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March 2014
PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDING
AND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING
CONTENTS
32
Features
Departments
32
36
40
46
Editorial ............................4
Press Time News ..................6
International Update ..............8
News of the Industry ............10
Business Briefs ..................14
Stainless Q&A ....................20
RWMA Q&A ......................22
Product & Print Spotlight ......26
Conferences ......................54
Coming Events....................56
Certification Schedule ..........60
Society News ....................63
Tech Topics ......................64
Erratum D9.1M/D9.1 ........64
U.S./European Welding
Standards Conf. ..............65
Guide to AWS Services ........80
Personnel ........................82
American Welder
Fact Sheet......................101
Learning Track ................102
Classifieds ......................110
Advertiser Index ................112
36
86
90
96
40
78-s
85-s
98-s
WELDING JOURNAL
EDITORIAL
Founded in 1919 to Advance the Science,
Technology and Application of Welding
Allen W. Sindel
Chair, AWS Technical Activities Committee
MARCH 2014
Officers
President Dean R. Wilson
Welldean Enterprises
Vice President David J. Landon
Vermeer Mfg. Co.
Vice President David L. McQuaid
D. L. McQuaid and Associates, Inc.
Vice President John R. Bray
Affiliated Machinery, Inc.
Treasurer Robert G. Pali
J. P. Nissen Co.
Executive Director Ray W. Shook
American Welding Society
Directors
U. Aschemeier (Dist. 7), Miami Diver
R. E. Brenner (Dist. 10), CnD Industries, Inc.
D. J. Burgess (Dist. 8), University of Tennessee
N. C. Cole (Past President), NCC Engineering
G. Fairbanks (Dist. 9), Fairbanks Inspection & Testing Services
T. A. Ferri (Dist. 1), Victor Technologies
P. H. Gorman (Dist. 20), Sandia National Laboratories
S. A. Harris (Dist. 4), Altec Industries
K. L. Johnson (Dist. 19), Vigor Shipyards
J. Jones (At Large), The Harris Products Group
J. Knapp (Dist. 17), Gas and Supply
T. J. Lienert (At Large), Los Alamos National Laboratory
D. E. Lynnes (Dist. 15), Lynnes Welding Training
C. Matricardi (Dist. 5), Welding Solutions, Inc.
S. P. Moran (At Large), Weir American Hydro
K. A. Phy (Dist. 6), K. A. Phy Services, Inc.
W. R. Polanin (At Large), Illinois Central College
W. A. Rice (Past President), OKI Bering
R. L. Richwine (Dist. 14), Ivy Tech State College
D. J. Roland (Dist. 12), Marinette Marine Corp.
R. W. Roth (At Large), RoMan Manufacturing, Inc.
N. Saminich (Dist. 21), NS Inspection and Consulting
K. E. Shatell (Dist. 22), Pacific Gas & Electric Co.
T. A. Siewert (At Large), NIST (ret.)
J. Stoll (Dist. 18), Bohler Welding Group U.S.
H. W. Thompson (Dist. 2), Underwriters Laboratories, Inc.
R. P. Wilcox (Dist. 11), Ford Motor 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
PRESS TIME
NEWS
Colfax Corp. Buys Victor Technologies for $947 Million
Irving Place Capital, New York, N.Y., a private equity firm, and Victor Technologies, St. Louis, Mo., a designer and manufacturer of metal cutting, gas control, and
specialty welding products, recently announced they have entered into a definitive
agreement to sell Victor Technologies to Colfax Corp. The global manufacturer of
gas- and fluid-handling along with fabrication technology products also owns ESAB,
Florence, S.C.
The all cash transaction values Victor whose brands include Victor, Tweco,
Cigweld, and Stoody at approximately $947 million, including the assumption of debt, and is subject to customary closing conditions.
We are pleased with the progress that we have made in partnership with Irving
Place Capital over the past several years as we have built Victor into a stronger company with a greater presence in key global markets and an improved offering for
our customers, said Martin Quinn, CEO of Victor.
IPC acquired Victor, which was previously named Thermadyne Holdings Corp.,
in a take-private transaction in December 2010. We are proud of the revitalization
of this 100-year-old company that has taken place as a result of our partnership with
Victors management team, said Douglas Korn, a senior managing director of IPC.
MEMBER
MARCH 2014
INTERNATIONAL
UPDATE
Community College Refurbishes Welding Shop
MARCH 2014
NEWS OF THE
INDUSTRY
MARCH 2014
IF WE DONT HAVE
YOUR FILTER,
NOBODY DOES
One call to Donaldson Torit is all it takes to fulll
all your ltration needs. Your call will be answered
by a ltration expert with access to lters of all
styles and sizes. And our Ready2Ship program
means your order will be out the door in less than
24 hours. Even if your dust collector is from another
manufacturer, the lter performance and quality
service of Donaldson Torit is only a phone call away.
Youre sure to get EXACTLY WHAT YOU NEED.
TMK IPSCO, Houston, Tex., has been awarded two threeyear contracts to provide both oil country tubular goods and line
pipe to Shell for onshore and offshore applications.
Currently, five of TMKs plants are providing pipe to Shell
under the contract. Welded and seamless oil country tubular
goods along with the companys UP brand connections are also
being delivered. Its Volzhsky and Sinarsky mills in Russia will
provide line pipe under Shells specification.
DonaldsonTorit.com
800.365.1331
2013 Donaldson Company, Inc.
WELDING JOURNAL
11
www.tokinarc.com
e-mail: trading@tokinar
ading@tokinarc.co.jp
12
MARCH 2014
TAKE A
WARRIOR
INTO
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prove it. Now theres an extraordinary machine thats as rugged and reliable as you are. Introducing Warrior
by ESAB. Designed with input from real-world welders like you and brought to life by ESABs leading-edge
engineering. Warrior is built with inverter technology and features a high-duty cycle, read-anywhere display,
and glove-friendly controls to give you the power to be your best, anywhere, anytime.
For more information, visit www.esabna.com/warrior or scan this QR code.
BUSINESS
BRIEFS
Hypertherm Transitions to a 100%
Employee-Owned Company
MARCH 2014
Dr. Jens Knig, Prof. Stefan Nolte, and Dr. Dirk Sutter (from left)
have developed ultrashort laser pulses from basic research into a
new tool for industrial mass production.
ing. This is because the ultrashort pulse only heats the material
locally and so intensely it is ejected and vaporized before the heat
can be transferred. This enables areas just a few micrometers in
diameter to be ablated.
ULTRA-CUT XT
INTEGRATED SYSTEMS
TM
The American Welding Society established the honor of Counselor to recognize individual
members for a career of distinguished organizational leadership that has enhanced the image and
impact of the welding industry. Election as a Counselor shall be based on an individuals career of
outstanding accomplishment.
To be eligible for appointment, an individual shall have demonstrated his or her leadership in the
welding industry by one or more of the following:
Leadership of or within an organization that has made a substantial contribution to the welding
industry. The individuals organization shall have shown an ongoing commitment to the industry, as
evidenced by support of participation of its employees in industry activities.
Leadership of or within an organization that has made a substantial contribution to training and
vocational education in the welding industry. The individuals organization shall have shown an
ongoing commitment to the industry, as evidenced by support of participation of its employee in
industry activities.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Counselor nomination form in this
issue of the Welding Journal. The deadline for submission is July 1, 2014. The committee looks
forward to receiving these nominations for 2015 consideration.
Sincerely,
Lee Kvidahl
Chair, Counselor Selection Committee
CLASS OF 2015
COUNSELOR NOMINATION FORM
DATE_________________NAME OF CANDIDATE________________________________________________________________________
AWS MEMBER NO.___________________________YEARS OF AWS MEMBERSHIP____________________________________________
HOME ADDRESS____________________________________________________________________________________________________
CITY_______________________________________________STATE________ZIP CODE__________PHONE________________________
PRESENT COMPANY/INSTITUTION AFFILIATION_______________________________________________________________________
TITLE/POSITION____________________________________________________________________________________________________
BUSINESS ADDRESS________________________________________________________________________________________________
CITY______________________________________________STATE________ZIP CODE__________PHONE_________________________
ACADEMIC BACKGROUND, AS APPLICABLE:
INSTITUTION______________________________________________________________________________________________________
MAJOR & MINOR__________________________________________________________________________________________________
DEGREES OR CERTIFICATES/YEAR____________________________________________________________________________________
LICENSED PROFESSIONAL ENGINEER: YES_________NO__________ STATE______________________________________________
SIGNIFICANT WORK EXPERIENCE:
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
COMPANY/CITY/STATE_____________________________________________________________________________________________
POSITION____________________________________________________________________________YEARS_______________________
SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________
IT IS MANDATORY THAT A CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE
SELECTED AS AN AWS COUNSELOR ACCOMPANY THE NOMINATION PACKET. IF NOMINEE IS SELECTED, THIS STATEMENT MAY
BE INCORPORATED WITHIN THE CITATION CERTIFICATE.
**MOST IMPORTANT**
The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All information and support material provided by the candidates Counselor Proposer, Nominating Members and peers are considered.
SUBMITTED BY:
PROPOSER_______________________________________________
AWS Member No.___________________
The proposer will serve as the contact if the Selection Committee requires further information. The proposer is encouraged to include a
detailed biography of the candidate and letters of recommendation from individuals describing the specific accomplishments of the candidate. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition
to the proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.
STAINLESS
Q&A
BY DAMIAN J. KOTECKI
in that 17-4PH is a martensitic grade while
17-7PH is a semiaustenitic grade. The heat
treatment to develop high strength in 174PH is simple because it is martensitic in
Condition A and therefore only requires
aging at about 900F (480C) to develop
maximum strength. But 17-7PH in Condition A is austenitic. It first needs to be
transformed to martensite (which involves
either cold work or thermal treatment)
followed by aging to develop maximum
strength. More about these treatments
later.
Table 1 lists the compositions of 174PH and 17-7PH stainless steels as given
in ASTM A693. It also includes the composition of ER630 filler metal from AWS
A5.9/A5.9M and the composition of the
17-7PH filler metal as given in AMS 5824
(there is no AWS specification for this
filler metal). It can be seen that the filler
metal compositions are somewhat more
restrictive than the base metal compositions. The higher nickel content of the 177PH and AMS 5824, as compared to that
of the 17-4PH and ER630, is responsible
for the retention of austenite to room temperature in the two former grades while
the two latter grades transform to martensite (Condition A in all four cases). A copper-rich phase precipitates during the
aging heat treatment of 17-4PH base
metal and ER630 weld metal. A destabilization of the austenite (cold work, deep
refrigeration or austenite conditioning
heat treatment) in the 17-7PH base metal
and AMS 5824 weld metal to induce
martensite transformation is necessary before the aging heat treatment of the 177PH and AMS 5824 weld metal.
In 17-4PH, Condition A is reached by
annealing at 1925F (1050C), while Condition A is reached in 17-7PH by annealing at 1950F (1065C), both followed by
cooling to room temperature. In the aswelded condition, the weld metal and
HAZ of both steels is essentially also Condition A, although it should be recognized
that both weld metals will contain some
ferrite (much more, on the order of 25%
in 17-7PH).
Mechanical properties of 17-4PH and
17-7PH are strongly affected by processing history after reaching Condition A.
ASTM A693 includes the minimum mechanical property requirements shown in
Table 2. There are additional mechanical
property requirements after cold working
to destabilize austenite in 17-7PH, but I
am assuming that cold work is not possible
in your structure. So I do not include those
requirements. The elongation requirements are also affected by thickness, and
Table 2 includes only requirements for 316
Mn
Si
Cr
Ni
Mo
Cu
Nb
Al
17-4PH
0.07
1.00
0.040
0.030
1.00
15.0 to
17.5
3.0 to
5.0
3.0 to
5.0
0.15 to
0.45
ER630
0.05
0.25 to
0.75
0.03
0.03
0.75
16.00 to
16.75
4.5 to
5.0
0.75
3.25 to
4.00
0.15 to
0.30
17-7PH
0.09
1.00
0.040
0.030
1.00
16.0 to
18.0
6.5 to
7.7
0.75 to
1.50
AMS 5824
0.09
1.00
0.025
0.025
0.50
16.00 to
17.25
6.50 to
7.75
0.75 to
1.25
17-4PH(630)
17-7PH(631)
Heat
Treatment
Condition
Tensile
Strength,
ksi (MPa)
Yield
Strength,
ksi (MPa)
Elongation
in 2 in.
%
Hardness,
Rockwell C
H900
H925
RH950
190 (1310)
170 (1170)
200 (1380)
170 (1170)
155 (1070)
180 (1240)
8
8
6
4048
3847
43 min
20
MARCH 2014
to 58 in. (8 to 16 mm) thicknesses. In thinner gauges, the tensile and yield strength
requirements do not change, but the elongation requirements do change.
Note that the tensile and yield strength
requirements of 17-4PH drop appreciably
with increase of the aging temperature
from 900 to 925F. ASTM A693 does not
address what happens to 17-4PH if it goes
through the entire RH950 processing that
would be used for 17-7PH, but it seems
likely that the 1750F austenite conditioning for the 17-7PH would return 174PH to Condition A (perhaps with not all
carbides dissolved). So RH950 would
somewhat overage 17-4PH and its
strength would be a little less than in the
H925 condition if the entire weldment
were run through the RH950 treatment
for 17-7PH. The austenite conditioning
treatment at 1750F will cause most of the
ferrite in the weld metal to transform to
austenite, so the weld metal responds to
the RH950 treatment much like the base
metal responds.
It may not be desirable or necessary to
take the entire weldment through the
RH950 treatment, but you can expect
lower strength. Harkins (Ref. 1) cites data
from General Electric that indicate typical mechanical properties of GTA weldments of 17-4PH to 17-7PH as 180 ksi
(1240 MPa) tensile strength, 165 ksi (1140
WELDING JOURNAL
21
RWMA
Q&A
Q: I am trying to weld a 0.031-in.-thick
steel ring to a 0.093-in.-thick steel oil filter thread ring Fig. 1. The ring is
about 3 in. in diameter and has six small
projections. This is being done in one hit
on a 250-kVA press welding machine. The
part is in a nest to align components. The
problem is that some of the projections
are good; some are low on strength
or have no fusion. We also noticed burn
marks on the flat part near the
projections.
A: Welding large parts with multiple projections can be a challenge. The last part
in your question regarding burn marks
near the weld zones gives me a clue as to
what is happening. I am betting that the
fixture holding the parts in line is actually preventing the two parts from completely coming together. This often happens when fixtures are used. It is important that the fixture does not restrict vertical movement of either part during the
entire weld sequence.
If the lower electrode area in line with
a projection has been eroded from welding on one spot, the welding current will
find a better path for conduction outside
the projection location and produce a
poor weld. Careful dressing of the electrodes should cure this problem. Also,
check to see which copper alloy is being
used for the lower electrode (against the
nonprojection side of the part). I usually
recommend the use of RWMA Class 11
tungsten-copper for this application since
it has the best balance of high surface
hardness and electrical conductivity.
Another thing to check is the absolute
parallel of the upper and lower electrodes when they are under full welding
force. Your 250-kVA press welding machine, if properly maintained, should
22
MARCH 2014
BY ROGER HIRSCH
A:
WELDING JOURNAL
23
The AWS Welding Handbooks are the must-have references for engineers, structural
designers, technologists, inspectors, welders, welding educators, and others who need to
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make sure youre on the cutting edge with new and updated material.
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Presents the latest developments in the basic
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chapters on the physics of welding and cutting;
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methods; residual stress; welding symbols;
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mechanized, automated, and robotic techniques;
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chapters, 2 appendices, 530 illustrations, 168
tables, hardbound. (2001).
WHB-1.9
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Additive Manufacturing
System Supports
Production of Metal Parts
26
MARCH 2014
high vibration, repetitive stress, and fatigue. Manufacturers in aerospace, automotive, home appliance, and consumer
electronics may find the material practical for end-use parts, like interior panels,
covers, environmental control ducting,
and vibration-resistant components, as
well as tools, manufacturing aids, and jigs
and fixtures used in the manufacturing
process. The nylon, offered in black, is
available for the Fortus 360, 400, and 900
systems.
Stratasys Ltd.
www.stratasys.com
(877) 489-9449
Equipment Brochure
Contains Helpful Tech Tips
The Welding and Cutting Equipment
Catalog presents an overview of flame
tools for professional welders and metal
Exact
www.exactonline.com
(855) 359-9256
WELDING JOURNAL
27
Manufacturing
Flux Cored
Welding Wire
Cobalt
Nickel
Hardface
Stainless
Alloy Steel
Tool Steel
Maintenance
Forge Alloys
Custom Alloys
Weiler Corp.
www.weilercorp.com
(800) 835-9999
Catalog Includes
Welding-Gear Booklet
The 2014 Equipment Catalog details
the companys GMAW, GTAW, and multiprocess equipment, plasma cutting systems, welding automation, fume control
systems, training products, orbital welding systems, accessories, and welding gear
products. The welding consumable section includes product numbers to enable
quick cross referencing or order placement. The catalog also features a boundin, removable copy of the companys
Welding Gear catalog, including Red
Line personal protection apparel,
VIKING autodarkening helmets, and
Radius tools. The catalog can be re-
COR-MET, INC.
12500 Grand River Rd.
Brighton, MI 48116
PH: 800-848-2719
FAX: 810-227-9266
www.cor-met.com
sales@cor-met.com
28
MARCH 2014
Classification Society
Releases Welding
Guidelines
Guidelines on the Welding of Duplex
Stainless Steels has been developed to help
shipyards safely and effectively make use
of new duplex steels that are being used
in the construction of cargo tanks for
chemical carriers. The guidelines, which
conform to ClassNK rules, provide a comprehensive summary of the requirements
for welding procedure specification certification and welding procedure qualification tests, including relevant precautionary measures for the welding of duplex
stainless steels. ClassNK has released the
guidelines for free via its website.
quested from the information below or
viewed on the Lincoln Library mobile
app on Apple iOS devices.
The Lincoln Electric Co.
www.lincolnelectric.com
(888) 355-3213
ClassNK
www.classnk.or.jp
+81-3-5226-2020
www.westchestergear.com
(800) 647-1900
WELDING JOURNAL
29
WORK
W
ORK
crease productivity, the feeder features
the option of a cold wire pendant, contains a dual-groove drive roll system, and
eliminates GTAW electrode stub loss. The
feed, dwell, delay start, and wire retract
times are set using the designated controls
on the face of the machine, and are continuously variable. It takes 12-in. wire
spools, and has a feed speed range of
0500 in./min. Acceptable wire sizes are
0.023, 0.030, 0.035, 0.045, and 116 in.
