2002 June - American Welding Society · Pipe and'Tube r~ f Welding ~ '~..~ Titanium Piping,...

June 2002

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PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY AND APPLICATION OF WELDING

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CONTENTS June 2002 . Volume 8 1 . Number 6

Features 31 Navy Upgrades Ship's Piping

Titanium piping is chosen to reduce life cycle costs for a new Navy vessel M. S a m m o n s

36 Subsea Structure Demands High-Quality GTA Pipe Welds A "young" fabrication yard gets its feet wet with a 68-ton, deep-water exploration structure threaded with stainless steel and alloy 625 piping R . O . B o w s

4 0 Orbital Welds Take Flight Cessna Aircraft Co. turns to orbital welding to join the titanium hydraulic lines on its fastest business jet

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Multiple-Wire Welding Boosts Steel Pipe Output A natural gas pipeline project gets on the fast track with a multiwire system that produces 40-ft longitudinal welds

Determining Marine Pipe Quality Alternative standards and fracture mechanics are used to develop acceptance criteria for high-pressure marine piping systems d. R. S t i l l a n d d. B . S p e c k

Welding Research Supplement 85 -S

90-8

95-S

The Stress Field Characteristics in the Surface Mount Solder Joints under Temperature Cycling: Temperature Effect and Its Evaluation The temperature cycling history of a surface mount solder joint was taken into account in the analysis of dynamic stress distribution Y. Y. Qian, X. Ma, and F. Yoshida

A Study of Weld Pore Sensitivity of Self-Shielded, Flux Cored Electrodes Both nitrogen and oxygen were found to greatly influence porosity formation in self-shielded flux cored welding O. W e i , O . H u , F. G u o , a n d D. d . X i o n g

Fume Model for Gas Metal Arc Welding A model intermediate between theoretical and empirical was developed to predict fume generation from the globular and spray transfer modes C. d . R e d O i n g

104-S Primary Circuit Dynamic Resistance Monitoring and its Application to Quality Estimation during Resistance Spot Welding A weld monitoring system was developed to analyze weld strength and nugget diameter Y. C h o a n d S. R h e e

AWS Web site http.www.aws.org

Departments Press-Time News ... . . . . . . . . . . . . . 6

Editorial . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Washington Watchword ........ 10

CyberNotes . . . . . . . . . . . . . . . . . . . . . . 1 4

News of the Industry . . . . . . . . . . . . 20

Letters to the Editor . . . . . . . . . . . . 22

New Products . . . . . . . . . . . . . . . . . . . . 24

Welding Workbook . . . . . . . . . . . . . . 60

Brazing Q&A . . . . . . . . . . . . . . . . . . . . . . 61

NJC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Coming Events . . . . . . . . . . . . . . . . . . 64

Society News ... . . . . . . . . . . . . . . . . . 69

Aluminum Q&A . . . . . . . . . . . . . . . . . . 95

New Literature ... . . . . . . . . . . . . . . . 97

Personnel . . . . . . . . . . . . . . . . . . . . . . 100

Red Hot . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Classifieds . . . . . . . . . . . . . . . . . . . . . . 108

Advertiser Index . . . . . . . . . . . . . . . . 110

Welding Journal (ISSN 0043-2296) is published monthly by the American Welding Society for $90.00 per year in the United States and p o s s e s -

s i o n s , $130 per year in foreign countries: $6.00 per single issue for AWS members and $8.00 per single issue for nonmembers. American Welding So- ciety is located at 550 NW LeJeune Rd., Miami, FL 33126-5671; telephone (305) 443-9353. Periodi- cals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Welding Journal, 550 NW LeJeune Rd., Miami, FL 33126-5671.

Readers of Welding Journal may make copies of articles for personal, archival, educational or research purposes, and which are not for sale or resale. Per- mission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright.

W E L D I N G J O U R N A L BB.1B

PRESS TIME NEWS

Weld Repairs Planned for Nuclear Reactor Head FirstEnergy Nuclear Operat ing Co.,

Akron, Ohio, recently submitted plans to the U.S. Nuclear Regulatory Commission (NRC) for the repair of the reactor pressure vessel head at the Davis-Besse Nu- clear Power Station in Toledo, Ohio. NRC must review and approve the repair prior to the start of work.

Boric acid seeping through cracks in two control rod drive mechanism nozzles corroded carbon steel in the reactor head.

The plan calls for cutting out the corroded area using robotic equipment and a high-pressure, waterjet abrasion technique. Robotic equipment will then be used to weld in a 6-in.-thick, corrosion- resistant, nickel-alloy plate. The plate will be about 17 in. in diameter and will cover the nozzle opening adjacent to the corroded area and another nozzle opening near the corrosion. A preliminary plan called for cutting out a 13-in.-diameter area around the corrosion damage. In the submitted plan, the diameter of the repair

was enlarged to encompass the other nearby nozzle to make the overall area stronger.

The reactor head is a dome-shaped structure 7 ft high, about 17 ft in diameter, and weighing about 150 tons. It is made from 6-in.-thick carbon steel and lined with stainless steel. It covers the reactor vessel.

Personnel from Davis-Besse, Fram- atome ANP Inc., and Welding Services, Inc., will perform the work, which is estimated to cost approximately $25 million. The repairs are designed to last for the remaining life of the plant and must comply with NRC requirements. The company ex- pects the plant to be in service by the third quarter of this year.

Prior to beginning the work, mock-ups will be used to demonstrate the effectiveness of the cutting, welding, and inspection techniques. The welds will be subjected to dye penetrant testing and ultrasonic or radiographic examination.

SME Receives Shingo Prize for Excellence The Society of Manufacturing Engi-

neers (SME) was recently awarded the Shingo Prize for Excellence in Manufac- turing for three separate bodies of work. These included a book written by Gary Conner and published by SME titled Lean Manufacturing for the Small Shop; a video series, Manufacturing Insights; and a technical journal article titled Evaluation o f the Plant Design o f Two Automotive Suppliers using the Manufacturing System Design and Decomposition.

Established in 1988, the Shingo Prize promotes awareness of lean manufacturing by recognizing companies that achieve world-class manufacturing status. The Re- search and Professional Publications category recognizes and promotes research and technical writing that supports the concept that world-class performance in quality, cost, and delivery can be achieved by applying lean manufacturing principals and techniques to core manufacturing and business processes.

Students Honored at FIRST Robotics Competition The FIRST (For Inspirat ion and

Recognition of Science and Technology) Robotics Competi t ion recently brought together more than 20,000 high school students, teachers, mentors, parents, and fans at Epcot® in Orlando, Fla., for "Zone Zeal," this year's contest.

Teams were honored for design excellence, competitive play, sportsmanship, and partnerships between schools, businesses, and communities. In addition, FIRST awarded $2 million in scholarships from leading universities, colleges, and companies to individual FIRST students.

FIRST was created to instill an appreciation of science in young people, their schools, and their communities. High school students and technical mentors work as a team to design and construct a robot that solves a problem using a "kit of parts" and a standard set of rules. This

year, the robots had to collect soccer balls, put them into goals, then move the goals into specified zones in order to earn points - - all in less than two minutes.

This year, #175 Buzz Robotics, Enrico Fermi High School, Windsor Locks, Conn., received the organization's most prestigious award, the Championship Chairman's Award. The award recognizes the team that built significant and lasting partnerships through the active mentoring of students by professional team members and sponsors. John Doerr , par tner at Kleiner Perkins Caufield & Byers, received the Founder 's Award for "exceptional service in advancing the ideals and mission of FIRST."

A complete listing of match results and scholarship winners can be found at the FIRST Web site at www.usfirst.org.

BI.1B JUNE 2002

Publisher Jeff Weber Assistant Publisher Christine Tarafa

Editorial Editor/Editorial Director Andrew Cullison

Features Editor Mary Ruth Johnsen Associate Editor Susan Campbell

Assistant Editor Doreen Yamamoto Peer Review Coordinator Doreen Kubish

Contributing Editor Bob Irving

Graphics and Production Creative Director Jose Lopez

Production Editor Zaida Chavez

Advertising National Sales Director Rob Saltzstein

Advertising Sales Promotion Coordinator Lea Garrigan Advertising Production Frank Wilson

Subscriptions Orlando Collado

American Welding Society 550 NW LeJeune Rd., Miami, FL 33126

(800) 443-9353, ext. 290

Publications, Expositions, Marketing Committee

G. D. Uttrachi, Committee Chairman ESAB Welding & Cutting

G. O. Wilcox, Vice Chairman Therrnadyne Industries J. D. Weber, Secretary

American Welding Society P. Albert, KrautkramerBranson

T A. Barry, Miller Electric Mfg. Co. C. E. Boyer, ABB Robotics

T C. Conard, ABICOR Binzel D. L. Doench, Hobart Brothers Co. J. R. Franklin, Sellstrom Mfg. Co.

N. R. Helton, Pandjiris, Inc. E. C. Lipphardt, Ex Off., Consultant

V. Y. Matthews, The Lincoln Electric Co. G. M. Nally, Consultant

R. G. Pali, J. P. Nissen Co. S. Roberts, Whitney Punch Press

J. E Saenger, Jr., Edison Welding Institute R. D. Smith, The Lincoln Electric Co. J. G. Postle, Ex Off., Postle Industries

E. D. Levert, Ex Off., Lockheed Martin Missiles and Fire Control L. G. Kvidahl, Ex Off., Northrop Grumman Corp. J. C. Lippold, Ex Off., The Ohio State University

Copyright © 2002 by American Welding Society in both printed and elec. tronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.

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'DITORIAL

A W S : T h e Next Generation The devastation of 9/11 and the business downturn that followed has had an impact on

everyone. The welding industry was not immune nor was the American Welding Society. AWS is facing the challenges, however, and I believe our great organization will be ahead of the curve as the economy strengthens. In the meantime, important decisions will continue to be made. The needs of our diverse membership will continue to be served. Our directors, volunteers, and staff will remain committed to the future of the welding industry. These are the tenets that have positioned AWS at the apex of the welding industry, and I am confident they will serve us well in the months ahead.

I am honored to serve as your president this year. It will be my responsibility, along with the board of directors, to maintain a steady course for the Society. I, like all who have pre- ceded me, will adhere to another, equally important, commitment: the education and training of the next generation of welding professionals. From entry-level welders to graduate research students, AWS continues to be the driving force in preparing individuals to serve our industry in a wide range of careers. However, we must also reinforce our resolve and dedication to encourage newcomers to enter our profession, become certified, and expand their horizons for the future. For those planning on college, we need to convey the wide spectrum of opportunities available within the welding industry. For those who are already a part of the industry, we need to seek out and develop their leadership qualities for Soci- ety service. On the corporate side, we must continue to build strong relationships with companies large and small. Great strides have been made in that direction through our Weld- ing Equipment Manufacturers Committee (WEMCO) and the end user-oriented Welding Industry Network (WIN).

We have restructured our marketing department and added a marketing research function to identify new member prospects and to stimulate demand for our products and services. We have tightened control of expenses across the board to provide a leaner, but more efficient, operation. Next year, the Welding Show will stand as the only exhibition dedicated solely to welding. New and revised standards and codes are expected to effectively add to our revenue stream, as are new educational offerings and the expanding services offered on the Web site. AWS certifications are among the most recognized and respected around the world and we anticipate they will continue to be in demand as we pursue new avenues with other industry organizations.

Internationally, we continue to enjoy solid relationships with our sister societies and counterpart organizations. This is important to AWS in the building of consensus on international standards and other industry activities.

In closing, I would like to briefly address the matter of image as it relates to our industry. We know the Society enjoys a positive perception among a majority of its members and peers. However, the general public and industry as a whole are virtually unaware of the role welding plays in the world today. They do not know of the value it adds to products that make life easier, protect our nation, and explore outer space, or that it provides a wide range of well-paying career opportunities. AWS must explore ways whereby parents, students, educators, engineers, business executives, and government agencies will form and maintain positive opinions about welding. This is another area in which I plan to be active throughout this year. In addition, I will call upon the WEMCO and WIN groups for their assistance in enlisting industry support and cooperation in the development and implementation of these image programs at the local, state, and national levels. With the production capabilities of the headquarters staff, I believe inroads can be made in establishing positive atti- tudes toward welding and its contributions to our great country.

Ernest D. Levert A WS President

E - = i JUNE 2002

aWeldlu Founded in 1919 to Advance the Science, Technology and Application of Welding

Officers President E. D. Levert

Lockheed Martin Missiles and Fire Control

Vice President T. M. Mustaleski BWXT-Y12 LLC

Vice President James E. Greet Moraine Valley Community College

Vice President Damian J. Kotecki The Lincoln Electric Co.

Treasurer Earl C. Lipphardt

Directors O. AI-Erhayem (At Large), JOMlnstitute

R. L. Arn (Past President), Teletherm Technologies, Inc.

A. J. Badeaux, Sr. (Dist. 3), Crossland High School

H. J. Bax (Dist. 14), Cee Kay Supply

M. D. Bell (Dist. 22), Preventive Metallurgy

L. J. Bennett (Dist. 21),Allan Hancock College

J. C. Bruskotter (Dist. 9), Project Specialists, Inc.

C. E Burg (Dist. 16),Ames Laboratory

Neal A. Chapman (Dist. 6), Entergy Nuclear Northeast

S. C. Chapple (Dist. 1 i), Midway Products Group

N. C. Cole (At Large), NCC Engineenng

W. J. Engeron (Dist. 5), Engineered Alloy~Systems & Supply

A. E Fleury (Dist. 2),A. E Fleury & Associates

J. R. Franklin (At Large), Sellstrom Mfg. Co.

J. A. Grantham (Dist. 20), WJMG West

J. D. Heikkinen (Dist. 15), Spartan Sauna Heaters, Inc.

W. E. Honey (Dist. 8),AnchorResearch Corp.

J. L. Hunter (Dist. 13 ),Mitsubishi Motor Mfg. of America, Inc.

R. D. Kellum (At Large), Willamette WeMing Supply

M. D. Kersey (Dist. 12), The Lincoln Electric Co.

R. C. Lanier (Dist. 4), Pitt Community College

G. E. Lawson (At Large), ESAB Welding & Cutting Products

V. Y. Matthews (Dist. 10), The Lincoln Electric Co.

J. L. Mendoza (Dist. 18), City Public Secvice

L. W. Myers (Past President), Consultant

G. H. Putnam (Dist. 1), ThermalDynamics

O. P. Reich (Dist. 17), Texas State Technical College at Waco

R. J. Tabernik (Dist. 7), The Lincoln Electric Co.

G. E. Uttrachi (At Large), WA Technology, LLC

P. E Zammit (Dist. 19), Brooklyn Iron Works, Inc.

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~VASHINGTOI~ WATCHWORD

BY HUGH K. WEBSTER AWS Washington Government Affairs Office

Ergonomics Redux In its continuing effort to address ergonomic injuries in the

workplace, the U.S. Occupational Safety and Health Administration (OSHA) has announced a new plan. Although not yet finalized, the plan apparently will utilize a combination of industry and task-specific targeted guidelines, increased enforcement, workplace outreach and assistance, and advanced research. A specific deadline for release of the plan has not yet been determined; however, the agency is expected to develop guidelines for certain high risk industries by the end of this year. In addition, OSHA intends to continue to utilize its general authority under federal law to address particularly egregious ergonomics problems at specific companies.

Unlike the comprehensive regulations prepared by OSHA and vetoed by Congress last year, the new rules will place more emphasis on compliance assistance by OSHA, including specialized training and information. Also, OSHA plans to focus on immigrant workers, especially those with limited English profi- ciency, since such workers tend to work in industries with high ergonomic hazard rates.

the event of national emergency. The legislation seeks to organize, in advance, teams of volunteers with technology and scientific expertise that can be mobilized on short notice in the event of terrorist attacks or other disasters. The legislation would also create a "virtual technology reserve," or database of private sector equipment and expertise, that emergency officials could call upon if necessary. Equally significant would be the creation of a Center for Civilian Homelands Security Technology Evaluation that would serve as a national clearinghouse and test center for innovative technologies related to emergency prevention and response.

OSHA has revisited the ergonomics

issue by devising a yet-to-be finalized

plan that will encompass guidelines,

increased enforcement, workplace out-

reach and assistance, and research.

Initiative Aims to Ensure Regulations Are Based on 'Sound Science'

A significant effort is being undertaken by the Administration to overhaul the regulatory process with respect to data, particularly scientific data, that federal agencies rely on in drafting regulations. This initiative reflects the philosophy of the current Administration and the mandate of the Data Quality Act, which becomes effective October 1. Both are aimed at ensuring the quality and integrity of scientific information and statistics utilized by federal agencies as the basis for their regulations. This initiative is particularly relevant in the environmental, occupational safety and health, and energy industries.

The Data Quality Act would also create a system in every agency through which any member of the public could challenge documents and regulations as being based on erroneous data. As with most issues in Washington, there is a significant political aspect to this. The business community has long believed federal agencies prepare regulations based on flawed assumptions and weak, or even incorrect, scientific studies and data. They see the current reform effort as a means to make the process more accurate and fair. The other side argues these efforts are, in fact, a thinly disguised attempt to invalidate certain existing regulations and delay or reduce the environmental, health, and other pro- tections contained in future federal regulations.

Expected Reduction in Labor Regulations The U.S. Department of Labor has announced its regulatory

agenda will represent up to a 40% reduction in regulations for the coming year. According to Labor, this reduction reflects, in part, the less activist approach to federal regulation of the current Administration, but is primarily attributable to regulatory agendas in the past that were unrealistic.

Lobbying Expenses Decrease for the First Time

For the first time since records have been kept, reported expenses for registered lobbyists have decreased. In the first six months of 2001, the most recent time period for which data is available, approximately $800 million was reported as being spent on lobbying Congress. In fact, this is a significantly under- stated figure since only amounts directly related to lobbying activity are required to be reported. Most lobbying costs are in background, preparation, and other indirect expenses. Regardless, the $800 million figure represents a 5% reduction from the previous year. This is the first reduction in lobbying expenses ever and apparently is due to the economic recession during that period.

Commerce Business Daily Ceases Publication, Web Sites Fill the Void

Commerce Business Daily (CDB) was once the best, and in many instances the only, source for information on potential government contracts. Published by the U.S. Government Printing Office, it was considered the official directory for federal agencies seeking contractors. After more than 50 years, the Commerce Business Daily has ceased publication. From a high of 55,000 in 1986, a period of significant military build up, subscriptions dropped to 2600 last year. Today, numerous privately sponsored Web sites have replaced the CBD as a source of information for potential government contractors. One of the most important government sites is FedBizOpps.gov, where federal agencies are required to announce larger contracts.

Science and Technology Emergency Mobilization Legislation Introduced

Bipartisan legislation has been introduced in Congress to facilitate the utilization of scientific and technology resources in

Contact the A WS Washington Government Affairs Office at 1747 Pennsylvania Ave. NW, Washington, DC 20006; e-mail [email protected]; FAX (202) 835-0243.

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~ Y B E R N O T E ~. A collection of industry news from the Internet

Women in Trades Focus of Web Site

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Tradeswomen Now and Tomorrow (TNT). The organization, which held its inaugural national meeting in March, is a network of organizations and individuals dedicated to promoting the cause of women in trade and technical fields. According to the Web site, its mission is "to promote policies and actions that achieve women's economic equity by increasing the number of women in trades and technical jobs, and by improving their working conditions." Its Web site offers a description of the organization and its mission, membership information, a list of participating organizations with links to their sites, and details about its working groups and inaugural meeting. The "Announcements" page provides information on meetings and organizations of interest to tradeswomen. The organization's chat room can also be accessed through that page.

E,H. W A C H S C O M P A N

http://www.tradeswomennow.org

Robotics Competition Highlighted

FIRST (For Inspiration and Recognition of Science and Technology). The organization's Web site details the FIRST Robotics Competit ion, which teams professionals with high school students to solve an engineering design problem. This year's events, which culmi- nated in April at the championship event at Epcot Center, reached more than 20,000 students on more than 600 teams.

The students and their mentors design and build a robot using a kit of parts and a standard set of rules. For this year's competition, called "Zone Zeal," robots collected soccer balls, put them into goals, then moved the goals into specified zones to collect points. According to the site, "The competition shows students that the technological fields hold many opportunities and that the basic concepts of science, math, engineering and invention are exciting and interesting."

The Web site provides tips on starting a team and how to serve as a mentor. It describes the kickoff, regional, and championship events. Key suppliers and resources for teams are listed and an interactive map helps visitors locate regional events, registered teams, and U.S. and international mentors. Information on the many scholarships available to FIRST team members is offered, as well as news items about the event.

http://www.usfirst.org

Products for Engineers

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GlobalSpec.com. Information on approximately 3.7 million products from suppliers in more than 130 product areas can be located on this Web site. The site connects engineers and other technical buyers with the products and manufacturers they need based on engineering specifications. Visitors can find products by browsing through a list of categories or they can type in a topic or manufacturer 's name. A search of "welding" brought up 10 categories that offer full information through the company's SpecSearch ~ system and another 13 offering directory listings.

Visitors get full access to the site after filling in the on-line registration form. Once registered, they can access technical articles and other reference materials as well as an on-line newsletter.

http:/ /www.globalspec.com

Site Detailslndustrial Gas and Cryogenic Products

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Rego Cryo-Flow Products. The company, based in Burlington, N.C., highlights its industrial gas and cryogenic valves, regulators, and relief valves on its Web site. Visitors can download the entire company catalog or individual pages in PDF format. The site also offers a company profile and a list of distributors.

http://www.regoproducts.com/cryoflow

Pipe Cutting, Beveling Tools Highlighted

E. H. Wachs Co. The company, based in Wheeling, I11., manufactures tools for cutting, beveling, and facing pipe and tubing. Its Web site offers detailed product information on its line of air-, hydraulic-, and electric-powered tools. Products can be purchased on-line and the site provides information on the company's equipment rental service. In addition, the "Technology Center" pages offer brief case studies detailing the solutions the company developed to solve problems in a variety of applications. It also includes on-line or downloadable versions of a pipe chart for fast conversions between U.S. customary and metric units of pipe sizes and schedules.

http://www.wachsco.com

m E ! JUNE 2002

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An I l l q G = Company

American Welding Society

Friends and Colleagues:

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

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

• Leadership of or within an organization that has made a substantial contribution to the welding industry. The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities.

• Leadership of or within an organization that has made a substantial contribution to training and vocational education in the welding industry. The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities.

For specifics on the nomination requirements, please contact Wendy Sue Reeve at 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 February 1, 2003. The committee looks forward to receiving these nominations for 2004 consideration.

Sincerely,

L. W. Myers Chairman, Counselor Selection Committee

DATE

AWS MEMBER NO.

HOME ADDRESS.

CLASS OF 2004 COUNSELOR N O M I N A T I O N FORM

(please type or print in black ink)

NAME OF CANDIDATE

YEARS OF AWS MEMBERSHIP

CITY

PRESENT COMPANY/INSTITUTION AFFILIATION

TITLE/POSITION

S T A T E . ~ Z l P CODE PHONE

BUSINESS ADDRESS.

CITY

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION.

STATE ZIP CODE. PHONE.

MAJOR & MINOR

DEGREES OR CERTIFICATES/YEAR

LICENSED PROFESSIONAL ENGINEER: YES

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE.

_ _ _ N O . STATE

POSITION

COMPANY/CITY/STATE.

YEARS

POSITION YEARS

SUMMARIZ E MAJOR CONTRIBUTIONS IN THESE POSITIONS:

SUGGESTED CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE SELECTED AS AN AWS COUNSELOR. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE INCORPORATED WITHIN THE CITATION CERTIFICATE.

**MOST IMPORTANT** The Counselor Selection Committee criteria are strongly based on and extracted from the categories identified below. All in-

formation and support material provided by the candidate's Counselor Proposer, Nominating Members and peers are considered.

SUBMII-I'ED 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.

NOMINATING MEMBER: AWS Member No. NOMINATING MEMBER: AWS Member No. NOMINATING MEMBER: AWS Member No. NOMINATING MEMBER: AWS Member No.

SUBMISSION DEADLINE FEBRUARY 1, 2003


Nomination of AWS Counselor

I. HISTORY AND BACKGROUND In 1999, the American Welding Society established the honor of Counselor to recognize indi-

vidual members for a career of distinguished organizational leadership that has enhanced the image and impact of the welding industry. Election as a Counselor shall be based on an individual's career of outstanding accomplishment.

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

• Leadership of or within an organization that has made a substantial contribution to the welding industry. (The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of participation of its employees in industry activities such as AWS, IIW, WRC, VlCA, NEMA, NSRP SP7 or other similar groups.)

• Leadership of or within an organization that has made substantial contribution to training and vocational education in the welding industry. (The individual's organization shall have shown an ongoing commitment to the industry, as evidenced by support of partici pation of its employees in industry activities such as AWS, IIW, WRC, VlCA, NEMA, NSRP SP7 or other similar groups.)

II. RULES A. B.

C.

D.

E. F. G.

III.

Candidates for Counselor shall have at least 10 years of membership in AWS. Each candidate for Counselor shall be nominated by at least five members of the Society. Nominations shall be submitted on the official form available from AWS headquarters. Nominations must be submitted to AWS headquarters no later than February 1 of the year prior to that in which the award is to be presented. Nominations shall remain valid for three years. All information on nominees will be held in strict confidence. Candidates who have been elected as Fellows of AWS shall not be eligible for election as Counselors. Candidates may not be nominated for both of these awards at the same time.

NUMBER OF COUNSELORS TO BE SELECTED 2001 Class of Counselors:

Year one, maximum of 20 Counselors selected, as determined by the committee 2002 Class of Counselors:

Year two, maximum of 20 Counselors selected, as determined by the committee 2003 Class of Counselors:

Year three, maximum of 15 Counselors selected, as determined by the committee 2004 Class of Counselors:

Year four, and thereafter: maximum of 10 Counselors selected, as determined by the committee

Return comoleted Counselor nomination oacka~e to: v

Wendy S. Reeve American Welding Society 550 N.W. LeJeune Road Miami, FL 33126

Telephone: 800-443-9353, extension 215

SUBMISSION DEADLINE: February 1, 2003

r iiq, ,f1,11 iiiii iI1 N I,[IIN II,T Pill Phi,nil lllHinl. ,1111,, - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

As the economy gets tighter and prices continue to rise, customers want quality, and they want it faster.

Companies that can meet the demands obviously have the edge.

Tampa Bay Steel is one of those companies. Tampa Bay Steel Corporation (TBSC) is a good ex-

ample of a company looking for better ways to keep the edge and sharpen it as demands increase.

Here's how TBSC is solving problems and looking for better ways to keep up with a steadily increasing demand.

Part of Tampa Bays' production involves the cutting of steel plate for OEM's, fabrication shops, and machine shops, a wide variety of customers and requirements.

Project specifications can call for cuts to be simple straight line cuts or complicated shapes. Orders come in daily specifying components to be made of plate steel which can vary in thickness from gauge material to 1 inch. The complexity of a project, metal type and thickness determines which cutting machine to use and how the machine configuration should be set up to use different plasma or oxy-fuel torch combinations.

To meet project specifications, TBSC uses plasma cutting machine torches mounted to tables.

Three of the cutt ing tables are equipped with regular plasma machine torches, and two are equipped with high definition torches. Heavier metals up to six inches are usually cut using ATTC oxy-fuel tips.

It was determined that by solving two concerns the company could save time and money.

Change out time (the time it takes to change torch components) was one concern and low pierce and shield cap life from the existing plasma parts was the other.

M a r k S t e w a r t ( lef t) a n d F r e d Wi l l i ams e x a m i n e a s h i e l d c a p .

To solve these problems, TBSC has experimented with several types of electrodes and shield caps.

Fred Williams, Supervisor of the burning department explained, "After trying several brands of plasma components we decided on ATTC parts. We get a substantial increase in pierces and shield cap life which of course means less change out time."

Mark Stewart, Operations Manager for Tampa Bay Steel explained. "We work together with ATTC to solve technical issues. For example: In one shield cap application, the shield cap used for a 100 amp high definition torch had a very small orifice, We worked in conjunction with ATTC and served as a Beta site to find a solution. We went to a larger orifice and extended the life of the component considerably. They work very closely with us."

said Mark "If we have a problem they go out of their way to help solve it." He went on.

Mark noted that when they use ATTC designed nozzles, on the high definition machines, they don't have to stock as many parts.

American showed them how their nozzle, would save them a substantial amount by using fewer shields - 10 times fewer when cutting with 100 amp torches. They also showed them how using the same shields, re- taining caps and swirl rings for both 70 and 100 amp cutting torches would save them even more money.

Williams points out how they also save money because the ATTC order system can get their orders filled and delivered quickly, usu-

ally within 24 hours. "We don't have to leave a table idle for lack of parts," he noted.

"American Torch Tip has filled all our needs in a timely manner, the product quality is excellent and the pricing is great. They definitely have given us a production edge," he concluded.

AME CAN A- C ° TORCH TIP

I 6212 29th Street East, Bragonton, FL 34203 rn 941-753-7557 0 800-342-8477 [3 Fax: 941-753-6917 [3 Int'l PO: 941-753-7562 E-Mail: [email protected] ~3 Web: www.americantorchtip.com [3 Offices & Warehouses in: Canada & England ® A T T C IS A R E G I S T E R E D T R A D E M A R K O F T H E A M E R I C A N T O R C H T IP C O M P A N Y © 2001 T H E A M E R I C A N T O R C H T IP CO.


~IEWS OF Till , J ~ INDUSTRY ,,,,

Repaired Cole Returns to Home Port

The USS Cole in the Gulf of Mexico dumtg its Jirst period undepvvay after being attacked in Aden, Yemen, in October 2000. The ship was being readied for its return home to Norfolk, Va., following a 14-month- long restoration at Northrop Grumman Corp. 's Ingalls Operations.

The USS Cole recently returned to its home port of Norfolk, Va., 18 months after the terrorist bombing in Yemen that tore a hole in its side and killed 17 crew members. The Aegis guided-missile destroyer underwent $250 million in repairs at Northrop Grumman

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Ship Systems' Ingalls Operations in Pascagoula, Miss., the same shipyard where the vessel was originally built.

Among other repairs and upgrades, the ship received two new engines and 17 stars were placed on the floor of the main passage- way to honor the sailors who died.

U.S. officials have blamed the bombing of the Cole on Osama bin Laden's al-Qaeda terrorist network. The ship was damaged in Aden, Yemen, in October 2000 when terrorists pulled alongside it in a small boat and set off explosives. The ship was transported to Pascagoula aboard the Norwegian heavy-lift ship Blue Marlin.

As many as 700 shipyard employees were assigned aboard the Cole. The work included the following:

• Removal and replacement of 550 tons of steel • Removal of all damaged structure, cables, pipe, ventilation,

and equipment • Refurbishment and reinstallation of shafts, blades, hubs, air

tubes, and valve rods • Replacement of the starboard main reduction gear • Installation of new universal engine controllers • Installation of a new stern flap for increased speed and fuel ef-

ficiency • Four air conditioning plant CFC upgrades • Replacement of three gas turbine generators • Replacement of 350,163 ft of electrical cables • Installation of a new galley • Restoration of all combat systems. During the ceremony to send the destroyer on its way to Norfolk,

Rear Adm. John G. Morgan, Jr., USN, commander, Cruiser De- stroyer Group Twelve, Enterprise Battle Group, told shipbuilders the following:

"I've come here today to talk to those men and women who are wearing hard hats, welder goggles, and dusty coveralls. I've come here to thank you. Through your brains and your brawn, you have given us a gift. That gift is 505 ft of American steel that is right behind me and I thank you for that gift. It is a gift to the Navy and it is a gift to America."

CB&I Relocates Its Welding & QA Technology Group

CBdd's time-of-flight-diffraction eqtdpment in use in Nigeria.

Chicago Bridge & Iron Co. (CB&I) recently moved its corporate Welding and QA Technology Group from Houston, Tex., to the company's Technology Center in Plainfield, IlL The group supports CB&I's worldwide subsidiaries, which design, fabricate,

and erect steel plate structures and related systems in more than 40 countries each year.

The 12-person staff provides welding engineering, heat treating, and quality assurance expertise. They operate a welding and machine shop, metallurgical laboratory, nondestructive testing laboratory, and mechanical testing laboratory. Recent projects include improvements to automated welding equipment, application of new materials and welding consumables, and patent-pending, high- speed, semiautomatic austenitic ultrasonic examination techniques.

Standards Technology Institute Formed

The American Society of Mechanical Engineers (ASME) has announced the formation of a new Standards Tech- nology Institute (STI) under ASME's Council on Codes and Standards. The purpose of STI is to direct, supervise, monitor, and otherwise organize development of technology vital to the promulga- tion and maintenance of codes and standards for ASME and other organizations. The Institute has formed a board of directors charged with fulfilling its mission under ASME society policies.

For several decades, the Welding Research Council (WRC), its Pressure Vessel Research Council (PVRC), and The Materials Properties Council (MPC) have been principally involved in providing ASME with much of its required technical support. The boards of directors of WRC and PRC view STI as a positive development that will enhance coordination and long-range planning. It will also strengthen volunteer participation in developing the technology for codes and standards. ASME has affirmed the need for a strong volunteer base to support the technical activities of STI. ASME welcomes and encourages participation of current WRC and MPC committee members in the new institute.

The boards of MPC and WRC have voted to support the formation of STI. A plan is being developed whereby many of the capabilities and resources of MPC and WRC will be available under the new institute. It is intended that the functionality of MPC and WRC continue and be strengthened under STI. MPC and WRC will be dissolved in the near future in accord with the laws governing not-for-profit organizations in New York State. Where appropriate, activities of MPC and WRC that are not concluded by the dissolution dates will move forward under STI. Sponsors of the many ongoing cooperative and other funded programs under WRC and MPC will be informed shortly of the details of pro- posals for how program assets will be trans- ferred and their activities continued.

STI will have the capability to develop drafts of standards and supporting documents, gathering necessary existing information and technology, and execute needed technology development programs for ASME and others. As is the case with MPC, PVRC, and WRC, opportunities for coop- ~ S a l l eration with international partners will be sought. ~ .,v It is anticipated that publications and workshops will be used to assist in fulfilling part of the mission of STI, to communicate regarding developments connected with the new technology. Funding for future projects will be obtained by solicitation from organizations interested in the topical areas.

TRUMPF Opens Laser Laboratory

The TRUMPF Inc. Laser Technology Center recently opened a new facility in Plymouth, Mich., that includes a state-of-the-art laser laboratory for development and validation of applications for industries ranging from automotive to medical. The laser laboratory occupies 25% of the 29,000-sq-ft laser technology center.

It features more than 15 different models of the company's lasers and laser machines. Included are two high-power HL series Nd:YAG lasers connected via flexible beam delivery cables to a laser robot cell. Three low-power HL series Nd:YAG lasers are also connected via beam delivery cables to the TRUMPF LASMA, a workstation for 2-D and 3-D cutting and welding of small workpieces. The laboratory also features CO 2 lasers.

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Call Today! 1 -800-332-9448 or visit us at www.welding.orgfor more information

• Some restrictions apply; please contact us for details. © 2002 Hobart Institute of Welding Technology St. of Ohio Reg. No, 70-12-0064HT

Circle No. 26 on Reader Info-Card I WELDING JOURNAL II,",,i ee

LETTERS TO TH£ EDITOR]

Women and Welding

Dear Editor: I teach welding part time at

Wenatchee Valley College. This is a new venture for me after [working in] welding and fabricating since 1965.

I have seen very few women involved

in the welding industry. It seems to be a lack of information about opportunities for better jobs and pay. I am glad you are doing articles on this subject.

[The Welding Journal has published a number of related articles] recently. One was about Connie Christopher at Portland Community College ("College

Gold Track=V Pipe Welding System: "Still The One"

I I1~] ¢ l l l U I I I U I ¢ ; ; ,

The latest Gold TrackT"V is better than ever and "still the one"... • That experienced pipe welders choose by name • That's field-proven for dependable performance • That's known for its easy operation • That users rely on for optimum process control • That set the industry standard for orbital pipe welding • That achieves critical code, quality and production requirements • That produces quality GTA welds with outstanding repeatability • That America's Navy Shipyards and power industry prefer • That's 1/3 the size with 40% more power than previous models • That you need to get your hands on nowt So call:

at 704-892-8872 or email

Ame~a" s Most E X ~ e ~ Orbital Welding Manufacturer

JUNE 2002

[email protected] 404 Armour St. Davidson, NC 28036


Opens Doors for Women Welders," January 2002) and another about Nanette Samanich ("Behind the Mask: Nanette Samanich," March 2002). I would like to put copies of them on our bulletin board at the college.

Robert Acklin East Wenatchee, Wash.

Dear Editor: I would like to express my congratula-

tions [to the Welding Journal] for the article on Nanette Samanich. She has to continue [her work] without obstacles.

I understand her situation very well. I 'm a woman who has a degree in chemistry and am also a welding engineer. Currently, I 'm preparing for a doctoral degree in welding. But, because I 'm a woman, customers who contact my company by phone with problems ask, "Uh, are you another secretary?" when they hear my voice. They are surprised a woman can solve their technical problems. They do appreciate [my expertise], but it's hard.

Thanks again for the article.

