle (shown with the blue lines in Fig. 6)
was close to 90 deg.
Fig. 5 Weld bead in the no root opening experiment (direction: right to left).
Small Root Opening Experiment
In this section, a 1.5-mm root opening

was tested. Except for the root opening, all
other conditions and parameters were unchanged from the no root opening experiment (shown in Table 2).
As can be seen from the recorded experimental data shown in Fig. 7, after
reaching the steady-state, the average base
metal current is approximately 238 A , and
the bypass current is around 164 A. Hence,
the total welding current in the steady-state
period was 402 A. The welding process was
relatively stable with only insignificant fluctuations within acceptable ranges.
Due to the root opening between the T
and the panel, the relative position among
the electrodes and the workpieces were
different from that in the no root opening

experiments. As a result, the values of
welding currents in the experiment with a
root opening are not exactly the same as
those in the no root opening condition although the wire feed speeds and the welding voltages are exactly the same.
As can be seen from the photo of the
weld bead (Fig. 8) and a typical cross section of the weld bead (Fig. 9), the convexity of the weld bead (shown with the
dashed lines in Fig. 9) has been reduced
by 50% approximately after the introduction of the root opening despite the reduction in the actual heat input (total
current). At the same time, the reentrant
angle (shown with the blue lines in Fig. 9)
has also been increased accordingly. The
effect of the root opening on the convexity
Table 2 Welding Parameters for Root Opening Experiments
Main Wire Speed (W1)

Bypass Wire Speed (W2)
Travel Speed (v)
Main Voltage (V1)
Bypass Voltage (V2)
Root Opening in T Joint
Value
Unit
90 (288.6)
300 (762)
50 (127)
28
28
0, 0.06, 0.12 (0, 1.5, 3)
in./min (cm/min)
in./min (cm/min)
in./min (cm/min)
V
V
in. (mm)
Lu 12-13_Layout 1 11/14/13 3:12 PM Page 393
Fig. 7 Currents and wire speeds plot in the small root opening experiment.
Fig. 8 Weld bead in the small root opening experiment (direction: right to left).
and reentrant angle is clearly demonstrated.

Large Root Opening Experiment
The root opening is increased to 3 mm

while other parameters and conditions are
unchanged.
As can be seen from Fig. 10, after
reaching the steady-state, the average base
metal current is 244 A approximately, and
the bypass current is around 152 A.
Hence, the total welding current within
the steady-state period is 396 A. The welding currents drifted more significantly than
those in the no root opening and the small
root opening experiments. The weld appears to be wider in the second half of the
weld where the base metal current is
greater Fig. 11.
As can be seen, the convexity of the

weld bead (shown with the dashed lines in
Fig. 12) in the large root opening experiment was greatly reduced compared to
the no root opening experiment. However,
the difference with that in the small root
opening was not significant. The reentrant
angle in the large root opening becomes
greater.
Results in the three root opening experiments clearly demonstrate the effectiveness of a root opening in reducing the
convexity and increasing the reentrant
angle for desirable weld bead geometry.
The penetration capability required to
produce a desirable weld bead is thus reduced by the root opening. To determine
which root opening is more appropriate
(1.5 or 3.0 mm), the authors noted that the
vertical leg size of the weld bead in the
Table 3 Experimental Conditions for Travel Speed Study Experiments
Exp 5.1
Exp 5.2
Exp 5.3
Exp 5.4
Exp 5.5
Exp 5.6
Exp 5.7
Travel Speed
in./min
(cm/min)
Incremental
Ratio
Main Wire
Speed
in./min (cm/min)
Bypass Wire
Speed
in./min (cm/min)
30 (76.2)
35 (88.9)
40 (101.6)
45 (114.3)
50 (127)
55 (139.7)
60 (152.4)
1.0
1.17
1.33
1.5
1.67
1.83
2.0
60 (152.4)
70 (177.8)
80 (203.2)
90 (228.6)
100 (254)
110 (279.4)
120 (304.8)
150 (381)
175 (444.5)
200 (508)
225 (571.5)
250 (635)
275 (698.5)
300 (762)
large root opening experiment is approximately 6 mm. However, the largest root
opening allowed in production is 4.76 mm
(316 in.) and for every 1.59 mm (116 in.) root
opening (over 116 in.), the weld size must
be increased by 116 in. accordingly. For example, if in. (6.35 mm) weld is needed
and there is a 3.18 mm (18-in.) (root opening between perpendicular and flat plates,
then the required leg size will become 7.92
mm (516 in.) (root opening 18 in. less the
permitted initial 116 in., this 116 in. is added
to the in. size required, resulting in 516
in.). As a result, the required leg size will
become 6.35 mm (14 in.) for the 4.76 mm
(316-in.) workpiece thickness if a 3-mm
(0.12-in.) root opening is used. Consequently, the heat input will be increased
due to the increase in the required mass.
On the other hand, for the 1.5-mm small
root opening (0.59 in., which is smaller
than the permitted 116 in.), the leg size can
still be equal to the thickness of the plate
(316 in.). Hence, the small root opening is a
more appropriate root opening size.
Analysis Methods
Once the root opening was selected for