The Benchtop
English Wheel
offers a 20-in.
throat and 18-in.
internal height.
Useful for metal
fabrication of
auto panels and
general metal
shaping,
the
frame is fabricated like large
bridge spans,
with
doubler
plates, and structural hardware. Other
features include a large, 8-in. wheel and
5-in. radius anvil wheel that can be indexed in different positions, and an X- and
Y-axis adjustment on the large forming
wheel that allows set up of the wheel to
personal preference.
CK Worldwide
Eastwood Co.
www.ckworldwide.com
(800) 426-0877
www.eastwood.com
(610) 705-5404
SSMART
MART
RT
CAN WE TALK?
The Welding Journal staff encourages an exchange of ideas with you, our readers.
If youd like to ask a question, share an idea or voice an opinion, you can call, write,
e-mail, or fax. Staff e-mail addresses are listed below, along with a guide to help you interact with the right person.
Publisher
Andrew Cullison cullison@aws.org,
Extension 249, Article Submissions
Editor
Mary Ruth Johnsen mjohnsen@aws.org,
Extension 238, Feature Articles
Associate Editor
Howard Woodward woodward@aws.org,
Extension 244, Society News, Personnel
Associate Editor
Kristin Campbell kcampbell@aws.org,
Extension 257,
New Products, News of the Industry
Managing Editor
Zaida Chavez zaida@aws.org,
Extension 265, Design and Production
Senior Production Coordinator/Manager
Brenda Flores bflores@aws.org,
Extension 330, Design and Production
30
MARCH 2014
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FD-B4
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Arc Welding as an
Additive Manufacturing
Process
The ASTM F42 committee was
formed to develop industry standards for
32
MARCH 2014
submerged arc welding heads for a combined capacity of 660 lb/h (Ref. 5). The
mandrels supported the weld beads and
provided the general shape, but the mandrel and adjacent diluted weld metal had
to be machined away after the component was produced.
In the 1980s and 1990s, Babcock and
Wilcox Co. (B & W) of Ohio advanced
the shape melting process by incorporating additional arc welding processes, incorporating robotics into the positioning
systems, and developing nonconsumable
preform devices. B & W established a robotic shape melting cell that used gas
metal arc welding (GMAW) and offline
path programming. The robotic cell used
a vision sensor to detect the shape and
position of the previously deposited weld
bead, which was used to modify the torch
position to maintain proper interlayer relationships and correct component dimensions (Ref. 3). Several other organizations throughout the world, including
Cranfield University in the UK and Indian Institutes of Technology in India,
continue to work in this exciting field of
arc-based additive manufacturing.
While much focus is on powder bed
processes for fine detail in smaller parts,
especially in the aerospace and medical
markets, commercially available equipment is limited in terms of part build envelope and build rate (Refs. 6, 7). At this
point, powder bed and other additive
manufacturing processes are competing
within themselves, emerging additive
manufacturing processes, and the conventional tools for manufacturing
processes, which themselves are also
being advanced.
Fig. 1 A Ti 6-4 weld deposit made with GTAW-HW. (Photo courtesy of Lockheed
Martin.)
Additive manufacturing is increasingly being realized as a potential faster,
better, cheaper paradigm for disruptive
manufacturing and will find many places
competing in future advanced manufacturing technologies (Refs. 6, 7). Additive
manufacturing is not a solution for all applications, any more than any other technology, but competing with and even
combined with other technologies, shows
a strong economic as well as technical ad-
vantage for the correct application. Additive manufacturing provides more tools
in the toolkit to develop the appropriate
solution. Additive manufacturing technologies are rapidly moving from the
realm of prototypes to production parts.
The work to be done is dependent on the
criticality and quality requirements of
each market, in terms of process qualification, quality assurance, and nondestructive evaluation requirements.
Fig. 2 A Ti 6-4 near-net shape control arm produced using GTAW-HW. (Photo courtesy of Lockheed Martin.)
WELDING JOURNAL
33
Table 1 Measured Content of Select Interstitial Elements in the Weld Deposit, Along with Nominal and Maximum Permissible Content of these
Elements in Ti 6-4 ELI Castings and Forgings
Element
Hydrogen
Nitrogen
Oxygen
34
MARCH 2014
Actual Composition
(wt-%)
0.0013%
0.0078%
0.077%
Nominal
Composition for Ti 6-4
ELI Castings (Ref. 8)
(wt-%)
0.006
0.010
0.11
Maximum Permissible
Composition for Ti 6-4
ELI Forgings (Ref. 9)
(wt-%)
0.0125
0.03
0.13
Table 2 Tensile Test Data for the Sub-sized Specimens along with Typical Tensile Test Properties of Bars Machined from Ti 6-4 ELI Castings
ID
Specimen
Orientation
Baseline
N/A
1
2
Weld Direction
3
4
Condition
Tensile
Strength
(ksi)
Yield
Strength
(ksi)
120
110
13
22
As-welded
137.0
133.4
124.5
116.1
10.9
9.3
31.9
25.6
Weld Direction
Solution heat
treatment + anneal
115.2
116.8
105.8
106.1
14.5
13.7
26.5
28.6
5
6
Weld Direction
Anneal
135.6
135.3
123.0
122.0
12.9
9.4
18.9
20.0
7
8
Build Direction
As-welded
136.3
134.6
119.2
117.4
9.7
10.9
28.8
38.0
9
10
Build Direction
Solution heat
treatment + anneal
113.6
113.2
101.8
103.3
13.3
12.2
26.5
31.8
11
12
Build Direction
Anneal
132.6
135.6
116.9
124.7
8.1
11.0
20.0
21.1
Conclusions
The use of arc welding processes for
producing components using a layer-bylayer approach has been investigated
over the last half century. The justification of this approach is application dependent. Some factors that have contributed to the use of arc welding for producing parts in a layer-by-layer approach
include lead time or availability of the
base material, price of the base materi-
als, duration of the subtractive machining process, or the cost or size limitation
of established additive manufacturing
technologies. Several arc welding
processes have been evaluated along with
numerous alloy systems. Although several advancements have been made, an
arc welding process has yet to be incorporated in a commercially available additive manufacturing system.
Although more process development
and understanding is required, EWI has
determined that GTAW-HW is suitable
for producing Ti 6-4 ELI parts out of
chamber using a layer-by-layer approach.
The conceptualized additive manufacturing system will incorporate GTAW-HW,
a 6-axis robot, and automation software
for true additive manufacturing (CADto-part) capability. The advantages of
such a system over existing additive manufacturing systems include lower capital
cost, an unlimited build envelope, and
higher production rates.
The ubiquitous nature of arc welding
implies a strong supply chain capability
and competitive cost environment for the
future. Industries that could benefit from
an arc-welding-based additive manufacturing system include space, aerospace,
nuclear, oil and gas, shipbuilding, and
heavy fabrication.
Elongation
(%)
Reduction in
Area
(%)
References
1. Taminger, K. M., and Hafley, R. A.
2006. Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape
Manufacturing.
2. ASTM Standard F2792-12a, Standard Terminology for Additive Manufacturing Technologies.
3. McAninch, M. D., and Conrardy,
C. C. February 1991. Shape melting A
unique near-net shape manufacturing
process. Welding Review International.
4. Irving, R. R. November 23, 1981.
Shape welding: A new concept in fabrication. Iron Age.
5. Shape welding. May 1990. Compressed Air Magazine.
6. Harris, I. D. May 2012. Additive
manufacturing A transformational advanced manufacturing technology. Advanced Materials and Processes. ASM International, pp. 2529.
7. Herderick, E., Kapustka, N. , and
Harris, I. D. November 2011. Additive
Manufacturing for Metals, A State-of-theArt Review. EWI Report No. MR1105.
8. Donachie, M. J. Jr. 2007. Titanium
A Technical Guide, Second Edition.
ASM International.
9. ASTM B381 06a, Standard Specification for Titanium and Titanium Alloy
Forgings.
WELDING JOURNAL
35
BY DEANNA THORNTON
DEANNA THORNTON is
global safety director of
marketing, KimberlyClark
Professional, Roswell, Ga.
MARCH 2014
Fig. 1 The special safety concerns for welders in confined areas include avoiding the
weld fume and using special ventilation safety measures.
Fig. 2 Welders complained that visibility was poor with the early welding helmets,
resulting in improved designs with larger visors.
Discussing Compliance
Observing work practices can lead to
improvements in workplace safety enforcement, policies, and standards, and
draw workers attention to the hazards
present in the workplace. The findings
have helped not only welding professionals but also benefited safety product manufacturers.
As an example, OSHA Instruction, Directive Number CPL 03-00-017, describes
policies and procedures for implementing
a National Emphasis Program to identify
and reduce or eliminate the incidence of
adverse health effects associated with occupational exposure to isocyanates, a family of highly reactive chemicals that is
linked to serious health problems such as
work-related asthma.
This instruction helps employers,
workers, and safety managers evaluate
their use of PPE during operations involving isocyanates, utilize effective wipe sampling evaluation methods, and implement
proper housekeeping measures, including
cleaning frequency and methods assessment. For example, the PPE should be
wipe-sampled for contamination including the inside of respirators and gloves.
In response to this new instruction,
safety managers and welders serving the
automotive, aviation, and metal-manufacturing industries are discussing the various ways to address and mitigate the
impact of isocyanates in the workplace
in collaboration with safety product
manufacturers.
By asking this question, a welder can ensure he or she is taking all necessary precautions to identify and mitigate potentially harmful workplace exposures. For
example, welders can experience occupational exposure to manganese in certain
welding fumes. Exposure to manganese
may be harmful, especially while working
in confined spaces such as storage tanks,
pipelines, or airplane compartments. To
minimize exposure, air-purification and
welding-fume extraction systems can be
implemented. By discussing these possible solutions, there can be more effective
strategies developed to reduce the impact
or chance of exposure Fig. 1.
Inspiring Innovations
Due to an engaged workforce and expanded safety dialogue, major strides are
being made in PPE. One significant improvement has been to the design of helmets with autodarkening filter technolWELDING JOURNAL
37
ASSORTED PURGE
KITS AVAILABLE
PURGE MONITORS
(OXYGEN TO 1PPM)
38
MARCH 2014
Fig. 1 An example of a three-dimensional shape produced by additive manufacturing. (Photo courtesy of Sciaky,
Inc.)
40
MARCH 2014
Fig. 2 The progression of the electron beam direct manufacturing process. A CAD file; B part buildup; C near-net shape;
D finished part. (Photo courtesy of Sciaky, Inc.)
selected material from external impurities. After the structure reaches near-net
shape, it undergoes minor postproduction machining until it reaches its completed state. To date, the Sciaky process,
referred to commercially as electron
beam direct manufacturing (EBDM), is
the only additive manufacturing approach that has produced metal structures more than 10 feet long.
The progression of the EBDM
process is as follows: from CAD file, to
part buildup on a substrate plate, to nearnet shape, to finished part (after minor
postproduction machining) Fig. 2.
According to Sciaky, the EBDM
process with its VX-300 electron beam
welding chamber (Fig. 2) has a standard
build envelope of 19 4 4 ft (L W
H), which allows manufacturers to produce very large structures/parts, with virtually no waste. Deposition rates typically range from 7 to 20 lb per hour, depending upon part geometry and the material selected. A dual wire-feed system
can be utilized with the process (Fig. 3)
to increase deposition efficiency, as well
as to easily switch to different deposition
materials.
In summary, the benefits of EBDM,
when compared to traditional manufacturing and prototype processes, are sig-
WELDING JOURNAL
41
42
MARCH 2014
Over the past three years, technologydriven organizations like the U.S. Department of Defense (DoD), Lockheed
Martin Aeronautics, Penn State University, DARPA, and the Tank Automotive
Research, Development and Engineering Center (TARDEC), a United States
Army laboratory, have entered into research and development projects to explore the viability of the EBDM process.
At the end of 2011, Sciaky entered a
DoD Mentor-Prote g e Agreement with
the Aeronautics business area of global
security giant Lockheed Martin to advance Sciakys EBDM technology. The
DoD and the manufacturing industry
identified EBDM for repair and discrete
part production as a game changer,
Fig. 4 The large electron beam welding chamber on the VX300 allows the manufacturing of large parts. (Photo courtesy
of Sciaky, Inc.)
Fig. 5 The Optomec LENS 850R system has five axes of motion and a build envelope of approximately 3 5 3 ft.
Fig. 6 The directed laser deposition process developed by
RPM Innovations for building relatively large, complex shapes.
WELDING JOURNAL
43
Change of Address?
Moving?
Make sure delivery of your Welding
Journal is not interrupted. Contact
Maria Trujillo in the Membership
Department with your new address information (800) 443-9353, ext. 204;
mtrujillo@aws.org.
For info, go to www.aws.org/ad-index
44
MARCH 2014
he newly renovated Toronto Congress Centre will open its doors wide
10:00 AM March 1820 for visitors
to explore FABTECH Canada. Hosted by
the Society of Manufacturing Engineers
(SME), it is the only event of its kind in
the country. FABTECH Canada will display the latest technologies and trends in
welding, fabricating, metal forming,
stamping, coating, cutting, and finishing.
This year, the exposition has been significantly expanded in exhibition floor space,
conference offerings, and scope.
Janine Saperson, SME show manager,
said, The decision to expand the show
was based on the success of the 2012 premiere event, which was the first time the
world-renowned FABTECH brand
launched a show in Canada. Cohosting
the event with SME are other industry
leaders including Fabricators & Manufacturers Association, Intl (FMA); American Welding Society (AWS); Precision
Metalforming Association (PMA); and
46
MARCH 2014
BY HOWARD M. WOODWARD
HOWARD M. WOODWARD
(woodward@aws.org) is associate
editor for the Welding Journal.
tial elements of the continuous-improvement techniques used by the Toyota production system and other successful companies worldwide. Registration is $179.
FABTECH Canada
March 1820
Toronto Congress Centre
650 Dixon Rd.
Toronto, ON M9W 1J1, Canada
(888) 322-7333
www.fabtechcanada.com
t
.PEFMT
t1PSUBCMF
t
$'.
t7
t1OFVNBUJD
The ideal solution for
employee comfort and
productivity!
TBMFT!TDIBFGFSGBODPNttXXXTDIBFGFSGBODPN
WELDING JOURNAL
47
The future your future is on full display at FABTECH. From 1,400+ exhibits with end-to-end
solutions in metal forming, fabricating, welding and nishing, to the industrys leading education
and peer-to-peer networking, this is your opportunity to capitalize on the future.
The answers and know-how you need for the challenges of tomorrow can be found at FABTECH.
Visit fabtechexpo.com for complete event details. REGISTER TODAY!
I want to encourage you to submit nomination packages for those individuals whom you feel
have a history of accomplishments and contributions to our profession consistent with the standards
set by the existing Fellows. In particular, I would make a special request that you look to the most
senior members of your Section or District in considering members for nomination. In many cases,
the colleagues and peers of these individuals who are the most familiar with their contributions, and
who would normally nominate the candidate, are no longer with us. I want to be sure that we take
the extra effort required to make sure that those truly worthy are not overlooked because no obvious
individual was available to start the nomination process.
For specifics on the nomination requirements, please contact Wendy Sue Reeve at AWS
headquarters in Miami, or simply follow the instructions on the Fellow nomination form in this issue
of the Welding Journal. Please remember, we all benefit in the honoring of those who have made
major contributions to our chosen profession and livelihood. The deadline for submission is July 1,
2014. The Committee looks forward to receiving numerous Fellow nominations for 2015
consideration.
Sincerely,
Thomas M. Mustaleski
Chair, AWS Fellows Selection Committee
Fellow Description
DEFINITION AND HISTORY
The American Welding Society, in 1990, established the honor of Fellow of the Society to recognize members for
distinguished contributions to the field of welding science and technology, and for promoting and sustaining the professional
stature of the field. Election as a Fellow of the Society is based on the outstanding accomplishments and technical impact of the
individual. Such accomplishments will have advanced the science, technology and application of welding, as evidenced by:
Sustained service and performance in the advancement of welding science and technology
Professional recognition
RULES
1.
2.
3.
4.
5.
6.
7.
NUMBER OF FELLOWS
Maximum of 10 Fellows selected each year.
Description of significant technical advancements. This should be a brief summary of the candidates most
significant contributions to the advancement of welding science and technology.
Publications of books, papers, articles or other significant scholarly works that demonstrate the contributions cited
in (1). Where possible, papers and articles should be designated as to whether they were published in
peer-reviewed journals.
Inventions and patents.
Professional recognition including awards and honors from AWS and other professional societies.
Meaningful participation in technical committees. Indicate the number of years served on these committees and
any leadership roles (chair, vice-chair, subcommittee responsibilities, etc.).
Contributions to handbooks and standards.
Presentations made at technical conferences and section meetings.
Consultancy particularly as it impacts technology advancement.
Leadership at the technical society or corporate level, particularly as it impacts advancement of welding technology.
Participation on organizing committees for technical programming.
Advocacy support of the society and its technical advancement through institutional, political or other means.
Note: Application packages that do not support the candidate using the metrics listed above
will have a very low probability of success.
Supporting Letters
Letters of support from individuals knowledgeable of the candidate and his/her contributions are encouraged. These
letters should address the metrics listed above and provide personal insight into the contributions and stature of the
candidate. Letters of support that simply endorse the candidate will have little impact on the selection process.
Return completed Fellow nomination package to:
Wendy S. Reeve
American Welding Society
Senior Manager
Award Programs and Administrative Support
8669 Doral Blvd., #130
Miami, FL 33166
Telephone: 800-443-9353, extension 293
SUBMISSION DEADLINE: July 1, 2014
CLASS OF 2015
CONFERENCES
Workshop on Major Changes in OSHA
Labeling and Safety Data Sheets
for Welding Products
March 3, 4
Miami, Fla.
Strategies will be presented to help consumables manufacturers meet new Globally Harmonized System (GHS) standards for
product classification, labeling, and hazard communication.
Sponsored by the AWS Safety and Health Committee. For further information, contact P. Henry, phenry@aws.org, (800/305)
443-9353, ext. 215.
Pipelines Conference
March 4, 5
Houston, Tex.
Welding has always been an integral part of pipeline construction, going all the way back to the days when hand-held oxyacetylene torches were used to connect pipes together in the field.
Current pipeline welding trends and whats expected in future
pipeline welding trends will be discussed.
topics presented by AWS and the Resistance Welding Manufacturing Alliance (RWMA).