Asun Valiente Spain

Kudos for WJ Staff

Dear Editor: I just wanted to take an opportunity to

thank you and your staff for the great job on the aluminum projection welding paper published recently in the Welding Journal ("Single-Sided Projection Welding of Aluminum Sheet," April 2002). Everything looked great and I appreciate your professionalism and especially your patience.

D. J. Spinella Alcoa Technical Center

Alcoa Center, Pa.

American Welding Society Founded in 1919 to Advance the Science, Technology and Application of Welding

? AWS Certification is the wel.ding industry's most respected sign of approval

JULY 2002 SEMINAR DATES EXAM DATES MIAMI, FL .............................. 7/14-19 .................................... 7/28/2002

NEW YORK, NY ........................ 7/14-19 .................................... 7/20/2002

SAN FRANCISCO, CA .............. 7/14-19 .................................... 7/20/2002

YORK, PA ................................ 7/7-12 ...................................... 7/13/2002

AUGUST 2002 SEMINAR DATES EXAM DATES CHARLOTTE, NC ...................... 8/11-16 .................................... 8/17/2002

COLUMBUS, OH ...................... 8/26-30 AT NBBPVl .................. 8/31/2002

HOUSTON, TX .......................... 8/11-16 .................................. 8/17/2002

INDIANAPOLIS, IN .................... 8/18-23 .................................. 8/24/2002

MIAMI, FL .............................. EXAM ONLY .............................. 8/8/2002

OMAHA, NE .............................. 8/18-23 .................................... 8/24/2002

SEPTEMBER 2002 SEMINAR DATES EXAM DATES CORPUS CHRISTI, TX .............. EXAM ONLY .............................. 9/21/2002

MIAMI, FL .............................. 9/15-28 .................................... 9/21/2002

MILWAUKEE, WI ...................... 9/8-13 .................................... 9/14/2002

PITTSBURGH, PA ...................... 9/15-20 .................................... 9/21/2002

REN0, NV ................................ 9/8-13 ...................................... 9/14/2002

SEATTLE, WA .......................... 9/8-13 ...................................... 9/14/2002

AWS re*erves the right to cancel or change the published date of an exam preparation seminar listed ff an insufficient number of registrations are received. Prices are subject to change without notice.

Seminar and Exam Schedule

Course Schedule

DL) Code Clinic ............................................ Sunday; 1 p,m.- 5 p,m,

Monday; 8 a.m.- Noon

~ I 1104 Code Clink .................................. Monday; 1 p.m.- 5 p.m.

Weldiag hspeetion 'reehnology .................. Tuesday-Thursday; 8 a.m.- 5 p.m.

~mal Inspection Workshop ........................ Friday; 8 a.m.- 5 p.m.

Exam .......................................................... Saturday; report for exam at 7:30 a,m,

To register or for more information on an exam prep course, call (800) 443-9353. ext. 229; to request an application for CWI exam qualification, call ext 273.

To find out about AWS Customized In-House Training and Quality Assurance Programs for your company, call AWS, toll-free at 1-800-443-9353, ext. 482, or check Hie box on the registration form.

Visit our website www.aws.org for additional dates.

PRODUCTS I Tube Alignment Tool Saves Time

The company's Centrator tube alignment tool allows the welder to achieve the right fitup. By inserting the tool into the pipe and turning the central actuating handle, two sets of conical fingers are drawn together, forcing the backing ring segments radially into the bores of the pipes to be aligned. Strong clamping forces hold the pipes firmly in close abut- ment, permitting welding to take place

For more information, circle number on Reader Informat ion Card.

without the need for tacking. Pipes with wall thicknesses up to 5% of pipe diameter are rounded and pipes up to 12 m in length can be welded by adding standard extensions. The tool can also be used on automatic welding stations where thicker wall pipes are welded. The tools can be operated pneumatically or hydraulically and are used in cross-country and offshore pipelines and for prefabricating pipe lengths for offshore use.

Weldlogic Europe Ltd. Blackstone Rd., Huntingdon, Cambridgeshire PE29 63F, United Kingdom

U0

Weld Control Interfaces with AC/DC Current

The HDC 1500 interfaces with any AC or DC constant current or constant voltage power source having remote contac- tor and output control. True crater condition control enables the operator to adjust crater output (voltage), crater speed (amperage), and crater time. The company offers five complete HDC 1500 packages; each includes a choice of power

source, shunt control, cable kit, RAD wire drive assembly, wire straightener, flux hopper, and OBT torch. Various power source options are available.

Miller Electric Mfg. Co. 1635 W. Spencer St., Appleton, WI 54912-1079

III

Welding Machine Is Gasoline Engine Driven

The company's industrial, gasoline-engine-driven Pipeliner 200G welding machine is designed for pipe welders and contractors. The machine offers 200-A DC at 60% duty cycle. It has five current

Every Blue box is built with guts and wired with soul.

A welder is a welder is a welder. Ulfless it's Blue. Strip away the cover, copper ~4re and controls, and you'll find the most dedicated, passionate and skilled people in the world. Empowered by a common sense o f purpose - - your success - - Miller people take their work serioush: While you may never meet line reps Lori and Larry, or need an applications engineer like Kevan, one thing's for sure: there are 1200 other folks just like them who bleed blue

just for you. To learn more, ~4sit or call 1-800-4-A-MILLER. And experience The Power o f Blue for yourself.

Miller

ranges with overlap in each range for shielded metal arc pipe welding and other arc welding processes where slope control is desired. Also featured is a 100-rpm, high-idle (CV) adjustment that provides additional fine tuning for performance on pipe. A DC exciter supplies pure DC current to the welding generator. The machine uses all-copper windings, provides 1750 W of DC auxiliary power at 115 V, and delivers staying power under load for grinding operations.

The Lincoln Electric Co. 22801 St. Clair Ave., Cleveland, O H 44117-1199

112

Industrial Magnets Designed for Heavy Applications

The company's line of industrial magnets is designed for heavy-duty shop floor applications. The products can be used for jigging, clamping, positioning, work holding, lifting, moving, and gripping. These industrial permanent magnets are available in a range of shapes including button, cylin- drical, flat, round, rectangular, and horseshoe, and in a multitude of sizes. The magnets are available in a variety of magnetic materials ranging from traditional ceramic and alnico to neodymium iron boron and samarium cobalt materials.

Strongridge Ltd. 113 106 East Dr., Brampton, Ontario, Canada L6T ICI

Ceramic Grain-Coated Abrasives Available in Fiber Discs

The company's ceramic abrasives are available in 4S-, 5-, 7-, and 9'/44-in. fiber discs designed to cut aggressively and engineered for high rates of stock removal in metal- working applications. The SF750 series grinds hardened steels, carbon steels, forg- ings, and castings where heat sensitivity is not important. The SF840 series grinds heat-sensitive metals like stainless steel and titanium. This particular series contains a self-lubricating layer that helps to reduce heat during the grinding process.

VSM Abrasives Corp. 1012 E. Wabash St., O'Fallon, MO 63366-2774

114

Bimetal Band Saw Blade Eliminates Tooth Strippage

Power through interrupted cuts and eliminate tooth strippage with the company's Rx® + bimetal band saw blade. The rigid isophonic TM tooth design mini- mizes harmonics during cutting to reduce noise levels. The blade improves cutting performance on structural steel, I-beam,

angle iron, channel iron, tubing, pipe, wide flange beams, and nested bundles. The blade is also available in extra-heavy set to avoid blade pinching.

American Saw & Mfg. Co. 115 301 Chestnut St., East Longmeadow, MA 01028-0504

Small Angle Grinder Features Powerful Motor

The company's 1701A grinder contains life-extending, epoxy-coated field windings, a 9.5-A motor, and a 5-in. wheel for

greater load capacity. The motor and body measure 11 in. in length and the 5-in. wheel offers metalworkers greater load capacity and more efficient mater ial removal. Epoxy-coated field windings offer motor protection for masonry and metal- working professionals and prevents dust and other mater ial from entering the motor. The grinder offers tool-free, easy- adjust "clic" guards and Service Minder rM brushes for easy use and preventive maintenance. The grinder also has a durable metal gear housing, a switch lock-on button, a spindle lock for easy wheel changes,

capabili ty to run off AC or DC power sources, and a two-position side handle.

Bosch Power Tools 116 4300 W. Peterson, Chicago, IL 60646

Inverter Welding Machine Is Powerful and Portable

The I 90 STS welding machine is portable, weighs 8 lb, and is a 115-V machine that puts out 90 A for ~-in., general- purpose electrode use. The machine can be taken on-site for repair jobs and comes equipped with ground clamp and electrode holder.

ArcOne 117 85 Independence Dr., Taunton, MA 02780

Welding Machine/Generator Runs on LPG

The company's GX271LPG is a multi- process, welding machine/generator for repair or construction work inside facto- ries per OSHA standards for applications where gasoline and diesel engines don ' t apply. Powered by a 20-hp Kohler air- cooled LPG engine, this welding machine provides up to 300 A of welding current at 60% duty cycle or 275 A at 100% duty cycle. Full range ouput control is provided in both CC and CV modes with arc force control in CC mode and inductance control in CV mode. Auxiliary ouput power is 9000 W, 100% duty cycle, 120/240 VAC.

Red D-Arc Welderentals 118 Airgas, Inc. 259 N. Radnor-Chester Rd., Ste. 100, Radnor, PA 19087

Software Boosts Ordering System Efficiency

JUNE 2002 I Circle No. 33 on Reader Info-Card

The company's FastPic4 v4.02 inventory management software features an advanced order processing module that improves system efficiency and order picking accuracy while reducing restocking time in welding applications. This module is valuable for the management of multiple workstations, storage areas, or locations of a SKU. The allocation method attempts to

pick the exact amount requested from the largest measure quantity available to min- imize overages when picking. Storage and retrieval optimization through this advanced order processing module can significantly reduce inventory and improve employee productivity and system through- put for welding parts operations. The standard interface protocol provides an efficient plug-and-play direct link between host systems. With this feature, users can download orders, receipts, and cycle count transactions, and import part and kit numbers. The software runs on Windows® 95, 98, NT, and 2000. It supports any TCP/IP network and is SQL/OBDC enabled. Fea- tures such as bar code scanning, bulk storage management, paper pick lists, pick banding, continuous batch picking, and a wide selection of supervisory reports and options are also available.

FastPic Systems 41 Eisenhower Dr., Ste., A, Westbrook, ME 04101

119

Gas Mixer Features Surge Tank Control Pressure Switch

The company offers its Model 8501 gas mixer for CO2/Ar. This mixing system is capable of 0-750 ft3/h of mixed gas, with

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a range of 0-50% CO 2 in Ar. The unit features a solid-state surge tank control pressure switch that withstands the mechanical wear of conventional pressure switches. The pressure in the surge tank is displayed with a digital readout on the inner door. Since the unit uses a solenoid valve/pressure switch/surge tank design, the mixed gas flow can be reduced to 0 ft3/h and still maintain a precise mixture. This model includes a 5-gal surge tank and lockable, gasketed steel enclosure.

Thermco Instrument Corp. RO. Box 309, La Porte, IN 46352

120

Pneumatic Hand-Held Beveler Is Lightweight and Heavy Duty

The company's pneumatic hand-held beveling machine is capable of producing clean-machined bevel angles of 15 to 75 deg and bevel widths between 0 and F~ in. (0 and 20 mm). The GBM-10 accurately bevels mild steel and aluminum in a wide variety of metal forms including plate, bar, strip, block, and large tube and pipe. This unit is ideal for chamfer, weld prep, and bevel applications. It is designed for heavy-

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THE ABOVE ARE JUST A FEW OF THE CORED WIRES THAT WE MAKE. FOR MORE I N F O R M A T I O N CALL:

Circle No. 12 on Reader Info-Card WELDING JOURNAL i ' ~ ' l

duty performance, yet weighs only 24.5 lb (11.15 kg). The beveler can be equipped with optional helix rollers that assist with the smooth operation of the unit.

Guilco International Inc. 21568 Alexande r Rd. , Cleveland, Oh io 44146

121

End Prep Tool Designed for Heavy-Wall Pipe

The company's portable, air-powered, inside-diameter clamping end prep tool is designed for use in the field by boiler- makers and pipe fitters for prepping heavy-wall pipe at any angle. Model D418 is designed for use by field personnel on pipe from 4.5 in. inside diameter to 18 in. outside diameter and features only eight sets of clamps for the full working range of the tool. No special operator training

is required. Capable of beveling, facing, and boring in one operation, the end prep tool uses the full range of standard TiN- coated cutting blades that are compatible with the company's tools.

ESCO Tool 122 50 P a r k St., Medf ie ld , M A 02052

Gloves Protect against High Temperatures

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The company's heat-resistant gloves offer a wool-lined, heavyweight Kevlar® terrycloth glove (305KWL) to protect against temperatures as high as 900°E The gloves provide protection from burns in addition to the cut resistance normally associated with Kevlar. The wool lining is natu- rally flame-resistant, offers extra insulation, and absorbs perspiration from the skin.

Kevlar will not melt, burn, or support com- bustion, is self-extinguishing, does not shrink when exposed to high heat, and has a low rate of electrical conductivity.

Wells Lamont Corp. 6640 W. Touhy Ave., Niles, I L 60714-4587

123

Magnetic Blocks Fixture, Lift, and Hold Parts

The company's Strong Hand modular magnetic locks are compact, yet extremely powerful, rare earth neodymium magnet blocks ideal for use in fixturing, lifting, and holding steel parts. The magnets also safely clean up iron and steel chips. The blocks are available in three sizes, with pull forces of 50 to 200 lb. Equipped with an on/off switch for safety and ease of use, the magnetism can be turned off during setup, then turned on when the user is

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We proudly announce the . . . . . " -~

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Beth Petcash District Sales Manage

Manfred Ti~ CEO and Pre

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Circle No. 37 on Reader Info-Card 1~4-'!1 J U N E 2002

ready. A mounting plate accessory is also available.

Valtra, Inc./Good Hand Inc. 7141 Paramount Blvd., Pico Rivera, CA 90660

Sensor Offers Force- Triggered Firing

124

The company's weld-through sensor system applies force measurement technology to traditional resistance welding techniques. By combining the WEL weld- through load cell with a WGM Weldme- ter, the electrode force at the time of firing for spot and projection welds is controlled. The system works equally well with differential air or hydraulic pressure sensors to provide consistent results.

Sensotec, Inc. 125 2080 Arlingate La., Columbus, Ohio 43228

Determinator Provides Single Analysis of Gases

The company's TCH600 nitrogen/ oxygen/hydrogen determinator provides single analysis for a wide variety of metal and inorganic applications. The instrument features re-engineered solid-state infrared and thermal conductivity detec- tors that provide lower detection limits and expanded instrument range. Dy- namic flow compensation ensures the integrity of the flow system while improving accuracy and precision for nitrogen determination in high-level oxygen materials. A powerful electrode impulse fur- nace can be ramped for separation of ox-

ides/nitrides. The easy-to-use Win- dows®-based operating system offers advanced diagnostics, extended archiving, and flexible reporting capabilities.

LECO Corp. 126 3000 Lakeview Ave., St. Joseph, M[ 49085.2396

Autodarkening Welding Lenses Come with Protection Plate Options

The company offers different protection plate options for its 9000 series of autodarkening welding lenses: high-heat outside protection plate for welders using high-amperage processes; heavy-duty outside protection plate for additional re- siliency to scratches and abuse; and passive filters used in place of the standard inside protection plate by users who want to extend the shade range of their lenses.

Horneil, Inc. 127 2374 Edison Blvd., Twinsburg, OH 44087

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! WELDING JOURNAL

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www.aws.org/jobfind With job categories for welders, engineers, inspectors and over 17 other materials joining industry classifications... I] i Companies can: ~i~ I • post, edit and manage your job listings easily and effectively, I any day or time ' ] !I ~ ~ p i • havequalifiedimmediatecandidatesaCCeSS to an entire rdsumd database of [

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Technology and Application of Welding

Upgrades Ship's Piping Titanium piping systems will be installed in the U.S. Navy's new LPD- 17 amphibious transport dock ships to reduce life cycle cost BY MIKE SAMMONS

I

I'lL,. 1 - - 7horouA, h gas coverage Ls intpor- rant in welding titanium, llere, .side .shields used to contain the gas shieldinL, are held in place by a hose chzmp.

MIKI- .S'AMMON.S" i.s product manager, Miller Electric MJ'g. Co.. Appleton, Wi.s., (800-426-4553).

he United States Navy is taking steps to ~tter its fleet by reducing life cycle costs. To :lp with this effort, the Navy enlisted orthrop Grumman Ship Systems' vondale Operations in New Orleans, La.

Avondale was founded in Marine Ways, Inc., a small, construction and repair

1938 as Avondale independent barge facility. Because

of demand for repair work and shipbuilding during and after World War II, business flourished and the company grew. Today, Avondale is part of Northrop Grumman Ship Systems and, with approximately 6000 employees, is the largest employer in Louisiana.

The company recently contracted with the U.S. Navy to install more than 12,000 ft of '/2- to 12-in., Grade 2 titanium piping in each new LPD-17 San Antonio-Class amphibious transport dock ship.

NELDING JOURNAL I 3

Fig. 2 - - The welder keeps the tip o f the filler metal in the argon shielding gas to eliminate the chance of atmospheric contamination.

titanium: the Light Choice Titanium, a corrosion-resistant, low-

density element, was chosen for the seawater piping systems on the LPD-17 ships because it is not affected by seawater and will not corrode. "Copper-nickel had traditionally been the material of choice for seawater piping," said Pat Hoyt, Avondale chief welding engineer. "The problem faced when it's used is high repair costs. Copper-nickel requires periodic replacement and causes many maintenance problems, whereas titanium offers a significant life cycle cost reduction. It's not unusual to replace the copper-nickel every five years. Once we install the titanium pipes, they will never have to be replaced."

Though the initial cost of titanium is higher than that of copper-nickel piping, the Navy decided to use the material because of its superior corrosion resistance. The San Antonio-class ships are designed to have a 40-year life span, and the idea is the piping system will last the duration. An additional benefit is titanium weighs almost 50% less than copper-nickel piping, allowing for future on-ship development and technologies to be added.

"The Avondale Alliance went to great lengths in designing this class vessel," Hoyt said. "They spent a lot of time with a computer design system that gave them a 3-D look at the ship before we even started building it. All aspects of the design were reviewed for producibility, ownership cost, and reliability, and the most cost-effective alternatives were put into the design."

JUNE 2002 I I

Powering the Process The fabrication of the titanium piping

was a process that Avondale welding operators were leery of until they became familiar with the uniqueness of the metal. After real- izing the way the metal reacts to welding, they compared it to welding stainless steel. Nevertheless, there are some very distinct differences that make the fabrication of titanium unique to Avondale's titanium welders.

"Titanium is very reactive," Hoyt said. "When heated above 500°F, it can react with the atmosphere and pick up contaminants if not handled correctly. Those contaminants make the weld brittle. To combat this, we incorporated new controls such as auxiliary argon shielding to blanket the weld area in argon." Hoyt feels proper shielding is the most critical aspect of the entire welding process. "Figuring out how to provide good shielding is not always easy to do, but it is vital to produce high-quality welds."

Avondale uses both manual and mechanized (GTAW) gas tungsten arc welding. An orbital pipe welding machine completes the arduous task of creating pipe welds. The company employs Maxstar TM 300 DX power sources from Miller Electric Mfg. Co. for manual GTAW on pipe ranging in size from 2 to 12 in. This machine is a portable DC 300-A power source.

"We needed something we could take to the work site with us," said Mark Duhe, Avondale titanium shop foreman. "We move around the shop quite a bit, and the weight of these power sources does not

prohibit that. We also needed a machine that had high enough amperage to weld 12- in. schedule 10 titanium pipe," he added.

Welders use the power source's memory to capture exact parameters for post- and preflow. The memory function aids in keeping continuity between operators.

Shielding the Weld Avondale welders use argon shielding

on all areas that exceed 500°F, and this shielding is provided by trailing or side shield devices. "We make the shields at Avondale and they provide excellent gas coverage," remarked Duhe. Trailing and side shields are constructed of 300 series stainless steel and they use an argon flow rate of 120 ft3/h. Trailing shields are used for mechanized welding. Side shields, used for manual welding, are held in place with a hose clamp and provide a 3- to 4-in. win- dow in which a weld is created - - Fig. 1.

The company uses cryogenic (liquid) argon tanks because the tanks are portable and provide a very dry source of argon. "The Navy requires a very low dew point for all shielding gasses," Duhe says. '~--60°F dew point ensures everything is as clean and dry as we can possibly make it."

"When using the manual power sources in coordination with the shielding devices, you should not move the shielding while welding," said Louis Buras, Avondale titanium welding operator. "We are required to check the interpass temperature with a digital thermometer, and when it is down to 600 degrees, we can

Fig. 3--Finished welds are checked against a color chart that gives an indication of their acceptability depending on the tint of the weld.

move the shielding. Paying close attention to the temperature of the interpass is essential because, by moving the shield too soon, the weld can be exposed to contaminants and be ruined."

In addition, the welder needs to pay close attention to the filler metal. "With titanium welding, the welder should leave the tip of the filler metal down in the argon bath to avoid tip contamination," said Buras - - Fig. 2. '~klso, because of the high melting temperature, the end of the filler metal stays molten for a longer period of time. So if you are not careful, the wire will stick to the leading edge of the weld pool. The best way to accomplish a good weld is to continuously feed the filler metal."

Color-Coded Welding To ensure quality welds, Avondale uses a

Navy-designed color chart of oxide film tints. "Navy standards play a big part in determining weld quality," said Richard King, Avondale quality assurance inspector. "The color chart (Fig. 3) has silver and varying degrees of yellow that constitute passing welds, and violet and blue colors for the rejectable welds."

The actual color is dependent on the oxide film thickness and is directly related to the temperature at which the weld was exposed to the atmosphere. "If a welder has not adhered to the 600-degree parameter for moving the shield, rejectable color may occur," King noted.

In the future, Avondale will also have the ability to rate welds using an ultrasonic hardness assessor. "This method will give us an indication of the surface as well as what has happened below the surface," King added. "It will add to our assessment techniques and will provide us with more than just the color chart."

Atmosphere Plays Its Part To further prevent contaminated welds, Avondale created a special workshop dedi-

cated to titanium welding. The 1650-sq-ft workshop houses six workstations and is air conditioned to aid in the dehumidification process, as well as keeping the work climate comfortable. Avondale eliminated the use of air tools in the shop because they have to be used with oils that can contaminate the welds. The company also sealed off the area to prevent the possibility of strong drafts that could disrupt shielding and ruin a weld. The workshop is used for final pre weld cleaning, fitting, and welding. However, a work area that alleviates the possibility of contaminants does not make the weld.

Avondale welding operators have to pass extensive testing including classroom work, assignments, and on-the-job-training to become certified titanium welders. "Right now we have 10 qualified employees, and we are looking to have 12 very soon. As important to the process as atmosphere, shielding, and power source might be, the employee is ultimately the one who has to make the decision. So we and the Navy take full measures to guarantee the right people are in that shop."

In the End: Cost Savings The titanium project was developed jointly by the U.S. Navy and Avondale with the

ultimate goal of cost savings. Historically, copper-nickel pipes are being changed out every five to seven years at a large expense to taxpayers. In addition, the ships are out of commission for 10 months to a year. The Navy and Avondale expect repair costs and ship-servicing time will decrease and life cycle savings will increase significantly.

"The addition of titanium piping is a small piece in a very large ship design puzzle," said Mike Seals, Avondale pipe superintendent, "but it is one that will ultimately save time and money."

Seals added, "Because this is a government program, we have had many dignitaries from various government agencies come in to see the progress on this new class of vessel. Every one of them has been amazed at the quality of the welds. That says a lot for our welding operators, their expertise, and their dedication to this project." •

Less handling, easier positioning, faster and cleaner welds.

i

Atlas Pipemate and Idler Rolls • Unit with idler rolls supports balanced

loads up to 1000 lb. • Rotates pipe and tube up to 17" dia. • Portable, low profile for shop or field • Dual speed 0 to 30 in/min or 0 to 60

in/min • High frequency filter prevents

interference with flEA welding

Atlas Rotary Table Positioners • Two models: 9" table, 100 lb. capacity,

10" tilt table, 200 lb. capacity • Heavy duty grounding circuit for stick

electrode, MIG or TIG welding • Low profile for bench mounting • Foot switch for feathering speed and

on/off control • Heavy duty steel construction • Front panel speed and rotation controls

Other handling and welding aids...Atlas Pipe Supports, ~ Atlas Roller Stands, Atlas Pipe Dollies

ATLAS WELDING ACCESSORIES, INC. Troy, MI 48099

.... ~, 8 0 0 - 9 6 2 - 9 3 5 3 email: [email protected]


I WELDING JOURNAL

Jackson N. Tracy Ferris State University Welding Engineering

Technology Airgas-Terry Jarvis

Memorial Scholarship

Derek A. Polaikis The Ohio State

University Welding Engineering Donald F. Hastings

Scholarship

"This scholarship is a kick-start to my career in Welding Engineering. Thank you to everyone who made this happen."

IT Shine M. Slack The Ohio State

University Welding Engineering Edward J. Brady


"With great appreciation I receive this honor and I look forward to making significant contributions in the field of welding."

"The 2002-2003 Donald F. Hastings Scholarship will be put to good use in my quest for further- ing my educational goal of becoming a welding engineer."

Zachary Klumpp Ferris State University Welding Technology Howard E. Adkins


"I am very grateful that this organization is so dedicated to the advancement of its industry by helping to pay for the education of its future."

Nathan Hoffman Ferris State University Welding Engineering

Technology William B. Howell


"Through the national scholarships offered by the AWS Foundation, students are able to realize their dreams in the welding industry....Your investment in me will pay-off for years to come"

Andrew Duncan University of Alberta, Edmonton, Canada Welding Engineering Praxair International

Scholarship

"Praxair and the AWS Foundation have shown that they understand how important community involvement is to the future success of the welding industry."

Derek Weeks The Ohio State

University Welding Engineering Matsuo Bridge Company, Ltd. of Japan

Scholarship

"It is an honor to receive this scholarship and your investment in me will prove to be a wise one. This scholarship money will greatly help me in my pursuit of a Welding Engineering degree."

lAnda Nicole Dutruch University of

Mobile Business Administration

James A. Turner, Jr. Memorial Scholarship

"I have been blessed to receive the James A. Turner, Jr. Memorial Scholarship... Thank you for believing in me and giving me this opportunity in my life."

Megan E. Saylor Montana Tech of the

University of Montana Welding Engineering

Technology John C. Lincoln


"This generous award not only validates my own efforts, but also serves to recognize the support I have received from my family and the faculty of Montana Tech."

Luar 6. Perez Delta College Welding Engineering

Technology Jerry Robinson - Inweld

Corporation Scholarship

Christopher J. Aultman Ferris State University Welding Engineering

Technology Amos & Marilyn

Winsand Scholarship

"Scholarships such as this help alleviate some of the financial strain of attending a university and it will also enable me to focus more time on academic studies,"

The Amos and Marilyn Winsand-Detroit Section Named Scholarship is sponsored by Mr. and Mrs. Amos Winsand, (past treasurer of AWS) and the AWS Detroit Section. The Scholarship is for an Associates or Bachelors degree in Welding Engineering, Welding Engineering Technology or related field. The recipient must be a resident of Michigan or attend a Michigan college.

Dien Tran St, Petersburg College Miller Electric

Manufacturing Co, Scholarship

Dien Tran, 21, and the U.S. welding representative for the World Skills Competition that was held September 13-16, 2001, in Seoul, Korea, was also the winner of the U.S. Open Weld Trials held May 6-10, 2001, at MAX lnternational.

By winning the Weld Trials, Tran not only earned the honor to represent the United States in the world competition, but also became a recipient of a $40,000, four-year educational scholarship donated by Miller Electric ifg. Company

Foundation, Inc. A Foundation of the American Welding Society

AWS Foundation, Inc. 550 N. W. LeJeune Road Miami, FL 33125 Phone: 880-443-9353 ext 293 Fax: 305-443-7559 e-mail: [email protected] Web.: www.aws.org

What's new for 2002 * Provides both U. S. standard and metric units of measure. • Has a new section on responsibilities of engineers, contractors,

inspectors and other personnel. • Revises sections on design of welded connections to clarify Code

intent, limits of fillet weld length in certain applications, definition of T-joints, fatigue limits of weld and joint types.

• Provides new data on through-thickness base metal loading. • Offers clarification on matching filler metals to various

construction materials. • Provides new guidelines for Charpy V-notch testing and new

commentary on ultrasonic testing.

Don't wait, order your copy now! To ORDER call 800-854-7179, fax 303-397-2740, email [email protected] or order via the Internet at www.global.ihs.com

American_Weldi Society Founded in 1919 to Advance the Science, Technology and Application of Welding

The Sonamet fabrication yard in Lobito, Angola.

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Subsea Structure Demands High-Quality GTA Pipe Welds A young fabrication yard in Angola gains a wealth of experience welding the piping systems for a subsea manifold

BY RICHARD O. BEWS

RICHARD O. BEWS ([email protected]) is Senior Welding and Materials Engineer, Stolt Offshore Ltd.

38

Lile "in its infancy" might describe the three-year-old Sonamet offshore fabrication yard on the west coast of the Angolan Republic, the completion of several prestigious projects has left little doubt the facility is growing up quickly.

The yard is an Angolan company jointly owned by Stolt Offshore Ltd., Sonangol, and Wapo. The multi- national work force has successfully completed a number of offshore structures ranging from conventional jackets and decks to more conceptual subsea systems for deepwater exploration and production. One of those structures, the Kuito 1C subsea manifold, is now situated offshore of Cabinda, Angola, in 400-ft-deep water. Its completion in June 2001 represented a major milestone for both the fabricator and the clients, ABB Offshore Systems and Cabinda Gulf Oil Co. Ltd., Chevron (CABGOC).

The manifold, which weighs approximately 68 tons, provided many "firsts" for the yard, not only in terms of it being the first structure of its kind for offshore Angola, but because it challenged the yard's technical ability to diversify into subsea technology.

Construction of the manifold required careful fabrication of approximately 23 tons of 22% duplex stainless steel and alloy 625 piping, flanges, and fittings, consisting of 114-, 168-, and 273-mm diameters with schedule 80 wall thickness.

Early on, the company recognized the technical requirements of the project and so constructed a purpose-built fabrication shop dedicated to pipe spool fabrication and completed spool installation. The shop, which measures 35 x 20 x 10 m, also provided the opportunity for employees to work with these materials in a clean environment, conducive to both quality and safe working practices.

I WELDING JOURNAL ~ r ~

Fig. 1 - - Macrosection from the duplex butt joint weld.

Personnel Training and Qualification

Although it may be stating the obvious, the fact remains that whether in Africa, the United States, Europe or any other location in the world, successful fabrication of duplex stainless and nickel-alloy steels is largely dependent on the degree of training and the available skill levels of the individuals involved.

In an effort to ensure fabrication would commence on a solid foundation, a dedicated group of experienced pipe welders and fitters were selected to undergo a period of training and qualification. The training encompassed both the handling practices and behavior characteristics associated with welding duplex and nickel-alloy stainless steels.

These craftsmen were of Indian, Pakistani, Nigerian, and Phillipine nationalities; however, it was an important mandate of both Sonamet and the Kuito 1C manifold project team that every opportunity should be taken to enhance the skills of the local An- golan work force. Consequently, four welders and two pipefitters were selected to attend the training program.

These welders had previous experience welding carbon steel pipe with the gas tungsten arc welding (GTAW) process. Along with the pipefitters, they spent a number of weeks training at the Sonamet training school. They then. spent several weeks honing their skills at the ABB Offshore Systems AS training center in Haugesund, Norway.

The extra training and experience gained from being in a totally different working environment proved fruitful. Each welder successfully earned an ASME Section IX 6G qualification on 168- mm-diameter x 7.11-mm wall thickness pipe. The pipefitters also completed their respective qualifications. Each qualification test was performed in the presence of an independent third party, namely a Det Norske Veritas representative. On completion of all testing, appropriate certificates were issued.

Welding Procedure Qualification

Following the training phase, two groups of welding procedures were identified for qualification. These included duplex-to-duplex (UNS $31803) and duplex-to-alloy 625 (UNS N06625) combinations, together with associated partial thickness and cap repairs.

Qualification was performed in the 6G position on l l4-mm- diameter x 8.56-mm wall thickness pipe.

To optimize efficiency and enhance productivity in welding these particular materials, the GTAW process was selected in conjunction with a 2.4-mm-diameter welding wire for the root weld and passes 2-4, followed by a 3.2-mm-diameter filler metal for the remaining passes.

JUNE 2002 I

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Fig. 2 - - Microstructure o f the duplex weld root (X400).

Table 1 - - Mechanical and Metallurgical Results from the Duplex Butt- Joint Weld

Charpy impact Average of Ferrite Content testing @ -35°C . 3 specimens

Weld Centerline 85 J Cap weld 44% Weld Interface 95 J Cap HAZ 52% Weld Interface + 2 mm 117 J Root Weld 46% Weld Interface + 5 mm 128 J Root HAZ 55%

(a) All specimens were subsize 10 x 5 ram.

Welding procedures were required to be qualified in accordance with the ASME Section IX Code. There were also some specific project requirements for mechanical and corrosion testing, which included Charpy impact testing at -35°C and pitting corrosion testing in accordance with ASTM G48 method A at a temperature of 22°C for a period of 72 h.

To enhance the corrosion resistance of the root pass, the established practice of utilizing an overmatched 25% Cr super duplex weld metal was adopted. The welds then successfully underwent visual, dye penetrant, and radiographic examination. Figure 1 shows a macrosection of the resultant duplex butt joint weld taken from the 6 o'clock position.

Table 1 summarizes mechanical and metallurgical results for this weld. As seen from the measured ferrite content, a balanced microstructure was produced, which is represented in the micrograph shown in Fig. 2. The micrograph indicates a desirable matrix of austenite and ferrite.

Following successful qualification of the duplex welding procedure, work began on qualifying the duplex-to-alloy 625 combination. For this dissimilar material butt joint weld, an ERNiCrMo- 14 classified welding wire was selected. A 2.4-mm-diameter filler metal was utilized for the root bead and passes 2-4 followed by a 3.2-mm-diameter filler metal for the remaining passes.

Following a mandatory period of familiarization because of the obvious differences in welding technique, operability, and weld pool behavior commonly associated with welding nickel-alloy steel, a procedure qualification was performed on 114-mm-diameter x 8.56-mm wall thickness pipe. The resultant weld was then subjected to 100% visual, dye penetrant, and radiographic examination.

Following successful NDE, the macrosection shown in Fig. 3 was obtained from the 6 o' clock position. Once again, the weld showed excellent cap and root profiles. The mechanical properties are summarized in Table 2.

Production Performance Once the qualification phase was complete, pipe spool fabrica-

tion commenced within the shop. A considerable volume of rela-

Table 2 - - Mechanical Test Results from the Duplex to Alloy 625 Butt-Joint Weld

Charpy impact Average of Average of testing @ -35°C ~, 3 specimens 3 specimens

(Duplex side) (Alloy 625 side)

Weld Centerline 30 J - - Weld Interface 41 J 45 J Weld Interface + 2 mm 104 J 45 J Weld Interface + 5 mm 124 J 46 J

(a) All specimens were subsizc IO x 5 ram.

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Fig. 3 - - Macrosection of duplex~alloy 625 butt-joint weld

tively complex pipe and fittings (Fig. 4) had to be carefully constructed into spools and installed into the structure.

Even if the project's success was only measured in terms of the quality of duplex and alloy 625 welding, the final repair rate statistic of 0.05% with a defect length of 60 mm from a tested length (visual, dye penetrant, and radiography) of 109.450 m represented excellent results. This statistic was especially impressive because many of the tie-in welds done in the field had to be made on an extremely compact structure with limited access - - Fig. 5.

Conclusion The Sonamet fabrication yard has not only demonstrated its

willingness to adapt and diversify, it has proven it has the facilities and technical capability to construct offshore equipment from conventional structures to more technologically challenging designs. These designs will continue to be required for the extensive deepwater exploration taking place offshore of Angola.

Additionally, the Kuito 1C subsea manifold project provided the fabrication yard with a wealth of knowledge about these in- creasingly popular corrosion-resistant alloys for the oil and gas industry in this part of the world. Such knowledge will undoubtedly prove to be invaluable for the fabrication yard's futureAl,

Acknowledgments

The author would like to thank ABB Offshore Systems and Cabinda Gulf Oil Company Ltd., Chevron (CABGOC) for allowing publication of this material, and Project Manager Herv6 Boone and Sonamet Base Manager Nicolas Monnot for assisting with this article.

Fig. 4 - - Welding of a 273-nlnz-diameter elbow to Tjitting.

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Fig. 5 - The Kuito 1C subsea mani]old.

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1" x 1.75" Bottom feed * Designed for trailing shield and other applications. 1.25" x 1.75" Top feed 1" x 3" Bottom feed 1" x 3" Top feed ._¢ 1" x 4" Bottom side feed 2.75" x 3" Bottom feed

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Orbital welding produces top-grade welds on titanium hydraulic lines for Cessna's fastest jet

Based on a stoly from Arc Machines, hzc., Pacoima, Cal(f, (818) 896-9556.