the modified joint design, the travel speed
was optimized, and the heat input was
then minimized. Such optimization and
minimization was conducted using quantitative analysis in addition to the qualitative comparison/analysis method used for
the root opening study. Before the optimization and minimization were performed, the methods for quantitative
analysis had to be specified first.
The leg sizes (vertical and horizontal)
were measured for each of the weld beads
as shown in Fig. 13. Specifically, for any
WELDING RESEARCH
Fig. 6 A cross section of weld bead in the no root opening experiment.
Lu 12-13_Layout 1 11/14/13 3:12 PM Page 394
Fig. 10 Currents and wire speeds plot in the large root opening experiment.
Fig. 9 A cross section of the weld bead in the small root opening experiment.
WELDING RESEARCH
Fig. 11 Weld bead in the large root opening experiment (direction: right to left).
weld bead, in order to ensure the accuracy

of the measurement, the beginning adjustment section for the arc-establishing period (50.8 mm/2 in. long approximately)
and the ending section (25.4 mm/1 in. long
approximately) for turning off the contactors of the two power supplies individually
were skipped from being measured. Then,
along the welding direction, the full length
of the rest of the weld in the steady section
was divided into N short sections with a
10-mm (0.393-in.) interval except for the
last section left that was not exactly 10 mm
long. Within each of these short sections
(section i for example), one maximum leg
size (maxi) and one minimum leg size
(mini) can be measured using a Vernier
caliper on both the horizontal (on the
panel) and the vertical (on the T) directions. In this way, a series of max-min pairs
Table 4 Experimental Parameters
Exp
6.1
Exp
6.2
Exp
6.3
Exp
6.4
Exp
6.5
Root Opening
Size
mm
Travel
Speed
in./min
(cm/min)
Main
Voltage
V
1.5
45
(114.3)
45
(114.3)
45
(114.3)
45
(114.3)
45
(114.3)
1.5
1.5
1.5
1.5
can be obtained for

each weld bead.
After obtaining
the raw data pairs as
specified
above,
analyses for travel
speed optimization
and heat input minimization can be conducted quantitatively.
To this end, four
major performance
indices can be calculated as shown in Fig.
13. The specific calcu- Fig. 12 A cross section of the weld bead in the large root opening
lations are as follows experiment.
using one weld bead
as example:
First, after comues the absolute maximum and miniparing the max-min pairs, two extreme valmum leg sizes can be found for both
horizontal and vertical directions, respectively. Then, the difference between these
two extreme values gives the extreme difference of the leg size. Third, within the
Bypass
Main Wire
Bypass Wire
steady section, the average leg sizes can be
Voltage
Speed
Speed
calculated by Equation 2.
V
in./min
(cm/min)
in./min
(cm/min)
28
28
28
28
28
28
28
28
28
28
70
(177.8)
80
(203.2)
90
(228.6)
100
(254)
110
(279.4)
382
(970.28)
338
(858.52)
294
(746.8)
250
(635)
206
(523.2)
x =
1
N
i =1
maxi + mini
(2)
Here, x represents either the horizontal