Aluminum Conference
May 28, 29
New Orleans, La.
The 17th Aluminum Welding Conference will feature a distinguished panel of aluminum-industry experts who will survey
the state of the art in aluminum welding technology and practice. This conference also provides several opportunities for you
to network informally with speakers and other participants, as
well as to visit an exhibition showcasing products and services
available to the aluminum welding industry.
The thermal effects from welding and heat treatment influence the microstructure and mechanical properties of welds. Various materials, such as carbon steels and other alloy grades, are
affected by heat treatment, which changes the weld metallurgy
and influences the final welded product. Better understanding
of the impact of welding and heat treatment practices can allow
for optimization of weld quality and reliability.
For more information, please contact the AWS Conferences and Seminars Business Unit at (800) 443-9353, ext. 223, or e-mail
ablanco@aws.org. You can also visit the Conference Department website at www.aws.org/conferences for upcoming conferences
and registration information.
54
MARCH 2014
,,,+*)(')(&%(&$#")$+'!* $&)$*)(')(&%(&$#")$+'!*
!( *)(#'& )&&()($ !!!*& +
++
+
++
COMING
EVENTS
Pipelines Conference. March 4, 5. Sheraton Houston Brookhollow, Houston, Tex. Sponsored by the American Welding Society.
Topics to include current and future pipeline welding trends. Contact P. Henry, phenry@aws.org; (800) 443-9353, ext. 215.
ABB Robotics Technology Days and Open House. March 13, 14.
1250 Brown Rd., Auburn Hills, Mich. Offering workshops, training, and demonstrations. To register, visit www.abb.com/robotics;
call (800) 435-7365.
2830. Atlanta, Ga. Sponsored by AWS and the Resistance Welding Manufacturing Alliance (RWMA), an AWS Standing Committee. Topics will include research results, projects, and industrial
experiences that describe significant advances in resistance welding technology. Visit www.aws.org/rwma, or contact P. Henry,
phenry@aws.org; (800/305) 443-9353, ext. 215.
Aluminium Brazil 2014. April 13. Centro de Exposies Imigrantes, So Paulo, Brazil. www.aluminium-brazil.com.
AKL 14, Intl Laser Technology Congress and Expo. May 79.
Aachen, Germany. Visit www.lasercongress.org/en/home/.
Metal & Steel Saudi Arabia 2014. April 710. Riyadh, Saudi Arabia. Visit www.metalsteelsaudi.com.
FABTECH India colocated with Weld India. April 1012. Pragati 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.
NDE Aerospace Materials and Structures IV. May 13, 14. Crowne
Plaza Hotel, St. Louis, Mo. American Society for Nondestructive
Testing, (800) 222-2768, www.asnt.org.
Metal & Steel Middle East 2014. May 1517. Cairo, Egypt. Visit
www.metalsteeleg.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.
U.S-Japan NDT Symposium. June 1620. Makena Beach and
Golf Resort, Maui, Hawaii. American Society for Nondestructive
Testing, (800) 222-2768, www.asnt.org.
56
MARCH 2014
Hotel, Dallas, Tex. Sponsored by AWS. Attendees will get a better understanding of the impact of welding and heat treatment
practices to optimize weld quality and reliability. Contact P.
Henry, phenry@aws.org; (800) 443-9353, ext. 215.
nology (SMT) 2014. Aug. 2527. Grand Hyatt Washington, Washington, D.C. American Society for Nondestructive Testing, (800)
222-2768, www.asnt.org.
Educational Opportunities
WELDING JOURNAL
57
58
MARCH 2014
CERTIFICATION
SCHEDULE
Certified Welding Inspector (CWI)
LOCATION
SEMINAR DATES
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
Edmonton, Canada
Exam only
Annapolis, MD
Apr. 27May 2
Detroit, MI
Apr. 27May 2
Corpus Christi, TX
Apr. 27May 2
Knoxville, TN
Exam only
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
Hartford, CT
June 2227
Orlando, FL
June 2227
Memphis, TN
June 2227
Miami, FL
Exam only
Los Angeles, CA
July 1318
Jacksonville, FL
July 1318
Omaha, NE
July 1318
Cleveland, OH
July 1318
Phoenix, AZ
July 2025
Louisville, KY
July 2025
Kansas City, MO
July 2025
Waco, TX
July 2025
Sacramento, CA
July 27Aug. 1
Denver, CO
July 27Aug. 1
Miami, FL
July 27Aug. 1
Milwaukee, WI
July 27Aug. 1
Corpus Christi, TX
Exam only
Chicago, IL
Aug. 38
Baton Rouge, LA
Aug. 38
Portland, ME
Aug. 38
Las Vegas, NV
Aug. 38
Philadelphia, PA
Aug. 38
Charlotte, NC
Aug. 1015
Mobile, AL
Aug. 1015
Rochester, NY
Exam only
Seattle, WA
Aug. 1015
San Diego, CA
Aug. 1722
Minneapolis, MN
Aug. 1722
San Antonio, TX
Aug. 1722
Salt Lake City, UT
Aug. 1722
EXAM DATE
Apr. 12
Apr. 12
Apr. 12
Apr. 12
Apr. 17
Apr. 19
Apr. 28
May 3
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
June 28
June 28
June 28
July 10
July 19
July 19
July 19
July 19
July 26
July 26
July 26
July 26
Aug. 2
Aug. 2
Aug. 2
Aug. 2
Aug. 2
Aug. 9
Aug. 9
Aug. 9
Aug. 9
Aug. 9
Aug. 16
Aug. 16
Aug. 16
Aug. 16
Aug. 23
Aug. 23
Aug. 23
Aug. 23
EXAM DATE
Apr. 5
July 19
SEMINAR DATES
Mar. 914
Mar. 2328
Apr. 27May 2
Apr. 27May 2
May 49
June 16
July 1318
July 27Aug. 1
IMPORTANT: This schedule is subject to change without notice. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications received after that time will be assessed a $250 Fast Track fee. Please verify application deadline
dates by visiting our Web site www.aws.org/certification/docs/schedules.html. Verify your event dates with the Certification Dept. to
confirm your course status before making travel plans. For information on AWS seminars and certification programs, or to register
online, visit www.aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.
60
MARCH 2014
WARNING
OSHA rules for welding consumables
labeling, classification, and
Safety Data Sheets have changed!
URGENT NEWS: The U.S. has adopted the United Nations
Globally Harmonized System of Classification and Labeling of Chemicals (GHS).
SOCIETYNEWS
BY HOWARD WOODWARD
woodward@aws.org
Justin Wilmoth (left photo) welds the finishing touches on the stainless steel time capsule. Right photo: The Welding Technology staff members are (from left) Terry Mayes, Steven Gore, Student Chapter Advisor Ray Sosko, John McPherson, and Greg Bellamy. Photos by Ray Sosko.
On December 13, 2013, Central Piedmont Community College (CPCC), Charlotte, N.C., celebrated its 50th anniversary with an open house to showcase a new
classroom building and inter a hermetically sealed stainless steel time capsule
designed by Steven Gore, program chair,
welding technology. The capsule project
was headed by AWS Student Chapter
members headed by Advisor Ray Sosko
and Welding Technology department students and staff including instructors Terry
Mayes, John McPherson, and Greg Bellamy; and Dr. Anver Classens, division director, Applied Technologies.
The welding work was performed by
Terry Mayess advanced students, including Adam Calton, Brandon Adams, Bryan
Durrette, Clarence Fowler, Conor
Pohlman, Derek Waldo, George Price,
James Brooks, Justin Wilmoth, and Scott
Willard. The time capsule was constructed from an 18-in.-long section of 12in.-diameter Schedule 10, Type 304 stainless steel, with a 12-in.-diameter end cap
of the same metal that was circumferentially welded using automatic gas tungsten
arc welding (A-GTAW) with ER 308L
filler metal. The other end consisted of a
standard Type 304 12-in.-diameter slip-on
flange that was welded by Justin Wilmoth
using manual GTAW and ER 308L filler
metal (see photo).
The CPCC 50th anniversary logo was
63
Tech Topics
Teambuilding behind the Scenes to Better Expedite AWS Standards
Shown with their inspirational Teamwork display are (from left) Willie Chinn, Yojaidy
Acosta, Sara Vidal, Alex Diaz, Vivian Perez, and Sissibeth Lopez.
Erratum
AWS D9.1M/D9.1:2012
Sheet Metal Welding Code
Page 61 Title Correct Guidelines for the Preparation of Technical Inquiries for Structural Welding Committee to read Guidelines for the Preparation of Technical Inquiries
Standard for Public Review
AWS was approved as an accredited
standards-preparing organization by the
American National Standards Institute in
1979. AWS rules require that all standards
be open to public review for comment during the approval process. The following
standard has been submitted for review.
D16.4M/D16.4:201X, Specification for
the Qualification of Robotic Arc Welding Personnel. Public review expires 3/4/14. Contact C. Lewis, ext. 215, for a draft copy.
New Standards Projects
Development work has begun to revise
the following standard. Affected individuals are invited to contribute to this work.
B1.10M/B1.10:201X, Guide for the Nondestructive Examination of Welds. This
guide addresses which examination
method visual, liquid penetrant, magnetic particle, radiographic, ultrasonic,
electromagnetic (eddy current), or leak
testing best detects various types of discontinuities. Acceptance criteria are not
addressed. Stakeholders: Welding industry. Contact E. Abrams, ext. 307.
64
MARCH 2014
Alex Diaz, associate director of operations, Technical Services Div., asked his team
members to analyze their strengths as well as
the strengths of their colleagues, then report
on how these strengths collectively define the
team. The key strengths reported were Motivation, Success, Creativity, Communication, Willingness, Collaboration, Skillful, and
Assertiveness. Graphic Artist Willie Chinn,
Marketing Div., then arranged these keywords to design an image highlighting a letter in each to spell the word TEAMWORK in
the brilliant colors of the codes, specifications, guides, and recommended practices
AWS publishes. The background images of
gears and AWS documents serve as an analogy, that like gears in a reliable timepiece,
the support arm of the Technical Services Div.
is always working in the background to facilitate production of its myriad publications.
Diazs team members include Standards Coordinator Yojaidy Acosta and Senior Standards Coordinators Sissibeth Lopez, Vivian
Perez, and Sara Vidal.
The U.S./European Welding Standards Conference participants are shown January 28 at AWS World Headquarters in Miami, Fla.
BY DENNIS HARWIG
The American Welding Society hosted
the U.S. and European Welding Standards Conference, which was jointly organized with the help of Gesellschaft fr
Schweitechnik Intl (GSI) Jan. 27, 28, at
its World Headquarters in Miami, Fla.
Seventy-seven welding industrialists from
around the world gathered for the event.
With increased globalization and complexity of supply chains, more and more
companies in Europe and in North
America have realized the need to be
knowledgeable about the many national
and international fabrication codes and
standards.
AWS partnered with GSI to prepare
the program for the event. Gesellschaft
fr Schweitechnik Intl is an innovative
service provider in all areas of joining, cutting, and thermal spraying. Founded in
1999 by The German Welding Society
(DVS), GSI is the result of a merger of
several German research institutes.
This conference bought together experts from both AWS and European standards-writing committees for the second
time. The 2012 meeting was held in Munich, Germany. This conference offered
a unique opportunity to present a number of U.S. and European welding standards on numerous topics to be compared
and discussed. Expert Panels were formed
to provide solutions and strategies to resolve the standards-conflict issues experienced by American fabricators.
The conference attendees also learned
about ISO 3834, Quality requirements for
fusion welding of metallic materials
Parts 1 through 5, a quality system for
welding fabricators. GSI provided statistical data indicating more than 5000 European companies have already completed this certification.
Both AWS and GSI are certifying bodies under the International Institute of
Welding (IIW) for United States markets.
ISO 3834 can be used independently or in
conjunction with ISO 9000 quality systems
to address the special process control requirements associated with fusion welding and allied processes. ISO 3834 provides a range of quality levels to accommodate the complexity and risk for structures from basic-to-high integrity, with a
heavy focus on the role of welding coordination. Under ISO 3834, fabricators can
map their countrys and/or companys
standards to other ISO and global standards, and use this quality system platform
to foster trade.
This conference benefited engineers,
inspectors, supervisors, and quality control personnel who are familiar with one
set of standards but needed to know more
about the other standards. The industrial
segment sessions were used to cover weld-
DENNIS HARWIG (dharwig@aws.org), an AWS Fellow, is chief technology officer for the American Welding Society, Miami, Fla.
WELDING JOURNAL
65
U.S. Experts Sought to Develop ISO Standard on Micro Melting Diffusion Bonding
The U.S. TAG (Technical Advisory
Group) that serves as the United States
National Committee to ISO/TC 44/SC 10,
Unification of Requirements in the Field
of Metal Welding, seeks United States ex-
Member-Get-A-Member Campaign
End of Campaign Final Tally
Michael A. Pelegrino, Chicago Section, is the campaign winner with 216 points earned.
Listed below are the members who participated in the 2013 AWS Member-Get-A-Member Campaign. The campaign ran from June 1 through Dec. 31, 2013. Members received
five points for each Individual Member recruited and one point for every Student Member recruited. See page 69 of this issue for campaign information and the prize list, or call
Rhenda Kenny, Membership Dept., (800/305) 443-9353, ext. 260, for information.
M. Pelegrino, Chicago 216
J. Compton, San Fernando Valley 120
J. Morris, Mobile 75
M. Anderson, Indiana 57
D. Ebenhoe, Kern 50
G. Fudala, Philadelphia 45
M. Box, Mobile 42
B. Scherer, Cincinnati 40
J. Russell, Fox Valley 36
K. Rawlins, Columbia 31
S. Lindsey, San Diego 31
R. Richwine, Indiana 30
S. Siviski, Maine 29
D. Schnalzer, Lehigh Valley 27
B. Trankler, W. Tennessee 27
J. Foley, Pittsburgh 25
D. Wheeler, Oklahoma City 25
G. Gammill, NE Mississippi 24
R. Hammond, Greater Huntsville 24
D. Saunders, Lakeshore 22
J. Ciaramitaro, N. Central Florida 21
F. Babish, Lehigh Valley 20
66
MARCH 2014
C. Daon, Israel 20
R. Jones, Atlanta 20
D. Crifase, Racine-Kenosha 20
M. Kress, Chattanooga 19
J. Theberge, Boston 19
J. Vincent, Kansas City 18
C. Donnell, NW Ohio 17
D. Bastian, Northwestern Pa. 16
G. Burrion, S. Florida 16
P. Kreitman, Chicago 15
S. Lathrop, Puget Sound 15
F. Oravets, Pittsburgh 15
R. Riggs, Tulsa 15
S. Schulte, Kansas City 15
J. Terry, Greater Huntsville 15
A. Duron, New Orleans 14
H. Hughes, Mahoning Valley 13
J. Goodson, New Orleans 12
S. Robeson, Cumberland Valley 12
J. Carney, W. Michigan 11
R. Poirier, Tidewater 11
T. Shirk, Tidewater 11
SECTIONNEWS
Shown at the Long Island Section meeting are (from left) Jack Billig, speaker Jennifer Trumino, Deborah McInnis, Chair Brian Cassidy,
Dist. 2 Director Harland Thompson, Ray OLeary, and Tom Gartland.
Shown at the New Jersey Section program are from left (back row) Seann Bradley, Larry
Abernethy, George Sheehan, (front row) Robert Petrone, Vince Murray, Jim Dolan, and
Harland Thompson, Dist. 2 director.
District 1
District 2
BOSTON
LONG ISLAND
NOVEMBER 11
Activity: Section members met at Baker
Testing in Rockland, Mass., where Tom
Ferri, Dist. 1 director, presented William
Elliott the District Certified Welding Inspector of the Year Award.
JANUARY 8
Speaker: Jennifer Trumino, sales manager
Affiliation: Mercer Abrasives
Activity: Ray OLeary received the District
Meritorious Award from Harland Thompson, Dist. 2 director.
NEW JERSEY
JANUARY 15
Speaker: Jeff Wiswesser, director, industrial services; and Michael Warner
Affiliation: Welder Testing and Training
Institute
Topic: Proper use of welding symbols
Activity: Harland Thompson, Dist. 2 director, presented Life Member certificates
to Larry Abernethy and George Sheehan.
Other awardees included Robert Petrone
(District Director), Jim Dolan (District
Meritorious), George Sheehan (District
Educator), and Seann Bradley (Speaker
of the Year).
WELDING JOURNAL
67
PHILADELPHIA
DECEMBER 7
Activity: The Section held a holiday meeting for board members at Riverwinds
Restaurant in West Deptford, N.J. The
event was hosted by Harland Thompson,
Dist. 2 director.
JANUARY 8
Speaker: Jay L.Ginder, senior application
engineer
Affiliation: ESAB Welding & Cutting
Products
Topic: New trends in flux cored wires
District 3
District 6
District 4
District 7
Central Piedmont C. C.
Student Chapter
DAYTON
DECEMBER 13
Activity: The college welding department
faculty and Student Chapter members,
headed by Advisor Ray Sosko, manufactured a time capsule to commemorate
Central Piedmont Community Colleges
50th anniversary in Charlotte, N.C. The
complete story appears on the first page
of Society News (see page 63).
Harland Thompson (far right), Dist. 2 director, is shown with wife Eileen and Ken
Temme, Philadelphia Section secretary.
MARCH 2014
TIDEWATER
JANUARY 9
Speakers: Stephen Williams, metallurgist,
Newport News Shipbuilding; and George
Suiter, master gunsmith, Colonial
Williamsburg
Topic: The successful casting of a colonialstyle cannon for Colonial Williamsburg
Activity: The program was held at Smoke
BBQ Restaurant in Newport News, Va.
District 5
Carl Matricardi, director
(770) 979-6344
cmatricardi@aol.com
OCTOBER 8
Speaker: Vern Mangold, consultant
Topic: Certification of robotic arc welding
personnel
Activity: The program was held at OTC
Daihen in Tipp City, Ohio.
NOVEMBER 12
Activity: The Dayton Section members
met at Miami County Fairgrounds in Troy,
Ohio. Gary Ward and Steve Roth from
Southern Ohio Forge and Anvil presented
demonstrations of various blacksmithing
techniques and offered attendees a chance
to try their hand at the art.
DECEMBER 10
Speaker: Uwe Aschemeier, Dist. 7 director
Affiliation: Miami Diver, welding engineer
Topic: Underwater welding
Activity: This Dayton Section program was
held at Giuliano Tavern in Miamisburg,
Ohio, for 17 attendees.