I JUNE 2002

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Fig. 1 - - After the supersonic Concorde, the Citation X # the world's fastest civil transport aircraft.

Fig. 2 - - To save weight, Cessna uses titanium hydraulic and fuel fines in the

jet's construction. The company now uses the orbital welding equipment shown

here to weld these lines.

" -:, ~ .- ~ " ~ ~ 1 ~ ~ c itation X from Cessna Aircraft Co. is the world's fastest business jet, certified for cruising at Mach 0.92 or

approximately 600 miles per hour - - Fig. 1. The program was launched in 1990 and the aircraft entered service with the first re- tail delivery in August 1996. The jet's high-speed cruise capability means it can save up to one hour's flight time on transcontinental U.S. flights, flying from Los Angeles to New York with normal wind conditions in 4 h 10 min. Because of its ability to cruise at high speed at high altitudes, Cessna says the Citation X consumes less fuel than other jets on a transcontinental flight. The Citation X can climb to 43,000 ft in just 30 min at its maximum takeoff weight, quickly rising to transcontinental and transatlantic crossing altitudes. The plane is certified to fly as high as 51,000 f t - where fuel efficiency is optimized and airline traffic is nearly nonexistent. Cessna recently announced major improvements to the aircraft, including increasing its maximum takeoff weight from 35,700 to 36,100 lb, making it possible to carry up to seven passengers with full fuel in a typically equipped airplane.

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each weld head can weld a wide range of tube or pipe sizes. Clamps are available in all standard inch and metric tube and pipe sizes.

The model 207 welding power supply controls weld parameters such as welding current , pr imary and background amperes, travel speed, weld bead overlap, delay of rotation at the start of the weld, and current downslope at the end of the weld. The enclosed weld heads used for small-diameter tubing provide a chamber filled with inert gas that enclos- es the entire joint during the weld. A timed prepurge and postpurge are usually used to time the flow of inert gas into the weld head before arc initiation and to continue the purge for a timed period after the arc has been extinguished. This allows the weld tool to cool sufficiently to prevent oxidation before the weld head is opened to remove the welded tube.

Getting Up and Running

None of the shop personnel at Cessna had experience with orbital welding but they were eager to learn. Arc Machines

Material preparation

is the key to

producing good

welds. offered a training program that helped provide all of the operators with a clear understanding of what was needed to produce quality welds. The setups for orbital welding are straightforward and include setting the speed, rotation, dwell, and penetrat ion parameters, which are different for each size of tubing. The operator is also responsible for selecting the right fitting, which is usually either a sleeve and a nut or a union.

"This is a very easy machine to operate," said Richard Stump, Cessna production foreman. "We have developed programs for all of the sizes we need to weld and the operator can easily change to the appropriate program and be pret- ty certain of producing parts that meet our demanding quality specifications. We use nondestructive testing on 100% of the welds. We have discovered that mate-

rial preparat ion is the key to producing good welds. During the cutoff operation, we are careful to avoid any contamination or burring in order to provide the clean and smooth surface required for high-quali ty welding. Both mater ia l preparat ion and welding are performed in a special controlled environment to avoid possible airborne contaminants."

Cessna learned the importance of material preparat ion when the orbital welding equipment was first set up and tested. Initially, preparat ion and welding were performed on the factory floor. However, problems caused by airborne contaminants were seen in a small number of cases, so Cessna built a special air- conditioned room apart from the factory floor. This solved the problem. While the room is air-conditioned, it is not a special environment such as the clean rooms used in the semiconductor industry.

The orbital welding equipment has proven to be reliable. More than 150,000 welds have been produced during the past five years with only a few brief downtime incidents for the equipment.

"Cessna has been successful because we have maintained the highest standards and ideals over the years," said Lyman Ratcliffe, manufacturing engineer, t

Symex Star-frac II Automatic Gouging System

Designed for continuous gouging of long seams in the manufacture of ships, pressure vessel tanks, bridges, etc.

Manufacturer of Quality Gouging Equipment

C.H. Symington & CO., Inc. 6063 Frantz Road, Suite 103

Dublin, Ohio 43017 USA

Tel: 614-766-2602 Fax: 614-766-2715

-A- High resolution voltage control capability regulates accurate gouging depth to a machine-like tolerance of +.015" (0.4mm) even over warped plate.

-A- Total weight (less travel system) is 2 0 Ibs.

.# Use with Symex 3/8" - 5/8" "Secur-Fit" Jointed Gouging Electrodes up to 1200 Amps.

-# Suited for out-of-position work due to its light weight.

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Output A linepipe manufacturer produced more pipe using innovative welding techniques that produced faster travel speeds and improved mechanical properties

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As a key supplier to the Gulfstream pipe project, Berg Steel Pipe Corp. of Panama City, Fla., had to find a way to produce high-quality, defect-free linepipe at top levels of productivity. To do this, the company employed a number of innovative welding systems, including a continuous joint tacking system and pipe welding stations that used multiple-wire welding techniques to weld the pipe inside and out.

In comparison to two-wire submerged arc welding (SAW) systems, Berg's techniques created welding travel speeds that were three times greater for welding the inside and four times greater for outside welding on 0.820-in.- thick pipes. In addition, total heat input was decreased by 25% while overall mechanical weld properties were improved. Overall, employing multiple-wire welding enabled Berg to produce 40-ft-long, 0.820-in.-thick pipes at a rate of 14 pipes per hour.

Fig. 3 - - The formed tube is tack welded at the laser-guided continuous tack welding station.

duce 5000 tons of pipe per month into a facility that produced more than 40,000 tons per month," said John Burton, Berg's general manager of production. "We needed to add the multiple-wire processes because we didn't have enough square footage to add more welding stations. We had to make use of the technology on the market to be the most efficient plant possible in the space available."

The company services customers ranging from oil and gas transmission companies to pipe distributors. The 275-employee company also manufactures structural piling and is qualified to produce linepipe to arctic specifications that have weld metal Charpy requirements to -50°E The company can supply products to such a broad range of customers because of the flexibility of its three-roll, bending-type forming process, which allows for quick changeovers.

The type of pipe produced is also varied. Berg can manufacture pipes in diameters ranging from 24 to 64 in. and wall thicknesses from 0.250 to 1.500 in. API Grade B through X80 can be handled at the company's facility.

The majority of offshore linepipe produced for the Gulfstream project was 36- in.-diameter, 0.820-in.-thick (20.8-mm) API 5L Grade X70 produced in 40-ft nominal lengths.

E l , ' ! JUNE 2002

Preparation of Plates

Before welding, Berg planed the plates to the precise width and beveled the plate edges for longitudinal joint welding - - Fig. 1. The plate was formed into a tubular shape by a three-roll bending machine (pyramid roll) - - Fig. 2. Forming was subsequently completed by rounding the longitudinal edges of the plate between a hydraulically cushioned top ball and matching hourglass roll.

Once the plate was formed into the proper tubular shape, the longitudinal weld was completed in three passes, beginning with a continuous tack weld. For the Gulfstream project, longitudinal welding procedures were qualified to both ASME Section IX and Berg's internal standards.

Tack Welding A tack welding system was designed to

secure the welding edges in proper alignment for welding and to provide continuous backing for subsequent inside submerged arc welding. This process was

completed using a welding system purchased to remedy a bottleneck the company had experienced in this stage of the manufacturing process.

In 1999, Berg had a single, DC 1500 power source. For every diameter change in pipe, the system required 45 min to change out the cage that positioned the plate edges for welding. To eliminate this, Berg installed a continuous tack welding system utilizing two DC 1000 power sources and a NA-5 control at The Lincoln Electric Co.'s suggestion. This CNC-controlled tack welding machine has hydraulic cylinders that automatically reposition themselves when the pipe diameter changes. This system reduced changeover time to approximately 5 min and eliminated some of the problems with closing the bevel for welding the company experienced with its former system.

The two power sources create a continuous joint tack using an open arc gas metal arc welding (GMAW) process at high speeds of 260 in./min. Commonly referred to as "buried arc," this process is characterized by low voltage, short arc length, and high travel speeds that allow for a deep penetrating weld at reduced heat inputs.

During tack welding, hydraulic rollers on the system hold the pipe joint together. A laser guidance system from Uhrhan

Fig. 4 - - F in ished p ipe is loaded on the barge f o r tran.sport to the lay barge.

& Schwill guides the arc in the weld groove and maintains radial alignment of the plate edges - - Fig. 3. Laser guidance eliminates the time needed previously by the operator to stop the weld and adjust items manually.

The company felt there were benefits to a continuous joint technique to close the formed pipe cylinder for welding. "Intermittent tack welds require the use of a backing flux or a copper backing bar during subsequent submerged arc welding, while ours does not," noted Fred Hafner, chief metallurgist/QA manager for the company. "This means we achieve higher productivity since the backing provided by the continuous joint provides the attributes for fast travel speeds and deep penetration in inside welding."

Using a buried arc process eliminated the weld spatter typical of globular transfer because the arc is buried in the weld pool. This process also required only a CO 2 shielding gas, eliminating the need for more expensive argon gas. For tack welding of 0.820-in.-thick pipe, the company used Lincoln's L-50 g2-in.-diameter wire electrode at 1500 A.

"Our tacking system is very reliable and helped relieve the problem of the arc outage we were experiencing," said Burton. "We also employed the use of CNC controls that can store data on a particular wall thickness so we can provide rapid changeovers by simply calling up previously stored information."

Inside Welding After the tacking process is completed,

run-off tabs are added to the joint areas at both ends of the pipe with a manual GMAW process. This allows the inside and outside systems to start and end welding on the run-off tabs rather than on the pipe itself. In this way, the large deposit of weld metal created at the start of this multiple-wire process or the concave area left at the end of the weld will not affect the pipe weld. The tab is removed after welding so what is left on the pipe is the best possible weld, not the undesirable weld metal from the start or end of welding.

The company has three four-wire inside welding systems utilizing AC 1200 power sources with NA-4 controllers. This SAW process, run at up to 1000 A, can produce a large-sized bead all in one pass. Although there is one power source per arc, all four wires are arranged in line and fed into a single arc pool. Since one arc may be deflected by others in multiple-arc welding, it is necessary to ensure such deflections are favorable to the weld profile. Inside submerged arc welding is conducted with constant-current AC power sources arranged successively 90 deg out of phase.

During inside welding, the pipe moves forward while all the welding equipment is mounted to a boom that travels the length of the 40-ft pipe. The arcs are buried

underneath the granulated flux. For the inside weld, a V-shaped guide

wheel sits in the groove of the joint to ensure alignment of the weld head in the weld groove. The weld penetrates into the continuous tack weld backing.

The four-wire process on the inside weld creates faster travel speeds - - up to 68 in./min on the Gulfstream pipe - - and the mechanical properties of the weld improve because there is less heat delivered per arc.

Depending on customer specifications, different types of wires are used at this station. For the Gulfstream project, '/,-in. Lincoln L-61 with a 761 pipe flux were the consumables of choice. This 761 flux was a special adaptation of the standard Lincoln 761 flux with different-sized particles to create better fluidity, bead shape, and edge tie-in to fill in the weld groove on the inside of the pipe.

Outside Welding In the last step of the welding process,

Berg uses two five-wire SAW stations to create outside welds that penetrate into the inside and completely consume the tack weld. There are three main advantages to using a five-wire process: 1) higher weld speeds, four times the speed of the standard, two-wire process; 2) reduced heat input that reduced grain coarsening in the heat-affected zone; and 3) time for impurities such as slag or porosity to escape prior to solidification because of the large, molten weld pool.

The outside system uses a DC lead wire to ensure complete penetration while the trail arcs are AC for fill and speed. Power sources for the lead wires are either two DC 1000 units in parallel or two DC 1500s; both set-ups use NA-3 controls. The AC trailing wires take advantage of AC 1200 units with NA-4 controls.

Laser joint tracking on the outside ensures the weld is positioned correctly in the weld groove. Since the arc is buried under a pile of flux and alignment can't be seen, this equipment facilitates positioning of the weld head.

For the 0.820-in.-thick Gulfstream pipe, the ~-in. DC lead wire operated at 1550 A with a weld speed of 90 in./min. Welding consumables were a combination of L-61 and L-70 wire and 995 flux. (L-70 wires are used when higher weld metal Charpy impacts were required. The addition of 0.5% Mo L-70 wire resulted in higher acicular ferrite contents in the weld; this improved the weld metal Charpy impact energy.) On pipe thinner than 14.3 mm, a four-wire process was used while all five wires were utilized for heavier wall thicknesses.

WELDING JOURNAL ~ l

Fig. 5 --Each finished pipe is hydrostatically pressure tested to ensure the integrity of the weMing.

Finishing Inspection After welding, run-off tabs and slag

are removed manually by operators using oxyacetylene cutting. The pipe ends are then sized between opposing hourglass rolls to ensure the uniform diameters and roundness essential for efficient field con- structions. Next, both ends of the pipe are simultaneously beveled for field girth welding. A stenciling machine labels and bar codes each pipe with a unique identi- fication before shipping via barge or rail to Gulfstream - - Fig. 4.

Because creating defect-free pipe is so important for high-pressure, natural gas applications, pipes are subject to many nondestructive tests. Berg uses automated ultrasonic inspection of the weld joint and film X-ray of the joint weld near the pipe ends. Per API 5L, Grade X70 pipes are hydrostatically tested for a minimum duration of 10 s at a pressure equivalent of at least 90% of the specified minimum yield strength - - Fig. 5. During the Gulfstream project, pipes were tested at higher pres-

sures for a minimum of 20 s at a combined stress of 100% of specified minimum yield strength. Dimensional inspection and internal and external visual inspections were completed on each length of pipe.

According to Burton, welding the pipe correctly the first time was critical for achieving high production rates. "In our pipe mill, a pipe that needs rework has to displace a new pipe in the production process," said Burton. "Removing or holding up a new pipe from production to correct a problem can be very costly."

What's to Come "In the future, we expect SAW sys-

tems to be replaced with software- controlled inverter welding systems that will allow complete manipulat ion of waveform and electronic phasing. We will then be able to change the waveform for each wire," said Hafner. "Such systems will provide even better control of weld penetration and arc deflection with higher productivity."

As for the Gulfstream project, phase one pipe has already been delivered and field installation is progressing. In the meantime, phase two pipe is being produced by Berg's high-speed welding processes. •

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T h r e e c a t e g o r i e s to su i t y o u r n e e d s . . .

oin an elite group of over O0 AWS Sustaining Company

Members and enjoy:

• Your choice of one of these money- saving benefits:

1. AWS Standards Library ($6,500 value) 2. Discount Promotional Package - save

on Welding Journal advertising and booth space at the AWS WELDING SHOW (save thousands)

3. 10 additional AWS Individual Memberships ($870 value)

Plus... • 10 AWS Individual Memberships

($870 value); each Individual Membership includes a FREE subscription to the Welding Journal, a FREE AWS publication (up to a $188 value), Members'-only discounts and much more

• Free company publicity- give your company a global presence in the Welding Journal, on the AWS Website, and at the AWS WELDING SHOW

• Exclusive usage of the AWS Sustaining Company logo on your company's letterhead and on promotional materials for a competitive edge

• An attractive AWS Sustaining Company wall plaque

• Free hyperlink from AWS's 40,000-visitors-a- month website to your company's website

• 200 complimentary VIP passes to the AWS WELDING SHOW

• An additional 5% discount off the already- reduced member price of any AWS conference or seminar registration

• Up to 62% off Yellow Freight shipping charges, outbound or inbound, short or long haul

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AWS Supporting Company Members enjoy:

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• Free publicity with your company listed each year in the Welding Journal and on the AWS Website

• An attractive AWS Supporting Company wall plaque to show your company's affiliation with AWS

• 200 complimentary VIP passes to the AWS WELDING SHOW to distribute as perks to both customers and your most productive staff

AWS Educational Institution Members enjoy:

• 3 AWS Individual Memberships ($261 value); each Individual Membership includes a FREE subscription to the Welding Journal, a FREE AWS publication (up to a $188 value), Members'-only discounts and much more

• Career advancement through top-notch AWS Certification programs and a host of other renowned educational courses

• Free publicity for your school - list your school's name, as well as your benefits and services in the WeMingJournal and on the AWS Website

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For more information on AWS Corporate Membership, call (800) 443-9353, ext. 253 or 260.

E-mail: [email protected] for an application. ~ American Welding Society

550 N.W. LeJeune Rd. Miami, Florida 33126 Visit our website at www.aws.org

your organization needs solutions. A W S m e a n s a n s w e r s .


Friends and Colleagues:

We're into the tenth year of the program, and 98 individuals have now entered into the fraternity of Fellows. Again, I 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, 1 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 Fellows 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 February 1, 2003. The Committee looks forward to receiving numerous Fellow nominations for 2004 consideration.

Sincerely,

Dr. Alexander Lesnewich Chairman, AWS Fellows Selection Committee

DATE

AWS MEMBER NO.

HOME ADDRESS

CLASS OF 2004 FELLOW N O M I N A T I O N F O R M

(please type or print in black ink)

NAME OF CANDIDATE

YEARS OF AWS MEMBERSHIP

CITY

PRESENT COMPANY/INSTITUTION AFFILIATION

TITLE/POSITION

STATE ZIP CODE PHONE

BUSINESS ADDRESS

CITY

ACADEMIC BACKGROUND, AS APPLICABLE:

INSTITUTION

STATE ZIP CODE PHON E

MAJOR & MINOR

DEGREES OR CERTIFICATES/YEAR

LICENSED PROFESSIONAL ENGINEER: YES

SIGNIFICANT WORK EXPERIENCE:

COMPANY/CITY/STATE

NO STATE

POSITION

COMPANY/CITY/STATE

YEARS

POSITION YEARS

SUMMARIZE MAJOR CONTRIBUTIONS IN THESE POSITIONS:

SUGGESTED CITATION (50 TO 100 WORDS, USE SEPARATE SHEET) INDICATING WHY THE NOMINEE SHOULD BE SELECTED AS AN AWS FELLOW. IF NOMINEE IS SELECTED, THIS STATEMENT MAY BE INCORPORATED WITHIN THE CITATION CERTIFICATE.

**MOST IMPORTANT** The Fellows Committee selection criteria are strongly based on and extracted from the categories identified below. All infor-

mation and support material provided by the candidate's Fellow Proposer, Nominating Members and peers is considered. Provide as much detailed information as possible regarding:

The candidate's accomplishments under areas identified below (use separate sheet for each category): A. Research & Development B. Education C. Manufacturing D. Design and Inventions E. Other (e.g., Standards Development, National and International Liaison) Evidence of accomplishment should include sustained service and performance in the promotion of joining technology; pub-

lication of papers, articles and books; innovative development of joining technology; service to AWS and other technical societies; and list and description of patents, awards and honors.

SUBMITTED BY: PROPOSER AWS Member No. The Proposer wil l serve as the contact if the Selection Committee requires further information. Signatures on this nominating form, or supporting letters from each nominator, are required from four AWS members in addition to the Proposer. Signatures may be acquired by photocopying the original and transmitting to each nominating member. Once the signatures are secured, the total package should be submitted.

NOMINATING MEMBER: AWS Member No.




SUBMISSION DEADLINE FEBRUARY 1, 2003


Nomination of AWS Fellows

I. 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 reputation and outstanding accomplishments of the individual. Such accomplishments will have advanced the science, technology and application of welding in specific areas such as research and development, education, manufacturing, design and other areas the Society may determine, as evidenced by:

* Sustained service and performance in the advancement of welding science and technology

* Publication of papers, articles and books which enhance knowledge of welding * Innovative development of welding technology

II. RULES A. B. C.

Candidates shall have 10 years of membership in AWS Candidates shall be nominated by any five members of the Society Nominations shall be submitted on the official form available from AWS Headquarters

D. Nominations must be submitted to AWS Headquarters no later than February 1 of the year prior to that in which the award is to be presented

E. Nominations shall remain valid for three years F. All information on nominees will be held in strict confidence G. No more than two posthumous Fellows may be elected each year

III. NUMBER OF FELLOWS TO BE ELECTED Maximum of 10 Fellows selected, as determined by the

selection committee

Return comDleted Fellow nomination Dackaee to; v

Wendy S. Reeve American Welding Society 550 N.W. LeJeune Road Miami, FL 33126

Telephone: 800-443-9353, extension 215

SUBMISSION DEADLINE: February 1, 2003

BY-THE-BOOK BRIDGE-BUILDING

Bridge wetdln9 Code

Get the latest facts and code requirements for bridge building with carbon and low-alloy construction steels. The American Welding Society has released the latest version of the DI.5 Bridge Welding Code, outlining requirements of the American Association of State Highway and Transportation Officials (AASHTO) for building highway bridges made from carbon and low-alloy construction steels. Chapters cover inspection, qualification, structural details, stud welding, welded joint details, workmanship and more. This new edition features the latest AASHTO revisions and

NDE requirements, as well as a section providing a "Fracture Control Plan for Nonredundant Bridge Members." The 250-page ANSI-approved document contains 35 tables, 77 figures, and several annexes. Welding and construction professionals and designers will find this book essential for all forms of bridge work.

NEW EDITION HIGHLIGHTS: • Implementation of U.S. Customary Units • Provisions for undermatching electrode

usage • Added commentary section • New requirements for the modified

WPS qualification tests

AWS Bridge Welding Code (D1.5M/D1.5:2002): List Price ................................ $180.00 AW$ Members .................... $135.00

To order your copy of the D1.5:2002 Bridge Welding Code. phone Global Engineering Documents at (800) 854-7179. or visit their webpage at: www.global.ihs.com.

~ American Welding Society Founded in 1919 to Advance the Science, Technology and Application of Welding

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Integrity can be ensured if alternative standards and fracture mechanics to develop a suitable acceptance criteria are implemented BY J. R. STILL AND J. B. SPECK

J. R. STILL is a Welding Engineer in Aberdeenshire, Scotland, and is currently working Jbr Amerada Hess, U.K. J. B. SPECK ([email protected]) is Manager, Plant Assessment Structural Integrity Technology Group, TWI Ltd., U.K.

l . ,~m JUNE 2002

Fig. 3 - - Pump area piping system.

M A N / r ~ N A53 N 1 7 . $ ~ p I~ I~AT/O~B~B~r r

e ~ m x ^WS ~ ~ S VOLTS W B ~ ~¢~T

. . . . . . . . . . . . . T - 2 12 ETIT.I DC-~E 200 ]0 31 3 1.2 ETIT- I DC-V]~ i~0 29 iJ

TIG(RO0"I~. SI~E1,DI~G(}/t~ FLO~' II, ATE 1~-15 I j ' T R J F ; ~ I I ~ % / t I ~ { ] O I ~ 0 ~ O i Ptr~GE R E q U I R ~

Fig. 2 - - Typical weld procedure for welding marine pipe work.

:W# ~ J * . J l

" - z l

_Fig. 4 Cargo handling piping located on vessel deck.

In the majority of vessels, marine piping systems are designed, constructed, and inspected by the shipyard in accordance with classification society rules. Inspection requirements imposed on marine piping systems are either visual or radiographic; the level of inspection of the latter can vary from 0 (at the discretion of the surveyor) to 10% to 100%.

With the introduction of the U.K. Design and Construction Regulations (DCR) SI 913 (Ref. 1), U.K. floating production, storage, and offloading (FPSO) vessel operators have the option to disregard or maintain class once the vessel has been installed offshore provided all safety-critical items have been identified. Marine piping systems that operate at high pressures or temperatures are classified as safety critical and are required to be inspected during construction and at regular intervals during production to ensure the integrity of the system has not been impaired.

Offshore operators contemplating the construction or conversion of a tanker to an FPSO seldom question the standard of weld quality of marine piping. However, it is doubtful class requirements are suitable for FPSO marine piping,

!i i

I WELDING JOURNAL

: T a b l e I - - Comparison of Classification Societies' NDE Requirements for Marine Piping

Piping Groups

I

II

II1

Classification Societies

A Diameter Thickness NDE

(mm) (ram) Applied

Any Over 100% 9.5 mm

> 114 Any 100% Full or spot (random) radiographic examination of welded joints in this group is not required.

NA

B C D Diameter Thickness NDE Diameter Thickness NDE Diameter Thickness

(ram) (mm) Applied (mm) (mm) Applied (mm) (mm)

<76.1 NA See Note >75 NA 100% <76.1 NA 1

<76.1 NA 100% >76.1 NA

>101.6 NA See Note >100 NA 10% >101.6 NA 1 Random

See Note See Note See Note

NDE Applied

10% Random

100%

10% Random

Note: Selected welds at the discretion of the surveyor. Normally taken as 10~.

Table 2 - - Examples of Marine Piping Inspection Requirements

Vessel System Diameter Thickness

i;

/i

Group 1 Steam Service

Flue Gas Group II

Cargo Handling Tank Cleaning Fire Fighting

(mm) (mm)

Vessel Pipe Work

300 (Sch 40) 9.5 500 (Sch 40) 9.5

600 12.7 250 (Sch 40) 9.3 65 (Sch 40) 5.2

Engine Room

Inspection Requirements

Visual Visual

Visual Visual Visual

Group I Steam Service 65 (Sch 160) 9.5 Visual

Boiler Blow-off 125 (Sch 80) 9.5 Visual Fuel Oil 200 (Sch 80) 12.7 100% Radiography Group II

Steam Service 125 (Sch 80) 9.5 Visual Heating Coil 250 (Sch 40) 9.5 Visual

Fig. 5 - - Incomplete joint penetration ck, fect. Fig. 6 - - Incomplete root penetration.

II IIlllll

Fig. 7 - - Repaired area due to melt-through.

l,,"[,~ JUNE 2002

Fig. 8A, B - - Examples of radiographs (positive images) of typical weld defects found in marine piping.

Marine Piping Standards

On comparing the inspection frequency of marine piping stipulated by four major classification societies, as illustrated in Table 1, it is evident the piping groups are similar. However, inspection requirements can differ slightly between classification societies. The selection of pipe diameter or wall thickness for marine piping systems can influence inspection requirements. Table 2 illustrates an example of marine systems for an Afromax tanker converted to an FPSO, w h e r e the NDE requirements were influenced by the pipe wall thickness (Classification Society A). In this instance, the classification society rules stated any systems with a pipe wall thickness of 9.5 mm or less required 100% visual inspection and all systems with a thickness of more than 9.5 mm required 100% radiography.

Welding

In the example described above, pipe materials selected for marine systems were predominantly carbon steel, as outlined in Table 3. The piping material was supplied either as seamless or ERW pipe (electrical resistance welded).

The welding process used for constructing the marine piping involved both gas tungsten arc welding (GTAW) and gas-shielded flux cored arc welding (GSFCAW). Marine piping is fabricated as spools containing butt- joint welds and flanged at either end for ease of installation or replacement, as illustrated in Fig. 1. Typical pipe welding procedure is outlined in Fig. 2. The root run was deposited using GTAW with 3.2-mm-diameter wire and hot pass, then filled using GSFCAW using 1.2-mm-diameter wire. Welding consumables selected for joining carbon steel pipes consisted of GTAW wire (AWS ER 70S-G) (Ref. 2), argon gas shielded, and GSFCAW (AWS E71T1) (Ref. 3) with a CO 2 gas shield. Minimum preheat temperature was ambient and maximum interpass temperature was 250°C. Installed marine piping is illustrated in the pump area of Fig. 3 and cargo handling deck piping in Fig. 4.

O ~ / r , , , ~ , l l l ~ . a 1.1~O11 k . ~ l l i . . 11 l l b t l I ~ . . .k l 1 l l l . l l J ~ 1 L 1 I , /1 t

yard Nominated C Si S P Mn

370 (Seamless) 0.25 0.35 0.04 0 . 0 4 0.30/0.90 Max Max Max Max

410 (Seamless) 0.30 0.35 0.04 0 . 0 4 0.30/1.06 Max Max Max Max

400 (Welded) 0.25 - - 0.04 0.04 - - Max Max Max

Number G3454, G3455, G3457.

l ¥ 1 ~ b l l t l l l l t . ~ t l l 1 I L I I J F I I . l g , ~

UTS Yield (N/mm2) tN/mmz) 370 Min 215 Min

410 Min 245 Min

400 Min 245 Min

El%

30 Min

25 Min

25 Min

]

~' 4 - - Example of Pipe Material and Weld Metal Chemical Analysis

C Si S P Mn Ni Cr Mo

Material 0.08 0.02 0.005 0.013 0.31 0.01 0.01 <0.01 CAW (Weld Metal) 0.04 0.61 0.007 0.012 1.22 0.03 0.01 0.01

Cu Nb Ti V

<0.01 <0.005 <0.005 <0.005 0.03 0.02 0.04 0.02

Proposed Inspection Requirements for Marine Piping Based on the Requirements of B3L3

CRUDE OIL DISCHARGE LINE

ed ASME B31.3 Service)

Inspection Requirements for FPSO Marine Service

Normal 10% butt-joint welds to be radiographed Note: For every one found to contain defects, the classification societies require an additional 10 butt- joint welds to be radiographed

Category D Up to a maximum of 50 butt-joint welds to be radiographed at random Note: For every one found to contain defects, the classification societies require an additional 10 butt joints to be radiographed

Category High Pressure Systems

100% Radiography

Acceptance Criteria As per classification socities' rules

Note: ASME B31.3 is a recognized piping standard used throughout the offshore oil and gas industry.

\

0 200 400 600 800 . . . ; ~.,f,

LOP I ~ , mm 2.H~ ' ~ ;

Fig. 9 Engineering critical assess m e n t ~ ! i " ~ (ECA) for marine piping butt-joint welds containing incomplete joint penetration defects.

As illustrated in Tables 1 and 2, classification society rules can dictate the inspection requirements for marine piping." Designing marine piping systems to classification rules provides the Sbll~ard with the oppoWanity to select the pipe diameter o r thickness for a particular agplicatiun. As illustrated in Table 2, this practice of limiting the NDE requirements through a design route is completely legitimate, aad the probability of defects going undetected is high. The vessel operator in this instance carried out additional radiography on both class I and II marine piping systems, as outlined in Table 2. More than 60% of the welds ~ e d were found to be out with the weld defect criteria of classifi~ti~ soeietyA.

llall

Weld defect type encountered was

macrosection removed from the weld area (Fig. 6) illustrates the extent of incomplete joint penetration. Figure 7 is an example of an area that needed repair because of melt- through. Examples of the radiographs (positive image) in Figs. 8 A and B taken from the welds examined reveal extensive incomplete joint penetration defects.

The extent of the defects encountered in marine systems examined must bring into question the fitness of class rules when applied to floating production, storage, and offloading vessels. Based on the above findings, offshore operators must decide whether class piping rules are adequate or if an alternative or modified standard should be applied for FPSO service. Another area adopted during the NDE exercise was the use of fracture mechanics to establish an engineering critical assessment (ECA) to provide assurance that any undetected defects would not fail prematurely.

In addition to the NDE program, representative samples of pipe material and weld metals were chemically analyzed. Examples

IEII ,essmllt

I level 2 engineering critical assessment (ECA) of incomplete joint penetration was performed in accordance with BSI PD 6493:1991 (ReL 4) and considered failures in terms of fracture or plastic collapse. The ECA excluded consideration of defect growth due to, for example, fatigue, envi- ronmentally assisted cracking, or creep. The tolerable range of incomplete joint penetration dimensions (i.e., depth and length) were determined and presented in the form of a failure loci. An example of an incomplete joint penetration failure locus for a crude oil discharge line is shown in Fig. 9.

nltm gntm

Corrosion monitoring of marine piping systems is not widely practiced. For an FPSO, it is advisable to establish an effective corrosion monitoring program (Ref. 5) if the vessel is destined to remain on station

incomplete root penetration rtg. 5. A contained in Table 4 . . . . for the duration of the field life.That can be

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up to 15 to 20 years without having to dock. The corrosion-monitoring technique applied should involve determining the wall thickness at strategic locations within the marine systems prior to operations com- mencing. Regular monitoring is advisable to ensure piping systems are free from corrosion or fatigue cracks where weld quality is questionable.

Summary

Designing marine systems for FPSO applications must take into account the service conditions and the ability to inspect and repair piping systems during the operational life of the vessel.

Several routes can be considered to achieve a standard of pipe quality suitable for prolonged service offshore. These include an alternative standard, such as ASME B31.3 modified as outlined in Table 5 (ReL 6), where an operator would select the welds to be inspected at random and the acceptance criteria applied would be in accordance with class rules. Another route would be the use of fracture mechanics (Ref. 7) to develop a suitable acceptance criteria and provide assurance that any weld containing known defects can be monitored at a convenient opportunity preventing the possibility of weld failure. •

References

1. SI 1996, No. 913.1996. A guide to the installation and mi~ellaneous aspects of amendments to the offshore installation (safety caseJ regulations 1992. Offshore installations and wells, Design and Construction regulations.

2. AWS A5.18 ER 70S-G (Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding).

3. AWS A5.20 E71T1 (Carbon Steel Electrodes for Flux Cored Arc Welding).

4. BSIPD6493: Guidance on methods for assessing the acceptability of flaws in fusion welded structures. 1991.

5. Still. J. R.. and Nelson. P. Development of Corrosion Monitoring in Offshore Production Industry. 1992, British Institute of NDT. vol. 34. no. 7, pp. 336-340.

6. ASTM B31.3: Code for Process Piping. 1996. New York. N.Y.: American Society of Mechanical Engineers.

7. BS 7910: Guide on methods for assessing the acceptability of flaws in fusion welded structures. 4th draft after public comment. 1999. London:

ii~i!

A5.01-93 Filler Metal Procurement Guidelines A5.1-91 Specification for Carbon Steel Electrodes for

Shielded Metal Arc Welding A5.8-92 Specification for Filler Metals for Brazing and

Braze Welding A5.9-93 Specification for Bare Stainless Steel Welding

Electrodes and Rods A5.10/A5.10M Specification for Bare Aluminum and Aluminum-

Alloy Welding Electrodes and Rods A5.11/A5.11M Specification for Nickel and Nickel-Alloy

Welding Electrodes for Shielded Metal Arc Welding A5.23/A5.23M Specification for Low-Alloy Steel Electrodes and

Fluxes for Submerged Arc Welding A5.25/A5.25M-97 Specification for Carbon and Low-Alloy Steel

Electrodes and Fluxes for Electroslag Welding A5.26/A5.26M-97 Specification for Carbon and Low-Alloy Steel

Electrodes for Electrogas Welding A5.29:1998 Specification for Low-Alloy Steel Electrodes for Flux

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To order, or for more information, phone Global Engineering Documents at: 800-854-7179, or visit their Webpage at:

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WELDING JOURNAL ~ l

4tELDIN6 WORKBOOK Datasheet 257a

Gas Tungsten Arc Welding of Pipe Except for thin-wall tubing, gas tungsten arc welding (GTAW)

of carbon steel pipe is normally used only for the root pass, and then only when exceptional quality is required. Since the GTAW bead tends to be thin, a second pass sometimes is made to prevent melting through the first bead when other processes are used to complete the pipe weld. If the quality requirements are very high, the GTAW process might be used to weld out the entire pipe.

Back purging is not generally required for welding carbon steel pipe. When the gas flow and nozzle sizes specified in the table below are used, sufficient shielding gas (usually argon) reaches the root surface to provide adequate protection.

The shape of the tungsten electrode tip has a substantial effect on the contour width of the weld face and on joint penetration. It should be shaped similar to a sharpened pencil. Shaping is done on a fine grit grinding wheel. A 60-grit, O to M silicon carbide grinding wheel is recommended. It should be used only for the purpose of grinding tungsten to prevent contamination of the electrode. Grinding marks should be parallel with the electrode axis for best results.

To make a root pass, first correctly position the electrode within the torch. With the welding torch in an upright position and the nozzle resting on the groove face, the electrode is adjust-

ed so that the end is almost flush with the bottom of the joint. The welding current should be direct current electrode nega-

tive (DCEN), using the amperage and gas flow recommended below. In the 5G position, tack welds should be made at the 7:30, 4:30, 1:30, and 10:30 positions. The root bead, whether 5G or 6G position, is started in the 6:00 location and the weld is made uphill to a 12:00 location on one side of the pipe. The same sequence is followed on the other side.

The weld is started by placing the nozzle against the bevels of the groove face with the torch at a work angle of zero and a push angle of up to 55 deg. Both the torch and welding rod remain at a work angle of zero during welding. The welding rod is positioned with a large drag angle close to the joint in preparation for insertion into the joint after the arc is started. When the switch is turned on, the torch is pivoted to a push angle of about 20 deg and the arc ignited. The filler metal is then brought to a drag angle of 45 to 70 deg, and welding proceeds with the electrode and the welding rod about 65 to 90 deg apart.

In the welding of pipe, the finished weld quality is a function of the alignment and dimensional control of the tack welded assembly. The dimensions shown in the figure below are highly recommended.

Procedures for Circumferential Butt Joints Welded with GTAW Process

Wall Passes Pass Filler Metal(a) Amperes Arc Nozz le Gas(c) EWTh-2 Travel Thickness No. Size ( i n . ) (DCEN)(b) Volts Size Flow Electrode Direction T (in.) (ft3/h) Size (in.)