or the vertical average leg size. The horizontal and vertical average leg sizes can
give the average leg size by averaging the
leg sizes in two directions together. At last,
the standard deviation of the leg sizes can
be calculated by Equation 3.
Lu 12-13_Layout 1 11/14/13 3:12 PM Page 395
Fig. 13 Measurement and analysis approach.
1
2
=
( x x ) E E E E E E E E E E E E E E E E E E E E E E E E E E E (3)
N i=1 i
where,E x i =
maxi E E ab s ( maxi x ) > ab s ( mini x )

mini E E ab s ( maxi x ) ab s ( mini x )
In the same way, these four quantitative performance indices were obtained on
the horizontal and vertical directions individually for all weld beads. By plotting
these four indices, the resultant plots show
the changing tendency of the statistical
data, and thereby quantitatively illustrate
the influence of the parameters being
studied.
The quantitative analysis was conducted together with the qualitative analysis. In particular, by comparing and
contrasting the cross sections of the weld
beads, the changes in the convexity with
the parameter being examined was clearly
demonstrated. This qualitative analysis
can provide a useful complementary to the
quantitative statistical analysis. By summarizing the indices and convexity of the

welds, the parameter value that maximizes
the leg sizes and minimizes the deviation
of the leg sizes with acceptable convexity
was selected as the optimal value for this
parameter.
Traveling Speed Optimization

Experiment Design and Study Approaches
In this section, a series of experiments

was conducted using different travel speeds.
In particular, the travel speed was increased
progressively at 5 in./min increments within
the attainable range from 30 to 60 in./min.
The wire feed speeds (main wire and bypass
wire) were adjusted proportionally with the
travel speed, as shown in Table 3, to maintain the linear deposition speed (mass deposition) unchanged. The Incremental
Ratio in Table 3 represents the ratio of the
travel speed relative to the lowest travel
speed in the series of experiments, and certainly also the ratio of the wire feed speed to
the lowest wire feed speed.
Table 5 Heat Input Comparison
Single Wire
Exp 5.1
Exp 5.2
Exp 5.3
Exp 5.4
Exp 5.5
Seven experiments, under the same

basic conditions (Table 1) as designed and
unchanged linear deposition speed, have
been conducted following the sequence
listed in Table 3. Figure 14 shows the plots of
the welding currents and wire feed speeds
recorded from the data-acquisition system.
As shown in Fig. 14, the welding currents are relatively stable after the establishment of the bypass arcs. Careful
observation of Fig. 14 shows that the fluctuation on the base metal currents is relatively strong when the travel speed equals
30, 35, and 40 in./min (the first three plots
in Fig. 14); when the travel speed, however, is equal to and greater than 45
in./min, then the base metal current becomes much smoother.
Figures 15 and 16 give the weld beads
and typical cross sections in the travel
speed study experiments, respectively.
From these photos, it can be seen that
when the travel speed is equal to and
lower than 45 in./min, there is no obvious
difference with the convexity of the weld
beads. All of them are fairly flat. However,
when the travel speed is equal to or
greater than 50 in./min, convexity begins
to appear, and with the increase in the
travel speed, the convexity of the weld
beads gets noticeably greater and greater.
In particular, the convexity of the weld
beads is approximately proportional to the
travel speed.
Main Wire
Speed
in./min
Total
Current
(A)
Travel
speed
(in./min)
Heat Input
(J/in.)
Heat Input
Ratio
75
70
80
90
100
110
400
320
380
420
465
510
30
45
45
45
45
45
22400
11947
14187
15680
17360
19040
100%
53%
63%
70%
78%
85%
Standard Deviation and Extreme