PITTSBURGH
JANUARY 14
Speaker: Steve Forde, vice president
Affiliation: Marcellus Shale Coalition
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Shown at the NE Tennessee Section tour are (from left) Jonaaron Jones, Scott Mulleur, Mark Cade, Evan Eschenberg, John Folk, Briza
Wolfe, Byington Solway Technology Center Instructor Chris Ottinger, Lucia Roussa, Patrick Ford, Thomas Bowling, Chance Littleford,
Erica Heckman, South Doyle Instructor Jim Thomas, Kristen Lloyd, Keith Daniels, Mike DiTrapani, Oak Ridge High School Instructor Jeff
Hankins, Paul Pipkin, Barry Slaven, and Tyler Wyatt.
Pittsburgh Section past chairs shown at the January program are John Folley (front) and
(from left) John Menhart, Dick LaFave, Ed Yevick, Tom White, Roger Hilty, Dave Daugherty, Tom Geisler, Carl Ott, and Bob Jackson.
District 8
NORTHEAST TENNESSEE
DECEMBER 12
Activity: The Section members attended
the open house held at Oak Ridge High
School in Oak Ridge, Tenn. Instructor Jeff
Hankins hosted the program that included
his students showcasing their welding skills
and use of a CNC plasma cutting system.
Erica Heckman presented her welded
gold-medal-winning metal sculpture. The
dinner was held at Ruby Tuesday in Oak
Ridge.
District 9
NEW ORLEANS
NOVEMBER 9
Activity: The Section hosted its 15th annual student welder competition hosted by
Randy Rovira with the New Orleans Pipe
71
Some of the participants are shown at the New Orleans Section student welder competition.
The student welders and Drake Well Section judges are shown at the Northwest SkillsUSA District welding competition.
District 10
CLEVELAND
DECEMBER 11
Activity: The Section hosted its annual
holiday party featuring an auction to benefit its scholarship fund. More than 100
attendees supported the live and silent
auctions to raise $11,000. Heading the
auction committee were Marilyn Harmon, Regis Holland, and Mike Sherman
who drew out the high bids as auctioneer. The event was held at Toscana Party
Center in Cuyahoga Heights, Ohio.
DRAKE WELL
JANUARY 9
72
MARCH 2014
Travis Crate (right) received the Section Educator and CWI of the Year Awards from
Mike Owens, Drake Well Section chair.
Activity: Chair Mike Owens presented
Travis Crate the Section Educator and
the Section CWI of the Year Awards. Rolf
Laemmer received the Section Meritorious Award. Ward Kiser, who was not
present, was named to receive the Dis-
17
Activity: The Drake Well Section members participated in the Northwest SkillsUSA District welding competition held at
the New Castle School of Trades in New
Castle, Pa.
JANUARY
MAHONING VALLEY
JANUARY 16
Speaker: Matthew Brady, regional engineer
Affiliation: American Institute of Steel
Construction
Topic: The new QC/QA specifications for
building with structural steel
Activity: Bob Brenner, Dist. 10 director,
presided at this awards-presentation program held at Columbiana County Career
& Technical Center (CCCTC) in Lisbon,
Ohio. Huck Hughes, advisor to the
CCCTC Student Chapter, received the
District and Section Educator Awards.
Awards were presented to Jeff Andrews
and William Cunningham (CWI of the
Year), Denny Naples and Donald Jessop
(Section Educator), and Mike Sampson
(Section Meritorious). Tom Kostreba,
chair, Northwestern Pa. Section, attended
the program.
JANUARY 21
Activity: Donald Jessop, a welding instructor at Plumbers & Pipefitters Local #396
Apprenticeship Program, received the Mahoning Valley Educator Award from
Kenny Jones, Section treasurer.
Shown at the Detroit Section program are (from left) Jeff Grivas, Ron Brown, Bill Forquer,
Wesley Doneth, and Sean Gleeson.
NORTHWESTERN PA.
DECEMBER 15
Activity: The Section hosted its annual
holiday party and awards-presentation
program at Barbatos Italian Restaurant
in Erie, Pa. Chair Tom Kostreba hosted
the program. The awardees included
Mark Brereton, District CWI of the Year;
Marty Siddall, Section Meritorious; Don
Adams, Section Educator, Jesse McIntosh, Section Educator; John Stempka,
Section CWI of the Year; and Vice Chair
Donna Bastian, District Private Sector
Educator.
NORTHWEST OHIO
MARK YOUR CALENDAR
District 11
Robert P. Wilcox, director
(734) 721-8272
rwilcox1@ford.com
DETROIT
JANUARY 16
Activity: Ron Brown, business development manager, hosted the program at EWI
in Madison Heights, Mich. Jeff Grivas with
Easom Automation, Sean Gleeson with
EWI, and Bill Forquer with Real Weld Sys-
APRIL 3, 6:009:00 PM
18th Annual Lincoln Electric
Motorsports Welding Program
Owens Community College
Perrysburg (Toledo), Ohio.
The public is invited. A Lincoln Electric speaker will discuss the materials and
welding processes that are used to fabricate competition vehicles. About 25 competition vehicles will be on display. A
VRTEX 360 virtual arc welding trainer
will be set up for guests to try their hand
at welding.
WELDING JOURNAL
73
Milwaukee Section past chairs are (from left) Robert Bruss, Roger Edge, David Biddle, Gail Beyer II, Robert Schuster, Craig Wentzel, Ken
Karwowski, and John Albanese.
Shown at FABTECH are (from left) Chicago Section Chair Eric Krauss, Linda Brissey, Pete Host, Robert Zimny, incoming Director-atLarge Rick Polanin, Dist. 13 Director John Willard, and Cliff Iftimie.
Shown at the Louisville Section awards-presentation dinner are (from left) Ben Coons, John Emmons, Tom Gillespie, Paul Twigg, Jim
Gillespie, Chair Bud Merill, Irvin Ziegler Jr., and Dan Hayes Sr.
MARCH 2014
Louisville Section members pose for a group shot during their Churchill Downs event.
District 12
LAKESHORE
JANUARY 9
Activity: The Section toured the Broadwind Towers & Heavy Industries facility in
Manitowoc, Wis., to study the manufacture of wind and drilling towers used in the
power-generation and shale oil industries.
Scott Wallermann, a Certified Welding Inspector, conducted the program. The dinner and business meeting were held at
Knoxs Silver Valley Supper Club.
MILWAUKEE
DECEMBER 19
Activity: The Section hosted its annual holiday party and past chairmens night at
Sprecher Brewery in Milwaukee, Wis. The
event included a tour of the brewery. Past
chairs in attendance included Robert
Bruss, Roger Edge, David Biddle, Gail
Beyer II, Robert Schuster, Craig Wentzel,
Ken Karwowski, and John Albanese.
District 13
John Willard, director
(815) 954-4838
kustom_bilt@msn.com
CHICAGO
NOVEMBER 19
Activity: The Section members participated in the FABTECH activities in
Chicago, Ill. Robert Zimny received his
Gold Member certificate for 50 years of
AWS membership and Linda Brissey received her Life Member certificate for 35
years of service to the Society from Nancy
Cole, AWS president.
District 14
LOUISVILLE
NOVEMBER 30
Activity: The Section sponsored race No.
5 at Churchill Downs in Louisville, Ky., to
boost awareness of the Section and the
American Welding Society. The race was
won by Jockey Joe Rocco Jr. riding Homesick Angel #12.
DECEMBER 17
Activity: The Louisville Section held its
awards-presentation dinner at Louisville
Yacht Club in Louisville, Ky. Jim Gillespie
received his Life Member certificate for
35 years of service to the Society, and John
Emmons and Paul Twigg received Silver
Member certificates for 25 years of service.
District 15
David Lynnes, director
(701) 365-0606
dave@learntoweld.com
District 16
Dennis Wright, director
(913) 782-0635
awscwi1@att.net
KANSAS
NOVEMBER 14
Speaker: David Landon, AWS vice president and manager of welding engineering
Affiliation: Vermeer Mfg. Co.
WELDING JOURNAL
75
JANUARY 18
Activity: The Kansas Section hosted its 5th
annual bowling tournament.
NEBRASKA
DECEMBER
Activity: The Section members presented
a week-long Certified Welding Inspector
training seminar and exam at Valmont Industries in Valley, Neb., for 30 participants.
District 17
Ozark Section member Brent Russell (right) is shown with J. Jones, Dist. 17 director, at Tin
Man Sheet Metal Workers Local 36.
DISTRICT 17
SEPTEMBER
Activity: J. Jones, Dist. 17 director, presented Caterpillar Work Tools, Inc., in
Waco, Tex., the District Director Certificate Award for its continued support of
the Society and using AWS codes and standards. Receiving the award were Facility
Manager Jon Stalnaker, CWI Jason Magnett, Bryan Neely, and Matt Lakata.
OZARK
DECEMBER
Activity: J. Jones, Dist. 17 director, presented Kenny McCoy the 20112012 District Director Certificate Award, and the
20112012 District and Section Private
Sector Instructor Awards to Brent Russell.
Shown at the Tulsa Section program are (from left) Chair Paul Wittenbach, speaker Ed
Overshiner, and Rich Howard, vice chair.
Topic: Implementing virtual reality welding for training and preemployment
screening
Activity: Following the talk, Jamie Kappler (Lincoln Electric) demonstrated the
VRTEX360 virtual arc welding training
76
MARCH 2014
TULSA
NOVEMBER 19
Speaker: Ed Overshiner, industrial products specialist
Affiliation: Miller Electric Mfg. Co.
Topic: Submerged arc welding
Activity: The program was held at Golden
Coral in Tulsa, Okla.
District 18
EL PASO
DECEMBER 19
Activity: The Section hosted its holiday
event and awards-presentation dinner at
Great American Land & Cattle Restaurant in Anthony, Tex. John Bray, Dist. 18
director, and Chair Jose (Pep) Gomez
presided. The awardees included Vince
Martinez (Section Meritorious), David
Twitty and Dino Robles (Section Educator), Chair Jose Gomez (Section CWI of
the Year), and Marco Costa (Student
Chapter). Dona Ana Community College
received the District Director Award for
its support of the Section.
El Paso Section members are shown at their holiday dinner December 19.
HOUSTON
JANUARY 15
Speaker: Hon. Edward M. Emmett
Affiliation: Harris County judge
Topic: The countys industrial growth
Activity: The Section hosted its past chairmens night event at Bradys Landing in
Houston, Tex., for 165 attendees. Honored
were its long-time AWS members including Roy Morton (56 years), Gold Members
Dick Wright and Larry Wilmesmeier (50),
Jim Bolton (49), John Stoll (39), Jon Lee
(35), Ron Theiss (34), Asif Latiff (28),
Robert Hunt (27), AWS Vice President
John Bray (25), Dennis Eck (24), Jerry
Koza (22), John Husfeld (13), and Justin
Gordy (11).
District 19
PUGET SOUND
JANUARY 9
Speaker: Barbara K. Henon
Affiliation: Magnatech LLC
Topic: Orbital welding in the biopharmaceutical industry
Activity: The program was held at Bellevue Coast Hotel in Bellevue, Wash.
SPOKANE
JANUARY 15
Speakers: Bill Tatt, Todd Kelsey
Affiliation: Bohler Welding Group USA
Topic: Cast iron welding and repair
Activity: The lecture and demonstrations
were held in the computerized classroom
and welding shop at Spokane Community
College. Following the talks, the members
had a chance to try their skills welding cast
iron and making other repairs.
District 20
DECEMBER 13
Activity: Several CSMSC members met at
the college in Golden, Colo., to congratulate Sindhu Thomas on her graduation
with a master of science degree. Attending were Advisor Prof. Stephen Liu, Steve
Klimowicz, Zhifen Wang, Ali AlShawaf,
Stephen Tate, Devon Gonzales, and Erik
Pfeif.
Bill Tatt (left) demonstrates cast iron welding at the Spokane Section program.
WELDING JOURNAL
77
Shown at the January CSMSC event are (from left) Zhifen Wang, Ali AlShawaf, Dr. Zhenzhen Yu, Cheryl Hawk, Nathan Switzner,
Advisor Prof. Stephen Liu, Erik Pfeif, Devon Gonzales, Stephen Tate, and Pedro Andrade.
Presenters at the FCC Lompoc job fair are (from left) Matthew Brown, Robbie Rhodes, Matthew Hoskins, Michael Lopez, Christopher Gandee, Dist. 21 Director Nanette Samanich, Warden Richard Ives, California Central Coast Section Chair Stan Luis, and
Rayvon Snowden.
CALIFORNIA CENTRAL
COAST
Shown (from left) are CSMSC members Steve Klimowicz, Zhifen Wang, Ali AlShawaf, Advisor Prof. Stephen Liu, Sindhu Thomas, Stephen Tate, Devon Gonzales, and Erik Pfeif.
JANUARY 16
Activity: The Colorado School of Mines
(CSM) Student Chapter members and Advisor Stephen Liu held a special meeting
to welcome Dr. Zhenzhen Yu who joined
the CSM faculty in January.
DECEMBER 9
Activity: At the invitation of Warden
Richard Ives, Chair Stan Luis and Dist.
21 Director Nanette Samanich joined
labor union and industrial leaders and employers to present a job fair for 90 inmates
preparing for release from the Federal
Correctional Complex in Lompoc, Calif.
(FCC Lompoc). The talks focused on job
and educational opportunities, apprenticeship programs, and scholarships in the
fields of welding, pipe fitting, and plumbing. Christopher Gandee from Lincoln
Electric demonstrated the VRTEX 360
virtual reality arc welding training system,
then offered each attendee the opportunity to try their skills using the technology.
District 22
Kerry E. Shatell, director
(925) 866-5434
kesi@pge.com
SACRAMENTO VALLEY
MARCH 2014
District 21
DECEMBER 15
Activity: The Section held its holiday party
at Cattlemens Steakhouse in the Sacramento, Calif., area. Dan Finnigan, with
Victor Technologies, received his Silver
Certificate for 25 years of membership in
the Society from Chair Ken Morris.
SUPPORTING
Equipment & Controls, Inc.
210 Riverfront Dr.
Monessen, PA 15062
Louis Smith Construction, Inc.
18500 Hwy. 53
Gulfport, MS 39503
AFFILIATE
Ameri-Force Management Services
9485 Regency Sq. Blvd., Ste. 300
Jacksonville, FL 32233
EDUCATIONAL INSTITUTIONS
Arkansas Welding Academy
1920 N. Redmond Rd.
Jacksonville, AR 72076
Erickson Engineering
9330 James Ave. S.
Bloomington, MN 55431
Fortis College
11499 Chester Rd., Ste. # 200
Cincinnati, OH 45150
Metalcraft Services
of Tampa, Inc.
10706 N. 46th St.
Tampa, FL 33617
Waxahachie ISD
1001 Hwy. 77 N.
Waxahachie, TX 75165
Welder Skill
Carrera 8 No. 15-44
Soacha, Bogota, Colombia
WorldSpec NDT Training
Div. of Hellier NDT
16631 W. Hardy R.
Houston, TX 77060
tions 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.
WELDING JOURNAL
79
INTERNATIONAL SALES
TECHNICAL SERVICES
Dean R. Wilson
deanwilsonaws@gmail.com
Welldean Enterprises
151 Oak Tree Circle
Glendora, CA 91741
PUBLICATION SERVICES
Director, Operations
Annette Alonso.. aalonso@aws.org . . . . . . .(299)
Technical Activities Committee
ADMINISTRATION
Executive Director
Ray W. Shook.. rshook@aws.org . . . . . . . . . .(210)
Sr. Associate Executive Director
Cassie R. Burrell.. cburrell@aws.org . . . . . .(253)
Welding Journal
Publisher
Andrew Cullison.. cullison@aws.org . . . . . .(249)
Editor
Mary Ruth Johnsen.. mjohnsen@aws.org . .(238)
Administrative Services
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
Lorena Cora.. lcora@aws.org . . . . . . . . . . . .(417)
MEMBER SERVICES
GOVERNMENT LIAISON SERVICES
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.
WEMCO Association of
Welding Manufacturers
Management Specialist
Keila DeMoraes....kdemoraes@aws.org . . . .(444)
80
MARCH 2014
Director
Rhenda A. Kenny... rhenda@aws.org . . . . . .(260)
Serves as a liaison between members and AWS headquarters.
CERTIFICATION SERVICES
Dept. information . . . . . . . . . . . . . . . . . . . . . . .(273)
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
Director, Operations
Martica Ventura.. mventura@aws.org . . . . . .(224)
PERSONNEL
Bunting Magnetics Hires
Territory Managers
Little executive vice president of the companys Safety and Graphics business. Previously, Little served as vice president and
general manager, Personal Safety division.
Succeeding Little in this post is Ashish
Khandpur who previously served as vice
president, research and development, Industrial Business.
Intelligrated Appoints VP
Greg Massey
Alex Schlosser
3M Announces Changes to
Safety Staff
Frank Little
Ashish Khandpur
Robotics Association
Elects Board Members
The Robotics Industries Association
(RIA), Ann Arbor, Mich., has named Stu
Shepherd, CEO, Americas, KUKA
Robot Group, chairperson. Joining Shepherd on the executive committee are Past
Chair Catherine Morris, ATI Industrial
Automation; First Vice Chair Joe
Gemma, Staubli Robotics; Second Vice
Chair Mike Jacobs, Applied Manufacturing Technologies; Secretary Curtis
Richardson, Spirit Aerosystems; and
RIA President Jeff Burnstein.
Obituaries
Pamela A. Michalski
Pamela (Pam) A. Michalski, 48, died
Jan. 4 in Lyndhurst, Ohio, after a long illness. She was a 20-year AWS member affiliated with the Cleveland Section. A
graduate of Case Western Reserve University, she served as a project manager
at Dominion East
Ohio. Michalski was
active in the AWS
technical committees
involved with writing
the qualification standards for welding inspectors and technicians, and held leadership positions in the
preparation of techPamela Michalski
nical standards for
welding pipe and tubing. She chaired the
B5F Subcommittee on Welding Technicians and the D10T Subcommittee on
Low-Carbon Steel Pipe, was second vice
continued on page 84
82
MARCH 2014
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B5A and B5B Subcommittees on Welding
Inspectors, B5I Subcommittee on Supervisor Programs, D10 Committee on Piping and Tubing, D10S Subcommittee on
Purging and Root Pass Welding, and
served as AWS representative to the API
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Welding as a Career
Gary Brunsman was introduced to
welding as a Boy Scout. He assisted in
maintenance and repair projects as a teen
then began his career as a production and
maintenance welder. Throughout his career, Brunsman was passionate about
supporting welding education and training others, helping many achieve welding qualifications, and teaching blueprint
reading and math to apprentices. Thats
why when he was offered a position at
Scarlet Oaks as a welding instructor, he
was more than eager for the challenge.