0.188 and 2 1, 2 ~: 65 to 75 13 5 15 ~2 uphill thinner

0.188 to 1 ~: 75 to 85 13 6 15 uphill 0.250 2+ 2, 3 ~ 90 to 100 14 6 15

0.250 to 1 ~2 90 to 100 14 6 15 ~ uphill 0.375 2+ 2+ ~ 90 to 100 14 7 18

0.375 to 1 ~_ 90 to 100 14 6 15 V~ uphill 0.50 2+ 2+ ~ 100 to 120 14 7 18

(a) ER70S-2 is preferred; ER70S-3 or ER70S-6 may be used. Refer to manufacturer's (b) DCEN = direct current electrode negative. (c) Welding grade argon.

recommendations for storage and handling.

37-1 /2 °

A

t Oto 1 /16 in.

t ,OT e#

f ~ - - 3 / 32 in. to 1 /8 in.

OT.V;' ROD ~

Excerpted from the Recommended Practices and Procedures for Welding Low-Carbon Steel Pipe ANSI/AWS D 10.12-89.

E,~el JUNE 2002

BRAZIN(

Q: We have been asked to braze a copper plug and two stainless steel tubes into a copper shell using BNi-7 filler metal. The copper is UNS C12200 and the stainless steel is type 304. While we are more familiar with brazing with gold-copper filler metals and would prefer to use them, the customer insists the assembly be brazed with BNi-7. We are not famil iar with this filler metal and have not found evidence it is recommended for brazing copper in any literature. Also, it appears the brazing temperature is too close to the melt ing point of copper. Is BNi-7 suitable for brazing copper? If so, can you give us information on the brazing process?

A : Gold-copper filler metals are certainly good for brazing these materials. How- ever, BNi-7 has been used for many years to braze copper to copper and copper to stainless.

As indicated in AWS A5.8, Specif ica- tion for Filler Metals for Brazing and Braze Welding, the brazing range is 1700-2000° F (927-1093°C). A suitable brazing temperature for the copper- to-copper joint is 1825°F (996°C) and 1850°F (1010°F) for stainless to copper. To braze both the copper and stainless parts at the same time,

BY R. L. PEASLEE

use the 1850°F (1010°C) temperature . The time at brazing temperature could be from 15 to 30 min. The longer time of 30 min may be desirable since it will improve the joint strength. The 1850°F brazing temperature is adequately below the melting temperature of copper.

No reference to the brazing atmosphere was made, so that gives you several options. A pure-dry hydrogen atmosphere with a dew point o f - 6 0 ° F (-51°C) or lower will be required to keep the 304 stainless bright and clean and ensure the flow of filler metal. Dissociated ammonia, nitrogen-hydrogen, or an argon atmosphere can also be used if the dew point is similar to that of the hydrogen. A partial-pressure-vacuum atmosphere is another suitable atmosphere if the partial pressure is around 1000-2000 mi- crons (133-266 Pa) to prevent heavy vaporization of the copper. Since the 304 and filler metal both contain chromium, this is the controlling element that requires a low- dew-point atmosphere.

The UNS C12200 copper is low oxygen and, therefore, can be brazed in hydrogen. If the copper was a UNS C1000, electrical tough pitch (ETP) or other tough pitch grade containing oxygen in the grain boundaries, processing in a hy-

drogen-containing atmosphere would em- brittle the copper. If the part was copper- to-copper brazed with BNi-6 or silver filler metal not containing zinc or cadmium, the parts could readily be brazed in a 100% dry nitrogen atmosphere.

BNi-6 has also been used to braze stainless steel to copper. If copper is brazed to copper with BNi-6 and held at the brazing temperature , the BNi-6 can be fully diffused into the copper.

BNi-7 and a 25% chromium modification of the BNi-7 are used as a coating on copper to prevent oxidation of copper on parts that will be operat ing at temperatures of 1500°F (850°C).

As you can see, BNi-7 and BNi-6 can be used for brazing copper to stainless, as well as other applications. •

R. L. PEASLEE is Vice President, Wall

Colmonoy Corp., Madison Heights, Mich. This

article is based on a column prepared for the

A WS Detroit Brazing and Soldering Section's

newsletter. Reader may send questions to Mr.

Peaslee c/o Welding Journal, 550 N W LeJeune

Rd., Miami, FL 33126 or via e-mail to

[email protected].

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Circle No. 46 on Reader Info-Card WELDING J O U R N A L

~IAVY JOININ~ CENTER 1 A MANTECH Center of Excellence Operated by EWl O

NJC Developing Adaptive Weld System to Reduce Ship Construction Costs

The Navy Joining Center (NJC) and Edison Welding Institute (EWI) are currently working with Electric Boat Corp. and Northrup Grumman Newport News to develop a system for real-time adaptive fill of multipass groove welds in Navy ship structures. The project aims to develop a fully adaptive welding method, improved laser vision capabilities, and robust welding parameters for thick-section steel weld joints. The system (Fig. 1) is based on a portable welding tractor, laser vision system, and gas metal arc welding equipment. This project was begun in response to the Navy's desire to reduce the construction cost of ships and submarines by increased use of automated welding.

Portable welding tractors have been used for years in submerged arc, gas metal arc, and flux cored arc welding. Current applications typically require the weld operator to make continuous adjustments to welding parameters and welding gun position as joints are welded. The emphasis of this project is to give the welding tractor more intelligence so it can function more autonomously, freeing the operator to put other tractors in operation or perform other duties. The benefits and goals of this project include

• Elimination of the need for 100% monitoring of the tractor operation • Reduction of rework by 50% resulting from improved quality and reduced defects • 100% increase in efficiency and arc- on time • Reduction of weld volumes (over- welding) • Accommodation of current joint preparation and fitup methods.

The technology being developed by this project focuses-on three areas. The first is d~x, elopment of robust welding parameters and an adaptive weld model for selected production applications. The model will accommodate changes in weld volume due to joint variations and will determine how each weld bead must be adapted (adjusted) for these changing conditions. A computer model is being developed that uses information from the vision system to calculate an adaptive welding strategy. The model will have the abil-

Fig. 1 - - Gas metal arc welding tractor equipment setup with "adaptive weld" multibead, multilayer (MBML) system.

ity to determine the placement and number of weld beads required in the multiple weld layers needed to complete a joint. This "multibead, multilayer (MBML) strategy" will then be used for adaptive control of the tractor and welding equipment.

The second area of development involves new joint recognition templates for the vision system. These templates will use the layer and bead information from the model to track the joint as well as size and place the weld bead in the correct location. The information generated by the template will also allow the system to correct any under- or overfill that might occur in a given layer.

Finally, several enhancements are being added to the welding system that will enable the definition of welding joints for shipyard applications. The number of welding parameters that can be adaptively

controlled has been increased. New software has been developed to improve com- munication between the tractor, vision system, and welding equipment.

When completed, the system will be demonstrated at both shipyards, then transitioned into production.

For further details, please contact Doug Ketron of the Arc Welding and Material Automation Group at EWI. Telephone: (614) 688-5150 or via e-mail: doug_ketron@ewi, org. •

r - i . J c Operated by

EIMi

The Navy Joining Center 1250 Arthur E. Adams Dr. Columbus, OH 43221 Phone: (614) 688-5010 FAX: (614) 688-5001 e-mail: NJC @ewL org www: http://ww~.ew~org Contact: Larry Brown

E. I , i JUNE 2002 I

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WELDING J O U R N A L E . ~ !

".OMIN6 EVENTS

Conferences and Exhibitions

• Third Weld Cracking Conference Causes and Cures. June 11-12, Royal Sonesta Hotel, New Orleans, La. Sponsored by AWS. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443- 9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

Steel Bridge Forum. June 12, Pittsburgh Hilton and Towers, Pittsburgh, Pa.; July 8, Virginia DOT Auditorium, Richmond, Va.; September 17, Rutgers University, New Brunswick Campus, Busch Campus Center, Piscataway, N.J. Sponsored by the American Iron and Steel Institute. Contact: Marjorie Burdetsky, (703) 536-4995; www.steel.org/infrastructure/sbf.

• 2002 EPRI Welding and Repair Technology, 5th International Conference. June 26-28, Marriott Grand Hotel, Point Clear, Ala. Sponsored by EPRI Repair & Replacement Applications Center. AWS is a nonfinancial sponsor for this event. Contact: Shane Findlan, EPRI Repair & Replacement Applications Center, (704) 547-6179, FAX: (704) 547-6109, e-mail: [email protected]; www.epri.com.

2002 World Congress on Powder Metallurgy & Particulate Materials. June 16-21, Walt Disney World Dolphin Hotel, Orlando, Fla. Sponsored by the Metal Powder Industries Federation. Contact: Metal Powder Industries Federation, 105 College Rd. East, Princeton, NJ 08540-6692, (609) 452-7700, FAX: (609) 987-8523; www.mpif.org.

12th Annual EPRI NDE Issues Meeting. July 8-12, Kingston Plantation, Myrtle Beach, S.C. Sponsored by EPRI. Contact: Susan Otto-Rodgers, (704) 547-6072, FAX: (704) 547-6168, e-mail: [email protected]; www.epri.com.

6th EPRI Piping and Bolting Inspection Conference. July 30-August 1, The Grand Marriott, Clear Point, Ala. Sponsored by EPRI. Contact: Susan Otto-Rodgers, (704) 547-6072, FAX: (704) 547-6168, e-mail: [email protected]; www.epri.com.

12th Biennial International Conference, Computer Technology in Welding and Manufacturing. August 28-29, University of Wollongong, Australia. Contact: Rachel Wall, TWI Ltd., Granta Park, Great Abington, Cambridge, CB1 6AL, United Kingdom; FAX: 44 (0) 1223 891264.

5th Conference on Aerospace Materials, Processes, and Environmental Technology (AMPET). September 16-18, Von Braun Center, Huntsville, Ala. Contact: Dawn Cross Stanley, (265) 544-1835, e-mail: [email protected]; http://ampet. msfc.nasa.gov.

• Conference and Exhibition on Gas Metal Arc Welding. September 17-18, Grosvenor Resort at Downtown Disney, Lake Buena Vista, Fla. Sponsored by AWS. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443- 9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

Note." A diamond ( • ) denotes an A WS-sponsored event.

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Aluminium 2002 World Fair & Congress. September 18-20, Exhibition Centre, Hall 3, Essen, Germany. Contact: 49 (0) 211- 90191-208; www.aluminium-2OO2.com

International Conference on Mathematical Modeling and Computer Simulation of Metal Technologies (MMT-2002). September 30-October 4, Raab Building, College of Judea and Samaria, Ariel, Israel. Contact: MMT-2002, Chairman Michael Zinigrad, P.O.B. 3, Science Park, Ariel 44837, Israel, 972-3- 9066217, FAX: 972-3-9066234, e-mail: zinigrad@research. yosh.ac.il or [email protected]; www.yosh.ac.il/research/mmt- 2002/index.htm.

Supermartensitic Stainless Steels 2002. October 3-4. Flanders European Conference Centre-Vlaams Europees, Brussels, Belgium. Organized by the Belgian Welding Institute in cooperation with the EC Growth Project JOTSUP. Sponsored by Stainless Steel World. Contact: Conference Secretariat Marie- Anne Sorgeloos, Sint-Pietersnieuwstraat 41, B-9000 GENT (Belgium), 32 (0) 9 264 32 54, FAX: 32 (0) 9 223 73 26, e-mail: [email protected]; www.stainless-steel-world.net.

Third International Conference on Education in Welding. October 13-16. LO-Skolen, Helsing~r, Denmark. Contact: JOM- Institute, Gilleleje Strandvej 28, DK-3250 Gilleleje, Denmark, 45 48355458, FAX: 45 48355457.

EuroBLECH 2002 - - The 17th International Sheet Metal Working Technology Exhibition. October 22-26, Exhibition Grounds, Hanover, Germany. In addition to the exhibition, the Inno-Meeting will take place from October 22-24. Euro- BLECH contact: Mack Brooks Exhibitions Ltd., 44 1707 278200, FAX: 44 1707 278201, e-mail: eb.project@mack- brooks.co.uk; www.euroblech.de. Inno-Meeting contact: EFB

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E.V., Welfengarten 1A, D-30167 Hanover, Germany, 49 511 9717511, FAX: 49 511 9717519, e-mail: [email protected]; www.efb.de.

International Welding/Joining Conference - - Korea 2002. October 28-30 Hilton Hotel, Kyongju, Korea. Sponsored and organized by the Korean Welding Society. Contact: Korean Welding Society, 82-42-828-6511, e-mail: [email protected]; www.kws.or.kr.

• Charting the Course of Welding at U.S. Shipyards Conference. November 13-14, Portsmouth, Va. Sponsored by AWS. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

• Conference on Welding Aluminum for Cars and Trucks. December 3-4, Detroit, Mich. Sponsored by AWS. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443-9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

• Seventh Robotic Arc Welding Conference and Exhibition. February 10-11, 2003, Orlando, Fla. Sponsored by AWS. Contact: AWS Conferences, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 449 or, outside the U.S., (305) 443- 9353 ext. 449, FAX: (305) 443-1552; www.aws.org.

Educat iona l O p p o r t u n i t i e s

Lincoln Electric Company Welding Design Seminars. The Lincoln Electric Company, Welding Technology Center, Cleveland, Ohio. Design of Weldments, June 4-6 and October 29-31. Design of Welded Structures, September 24-26. Fracture and Fatigue Control in Structures, October 15-17. Contact: Registrar, Professional Programs, The Lincoln Electric Company, 22801 St. Clair Ave., Cleveland, OH 44117-1199, (216) 383-2240, FAX: (216) 383-8025; www.lincolnelectric.com/ knowledge/training/seminars.

Fundamentals of Corrosion and Its Control. June 24-26; and October 21-23, LaQue Center for Corrosion Technology, Inc., Wrightsville Beach, N.C. Contact: LaQue Center for Corrosion Technology, Inc., P.O. Box 656, Wrightsville Beach, NC 28480,

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(910) 256-2271, FAX: (910) 256-9816, e-mail: [email protected]; www.laque.com.

EPRI Nuclear Plant Improvement Seminar. July 15-16, Gideon Putnam Hotel and Conference Center, Saratoga Springs, N.Y. Contact: Brent Lancaster, CCM, Conference Manager, (704) 547-6017; e-mail: [email protected]; www.epri.com.

Victor 2002 Training Seminars. Victor Equipment Company will be conducting training programs for gas apparatus and service repair technicians, end users, and sales personnel in 2002. For a complete schedule, contact: Aaron Flippen, (940) 381-1217; www. victorequip, com.

The Fabricators & Manufacturers Association, International (FMA), and the Tube and Pipe Association, International (TPA) Courses. A course schedule through June is available by calling (815) 399-8775; e-mail: [email protected]; www.fmametal- fab.org.

i~ ,1= JUNE 2002

Malcom Plastic Welding School. A comprehensive two-day, hands-on course that leads to certification in accordance with the latest European DVS-approved plastic welding standards for hot gas and extrusion welding techniques. Contact: Sheila Carpenter, Administration, Malcom Hot Air Systems, 1676 E. Main Rd., Portsmouth, RI 02871, (888) 807-4030, FAX: (401) 682-1904, e- mail: [email protected]; www.plasticweldingtools.com. Hellier NDT Courses. A course schedule is available from Hellier, 277 W. Main St., Niantic, CT 06357, (860) 739-8950, FAX: (860) 739-6732.

Shielded Metal Arc Welding of 2-in. Pipe in the 6G Position - - Uphill. Hobart Institute of Welding Technology, Troy, Ohio. This course is designed to develop welding skills necessary to produce quality multipass welds on 2-in.-diameter, schedule 160 mild steel pipe (0.436-in. wall thickness) in the 6G position using E6010 and E7018 electrodes. For further information, contact: Phil Pratt, President, Hobart Institute of Welding Technology, 400 Trade Square East, Troy, OH 45373, (800) 332-9448, FAX: (937) 332-5200; www.welding.org.

The Total Welding Rod Protection System: Airtight storage and inventory control for welding electrodes and filler metals with genuine Rod Guard ® welding accessories. • Airtight Threaded cap with long-lasting neoprene seal.

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2002 Motor Sports Welding School. Classes are scheduled at Lincoln Electric headquarters in Cleveland, Ohio. For more information and a complete schedule, contact: Lincoln Electric

Motorsports Welding School, 22801 St. Clair Ave., Cleveland, OH 44117, (216) 383-2461, FAX: (216) 383-8088, e-mail: lori_bollas @lincolnelectric. com; www.lincolnelectric.com.

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Boiler and Pressure Vessel Inspectors Training Courses and Seminars. To obtain a 2002 schedule of training courses and seminars conducted by the National Board of Boiler and Pressure Vessel Inspectors at its Training and Conference Center in Columbus, Ohio, contact: Richard McGuire, Manager of Training, (614) 888-8320, e-mail: r m c g u i r e @ n a t i o n a l b o a r d . org ; www.nationalboard.org.

Welding Skills Training Courses. Courses include weldability of ferrous and nonferrous metals, arc welding inspection and quality control, preparation for recertification of CWIs, and others. For a complete schedule, contact: Hobart Institute of Welding Technology, 400 Trade Square E., Troy,

OH 45373, (800) 332-9448 or, outside the U.S., (937) 332-5000, FAX: (937) 332-5200; www.welding.org.

Structural Welding: Design and Specification Seminars. Conducted by the Steel Structures Technology Center (SSTC). For 2002 schedule and locations, contact: SSTC, (248) 344-2910, FAX: (248) 344-2911; www.steelstructures.com.

2002 Metalforming Seminars. Conducted by the Precision Metalforming Association (PMA). Seminar topics include stamping, tool and die, press operation, punch and die, metalforming controls, lean manufacturing, advance quality planning, and more. Many programs are available as on-line seminars. For a complete PMA 2002 Educational Program schedule, contact, PMA, 6363 Oak Tree Blvd., Independence, OH 44131-2503, (216) 901-8800, FAX: (216) 901-9190, e-mail: [email protected]; www.metalforming.com.

Machine Safeguarding Seminars. Conducted by Rockford Systems, Inc. For schedule and more information, contact: Rockford Systems, EO. Box 5525, Rockford, IL 61125, (800) 922- 7533 or, outside the U.S., (815) 874-7891, FAX: (815) 874-6144; www.rockfordsystems.com.

ASME International w Section IX Welding Guide. Course #ZCD996. Introduction and review of Section IX welding infor-

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Circle No. 44 on Reader Info-Card WELDING J O U R N A L l , ' l r n

Educational Opportuni t ies

A W S Schedule - - C W I / C W E Prep Courses and Exams

Exam application must be submitted six weeks before exam date. For exam information and an application, contact the AWS Certification Dept. , (800) 443-9353 ext. 273. For exam prep course information, contact the AWS Educat ion Dept. , (800) 443-9353 ext. 229.

Cit ies E x a m Prep C W I / C W E Courses Exams Cit ies E x a m Prep C W I I C W E

Courses Exams Beaumont, Tex. June 3-7 June 8

(API 1104 Clinic also offered) Miami, Fla. September 16-20 September 21 Boston, Mass. June 3-7 June 8 (API 1104 Clinic also offered) Charlotte, S.C. August 12-16 August 17

(API 1104 Clinic also offered) August 26-30 August 31 (API 1104 Clinic also offered)

Columbus, Ohio

Corpus Christi, Tex . EXAM ONLY September 21 El Paso, Tex. June 17-21 June 22

(API 1104 Clinic also offered) Fargo, N.D. June 17-21 June 22

(API 1104 Clinic also offered) Houston, Tex. August 12-16 August 17

(API 1104 Clinic also offered) August 19-23 August 24 (API 1104 Clinic also offered)

Indianapolis, Ind.

Kansas City, Mo. June 3-7 June 8 (API 1104 Clinic also offered)

Long Beach, Calif. June 24-28 June 29 (API 1104 Clinic also offered)

Miami, Fla. June 10-14 June 15 (API 1104 Clinic also offered)

Miami, Fla. July 15-19 July 20 (API 1104 Clinic also offered)

Miami, Fla. EXAM ONLY August 8

Milwaukee, W i s . September 9-13 September 14 (API 1104 Clinic also offered)

Minneapolis, Minn. June 24-28 June 29 (API 1104 Clinic also offered)

New York, N.Y. July 15-19 July 20 (API 1104 Clinic also offered)

Omaha, Neb. August 19-23 August 24 (API 1104 Clinic also offered)

Pittsburgh, Pa. September 16-20 September 21 (API 1104 Clinic also offered)

Reno, Nev. September 9-13 September 14 (API 1104 Clinic also offered)

Sacramento, Calif. June 10-14 June 15 (API 1104 Clinic also offered)

San Francisco, Calif. July 15-19 July 20 (API 1104 Clinic also offered)

Seattle, Wash. September 9-13 September 14 (API 1104 Clinic also offered)

Seattle, Wash. September 9-13 September 14 (API 1104 Clinic also offered)

York, Pa. July 8-12 July 13 (API 1104 Clinic also offered)

manent markson metal, wood, plastic, glass, cardboard, etc. They write on any surface: rough or smooth, wet or oily; even marks underwater.

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Industry Leaders Honored by AWS at Welding Show 2002 in Chicago

During the American Welding Society's (AWS) Welding Show 2002, held March 3-7 in Chicago, Ill., the Society honored those in industry whose achievements have been recognized as advancing the science and technology of Welding. The following individuals were cited for their accomplishments at the Annual Awards Luncheon. M. J. Cieslak

COMFORT A. ADAMS LECTURE AWARD

"Welding: Physics to Politics"

Michael J. Cieslak is director of Materials and Process Sciences Center for Sandia National Laboratories and an adjunct professor at both the Colorado School of Mines and The Ohio State University. He received his Ph.D. in materials engineering from Rensselaer Polytechnic Institute in 1983.

Since joining Sandia in 1983, Cieslak has held a variety of positions including senior manager in the Advanced Concepts Group, AWS Congressional Science Fellow/Legislative Fellow for U.S. Sen. Jeff Bingaman (D-N.M.), deputy director for Long Range Planning for the Materials and Process Sciences Center, program manager in the Advanced Design and Production Technologies Initiative Office, and manager/supervisor in three Sandia technical departments. Immediately prior to his appointment as director, he was deputy director of Operations and Planning for the Materials and Process Sciences Center.

Cieslak was elected a Fellow of AWS in 1997 and of ASM International in 1992. He is the recipient of several AWS award recognitions and his research interests include the weldability and transformation-related effects in fusion welds of advanced alloys. He has written more than 150 papers and presentations in the fields of welding, phase transformations, solidification, diffusion, corrosion, and fly-fishing.

ADAMS MEMORIAL MEMBERSHIP AWARD

John N. DuPont received his Ph.D. in materials science and engineering from Lehigh University, Bethlehem, Pa. He joined the Materials Science and Engineering Department at Lehigh as assistant professor in 1999, where he directs industrial- and government-sponsored research in the areas of welding process modeling and optimization, solidification modeling, weldability, mechanical behavior of welds, erosion/corrosion behavior of weld overlays and Laser Engineered Net Shaping (LENS). DuPont teaches undergraduate and graduate classes in solidification, physical metallurgy, introductory materials science and welding metallurgy. He has written for more than 80 publications, edited two books, one book chapter, and holds one U.S. patent.

DuPont is a principal reviewer for the Welding Journal's Welding Research Supplement and a reviewer for the Journal of Materials Engineering and Performance. He serves as chair of the American Society for Metals Committee on Fusion Welding and is a member of the American Welding Society's Awards, Research & Development, and Handbook Committees. Among his many honors, DuPont became an ASM Scholar in 1990 and received an AWS National Fellowship Award in 1995. In 2000, he was the recipient of a Career Award from the National Science Foundation, and he was a Young Investigator Award winner from the Office of Naval Research for his research on laser beam welding and surface treatment of combatant

J. N. DuPont P. Kimbrell

ships. Also in 2000, DuPont received the National Science Foundation's Presidential Early Career Award for Scientists and Engineers from President Clinton for "initiating a highly collaborative and interdisciplinary education and research effort in manufacturing using Laser Engineered Net Shaping (LENS) processing."

HOWARD E. ADKINS MEMORIAL INSTRUCTOR

MEMBERSHIP AWARD

Paul "Don" Kimbrell has more than 18 years of experience teaching secondary and postsecondary welding technology at Granite City Senior High School, Granite City, IlL He is also a part-time instructor at Southwestern Illinois College in Belleville, IlL

Kimbrell has been a VICA advisor and sponsor of the High School SkillsUSA/VICA Club for the past 12 years. Kimbrell's welding program at Granite City Senior High School went from near collapse to overflowing with more than 100 students enrolled per day during the 2001-2002 year.

I WELDING JOURNAL I !~ i l

V. M. Malin J. W. Elmer A. T. Tentya A. R. Marder

Kimbrell received formal welding training and experience in the United States Air Force as a metal processing specialist. After four years of military welding, he worked on boiler pressure vessels, automotive and railway equipment, structural fabrication and erection, heavy equipment machinery repair, shipbuilding, refrigeration equipment, automation/robotics programming, and trouble-shooting welding problems.

Kimbrell has cowritten maintenance repair curriculum on GMAW, GTAW, SMAW, PAW, and oxygen cutting operations. He is the recipient of the 1994 and 2000 Section Educator Award from the AWS St. Louis Section and the 1995 and 1998 District Educator Award from AWS District 14.

James C. Odom graduated from Jefferson Davis Community College in 1988. As a welding instructor with Escambia-Brewton Career Technical Center (EBCTC) in Brewton, Aia., his welding program served as a role model for others, despite cutbacks in state funding. Through part0ering with local industry, he supplemented the program's funding and provided an excellent opportunity for technical training for all his students.

As a Navy Reserve Chief Petty Officer, Odom also teaches and has streamlined procedures and curriculum for training that affects 12,000 reservists worldwide, gaining him recognition and com- mendations in the United States Navy.

ARSHAM AMIRIKIAN MEMORIAL MARITIME

WELDING AWARD

"Root Weld Formation in Modified Refractory Flux One-Sided Welding:

Part 1 ~ Effect of Welding Variables"

Valdemar Malin received his Ph.D. in welding and metallurgical engineering from Leningrad Polytechnical Institute, U.S.S.R. For 16 years, he worked as a welding engineer and manager at a shipyard and was involved in production and research, including automation, tungsten arc characteristics, and metallurgy of dissimilar welded joints, for which he received several awards.

In 1970, in cooperation with the Paton Institute, Malin developed an award-winning air plasma arc cutting process. In 1971, he developed variable- polarity GTAW that improved the capability of modern equipment for welding aluminum, and, in 1974, an award-winning automatic line for shipboard pipe production.

Since 1979, Malin has continued his research in the United States at GARD (Siemens), Niles, Ill., and Northwestern University, Evanston, I11. His research focuses on new welding processes, metallurgy, fabrication, automation, and consulting for industry and the U.S. government. Currently, he is owner of Malin's Welding Consultants, Inc.

Malin's innovative approach to welding automation earned him design awards for a six-electrode GMA system for welding pump impeller assemblies (1983) and for a computerized pulsed- arc synergie GMA system for welding military bridge aluminum deck panels (1991). He developed several new welding processes, including mold solidification welding (MSW) for surfacing steel with copper alloys (1986) and the modified refractory flux (MRF) method for one-side ship-erection welding (1999).

Malin has written more than 50 articles and two books, holds several patents, and has received numerous awards for his research. He currently serves as a principal reviewer for the Welding Journal's Welding Research Supplement and on various committees of professional societies, including the AWS and Commission XII of the American Council of the International Institute of Welding.

ROBERT J. CONKLING MEMORIAL AWARD

First Place B High School MacArthur High School

San Antonio, Texas

First Place - - Post Secondary Pinellas Vo-Tech School (PTEC)

Clearwater, Florida

A. F. DAVIS SILVER MEDAL AWARD

Machine Design

"An Enhanced Faraday Cup for Rapid Determination of Power Density Distribution in Electron Beams"

John W. Elmer received his Sc.D. in metallurgy from the Massachusetts Institute of Technology in 1988. He has held various welding-metallurgy positions at Lawrence Livermore National Laboratory, Livermore, Calif., since 1982 and is presently deputy program element leader for stockpile joining and metallurgy.

Elmer is the principal investigator for a DOE/Office of Basic Energy Sciences research program to investigate weld phase transformations through the use of synchrotron radiation. He has authored or coauthored more than 60 technical papers in the fields of materials joining, metallurgy, rapid solidification, high-energy-density beam/materials interactions, and the kinetics of phase transformations under nonisothermal conditions.

Elmer is a member of AWS and ASM International; he serves as a technical reviewer for the Welding Research Supplement of the Welding Journal, a key reader for Metallurgical and Materials Transactions, and a member of the editorial board of the Science and Technology of Welding and Joining. He is on the AWS Technical Papers Committee and serves on two of the Society's technical awards committees. In 2000, Elmer became a Fellow of the American Welding Society. In 1991 and 2001, he received the AWS William Spraragen Award and, in 1995, he received the Professor Masubuchi- Shinsho Corporation Award from AWS. He holds seven U.S. patents for inventions relating to the measurement of power density distribution in electron beams.

Alan T. Teruya earned his M.S. degree in engineering from Harvey Mudd College, Claremont, Calif., in 1984. Since then, he has worked at Lawrence Livermore National Laboratory (LLNL), Livermore, Calif., as an electronics engineer specializing in data acquisition and control systems.

From 1990 to 1996, he was a member of LLNEs Electronic Engineering's Chemistry and Materials Science Group. As a member of this group, he first worked on the measurement of power density distribution in electron beams. His current primary assignment is on sensors and measurement for missile flight testing.

D'j[om JUNE 2002 I

Teruya is named coinventor on five U.S. patents for inventions relating to the measurement of power density distribution in electron beams.

Maintenance and Surfacing

"Experimental Evaluation of Fe-AI Claddings in High-Temperature

Su/fidizing Environments"

Stephen W. Banovic received his Ph.D. in materials science and engineering from Lehigh University, Bethlehem, Pa. He is a project leader in the Metallurgy Division of the National Institute of Standards and Technology. His research interests include weldability and corrosion resistance of dissimilar metal welds, coatings for thermal barri- er applications, and formability of lightweight sheet metals and tailor-welded blanks.

Banovic was awarded a National Research Council Postdoctoral Associateship in 2000 for his work in microstructural influences on the ori- gins of heterogeneous plastic deforma- tion surface patterns. He was also awarded a National Science Foundation Trainee ship Award in 1994. Banovic is a member of AWS, TMS, ASM International, NACE, and SAE and is involved with two research teams through the U.S. Council on Automotive Research (USCAR) aimed at the economical application of lightweight sheet metals for outer body panels.

John N. DuPont See biography under

Memorial Membership Award. Adams

Arnold R. Marder earned his Ph.D. in metallurgy and materials science from Lehigh University, Bethlehem, Pa., in 1968. He is currently a professor in the Department of Materials Science and Engineering and associate director of the Energy Research Center at Lehigh. Prior to joining Lehigh's faculty in 1986, he was employed for 21 years by Bethlehem Steel Corp.'s Homer Research Laboratories.

Marder's present research interests include processing-structure-property relationships of materials. In particular, his research involves coatings and alloys for ambient and high-temperature environments including erosion, oxidation, and sulfidation. He has an ongoing interest in the physical metallurgy of steel and is involved in research on weld overlay coating of superalloys and iron alummide intermetallics, as well as weldability studies of Cr-Mo steels.

Marder has published more than

170 technical papers, edited three books, and received 20 U.S. and foreign patents. Among his honors are the ASTM Joseph Vilella Award for Metallography in 1974 and 1994, the 1996 AWS Charles H. Jennings Memorial Award, and, in 1998, the AWS William Spraragen Award.

DALTON E. HAMILTON MEMORIAL CWl OF THE

YEAR AWARD

Kenneth R. Stockton received his A.S. degree in mechanical drafting from Middlesex County College, N.J., in 1975, and continued his education at the General Technical Institute of Welding in Linden, N.J. In 1994, he attended the Hobart Institute of Welding Technology, Troy, Ohio, and, in 1996, the HeUier NDT Institute in Connecticut. He has been an active CWI and CWE since 1994.

Stockton joined Public Service Electric and Gas (PSE&G) in Sewaren, N.J., in 1984 as a welder mechanic. In 1997, he accepted a position with PSE&G, Maplewood Testing Service in Maplewood, N.J., as a test engineer with the NDE Group.

Stockton served as chairman for the AWS New Jersey Section in 1997-1998 and has been Student Activities chairman since 2001. He received the AWS Section and District Dalton E. Hamilton CWI of the Year Awards in 1998 and 2001 and the Private Sector Instructor of the Year Award in 2001. He has been a VICA judge for the New Jersey area since 1995.

W. H. HOBART MEMORIAL AWARD

"Hot Tap Weld Prevents Offshore Piping System Shutdown"

Jack Still has been employed for the last 24 years by Britoil/BP, Shell Expro and, eventually, Amerada Hess in numerous activities such as construction techniques, welding engineering, and material and weld metal selection.

Still earned a M.Sc. in welding technology from Cranfield University. His other academic qualifications include chartered engineer and certified European welding engineer. He holds membership in the Institute of Materials, the Welding Institute, and the British Institute of Non-Destructive Testing and is a member of AWS, NACE, and ASM. Still has published more than 46 technical papers. In 1988, he was awarded (jointly) the Welding

J. Still J. Stropki

Institute's Sir Charles Lillicrap Medal for a paper on the '~pplication of Fracture Mechanics to Offshore Platform Installation."

"Hot Tap Weld Prevents Offshore Piping System Shutdown"

Peter Mackie is Project HSEQ manager for Halliburton KBR Production Services in Scotland. He joined the company in 1980 and has held the positions of HSEQ co-coordinator, QA manager, QA/QC engineer, and QA/welding engineer.

His experience is with onshore and offshore pipework fabrication and construction, construction engineering projects, control and responsibility of welding/heat treatments, NDE specialty project applications, and QA requirements.

Peter Hummelgaard received his B.S. in structural engineering in 1991. Since then, he has been with MT Services, Esbjerg, now MT Hojaard A/S, as a welding engineer involved with prefabrication of pipe installations in the North Sea. His duties include the preparation of welding procedures, certification of welders, and introduction of EDP-based welding and collection of welding data. He has held the position of project manager for major repair and modification tasks on drilling rigs for Maersk Contractors, Sedco Tranocean, and ENSCO Netherlands B.W

Hummelgaard is a member of the control group of Carl Bro Industry and Marine Certification Department and sur- veys their accredited activities. He is also a member of the J~M Institute in Denmark.

HONORARY MEMBERSHIP AWARD

Dr. Michael J. Cieslak See biography under Comfort A.

Adams Lecture Award.

John Stropki is executive vice president and president, North America, of The Lincoln Electric Co. As head of the North American region, he is responsible for all sales, marketing, service and manufacturing operations in the United States and Canada.

WELDING JOURNAL I IrAi l

O. Al-Erhayem B. Braithwaite J. C. Lippold C.-C. Huang

He has been with Lincoln Electric for 29 years, starting with the company as a college student in 1969 working part- time. Upon graduating in 1972 with a bachelor's degree in industrial engineering from Purdue University and an MBS from Indiana University, he joined Lincoln full time as a sales trainee. He has held various positions of increasing responsibility over the years including district manager, national sales manager for Canada, and senior vice president for sales. Stropki assumed his current position in 1995 and was elected to the Lincoln Electric Holdings, Inc., Board of Directors in 1998.

In addition to being a member of AWS, Stropki's professional memberships include the Society of Marketing Executives, Manufacturers Alliance Presidents Council, and the National Welding Supply Association. He is a member of the Board of Governors of the National Electrical Manufacturers Association (NEMA), a member of NEMA-1 Board of the Division 1 - - Industrial Automation Section, serves as chairman of NEM~/s Arc Welding Section, and was a member of the Leadership Cleveland Class of 1995-1996. In 1998, Stropki was named the recipient of Purdue University's Outstanding Industrial Engineer Award.

INTERNATIONAL MERITORIOUS CERTIFICATE AWARD

Osama AI-Erhayem is the general secretary of the Institute for the Joining of Materials (JOM) in Denmark. In addition, he is an associate professor of welding and engineering materials at the Technical University of Denmark in Copenhagen.

After earning a Ph.D. in Germany, A1-Erhayem went to work with numerous German and Danish industries. He is cred- ited with introducing welding engineer courses to the technical education curricu- lums in Denmark and has been the head of the Welding Department at the Helsing0r Institute. A1-Erhayem founded JOM in 1979 to serve as a forum for the presentation of results in welding research and development. JOM publishes the International Journal for the Joining of Materials.

B'P, I I JUNE 2002 I

A1-Erhayem has had a long relationship working with AWS in Europe and is founder of the Society's Scandinavian Section, which was chartered in 1994.

Beven Braithwaite was appointed chief executive of The Welding Institute (TWI) in June 1988, having previously been the managing director since 1984, and prior to that director of development. He was appointed to the Executive Board in 1966, and since that time has had a particular interest in the industrial applications of R&D and the development of effective means of transferring advanced technologies to industry.