Difference Analysis
Standard deviation and extreme difference are two important performance indices in statistics that are used to describe
the spread of the distribution of a group of
experimental data (Refs. 2224). Using
the statistical data of the seven experiments with different travel speeds, Fig. 17
shows the changing tendency of the standard deviation and extreme difference of
the leg sizes.
It is not difficult to see that when the
travel speed is at 30 in./min (lowest travel
speed), the standard deviation and the extreme difference in the leg sizes are both
at their largest. The high standard deviation and extreme difference are actually
coherent to the fluctuating base metal current (see the first plot in Fig. 14) and the
rough surface and uneven edges of the
weld bead with 30 in./min travel speed (see
the first photo in Fig. 15) because fluctuations in base metal current increase the
fluctuations in the penetration capability,
and thus evenness of the welds produced.
Then, as the travel speed increases (from
35 to 45 in./min), the standard deviation
WELDING RESEARCH
Experimental Results and

Analysis
Lu 12-13_Layout 1 11/14/13 3:12 PM Page 396
WELDING RESEARCH
Fig. 15 Weld beads from the travel speed study experiments.
evaluate
the
welding performance for fillet
joints. In practice, the average
and minimum leg
sizes of the weld
beads are more
of a concern.
Figure 18 shows
the changing tendency of the average and minimum
Fig. 14 Currents and wire speeds in the travel speed study experiments.
leg sizes. It can be
seen that, with the
increase in the
travel speed, the
average and miniand extreme difference both become
mum leg sizes increase gradually at the besmaller, reaching their lowest points at 45
ginning, reach their largest sizes between 35
in./min, and then rise a little bit as the
and 45 in./min, and then decrease gradutravel speed continues to increase (from
ally. Because making weld beads absolutely
45 to 60 in./min).
symmetrical on both the vertical and horiFrom 35 to 60 in./min, however, the dezontal directions is relatively difficult in labviations and the extreme differences are all
oratory but it may not be in shipyards, the
relatively small. Hence, 35 to 60 in./min can
average leg size, i.e., the average between
be considered as an acceptable range for the
the weld sizes in the two directions as given
travel speed. Although in the vertical direcby the black line in Fig. 18, may be a better
tion the deviation and extreme difference
measurement for the weld size. Considerare very low at 35 in./min, the speed of 45
ing the average leg sizes together with the
in./min is still a better choice because both
vertical and horizontal minimum sizes, 45
directions should be equally important.
in./min is optimal.
speed is too slow or too fast. The travel

speed from 35 to 50 in./min is considered
most appropriate to produce welds meeting size and smoothness requirements.
Specifically, the changing tendencies of
the quantitative indices are coherent to
the changes on the convexity and shapes
of the weld beads, and can be explained
through the physical process. When the
travel speed is relatively slow, the wire
feed speeds (main and bypass wire) have
to be reduced accordingly due to the limit
on the constant linear deposition speed
(mass deposition). Naturally, the welding
currents will be relatively low because of
the reduced wire feed speeds. Unfortunately, the welding currents fluctuate
more in their low ranges Fig. 14. As a
result, the fluctuating welding currents
lead to the relatively large standard deviation and extreme difference. On the contrary, if the travel speed is too fast, the
formation of even welds at high speed becomes an issue resulting in large standard
deviations and extreme differences in the
leg sizes as well as uneven narrow and convex weld beads. Therefore, the quantitative statistical results and the qualitative
analysis on the convexity of the welds both
suggest the moderate 45 in./min is the optimal travel speed for the DE-SAW
process for fillet joints.
Average and Minimum Leg Size Analysis
Remarks on Travel Speed Optimization
Heat Input Minimization
In addition to the standard deviation

and extreme difference, the average leg
sizes and minimum leg sizes are two other
important indices that can be used to
From the changing tendencies of all the

four important performance indices, it is
apparent that both the leg sizes and their
distributions are undesirable if the travel
With the root opening and travel speed

selected/optimized, the heat input for fillet
welds using the DE-SAW process can be
minimized.
Lu 12-13_Layout 1 11/14/13 3:13 PM Page 397
adjusted accordingly to maintain the linear