He taught at the school, which is part of
the Great Oaks Career Campuses in
Cincinnati, for eight years, and although
86
MARCH 2014
BY MELISSA GOMEZ
MELISSA GOMEZ
(mgomez@aws.org) is editorial
assistant of the Welding Journal.
87
5 A kitchen sink, chair leg, and furnace pipe were upcycled to create this
charming yard flower.
MARCH 2014
In the Works
Currently, Brunsman is working on a
three-step approach toward retirement. Gallery of Dixie, which he plans
to expand, takes care of the first step.
Second is to start training welding technicians, artists, auto technicians, and re-
Blogs
GET
CONNECTED
Podcasts
Onl Courses
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ces
Virtual Conferences
Educational Resources
5, 4, 3, 2, 1...
Getting the New Years
Eve Ball Done!
As the iconic Times Square ball lowers to
ring in the next 365 days, its journey is
followed worldwide
BY KRISTIN CAMPBELL
KRISTIN CAMPBELL (kcampbell@aws.org)
is associate editor of the Welding Journal.
90
MARCH 2014
Fig. 1 This group shot, taken by Playbill for its Broadway Yearbook during the 20082009 season, features Hudson employees.
(Photo by Brian Mapp/Playbill Inc. Used by special permission.)
2
Fig. 2 The 4-in.-tube pentagon frames,
shown in plywood jigs, were tied together with 4-in. tubes coped for making
hexagons.
91
Aluminum Importance
and GTAW
Aluminum, predominantly Alloy
6061, makes up the balls frame. Hudson
purchased the material from Yarde
Metals, Inc., Hauppauge, N.Y.
Employees Jerry Valenzuela and
Anthony Robinson performed a majority
of the gas tungsten arc welding (GTAW)
with 5356 filler metal Fig. 3. They
were aided by Donald C. Wright Jr.,
Hament Kallica, James Starr, Josh
Braun, Gabriel Tepoxteco, and John
Sissilli with 32 other welders/fitters.
The work gave a big boost to the
quality and confidence of our welders,
Bardwell said.
Its skeleton, made out of 4-in.-diameter 14-in.-wall 6061 aluminum tubes,
came together with partial joint penetration square groove welds and fillet welds.
I think the biggest challenge was the
design and preparation of the joints in
the skeleton frame. The copes were at
difficult angles and not orthogonal. The
bevels needed to change as the dihedral
angle changed, Bardwell explained.
Three identical weldments, approximately 12 6 4 ft in size, were constructed to form the ball Fig. 4.
Eventually, these were placed upright on
an engraved plywood floor pattern and
connected with more coped struts.
South Plainfield Engineering, South
Plainfield, N.J., cut and bent secondary
aluminum attachment frames. In addition, flat pieces with complicated, coped
tubes were subcontracted.
92
MARCH 2014
4
Fig. 4 Three identical weldments,
about 12 6 4 ft, form the ball.
Fig. 5 The balls triangular faces are
created by the LED support frames,
behind which is the hexagonal/pentagonal skeleton. A Triangular LED
support frame; B completed segment showing the LEDs and crystals.
5B
5A
8
Fig. 6 An example of a tent to contain
the LED support frame is shown.
Fig. 7 The purpose for struts inside the
skeleton are to attach lifting ropes, among
other factors.
Fig. 8 The balls colorful LEDs were
tested and programmed for proper working order.
Finishing Details
Inside the skeleton are extra struts
for attaching the lifting ropes, guide
wheels, and electronics Fig. 7. Two of
the hexagonal openings have no tents
attached as that would delineate the
poles path and balls center.
With the latest ball, we tried to minimize the gap, using narrow stainless
tube to contain the LED fixtures,
Bardwell added, to create cohesive
edges between facets. I think this is suc-
WELDING JOURNAL
93
Inspection Practices
In addition, one of Bardwells responsibilities is Hudsons quality assurance
program. He has developed its welding
procedures and done testing for procedure qualification records (PQR) and
welder qualification records (WQR).
On difficult projects, or when
requested by a client, we use outside
inspectors. John Brooks of John H.
Brooks & Associates in Middletown,
N.J., was used this time, Bardwell said.
He added Brooks gave invaluable
assistance in developing procedures for
the tubular joints and did visual inspection throughout the construction period.
AWS D1.2:1997, Structural Welding Code
Aluminum, was adhered to.
The coupon testing for their PQR
94
MARCH 2014
Earning a Special
Welding Distinction
During a ceremony this year on
January 6, the AWS Extraordinary
Welding Award went to the Times
Square New Years Eve Ball.
Dean Wilson, AWS president, presented this honor at the annual ceremony
to relight and raise the ball back up the
130-ft pole atop One Times Square
Fig. 10. The ball will remain there for visitors to see until it drops back down to
ring in 2015.
10
Appreciation Aspects
Now, after learning about all the
steps that went into this balls creation,
perhaps you will have a newfound
respect and admiration for the structure
while waiting for next year to arrive.
It has been a kick, Bardwell said of
helping to make such a famous structure.
Most of my work is indoors, and seen by
a fairly small audience, often lasting for
less than a year or two. The ball sits in an
extreme environment [and fortunately
withstood Hurricane Sandys wrath]. It is
seen and enjoyed by millions.
MARCH 2014
97
Perseverance Pays
As her year of training wound down,
McNish-Rodriguez prepared to bring a
host of new ideas back to Fort Lee. But
what wont change is the attitude that
enabled her to succeed as a female
welder and chief warrant officer in the
U.S. Army.
Being in the Army as a female and
an Allied Trades warrant officer has its
challenges, as in any profession, she
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MARCH 2014
International symposium on
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April 2830, 2014 / Atlanta
Flash We
Welding
elding Techniques
Techniquees for Coil Joining of Advanced High Strength Steels
Mike Prokop
kop (T
(Taylor
Taaylor Winfield) and Jerry Gould (EWI)
(
Resistance Spot W
Welding
elding Gun with Force Amplification
Jonny Kaars and Peter Mayr (Chemnitz University)
Development of In-Process W
Welding
elding Current and Electrode Force Control
ol Process for Indirect Spot We
W
Welding
el
elding
Muneo Matsushita, Rinsei Ikeda and Kenji Oi (JFE Steel)
Influences of T
Tempered
empered Pulses on Resistance Spot W
Welding
elding of Hot Press Forming Steels
J. Hou, D. Saha, S. Nayak, K. Chan, N. Scotchmer
Scotchmer,r, N. Zho
Zhou, and A. Gerlich
Improvements
vements in the Resistance We
Weldability
Weldability
elda
and Properties of Thick-Thin Aluminum Alloy Combinations
Anthony Ananthanarayanan
Revised W
Work
Wo
ork of ISO 14270 on Mechanized
Mechanize Peel
Kin-ichi Matsuyama (Osaka University)
Resistance Spot W
Welding
elding of High Strength Dual Phase Steels
Murali T
Tumuluru
umuluru
Resistancee W
Welding
elding
e
of Stranded-W
Stranded-Wire
ire Aluminum Cables to Connectors for Hybrid Automotive Applications with
No Pre-Cleaning or Plating of the Parts We
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Welded
elded
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Anthony Ananthanarayanan
Co-sponsor with
V
Visit
isit www.aws.org/conferences
www
w..aws.org/conferences
.aws.org/conferenc or call (800) 443-9353 ext 234.
Location of Service
Equipment
The purpose of this provision is to prevent contamination of the atmosphere of
a confined space by possible leaks from
gas cylinders or fumes from welding power
sources or similar equipment and to minimize the possibility of electric shock.
Compressed Gas Cylinders and Welding Power Sources. When welding or cutting in confined spaces, gas cylinders and
welding power sources are to be located
outside the confined space.
Heavy Portable Equipment on Wheels.
Heavy portable equipment mounted on
wheels is to be secured in position to prevent accidental movement before operations are started in a confined space.
Ventilation Ducts. Ducts used to provide local exhaust ventilation for welding,
cutting, or related operations are to be
constructed of noncombustible materials.
These ducts are to be inspected as necessary to ensure proper function and that the
BY HOWARD M. WOODWARD
HOWARD M. WOODWARD
(woodward@aws.org) is associate editor
of the Welding Journal.
Graduation day for Class 7. Shown from left are (front row) Jimnesia Jackson, Melvin Price, Victoria Perales, and Daymon Williams, (back
row) CWI/CWE Instructor Matt Alexander, Justin Yancer, Jeff Brush, Mike North, Ed Beamon, Clifford Coston, Rich Kobman, and
CWI/CWE Instructor Jason North.
continued on page 104
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
For the latest conference information and registration visit our web site at
www.aws.org/conferences or call 800-443-9353, ext. 2
Student Ed Beamon (left) is shown working with Welding Instructor Matt Alexander in the
Merrill Institute lab.
Instructor Jason North (left) works with Dan Hansen (center) and Jeremy Lewis on a brazing bronze project.
students with the foundation for a successful career with real-world, experiential, project-focused training using stateof-the-art machines and equipment to
develop the competencies and proficiency required by employers. Most importantly, this certification is recognized
and accepted industry-wide.
Prescreening
Merrill recognizes that some prospective students do not have the basic qual-
Impact Testing
X-Ray Diffraction
Hydrogen Cracking
Vince Cohoon practices gas metal arc welding with an uplhill progession.
Merrill Institute
www.merrillinstitute.com
520 Republic Ave.
Alma, MI 48801
Office: (989) 462-0322
Contact:
Mark Johnston, Director
Merrill Institute
info-min@merrillinst.com
Industry Notes
Electrical Builders, Inc., a high-power conductor service
provider and AWS Sustaining Member Company, is celebrating a milestone in 2014 with its 40th year in business. From beginnings out of a home office in Kimball, Minn., it has expanded
resulting in power projects throughout North America, including servicing 60% of the domestic nuclear fleet.
Harvest Technologies, Belton, Tex., an additive manufacturing
service bureau, recently added to its in-house fleet of 3D printers an XL-sized Fortus 900mc machine and will soon take delivery of two mid-sized Fortus 400mc machines.
TST Tooling Software Technology, LLC, Clarkston, Mich., and
Vero Software have made a grant of Edgecam software with a
retail value of $750,000 to Lawrence Technological University.
Its Blue Devil Motorsports teams can use this to create parts
to assemble its vehicles for international competitions.
The Boy Scouts of America has presented its North Star Award
to The Lincoln Electric Co., Cleveland, Ohio, for its support
of the Welding Merit Badge program. The companys group
at Tennessee Rand has also been recognized by the Small Business Institute for Excellence in Commerce with the 2013 Tennessee Excellence Award. In addition, Lincoln has been named
Top Plant of 2013 by Plant Engineering magazine.
NuCor Steel has donated 60 tons of steel to the welding and
truck driver training programs at Greenville Technical College.
Its Darlington, S.C., operation donated the steel to be used by
welding students at the Brashier and Barton campuses. Three
students and their instructor took 8 h to drive the round trip
and spent another hour at the site loading/securing the steel
that is valued at $46,000.
BUSINESS BRIEFS
continued from page 14
The merger of the FANUC companies in the Americas better enables us to accomplish our mission of increasing the competitiveness of North and South American manufacturers by creating opportunities for them to maximize their efficiency, reliability, quality, and profitability, said Rick Schneider, president
and CEO, FANUC America Corp.
Also, in related company news, FANUC Corp. has been named
the 26th most innovative company in the world and sixth topranked innovator in Asia by Forbes. Additionally, FANUC America Corp. has been recognized as one of Michigans top 100 workplaces by the Detroit Free Press.
COMING EVENTS
continued from page 58
Bring Brand
Awareness to Your Company
Lea Paneca
lea@aws.org
(800) 443-9353, ext. 220
Sandra Jorgensen
sjorgensen@aws.org
(800) 443-9353, ext. 254
CLASSIFIEDS
CAREER OPPORTUNITIES
CERTIFICATION
& TRAINING
2014
Quality Assurance Manager
Select-Arc, Inc., the manufacturer which sets The Standard of Excellence in Tubular
Welding Electrodes, is expanding and seeking a Quality Assurance Manager for our
headquarters in Fort Loramie, Ohio.
This position, which reports to Executive Management, is responsible for all aspects of
effective implementation of ISO 9001, Military, Automotive, ASME (NCA 3800) and other
industry / customer Quality Management Systems requirements. Candidates should have
good communication skills and the ability and the experience to interface with all functions
of the organization, including customer and supplier interaction. Multi-Plant Quality System
experience is a plus.
Candidates will be responsible to perform as the Management Representative and ensure
that Quality Goals and Objectives are established and deployed within the organization(s).
Select-Arc will consider candidates with the following experience:
ASME, Military, ISO 9001 and Automotive Quality System Management. Strong ASME &
Military is preferred and a plus.
CQM, CQE or CQA (IRCA) Certification
Quality System or Lead Auditor Certification/Managing Internal Audits
Managing Multi-Plant Internal Audits and Supplier-Based Audits
Control Plans, PPAP and PFMEA
A minimum of 5 years experience, preferably in a continuous process or welding-related
industry
Welding Technology or Engineering/Technical related discipline
Quality Data Analysis & Reporting Systems
The position will require travel (up to 10%) to fulfill job requirements. Competitive salary,
relocation and comprehensive benefits packages are offered.
E-mail: mseitz@select-arc.com , fax: 888-511-5217 or mail resume to Melvin Seitz,
Quality Manager at Select-Arc, Inc., 600 Enterprise Dr., PO Box 259, Fort Loramie, OH,
45845. No Phone Calls, Please. Select-Arc, Inc. is an Equal Opportunity Employer.
Lea Paneca
lea@aws.org
(800) 443-9353, ext. 220
Sandra Jorgensen
sjorgensen@aws.org
(800) 443-9353, ext. 254
CWI PREPARATORY
80+ HOUR COURSE
MORE HANDSON/PRACTICAL APPLICATIONS
info@realeducational.com
CERTIFICATION
& TRAINING
SERVICES
sales@mitrowskiwelding.com
(800) 218-9620
(713) 943-8032
Hawkeye
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ADVERTISER
INDEX
Arcos Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IBC
www.arcos.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 233-8460
Magswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
www.magswitch.com.au . . . . . . . . . . . . . . . . . . . . . .(303) 468-0662
AWS Education Services . . . . . . . . . .62, 85, 89, 99, 103, 105, 107
www.aws.org/education/ . . . . . . . . . . . . . .(800) 443-9353, ext. 455
Midalloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
www.midalloy.com . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 776-3300
Cor-Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
www.cor-met.com . . . . . . . . . . . . . . . . . . . . . . . . . . .(800) 848-2719
TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
www.us.trumpf.com . . . . . . . . . . . . . . . . . . . . . . .web contact only
Greiner Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
www.greinerindustries.com . . . . . . . . . . . . . . . . . .(800) 782-2110
Weld Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
www.weldengineering.com . . . . . . . . . . . . . . . . . . .(508) 842-2224
ABSTRACT
In this study, the influence of solute content and heat input on microstructure was
investigated for gas tungsten arc (GTA) bead-on-plate welding of the aluminum alloys 1050A (Al 99.5) and 6082 (Al Si1MgMn). Temperature measurements in the solidifying weld pool showed that parameters such as solidification growth rate, cooling
rate, local thermal gradient, and solidification time vary significantly along the solidification front (between weld centerline and weld interface). As a result, the obtained thermal data were used to explain the corresponding grain morphology from
the first part of this study. On the basis of this comparison, an analytical approach was
used to model the transition from columnar-to-equiaxed grain growth (CET). This
model allows the prediction of critical values for both solidification growth rate and
thermal gradient, at which the CET occurs.
KEYWORDS
Aluminum
Gas Tungsten Arc Welding
(GTAW)
Columnar-to-Equiaxed
Transition (CET)
Thermal Analysis
H=
U I
v
(1)
(2)
It should be noted that the above solidification parameters and the corresponding microstructure vary strongly along
the solidification front. In fusion welds,
two different grain morphologies are frequently observed. At the weld interface,
grains often start growing with a columnar
shape. While these columnar grains grow
toward the weld center, the solidification
conditions at their leading edge change.
Both dT/dt and R increase and G decreases (Ref. 15). As a consequence, the
WELDING JOURNAL 69-s
WELDING RESEARCH
GCET = 0.617 N 0 3
( TN )3
1
TC ,CET
C ,CET
(3)
WELDING RESEARCH
N0 =
Fig. 2 Weld bead (cross section) and location of thermocouple within the weld metal (along y axis).
1
d3
(4)
G D
+ A R 0.5
R
(5)
0.5
(6)
Table 1 Chemical Composition of Base Metals as Measured by Optical Emission Spectrometer (ICP-OES)
Alloy
1050A
(Al 99.5)
6082
(Al Si1MgMn)
70-s
Fe
0.24
Cu
0.01
Mn
0.004
Mg
0.001
Cr
0.001
Ni
0.004
Zn
0.01
Ti
0.008
B
0.0003
V
0.01
Zr
0.001
Al
Bal.
0.86
0.42
0.09
0.43
0.75
0.06
0.01
0.07
0.032
0.0001
0.01
0.003
Bal.
(8)
where is the angle between the directions of welding speed and R at a particular point at the solid-liquid interface, as
illustrated in Ref. 10.
Part 1 of this study presents results from
GTA welding of three aluminum alloys
where welding speed and grain refiner additions were varied in order to investigate
their influence on microstructure and nucleant particles (Ref. 10). In this second
Experimental
Two different wrought aluminum alloys
were used in this study: Alloy 1050A (Al
99.5, temper H14) and Alloy 6082 (Al
Si1MgMn, temper T6), whose chemical
compositions are shown in Table 1. The
base metals were delivered in 3-mm-thick
plates and cut into 140 60 3-mm-thick
weld coupons that were cleaned by degreasing and etching for 15 min with an
etchant consisting of 869 mL H2O, 125 mL
65% HNO3, and 6.25 mL 48% HF. Each
weld coupon was placed in a fixture and a
GTA bead-on-plate weld (single pass,
complete penetration) was produced as illustrated in Fig. 1 left.