Braithwaite graduated from Cambridge University in 1961 with a mechanical science degree. He is the orig- inator of a number of patents in both the welding process and design fields and is the author of articles and papers concerned with application, innovation, and management of R&D. He is a Council Member of the United Kingdom Research Council responsible for science funding in universities and he is currently president of the International Institute of Welding (IIW). Braithwaite initiated the development of Granta Park, a joint venture Science Park between TWI and MEPC, and is a director of Granta Park Limited. He was awarded the OBE in 1991 and elected to the Royal Academy of Engineering in 1999.

WILLIAM IRRGANG MEMORIAL AWARD

John C. Lippold received his B.S., M.S., and Ph.D. degrees in materials engineering from Rensselaer Polytechnic Institute, Troy, N.Y. From 1978 to 1985, he worked at Sandia National Laboratories as a member of the technical staff, specializing in the area of stainless steel and high- alloy weldability. From 1985 to 1995, Lippold worked for Edison Welding Institute and served as an adjunct professor in the Welding Engineering Department at The Ohio State University (OSU). In 1995, he joined the faculty of the welding engineering program at OSU. In addition to his academic duties, he is the director of the National Excellence in Materials Joining Education and Training

(NEMJET) program at OSU and is currently leading an effort to develop a distance learning welding engineering degree program.

For more than 25 years, Lippold has been actively involved in research programs designed to gain a better understanding of welding metallurgy and the properties of engineering materials. His research has involved both fundamental and applied topics with a high degree of industrial relevance. He has been actively involved in the evaluation of weldability test information. Based on this research, Lippold has published more than 150 technical papers and reports and has made more than 300 technical presentations. He is recognized internationally in the field of stainless steel and high-alloy welding metallurgy, and weldability testing.

Lippold has won several AWS-sponsored awards including the Charles H. Jennings Memorial Award (1977 and 1980), the William Spraragen Memorial Award (1979 and 1992), the Warren E Savage Memorial Award (1993 and 1999), the McKay-Helm Award (1994), and the James E Lincoln Gold Medal Award (1983). He has also been the recipient of the Buehler Technical Paper Merit Award (1985 and 1989) from the International Metallographic Society. In 1994, Lippold was elected an ASM Fellow and, in 1996, became a Fellow of AWS. In 1997, he presented the Comfort A. Adams Memorial Lecture at the AWS Annual Convention in Los Angeles. He serves on a number of professional society committees and is currently chair of the AWS Technical Papers Committee.

CHARLES H. JENNINGS MEMORIAL AWARD

"Partially Melted Zone in Aluminum Welds: Solute Segregation and

Mechanical Behavior"

Chen-Che Huang received his M.S. in mechanical engineering in 1996. From 1996 to 1998, he served in Taiwan's military service as an intelligence officer.

Huang is currently a Ph.D. candidate in the Department of Materials Science and Engineering at the University of Wisconsin-Madison. He has been a coau- thor of several technical papers and a member of the Chinese Engineering Association and AWS.

Sindo Kou received his Ph.D. in materials science and engineering from the Massachusetts Institute of Technology, Cambridge, Mass.

In 1983, Kou joined the University of Wisconsin-Madison and became a full professor in 1985. He is currently chair of the Department of Materials Science and Engineering. His recent

S. Kou H. D. Solomon M. A. Quintana J. E. McLane

research includes welding metallurgy of aluminum alloys, Marangoni flow in weld pools, microgravity fluid physics, and semiconductor crystal growth. He has written numerous journal articles, authored Welding Metallurgy (New York, N.Y.: Wiley, 1987), and holds five U.S. patents for his crystal growth work.

The honors Kou has received include the 1980 John Chipman Award from the Iron and Steel Society of AIME, the 1986 AWS Adams Memorial Membership Award, the 1999 Chancellors' Award for Distinguished Teaching from the University of Wisconsin, and the 1999 Benjamin Smith Reynolds Award for Excellence in Teaching from the College of Engineering, University of Wisconsin.

JAMES F. LINCOLN GOLD MEDAL AWARD

"A Statistical Analysis of Brazed Joint Fatigue Behavior"

Harvy D. Solomon received his Ph.D. from the University of Pennsylvania. He has been employed at the General Electric Global Research Center (formerly the Corporate Research and Development Center) since 1968.

Solomon is concurrently an adjunct associate professor at Union College, Schenectady, N.Y., where he teaches a course on welding metallurgy and has been a lecturer and director of the college's summer course on fatigue and fracture.

Solomon is the recipient of numerous technical awards, including the 1979 ASTM Joseph Vilella Award, the 1986 IEEE-CHMT Prize Paper Award, and the 1998 AWS Prof. Dr. Rene Wasserman Award.

Solomon is the holder of 14 U.S. patents and has authored more than 85 open literature publications, including a section on duplex stainless steels for the Encyclopedia of Materials Science and Technology and a section on weld solidification for the 1993 ASM Metals Handbook, Vol. 6.

MCKAY-HELM AWARD

"Inclusion Formation in Self-Shielded Flux Cored Arc Welds"

Marie A. Quintana has been involved in welding research for more than 20 years. She is a graduate of the University of Connecticut and the University of California, Berkeley, where she earned degrees in metallurgy and materials science. Quintana has been with The Lincoln Electric Co. since 1995 and is currently responsible for new product development in welding consumables.

Quintana has been an active partici- pant on the AWS A5 Filler Metal Committee and various subcommittees and task groups for 18 years. Her interests are focused on the development of test methods for hydrogen control of welding consumables. Quintana is also an active member of the Society of Women Engineers, where she currently serves as national scholarship chair.

John E. McLane has specialized in electron microscopy throughout his 36- year career. His positions have included geologist with the U.S. Geological Survey, Washington D.C.; marine geologist, U.S. Naval Oceanographic Survey, San Diego Calif.; criminalist, Dade County Crime Lab, Miami, Fla.; senior research scien- tist, Smith Energy Services, Golden Colo.; electron microscopy specialist, Adolph Coors Co., Golden, Colo.; engineer, The Lincoln Electric Co., Euclid, Ohio; and technologist with Eveready Battery Co. in West Lake, Ohio.

McLane has authored or coauthored 16 professional papers dealing with subjects such as forensics, mineralogy, biolo- gy, lunar mineralogy, and metallurgy. Presently, he is involved in the research and development of cathode materials for use in alkaline batteries.

Sudarsanam Suresh Babu is a senior research and development staff member at Oak Ridge National Laboratory (ORNL), Oak Ridge, Tenn.

Before joining ORNL in 1993, Babu worked as a postdoctoral researcher at Tohoku University, Japan. He has nine years of both fundamental and applied

S. S. Babu S. A. David

research experience at ORNL in the area of welding metallurgy of steels and nickel- based superalloys. His work at ORNL relates to phase transformation issues related to low-alloy steels, inclusion formation, nonequilibrium solidification, and application of computational thermo- dynamics and kinetics to corrosion issues. He is also involved in the application of state-of-the-art characterization tools including atom probe tomography, synchrotron diffraction, and neutron diffraction for understanding interaction between weld thermal cycles, phase stability, and diffusion in complex alloys.

Babu has published 47 journal articles and numerous conference proceed- ings. He has been instrumental in the development of on-line computational models that enable industries, academics and research institutions to use state-of- the-art computational models. He received the Professor Masubuchi/MIT Award and W. E Savage Award from AWS in 1998. He also received the Research & Development Accomplishment Award from UT- Battelle in 2000.

Stan A. David received his Ph.D. degree in metallurgical engineering from the University of Pittsburgh. He currently holds adjunct professorships at the University of Pittsburgh, Pittsburgh, Pa., and Colorado School of Mines, Golden, Colo.

In 1997, David joined Oak Ridge National Laboratory (ORNL), where he is corporate fellow of UT-Battelle and leader of the Materials Joining and Nondestructive Testing Group in the Metals and Ceramics Division. He is a Fellow of The Minerals, Metals, and Materials Society (TMS), American Association for the Advancement of Science, ASM International, and the American Welding Society. David is the editor-in-chief of Science and Technology of Welding and Joining, published by the Institute of Materials in London.

David is the recipient of numerous awards including the Distinguished Alumnus Award from the University of Pittsburgh and the AWS Warren E Savage Memorial Award. In 1997, he was awarded the Elegant Work Prize of the

WELDING JOURNAL l ~ l

1~ Takahashi W. M. Thomas D. F. Bovie B. J. Bastian V. R. Davd Z O. Milewski

Institute of Materials, London, for his publication on single-crystal welding; in 1996, he received the AWS William Irrgang Memorial Award; and, in 1994, the Champion H. Mathewson Award from TMS.

David has contributed to more than 200 papers in the fields of solidification and welding metallurgy and is the editor of several international conference pro- ceedings. He also serves on several national committees of professional societies and industrial advisory boards.

PROF. KOICHI MASUBUCHI AWARD

Kunio Takahashi received his doctoral degree in welding engineering from Osaka University in Japan in 1993. He joined the Tokyo Institute of Technology in 1990 as a research associate and, since 1997, has held the position of associate professor.

Takahashi's doctoral thesis was on electron spectroscopic analyses for surface and interracial valence states of materials. He has proposed a simple formula for surface energy using quantum mechanics and has also constructed a unique adhesion force measurement system in an ultrahigh vacuum chamber of surface analysis apparatus. Applications of science to joining technology are the focus of his research, and his current research work is on joining science and technology for microassembly.

At the Tokyo Institute of Technology, Takahashi is involved with the International Development Engineering Department, established for the international education of engineering. He is also active in the Japan Welding Society.

SAMUEL WYLIE MILLER MEMORIAL MEDAL AWARD

Wayne M. Thomas is principal research engineer in the Innovation Unit at The Welding Institute, Ltd, Great Abington, Cambridge, United Kingdom. He received his M.Phil. degree in materials technology from Brunel University and has recently gained CWng and FWeldl status.

D £ 1 JUNE 2002

Thomas is author of numerous technical papers and has been responsible for the conception and/or development of a number of emergent technologies. He has been awarded the Sir William J. Larke Medal in recognition of the advancement of knowledge or practice in respect of the welding process, and the Welding Process Technology Award for the invention and development of the friction stir welding method.

NATIONAL MERITORIOUS AWARD

D. Fred Boric received his MBA degree from the University of Chicago. He is also a graduate of the Executive Program from the University of Chicago.

Prior to his retirement, Bovie was president and chief executive officer of the ESAB Group, the North American subsidiary of ESAB Sweden.

He began his welding career at Airco as an application engineer in the gas and welding unit, and later served in various marketing and operating management positions. He served as vice president and general manager of Airco's arc equipment and filler metal business. In 1980, he joined Alloy Rods Corp. as president and was instrumental in guiding Alloy Rods through a lever- aged buy-out and an Employee Stock Ownership Plan, and a sale in 1989 to the ESAB Group.

He is a Life Member of AWS, a member of the AWS 2001 class of Counselors, and a past director-at-large.

Bernhard J. Bastian holds a master's degree from Rensselaer Polytechnic Institute, Troy, N.Y., and has done postgraduate studies in mechanical engineering and materials at the University of Michigan. He is currently a consultant with Benmar Associates.

As an AWS Fellow, a past AWS director-at-large, a Distinguished Mem- ber, and recipient of the District 11 Meritorious Award, Bastian has been an active member of AWS for more than 45 years. He chaired the Detroit Section's Sheet Metal Welding Conference I in 1984 and has since

acted as either technical session chairman and/or technical advisor. He has served on various AWS committees including the C1 Resistance Welding Committee, the D8 Automotive Resistance Welding Committee, the Welding Handbook Committee, and Conference Committee.

Bastian developed welding standards and weld test procedures at Ford Motor Co., where he was secretary of the Welding Committee, and he helped design and develop the Gleeble while at Rensselaer.

Bastian has written articles for the Welding Journal, the SAE Journal, and for Chrysler and Ford house publications. For 17 years, he taught welding and related courses at Henry Ford Community College.

ROBERT L. PEASLEE BRAZING AWARD

"Precision Laser Brazing Utilizing Nonimaging Optical Concentration"

Vivek R. Dav~ is currently the group leader for NMT-10, Manufacturing and Process Technology, at the Los Alamos National Laboratory's Nuclear Materials and Technology (NMT) Div. He completed his doctorate in 1995 both in materials engineering from the Massachusetts Institute of Technology.

Davr's professional experience is both in the aerospace sector at the Pratt & Whitney Div. of United Technologies as well as at Los Alamos, first with the Materials Science and Technology (MST) Div. and, at present, with the NMT Div.

Dav6 has published numerous articles in the areas of materials engineering and joining. He is currently a principal reviewer for the Welding Journal's Welding Research Supplement and par- ticipates on the C3 Committee.

Robert W. Carpenter is currently a technician with Los Alamos National Laboratory's Materials Science and Technology Div., with the Metallurgy Group, MST-6, in the Welding and Joining Section. The MST-6 Welding Section is the largest in the Department of Energy complex and performs extensive research

and development activities in support of numerous programs within the lab as well as with industrial partners. Carpenter's expertise is in laser welding and laser materials processing.

Dane I". Christensen completed his undergraduate engineering studies at Rice University and is presently a graduate student in mechanical engineering at University of California, Berkeley, conducting research in micro electro- mechanical systems (MEMS) technology. During the summers, he has worked at the Los Alamos National Laboratory, on numerous occasions working in both the Nuclear Materials and Technology Div. as well as the Materials Science and Technology Div.

John O. Milewski is currently welding team leader at the Los Alamos National Laboratory. He earned a M.S. in electrical engineering from Vanderbilt University.

In 2002, Milewski was elected an AWS Fellow. His involvement in AWS activities include chairman of the AWS C7B Electron Beam Subcommittee, second vice chairman of the C7 High- Energy Beam Committee, member of the Technical Papers and Awards Committees, and as a principal reviewer for the Welding Journal's Welding Research Supplement. He has also served as the U.S. delegate for the High-Energy Beam Commission of the International Institute of Welding.

Milewski has published more than 24 technical papers. His research interests focus on high-energy-beam welding, process modeling, and weld model validation. He holds numerous patents related to laser welding and was a core- cipient of a R&D 100 award in 1994 for the development of Directed Light Fabrication (DLF), a process to fuse metal powder into fully dense three- dimensional shapes.

PLASMA ARC CUTTING AWARD

Catherine Anne Brawley received a Master of Fine Arts degree from Indiana University in 1993. She is a full- time artist and assistant professor of art at Palo Alto College, a College of the Alamo County College District, where she teaches ceramics and sculpture.

Brawley works with a variety of materials in her sculptures, including clay and wood, but steel has always been the main component. In 1996, she received a grant from the city of San Antonio to design an outdoor sculpture for the newly renovated Henry B. Gonzalez Convention Center. With this commission, she began to work primarily

C. A. Brawley J. A. Danaher

in aluminum. As a result, she has received several commissions to create large-scale, outdoor public sculptures around San Antonio.

Crawley's sculpture class is currently involved in a public art project working with at-risk youths to create several life-size rocking horses. Many of her students are actively involved with the low-rider culture of San Antonio; therefore, they have designed one of the horses with hydraulic components so it will rear up. This is an ongoing project through which college students mentor area youth in a creative classroom environment.

PLUMMER MEMORIAL EDUCATIONAL LECTURE

AWARD

"A New Approach for Welding Engineering Education: The Trials,

Tribulations, and Triumphs of Distance Learning"

John C. Lippold See biography under William

Irrgang Memorial Award.

PRIVATE SECTOR INSTRUCTOR MEMBERSHIP AWARD

James A. Danaher has been employed for the last 12 years by the New York City Metropolitan Opera. Throughout the year, he teaches basic, intermediate, and advanced welding to members of the International Alliance of Theatrical Stage Employees (IATSE) Local One AFL-CIO, usually within the Electric Shop of the Metropolitan Opera. Currently, he serves on the Technology Committee of IATSE Local One, which is responsible for the development of training programs in all areas of stage work.

His students have been responsible and noted for their work in the many diverse aspects of the entertainment industry. Some of his students welded the Millennium Ball in Times Square. They have also created various scenic elements and props for Broadway the- aters, theme parks, rock shows, con- certs, and casinos.

S. Green K. Lyttle

Danaher has worked as a journey- man sheet-metal worker, pipe fitter, and scenic carpenter. He ran the CBS Television Metal Shop for 11 years. At CBS, he built scenery and models for most of the network's newscasts and soap operas. He has been a member of AWS for 14 years and served as the Section chairman for the Long Island Section from 1995 to 1996. In September 2001, he was awarded the District 2 Private Sector Instructor Membership Award recognized at the District level.

In 1984, Sandra Green entered into the Concho Career Institute in San Angelo, Tex. She graduated with the highest G.EA. in the school's history, as well as being the first female graduate. After graduation, she joined Triplex Sign Co. constructing custom electric signs and catwalks. In 1987, she joined Andrew Corp.'s Towers Div. in Denton, Tex., welding communicat ions support systems. She served on the company's safety team for several years and was a H A Z C O M trainer. Continuing her education, Green has also taken courses at Missouri Western State College, Texas Woman's University, and Rochland College.

Green has been with American Trades Institute in Dallas, Tex., since 1997 and is currently lead-welding instructor. At the Institute, she structured the welding program with emphasis on structural applications, utilizing AWS D1.1 as her main curriculum guide. As part of this curriculum development she has written comprehensive exams for all courses, supporting technical materials, and viable skills assessment tests including WPSs. She also serves on the Institute's Advisory Board.

Green has been a member of AWS for five years, is the recipient of two AWS District 18 Private Sector Welding Instructor Membership Awards, serves as AWS North Texas Section chair of student scholarships, sponsors AWS student memberships, and is an AWS CWI.

WELDING JOURNAL Ir~.- !

G. Oertelt 17. D. Smith H

SAFETY AND HEALTH AWARD

Kevin A. Lyttle received his M.S. in metallurgy from New York University and his MBA from Cleveland State University. He has been actively involved in the welding industry for more than 25 years.

Lyttle has participated in a wide range of AWS education, safety, and health committees. He has been a long- time member of the Fumes and Gases Committee and acted as chair for nine years. He chaired the Safety and Health Committee from 1992 until 1999 and was involved in numerous projects including several programs conducted at the Harvard School of Public Health dealing with welding fume issues.

Lyttle holds several patents in the areas of gas metal arc welding and shielding gases for that process. He has presented numerous papers and written several articles dealing with GMAW, shielding gases, and improvements in welding technology. As a result of his AWS committee work, Lyttle has authored and delivered presentations in the United States, and abroad, covering a wide range of topics in the welding fumes area. He has been involved in providing a series of educational lectures dealing with this and related subject areas such as fume measurement and technologies that can be used to reduce fume exposure.

WARREN F. SAVAGE MEMORIAL AWARD

"Effect of Thermal Cycling on Friction Stir Welds of 2195 Aluminum Alloy"

Gerhard Oertelt received his Dipl.- Ing in engineering from the University of Leoben, Austria, in materials science. He is currently with AVL List GmbH, Graz, working in mechanical development centering on powertrain systems. His main responsibilities focus on experimental strength analysis and safety assessment of engine components (fatigue tests), material investigations, development of material test programs, failure analysis, project management, and production engineering issues. He has FAA private pilot and instrument

flight rating licenses along with additional training for the FAA commercial pilot/multiple engine rating license.

Sudarsanam Suresh Babu See biography under McKay-Helm

Award.

Stan A. David See biography under McKay-Helm

Award.

Ed Kenik received his Ph.D. in metallurgy and materials sciences from Case Western Reserve University. He joined the Metals and Ceramics Div. at Oak Ridge National Laboratory (ORNL) in 1974. He is currently a distinguished R&D staff member. Kenik served two terms as leader of the Microscopy and Microanalytical Sciences (M&Ms) Group and was director of the Shared Research Equipment (SHARE) Collaborative User Program (1979-1999).

Kenik has authored or coauthored more than 220 technical publications on both methods and applications of analytical electron microscopy and atom probe analysis to a variety of materials science problems. His research areas include advanced alloys and ceramics, phase transformations, radiation damage, surface modification of materials, deforma- tion and fracture, nanophase materials, segregation phenomena, and catalysts. He served as adjunct professor at Vanderbilt University during 1980-1999. He has been a member of both TMS and ASM International since 1968 and, in 1997, was elected a Fellow of ASM International.

SILVER QUILL EDITORIAL ACHIEVEMENT AWARD

Advanced Materials & Processes Margaret W. Hunt, Editor

"Welding Processes for Aeronautics"

by Patricio Mendez and Thomas Eagar

WILLIAM SPRARAGEN MEMORIAL AWARD

"The Determination of Hydrogen Distribution in High-Strength

Steel Weldments Part I: Laser Ablation Methods"

Rodney D. Smith II received his Ph.D. in applied chemistry from Colorado School of Mines, Golden, Colo., in 1999. The topic of his Ph.D. thesis was the development of advanced methods for the determination of total and diffusible hydrogen in welded high- strength steels.

In 1999, Smith joined DCH Technology in Valencia, Calif., and began work on various hydrogen safety devices including the fiber-optic hydrogen sensor being developed at the National Renewal Energy Laboratory (NREL) in Golden, Colo. In 2001, he left DCH and is currently continuing his work on hydrogen sensors at NREL as a member of the Basic Sciences Center.

Gary P. Landis received his Ph.D. in geology-physical chemistry in 1972 from the University of Minnesota.

He has held faculty positions at the University of Minnesota, Carleton College, University of New Mexico, and as a visiting staff appointment at Los Alamos Scientific Laboratories and several minerals exploration industry positions before joining U.S. Geological Survey (USGS) in 1979. His research on stable isotope and gas geochemistry of ore deposits, paleoclimate studies (ice cores), nobel gas geochemistry, evolution of ancient earth atmospheres, and paleobi- ology (evolution, extinction, and dinosaurs) has appeared in more than 180 published papers, abstracts, and books.

Currently, Landis is a USGS project chief applying noble gas geochemistry to studies of groundwater, magma (volcanic) gases and mineral deposits, and cosmo- genic nuclide surface exposure age dat- ing. He is involved in developing new lines of research at the interface between earth and life science to better understand ecosystem balance, trophic levels, and feeding habits and migratory behavior of managed wildlife species.

Iman Maroef is a postdoctoral research associate at the Metallurgical and Material Engineering Department, Colorado School of Mines (CSM). In this position, he has worked in different research areas within the discipline of physical and welding metallurgy, including hot forming and hot ductility study of metals, as well as failure analysis. He received his Ph.D., with a research emphasis in hydrogen management in welding metallurgy, from CSM in 1999.

Maroef's previous background was mechanical engineering. After completion of his undergraduate study, he worked as a mechanical and manufacturing engineer for a heavy industry fabricator for two years prior to his graduate study in the U.S.

David Olson received his Ph.D. in materials science from Cornell University and has done postdoctoral work at The Ohio State University. Currently, he is the John H. Moore distinguished professor of Physical Metallurgy at Colorado School of Mines, Golden, Colo.

BIr~,'lB JUNE 2002 I

Olson is an active member of many technical committees for professional societies and government organizations, including U.S.-sponsored visiting teams to India and Argentina. He is the recipient of numerous awards, honors, and recognitions from AWS and other professional and educational institutions including being named both an AWS and ASM Fellow. In April 2000, he received the 1999 TTCP Achievement Award from the U.S. Department of Defense and the recognition of Foreign Member of the National Academy of Sciences (Materials Science) of Ukraine, Kiev.

Thomas R. Wildeman has been teaching and conducting research at the Colorado School of Mines (CSM) for more than 25 years. He is currently a professor of chemistry and geochemistry with 30 years of research experience in trace element and environmental geochemistry, in methods of chemical analysis, and in theories and methods in education.

For the last eight years, Wildeman's research has concentrated on the use of constructed wetlands and passive bioreactors for the removal of metal contaminants. On the education side, he helped institute the Faculty Development Program at CSM, serving on the founding committee of the McBride Honors Program and was the Principal Tutor in 1983-1984 and principal investigator on a National Science Foundation Precollege Teacher Enhancement Grant from 1987-1990.

Since 1987, Wildeman has received a number of local, state, and national awards for teaching and for research on the remediation of acid mine drainage. He is a member of seven different technical organizations and has served at the national level within the Geochemistry, Environmental Chemistry, and Education Divisions of the American Chemical Society.

Wildeman has authored one book and more than 80 refereed articles, and 90 published abstracts.

R. D. THOMAS MEMORIAL AWARD

Martin Prager received his Ph.D. in materials engineering from UCLA in 1969.

From 1969 to 1974, Prager was with Copper Development Association as manager of Application Engineering. From 1974 to 1985, he had a private practice in New York City consulting with major corporations and industrial associations, specializing in materials for petroleum, marine, aerospace, con-

D. Olson M. Prager

struction, power, and electrical applications. Prager joined The Materials Properties Council, Inc., as its executive director and CEO in 1985. He organizes and manages programs on hydrogen pressure vessels, dissimilar metals welds, bolting, carbine rotors, stress corrosion, elevated temperature properties, remaining life assessment, and many other subjects. He is also executive director of the Pressure Vessel Research Council and Welding Research Council and is responsible for management of these two international research organizations.

Prager has been the recipient of numerous awards including the 1977 recipient of lEE Award for Best Substation Paper and the 1978 recipient of the AWS A. E Davis Silver Medal for Structural Welding. He is also a member of the Board of Directors for the International Institute of Welding.

ELIHU THOMAS RESISTANCE WELDING AWARD

John M. Sant attended Carnegie Institute of Technology (now Carnegie Mellon University) and received is B.S. in mechanical engineering in 1948. In 1950 he joined Federal Machine and Welder Co., as a designer/detailer. Through various mergers, the company became known as Wean Inc., from which he retired in 1988 as vice president of engineering and general manager.

Sant's professional activities include chairmanships of technical committees with the Resistance Welder Manufacturers Association, National Electrical Manufacturers, American Society of Mechanical Engineers, and the American Welding Society.

GEORGE E. WILLIS AWARD

Ralph E. Long received his doctorate degree in industrial technology from the University of Northern Iowa. He joined Northern States Power Company in 1982 and, prior to his retirement in 1992, his work included all welding and QA training. He was the coordinator of

J. M. Sant R. E. Long

accreditation for all corporate training by the Institute of Nuclear Power Operations. He has also been director of the B.S. Welding Technology Program at Utah State University's College of Engineering.

Since his retirement, his work as a consultant includes development of quality assurance systems procedures for the International Institute of Welding's (IIW) International Accreditation Board, program evaluation of distance learning for IIW, lead auditor of IIW, and the NEMJET project with Edison Welding Institute. He has also worked as an Assessor for AWS on Approved Test Facilities.

Long's professional and association activities include serving as an AWS District director, chairman of the AWS Education Committee, an AWS Director-at-Large, a member of the AWS Certification Committee, the U.S. delegate to IIW from 1977 to 1997, and chairman of Commission XIV, Welding Instruction from 1996 to 2002. He has published numerous articles for professional journals as well as papers on welding instruction to Commission XIV of I IW.•

AWS Membership Will Be Extended for Those Called to Serve

Amer ican Welding Society members who are called to active duty with the National Guard or the Reserves due to the events of September 11, 2001, will be issued compl imentary membership credit for the period of their service.

To receive the courtesy of membersh ip extension, members should call the AWS Membership Depar tment at (800) 443-9353, ext. 480, upon returning to the civilian work force.

This is the AWS's small way of expressing gratitude for your service to our coun t ry . •

WELDING JOURNAL l / |

AWS Membership Member As of Grades May 1, 2 0 0 2

Sustaining Companies ..................... 420

Supporting Companies .................... 269

Educational Institutions .................. 265

Total Corporate Members .... 954

AWS Distinguished Member The following member has attained the status of Distinguished Member for his

participation in the Society's leadership, technical, and education activities.

Osama AI-Erhayem Scandinavia

To qualify for distinguished membership status, applicants must accrue 35 points or more from at least three of these four categories: national AWS leadership, local AWS leadership, professional development, and AWS membership recruitment. If you believe you qualify, contact the AWS Membership Department at (800) 443-9353 ext. 480 or FAX (305) 443-7559.0

Individual Members .................... 43,467

Student Members .......................... 4,574

Total M e m b e r s .... 48,041

Amer ican Welder Gear Available on the AWS Web Site

The American Welding Society proudly introduces a new line of American Welder Gear. The line car- ries more than 60 products ranging from pens to apparel to watches. AWS members receive a 10% discount on purchases. To check out the full line of Gear, visit www.aws.org/gear/ or call (800) 443-9353 to request a catalog.0

AWS Distinguished Member Award Program Updated

The AWS Distinguished Member Award Program, created by the AWS Board of Directors to recognize outstanding service and commitment of AWS Members to their Society and the welding industry, has been updated.

To qualify for AWS Distinguished Member status, applicants must accrue 35 or more points from at least three categories: National AWS Leadership, Local AWS Leadership, Professional Development, and AWS Membership Recruitment. The ways in which a Member accumulates points has been expanded. If you believe you qualify and would like an application, contact Cassie Burrell, Associate Executive Director, at [email protected] or (800) 443-9353, ext. 253.0

JOM to Host Third International Conference on Education in Welding

tion information, contact: Osama Strandvej 28, DK-3250 Gilleleje, join _a ws @post 10. tele. dk. •

The Institute for the Joining of Materials (J~M) will host the Third International Conference on Education in Welding from October 13 through 16 at the LO-Skolen Centre for Conferences and Adult Education in Helsingor, Denmark. This is the third in a series of educational conferences with the goal of enhancing the transfer of welding technologies through education, helping meet industrial needs for qualified personnel, improving knowledge in codes and standards for fabrication, and presenting guidelines for qualification programs and instructor effectiveness. The series was designed to provide an open forum to explore the various approaches to education and training currently in practice throughout the world. In addition to the Conference, there will be an exhibition of teaching aids, standards, and software relevant to welding education and training.

Contributions in the way of papers, workshops, and other presentations are cordially invited. To submit a short abstract and brief description of your intended paper, workshop, video, software, or presentation, or for registra-

AI-Erhayem, J ~ M Institute, Gilleleje Denmark, FAX: 45 48355458, e-mail:

AWS Welcomes New Supporting Companies New Educational Institutions

Corporaci6n Mexicana de Investigaci6n en Materiales S.A. de C.V.

Blvd. Oceania #190 Fracc. Saltillo Coahuila 25290 Mexico

Pontificia Universidad Catolica del Peru Av. Universitaria Cdra. 18 Lima 32 Peru

Tennessee Technology Center at Elizabethton

426 Highway 91 Elizabethton, TN 37644

Tennessee Technology Center at Knoxville

1100 Liberty St. Knoxville, TN 37919

Tennessee Technology Center at Livington

740 High Tech Dr. Livingston, TN 38570

New Supporting Companies

Delta-Unibus Corp. 515 Railroad Ave. North Lake, IL 60164

Everycontractor.com 3654 N. Rancho Dr., Ste. 102 Las Vegas, NV 89130

Marion Steel Fabrication, Inc. 2301 South Western Ave. Marion, IN 46953

B'~:m JUNE 2002 I

DISTRICT 1 Director: Geoffrey H. Putnam Phone: (802) 4 3 9 - 5 9 1 6

CONNECTICUT MARCH 11-16 Speaker: Ted Weber, instructor. Activity: The Section hosted a CWI Prep Course and Examination. Ten people attended the course and 21 people sat for the exam.

DISTRICT 2 Director: Alfred F. Fleury Phone: (732) 8 6 8 - 0 7 6 8

DISTRICT 3 Director: Alan J. Badeaux, Sr. Phone: (301) 4 4 9 - 4 8 0 0

READING FEBRUARY 21 Speaker: Derrick Miller, district sales manager. Affiliation: Harris Calorific, Inc. Topic: Torches and gauges: types, sizes, and safety. Miller also discussed his involvement at the World Trade Center during the days following the attack on the towers.

MARCH 6 Speaker: Tim Stott. Affiliation: Miller Electric Mfg. Co. Topic: Using the GTAW processes. This was the first of three seminar sessions held by the Section.

MARCH 13 Speaker: Charles Minnick, training fa- cilitator. Affiliation: Miller Electric Mfg. Co. Topic: The GMAW processes. Activity: The second installment of the Section's seminar included hands-on demonstrations.

YORK-CENTRAL PENNSYLVANIA .APRIL 4 Speaker: Carlos Rosati, FBI agent. Affiliation: Federal Bureau of Investi- gation, Laboratory Division, Washing- ton, D.C.

Attendees at the CWI Prep Course and Examination held by the Connecticut Section.

Charles Minnick, left center, explaining the GMA W process to Reading Section members prior to hands-on demonstrations.

Topic: Solving crimes through the examination of metals. Activities: Student Chapter members from York County School of Technol- ogy and Maryland's Carroll County Ca- reer Center attended the meeting. Vice Chairman George Bottenfieid presented Chairman Mike Bunnell with a Certificate of Appreciation for his work as chairman for the 2001-2002 term. At- tending the meeting were Maryland Section Chairman Ron Mealey and his wife and Ken Ellis, who once served as Maryland Section treasurer.

Reading Section Chairman Francis Butkus, left, with guest speaker Derrick Miller.

m

] WELDING JOURNAL

DISTRICT 5

A WS Student Chapter members from the York County School of Technology and Maryland's Carroll County Career Center at the York-Central Pennsylvania Section's April meeting.

Reading Section Seminar Chairman Dave Hibshman, left, presenting a speaker's gift to Tim Stott.

York-Central Pennsylvania Vice Chair- man George Bottenfield, left, presenting Chairman Mike Bunnell with a Cer- tificate of Appreciation.

DISTRICT 4 Director: Roy C. Lanier Phone: (252) 3 2 1 - 4 2 8 5

York-Central Pennsylvania Section Vice Chairman George Bottenfield, left, presenting a speaker's gift to Carlos Rosati.

l : g l JUNE 2002 I

Guest speaker Fred Ciampi, left, with Southwest Virginia Section Chairman Daniel Hatter.

SOUTHWEST VIRGINIA MARCH 20 Speaker: Fred Ciampi, welding engineer. Affiliation: National-Standard Welding Products. Topic: Troubleshooting gas metal arc welding.

Director: Wayne J. Engeren Phone: (404) 5 0 1 - 9 1 8 5

Jeremy Cass demonstrating equipment for the South Carolina Section.

NORTH CENTRAL FLORIDA NOVEMBER 20, 2001 Speaker: Greg Hofmann, production manager. Affiliation: Emergency One, Ocala, Fla. Activity: The Section toured the Emergency One facility and saw how fire trucks are welded together.

MARCH 12 Speaker: Gary Swanson. Affiliation: Gainesville Regional Utilities (GRU), John R. Kelly Power Plant. Activity: Section members toured GRU's John R. Kelly Power Plant.

SOUTH CAROLINA MARCH 21 Speaker: Jeremy Cass, owner. Affiliation: J. T. Cass Enterprises, Charlotte, N.C. Activity: Air Star held a steak cookout and hosted equipment demonstrations by J. T. Cass Enterprises.

DISTRICT 6 Director: Neal A. Chapman Phone: (315) 3 4 9 - 6 9 6 0

ROCHESTER MARCH 27 Speakers: Jim Biegas, Guy Hughson, and Heath Stricldand. Affiliations: Rochester Welding, Mahaney Welding, and Jackson Welding, respectively. Topic: Metal finishing and grinding and products, equipment, and tools. Activities: Vendors demonstrated new products and applications for members.

APRIL 6 Activity: The Section held a seminar on welding symbols.

DISTRICT 7 D ISTRICT 8 D ISTRICT 9 Director: Robert J. Tabernik Phone: (614) 4 8 8 - 7 9 1 3

Chip Cable performing magic tricks during his presentation to Pittsburgh Section members.

Beaver Valley Area Vo-Tech students at the Pittsburgh Section's Student Night meeting

Director: Wallace E. Honey Phone: (256) 3 3 2 - 3 3 6 6

Students competing for first place in cutting through a piece of railroad track at the Holston Valley's First Annual Student Night.

HOLSTON VALLEY MARCH 12 Activity: The Section held its First An- nual Student Night at the Tennessee Technology Center. Contests were held to see who could cut through a piece of railroad track first. John Deere, Hol- ston Gases, and Air Gas donated prizes for the event and a cookout was held.

APRIL 2 Speaker: Vaughn Stroup. Affiliation: Industrial Machine Repair and Welding Supply. Topic: Automated welding and cutting.

NORTHEAST MISSISSIPPI MARCH 21 Speaker: R. O. Shepherd. Affiliation: Miller Electric Mfg. Co. Topic: The latest in Miller equipment.

Director: John Bruskotter Phone: (504) 3 6 7 - 0 6 0 3

New Orleans Section First Vice Chair- man~Program Chairman Lenis Doiron, left, and Chairman Tony DeMarco, right, presenting a speaker's award to Glenn "Bo" Payton.

NEW ORLEANS MARCH 19 Speaker: Glenn "Bo" Payton, project manager. Affiliation: Grand Isle Shipyard, Inc., Gretna, La. Topic: Innovative equipment and techniques and safety. Activities: Payton demonstrated the Tux life vest. The Section held Student Night. All students received welding helmets and $25 gift certificates from Industrial Welding Supply and $25 each from Grand Isle Shipyard. Industrial Welding Supply sponsored the meeting. Twenty-five year Silver Member plaques were presented to Arthur Lang, War- ren Pitre, Jr., and Art Varvoutis.