deposition rate unchanged. When viewing
Table 4, one should note that the diameter
of the main wire and that of the bypass wire
are different (2:1 approximately, see Table
1). The adjustment on the bypass wire
speed is exactly calculated based on this diameter ratio.
After conducting these five experiments, the leg sizes (vertical and horizontal) were measured for each of the five
weld beads with the same method shown
in Fig. 13. Similarly, the analysis as to the
welding performances was qualitative and
quantitative. In addition, the heat input
was now added as another measurement.
If the weld sizes are all acceptable within a
certain range of the linear deposition, then
the lower heat input resulted from the
lower main wire feed speed should be selected to minimize the heat input to the
maximum.
Fig. 16 Cross sections of weld beads in the travel speed study experiments.
Fig. 17 Standard deviation (left) and extreme difference (right) in leg sizes in the travel speed study experiments.
Experiment Design
Different from the constant ratio used

in the travel speed optimization, if the
ratio between the main and bypass wire
feed speeds can be adjusted, then the
same linear deposition rate can be
achieved at reduced/increased main wire
feed speed (thus the total current that determines the heat input), but higher/lower
bypass wire feed speed does not affect the
heat input directly, so the heat input can
be adjusted.
Hence, a series of experiments was conducted with the parameters shown in Table
4 to optimize the heat input, i.e., to determine the minimal heat input (with corresponding welding parameters) needed to
produce acceptable welds. In particular, the
main wire feed speed has been increased
progressively at the 10 in./min increment
within the attainable range of 70 to 110
in./min. Simultaneously, the bypass wire
speed (from 382 to 206 in./min) has been
Under the same basic conditions (Table

1) and unchanged linear deposition speed
as designed, five experiments were conducted following the sequence listed in
Table 4. Figure 19 shows the plots of the
experimental data recorded from the dataacquisition system.
As shown in Fig. 19, with the increase
of the main wire speed (from 70 to 110
in./min) and the decrease of the bypass
wire (from 382 to 206 in./min), the heat
input consequently increased, and the average steady-state base metal current (red
lines in Fig. 19) increased accordingly.
Careful observation on Fig. 19 also shows
that the fluctuation on the base metal current is relatively strong and obvious when
the wire feed speed is set at 70 in./min.
Apart from this, the welding processes in
the four experiments are quite stable.
Figures 20 and 21 give the weld beads
and typical cross sections in the heat input
optimization study respectively. From
these photos, it can be seen that when the
main wire feed speeds equal 70 and 110
in./min (two extreme settings in this series), the weld beads appear to be convex.
Additionally, at 70 in./min, the edges of
the weld bead are quite rough and uneven.
However, when the main wire speed is between 80 and 100 in./min, the quality of
the weld beads is quite satisfactory. Especially, when viewing the typical cross sections, the surface and reentrant angle of
the weld beads within this range are all
fairly acceptable.
Standard Deviation and Extreme
Difference Analysis
Similar to the quantitative analysis

used in the travel speed optimization, four
WELDING RESEARCH
Experimental Results and