A backing made of copper was used to
avoid unwanted melt through. The welding setup was, for purposes of comparison,
very similar to the first part of this study
Alloy 1050A
(Al 99.5)
2.0
4.2
6.0
8.0
10.0
11.5
2.0
174
180
186
190
192
195
170
11.1
11.3
11.6
11.6
11.7
11.6
10.7
AC (80% electrode negative, 20% electrode positive)
50 Hz
W + 2% CeO2, diameter 3.2 mm, point angle 30 deg
50% Ar, 50% He
26 L min-1
3 mm
Alloy 6082
(Al Si1MgMn)
4.2
175
11.2
6.0
181
11.2
8.0
184
11.2
10.0
190
11.2
11.5
196
11.8
WELDING RESEARCH
Fig. 3 Approximation of grain growth direction in horizontal x-y plane (mid-length and depth
of weld metal; y = 0: centerline, y = 3 mm: weld interface). GTA bead-on-plate weld (no grain
refiner additions, welding to the left), Alloy 6082, plate thickness 3 mm, welding speed 8 mm s1,
heat input 258 J mm1.
WELDING RESEARCH
Fig. 6 Cooling curves (mean values) at weld centerline (y = 0). GTA welding, plate thickness 3 mm.
Table 3 Thermal Conductivities, (Ref. 26), Equilibrium Liquidus and Equilibrium Solidus
Temperatures (Refs. 26, 27), and Solidification Ranges for Alloys 1050A and 6082.
Parameter
Alloy 1050A
(Al 99.5)
Alloy 6082
(Al Si1MgMn)
Thermal conductivity
Liquidus temperature
Solidus temperature
Solidification range
210 W (mK)-1
657 C
646 C
11 K
170 W (mK)-1
650 C
550 C
100 K
Table 4 Critical Parameters CET, RCET, GCET, and TC,CET for the Transition from Columnar to Equiaxed Grain Growth (CET)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
72-s
Parameter
Unit
Welding speed v
Ti content
Grain size d
CET
RCET
GCET
GCET/RCET
TN
N0
TC,CET
D
A
TC,CET
A*
TC,CET*
mm s-1
wt.-%
m
deg
mm s-1
K mm-1
Ks mm-
K
mm-
K
mm s-1
s1/2K mm-1/2
K
s1/2K mm-1/2
K
Equation
(10)
(8)
(4)
(3)
(7)
(7)
Alloy 1050A
8
0.02
33
37
6.4
53
8.3
10
0.02
28
45
7.0
50
7.1
27826
3.0
45554
2.4
5.1
1.2
3.0
5.3
0.9
2.4
Alloy 6082
6
0.02
52
0
6.0
53
8.8
1.0
7112
4.5
0.003
2.0
4.9
1.8
4.5
8
0.02
55
23
7.3
52
7.1
10
0.02
57
45
7.1
47
6.6
6011
4.7
5400
4.4
5.4
1.7
4.7
5.3
1.7
4.4
nondimensional parameters that were adjusted in each case on the grain morphology of the corresponding weld as
demonstrated in Fig. 3.
After approximating the grain growth
direction for each alloy and welding speed
according to Equation 9, the angle between and R was determined with Equation 10, which originates from Equations
8 and 9. For purposes of simplicity, the
grain growth curvature in the vertical y-z
plane (which also influences R) was neglected. This is a good approximation because here, the grain growth direction was
observed to be most often parallel to the
(horizontal) y axis.
y = a xb
(9)
Fig. 7 Cooling rate dT/dt at liquidus temperature, dependent upon horizontal position in weld pool
(y = 0: centerline; y = 3 mm: weld interface). GTA welding, plate thickness 3 mm.
b 1
dy
y b
= arctan = arctan a b
a
dx
In a last step, R was calculated with Equation 8 dependent upon welding speed v
and the position in the weld pool (y). In
this calculation step, it was assumed that
dendrites are oriented in the same direction as grain growth due to competitive
growth and that grains grow normal to the
solid-liquid interface (Ref. 22). This is considered to be a reasonable approximation
Fig. 3. In other words, welding speed
provides in Equation 8 an order of magnitude upper limit for R at each position in
the weld pool.
Note that y is the direction transverse
to the welding direction (y = 0: centerline,
y = 3 mm: weld interface) Fig. 3. As
one can see in Fig. 4, the calculated R values are maximum at the centerline (y = 0),
where they correspond to welding speed,
and they are minimum at the weld interface (y = 3 mm). Interestingly, for Alloy
6082, higher minima were observed at the
weld interface than for Alloy 1050A. This
is due to the angle that was found at the
weld interface to be generally lower for
Alloy 6082 than for Alloy 1050A.
Thermal Conditions
Fig. 8 Thermal gradient GL at liquidus temperature, dependent upon horizontal position in weld metal
(y = 0: centerline; y = 3 mm: weld interface). GTA welding, plate thickness 3 mm.
WELDING RESEARCH
(10)
Fig. 9 Thermal gradient GS at solidus temperature, dependent upon horizontal position in weld metal
(y = 0: centerline; y = 3 mm: weld interface). GTA welding, plate thickness 3 mm.
WELDING RESEARCH
Fig. 10 Ratio GL/R at liquidus temperature TL, dependent upon horizontal position in weld metal
(y = 0: centerline; y = 3 mm: weld interface). GTA welding, plate thickness 3 mm.
74-s
Fig. 11 Solidification time tS, dependent upon horizontal position in weld metal (y = 0: centerline;
y = 3 mm: weld interface). GTA welding, plate thickness 3 mm.
Fig. 12 Predominant microstructure in R-G space and columnar-to-equiaxed transition (CET), calculated with Equations 3 and 7 using A (CET) and the adjusted A* (CET*), CET and CET* are mean
values for each alloy at a constant Ti content of 0.02 wt-%. GTA welding, plate thickness 3mm.
WELDING RESEARCH
parameters such as dT/dt, G and G/R. Accordingly, the grain morphology was predominantly equiaxed at high welding
speeds and thus high dT/dt, low G/R and
low tS values (Ref. 10). Nevertheless, a recent study on Al fusion welding revealed, at
constant chemical composition, for laser
beam (LB) welds a three times lower solidification time than for GTA weld metal.
This large difference explains why the mean
weld metal grain size and the tendency for
columnar grain growth were found to be
generally higher in LB welds than in GTA
welds (Ref. 37).
WELDING RESEARCH
Conclusions
A thermal analysis of aluminum GTA
bead-on-plate welds (Al Alloys 1050A and
6082) with Type K thermocouples has revealed the thermal conditions along the
solidification front of the weld pool. In
comparison to the weld centerline, temperature measurements next to the weld
interface disclosed the following:
Lower solidification growth rates (R)
Lower cooling rates (dT/dt)
76-s
Appendix
List of symbols
Symbol
Dimension
deg
A, A*
s1/2 K mm-1/2
a, b
C0
wt-%
mm s1
dT/dt
K s1
K mm1
GL
K mm1
GS
K mm1
GCET
K mm1
J mm1
Heat input
Arc current
Meaning
Angle between directions of and R
Material constants
Grain size
Liquid diffusion coefficient
Cooling rate
mL
K wt-%1
N0
m-
mm s1
Curvature undercooling
tS
Solidification time
Temperature
TL
Liquidus temperature
TS
Solidus temperature
TC
Constitutional undercooling
TC,CET,
TC,CET*
TN
TG
Arc voltage
mm s1
mm
Welding direction
mm
Welding speed
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
Applications of high-strength steel to car bodies with higher than 1 GPa grade
tensile strength have dramatically increased. Twin-induced plasticity (TWIP) steel
maintains high strength and secure high ductility, featuring a high content of Mn. In
spite of these advantages, the resistance spot weldability is poor. To improve the
weldability, conventional AC and MFDC resistance spot welding, and other various
types of joint technology have been required and developed. In this work, MFDC
constant power control (CPC) welding was applied to improve the weldability of 1
GPa grade TWIP steel, and the welding characteristics were analyzed. To investigate
the fundamental weldability of TWIP steel, tensile shear strength, suitable welding
range, and welding signal were analyzed. Compared to MFDC constant current control (CCC) welding, CPC welding has the advantage of reducing expulsion at the
early stage of the welding process; therefore, it is possible to apply higher heat input
to the weld. As a result, it was found that larger nugget size and higher tensile shear
strength were obtained in CPC welding than CCC welding. To compare the characteristics of these two welding methods, welding signals were analyzed and high-speed
images were used for observing the difference in the nugget growth mechanism. Furthermore, this work evaluated the adaptability of CPC welding according to electrode force changes and coating conditions.
Introduction
In response to the deterioration of the
global environment, strict regulations of
fuel efficiency to reduce CO2 emissions
have been enforced. In particular, corporate average fuel efficiency (CAFE) standards suggest regulations that affect the
fuel efficiency of automobiles, automobile
sales, price, and fuel consumption (Ref.
1). The large size of automobiles, the addition of reinforcing parts for safety, and
an increase in electronics for the convenience of drivers have increased the weight
of car bodies. Under these conditions, the
automobile industry has been developing
lightweight vehicle technology to solve the
problem, especially concentrating on reducing weight with the application of highstrength steel (HSS) (Ref. 2).
Over the last several years, the application of HSS sheet to automobiles for the
purposes of increasing collision safety and
reducing weight has been expanded. Also, it
was reported that the rate of adoption of
J. YU and S. RHEE (srhee@hanyang.ac.kr) are
with the Department of Mechanical Engineering,
Hanyang University, Seoul, Korea. D. CHOI is
with Product Application Center, POSCO, Korea.
78-s
KEYWORDS
TWIP980
High Strength Steel
MFDC Constant Power Control
Welding
Weldability
Welding Signals
TWIP980
Mn
Etc.
Fe
0.60
18.0
Al
Bal.
Conditions
Welding machine
Air-pressure control
type
MFDC 130 kVA
20C
6 L/min
2.0 / 3.0 / 5.0
300
150 / 200 / 250 / 300 /
350
Cooling temperature
Cooling rate
Electrode fore (kN)
Hold time (ms)
Welding time (ms)
B
Fig. 2 Suitable welding range of TWIP980. A Lobe diagram of CCC welding; B lobe diagram of CPC welding.
nique, Kim (Ref. 14) controlled the welding power of the RSW system and conducted computer simulations to illustrate
the performance of the controller. However, the RSW process primarily applied
for sheet metal was MFDC CCC welding,
which showed its technical limitations in
the case of the application of welding
HSS. In that aspect, the MFDC constant
power control (CPC) method was developed to solve the limitation problems and
apply it to actual manufacturing process.
Therefore, more studies on the differences between CPC welding characteristics and the conventional welding characteristics need to be conducted.
In this work, MFDC CCC and CPC
welding were applied to 1 GPa grade TWIP
steel in order to compare the characteristics
of each welding process. A lobe diagram
was used to compare suitable welding
ranges. For comparison analysis on each
welding mechanism, welding signals and
high-speed images were used. Furthermore, to investigate the adaptability of CPC
welding to the changes in the welding condition, comparison tests on CCC and CPC
Materials
The material used in this work was coldrolled TWIP steel sheet of 980 MPa grade.
The chemical composition of TWIP980 is
indicated in Table 1. TWIP980 is composed
of 18% Mn, 0.6% C, and Al as a minor alloying element. The test steel sheet is 1.4
mm thick; uncoated and GI-coated steel
were used as well. To analyze the fundamental welding characteristics of the test
material and the mechanisms of CCC and
CPC welding, uncoated TWIP980 was
used. The coating amount of the GI-coated
TWIP980 was 60 g/m2, which was used to
evaluate the adaptability of CPC welding to
a coating layer.
WELDING RESEARCH
WELDING RESEARCH
was developed as shown in Fig. 1. The developed welding system was a MFDC
RSW machine with 1 kHz switching frequency. By controlling pulse width modulation (PMW), two modes, CCC welding
and CPC welding are possible in the same
welding machine. The welding timer receives the welding current feedback from
the transformer (a Bosch Rexroth
PGS6130), and welding voltage feedback
from both electrode tips. With the use of
the developed welding system, it is possible to maintain the additional experimental conditions including electrode force,
electrode alignment, welding gun, and a
cooling condition equally in CCC and
CPC modes. Aside from the welding
timer, a Rogowski coil (DC flex, PEM
Corp.) for current measurement was installed to measure the welding signals that
were actually given to the weld, and both
tips of the electrode were clipped to measure the voltage. By using an analog-to-digital converter (a National Instruments
NI9229), analog current and voltage were
measured at the same time with a rate of
50,000 samples per second per channel.
Since the control frequency of the MFDC
RSW machine used was 1 kHz and the
sampling rate was 50 kHz, 25 data per 0.5
ms were used for resistance and power calculation. Digitized welding voltage and
current in root mean square (RMS) value
were computed per 0.5 ms. Finally, resistance and power were calculated with
Equations 1 and 2 as follows:
r(t) = v(t)/i(t)
(1)
p(t) = v(t)/i(t)
(2)
where, i(t) is the RMS value of the welding current, v(t) is the RMS value of the
welding voltage, r(t) is the resistance, and
p(t) is the power (Ref. 15).
Cu-Cr dome-type electrodes having a
tip diameter of 6 mm and a tip radius of 40
mm were used, and the electrode tips were
conditioned by making 50 welds prior to
80-s
Results and
Discussion
Fig. 5 Welding signals of CPC welding. A Without expulsion (3.0 kN/7.5 kW/350 ms); B with expulsion (3.0 kN/8.0 kW/350 ms).
Tensile Shear
Strength (N)
Average Tensile
Shear Strength (N)
2.0
12752
13173
12070
12665
(Expulsion)
3.0
12783
12797
12848
5.0
10650
10898
10953
Force (kN)
Tensile Shear
Strength(N)
Average Tensile
Shear Strength(N)
2.0
13850
14080
13888
13939
12809
3.0
12674
12833
12816
12774
10834
(Insufficient TSS)
5.0
12390
12655
12065
12370
WELDING RESEARCH
Fig. 4 Welding signals of CCC welding. A Without expulsion (3.0 kN/5.5 kA/350 ms); B with expulsion (3.0 kN/6.0 kA/350 ms).
WELDING RESEARCH
Tensil Shear
Strength (N)
CCC
3.0 kN
11870
12477
12693
12347
CPC
3.0 kN
13296
13149
12738
13061
WELDING RESEARCH
Fig. 7 Resistance and power signals according to the electrode force. A CCC welding; B CPC welding.
Fig. 9 Resistance and power signals of uncoated and GI-coated TWIP steels. A CCC welding; B CPC welding.
WELDING RESEARCH
Fig. 10 Welding current profiles of CPC welding of uncoated and GIcoated TWIP steels.
welding, to improve resistance spot weldability of 1 GPa grade TWIP steel. The following conclusions were drawn from the
investigation on the weldability of the
MFDC constant power welding and constant current welding to 1 GPa grade
TWIP steel:
1. By evaluating fundamental weldability, this work obtained the suitable welding range of both CCC and CPC welding
for TWIP980 steel. Furthermore, it was
found that the suitable welding range for
CPC welding was larger than that of CCC
welding with regard to total heat input.
Also, it was found that nugget diameter
was proportional to tensile shear strength.
2. Constant power control welding reduced expulsion because it prevents excessive heat input to the weld durging the
early stage of the process. Therefore, the
suitable welding range for CPC welding
was expanded.
3. Due to the heat input profile (i.e., a
different power profile) of CPC being different from CCC welding, there are different nugget growth mechanisms between
CPC welding and conventional welding
84-s
1. Goldberg, P. K. 1998. The effects of the corporate average fuel efficiency standards in the
U.S. Journal of Industrial Economics 46(1): 133.
2. Oikawa, H., Murayama, G., Sakiyama, T.,
Takahashi, Y., and Ishikawa, T. 2007. Resistance spot weldability of high strength steel
(HSS) sheets for automobiles. Nippon Steel
Technical Report (95): 3945.
3. Nonaka, T., Taniguchi, H., Goto, K., and
Yamazaki, K. 2003. Development of ultrahighstrength cold-rolled steel sheets for automotive
use. Nippon Steel Technical Report (88): 1315.
4. Nielsen, C. V., Friis, K. S., Zhang, W., and
Bay, N. 2011. Three-sheet spot welding of advanced high-strength steels. Welding Journal 90
(2): 32-s to 40-s.
5. Bracke, L., Verbeken, K., Kestens, L., and
Penning, J. 2009. Microstructure and texture
evolution during cold rolling and annealing of a
high-Mn TWIP steel. Acta Materialia 57(5):
15121524.
6. Barbier, D., Gey, N., Allain, S., Bozzolo,
N., and Humbert, M. 2009. Analysis of the tensile behavior of a TWIP steel based on the texture and microstructure evolutions. Materials
Science and Engineering A 500(1-2): 196206.
7. Chuko, W. L., and Gould, J. E. 2002. Development of appropriate resistance spot welding practice for transformation-hardened
steels. Welding Journal 81(1): 1-s to 7-s.
ABSTRACT
In this investigation, an attempt has been made to evaluate the quality level
for imperfections of gas metal arc welding (GMAW) by capturing the images in
a vision system and processing them using neural networks. The level of imperfections is assumed by approximating the surfaces of the welded images with a
Gaussian distribution. Images of welded joints based on surface variations are
classified as a good weld, excess weld, insufficient weld, and no weld (as per standard EN25817). Primarily, images of butt joint beads in GMAW were extracted
through a charge-coupled device (CCD) camera of a machine vision system. Afterward, the gray level values of the pixels from the captured images were assumed to fit a Gaussian distribution, fitness was tested through the chi-square
test, and then the characteristics of the distribution were considered as a feature
extraction. Finally, images of the welded joints were classified into one of the four
predefined ones based on quality of level for imperfections as per standard by
using an artificial neural network (ANN) with backpropagation (BP) and ANN
with differential evolutionary algorithm (DEA) separately. In this technique, 80
images of welded joints were tested and 96.25% overall accuracy was achieved.
When the same method was used in an average grayscale-2D feature vector, only
a 95% accuracy level was achieved. The results obtained by ANN using DEA
were closer to ANN using BP, but the computational time of ANN using DEA
was shorter.
Introduction
In the manufacturing industries, welding plays a major role as a crucial manufacturing process for producing a countless number of industrial goods from
buildings to bridges and cars to computers. Among various welding processes,
GMAW is a semiautomatic or automatic
arc welding process in which a continuous
and consumable wire electrode and a
shielding gas are fed through a welding
gun for joining metals. It is a major weldG. SENTHIL KUMAR (senthilgandhi@
ymail.com) is an associate professor with the
Dept. of Mech., Velammal College of Eng. &
Tech., Madurai, Tamil Nadu, India. U. NATARAJAN is an asst. professor with the Dept. of Mech.,
A. C. College of Eng. & Tech., Karaikudi, Tamil
Nadu, India. T. VEERARAJAN is the dean, Dept.
of Mathematics, Velammal College of Eng. &
Tech., Madurai, Tamil Nadu, India. S. S. ANANTHAN is the sr. deputy general manager, Welding
Research Institute, BHEL, Tiruchirapalli, India.
ing method for fabricating many engineered artifacts and structures such as
cars, ships, space shuttles, offshore drilling
platforms, and pipelines.