..... i ~

PITTSBURGH MARCH 12 Speaker: Chip Cable, president. Affiliation: Weld Tooling, Pittsburgh, Pa. Topic: Six advantages of automated mechanized cutting and welding equipment. Included in the presentation were magic tricks and balls of fire. Activity: The meeting also honored students with Student Night. Each student received a gift donated by The Lincoln Electric Co. and presented by Treasurer Dave Daugherty.

Holston Valley Section members gather together for a photograph during the Section's March meeting.

WELDING JOURNAL l l : t l l

Attending the New Orleans Section's Student Night are, front row from left, Regi- nald Singleton, Gregg Villematte, Dave McCann, Raymond Cooper, back row from left, Education Chairman David Foster, Ricky Fabra, and Chairman Tony DeMarco.

New Orleans Section First Vice Chairman~Program Chairman Lenis Doiron, left, Chairman Tony DeMarco, second from left, and District 9 Director John Bruskotter, right, presenting 25-Year Silver Member plaques to, second from right, Warren Pitre, Jr., and Arthur Lang, third from right.

DISTRICT 10 Director: Victor Y. Matthews Phone: (216) 3 8 3 - 2 6 3 8

Affiliation: Stud Welding Associates. Topic: Stud welding principles and demonstrations.

DISTRICT 1 1 Director: Scott C. Chapple Phone: (734) 2 4 1 - 7 2 4 2

NORTHWEST OHIO MARCH 28 Speaker: Mark Johnson, QC manager. Affiliation: Industrial Piping Systems, Luckoy Generating Station. Activity: Members toured the four unit,

• gas-/oil-fired, turbine/generator generating stations.

Guest speakers, from left, Shaun Blott and Steve Kusik accepting speakers' gifls from, A WS Treasurer Earl Lipphardt, right, and Mahoning Valley member Amy Sherwood.

MAHONING VALLEY APRIL 18 Speakers: Steve Kusik and Shaun Blott.

/SkPRIL 9 Speaker: Jason Keys, district manager. Affiliation: The Lincoln Electric Co., Toledo, Ohio. Topic: Motor sports welding and new products from Lincoln. Activity: Sixteen competition vehicles were on display including sprint cars, dragsters, pulling tractors, trucks, Indy cars, and street rods.

DISTRICT 12 Director: Michael D. Kersey Phone: (262) 6 5 0 - 9 3 6 4

DISTRICT 13 Director: J. L. Hunter Phone: (309) 8 8 8 - 8 9 5 6

DISTRICT 14 Director: Hil Bax Phone: (314) 644-3500 , ext. 105

TRI RIVER FEBRUARY 27 Speakers: John Durbin, welding department chairman; Earl Young, QC manager; and Daniel Appelgate. Affiliations: Ivy Tech; Industrial Contractors, Inc.; and AK Stell Rockport Works, respectively. Activity: The Section held its Annual Student Night. Featured was a "Stump the Experts" session with the guest speakers as the experts. The experts also had the opportunity to ask questions of the students. Donated prizes were awarded to the winners of the contest.

SANGAMON VALLEY MARCH 20 Speaker: Chris Lnhan, welding engineer. Affiliation: Caterpillar, Inc. Topic: Weld failure and defects.

MISSISSIPPI VALLEY APRIL 4 Speaker: Larry Sparks, regional sales manager. Affiliation: AlcoTec Aluminum. Topic: Alloy selection and welding aluminum.

DISTRICT 15 Director: J. D. Heikkinen Phone: (218) 7 4 1 - 9 6 9 3

NORTHERN PLAINS FEBRUag¥ 25 Speakers: Mark Salz, Douglas Fteyer, and Lee Larson, secretary/treasurer. Affiliations: Miller Electric Mfg. Co., Praxair, and Northern Plains AWS Section. Activities: The Section held Demo Day. Salz spoke on Miller's engine-driven welding machines, Fteyer discussed shielding gases, and Larson talked about AWS and available scholarships and demonstrated titanium welding.

m;P,I JUNE 2002 I

DISTRICT 18 Director: John Mendoza Phone: (210) 8 6 0 - 2 5 9 2

Northern Plains Section Secretary~Treasurer Lee Larson, center, taking question during his presentation on titanium welding.

Welding Engineer Dan Heintz during his presentation on automated weld cladding for Sabine Section members.

Participating in the Northern Plains Behind the Mask Welding Contest are, front row from left, Mike Granlie, Dan Rice, Josh Aus, Joshua Gubrud, Ken Knott, back row from left, Brian Johnson, Lance Staabe, Andy Gwost, Dan Erberhardt, and Matt Howe.

MARCH 7 Activity: The Section held a Behind the Mask Welding Contest at North Dakota State School of Science. More than $3000 in prizes were donated by area businesses. The contest was mod- erated by Dave Lynnes and Secretary Treasurer Lee Larson.

DISTRICT 16 Director: C. F. Burg Phone: (515) 2 9 4 - 5 4 2 8

DISTRICT 17 Director: Oren P. Reich Phone: (254) 8 6 7 - 2 2 0 3

NORTH TEXAS MARCH 19 Speaker: David Day, manufacturing engineer manager. Affiliation: SPX Dock Products. Topic: Manufacturing with semiautomatic and robotic welding. Activities: Members toured the SPX Dock Products plant and saw its semiautomatic welding stations, robotic welding system, bulk packaging of GMAW wire, and centralized fume extraction system.

Guest speaker Scott Funderburk, right, with East Texas Section Chairman Yoni Adonyi.

EAST TEXAS MARCH 21 Speaker: Scott Funderburk, technical sales representative. Affiliation: The Lincoln Electric Co., Houston, Tex. Topic: The Northridge earthquake and its implications for welding. Activity: LeTourneau University Student Chapter members also attended the meeting.

I Houston Section Chairman Chris Bloch presenting a speaker's award to Naomi Stevens.

A WS Past President John Bartley and his wife, Patty, at the Houston Section's April meeting.

WELDING JOURNAL IE:.kll

Lake Charles Section officers at the Annual Crawfish Boil. Pictured are, kneeling from left, Tac Edwards, Andy Davis, standing from left, James Veillon, James Bobo, David Savoy, Kermit Babaz, and Drew Fontenot.

DISTRICT 19 Director: Phil Zammit Phone: (509) 4 6 8 - 2 3 1 0 ext. 120

ALASKA APRIL 13 Activity: The Section hosted a CWI Prep Seminar and Examination.

April 19 Activity: Section members met to vote on officers for the 2002-2003 term.

DISTRICT 20 Director: Jesse A. Grantham Phone: (303) 4 5 1 - 6 7 5 9

Lake Charles Section members, from left, James Veillon and Kermit Babaz with their respective awards.

SABINE MARCH 21 Speaker: Morris Weeks, president. Affiliation: Weeks Laboratories, Nederland, Tex. Topic: Welder procedure qualifications.

APRIL 16 Speakers: Jeff Stark, manager, and Dan Heifrich, sales manager. Affiliation: Beaumont Constructors and Fabricators, Beaumont, Tex. Activity: The Section received a plant tour and watched automated weld cladding demonstrations.

HOUSTON APRIL Speaker: Naomi Stevens Affiliation: Matsuo America Co. Topic: International involvement of AWS. Activity: AWS Past President John Bartley and his wife, Patty Bartley, attended the meeting.

San Antonio Program Committee Chair- man AI Marin, right, with guest speaker Frank Duran.

SAN ANTONIO APRIL 9 Speaker: Frank Duran. Affiliation: South San Antonio Independent School District. Topic: Vocational training opportunities available in the school district.

LAKE CHARLES APRIL 17 Speaker: A. J. Smith, Cajun comedian. Activity: Members enjoyed the Section's Annual Crawfish Boil. Kermit Babaz received the Private Sector Instructor Award and James Veinon was presented with the Meritorious Service Award and the Dalton E. Hamilton CWI of the Year Award. Plaques of Appreciation were presented to several corporations that served as Section sponsors for the year.

Chip Tolle, left, presents a speaker's gift to Walter Reuter at the Eastern Idaho~Montana Section's January meeting.

Eastern Idaho~Montana guest speaker Don Schwemmer during his presentation to members.

m:sm JUNE 2002

EASTERN IDAHO/ MONTANA JANUARY 31 Speaker: Walter Reuter. Affiliation: INEEL, Idaho Falls, Idaho. Topic: Structural Integrity. The cost of premature failure and potential methods of improvement.

MARCH 15 Speaker: Don Schwemmer, CEO. Affiliation: AMET, Inc., Rexburg, Idaho. Topic: The history of AMET and its welding projects. Activity: Members toured the AMET facility.

APRIL 5 Speaker: Paul O'Leary, welding professor. Affiliation: Montana Tech, Butte, Mont. Topic: Welding and the Indonesian copper industry. Activity: The Section's tour of Montana Tech's welding department included a demonstration of its new Lincoln welding robot. Later that afternoon, members toured the ASIMI silicon plant to gain a greater understanding of the silicon production process and the welding and QA processes used in the plant.

DISTRICT 21 Director: F. R, Schneider Phone: (858) 6 9 3 - 1 6 5 7

Posing at the Los Angeles~Inland Em- pire's February meeting are, from left, Bob Gibson, guest speaker Al Cangahuala, Eddie Bubigkeit, and Secretary~Treasurer Gene Lofton.

LOS ANGELES/ INLAND EMPIRE FEBRUARY 28 Speaker: Al Cangahuala. Affiliation: Jet Propulsion Laboratory. Topic: A Mars Odyssey - - The building of the new Mars rovers.

Guest speaker Dave Morlan, center, during his presentation to the San Diego Sec- tion, with Aide Chris Shipp, rear, and student Matt Cruson, front.

SAN DIEGO MARCH Speakers: Dave Morlan, instructor, and Chris Shipp, aide. Affiliation: ROP Welding Academy, El Cajon, Calif. Topics: Training and testing/certifying students and exposing them to AWS technical meetings and membership.

HAWAII MARCH 21 Speaker: Truman Rock'wood, president and founder. Affiliation: Intek Systems. Topic: Portable remote visual inspection equipment.

DISTRICT 22 Director: Mark Bell Phone: (209) 3 6 7 - 1 3 9 8

Artist Andy Weaver, left, with an example of his work and Dale Flood during the Sacramento Valley Section's April meeting.

SACRAMENTO VALLEY MARCH 20 Speaker: Mark Bell, principal consultant and AWS District 22 director. Affiliation: Preventive Metallurgy. Topic: Weld failure - - Don't blame the welder. A discussion on the numerous metallurgical flaws that lead to weld and base metal failure.

April 17 Speaker: Andrew Weaver, artist. Activity: Weaver brought several pieces of his art for display and discussed concepts, blacksmithing, welding, and coating of his indoor and outdoor artwork.

I.

District 22 Director Mark Bell, standing, during his presentation to the Sacramento Val- ley Section.

WELDING JOURNAL D:]rm

FRESNO MARCH 21 Speaker: Will Bellis, EE. and CWI. Affiliation: Advantage Technical Services. Topic: Building a pipeline on a floating iceberg: Alaskan North Slope pipeline construction.

INTERNATIONAL SECTIONS

Guest speaker Charles Louppe, left, with Emirates Welding Section Chairman Bernard D'Silva during the Section's Feb- ruary meeting.

EMIRATES WELDING FEBRUARY 27 Speaker: Charles Louppe. Affiliation: Soudakay S.A., Belgium. Topic: Ship cladding by submerged arc and electroslag processes. •

STUDENT ACTIVITIES

Brigham Young University-Idaho Student Chapter members Steve Bevens, back, and Tyler Webb in the jackets with the "Stingers" logo they designed.

DISTRICT 20 Director: Jesse A. Grantham Phone: (303) 4 5 1 - 6 7 5 9

BRIGHAM YOUNG UNIVERSITY- IDAHO STUDENT CHAPTER JANUARY 31 Activity: Student Chapter members designed a logo for their group, which

Brigham Young University Student Chap- ter member Bron Wescott with the drop forge he designed and built.

they call "Stingers." Jackets were made for each of the members bearing the new Stingers logo.

MARCH 15 Speaker: Bron Wescott. Affiliation: Brigham Young University - Idaho AWS Student Chapter. Activity: Student Chapter member Wescott designed and built a drop forge, which he demonstrated for other members.O

Can We Talk?

The Welding Journal staff encourages an exchange of ideas with you, our readers. If you'd 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 Jeff Weber [email protected]; Ext. 246 Reprint Permission Copyright Issues

Assistant Publisher Christine Tarafa [email protected]; Ext. 213 Marketing

Editor/Editorial Director Andrew Cullison

[email protected];, Ext. 249 Article Submissions

Features Editor Mary Ruth Johnsen [email protected]; Ext. 238 Feature Articles

Associate Editor Susan Campbell [email protected]; Ext. 244 Society News

Assistant Editor Doreen Yamamoto [email protected]; Ext.; 226 New Products

Creative Director Jose Lopez [email protected]; Ext. 416 Avertising and Design

Production Editor Zaida Chavez [email protected]; Ext. 265 Design and Production

Advertising Sales Director Rob Saltzstein

[email protected]; Ext. 243 Advertising Sales

Advertising Production Coordinator Frank Wilson

[email protected]; Ext. 465 Advertising Production

Advertising Coordinator Lea Garrigan

[email protected]; Ext. 220 Production and Promotion

Peer Review Coordinator Doreen Kubish

[email protected]~,, Ext. 275 Peer Review of Research Papers

Welding Journal Dept. 550 N.W. LeJeune Rd. Miami, FL 33126 (800) 443-9353 FAX (305) 443-7404

ll:.~:I JUNE 2002

Standards Notices ISO Draft Standards for Public Review

Copies of the following Draft Inter- national Standards are available for review and comment through your national standards body, which in the United States is ANSI, 25 W. 43 St., Fourth Floor, New York, NY 10036, (212) 642-4900. Any comments regarding ISO documents should be sent to your national standards body.

In the United States, i f you wish to participate in the development of lnternational Standards for welding, contact An- drew Davis at AWS, 550 NW LeJeune Rd., Miami, FL 33126, (800) 443-9353 ext. 466, e-mail: [email protected]. Otherwise, contact your national standards body.

ISO/DIS 17660, Welding of reinforc- ing steel.

ISO/DIS 18273.2, Welding consumables - Wire electrodes, wires and rods for welding of aluminium and aluminium alloys - - Classification.

ISO/DIS 18278-1, Resistance welding - - Weldability - - Part 1: Assessment o f weldability for resistance spot, seam and projection welding of metallic materials.

ISO/DIS 18278-2, Resistance welding - - Weldability - - Part 2: Alternative procedures for the assessment o f steel sheets for spot welding.

Revised Standard Approved by ANSI

D8.9M:2002, Recommended Practices for Test Methods for Evaluating the Re- sistance Spot Welding Behavior o f Auto- motive Sheet Steel Materials. Approval date: April 3, 2002.0

AWS International Schedule m CWI/CWE Prep Courses and Exams

MEXICO: In Monterrey, N.L.

June 24-28, Training, June 29, Exam Nov. 4-8, Training, Nov. 9, Exam

Contact. Martha Laura Garcia, DALUS S.A., Tel: (5281) 83861717, FAX: (5281) 83864780, e-mail: martha.garcia@ dalus.com. •

Personnel and Facility Qualification Commit tee Meets in Houston

Personnel and Facility Qualification Committee officers-elect with A WS Vice President Tom Mustaleski at the January meeting in Houston. Pictured, from left, are Scott Ten- nant, First Vice Chair; Jim Harris, Chair; Vice President Mustaleski; and Paul Evans, Second Vice Chair.

AWS Publication AWS Releases Bridge Welding Code

The American Welding Society (AWS) has released a new edition of its Bridge Welding Code (AWS D1.5:2002). A joint publication of AWS and the American As- sociation of State Highway and Transportation Officials (AASHTO), this code covers the requirements for welding highway bridges made from carbon and low-alloy construction steels.

Originally developed to provide uniformity in bridge fabrication and construction, the newest edition of Bridge Welding Code relies on the expertise of AWS and AASHTO committees, which include representatives from welding companies, aca- demia, state departments of transportation, and the Federal Highway Administra- tion. Bridge Welding Code includes sections on a variety of bridge-welding processes, welding procedure specification qualification, and inspection of welds.

The new edition of Bridge Welding Code is 355 pages and includes 36 tables and 80 figures. AWS D1.5:2002, Bridge Welding Code, lists for $180; $135 for AWS members.

Ordering Information

AWS publications can be purchased through Global Engineering Documents by calling (800) 854-7179, (303) 397-7956 outside the United States, on-line at www.global.ihs.com., or through the AWS e-Store at www.aws.org. •

WELDING JOURNAL m:~l

2 0 0 1 - 2 0 0 2 Member-Get -A-Member Campaign

Listed below are the people participating in the 2001-2002 Member-Get-A-Member Campaign. For campaign rules and a prize list, please see page 85 o f this Welding Journal.

I f you have any questions regarding your member proposer points, please call the Membership Department at (800) 443-9353 ext. 480.

Winner's Circle (A W S M e m b e r s s p o n s o r i n g 20 o r m o r e n e w I n d i v i d u a l M e m b e r s , p e r year, s ince June 1, 1999 . )

J. Compton, San Fernando Valley** E. H. Ezell, Mobi le** J. Merzthal, Peru* B. A. Mikeska, H o u s t o n * W. L. Shreve, Fox Valley* G. Taylor, Pascagoula* T. Weaver, J o h n s t o w n / A l t o o n a * G. Woomer, J o h n s t o w n / A l t o o n a * R. Wray, N e b r a s k a *

* D e n o t e s the n u m b e r o f t i m e s an In - d i v i d u a l M e m b e r has a c h i e v e d W i n n e r s Circle status. S ta tus will be a w a r d e d at the close o f each m e m b e r s h i p c a m p a i g n year.

President's Guild (A W S M e m b e r s s p o n s o r i n g 20 o r m o r e n e w Ind i v idua l M e m b e r s be tween J u n e 1, 2001, a n d M a y 31, 2002.)

G. W. Taylor, Pascagoula - - 43 J. Merzthal, Peru - - 32 R. L. Peaslee, Detroi t - - 31 J. Compton, San Fernando Valley - - 28

President's Round table (A W S M e m b e r s sponsor ing 1 1 - 1 9 n e w In- d i v idua l M e m b e r s be tween J u n e 1, 2001, a n d M a y 31, 2002.)

A. W. Stephenson, Re ad i ng - - 18 T. A. Ferrl, B o s t o n - - 16 J. Grantham, Colorado - - 14 B. McGrath, M o b i l e - 11

President's Club (A W S m e m b e r s sponsor ing 6 - 1 0 n e w In - d i v idua l M e m b e r s be tw een J u n e 1, 2001, a n d M a y 31, 2002.)

S. Abarca, Il l inois Valley - - 10 S. R. Bollhorst, Ind iana - - 10 D. Garcia, Florida West Coas t - - 10 S. Siu, British C o l u m b i a - - 9 J. McCarty, St. L o u i s - - 8 D. W. Peters, Chicago - - 7 W. L. Shreve, Fox Valley - - 7 R. Brofft, Louisv i l le - - 6 E Buck, Detroi t - - 6 E. Ezell, Mobi l e - - 6 M. Hyzny, Nor th Central Florida - - 6 S. Johnson, Central Texas - - 6 L. G. Kvidahl, Pascagoula - - 6 R. Merreighn, Mississ ippi Valley - - 6 D. J. Schulte, S i o u x l a n d - - 6

President's Honor Roll (A W S m e m b e r s s p o n s o r i n g 1 - 5 n e w In - d i v idua l M e m b e r s be tw een J u n e 1, 2001, a n d M a y 31, 2002. Only those sponsor ing 2 o r m o r e A W S I n d i v i d u a l M e m b e r s are listed. )

C. Dynes, Kern - - 5

N. Goel, L o n g I s land - - 5 S. Snyder, N e w Orleans - - 5 D. Tweedie, Jr., Washington, D .C . - - 5 T. Flynn, At lan ta - - 4 J. M. Hunt, Tulsa - - 4 B. Walsh, Alaska - - 4 E Baldwin, Peoria - - 3 M. Blick, Colorado - - 3 R. De Los Santos, Mex ico - - 3 W. Heinz, San Francisco - - 3 B. Huff, S a n g a m o n Valley - - 3 R. Johnson, Detroi t - - 3 C. Mezzic, N e w Orleans - - 3 E Patel, Mobi l e - - 3 S. Prost, British C o l u m b i a - - 3 D. Russell, Jr., Chat tanooga - - 3 J. S. Stiles, Florida West Coas t - - 3 J. S. Armstrong, Eas t Texas - - 2 D. Baldry, British C o l u m b i a - - 2 T. L. Bertchie, Colorado - - 2 J. Bobo, L a k e Charles - - 2 R. Bowen, Por t land - - 2 G. Callender, San Fernando Valley - - 2 C. Cleve Casey, A r i z o n a - - 2 J. Clow, J~,t.K. - - 2 T. Cormier, M a i n e - - 2 R. Corsaro, Niagara Front ier - - 2 C. Crumpton, Jr., Florida West C o a s t - - 2 L. Cudnohufsky, Upper Peninsu la - - 2 T. Day, M a i n e - - 2 R. A. Graf, A r r o w h e a d - - 2 B. Hallila, N e w Orleans - - 2 D. L. Hatfield, Tulsa - - 2 R. A. Hauck, Syracuse - - 2 M. Hernandez, L A / I n l a n d E m p i r e - - 2 J. Ivy, Pascagoula - - 2 B. Jacobs, C o l u m b u s - - 2 T. Jones, L A / I n l a n d E m p i r e - - 2 Z. Keniston, Syracuse - - 2 J. Koster, Western Mich igan - - 2 S. Moran, Fox Valley - - 2 A. Mydland, S p o k a n e - - 2 R. Painter, H o l s t o n Valley - - 2 D. Pelet, L a n c a s t e r - - 2 S. W. Roach, H o l s t o n Valley - - 2 E. Soto Ruiz, Puer to R i co - - 2 J. Taylor, Utah - - 2 C. L. Tsai, Taiwan In terna t ional - - 2 R. Wiese, N e w Jersey - - 2 R. R. Withers, B i r m i n g h a m - - 2 R. Wright, Sou thern Co lorado - - 2 R. Zabel, Sou theas t N e b r a s k a - - 2

Student Sponsors (A W S m e m b e r s sponsor ing 3 o r m o r e n e w A W S S t u d e n t M e m b e r s b e t w e e n J u n e 1, 2 0 0 L a n d M a y 31, 2002.)

P. Baldwin, Peoria - - 104 B. Huff, S a n g a m o n Valley - - 64 A. Demarco, N e w Orleans - - 48 E. S. Ruiz, Puer to R ico - - 38 K. Ellis, M a r y l a n d - - 33 J. H. Sullivan, Mobi l e - - 33 H. Madron, M a r y l a n d - - 26 A. Reis, Pit tsburgh - - 26 T. Huston, Pit tsburgh - - 25 T. Buckler, Jr., C o l u m b u s - - 24 S. E. Hower, R e a d i n g - - 23

R. A. Large, M a n c h e s t e r - - 23 S. Green, Nor th Texas - - 23 P. Walker, O z a r k - - 23 J. Cox, Nor the rn P l a i n s - 22 R. Durham, Cinc inna t i - - 21 K. Geist, Olympic - - 21 M. Pointer, Sierra N e v a d a - - 21 R. L. Vann, Sou th Carol ina - - 21 J. Pelster, Sou theas t N e b r a s k a - - 20 D. Roskiewich, Phi lade lphia - - 20 J. Hayes, O k l a h o m a City - - 19 R. McKeown, British C o l u m b i a - - 19 L. C. Davis, N e w Orleans - - 18 D. Nelson, Puge t S o u n d - - 18 W. Kielhorn, E a s t Texas - - 17 K. Langdon, J o h n n y A p p l e s e e d - - 17 E Mong, Pit tsburgh - - 17 S. Siviski, M a i n e - - 17 E Juckem, Madison-Be lo i t - - 16 D. Marks, Leh igh Valley - - 16 A. Blakeney, N e w Orleans - - 15 D. Hatfield, Tulsa - - 15 D. Ketler, Wil lamet te V a l l e y - - 15 B. Lavallee, Nor thern N e w York - - 15 M. Anderson, I nd iana - - 13 W. P. Miller, Jr., N e w J e r s e y - 13 E Wernet, Leh igh Valley - - 13 R. Grays, Kern - - 12 L. Heath, M a r y l a n d - - 12 T. Pinson, Lex ing ton - - 12 R . R u x , W y o m i n g - 11 S. Caldera, P o r t l a n d - - 10 T. Geisler, Pit tsburgh - - 10 R. Samanich, N e v a d a - - 10 P. Betts, Mobi l e - - 9 R. Brown, L , 4 . / I n l a n d E m p i r e - - 9 E Childers, O k l a h o m a City - - 9 A. Honegger, L A / I n l a n d E m p i r e - - 8 J. Livesay, Nashvi l l e - - 8 G. Diseth, Puget S o u n d - - 8 R. Felix, L o n g Bch . /Orange Cnty. - - 7 D. Marquis, O z a r k - - 7 J. Swoyer, Leh igh Valley - - 7 S. Zwilling, Louisv i l le - - 7 S. Gore, Charlot te - - 6 R. Hilty, Pit tsburgh - - 6 C. Kipp, Leh igh Valley - - 6 J. McCarty, St. L o u i s ----6 J. Smith, Jr., Mobi l e - - 6 R. Zabel, Sou theas t N e b r a s k a - - 6 R. Brooker, M a i n e - - 5 A. Price, H o u s t o n - - 5 B. Suckow, Nor thern Plains - - 5 R. J. DePue, Olean-Brad ford - - 4 E Henry, L A / I n l a n d E m p i r e - - 4 S. Hoff, S a n g a m o n Valley - - 4 T. Kienbbaum, Colorado - - 4 J. McKay, Jr., Cleve land - - 4 W. Sartin, L o n g B c h / O r a n g e Cnty - - 4 D. Combs, Santa Clara Valley - - 3 W Galvery, Jr., Long Bch/Orange Cnly - - 3 R. Huston, Olymp ic - - 3 J. Johnson, Nor the rn Pla ins - - 3 H. Jackson, L A / l n l a n d E m p i r e - - 3 W. Kastner, L A / I n l a n d E m p i r e - - 3 J. Mahoney, N o r t h Central Florida - - 3 A. Perazzone, A r i z o n a - - 3 J. L. Sullivan, Hols ton Valley - - 3 0

~ I I J JUNE 2002 I

I

Long Sleeve Denim Shirt AWS Members: $26.10 Non-members: $29.00

Available in these colors: Indigo

Item #: 900

Two-Tone Denim Cap AWS Members: $12.60 Non-members: $14.00

Available in these colors: Denim/Black, Denim/Navy,

Denim/Tan Item #: 52691

Cotton T-shirt AWS Members: $1-~.-~0 Non-members: $16.00

Available in these colors: Black, Charcoal, Lt. Oxford, Natural, Navy, Red,

Royal, White Item #: 03212

Sweatshirt AWS Members: $17.10 Non-members: $19.00

Available in these colors: Navy, White, Red, Ash, Black, Royal

Item #: 04160

Outer Banks Pique Golf Shirt AWS Members: $24.30 Non-members: $27.00

Available in these colors: Red Body with Black & White Trim, Putty Body with Black & White Trim, White Body with Red & Navy Trim, Royal

Blue Body with Black & White Trim Item #: 5040

Men's or Women's Prestige Watch AWS Members: $a9.50/each Non-members: $55.00/each

Water Resistant - 3 ATM Scratch Resistant Crystal Lens

Item #: TL-1351S

Stainless Steel Traveler Mug AWS Members: $14.-~0 Non-members: $16.00

Item #: ST16

Solid Color Club Duffle AWS Members: $30.60 Non-members: $34.00

Available in Navy or Black Item #: 4252

TOP FLITE Goff Balls AWS Members: $5.a0/sleeve Non-members: $6.00/sleeve

Item #: TOP FLITE XL2000

Nominees for National Off ice

Only Sustaining Members, Members, Honorary Members, Life Members, or Re- t ired Members who have been members for a per iod of at least three years shall be eligible for election as a Director or National Officer.

It is the duty of the National Nominating Committee to nominate candidates for national office. The committee shall hold an open meeting, preferably at the Annual Meet- ing, at which members may appear to present and discuss the eligibility of all candidates.

To be considered a candidate for positions of President, Vice President, Treasurer, or Director-at-Large, the following qualifications and conditions apply:

President: To be eligible to hold the office of President, an individual must have served as a Vice President for at least one year.

Vice President: To be eligible to hold the office of Vice President, an individual must have served at least one year as a Director, o ther than Executive Direc tor and Secretary.

Treasurer: To be eligible to hold the office of Treasurer, an individual must be a member of the Society, o ther than a Student Member , must be frequently available to the National Office, and should be of executive status in business or industry with experience in financial affairs.

Director-a t -Large: To be eligible for election as a Director-a t -Large, an individual shall previously have held office as Chairman of a Section; as Chairman or Vice Chairman of a standing, technical or special commit tee of the Society; or as District Director.

Interested parties are to send a letter stating which particular office they are seeking, including a s ta tement of qualifications, their willingness and ability to serve if nominated and elected, and 20 copies of their biographical sketch.

This material should be sent to Richard L. Arn, Chairman, National Nominat ing Committee, American Welding Society, 550 NW LeJeune Rd., Miami, FL 33126.

The next meet ing of the National Nominat ing Commit tee is currently scheduled for Apri l 2003, in Det ro i t , Mich. The terms of office for candidates nomina ted at this meeting will commence June 1, 2004. •

Honorary-Meritorious Awards The Honorary-Meritorious Awards Committee has the duty to make recommendations

regarding nominees presented for Honorary Membership, National Meritorious Certificate, William Irrgang Memorial, and the George E. Willis Awards. These awards are presented in conjunction with the AWS Exposition and Convention held each spring. The descriptions of these awards follow, and the submission deadline for consideration is July 1 prior to the year of presentation. All candidate material should be sent to the attention of John J. McLaughlin, Secretary, Honorary-Meritorious Awards Committee, 550 NW LeJeune Rd., Miami, FL 33126.

National Mer i tor ious Cert i f icate Award: This award is given in recognition of the candidate's counsel, loyalty, and de- votion to the affairs of the Society, assistance in promoting cordial relations with industry and other organizations, and for the contribution of time and effort on be- half of the Society.

Will iam Irrgang Memoria l Award: This award is administered by the American Welding Society and sponsored by The Lin- coln Electric Co. to honor the late William Irrgang. It is awarded each year to the individual who has done the most to enhance the American Welding Society's goal of advancing the science and technology of welding over the past five-year period.

George E. Willis Award: This award is administered by the American Welding So- ciety and sponsored by The Lincoln Elec- tric Co. to honor George E. Willis. It is awarded each year to an individual for promoting the advancement of welding internationally by fostering cooperative participation in areas such as technology transfer, standards rationalization, and promotion of industrial goodwill.

In ternat ional Mer i tor ious Cert l f l . cate Award: This award is given in recognition of the candidate's significant contributions to the worldwide welding industry. This award should reflect "Service to the International Welding Community" in the broadest terms. The awardee is not required to be a member of the American Welding Society. Multiple awards can be given per year as the situation dictates. The award consists of a certificate to be presented at the award's luncheon or at another time as appropriate in conjunction with the AWS President's travel itinerary, and, if appropriate, a one-year membership to AWS.

Honorary Membersh ip Award: An Honorary Member shall be a person of acknowledged eminence in the welding profession, or who is accredited with exceptional accomplishments in the development of the welding art, upon whom the Ameri- can Welding Society sees fit to confer an honorary distinction. An Honorary Mem- ber shall have full rights of membership. •

It is the intent of the American Welding Society to build the Society to the highest quality standards possible. We welcome any sugges- tions you may have.

Please contact any of the staff listed on the previous page or A WS President Ernest D. Levert, Sr. Staff Engineer, Lockheed Martin Missiles and Fire Control, P.O Box 650003, Mail Stop WT-48, Dallas, TX 75265-0003.

AWS M I S S I O N S T A T E M E N T

The mission o f the Amer ican Welding Society is to provide quality products and services to our members a n d t h e industry which will advance the science, technolo-

gy and application o f materials-joining throughout the world.

AWS FOUNDATION, INC. 550 NW LeJeune Rd.

Miami, FL 33126 (305) 445-6628

(800) 443-9353, ext. 293 Or e-mail: [email protected]

General Information (800) 443-9353, ext. 689

Chairman, Board of Trustees Ronald C. Pierce

Director of Development Robert B. Witherell

The AWS Foundation is a not-for-profit corporation established to provide support for

educational and scientific endeavors of the American Welding Society. Information on

gift-giving programs is available upon request.

IS09001 Registered Organization

~ ' . l JUNE 2002 I

IEDUCATION INDUSTRIAL TECHNOLOGY TECHNICAL I

AUTHOR APPLICATION FORM 84th Annual AWS Convention, Detroit, Michigan, April 8-10, 2003

Please complete both front and back of this form legibly. This completed form is to accompany the 300-500 word summary described on the back.

Author 's name Check how addressed: Dr. Q Other Tit le or posi t ion C o m p a n y or organizat ion Mai l ing address City. State Z ip/Posta l Code Count ry Area/Count ry Code Te lephone FAX e-mai l address

For jo in t authors, give names and FULL MAILING addresses of other authors (list separately and attach ff necessary):

Author 's name Check how addressed: Dr. • Other Tit le or posi t ion C o m p a n y or organizat ion Mai l ing address City Area/Count ry Code Author 's name Tit le or posi t ion Mai l ing address

State Zip/Posta l Code Count ry Te lephone FAX

Check how addressed: Dr. [3 Other C o m p a n y or organizat ion

e-mai l address

City. State Area/Count ry Code

Z i p / P o s t a l Code Count ry Te lephone FAX e-mai l address

P R O P O S E D T I T L E ( 1 0 w o r d s o r l e s s ) :

P l e a s e c h e c k a p p r o p r i a t e c l a s s i f i c a t i o n :

R e s e a r c h - O r i e n t e d - - new science or new research. This paper presents new, unpubl ished work in sc ience or eng ineer ing in jo in ing or al l ied processes.

A p p l i e d Technology - - new or unique application. This paper appl ies known pr inc ip les of jo in ing sc ience or eng ineer ing in a unique, unpubl ished appl icat ion.

E d u c a t i o n - - welding education-related topic. For, about, or per ta in ing to we ld ing educators and t ra iners at all levels, their methods, and their successes.

Is this paper an or iginal contr ibut ion? Is this paper a progress report? Is this paper a rev iew? Is this paper a tutor ial? What are the we ld ing process(es) used? What are the mater ia ls used?

Yes No Yes No Yes No Yes No

The main emphas is is more Q process or iented or Q mater ia ls or iented The industr ies this paper most appl ies to are

K E Y W O R D S :

Please rank the top four in order of impor tance (i.e., 1 = most important ; 2 = second most important , etc.):

_ _ GTAW _ _ Hardfacing __ Piping/Tubing _ _ GMAW _ _ Thermal Spraying _ _ Pressure Vessels _ _ SMAW _ _ C-Mn Steels _ _ Weld Process Simulation _ _ SAW _ _ Cr-Mo Steels _ _ Process Control/Monitoring _ _ PAW _ _ High-Strength Steels _ _ Weld Design Advisors

FCAW _ _ Stainless Steels _ _ Numerical Analysis _ _ ESW _ _ AI-AIIoys _ _ Residual Stress/Distortion _ _ EBW _ _ Ni-AIIoys _ _ Fracture/Fatigue _ _ LBW _ _ "R-Alloys _ _ Automation _ _ Resistance Welding _ _ Cu-AIIoys _ _ Robotics _ _ Forge Welding _ _ Advanced Materials _ _ Sensors _ _ Friction Welding _ _ Polymeric Materials _ _ Arc Physics _ _ Diffusion Welding _ _ Ceramics _ _ Corrosion _ _ Brazing/Soldering _ _ Consumables/Fluxes _ _ NDE _ _ Surfacing/Cladding _ _ Weldability Testing _ _ Other

for AWS use: I T E

Author(s) of Proposed Papec

Paper Title:

Summary Code: (for AWS use only)

INTENDED AUDIENCE: (please check) Q Technical/Research-Oriented ~1 Applied Technology - Industrially-Oriented [~ Welding Education-Oriented

GUIDELINES FOR SUMMARY: TECHNICAL PAPERS Each summary for a technical paper should be divided into four main sections:

Introduction/Background Section (100 words max.) Why the work was done, e.g. build on previous work, test/validate previous work; what is the "starting point;" how it relates to previous work and by whom; list key references.

• Procedure Section (100 words max.) Detailed (data base) description of approach and why this approach was taken.

• Results and Discussion Section (200-300 words max.) Detailed description of results with emphasis on

* what was found * why the results are "new" or original; what is added or what is corrected * why the results are of value

Inclusion of up to two pages of tables, graphs or diagrams is encouraged. • Conclusion Section (100 words max.)

Summary of main conclusions and recommendations for continuing work. Compare results with premise or hypothesis; if premise was proven wrong, say so!