Analysis
Lu 12-13_Layout 1 11/14/13 3:13 PM Page 398
WELDING RESEARCH
performance indices were calculated. According to the statistical data from the five
experiments with different heat inputs,
Fig. 22 shows the changing tendency of the
standard deviation and extreme difference
on the leg sizes.
After taking the data on both horizontal and vertical directions into consideration, it can be seen that when the main
wire feed speed was at 70 in./min (lowest
heat input in the series of experiments),
the standard deviation and extreme difference of the leg sizes were both at their
largest. Then, from 80 to 100 in./min, the
standard deviation and extreme difference
of the leg sizes are both on a declining
trend. Actually, the deviation and the extreme difference are all relatively small
within this range. Hence, 80 to 100 in./min
can be considered as an acceptable range
for the heat input. Comparatively, the heat
input when W1 = 100 in./min gave the best
performance. At last, when the main wire
feed is close to 110 in./min (the highest
wire feed speed in the series of experiments), both the standard deviation and
extreme difference rise up rapidly.
The changing tendencies on deviation
and extreme difference are coherent to the
welds shown in Figs. 20 and 21. From W1 =
80 in./min to W1 = 100 in./min, the surfaces
of the weld beads are relatively smooth, and
the edges of the welds are quite uniform.
However, when the heat input is either too
high or too low, the surfaces of the welds appear to be convex and the edges of the welds
are relatively rough and uneven. Hence,
simply from the standard deviation and extreme difference of the leg sizes, the appropriate range of the main wire feed speed
(represents the range of heat input) should
be between 80 and 100 in./min.
Fig. 18 Changing tendency of average leg sizes (left) and minimum leg sizes (right) in the travel speed
study experiments.
Average and Minimum Leg Sizes Analysis
In addition to the deviation and the extreme difference, Fig. 23 shows the changing tendencies of average and minimum
leg sizes. By referring to the statistical data
on both horizontal and vertical directions,
it can be seen that the average and minimum leg sizes are all on the rising trend at
the beginning. After reaching their largest
sizes when the main wire speed equals 90
in./min, the leg sizes become shorter instead of increasing with the continuing rising of the heat input. This decreasing
phenomenon was different from our previous expectation. The excessive penetration that appeared following the high heat
input should be the major reason for the
narrow and uneven welds.
In typical applications, the vertical and
horizontal leg sizes must be greater than
the thickness of the workpieces (4.7 mm
approximately). From this point of view,
only the leg sizes that resulted from the
heat inputs W1 = 90 in./min and W1 = 100
Fig. 19 Current and wire speed plots in the heat input experiments.
in./min are fully qualified. At 80 and 110

in./min, although the average leg sizes are
acceptable, the minimum leg sizes are excessively undersized. And after observing
Lu 12-13_Layout 1 11/14/13 3:13 PM Page 399
Fig. 21 Cross sections of weld beads in the heat input experiments.
Table 5 represents the heat input in relation to that of the benchmark.

Table 5 clearly shows that the DE-SAW
process with 1.5-mm root opening lowers
the heat input. Meanwhile, as analyzed in
the quantitative comparison, the welding
sizes at W1 = 90 in./min and W1 = 100
in./min are all satisfactory.
Remarks on Heat Input Optimization
Fig. 22 Standard deviation and extreme difference of leg sizes in the heat input experiments.
From the changing tendencies of all the

four important performance indices and
the convexity of the welds, it is apparent
that both the leg sizes and their distributions are undesirable if the heat input is
too low or too high. Meanwhile, on the
premise of minimizing the heat input, it is
reasonable to say that the heat input when
the main wire feed speed equals 90 in./min
with a bypass wire feed speed of 294
in./min is optimal with a 30% reduction on
the heat input relative to the conventional
SAW process for fillet joints. As further
demonstrated in Fig. 24, the resultant
welds appear to be visually acceptable.
Conclusions and Future Work
Fig. 23 Changing tendency of average and minimum leg sizes in the heat input experiments.
the weld beads at 80 and 110 in./min,

more than one spot appeared along the
welds where the leg size was less than 4.7
mm. Hence, considering the average leg
sizes together with the vertical and horizontal minimum sizes, only the heat inputs
when the main wire feed speed equals 90
and 100 in./min can be accepted.
Heat Input Comparison
Heat input reduction is the primary

purpose to use the DE-SAW process.
Table 5 shows the heat input comparison
among the five heat input optimization experiments and shipyard single-wire SAW
benchmark. The Heat Input Ratio in
The use of a root opening in a T-joint