The level of imperfections of the welds
are assessed through various inspection
processes. Nondestructive examination
(NDE) is one of the major inspection
methods for welding in industry. The
NDE technology for weld inspection has
KEYWORDS
Gas Metal Arc Welding
(GMAW)
Welding Defects
Vision System
Gaussian Distribution
Chi-Square Test
Backpropagation Neural
Network (BPN)
Differential Evolutionary
Algorithm (DEA)
WELDING RESEARCH
Fig. 1 A Schematic diagram of a machine vision system for GMAW inspection; B Rapid 1 V3.4 machine vision system for acquiring the images.
Table 1 Computations of Observed Frequencies in Images for a Good Weld in Butt Joint
Class Interval
Mid Value
xi
WELDING RESEARCH
118
1936
3754
5572
7390
91108
109126
127144
145162
163180
181198
9.5
27.5
45.5
63.5
81.5
99.5
117.5
135.5
153.5
171.5
189.5
Total
Average Grayscale
(Intensity) Value
i
Percentage of
Intensity Value
1432.00
2092.00
2437.20
3313.00
2333.00
3494.00
2250.10
2085.80
1184.00
1655.80
921.00
23197.90
6.17
9.01
10.50
14.28
10.05
15.06
9.69
8.99
5.10
7.13
3.97
100
Frequency
fi
fi = (i/i)100
6
9
11
14
10
15
10
9
5
7
4
100
86-s
Fig. 3 Different types of acceptable and unacceptable weld profiles in butt joints as per EN 25817. A Good weld; B excessive reinforcement weld;
C insufficient weld; D no weld.
Fig. 4 Four images of a good weld captured with illuminations from four different zones. A Zone
1; B zone 2; C zone 3; D zone 4.
WELDING RESEARCH
and thickness of the workpiece, respectively. Good welds refer, when the reinforcement height (h) has neither been satisfied h 1 mm + 0.15b, maximum of 7
mm, and also has not been satisfied under
groove height h1 0.1t, maximum of 1
mm. Figure 3B shows the excessive reinforcement weld. When the reinforcement
height (h) of the weld lies between 1 and 7
mm, it may be considered as excessive reinforcement. Figure 3C refers to an insufficient weld. When the under groove
height (h1) lies between 0.1 and 1 mm, it
may be considered as an insufficient weld.
Figure 3D illustrates the no weld. In this
type, the groove surface is not filled.
Experimentation
WELDING RESEARCH
Fig. 5 Four images of excess weld illuminated from four different zones. A Zone 1; B zone
2; C zone 3; D zone 4.
Table 2 Computations of Expected Frequencies in Image for a Good Weld in Butt Joint
Class Interval
Mid Value
xi
Observed Frequency
(fi)
di
fidi
118
1936
3754
5572
7390
91108
109126
127144
145162
163180
181198
9.5
27.5
45.5
63.5
81.5
99.5
117.5
135.5
153.5
171.5
189.5
6
9
11
14
10
15
10
9
5
7
4
100
-4
-3
-2
-1
0
1
2
3
4
5
6
11
-24
-27
-22
-14
0
15
20
27
20
35
24
54
Total
one after the other. Both the lighting system and camera are controlled by a computer. During inspection, succeeding operations such as image capturing and
inspection of the objects are executed by
the computer.
there is a complete penetration and fusion of the weld and base metal throughout the thickness of the joint. In partial
joint penetration, the material penetrates partially. Based on the values obtained from the various measurements of
the welded surface, acceptance or level
for imperfections in the weld will be decided in conformity with EN 25817. The
scrutiny of welding defects in the butt
joints inspected leads to the classification of welds as a good weld, excess weld,
insufficient weld, and no weld.
Figure 3 depicts the different types of
acceptable and unacceptable groove weld
profiles in butt joints based on standard
EN 25817:1992. Figure 3A shows the
image of a good weld; h, b, and t denote
reinforcement height, width of the weld,
1
e
f(x) =
2 2
(x )2
2
Where parameter is the mean (location of the central tendency) and 2 is the
variance (measure of the deviation from
the mean of the distribution).
The distribution with = 0 and 2 = 1
is called the standard normal distribution.
This is also considered the most prominent probability distribution in statistics.
There are several reasons for this. First,
the normal distribution is tractable analytically; that is, a large number of results involving this distribution can be derived in
Fig. 6 Four images of insufficient weld illuminated from four different zones. A Zone 1;
B zone 2; C zone 3; D zone 4.
118
1936
3754
5572
7390
91108
109126
127144
145162
163180
181198
Mid Value
xi
Frequency
(fi)
di
fidi
fidi2
9.5
27.5
45.5
63.5
81.5
99.5
117.5
135.5
153.5
171.5
189.5
6
9
11
14
10
15
10
9
5
7
4
100
-4
-3
-2
-1
0
1
2
3
4
5
6
11
-24
-27
-22
-14
0
15
20
27
20
35
24
54
96
81
44
14
0
15
40
81
80
175
144
770
Total
explicit form. Secondly, the normal distribution arises as the outcome of the central
limit theorem, which states that under
mild conditions, the sum of a large number of random variables is distributed just
about normally. Finally, the bell shape
of the probability curve of the normal distribution makes it a convenient choice for
modeling a large variety of random variables encountered in practice. For this
reason, the normal distribution is commonly used in practice, and is used
throughout statistics, natural sciences, and
social sciences as a simple model for complex phenomena.
The chi-square test has a large number
of applications in statistics. It is powerful
for testing the significance of the discrepancy between theory and experiment; was
given by Prof. Karl Pearson in 1900; and is
known as chi-square test of goodness of
fit. It can determine whether the deviation of the experiment from theory is just
by chance or it is really due to the vast difference between theoretical and observed
values. Though it is an approximate test
for larger values of n, the chi-square test
of goodness of fit is a valid test for small
values of n.
Random samples have been drawn
from a normal population with a specific
variance (2), the calculated values are
compared with the critical values of the
chi-square distribution corresponding to a
WELDING JOURNAL 89-s
WELDING RESEARCH
1
=
N
i =1 (fi d i 2 ) ( i =1 fi d i )
N
(4)
Fig. 7 Four images of no weld illuminated from four different zones. A Zone 1; B zone 2; C
zone 3; D zone 4.
WELDING RESEARCH
Table 4 The Expected Frequencies of Grouped Interval for a Good Weld in Butt Joint
Class
Mid Value
Interval
xi
118
1936
3754
5572
7390
91108
109126
127144
145162
163180
181198
9.5
27.5
45.5
63.5
81.5
99.5
117.5
135.5
153.5
171.5
189.5
-1.67
-1.30
-0.93
-0.57
-0.20
0.17
0.54
0.90
1.27
1.64
2.01
(z)
Nc /
Expected Frequency
0.0990
0.1714
0.2589
0.3390
0.3910
0.3931
0.3447
0.2661
0.1781
0.1040
0.0529
( (z)
3.6382
6.2976
9.5125
12.4556
14.3662
14.4434
12.665
9.7771
6.5438
3.8212
1.9437
(fi)
4
7
10
13
15
15
13
10
7
4
2
100
Total
few important levels of significance (chisquare table), and then used to decide
whether the null hypothesis may be accepted or rejected. In the present case, the
null hypothesis assumed is that the crosssection curve of the welded surface is a
normal curve.
After the conversion of the grayscale
image, the values of pixels of images in all
rows and columns are added and the percentage of pixel values is calculated and
taken as frequency (fi). The arithmetic
mean of a set of observations is the sum of
the observed values divided by their number. The arithmetic mean of this distribution is calculated as follows:
= A +
f d
i =1 i i
(2)
Z=
(x A )
i
x
i
(5)
d =
(3)
Features
Gaussian Distribution
Properties
F1
Mean
F2
Standard deviation
Formula
= A+
in=1 fi d i
1
=
N
(6)
1
(7)
Coefficient of variation
F3
C .V = 100 *
(8)
Median
F4
hN
M = 1+ c
f2
(9)
Mode
F5
Mo = 1+
h(f -f )
1
2f -f -f
1
Feature Extraction
A feature is a value describing an object in a numerical form and the selection
of the best features is essential for the success of any classification algorithm.
Rather than using the raw data directly,
some measures or descriptors are often selected upon which the classes of the observed objects are determined by the classifier. These measures, commonly called
features, are generally of a much lower dimension than the data space. The process
of searching for internal structure in data
items, that is for the features or properties
of the data, is called feature extraction.
The process of choosing desirable features
from the initial set of observations is called
feature selection. The relevancy of extracting features is determined either by
trial and error or based on an automatic
feature selection procedure (Ref. 10).
Extracting desirable features is an extremely difficult task and problem dependent (Ref. 8). To distinguish welds
from nonwelds, features with discriminating capability must be identified (Ref. 9).
In this process, the gray level values of the
pixels from the captured images are assumed to fit a Gaussian distribution, test
the fitness through 2 test, and then characteristic of the distribution is considered
as a feature extraction. Then true color
images are converted into a grayscale
image. After this selection, a region of interest is cropped for further processing.
Finally, features of the images are computed as shown at right.
The average gray values of pixels in the
cropped images were calculated and tabu-
(10)
Pearsons coefficient
of skewness
F6
3 (M M )
0
(11)
Bowleys coefficient
of skewness
F7
S =
Q + Q 2M
3
Q Q
3
c N
where Q = l + m
1
f 4
c 3N
Q =l +
m
3
f 4
(12)
Coefficient of kurtosis
F8
=
4
4
2
2
(13)
where
WELDING RESEARCH
WELDING RESEARCH
1
2
3
4
5
6
7
8
11
10
13
15
15
13
10
13
lated. In this work, 80 welded image samples are taken into account in the classification process. Table 6 shows the values of
the Gaussian feature for welded images in
a butt joint.
ANN Using a BP Classifier
(Oi Ei)2
92-s
W = O
ij
Ei
16
1
1
25
0
9
25
16
Total = 5.43
1.45
0.10
0.07
1.60
0.00
0.69
0.83
0.69
E =
(T
pi
- O )2
pi
(14)
E = E
pj
pi
(16)
X2=(Oi Ei)2
(15)
(17)
pj = Opi (1 Opi)OpiWjk
(18)
Fig. 14 Classification performance of neural network using a Gaussian distribution-based feature vector in a butt joint.
x
x
(19)
max
the ANN.
The weights between input layer and
hidden layer and weights between hidden
layer and output layer are generated randomly for the selected topology 4-5-5-1 of
the network.
The number of training patterns used
for training is 80.
The patterns were normalized.
The training was done offline using
the computer.
WELDING JOURNAL 93-s
WELDING RESEARCH
Table 6 The Values of Gaussian Feature for Welded Images in Butt Joint
Sample No.
WELDING RESEARCH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
94-s
Gaussian Feature
F1
89.55
89.52
89.46
89.56
89.32
89.25
89.23
89.76
89.73
89.67
89.37
89.31
89.13
89.71
89.17
89.69
89.96
89.39
89.93
89.74
85.365
85.87
85.59
85.46
85.71
85.78
85.95
85.64
85.17
85.82
85.34
85.93
85.76
85.43
85.28
85.14
85.39
85.41
85.67
86.12
87.34
87.25
87.49
87.19
87.76
87.45
84.42
87.69
87.17
87.49
87.92
87.93
87.97
87.75
87.71
87.95
87.76
87.43
87.42
87.12
85.05
85.63
85.61
85.6
85.61
85.84
85.74
85.13
85.12
85.46
85.75
87.49
85.15
87.69
87.26
85.79
85.45
87.16
85.19
85.16
F2
43.69
43.96
43.94
43.67
43.13
43.19
43.71
43.17
43.31
43.76
43.75
43.57
43.28
43.82
43.59
43.95
43.63
43.36
43.68
43.86
48.75
48.65
48.54
48.98
48.89
48.45
48.87
48.56
48.78
48.12
48.21
48.13
48.73
48.31
48.76
48.19
48.91
48.37
48.67
48.46
39.74
39.75
39.78
39.48
39.71
39.52
39.64
39.65
39.44
39.88
39.54
39.61
39.63
39.75
39.48
39.24
39.32
39.37
39.78
39.66
42.99
42.35
42.61
42.68
42.23
42.98
42.95
42.56
42.16
42.76
42.78
42.79
42.96
42.93
42.16
42.16
42.35
42.96
42.75
42.19
F3
48.80
48.63
48.87
48.36
48.78
48.93
48.39
47.56
47.32
47.81
47.49
47.65
47.23
47.18
47.94
47.42
47.24
49.72
49.27
49.51
57.73
57.78
57.87
57.79
57.97
57.13
57.64
57.12
57.91
57.46
57.31
57.73
57.21
57.19
57.43
57.49
56.72
56.71
56.76
56.71
46.09
46.93
46.23
46.37
46.21
46.19
46.75
46.92
46.78
46.22
46.23
46.27
46.51
46.19
46.11
46.17
46.12
46.13
46.28
46.37
51.85
51.12
51.45
51.13
51.42
51.48
51.28
51.23
51.57
51.75
51.79
51.89
51.59
51.26
51.23
51.42
51.78
51.26
54.19
51.28
F4
87.78
87.92
87.49
87.43
87.61
87.16
87.33
87.29
87.94
87.71
87.17
88.43
88.34
88.56
88.12
88.21
88.67
88.76
88.72
88.27
83.65
84.23
84.76
84.19
84.79
84.77
82.73
82.19
82.71
82.39
82.57
84.12
84.76
84.49
84.37
84.39
84.74
84.93
85.46
85.23
87.14
87.18
87.12
87.19
87.46
87.43
87.42
87.19
87.56
87.28
87.49
87.22
87.88
87.87
87.43
87.65
87.66
87.44
87.11
87.42
83.89
83.12
83.16
83.17
83.26
83.71
83.28
83.42
83.65
83.61
83.94
83.69
83.67
83.49
83.17
83.47
83.46
83.79
83.44
83.22
F5
80.92
80.12
80.64
80.56
80.17
80.75
80.67
80.71
80.65
80.76
80.57
81.12
80.69
80.46
80.21
80.79
80.97
80.96
81.21
81.75
80.65
80.25
81.45
80.94
80.26
80.74
80.92
81.46
81.63
80.39
81.27
80.76
80.94
81.92
80.70
80.52
80.41
80.37
80.18
81.28
85.112
85.42
85.72
87.46
87.12
87.45
87.49
87.16
87.18
87.49
87.43
87.44
87.42
87.43
87.49
87.59
87.56
87.26
87.26
87.13
80.54
80.12
80.16
80.13
80.17
80.75
80.19
80.43
80.45
80.77
80.33
80.23
80.56
80.44
80.66
80.96
80.39
80.37
80.27
80.29
Type of Weld
F6
0.040
0.034
0.043
0.023
0.064
0.079
0.097
0.046
0.032
0.072
0.014
0.039
0.043
0.059
0.095
0.093
0.034
0.041
0.027
0.022
0.035
0.029
0.027
0.038
0.041
0.039
0.040
0.042
0.045
0.055
0.032
0.033
0.046
0.048
0.053
0.039
0.036
0.032
0.033
0.029
0.004
0.006
0.007
0.002
0.003
0.005
0.001
0.008
0.012
0.013
0.019
0.017
0.016
0.018
0.019
0.020
0.023
0.015
0.016
0.017
0.026
0.026
0.021
0.022
0.024
0.027
0.029
0.026
0.024
0.023
0.022
0.027
0.021
0.029
0.025
0.026
0.028
0.030
0.034
0.038
F7
0.057
0.075
0.089
0.098
0.071
0.017
0.029
0.092
0.037
0.073
0.091
0.019
0.044
0.066
0.099
0.015
0.056
0.019
0.029
0.039
0.026
0.024
0.021
0.018
0.017
0.012
0.025
0.027
0.031
0.028
0.015
0.029
0.036
0.044
0.024
0.014
0.021
0.032
0.033
0.048
-0.019
-0.011
-0.015
-0.017
-0.018
-0.012
-0.014
-0.016
-0.020
-0.016
-0.022
-0.021
-0.025
-0.011
-0.013
-0.015
-0.017
-0.012
-0.022
-0.018
0.011
0.012
0.015
0.017
0.019
0.018
0.016
0.015
0.014
0.016
0.012
0.016
0.017
0.018
0.011
0.021
0.023
0.022
0.026
0.028
F8
3.317
3.32
3.23
3.63
3.36
3.39
3.93
3.78
3.87
3.89
3.98
3.45
3.54
3.65
3.56
3.61
3.16
3.17
3.71
3.82
2.503
2.58
2.81
2.96
2.17
2.36
2.28
2.95
2.83
2.92
2.67
2.84
2.39
2.87
2.38
2.54
2.62
2.69
2.32
2.94
3.350
3.36
3.37
3.39
3.38
3.31
3.33
3.38
3.39
3.31
3.34
3.36
3.35
3.37
3.39
3.34
3.31
3.37
3.31
3.39
2.784
2.77
2.79
2.74
2.75
2.76
2.73
2.71
2.79
2.73
2.74
2.63
2.64
2.65
2.69
2.61
2.63
2.68
2.69
2.64
No weld
Insufficient weld
Excess weld
Good weld
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
Normalized Values
0.995442
0.995109
0.994442
0.995554
0.992886
0.992108
0.991885
0.997777
0.997443
0.996776
0.993442
0.992775
0.990774
0.997221
0.991218
0.996999
1
0.993664
0.999667
0.997554
0.9912332
0.9970971
0.9938458
0.9923363
0.9952392
0.996052
0.998026
0.9944264
0.9889689
0.9965165
0.9909429
0.9977938
0.9958198
0.9919879
0.9902462
0.9886205
0.9915235
0.9917557
0.9947747
1
0.9928953
0.9918154
0.9945436
0.9911333
0.9976128
0.9940889
0.9596453
0.9968171
0.990906
0.9945436
0.9994316
0.9995453
1
0.9974991
0.9970444
0.9997726
0.9976128
0.9938615
0.9937479
0.9903376
0.9698939
0.9765082
0.9762801
0.976166
0.9762801
0.978903
0.9777626
0.9708062
0.9706922
0.9745695
0.9778766
0.9977192
0.9710343
1
0.9950964
0.9783328
0.9744555
0.993956
0.9714905
0.9711484
0.993881
1
0.999545
0.993403
0.981119
0.982484
0.994313
0.982029
0.985214
0.99545
0.995223
0.991128
0.984531
0.996815
0.991583
0.999773
0.992493
0.986351
0.993631
0.997725
0.99540629
0.99326256
0.99101674
1
0.99816252
0.98917926
0.99775419
0.99142507
0.9959167
0.98244181
0.9842793
0.98264598
0.99489588
0.98632095
0.99550837
0.98387097
0.99857085
0.98754594
0.99367089
0.98938342
0.99661484
0.99674022
0.99749248
0.98996991
0.99573721
0.99097292
0.99398195
0.9942327
0.9889669
1
0.99147442
0.99322969
0.99373119
0.99674022
0.98996991
0.98395186
0.98595787
0.98721163
0.99749248
0.99448345
1
0.98506699
0.99111463
0.99274284
0.98227577