GUIDELINES FOR SUMMARY: OTHER PAPERS (INCLUDING TUTORIALS) Summaries for other types of papers should be divided into two main sections:

• Introduction/Background Section (400 words max.) This section should begin with a description of why a paper or tutorial in this field is of value to the welding community, highlighting specific communities (if appropriate) for which this work is targeted. Once this has been established, the author should describe key work in this field including a brief description of the results obtained and the conclusions drawn for each reference (if appropriate) and provide the audience with an integration of these separate activities into a "continuum."

• Conclusion Section (100 words max.) This section should reiterate the key areas of value for this paper and provide guidance on the usage of this information - - how and by whom.

_ _ l - y p e , 1.5 spaced, using a 12-pitch element or a minimum 10 point font. The summary must not be less than 300, but not more than 500, words. Please attach to this completed form and return to the address below. Email submissions must include the information requested on this form.

Be sure to give enough information to enable the review committee to get a clear idea of the content of the proposed paper. Please remember your intended audience. Technical papers will be judged on technical merit. A paper should not emphasize product names; use generic terms after the first mention of a trade-named product.

. A p p l i c a t i o n Form and Summary MUST be postmarked no later than July 31, 2002 to ensure consideration for inclusion in the Professional Program of the 84th Annual AWS Convention in Detroit.

Recognizing that the audience will be largely American, the use of "customary U.S. units" is recommended for the presentation; the written version of the paper should report in units used in the work, but should consider including the "customary U.S. equivalents" to facilitate understanding.

.___._Applications may also be submitted by fax (305-443-7559). An application may also be obtained by visiting our website at <www.aws.org>.

PRESENTATION AND PUBLICATION OF PAPERS: Has material in this paper ever been previously published or presented in a meeting? Yes When and where?

No

Papers accepted for presentation become the property of the Society with original publication rights assigned to the Welding Journal You may elect to submit your paper to Peer Review for publication in the Welding Journal Research Supplement

Author's signature Date

Return this form, completed on both sides, with the 300---500 word summary to Technical Papers Editor, AWS Headquarters, 550 N. W LeJeune Road, Miami, FL 33126. MUST BE POSTMARKED NO LATER THAN JULY 31, 2002.

4LUMINU~ r~: ('+~ Q&A

The following two questions are associated with a form of cracking that may occur when welding some aluminum base alloys. This problem, which is relatively common, is associated with solidification crack sensitivity and is, in turn, directly related to the actual chemistry o f the weld pool. To appreciate this problem, we need to understand additions o f various alloying elements can seriously affect aluminum's crack sensitivity. The specific alloying elements can be identified along with the amount or range at which these elements increase solidification crack sensitivity. This information can be obtained from solidification crack sensitivity curves (Fig. 1) and used during welding procedure development to prevent undesirable chemistry mixtures in the weld. Consideration should also be given when evaluating the cause of cracking to any differences in welds associated with weld size and variations in tensile stresses introduced by shrinkage, joint expansion, or externally applied loads.

Q: I am experiencing a weld cracking problem on our gas tungsten arc welding

BY TONY ANDERSON

A L L O Y C O N T E N T v s . C R A C K SENSITIVITY

> ~ - o

I t °

_~°

2 3 4 5 6 7 COMPOSITION OF WELD-PERCENT ALLOYING ELEMENT

Fig. 1 - -A l loy content vs. crack sensitivity.

(GTAW) production line where we weld thinner sections of 6063-T6 sheet material. We are often required to perform outside corner welds where we sometimes use little or no R4043 filler material, depending on joint fitup. Why do you think the welds are cracking? Why do only some of them crack?

A : We should start by considering the crack sensitivity of 6xxx series base mate-

D I L U T I O N E F F E C T O N WELD COMPOSITION

-: M° 1 20% F ILLER METAL 80% BASE METAL

60% F ILLER METAL 40% BASE METAL

Fig. 2 - - Dilution effect on weld composition.

rial. Aluminum/magnesium/silicon base alloys (6xxx series) are highly crack sensitive because they contain approximately 1.0% magnesium silicide (Mg2Si), which falls close to the peak of the solidification crack sensitivity curve - - Fig. 1 at the AI- Mg2Si curve. The Mg2Si content of these materials is the primary reason no 6xxx series filler metals are made. The cracking tendency of these alloys is lowered to acceptable levels during arc welding by di-

ECONOMICALLY PRICED TUNGS TEN GRINDER

SAFETY: Enclosed diamond wheel grinding area

WELD QUALITY: 20 Ra finish improves tungsten life, starting & arc stability

PRODUCTW1TY: Longitudinal diamond grind your tungsten under 30 seconds

VALUE: Diamond flat, grind & cut your tungsten economically

w w w . d i a m o n d g r o u n d . c o m'~;i~: P h o n e ( 8 0 5 ) 4 9 8 - 3 8 3 7 • FAX ( 8 0 5 ) 4 9 8 - 9 3 4 7

E m a i l : s a l e s @ d i a m o n d g r o u n d . c o m


lution of the weld pool with excess magnesium (by use of 5xxx series A1-Mg filler metals) or excess silicon (by use of 4xxx series AI-Si filler metals). When we GTA weld thin materials, it is often possible to produce a weld, part icularly on corner joints, by melting both edges of the base mater ia l together without adding filler material . In the majori ty of arc welding applications with this base material , we must add filler material if we want consis- tently crack-free welds. A possible excep- tion would be counteracting the cracking mechanism by maintaining a compressive force on the parts during the welding op-

eration, which requires specialized fabrication techniques and considerations. This method, however, is seldom used.

I suspect the welds in question that do not crack are those that have had filler material added during welding. My advice for reducing crack sensitivity is for you to ensure filler metal is added to all welds.

Q: I am having cracking problems with my a luminum groove weld procedures. I am gas metal arc welding (GMAW) a 6061-T6 base material, ¾-in. thick, with a square edge preparation. The welds crack immediately after welding. The cracks are

Insight, Industry Advancement and Problem Resolution for Pipe Welding Applications

Guide for Welding Mild Steel Pipe 48 pages loaded with information including 10 tables and 19 line drawings and photo- graphs. ANSI Approved, published in 2000. Supercedes D10.12-89. D10.12M/D10.12:2000 ...................... 44.00 AWS Members .................................... 33.00

Recommended Practices for Root Pass Welding of Pipe without Backing ANSI Approved. Reaffirmed 1992, 20 pages. D10.11-87R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.00 AWS Members .................................... 33.00

Recommended Practices for Local Heating of Welds/n Piping and Tubing Rather than a summary of current practice, this standard presents recommended practices based on an ordered assessment of available research and information. 16 tables, 23 figures, 8 annexes, 101 pages. U.S. Customary and metric. Published in t999. ANSI Approved. D10.10/[)10.10M:1999 ...................... 68.00 AWS Members .................................... 51.00

Recommended Practices for Welding Austenitic Chromium.Nickel Stainless Steel Piping and Tubing ANSI Approved. Reaffirmed 2000, 34 pages D10.4-86R .......................................... 32.00 AWS Members .................................... 24.00

Recommended Practices for Brazing of Copper Pipe and Tubing for Medical Gas Systems ANSI Approved. Published in 1995, 7 pages. D10.13/[)10.13M:2001 ...................... 48.00

,~rs ..................................... 36.00

I ~ I , ' ! JUNE 2002

Recommended Practices for Welding of Chromium-Molybdenum Steel Piping and Tubing ANSI Approved. Published in 1996, 8 pages. D10.8-96 ............................................ 32.00 AWS Members .................................... 24.00

Guide for the Gas Shielded Arc Welding of Aluminum and Aluminum Alloy Pipe This important pipe welding standard contains sections including welding characteristics of aluminum; processes; materials; preparation; conditions; backing; technique; heat treatment; and safety and health. 29 pages, 13 tables, 5 figures. U.S. Customary Units and metric; pipe sizes listed as diameter nominal (DN) and nominal pipe size (NPS). ANSI Approved. Published in 2000. D10.7M/D10.7:2000 .......................... 56.00 AWS Members .................................... 42.00

Recommended Practices for Gas Tungsten Arc Welding of Titanium P/ping and Tubing Includes information on weld quality tests and safety. ANSI Approved. 19 pages, published in 2000. D10.6/D10.6M:2000 .......................... 44.00 AWS Members .................................... 33.00

To order, or for more information, phone Global Engineering Documents at: 800-854- 7179, or visit their Webpage at: www.global.ihs.com.

~ AmwicanWelding Society Founded in 1919 to Advance the Science, Technology and Application of Welding


I

located in the center of the welds and run along the welds' length. I am using ER5356 filler material.

A : If we consider the alloying effect of magnesium in aluminum, we see weld crack sensitivity increases sharply with an increased Mg content up to about 1.5% and then decreases with further Mg additions - - Fig. 1 at A1-Mg curve. With this problem, we must consider the effect of joint design on base metal and filler metal dilution. Square groove welds in this material can be particularly susceptible to cracking because very little filler metal is mixed with the base material during welding. If we examine Fig. 2, we can see the difference in the amount of Mg in each of the joint designs. The square groove showing dilution of 20% of the 5% Mg found in the 5356 filler material plus 80% of the 1% Mg found in the 6061 base alloy provides a total Mg content in the weld of around 1.8%. In comparison, the single-bevel groove weld configuration has 60% of the 5% Mg in the filler metal and 40% of the 1% Mg found in the base metal and provides a much higher Mg content in the weld of around 3.2%.

If we look again at Fig. 1, we can see at the AI-Mg curve there is considerable difference in crack sensitivity between a weld with 1.8% Mg and one with 3.2% Mg. The 1.8% Mg weld is marginally past peak crack sensitivity and the 3.2% weld is well beyond that point.

My recommendation is to evaluate the use of a V-groove weld preparation, which will introduce more filler metal into the weld metal mixture and lower crack sensitivity. 0

TONY ANDERSON is Technical Services

Manager for Alco Tec Wire Corp., Traverse

City, Mich. He is Chairman of the AWS

DIOH Subcommittee on Aluminum

Piping and D8G Subcommittee on

Automotive Arc We ld ing - Welding, Vice

Chairman of the A WS D1 G

Subcommittee 7 on Aluminum Structures,

and Chairman of the Aluminum

Association Technical Advisory

Committee for Welding and Joining.

Questions may be sent to Mr. Anderson c/o

Welding Journal 550 N W LeJeune Rd.,

Miami, FL 33126 or via e-mail at tander-

[email protected].

¥EI4 Ill~ S ~ LITERATURE

Catalog Features Pipe Cutting and Beveling Machine Products

The company's 14-page catalog features pictures of its complete line of portable pipe cutting and beveling machines and accessories. Single- and double-master chain clamps and precision- spacing wedges are among the products currently available for purchase.

H & M Pipe Beveling Machine Co., Inc. 128 311 E. Third St., Tulsa, OK 74120-2417

Tube Fabrication Tools Highlighted

The company's Brass Products Divi- sion catalog No. 3510 contains a complete listing of its expanded line of tube fabrication tools for use in pneumatic and hydraulic applications. The catalog contains product descriptions and options for various tube cutting machines for hard or soft ferrous and nonferrous metals, including thin-wall steel, stainless steel, titanium, Monel®, and other metal alloys; different lever- and spring-type tube benders; flar- ing tools for standard and metric tubing; punch and screw-type swaging tools; complete tubing tool kits; and a selection of accessory fabrication, assembly, and service tools.

Parker Hannifin Corp. 300 Parker Dr., Otsego, MI 49078

129

Video Showcases Company's Metalforming Capabilities

The company's six-minute video highlights its core operations from order entry, product development, manufacturing, final

For more information, circle number on Reader Information Card.

assembly to shipping. The video also showcases the company's product line that includes a Multiple Transfer® press and fourslide and CNC slideforming machines. It is available in VHS format or as a CD.

The U.S. Baird Corp. 1700 Stratford Ave., Stratford, CT 06615-0887

130

Leaflet Features Resistance Welding Equipment

Brochure Features Portable Air Cleaner

The full-color brochure showcases the TM 1000 portable unit for shop and plant air cleaning. The units source capture pol- lutants and fumes when grinding, welding, cutting, gluing, and more, using a variety of attachments. The operator can roll a unit to a work area, plug it into any 120-V

The company's six-page, full-color product leaflet features its resistance welding equipment. The leaflet provides details of the entire product line, including wire mesh welding machines and standard projection, spot, butt joint, and seam welding machines.

Meritus Unit 4, London Road Business Park, 222 London Rd. St. Albans, Hertfordshire All IPN England

131

Catalog Details Expanded Line of Maintenance Products

The company's catalog includes its expanded line of maintenance products featuring more than 200 new items. A Con- tractor Sweeps category has been added featuring a strong bolt-through handle and heavy-duty wing brace. Contractor Sweeps are designed to be durable in heavy-duty applications such as construction and heavy manufacturing. Color- coded handles designate paint brush fill type and quality level. More than 25 paint brushes have been added to the line, including an expanded sash brush selection and specialty items such as foam applica- tors, minirollers, and pipe rollers.

Weiler Corp. 132 One Wildwood Dr., Cresco, PA 18326-0149

single-phase outlet, and choose the right attachment for the job. Attachments include articulated source-capture arms in various sizes, dual-articulated arms (for use by two operators), downdraft table, back- draft hood, and long-reach flexible hose with hood.

Micro Air 133 P.O. Box 1138, Wichita, KS 67201

W e l d i n g Fi l ter C a t a l o g Of fe red on C D - R O M

The company's free welding filter catalog is available on CD-ROM. The catalog contains cross references, filter drawings, installation instructions, and pricing. Re- placements are available for Torit, Micro Air, Airflow Systems, Metal Fab, Aercol- ogy, Oskar, Farr, AAE TDC, Airguard, Nordson, and more. For welding applications with unburned hydrocarbons (oily soot) in the smoke or fume, the company's Spun bond H.O. (hydro-oleo phobic) is available. Call (800) 579-8797 to receive a catalog.

CanAm Filter Group 130 Production Ct., Louisville, KY 40299

B r o c h u r e S h o w c a s e s C o m p a n y ' s C o n s t r u c t i o n Exper t ise

The company's brochure highlights its expertise in construction arc welding, empha- sizing the welding process solutions. Also included are arc welding equipment, consumables, engineering solutions, research and development, training, and productivity offered to the construction industry.

The Lincoln Electric Co. 134 22801 St. Clair Ave., Cleveland, OH 44117-1199

Cata log H igh l igh ts P n e u m a t i c Tools

The company's 84-page color catalog covers its complete line of pneumatic tools. The product line includes vertical, die, and right-angle grinders, pile cutters, and sanders; horizontal Type 1 or Type 27 cone and burr grinders; sanders; scalers; chipping hammers; rammers; air saws; air drills and routers; power supply motors and guards; adaptors; and special accessories. An overview of the company's technical support and custom tool design and build capabilities are offered along with reference charts for

One anBancl,

cAllant°g~thjry::~b ' . .

:7" ~ It takes 0nly five rain- band and beveling machine head g. Here are some other great numbers: tds provide a cutting range of 10"- to 96"-

are available to cut pipe dimneters up to ires work in concert to make H&M the

veling Machine Company, Inc. I St. / Tulsa, OK 74120-2417 -9984 / Fax (918) 582-9989 m@hmpipe,com / www, hmpipe,com

I~I : l l JUNE 2002


I

AT LAST AVAILABLE!

TEST OUR ALLOYS: - - SILVER BRAZING ALLOYS (FLUXCOATED TOO)

- - CADMIUM FREE ALLOYS (FLUXCOATED TOO)

- - STANDARD CADMIUM BEARING ALLOYS

(FLUXCOATED TOO) - - NICKEL BEARING ALLOYS - - COPPER PHOSPHORUS SILVER ALLOYS - -ALL RELATED FLUX (PASTE OR POWDER) ~.~ - - FLUXCOATED BRASSES 0 " , 4 ~ - - FLUXCOATED ALUMINUM ALLOY~ ,~.¢~

(NEU,TRAL FLUX) ~ ~ ], ~ , ' ~ -

A NEW AND ADVANCED PROCESS.~/~_ OUR COVERING IS PERFECTLY: ~ ' - / ~ " - ~ --PLASTIC . . . . . ~ . ~ ' ~ ~ - BENDABLE / / ' / / - - STRONG ~.- v ~ ' - ~ . / " - ~ / -- UNALTE~BLE /NO CHEMICAL " - ~ "

CORROSION BETWEEN THE COVERING AND ITS OWN ROD)

- - EXTREMELY ACTIVE - - EASILY REMOVABLE WITH WATER - - ABSOLUTELY THE BETFER

FLUXCOVERING

Aurall LEGHE SPECIALI PER SALDATURA

Via lsonzo 8/B-24040 Stezzano - Bergamo - Italy

Tel. 035/591734-591477 Fax 035/591976

Website: www.aurall.it Email: [email protected]


selecting and ordering tools and expanded product specifications and dimensions. The literature also includes information on the safe operation of air tools.

T. C. Service Co. 135 38285 Pelton Rd., Willoughby, OH 44094

Catalog Provides Welding and Cutting Solutions

The company's full-color, 84-page catalog for 2002 presents detailed descriptions of technologies and products used to solve welding and cutting challenges faced by actual customers. Technical specifications, features, and benefits of the company's welding and plasma cutting products and accessories are included. The Help Me Choose section guides readers toward se-

lecting the best welding or cutting product for a desired application including information on advantages and disadvantages of various welding/cutting processes.

Miller Electric Mfg. Co. 1635 W. Spencer St., Appleton, WI 54912-1079

136

Staggered Truss Design Guide Offered

The American Institute of Steel Con- struction, Inc. (AISC) has produced a design guide on staggered truss framing systems. Steel Design Guide Series 14: Staggered Truss Framing Systems is aimed at designers of midrise apartments, hotels, motels, dor- mitories, hospitals, and other structures for which low floor-to-floor height is desirable. Topics on general information regarding staggered truss framing systems, diaphragm action with hollow core slabs, design of truss members, connections in staggered trusses, seismic design, and fire protection of staggered trusses are addressed. The Design Guide is available to AISC members for $26, $39 to nonmembers. Copies may be ordered from the AISC bookstore, www.aisc.or,g/bookstore.html.

AISC, Inc. 1 E. Wacker Dr., Ste. 3100, Chicago, IL 60601-2001

Guide Features Ultrasonic Parts Cleaning Systems

The company offers a guide for its line of ultrasonic parts cleaning systems titled "You Don't Have to Live and Breathe Your Work." The guide describes systems designed for small- to medium-sized machine shops, parts manufacturers, and metal finishers. Meeting all EPA standards, the systems use safe, non- toxic soaps and ultrasound to degrease, clean, and pref'mish parts and components. The systems eliminate the need for toxic solvent baths and manual labor. Four models of varying bath size and power are offered. For other applications, the company manufactures a full line of tabletop units and can supply custom systems as needed.

Omegasonics 137 330 E. Easy St., Ste. A, Sirai Valley, CA 93065

MICRO ~ I N G SYSTEM WELDLOGIC "MICRO-TIG" / PLASMA SYSTEM

iS THE MOST ADVANCED AND ACCURATE FORM OF PRECISION WELDING AVAILABLE

• MINIMAL STRESS ~ DISTORTION • MINIMAL HEAT ARC STABILITY DOWN TO. 1 AMP • NO ARC WANDER

NO HIGH FREQUENCY BURNING • PRECISE STARTS IN DEEP POCKETS #1 CHOICE OF WELDING PROFESSIONALS

WELDLOGIC INC.~ ~---~--.~'- % 2550 Azurite Circle, Newbury Park, California 91320 - - Phone (805) 498-4004 • FAX (805) 498-1761

W e l d i n g S o l u t i o n s For ~ . - • " Website: www.weldlogic.com • E-mail: [email protected] Advanced Manufacturing x "


PERSONNEl

Motoman Promotes Vice President

experience in the human resources field. His previous work experience includes human resources manager at HSSF Huffy Corp. and director of human resources at The Greentree Group.

Mike Gabbard

Motoman, Inc., Dayton, Ohio, has promoted Mike Gabbard to vice president of the Human Resources & Facilities Group. Gabbard, who joined the company in 1999 as senior director of human resources, has more than 17 years of

CONCOA Adds Managers

CONCOA, Virginia Beach, Va., has added two area managers to oversee its sales in key domestic territories.

Gary Butner was named area manager of the southeast region and Russell Christiana to the central U.S. and Canada region. Their responsibilities include spear- heading sales and developing new markets and working with distributors.

Robotic Production Technology Names Managers

Robotic Production Technology, Auburn Hills, Mich., has named Dave

Vibratory Stress Re l ie f Reduces Res idual Stresses

Due to Welding " F o r m u l a 6 2 " m e t h o d utilizes h igh ampli- tude vibra t ions to r educe peak residual stresses c lose to yield stress levels near the weld center line. Vibrations remove high tensile

residual stresses due to welding in ferrous and non-ferrous metals. S e n d f o r

f r e e b r o c h u r e . STRESS RELIEF EnGINEERInG c o m p A n Y

1725 Monrov iaAve . , A-I • Cos ta Mesa, CA 92627 (949) 642-7820 • FAX (949) 642-0430


S P E C I A L T Y C O R E D WIRE AND C O A T E D E L E C T R O D E S

' ' I ) \ -

(810) 227-3251 www.cor-met.com

FAX: (810) 227-9266

iHolol J U N E 2002


I

DiBiase [AWS] sales manager. In this position, he will manage all sales functions of the company. Prior to his appointment, DiBiase served as director of sales at Flow International, where he was responsible for worldwide sales for the Flow Robotics Systems Group.

Janine Krasicky has been named marketing manager. She is responsible for developing a corporate marketing plan to build name and brand recognition for the company. Krasicky previously served as public relations specialist for FANUC Robotics North America, Inc.

US Inspection Announces Promotions

Mark Koehler

US Inspection Services, Dayton, Ohio, announced the promotion of Mark Koehler [AWS] to regional manager of its Ohio Valley district. In this position, he will oversee all aspects of sales and operations for the company's Charleston, W.Va., and Cincinnati and Marietta, Ohio, offices.

Glen Wood [AWS] has been promoted

Glen Wood

to regional sales manager of the Ohio Valley district. In this position, he will be responsible for all sales, marketing, and customer service for the company's Cincinnati and Marietta, Ohio, and Charleston, WVa., facilities. Wood has more than 20 years of experience in the nondestructive testing industry, starting as a NDE technician and quality assurance manager.

LA-CO/Markal Names Managers

Todd Sho[]Htt

LA-CO Industries, Inc./Markal Co. announced Todd Shoffeitt has joined the company as marketing manager for the industrial/welding division. Shoffeitt is responsible for advertising, sales promotion, and other marketing programs for industrial distributors and their customers. Prior to joining the company, he was marketing manager for TW Metals in Carol Stream, Ill.

Also in the industrial/welding division, Jay Campbell was named regional sales manager for the southeastern United States, as well as areas west of the Mississippi. Campbell previously served as regional sales manager for Crown North American Professional Products. He holds a B.S. degree from Pittsburg State University.

Unitek Miyachi Names Marketing Officer

Unitek Miyachi International, Monrovia, Calif., has named Henry R. Andersen chief marketing officer. In this position, he is responsible for the marketing vision as well as coordination of the sales and marketing programs for the company and its subsidiaries worldwide. Andersen's experience includes having

Member Milestone ASME Names Fellow

Samuel D. Reynolds, Jr. [AWS], EE., has been named a Fellow of the American Society of Mechanical Engineers (ASME) International. Fellow status is conferred upon a member with at least ten years active engineering practice who has made significant contributions to the field.

Reynolds, who is a consultant, earned his bachelor of science degree in metallurgical engineering from Lehigh University, Bethlehem, Pa. In addition, he has been named a Fellow of the American Welding Society and the American Society for Metals and is a member of the National Association of Corrosion Engineers.

served as director of global marketing and new business development at Stanley Electric Co., Ltd., and general manager, European planning and development at Mitsubishi Heavy Industries, Ltd. He holds a B.A. from Harvard University in Physics and Japanese literature, an M.S. from Columbia University, and a M.B.A. from INSEAD in Fontainebleau, France.

Wall Colmonoy Appoints Technical Sales Representative

Gilbert Brisson

Gilbert Brisson has joined Wall Colmonoy (Canada) Inc. as technical sales representative. He is responsible for maintaining and expanding sales of the company's Colmonoy® hard-surfacing alloys and Nicrobraz® brazing filler metals in Canada. Brisson has more than 16 years of experience in the welding industry and obtained a welder/fitter certificate from St. Lawrence College in Cornwall, Ontario.

Lincoln Expands Sales Force

The Lincoln Electric Company, Cleveland, Ohio, recently added 15 new technical representatives to its sales force. The individuals will offer both sales and

technical support to distributors and customers within district offices throughout the United States and Canada. They are Michelle Adams, Charlotte, N.C.; Tim Cordonnier, Moline, Ill.; Denny Davis, Atlanta, Ga.; Jonathan Davis, Baton Rouge, La.; Greg Doria [AWS], Montreal, Canada; Kevin Fleming [AWS], Grand Rapids, Mich.; Regis Geisler [AWS], Los Angeles, Calif.; Johnny Harvill, Atlanta, Ga.; Daniel Hernandez, Houston, Tex.; Kent Johns, New York, N.Y.; Kevin Korabik, San Francisco, Calif.; Adam Laabs [AWS], Minneapolis, Minn.; Brian Muenchau, St. Louis, Mo.; Megan Myhre, Indianapolis, Ind.; and Bill Narducci [AWS], Pittsburgh, Pa.

Obituary William J. Farrell

William J. Farrell [AWS] died Wednesday, January 9, of Parkinson's dis- ease at St. James Hospital and Health Center in Olympia Fields, Ill.

In the 1930s, Farrell won a scholarship to the Cooper Union engineering school. After graduating, Farrel joined Consolidated Edison. He then moved to Sciaky Inc. During his 40-year career with Sciaky, Farrell worked on welding methods that could hold up to intense stress and pio- neered welding techniques for rockets and nuclear submarines. Early in the Cold War, he volunteered as a consultant to the Atomic Energy Commission and the National Academy of Science devising methods of safely housing nuclear warheads and reactor fuel. Farrell retired from Sciaky in 1986 as a senior vice president. After retiring, he helped Argonne National Laboratory design the Advanced Photon Source, a high-power particle accelerator that could capture images of molecules in motion. Despite the doubts of other scientists, Farrell created the machine from aluminum.

Survivors include his wife, Margaret Brown Farrell; two sons, Brian and William; three daughters, Joan Data, Carol Budzik, and Nancy Ferrario; and 11 grandchildren and three great-grandchildren.

I WELDING JOURNAL i b ] i l

102

RED HOT! Products

Welding Positioners

AII-Fab Corporation manufactures welding positioners from 200-lb. to 1250-1b. capacity. Standard features include infi- nitely variable speed table rotation, on/off foot control, 135-degree table tilt and 120-volt input power. For a complete catalog and price sheet contact AII-Fab.

Absolutely The Best Fluxcovering We have been producing our products for the welding industry for over 25 years. We produce high quality products such as: ° Silver Brazing Alloys with or no Cadmium

AII-Fab Corp. 1235 Lincoln Road Allegan, MI 49010 (616) 673-6572 FAX: (616) 673-1644 E-mail: [email protected]

Stop By Our Website www.abpaper.com

AB Paper Company was established in 1983 for the purpose of prefabricating water-soluble materials for the pipe welding industry. Our Shur-Purge TM and Shur- Gap® products are used worldwide to expedite welding set-up and completion. They save valuable time and give positive, proven results time and time again. AB Paper Company P.O. Box 622 Centralia, WA 98531 (800) 408-0739 FAX: (360) 740-0738

Model 9-500C Weld Head As with our 9-500 weld head, the Model 9-500C is a precision orbital GTAW (TIG) welding head, designed for fusion butt welding of tubing, mini fittings, valves and other components having stick-outs as short as 0.25" (6.35mm). Whereas our Model 9-500 is air- cooled, the Model 9-500C is air or water-cooled. Both of these heads have a capacity of up to 1/2" (12.7mm) O.D. The 9-500C is capable of high duty cycle applications, and is provided with a Quick Release Kit. The Quick Release Kit (also available for

the 9-500) allows remote loading of the clamp assemblies, providing an unobstructed (360 degree) view of the weld joint, and facilitates the use of multiple clamp assemblies to further increase the duty cycles. A wide variety of tooling is available (and interchangeable) for both these heads. Please visit our website at www.arcmachines.com. Arc Machines Inc. 10500 Orbital Way Pacoima, CA 91331 (818) 896-9556 FAX: (818) 890-3724

(Fluxcoated too) • Copper Phosphorus Silver Alloys • All related Flux: Electrodes and Nickel Bearing Alloys. We have excellent technical help for our customers, quality products and competitive prices. This and more is Aurall! Aurall S.r.l. Leghe Speciali Per Saldatura via Isonzo 8/B 24040 Stezzano - Bergamo - Italy (035) 591-734-591477 FAX: (035) 591976 Website: www.aurall.it

New Long Life MIG Welding Contact Tip Improves Productivity Diamond Tips combine the unique advantages of the Bernard Elliptical Tip with a new, special copper alloy featuring exceptional hardness and electrical conductivity not found in chrome-zirconium or standard copper tips. Field tests confirm Diamond Tips can offer as much as 2 to 8 times the life of standard copper tips. Bernard Front End Conversion Kits allow these tips to be used on common competitor MIG guns, too. Call for more information. Bernard Welding 449 West Corning Road, Box 667 Beecher, IL 60401 (708) 946-2281 FAX: (708) 946-6726 E-mail: [email protected]

Burny! Performance Matched Drives And Control Solutions

The new Burny® ServoPak AC8, from Cleveland Motion Controls, is a brushless, AC servodrive system for shape-cutting that provides 8 Amps of continuous output current and is capable of up to lkW continuous and 2kW peak power per axis. It is available in 2- axis or 3-axis drive packages specially designed for cantilever or gantry machines. When combined with the Burny 10 LCD shape-cutting motion controller, it can increase productivity and reduce costs.

Burny Products 7550 Hub Parkway Cleveland, OH 44125-5794 (800) 308-3399 or (216} 524-8800 Website: www.burny.com

Atlas 500 Welding Positioner Atlas Model 500 Welding Positioner can increase production and cut costs. • Designed to Handle 500 Ibs. • 1/4 HP DC Motor • 400 Amp Grounding Circuit • On/Off Foot Switch • Front Panel Speed and

Rotation Controls • Full Speed Jog for Stitch

Welding • Dynamic Braking Atlas Welding Accessories RO. Box 969 Troy, MI 48099 (248) 588-4666 (800) 962-9353 FAX: (248) 588-3720

The SYMEX 4/0 cable connector MODEL TPL-4 is precision machined from premium extruded brass to provide the following features: * Fully matched taper with a

positive-lock solid pin design * Resists vibration * No twisting or turning ensuring

high conductivity, maximum efficiency and no arcing or burning

* Equipped with two allen screws to provide better conductivity

* Fully insulated C.H. Symington & Co., Inc. 6063 Frantz Road, Suite 103 Dublin, OH 43017 USA (614) 766-2602 FAX: (614) 766-2715

RED HOT|,,ro,u,,, Faster And Easier Weld_IT To help you find solutions to your welding challenges, faster and easier Weld_IT and Weld_IT Networks have been upgraded to Windows 2000, ME, and XP. Benefit from the Cost Estimator, Welding Procedure generator and extensive Welding Textbook. The Exam Module makes knowledge testing quick and simple. Visit GCIL at www.cwbgroup.com or HIWT our exclusive U.S. distributor for more information.

Gooderham Centre For Industrial Learning 7250 West Credit Avenue Mississauga, On. L5N 5NICanada (905) 542-2176 FAX: (905) 542-1837 Website: www.cwbgroup.com

Clamshell Series Debut

D.L. Ricci Corp. is introducing our MS Heavy Duty Clamshell Lathe designed for O.D. diameters from 14" to 42" and all wall thickness of pipe. The MS is ideal for cutting and beveling work on P-91 heavy wall piping and Stainless Steels. This versatile machine is also well suited for O.D. Turning and Flange Facing. Sales, Rental, Service.

D.L. Ricci Corp. 5001 Moundview Drive Red Wing, MN 55066 (651) 388-8661 FAX: (651) 388-0002 Website: www.dlricci.com

DuraBore Portable Drilling Machine

CML USA, Inc. presents the DuraBore portable magnetic base drilling system and center free annular cutters. The DuraBore's lightweight compact design easily accom- modates most hole drilling applications. It's rugged, all cast aluminum exterior is fabricator tough, improving productivity while reducing costly maintenance. The sealed arbor system maximizes coolant flow to cutter's edge increasing tool life and minimizing work piece cleanup. The exterior coolant tank removes quickly without leaking for refill or to accommodate compact areas.

CML USA Ercolina® 10227 General Drive Orlando, FL 32824 (407) 857-1122

4 E _ C O R - M E T o ~ SPECIALTY CORED WIRES

COATED ELECTRODES SOLID WIRE MIG AND TtG

Cored Welding Wire Guide This brochure shows Cor-Met's wide offerings of sizes and alloys in Cored Welding Wires, Stick Electrodes and TIG wires (both spools and cut lengths). It includes descriptive, classification and physical data on low alloy steels, cobalt-base and nickel-base alloys, tool and stainless steels, and hard-facing alloys. Alloys are available for resistance to high temperatures, erosion and corrosion; cored wires, electrodes and TIG and MIG solid alloy steels; cast iron and stainless steel. Cot-Met inc. 12500 E. Grand River Brighton, MI 48116 (800) 848-2719 FAX: (810) 227-9266 Website: www.cor-met.com

WeldOffice T M Software Automatic creation and management of WPS, PQR, WPQ Welding Procedures Welder Qualifications & Welder Maintenance Expiration Reports NDE Reports Base Metals & Filler Metals Joint Details QA/QC Activities Production Welding Electronic Signatures Multi Codes/Standards Code Checking & Custom Reporting Complete solutions for QA/QC management of plants, fabrication shops and con-

struction projects. Free Demo at www.weldoffice.com. C-spec P.O. Box 27604 Concord, CA 94527 (888) 673-9777 toll free or FAX: (925) 930-8223

I ~ ' ~ 4 ~ New Pneumatic Clamps

DE-STA-CO's newest family of pneumatic clamps is ideal for dirty spot and MIG welding environments. All models feature an enclosed cylinder rod and a lower, narrower mounting

profile. The non-pivoting cylinder can be hard-piped into fixtures. Holding capacities range from 390 to 700 Ibs.The clamps are designed to withstand a maximum intermittent temperature rating of 250 degrees Fahrenheit.

DE-STA-CO Industries 2121 Cole Street Birmingham, MI 48009 (248) 594-5600 FAX: (800) 682-9686 (non-US) 248-644-3929 website: www.destaco.com

Tri-Mix T M Tungsten Diamond Ground Products, Inc., offers Tri- Mix TM tungsten. This premium quality tungsten material is non-radioactive and offers superior performance in TIG and plasma welding applications. It is blended with three rare earth elements that scientifically balance the migration and evaporation rates to extend service life with increased number of arc starts and fewer misfires. Its lower work function requires less energy to start and also runs cooler. Free samples available on request. Diamond Ground Products, Inc. 2550 Azurite Circle Newbury Park, CA 91320 (805) 498-3837 FAX: (805} 498-9347 E-maih [email protected]

WRC number. The unit is battery operated boasts a large LCD display, statistical evaluation, and RS232. Fischer Technology, Inc. 750 Marshall Phelps Rd. Windsor, CT 06095 (800) 243-8417 FAX: (860)688-8496 E-mail:[email protected] Website: www.Fischer-Technology.com

On-Site Measurement, Feritscope MP30

The Feritscope MP30 is for quick, rugged, on-site measurement of ferrite content. Ideal for constructional steels, welded claddings, austenitic stainless steel and duplex steels. The instrument is designed for non-destructive measurement in the range of 0-80% Fe or 1-120

103

eEl) HOT|!proa,c,, New Line Of Heavy-Duty, Air-Powered 1 HP Tools

Dynabrade, Inc. is proud to introduce a brand new line of heavy-duty 1 HP air tools. The tools are excellent for heavy-duty grinding and finishing and are ideal for use in foundries, welding shops, steel

plants, shipyards and fabrication plants. The new tool line includes Dynastraight air powered abrasive finishing tools. Ranging from 950 - 3,400 RPM, these tools are ideal for surface conditioning on materials such as stainless steel, fiberglass and composites. The tools are used with abrasive flap wheels, surface conditioning discs and pneumatic wheels for use with coated abrasive or Scotch-Brite belts. Dynabrade, Inc. 8989 Sheridan Drive Clarence, NY 14031 (800) 828-7333 FAX: (716) 631-2073

User-Friendly. FEMA-Tough. Involved in bridge/structural fabrication? Don't miss ESAB's Coreshield® 6/Coreshield® 8 brochure, outlining the outstanding characteristics of these new self- shielded, flux-cored wires. Both offer FEMA 353 Specification for seismic areas - plus welder appeal no other wire comes close to. They've actual- ly helped fabricators certify welders in record time.