between the perpendicular and flat plates
provides an effective way to reduce the
penetration required to produce desirable
weld beads. The heat input reduction capability of the DS-SAW process can thus
be effectively utilized to produce desirable
fillet welds with minimized heat input. A
1.5-mm root opening is recommended for
fillet welding on 316-in.-thick plates.
Quantitative and qualitative analysis
methods were used to optimize the welding parameters for minimized heat input.
The resultant optimized practice for DESAW of 316-in. fillet welds is to use a 1.5mm root opening, 45 in./min travel speed,
WELDING RESEARCH
Fig. 20 Weld beads in the heat input experiments.
Lu 12-13_Layout 1 11/14/13 3:13 PM Page 400
90 in./min feed speed for 332-in. (2.4-mm)

diameter main wire and 294-in./min feed
speed for 0.045-in.- (1.2-mm-) diameter
bypass wire.
The optimized practice results in 30%
reduction in heat input from the shipyard
single-wire benchmark.
The use of a root opening introduces
an additional procedure in production.
Quick and economic methods need to be
developed to set the root opening conveniently with the needed accuracy. Weakly
magnetized steel spacers of the workpiece material appear to serve this purpose well although the effectiveness
needs to be verified.
In general, the distortion increases with
he heat input, and the cost and time
needed for distortion correction increase
with the degree of the distortion. Studies
are needed to quantify the cost and time
reductions due to the heat input reduction
provided by the proposed method before
it may be considered for possible use in
production.
WELDING RESEARCH
Acknowledgment
This work was funded by the Navy
under contracts N65538-08-M-0049 and
N00024-09-C-4140 and Kentucky Cabinet
for Economic Development (CED) Office
of Commercialization and Innovation
through Kentucky Science and Engineering Corp. under agreements KSTC-184512-08-038 and KSTC-184-512-09-067.
The authors also appreciate the approval
for public release from the Navy
(5720/00DT 2013-0033).
References
1. Holliday, D. B. 1993. Gas-metal arc welding. ASM Handbook. 10th ed., vol. 6: ASM International, Materials Park, Ohio.
2. Wang, G., Huang, P. G., and Zhang, Y.
M. 2003. Numerical analysis of metal transfer
in gas metal arc welding. Metallurgical and Materials Transactions B: Process Metallurgy and
Materials Processing Science 34: 345354.
3. Meyer, D. W. 1993. Flux-cored arc welding. ASM Handbook. 10th ed., vol. 6: ASM International, Materials Park, Ohio.
4. The Welding Handbook for Maritime
Welders. 10th ed., Barwil Unitor Ships Service.
5. Welding Handbook. 1991. 8th ed., vol. 2.
ed. R. L. OBrien. Welding processes: American Welding Society, Miami, Fla.
6. Su, H., Hu, J., and Guo, H. 2010. Submerged arc welding procedure improvement
based on human-machine operation analysis.
3rd International Conference on Information
Management, Innovation Management and Industrial Engineering, ICIII 2010, Kunming,
China: IEEE Computer Society.
7. Submerged Arc Welding. 1982. Miller Electric Mfg. Co.
8. Ogborn, J. S. 1993. Submerged arc welding. ASM Handbook. 10th ed., vol. 6: ASM In-
Fig. 24 Cross sections and metallic phases when W1 = 90 in./min.
ternational, Materials Park, Ohio.

9. Yang, X., et al. 2011. Twin-wire submerged arc welding process of a high-strength
low-alloy steel. Journal Wuhan University of
Technology, Materials Science Edition 26:
114117.
10. Bruce, G. J., and Eyres, D. J. 2012. Ship
Construction, 7th ed., Butterworth-Heinemann.
11. The National Shipbuilding Research
Program. 1976. Proceedings of the REAPS Technical Symposium, Paper No. 14, Shipbulding
Equipment at Mitsubishi.
12. Zhang, Y. M., Jiang, M., and Lu, W.
2004. Double electrodes improve GMAW heat
input control. Welding Journal 83(11): 3941.
13. Li, K. H., and Zhang, Y. M. 2007. Metal
transfer in double-electrode gas metal arc welding. Journal of Manufacturing Science and Engineering, Transactions of the ASME 129: 991999.
14. Li, K. H., Chen, J. S., and Zhang, Y. M.
2007. Double-electrode GMAW process and
control. Welding Journal 86(8): 231-s to 237-s.
15. Li, K. H., and Zhang, Y. M. 2008. Consumable double-electrode GMAW Part 1: The
process. Welding Journal 87(1): 11-s to 17-s.
16. Li, K. H., and Zhang, Y. M. 2008. Consumable double-electrode GMAWPart II:
Monitoring, modeling, and control. Welding
Journal, 87(2): 44-s to 50-s.
17. Li, K. H., et al. 2008. High-strength steel
welding with consumable double-electrode gas
metal arc welding. Welding Journal 87(3): 57-s