0.99972088
0.99902307
0.98995162
0.98064756
0.99460365
0.99506885
0.99530145
0.99925568
0.99855787
0.98064756
0.98064756
0.98506699
0.99925568
0.99437105
0.98134537
0.981657
0.978077
0.982904
0.972647
0.981094
0.984111
0.97325
0.956557
0.95173
0.961585
0.955149
0.958367
0.94992
0.948914
0.9642
0.953741
0.950121
1
0.990949
0.995776
0.99596343
0.99672244
0.99827497
0.99689495
1
0.98550975
0.9943074
0.98533724
0.99896498
0.99120235
0.9886148
0.99585993
0.98688977
0.98654476
0.99068484
0.99171986
0.97843712
0.97826462
0.97912713
0.97826462
0.98216493
1
0.98508417
0.98806733
0.984658
0.98423183
0.9961645
0.99978692
0.99680375
0.98487108
0.98508417
0.9859365
0.9910505
0.98423183
0.98252717
0.98380567
0.98274025
0.98295333
0.98614958
0.98806733
0.95691087
0.94334748
0.94943717
0.94353202
0.94888356
0.94999077
0.94630006
0.94537738
0.9516516
0.95497324
0.95571139
0.95755674
0.95202067
0.94593098
0.94537738
0.94888356
0.95552685
0.94593098
1
0.94630006
0.989049
0.990536
0.985692
0.985016
0.987044
0.981974
0.983889
0.983438
0.990762
0.98817
0.982087
0.996282
0.995268
0.997747
0.99279
0.993804
0.998986
1
0.999549
0.994479
0.9788205
0.9856073
0.99180903
0.98513925
0.99216007
0.99192605
0.96805523
0.96173648
0.9678212
0.96407676
0.96618301
0.98432015
0.99180903
0.98864966
0.98724549
0.98747952
0.99157501
0.99379827
1
0.99730868
0.99157943
0.99203459
0.99135184
0.99214838
0.99522076
0.99487938
0.99476559
0.99214838
0.99635867
0.99317251
0.99556213
0.99248976
1
0.99988621
0.99487938
0.99738279
0.99749659
0.99499317
0.99123805
0.99476559
0.99947582
0.99023112
0.99070765
0.99082678
0.99189898
0.99725995
0.99213724
0.9938051
0.99654515
0.99606862
1
0.99702168
0.99678342
0.99463903
0.99082678
0.99440076
0.99428163
0.99821301
0.99404336
0.99142244
Output
0.989933
0.980061
0.986422
0.985443
0.980673
0.987768
0.986789
0.987278
0.986544
0.98789
0.985566
0.992294
0.987034
0.98422
0.981162
0.988257
0.990459
0.990336
0.993394
1
0.98452148
0.97961426
0.9942627
0.98803711
0.97973633
0.9855957
0.98779297
0.99438477
0.99645996
0.98132324
0.99206543
0.98583984
0.98803711
1
0.98510742
0.98291016
0.98156738
0.9810791
0.97875977
0.9921875
0.9717091
0.97522548
0.97865053
0.99851581
0.99463409
0.99840164
0.99885832
0.99509076
0.9953191
0.99885832
0.99817331
0.99828748
0.99805914
0.99817331
0.99885832
1
0.9996575
0.99623245
0.99623245
0.99474826
0.994849308
0.989624506
0.990118577
0.989748024
0.990242095
0.997406126
0.99048913
0.993453557
0.993700593
0.997653162
0.992218379
0.990983202
0.995059289
0.993577075
0.996294466
1
0.992959486
0.992712451
0.991477273
0.991724308
0.04
0.034
0.043
0.023
0.064
0.079
0.097
0.046
0.032
0.072
0.014
0.039
0.043
0.059
0.095
0.093
0.034
0.041
0.027
0.022
0.035
0.029
0.027
0.038
0.041
0.039
0.04
0.042
0.045
0.055
0.032
0.033
0.046
0.048
0.053
0.039
0.036
0.032
0.033
0.029
0.004
0.006
0.007
0.002
0.003
0.005
0.001
0.008
0.012
0.013
0.019
0.017
0.016
0.018
0.019
0.02
0.023
0.015
0.016
0.017
0.026
0.026
0.021
0.022
0.024
0.027
0.029
0.026
0.024
0.023
0.022
0.027
0.021
0.029
0.025
0.026
0.028
0.03
0.034
0.038
0.057
0.075
0.089
0.098
0.071
0.017
0.029
0.092
0.037
0.073
0.091
0.019
0.044
0.066
0.099
0.015
0.056
0.019
0.029
0.039
0.026
0.024
0.021
0.018
0.017
0.012
0.025
0.027
0.031
0.028
0.015
0.029
0.036
0.044
0.024
0.014
0.021
0.032
0.033
0.048
-0.019
-0.011
-0.015
-0.017
-0.018
-0.012
-0.014
-0.016
-0.02
-0.016
-0.022
-0.021
-0.025
-0.011
-0.013
-0.015
-0.017
-0.012
-0.022
-0.018
0.011
0.012
0.015
0.017
0.019
0.018
0.016
0.015
0.014
0.016
0.012
0.016
0.017
0.018
0.011
0.021
0.023
0.022
0.026
0.028
0.833417
0.834171
0.811558
0.91206
0.844221
0.851759
0.987437
0.949749
0.972362
0.977387
1
0.866834
0.889447
0.917085
0.894472
0.907035
0.79397
0.796482
0.932161
0.959799
0.84560811
0.87162162
0.94932432
1
0.73310811
0.7972973
0.77027027
0.99662162
0.95608108
0.98648649
0.90202703
0.95945946
0.80743243
0.96959459
0.80405405
0.85810811
0.88513514
0.90878378
0.78378378
0.99324324
0.98820059
0.99115044
0.99410029
1
0.99705015
0.97640118
0.98230088
0.99705015
1
0.97640118
0.98525074
0.99115044
0.98820059
0.99410029
1
0.98525074
0.97640118
0.99410029
0.97640118
1
0.99784946
0.99283154
1
0.98207885
0.98566308
0.98924731
0.97849462
0.97132616
1
0.97849462
0.98207885
0.94265233
0.94623656
0.94982079
0.96415771
0.93548387
0.94265233
0.96057348
0.96415771
0.94623656
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.75
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
Type of Weld
No weld
Insufficient weld
Excess weld
Good weld
WELDING RESEARCH
Sample No.
Type of Weld
1
2
3
4
Training Data
Testing Data
20
20
20
20
80
20
20
20
20
80
Good
Excess weld
Insufficient weld
No weld
Total
1
2
3
4
Type
of
Weld
Good weld
Excess weld
Insufficient weld
No weld
Total
Number
of Sample
20
20
20
20
80
Correct
Incorrect
BP DEA
BP DEA
19
19
20
19
77
WELDING RESEARCH
19
19
19
19
76
1
1
0
1
3
1
1
1
1
4
Results
Correct
Incorrect
(%)
(%)
BP DEA
BP DEA
95
95
100
95
96.25
95
95
95
95
95
5
5
0
5
3.75
5
5
5
5
5
(21)
PG = {l1G, l2G,...,lmG}
Differential evolution algorithm
(DEA) is a heuristic method for optimizing nonlinear and nondifferentiable continuous space functions. Hence, it can be
applied to global searches within the
weight space of a typical neural network.
In this work, a very popular feed forward
multilayer perceptron neural network
(MLPNN) was used. Training a MLPNN
to recognize the objectors is typically realized by adopting an error correction strategy that adjusts the network weights
through minimization of learning error.
E = E (Y0, Y)
(20)
96-s
(22)
(23)
The network was trained at 0.0001 allowable errors. It can be seen that the
error coverage was 7.8222e-005. The performance of the proposed classifier has
been evaluated in terms of recognition
rate and execution time. The classification
performance of the network using a
Gaussian distribution-based feature vector in a butt joint is shown in Table 9. For
individual comparison, it was found that
the accuracy varies with the type of defect.
The results obtained by ANN using BP
shows the highest accuracy is 100% for insufficient welds and the lowest is for excess, good, and no welds (90%). The overall accuracy is 96.25%. In ANN using
DEA, 95% is the greatest accuracy
achieved in all types of welds. The overall
performance of neural networks in a butt
joint is shown in Table 10.
Figure 14 depicts the classification performance of neural networks using a
Gaussian distribution-based feature vector in a butt joint.
In comparison of computational times,
ANN using DEA computational time was
shorter than that of ANN using BP. Table
11 and Fig. 15 show the comparison of
overall computational time for the inspection system in a butt joint. These images
were used in the average grayscale-2D feature vector method. In the average
grayscale-2D feature vector, the average
gray levels and percentage of the highlights were extracted from the digitized
images of welded joints and then average
values of pixels in the cropped images
were computed as follows (Ref. 12):
S. No.
Feature Extraction
Method
Overall Performance
BP
DEA
1.
2D feature vector
95%
95%
2.
96.25%
95%
Feature Extraction
Method
1.
2.
2D feature vector
Gaussian distribution features
x =
1
(24)
I (x , y)
( x , y ) R 1
(25)
Conclusion
The vision inspection of welded joints
using a Gaussian distribution-based feature image extraction has been developed as well as verified with real-time
practices. In this technique, four zones of
LEDs were used for efficient extraction
of shape information, which is used to
characterize the weld nature. The classi-
32
33
WELDING RESEARCH
ABSTRACT
WELDING RESEARCH
An implant test was used to investigate the effect of welding conditions on the
susceptibility of a blast-resistant steel, BlastAlloy-160 (BA-160), to heat-affected
zone (HAZ) hydrogen-induced cracking (HIC). The lower critical stress (LCS)
was determined using the implant test with different heat input conditions and
preheat temperatures. Welding was performed using the gas metal arc process and
hydrogen was introduced using an Ar-15%H2 shielding gas. The microstructure
of the coarse-grained heat-affected zone (CGHAZ) of BA-160 was characterized
by means of both optical and transmission electron microscopy. The CGHAZ microstructure of the as-welded, low-heat-input welds consisted of untempered
martensite with some retained interlath austenite. Increased heat input leads to
the formation of lower bainite, decreasing the hardness of the microstructure. Use
of preheat for low-heat-input welds also slightly reduced CGHAZ hardness, and
the microstructure is predominantly martensite with the possibility of some bainite. It was shown in the implant test results that both increasing heat input and
using preheat improved the HIC resistance of the HAZ. The fracture behavior
was studied using scanning electron microscopy. It was shown that both welding
with high-heat input and applying preheat resulted in an increase in fracture morphology dominated by microvoid coalescence with no intergranular fracture.
Introduction
Steels are currently being used as the
principal structural material in naval ship
construction, primarily because of their
relatively low cost and good combination
of mechanical properties. For many years,
the U.S. Navy has focused on developing
stronger and tougher steels for the hull
and deck applications (Refs. 13). The
projected property requirements for highstrength, blast-resistant naval steels
needed for future ship applications is impact fracture toughness above 115 J
at 64C with a yield strength in the range
from 1030 to 1240 MPa. These steels
should possess good formability and weldability, especially good resistance to heataffected zone (HAZ) hydrogen-induced
cracking (HIC) (Ref. 4).
X. YUE (yuexinosu@gmail.com), X.-L. FENG,
and J. C. LIPPOLD are with the Welding Engineering Program, The Ohio State University,
Columbus, Ohio.
98-s
KEYWORDS
High-Strength Steels
Hydrogen-Induced Cracking
Heat Input
Preheat
Implant Test
CGHAZ Microstructure
Fracture Behavior
BA-160
Fig. 2 The implant test system (OSU-MITS) and specimen. A Schematic drawing of the implant
test; B full view of the OSU-MITS; C close-up view showing an implant specimen under loading
and an unloaded one on the top right corner ; D the implant specimen.
BA-160
SuperArc LA-100
Mn
0.059
0.05
0.06
0.001
1.63
1.69
Si
Cu
Ni
3.39
0.11
0.14
6.8
1.88
1.96
Cr
1.9
0.04
0.06
Mo
Nb
Ti
Al
Zr
0.016
0.03
0.04
0
0.01
0
0.01
WELDING RESEARCH
Fig. 3 Macrostructure of implant test specimens welded under different conditions. A Weld with low heat input; B weld with high
heat input; C weld with low heat input, preheat at 150C before
welding; D macrostructure of a fractured implant specimen after
loading showing the fracture path.
WELDING RESEARCH
Weld Macrostructure
Step
1. Austenitization
2. Liquid nitrogen hold
3. Tempering
4. Tempering
Temperature,C
Duration
900
196
550
450
1h
30 min
30 min
5h
Water quench
Air warm to room temp
Water quench
Air cool to room temp
Fig. 4 Vickers hardness measurements taken along the axis of the implant specimen. A Weld with low heat input; B weld with high heat input;
C weld with low heat input, preheat at 150C before welding.
Fig. 5 Optical micrographs for the CGHAZ of BA-160. A Weld with low heat input; B weld with high heat input; C weld with low heat input, preheat at 150C before welding.
A36 steel
0.5 (12.7)
2 (50.8)
4 (101.6)
3.5 (88.9)
in. (mm)
in. (mm)
in. (mm)
in. (mm)
in. (mm)
0.201 (5.1)
Implant specimen
Material
Total length of implant
specimen
in. (mm)
Type of thread
Pitch
in. (mm)
Major diameter in. (mm)
Minor diameter in. (mm)
Thread length
in. (mm)
Thread angle
Thread root radius in. (mm)
BA-160
1 (25.4)
10-32 UNF
1/32 (0.79)
0.1900 (4.83)
0.1517 (3.85)
0.5 (12.7)
60 deg
0.004 (0.1)
WELDING RESEARCH
Fig 6 Bright-field TEM micrographs for the CGHAZ of BA-160. A Weld with low heat input; B weld with high heat input; C weld with low heat
input, preheat at 150C before welding.
WELDING RESEARCH
Fig. 7 Implant test results for BA-160. A Weld with low heat input; B weld with high heat input.
Table 4 Summary of Microstructure, Hardness, and Implant Test Results for Different Welding Conditions for BA-160
Welding Conditions
Low HI
(33 kJ/in.)
High HI
(66 kJ/in.)
Low HI
(33 kJ/in.), preheat
at 60C
Low HI
(33 kJ/in.), preheat
at 100C
Low HI
(33 kJ/in.), preheat
at 150C
M+B
M+(B)a
370
91 ksi
(627 MPa)
358
96 ksi
(661 MPa)
368
94 ksi
(648 MPa)
366
103 ksi
(710 MPa)
363
107 ksi
(737 MPa)
CGHAZ microstructure
b
(a) M represents martensite; B represents bainite; (B) represents possible formation of bainite in the microstructure.
(b) Avg means the average hardness of the CGHAZ, which is determined by taking the average of hardness data points in the CGHAZ region
together. The approximate boundary of CGHAZ is determined by metallographic observation.
Fig. 9 Fracture morphology of implant specimen, weld with low heat input, failed after 17 min under
tensile stress of 107.9 ksi. A General fracture appearance; B intergranular; C quasi-cleavage;
D microvoid coalescence.
Fig. 10 Fracture morphology of implant specimen, weld with high heat input, failed after 139 min
under tensile stress of 107.9 ksi. A General fracture appearance; B quasi-cleavage; C microvoid coalescence.
WELDING RESEARCH
WELDING RESEARCH
Fig. 11 Fracture morphology of implant specimen weld with low heat input and preheat of
100C, failed after 80 min under tensile stress of
107.9 ksi. A General fracture appearance; B
quasi-cleavage; C microvoid coalescence.
heat effect on reducing the cracking tendency. The implant test results are shown
in Fig. 8AC. It can be seen that with preheat before welding, all three curves show
that the incubation time prior to failure is
longer than that without preheat at equivalent tensile stress levels, as compared to
Fig. 7A, indicating applying preheat reduces HAZ cracking tendency. This is because applying preheat can reduce the diffusible hydrogen content, and thereby a
longer incubation time is required to
reach the critical hydrogen level to cause
cracking to occur. This is one evidence indicating that preheat is effective to alleviate the HAZ HIC cracking tendency for
BA-160.
The LCS with preheating at 60C was
determined to be 94 ksi (648 MPa), which
is slightly higher as compared to 91 ksi
(627 MPa) without preheat. Increasing the
preheat temperature to 100C, the LCS
was increased to 103 ksi (710 MPa), and
this was also with a concomitant increase
in incubation time. By further increasing
the preheat temperature to 150C, the
LCS was increased to 107 ksi (737 MPa).
This clearly indicates that increasing preheat temperature is beneficial to reduce
HAZ cracking tendency for BA-160. However, increasing preheat temperature to
150C to reduce cracking was not so effective compared with the 9-ksi LCS increase
from preheat at 60 to 100C. Based on the
implant test results, it is shown that applying preheat and increasing preheat temperature are beneficial to reduce the
cracking tendency for BA-160. One reason is that applying preheat results in a
lower cooling rate, which leads to the formation of a lower hardness microstructure
in the CGHAZ as found in the Vickers
hardness test results. The other reason is
that preheat is effective to reduce the diffusible hydrogen level in the HAZ as discussed previously.
Conclusions
1. Using low-heat-input welding conditions (33 kJ/in.), the CGHAZ microstructure of BA-160 is lath martensite with retained austenite. With high heat input (66
kJ/in.), lower bainite forms in the
CGHAZ. The mixture of martensite and
lower bainite has a lower hardness as com-
Acknowledgments
WELDING RESEARCH
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