to 64-s.
18. Li, K. H., and Wu, C. S. 2009. Mechanism of metal transfer in DE-GMAW. Journal
of Materials Science and Technology 25: 415418.
19. Li, K. H., and Zhang, Y. M. 2010. Interval model control of consumable double-electrode gas metal arc welding process. IEEE
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20. LT-7 Lightweight Tractor Service Manual.
2010: Lincoln Global, Inc.
21. Key, J. F. 1993. Arc physics of gas-tungsten arc welding. ASM Handbook, 10th ed., vol.
6: ASM International, Materials Park, Ohio.
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24. Ziemer, R. E., and Tranter, W. H. 2008.
Principles of Communications. 6th ed.: John
Wiley, New York.
AWS Expands International Services

With international membership on the rise, the American
Welding Society (AWS) launched a series of country-specific
websites known as microsites for members to access information in their native languages.
Multilingual microsites are now live for Mexico at
www.aws.org/mexico, China at www.aws.org/china, and Canada
(English/French) at www.aws.org/canada. They feature information on services offered by AWS in each country, membership benefits, exposition information, online education, and access to AWS publications and technical standards.
Other countries will be added later.
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December 2013_4/06 Cover 11/13/13 9:52 AM Page C1

WELDING JOURNAL VOLUME 92 NUMBER 12 DECEMBER 2013

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THE STANDARD OF EXCELLENCE IN:

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December 2013 Volume 92 Number 12

Aluminum Weld-Quality Solutions Come in Threes

Tips for Job Shops

Welding and Cutting Fair Attracts a Worldwide Audience

How Wire Diameter Affects Aluminum Welding

The American Welder

AWS Scholarships Proved a Channel to Success

Women Learn Welding Skills for New Careers

AWS website www.aws.org

Welding Research Supplement

363-s Effect of Adhesive Characteristics on the Weld Quality

Welding Journal (ISSN 0043-2296) is published

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Its Been a Very Good Year

Founded in 1919 to Advance the Science,

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White House Manufacturing Board Revived

Legislation Introduced to Reform Patent

OSHA Publishes PEL Comparison Chart

NIST Sets Up Website for Manufacturing

Bill Introduced to Facilitate Cross-Border

U.S. Implements First Export Control

Water Infrastructure Legislation

Contact the AWS Washington Government Affairs Office at

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Andringa Inducted into Manufacturing Hall of Fame

Welders Sought in Western Canada

Grant Helps Wisconsin Indianhead Technical College

Publisher Andrew Cullison

American Welding Society

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North Americas largest

For all of your rolling, forming

NI DECEMBER 2013_Layout 1 11/13/13 4:02 PM Page 10

Ironworkers Union in California to

cored arc welding processes and oxyfuel cutting. The program

Ingalls Shipbuilding Starts Constructing

Attendees from the previous Ironworkers Womens Welder Program

Huntington Ingalls Industries Ingalls Shipbuilding division,

NI DECEMBER 2013_Layout 1 11/13/13 4:03 PM Page 11

Designed to replace the 378-ft Hamilton-class high-endurance

Serving It Up Weld Done: High School

Gas metal arc welding was used during fabrication of a 20-ft-long

TECHNOLOGY FOR THE WELDERS WORLD.

Joined at the hip.

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One Bad Weld Could Cost You Million$

Over 3,000 Contractors