ESAB Welding 8, Cutting Products 411 S. Ebenezer Road Florence, SC 29501-0545 (800) ESAB-123 Website: www.esab.com

Universal CNC Benders & Angle Rolls New For 2000 Eagle Bending Machines offers 100+ fast, accurate and labor saving benders for profiles, sections, tube & pipe. Eagle provides superior quality, rapid delivery, custom tooling and the

EZ ARC Welding Systems GENTEC offers affordable solutions to work station design. The EZ ARC product line includes complete welding workstations that accommodate a wide variety of part configurations. Components are attached to base rail system fixture parts for optimum results on a repetitive basis. Automation may be achieved using

~ " ~ _ . ~ r . l i O largest selection of benders available. The new BA-35 & BA-50 CNC Section Benders incorporate industrial PCs, large graphics, direct radius input, unlimited memory, unmatched precision with sizes to 2" Scd. Pipe, 2-1/2" Angle, 4" Flats. Eagle Bending Machines, Inc. P.O. Box 99 Stapleton, AL 36578 (251) 937-0947 FAX: (251) 937-4742

Materials Joining Solutions

This full color brochure tells how, as an EWl member, you have access to

the largest materials joining information and technology transfer network in North America. EWl services include consultation, design review, material and process implementation, automation, trouble shooting, testing, and education and training. EWl membership can help your business improve productivity, quality, and customer satisfaction while reducing costs and improving profits.

Edison Welding Institute (EWI) 1250 Arthur E. Adams Dr. Columbus, Ohio 43221 (614) 688-5000 FAX: (614) 688-5001 Website: www.ewi.org

optional Sequencer. The product line also includes Welding Positioners and Turning Roils. Genstar Technologies Co., Inc. 4525 Edison Ave. Chino, CA 91710 (909) 606-2726 E-Mail: [email protected] Website: www.genstartech.com

Saddle-Type Cutting & Beveling Machines H&M's Beveling Machines are constructed of lightweight, hard-anodized aluminum, assuring durability and easy transportation. The rear-mounted short saddle makes cutting and beveling effort- less in tight locations. Each machine's rear gear and saddle is calibrated to +-.025 concentricity and +.015 square- ness. The unique "split horseshoe" design with its quick-acting boomer assembly securely locks the machine to the pipe for a complete 360-degree rotation, making repositioning unnecessary. H&M Pipe Beveling Machine Co. 311 East 3rd Street Tulsa, OK 74120 (918) 582-9984 FAX: (918) 582-9989

One Welding Coupon Qualifies all Thicknesses

According to the latest ASME Section IX Code, the SUPER COUPON replaces testing on both 2" and 6" pipe coupons. It will qualify a welder for all thicknesses and all diameters down to 1" OD. It is suitable for bend testing or radiography. Various end preparations and lengths are available. For these and

other coupons, visit our website.

Fischer Engineering Company 8220 Expansion Way Dayton, OH 45424 (937) 754-1750 FAX: (937) 754-1754

1 0 4 Website: www.fischerengr.com

FREE Weld Training CD Learn how to stay on top of the welding industry, to increase your productivity, reduce liability, and much more on this new CD from The Hobart Institute of Welding Technology. This CD contains valuable information about the many welding skill enhancement, technical training and certification services they offer. The CD is free and is available by calling 800-332-9448, or visiting online at www.welding.org. The Hobart

Institute is centrally located in Troy, Ohio. Hobart Institute of Welding Technology 400 Trade Square East Troy, OH 45373 (800) 332-9448 Website: www.welding.org

RED HOTI

the plating process or mar the J.P. Nissen Co. P.O. Box 339 Glenside, PA 19038 (215) 886-2025 FAX: (215) 886-0707

Products New Paint Marker Designed to Disappear In Pre-Galvanizing Pickling Bath The Galvanizer's Feltip Paint Marker contains a paint specially formulated by J.P. Nissen Co. for fabricators who have their material galvanized. The valve-action marker writes easily on rough or smooth steel, even if the surfaces are wet or oily. The marks won't chip, peel, fade, or rub off. They will withstand heat and weathering. However, they will be completely removed by the pickling bath prior to galvanizing. The marks will not interfere with finished plated surface.

1 N-S Brush-Pack" Let-Off System Boosts Welder Efficiency. N-S Brush-Pack® let-off system virtually eliminates brake tension problems when using N-S Tru-Trac' and 4-2-5 Trigger -Trac' bulk packaging. Welders waste less time making let-off adjustments and spend more time welding. With no moving parts, no liners to replace and no tools for installation, this system also reduces changeover/setup time by up to ten minutes. For product information contact:

National-Standard 1618 Terminal Road Niles, Michigan 49120 (800) 777-1618 FAX: (616} 683-9276 Website: www.nationalstandard.com

J.W. Harris Perfect Circle TM

All-Position Flux-Core Wire This data sheet gives details on Perfect Circle TM, the new all-position, flux-core wire from J.W. Harris. Perfect Circle TM (E71T-1) is formulated to deposit X-ray quality welds in flat, vertical up, horizontal and overhead positions. Ideal for shipyard, automotive, structural and related fabrication, Perfect Circle TM

gives the welder a high deposition rate, easy slag removal and low spatter for easy postweld cleaning.

J.W. Harris Co., Inc. Mason, OH 45040 (800) 733-4043 FAX: (513) 754-8778 Website: www.jwharris.com [email protected]

NEW! Meter Length Rod Guard® Cannister Now Available

Now in our 21st year of the original, patented Rod Guard® line, K.I.W.O.T.O., Inc. features the new meter length, in addition to the 36" cannister for bronze and TIG rod. Just ask for our full-color, four-page brochure containing detailed descriptions of all welding electrode storage cannisters and accessories. Includes part numbers, capacities, packaging information and other features. Available from your local welding supply distributor or call, fax or write for more information. K.I.W.O.T.O., Inc. P.O. Box 1526 - WJ Benton Harbor, MI 49023-1526 (616) 926-4444 FAX: (616) 926-8308 E-Mail: [email protected] Website: www.rodguard.com

Gold Track V Orbital Pipe Welding System Liburdi Dimetrics' 500-Ampere, 100% duty cycle Gold Track V is the newest generation of full-function, programmable GTA welding systems for orbital and linear pipe applications. Complete with Travel, Wire Feed, Arc Voltage Control and Oscillation functions, the Gold Track V accepts the company's full line of orbital pipe weld heads, as well as tube-to-tube sheet and orbital tube weld heads. Liburdi Dimetrics 404 Armour Street Davidson, NC 28036 (704) 892-8872 FAX: (704) 892-4713 E-Maih [email protected]

Power MIG TM 300 The Power MIG 300-a single phase, multi- process, synergic wire feeder welding package for the professional welder. This ready-to-weld package is unbeatable when it comes to superior multi-process welding. The synergic design, traditionally only available in more expensive welders, gives you ultimate control over the arc by automatically aligning wire feed speed and voltage. It also offers top quality aluminum welds with push-pull wire feed capability, not usually available in competitive

models. True MIG pulsing and Pulse-on-Pulse TM capabilities ensure that superior feeding is matched by high quality arc performance. Lincoln Electric Company 22801 St. Clair Ave. Cleveland, OH 44117 (216) 481-8100 Website: www.lincolnelectric.com

Flexible Track Allows Large Diameter Circular ID/OD Welds Magnatech introduces a flexible track system for use with their Pipeliner (FCAW) and Pipemaster (GTAW) systems; shown here in a 11' ID stainless duct FLX-Track 8' track sections interlock to form longer lengths and mount using magnets or vacuum cups. ID, OD, or compound curva- ture welds can be made with mechanical weld speed and quality.

MAGNATECH LIMITED PARTNERSHIP 6 Kripes Road, P.O. Box 260 East Granby, CT 06026 USA (860) 653-2573 FAX: (860) 653-0486 Web: www.magnatech-lp.com E-Maih [email protected]

New CST 250 Inverter for Stick/TIG Field Welding Offers Best-Of-Class Arc, Simple Operation

Designed specifically for construction, maintenance and repair in power plants, shipyards and petrochemical plants, the new CST(TM) 250 Stick/q-IG inverter from Miller Electric weighs just 40 lb. It provides a 250 amp DC welding output at 50 percent duty, offers best-of-class arc performance and features the industry's simplest operator interface. It is also available in a multiple arc rack system.

Miller Electric Mfg. Co. 1635 West Spencer St. Appleton, Wl 54914 (800) 426-4553 FAX: (877) 327-8123 105

106

RED

" 0 % qlD :I'!. O

DryRod®ll Ovens The Phoenix DryRod®ll portable oven line protects welding rods from hydrogen producing moisture by holding the electrodes at an average stabilized temperature of up to 300°F(149°C). Four capacities are available: 10 Ibs. (Skg), 20 Ibs. (lOkg), 50 Ibs. (25kg), and 150 Ibs. (70kg). The 10-1b size is a

basic oven available in 120V or 240V with an insulated latching lid. The three larger sizes all come standard with adjustable thermostat (1000- 300°F), digital thermometer, on/off indicator light and 120V/240V selec- tor switch. The 50-1b and 150-1b ovens feature wheels and handle for easy transport. The 150-1b size is also available in a "bench" version. The wire wrap heating element on all units assures superior heating performance. The ovens have a durable, high visibility yellow, powder coat finish. I Phoenix International, Inc.

6161 N. 64th Street ~ T ! x ! M i l w a u k e e , Wl 53218

. . . . . . . . . . . . . (414) 431-2600 or FAX: (414) 438-0238

PR-Text EQUOTIP & EQUOSTAT

PROCEQ is a manufacturer of portable hardness testers for metals. EQUOTIP is based on the LEEB rebound principle and is

Vibratory Stress Relief

"FORMULA 62" portable stress relief unit puts an end to the high cost of thermal stress relief. Work is performed in-house, no transportation or clean-up required. Procedures are quick and easy to follow. Use on weldments or machined parts from one pound to tons in the shop or field.

Stress Relief Engineering Company

1725 Monrovia Ave., A-1 Costa Mesa, CA 92627 (949) 642-7820 FAX: (949) 642-0430

Tweco TM Spray Master' MIG Welding Guns Work In "High Heat" Applications For demanding spray and pulse welding applications - - even "high heat" situations -

ideal for heavy, massive parts. EQUOSTAT is based on the

Rockwell principle and used for thin, small or coated parts.

PROCEQ USA, Inc. 1005 Beaver Grade Rd. Suite 102 Coraopolis, PA 15108 (412) 264-8440 or Toll free: 1-800-839-7016 FAX: (412) 264-8441 Website: www.proceq-usa.com E-maih [email protected]

Metal-Cored Electrode For Harsh Conditions

Select-Arc introduces a carbon steel, composite metal-cored electrode that features higher manganese and silicon contents to provide more deoxidation and a flatter bead geometry. The extra deoxidizers make Select 70C-6 the ideal choice to handle demanding applications such as heavier sheet metal fabrication, structural work, pipe welding and the welding of hot water heaters as well as general purpose welding. Select-Arc, Inc. P.O. Box 259 Fort Loramie, OH 45845-0259 (800) 341-5215 FAX: (937) 295-5217 Website: www.select-arc.com

Smith Equipment

Smith Equipment offers 24-hour shipping for most specialty gas regulator configurations. They offer extreme configuration flexibility, competitive pricing, superior performance and quality, easy-to-read gauges. Regulators can be configured for corrosive or non-corrosive applications to fit your specific needs. Choose from single or

two-stage cylinder regulators or single stage line regulators. Many configurations available. 100% tested and made in the USA.

Smith Equipment 2601 Lockheed Avenue Watertown, SD 57201 (800) 843-7912 FAX: (800) 685-3370 Website: www.smithequipment.com E-mail: [email protected]

Spray Master air-cooled MIG guns from Tweco TM Products Inc. provide optimum performance. Engineered to be operator-friendly, Spray Master series guns feature short conductor tubes (allowing operators to get closer to the workpiece) and an ergonomic-designed handle. The SprayMaster series welding guns are also easy and economical to maintain and repair. Tweco/Arcair A Thermadyne Company 4200 West Harry Wichita, KS 67209 (800) 231-9353 (316) 942-1421 (Intl.) FAX: (316) 942-8333

New, Portable CutMaster TM 75 Designed For Demanding Conditions

The CutMaster TM 75 from Thermal Dynamics combines the reliable CutMaster "power supply" design with our versatile SureLok TM torch to deliver the most advanced plasma cutting technology available. The CutMaster 75 with-

stands the most demandin I workplace conditions, while meeting the highest standards of operator safety and moisture resistance. For cutting light steel, stainless and aluminum in virtually any application, ask about our complete line of plasma cutting systems. Thermal Dynamics--A Thermadyne Co. 82 Benning Street West Lebanon, NH 03784 (800) 752-7621 or Intl. (603) 298-5711 FAX: (800) 221-4401

(608) 298-0558 (Intl.)

New Power-Master TM 500P Delivers Flexible Welding Capability The Power-Master TM 500P heavy-duty inverter power source from Thermal Arc delivers multiple weld processes necessary for all manufacturing environments - Gas Tungsten Arc Welding (GTAW), Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW) and Pulsed Gas Metal Arc Welding (P-GMAW). Power- Master is a high-amperage, energy efficient power source featuring 24 factory-

installed pulse programs in the Pulsed GMAW mode that can quickly switch between weld processes. Thermal Arc--A Thermadyne Company 2200 Corporate Drive (800) 255-5846 or (937) 440-0100 (Intl.) FAX: (800) 332-0946

RED HOTt,,o,°c,, New Beveling Machine Delivers More Power and Precision for Pipeline Industry Tri Tool's, new Model PFM 1632 is a portable ID mount machine for beveling, facing, and/or coun- terboring 16" through 32" pipe offers the widest size range in

Trailing Shield Kit The Weld Hugger Trailing Shield kit is an inert cover gas system designed to uniformly flow cover gas over and behind the weld pool to reduce part oxidation and discolorization. The kit's all stainless steel nozzles and manifold tube can be bent to con-

the industry. This machine, the most powerful in its class, has been designed with twin hydraulic motors powering a helical drive gear system attached to a main spindle for smooth power and optimum surface finish. The PFM 1632 features two auto-feed hydraulic cylinders with rapid and slow feed for fast and accurate cutting head control and a large diameter mandrel shaft for increased stability during heavy cutting operations. Tri Tool Inc. 3806 Security Park Dr. Rancho Cordova, CA 95742 (916) 351-0144

Monsterous Savings w i t h the

Monster

Monstrous Savings With The Monster Coupon Triangle Engineering's NEW 2-3/4" O.D. x 5/8" wall AIO6B Welder Qualification coupon can save 80% weld time and material vs. 6XXH coupons. The Monster Coupon will qualify for unlimited thickness and diameters as small as 1" O.D. using two weld processes. Take advantage of the ASME Section IX Code changes. Coupons available from stock in quantities fromlO pcs to full pallets of 250 pcs. Triangle Engineering Inc. 6 Industrial Way W. Hanover, MA 02339 (781) 878-1500 FAX: (781) 878-2547 Website: www.trieng.com

Wear-Resistant Products Wall Colmonoy offers wear-resistant products and services: • Nickel and Cobalt hardsurfacing

alloys; powder, rod, castings, and ingot.

• Thermal spray equipment. • Training and technical assistance

Improve the performance and service life of your machinery with high-quality alloys and 60+ years of hardfacing experience.

Wall Colmonoy Corp. 30261 Stephenson Highway Madison Heights, MI 48071 (248) 585-6400 FAX: (248) 585-7960 Website: www.wallcolmonoy.com

D D

form to the geometry of many parts. The complete kit price is $249.95. To order, call toll-free or visit our website.

Weld Hugger LLC 7201 West Oakland St. Chandler, AZ 85226-2434 (877) 935-3447 FAX: (480) 940-9366 Website: www.weidhugger.com

The Most Accurate Low Current Welding System on the Market The precision weld fabrication of delicate heat-sensitive assemblies is now a prac- tical reality. Finally there is an alternative to complicated and costly beam welding systems. Very low-heat, high-speed welds can now be made in materials as thin as .001" and as thick as .125" with the Weldlogic PA-IO/IOO-STD. Thousands of these productive systems are in daily use throughout the world. Contract welding services also available.

~ ' ~ ~i: ~

cuts with a bevel, miter cuts at any angle or ing branch pipes.

Watts Specialties 800 Fife Way Milton, WA 98354 (253) 922-1414 FAX: (253) 922-6808 Website: www.watts-specialties.com

Long Pipe Saddle Miter Machine

The Watts Specialties W- 132-LPSM Long Pipe Saddle Miter Machine is designed for rapid cutting of complex pipe contours. This versatile machine is capable of making straight saddle-miter cuts for attach-

Weldlogic Inc. 2550 Azurite Circle Newbury Park, CA 91320 (805) 498-4004 FAX: (805) 498-1761 E-Mail: [email protected]

MARKAL THERMOMELT® Heat Stiks ideal For Welders LA-CO Industries, Inc.'s new Markal Thermomelt(~ Heat Stik temperature indicator stick is now 33 percent larger, providing long-lasting, accurate surface temperature measurement (accurate to plus or minus one percent). A full range of Thermomelt Stiks are available in 88 exact temperature ratings, from IO0°F to 2200°F.

t.A-CO Industries, Inc./Markal Co. 1201 Pratt Boulevard Elk Grove Village, IL 60007 (847) 956-3867 FAX: (847) 956-9885 Website: www.laco.com

BCLOSlVBY FOR R! INDEPENDENT WELDING SHOP!

AWS Affiliate Company Members receive: AWS Individual 3.lcmbcrship • Group of AWS Pocket Handbooks

107

LASSIFIED$

BUSINESS FOR SALE

Welding Instructor Northland Community and

Technical College in Thief River Falls, Minnesota, is currently accepting applications for a full-time Welding Instructor.

Application Procedure: A letter of application, resume, copy of college transcripts, and

names of three professional references are to be forwarded to Northland Community and

Technical College, Becky Holthusen, Director of Human Resources, 1101 Highway One

East, Thief River Falls, MN 56701. The position is open until filled;

however, screening of applications will begin June 17, 2002. Additional information is

available on the Web site at www.northland.cc.mn.us.

Equal Opportunity Employer and Educator.

AWS CWI & NDT LAWCRANOALL

a division of Law Engineering and Environmental Services, Inc.

The San Diego office of a leading national engineering firm has an immediate need for AWS Certified Welding Inspectors with NDT Level II to join us in California performing owner QA on the State Bridge Retrofit program. This is aprevailing wage project. The ideal candidate will have current AWS CWl, UT Shearwave/Flaw Detection experience and RT Film Interpretation experience in accordance with AWS D1.5. Travel required. Send resume to

L A W C R A N D A L L

Attn: L. Tackett 9177 SkyPark Ct., Ste. A

San Diego, CA 92123 Fax: (858) 268-1352

E-maih [email protected] (M/F/D/V, EOE)

I t lAVE 30 YEARN I':Xi'I';RI I:N( "1' AS A NATIONWIDE WELDING ENGINEERING SPECIALIST

Numerous client companies have engaged me to recruit welding pros at various levels of expe~ience.

If your experuse is Welding Engineering:

Call 732-390-4600 • Fax 732-390-9769 e-mail [email protected] or Mail Resume to

Bill Elias, Dept WE PO Box 396. E.Brunswick, NJ 08816

ELIAS ASSOCIATES "Annually A National Award Winning Search Firm"

WELDING ALLOYS SALES Our expansion program for 2002 requires additional salespeople. We require candidates that are totally familiar with maintenance

welding alloy consumables. Qualified persons should contact

our E-mail address at rep_opp @ vulcan-systems.com

Phone: (989) 739-8050 Fax: (989)739-8062

Manufacturers Reps WANTED

Calling on Welding &

Safety Distributors Territory -Tenn, GA., AL.,

So. Carolina, Florida (to Orlando).

Email: ojolano @ aol.com

Electrode & Wire Products

Factory Liquidation Sale Stick Electrode

E 6013 All Sizes $10 / 50 lb. Box

($.20 per lb.) Tel. 407-850-0000 Fax: 407-850-5585

B U S I N E S S FOR S A L E

Retiring: Est. 1983, make bench-top proprietary pulse arc and resistance welders for industry. International market, medical, jewelry, dental, ap- pliance, automotive, etc. Strong GP, 86% with 20% BTE, N.E. Local.

Business 4 Sale

PO Box 893 East Greenwich, RI 02818

We Buy & Sell Surplus

Welding Rod & Wire All types, sizes & Quantities

Carl us first!

800-523-2791 PA: 610-825-1250

FAX: 610-825-1 S53

ATTENTION! Welding Equipment Sales Personnel We pay you for finding us good used

welding systems, seamers, positioners, manipulators, turning rolls, etc.

We will buy your customers' trade-ins.

WELD PLUS, INC. 1-800-288-9414

We buy and sell WELDING RODS & WIRE

**ALl. TYPES ** ALL SIZES ** A[I. QUANTITIES

Excess Welding Alloys, Inc. A division of Weld Wire Company Inc.

800-523-1266 FAX 610-265-7806 www.weldwire.net

IEDt:| JUNE 2002

t =

USED, RECONDITIONED WELDING MACHINERY

Jetline "Jetstar" Dabber System for Jet Engine Rebuilding! 1998 Pandjiris 8-ft Cold Wire TIC Seamer "Like New." Two Koike-Aronson GE-500 Geared Elevation Positioners. Loads of positioners up to 75 tons. Pandjiris and Aronson manipulators on travel cars up to 15 x 22 ft. Turning rolls up to 200 tons. Longitudinal seam welders up to 18 ft. Planishers, Thermal PAK-45 plasmas, Arc Machines & Astro-Arc Orbital Welders.

WELDING-RELATED M A C H I N E R Y IS OUR ONLY BUSINESS TALK TO US - WE KNOW WELDING

Web site: weldplus.com E-Maih [email protected] WELD PLUS, INC. CINCINNATI, OHIO

800-288-9414 Jack, Pete, Paul, or Dennis. Fax: 513-467-3585

[ - Z - ~ P L A T E N S !

Re-Ground Tops I l FOB: Shipping Point • Call for Details ;, ! Weldsale Company (215) 739-7474 w! L ~-" ~ ~l~'wm..eld-.,-~le'm.-©©°mm.. -,--" - - ,J

EQUIPMENT RENTAL f

RED-D-ARC Welderentals

www.red-d-arc.com

All Types of Welding and Positioning Equipment for Rental and Lease

1-800-245-3660 Service Centers Across North America

Your N e w Best Friend...

|W "" .ID

The FREE t ~ Co~umer t~ Action Website - it's got thousands of links to companies. And government agencies - the names, numbers, advice, and connections you need to get your wrongs righted.

Log on to ~ . p u e b l o . g s a . g o v , and click on the FREE Consumer Action Website.

w w w . p u e b l o . g s a . g o v

A PUBLIC SERVICE OF THE U.S. GENERAL SERVICES A D M I N I S T R A T I O N

M i t r o w s k i Welding & Positioning Equipment (800) 21 8-9620 (71 3) 943-8032

1 315 College, South Houston, TX 77587 [email protected] www.mitrowskiwelding.com

S A L E S - R E N T A L - R E B U I L D Welding positioners, tank turning rolls,

manipulators, seamers, welding machines

INDEPENDENT INDUSTRIAL REPS W a n t e d

To demonstrate to existing customers maintenance welding alloys. • Consumable Market • Repeat Customers • Complements Industrial Rep's

present line(s) of products 1-800-642-9885

i•'̧ !•¸• CERTIFICATIONj T R A I N I N G

REAL EDUCATIONAL SERVICES, INC. Training

CWI PREPARATORY NEW! 2 WEEK COURSE!

Course Guarantee - Pass or Repeat FREE! Pascagoula, MS Aug 12-23, Oct 7-18

Houston, TX July8-19 Houma, LA Sept 9-20

CWl PREPARATORY Pascagoula, MS Aug 19-23, Oct 14-18

Houston, TX July 15-19 Houma, LA Sept 16-20

Test follows on Saturday at same facility RT FILM INTERPRETATION Pascagoula, MS July 29-31

Houma, LA Oct 2-4

ASME WELDING PROCEDURES Learn How to Write & Review Procedures

Pascagoula, MS Aug 1-2 ASME OUALITY CONTROL

Pascagoula, MS July 22-26, Sept 23-27 For our entire class schedule, call

1-800-489-2890 GET REAL TRAINING!

www. rea leducationa I. corn

A T T E N T I O N Weldin~

Engineenng Professional

Engineers (PE) If you possess a current PE license in welding engineering, you may be eligible to receive the IIW International Welding Engineer diploma. For more information, contact Jeff Hufsey at [email protected]

WELDING JOURNAL m[0;t]

• AIG Auto Insurance (800) 290-05 ! 9

• Airborne Express (800) 636-2377 (Group # N2*Y246)

• MBNA Credit Card New Appficants (800) 847-7378

• United Group Programs (888) 5-WELDER

• Car Rentals 1.Alame

(800) 354-2322 (Code 208827BY) 2. Hertz

(800) 654-2200 (Code 75461) 3. Budget

(800) 52%0700 (Code T400200) & National

(800) 328-7949 (Code 5650822)

• Long-Term Preferred Care (800) 742-1110 AmemanWehflng Somty

MT IN MJlt @ www.aws.org/gear More than 60 products to &oose from/

4DVERTISIN( ~ : INDEX

Paper ...................................................... www.abpaperocom .......................... 29, 102

Al l Fab Corp ................................................. www.all fabcorp.com ...................... 63, 102

Amer ican Torch T i p Co ............................... www.americantorcht ip.com .................. 19

A rc Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ~ . a r c m a c b i n e s . c o m .................. 58, 102

Atlas Welding Accessories lnc ................... v~w.at lasweld.com ....................... .33, 102

Aura l l s.r.I .................................................... www.aural l . i t .................................. 98, ]02

AWS Cer t i f icat ion Dept ............................. WWWoaWS.Org ................................ 95, 97, 99

AWS Educat ion Services ............................ www.aws.org ............................................ 23

AWS Foundat ion Dept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.aws.org ...................................... 34, 35

AWS Membersh ip Services . . . . . . . . . . . . . . . . . . . . . . . . www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 49, 91

AWS Technical Services .............................. www.aws.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 59,

Bereich Robot .............................................. www.smt-systeme.de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Bernard Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.bernard-welding.com ........ IFC, I02

C. H. Symington .......................................... www.chsymington.eom .................. 43, 102

Canadian Welding Bureau . . . . . . . . . . . . . . . . . . . . . . . . . . ~ . c w b g r o u p . c o m ........................ 63, 103

Cleveland Mo t ion Contro ls . . . . . . . . . . . . . . . . . . . . . . . . w~.cmccon t ro l s . com .................... 15, I 02

C M L USA .................................................... www.ercoliua-nsa.com .................. 65, |03

C o r - M e t ........................................................ ~ . c o r - m e t . c o m .................. 27, 100, 103

C-Spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.weldoffice.com ...................... 63, 103

D.L. Ricci ...................................................... www.dlricci.com .............................. 65, I03

D e - S t a - C o ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . d e s t a c o . c o m .... . . . . . . . . . . . . . . . . . . . . . . . . 65 , 103

D i a m o n d G r o u n d P r o d u c t s .. . . . . . . . . . . . . . . . . . . . . . . w w w . d i a m o n d g r o u n d . c o m ..... . . . . . . . 95 , 103

D y n a b r a d e , I n c ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . d y n a b r a d e . c o m .... . . . . . . . . . . . . . . . . . . 68 , 104

E a g l e B e n d i n g M a c h i n e s , l n c . . . . . . . . . . . . . . . . . . . . . w w w . e a g l e b e n d i n g m a c h i n e s . c o m . . 4 8 , 104

E d i s o n W e l d i n g I n s t i t u t e ... . . . . . . . . . . . . . . . . . . . . . . . . . w w w . e w i . o r g ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 , 104

E S A B W e l d i n g & C u t t i n g ... . . . . . . . . . . . . . . . . . . . . . . . . . w w w . e s a b . c o m ... . . . . . . . . . . . . . . . . . . . . . . . . . O B C , 104

F i s c h e r E n g i n e e r i n g ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . f i s c h e r c n g r . c o m ... . . . . . . . . . . . . . . . . . . . 29 , 104

F i s c h e r T e c h n o l o g y , l n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . F i s c h e r - T e c h n o l o g y . c o m ........ 58 , 103

G e n s t a r T e c h n o l o g i e s C o , I n c .. . . . . . . . . . . . . . . . . . . . w w w . g e n s t a r t e c h . c o m .................... 13, 104

H & M P i p e B e v e l i n g M a c h i n e , I n c . . . . . . . . . . . w w w . h m p i p e . c o m .... . . . . . . . . . . . . . . . . . . . . . . . . 98 , 104

l i l i D I JUNE 2002

H o b a r t I n s t i t u t e .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d i n g . o r g ... . . . . . . . . . . . . . . . . . . . 20 , 21 , 104

J P. N i s s e n , J r . C o .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . n i s s e u m a r k e r s . c o m .... . . . . . . . . . . 68 , 105

J . W. H a r r i s .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . j w h a r r i s . c o m .... . . . . . . . . . . . . . . . . . . . . . . . . 1, 105

K . I . W . O . T . O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . r o d g u a r d . c o m ..... . . . . . . . . . . . . . . . . . . . 66 , 105

K o i k e A r o n s o n , I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . k o i k e . c o m ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

L A - C O I n d u s t r i e s I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . l a c o . c o m ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 107

L i b u r d i D i m e t r i c s .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . d i m e t r i c s . c o m ..... . . . . . . . . . . . . . . . . . . . 22 , 105

L i n c o l n E l e c t r i c C o m p a n y .... . . . . . . . . . . . . . . . . . . . . . . w w w . l i n c o l n e l e c t r i c . c o m .... . . . . . . . . . . . . . . . . . . 105

M a g n a t e c h .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . m a g n a t e c h - l p . c o m ..... . . . . . . . . . . . 26 , 105

M i l l e r E l e c t r i c .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . m i l l e r w e i d s . c o m .... . . . . . . . . . . 24 , 25, 105

N a t i o n a l S t a n d a r d .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . n a t i o n a i s t a n d a r d . c o m ..... . . . . . . . 7, 105

P f e r d , I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . p f e r d . c o m .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

P h o e n i x I n t e r n a t i o n a l .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . p h x - i n t e r n a t i o n a l . c o m .... . . . . . . . . . . . . 106

P r o c e q U S A .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . p r o c e q . c o m ... . . . . . . . . . . . . . . . . . . . . . . . . . 28 , 106

S e l e c t - A r c , l n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . s e l e c t - a r c . c o m .... . . . . . . . . . . . . . . . . I B C , 106

S m i t h E q u i p m e n t .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . s m i t h e q u i p m e n t . c o m ............ 59 , 106

S t r e s s R e l i e f E n g i n e e r i n g C o m p a n y .......... e m a i h f o r m u l a 6 2 @ a o l . c o m ........ 100, 106

T h e r m a l D y n a m i c s ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . t h e r m a l - d y n a m i c s . c o m ..... . . . . . 9 , 106

T r i a n g l e E n g i n e e r i n g ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . t r i e n g . c o m ..... . . . . . . . . . . . . . . . . . . . . . . . . . 6 7 107

"l~'i Too l I n c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . t r i t o o l . c o m ..... . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 107

Tweco S p r a y m a s t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . t w e c o . c o m ..... . . . . . . . . . . . . . . . . . . . . . . . . . 11 106

V i c t o r E q u i p m e n t .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . v i c t o r e q u i p . c o m .................... 12 106

W a l l C o l m o n o y .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w a l l c o l m o n o y . c o m .................. 61 107

W a t t s S p e c i a l t i e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w a t t s - s p e c i a l t i e s . c o m ... . . . . . . . . . 65 107

W e l d H u g g e r , L . L . C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d h u g g e r . c o m ..... . . . . . . . . . . . . . . .39 107

W e l d L o g i c P r o d u c t s .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w w w . w e l d l o g i c . c o m ... . . . . . . . . . . . . . . . . . . . . . 99 107

I F C = I n s i d e F r o n t C o v e r

I B C = I n s i d e B a c k C o v e r

O B C = O u t s i d e B a c k C o v e r

<• SUPPLEMENT TO THE WELDING JOURNAL, JUNE 2002 (W R (~ Sponsored by the American Welding Society and the Welding Research Council

The Stress Field Characteristics in the Surface Mount Solder Joints under

Temperature Cycling: Temperature Effect and Its Evaluation

Dynamic stress distribution was analyzed with regard to the temperature cycling history of the solder joint

BY Y. Y. QIAN, X. MA, AND F. YOSHIDA

ABSTRACT. Finite element analysis is one of the few methods for obtaining stress field information on surface mount solder joints under temperature cycling because of the difficulty with the experimental method. In this study, the effect of temperature history was considered in order to avoid unilateral analysis, which takes only one time into account. Analy- sis results show temperature cycling leads to stress cycling and a thermal ratchetting effect, e.g., the accumulation of inelastic strain. Furthermore, stress field distribution in the solder joints had a dynamic feature during temperature cycling and was related to temperature history, such as the value and the site of maximum equivalent stress. Relative damage stress is put forward as the dominant mechanical factor because of void damage failure in solder joints and their history of de- pendence on stress field distribution under temperature cycling. Analysis results indicate the most dangerous condition for failure is in the high temperature hold time during temperature cycling, which correlates to already known experimental data.

Introduction

The finite element method (FEM) has

Y. Y. QIAN attd X. MA are with the National Key Laboratory of Welding, Harbin Institute of Technology, Harbin, P.R.C. E YOSHIDA is with the Department of Mechanical System En- gineering, Hiroshima University, Higashi-Hi- roshima, Japan.

been widely used for studying the stress- strain response of solder joints under temperature cycling (Ref. 1). The applications of FEM results are 1) the induc- ing of cyclic inelastic strain range into the Manson-Coffin equation to predict thermal fatigue life (Refs. 2, 3); 2) predicting crack initiation sites according to the site of maximum equivalent stress or strain (Refs. 4, 5); and 3) design optimization of solder joints based on the comparison of equivalent stress distribution (Refs. 6, 7).

In application 1 above, the major focus is on the constitutive relationship of the solder alloy in order to model its nonlinear mechanical response more accurately. This study is not concerned with this. In above applications 2 and 3, the major focus is how to determine the most critical stress distribution. In the literature, conclusions were usually based on the equivalent stress distribution in the solder joint at a single time. This presents two problems: 1) the only external load is from temperature cycling, which means

KEY WORDS

Stress Field Damage Stress Solder Joint Temperature History Temperature Cycling

the stress distribution should be dynami- cally changing at different times during the whole temperature history. Further- more, the mechanical properties of the solder changed with temperature . Al- though there is a time for the stress distribution's maximum abstract value, the solder alloy may have had its best properties at that same time. 2) Interface void damage is the main failure mechanism of the solder joint (Refs. 8-10), and such phenomenon is dependent on stress triaxiality, not equivalent stress (Refs. 11-13). Therefore, considering only equivalent stress is not suitable. In this study, we first analyzed the dynamic stress distribution in the solder joint from its temperature history. Then, a new mechanical concept was proposed in which temperature history was taken into account and used to explain the experimental data.

Finite Element Modeling

A simulated surface mount assembly used for the accelerating thermal fatigue life test is shown in Fig. 1. A ceramic board (Ni-plated) was soldered with a FR-4 board (Cu pad on it) using Sn60- Pb40 solder alloy. The joining area of every solder joint was 1 x 2 ram, and the thickness of the joint was 0.2 mm. Com- mercial nonlinear finite element program MARC 7.0® and prepost processing program MENTAT 3.1® were used for numerical simulation and the work was carried out in a Sun-Ultral 1® workstation. Figure 2 is the corresponding two-dimen-

WELDING JOURNAL l:g"ll~l

WELDING RESEARCH

10 ~ Ceramic (AI2Os) , f J I I

~'~ FR-4 board Sn60-Pb40 solder

Fig. 1 - - Schematic of simulated surface mount assembly (mm).

~ 1 [ I I I I I I I I I I ~ + ~ 1 1 1 1 1 I I I I I I ~

Fig. 2 - - Two-dimensional finite element model of simulated surface mount assembly shown in Fig. 1.

~ - - ~ - ~ Ccr~nic Board

/ I

\

j ~ FR~

$ i Sn60-Pb40 solder alloy

Board

Fig. 3 - - Enlarged model of the solder joint part in Fig. 2.

300 t------/-- / I /

L/ 2 0 0 I- 218K

| ' dO = i 0 120

Time (min)

, i

1 8 0

Fig. 4 - - Profile of temperature cycling load (15 min dwell time, 15 min ramp time).

Table 1 - - M a t e r i a l P a r a m e t e r s Used in F E M Calcu la t i on

Temperature E (MPa) Poisson Ratio (K)

131000 0.3 Ceramic 293 (A1203) 316

349 411 473

CrE a (10-6/K)

5.4 6.6 7.4 8.5 9.2

Yield Stress (MPa)

FR-4

Sn60Pb40 Solderalloy

22000 0.28 18.0 218 47966 0.3516 24.1 43.2 238 46892 0.3540 24.6 37.51 258 45779 0.3565 25.0 32.05 278 44377 0.3600 25.2 29.86 295 43251 0.3628 25.4 29.1 323 41334 0.3650 26.1 22.96 348 39445 0.3700 26.7 17.4 373 36854 0.3774 27.3 12.31 398 34568 0.3839 27.9 9.35

sional finite e lement model and Fig. 3 is the enlarged model of the solder jo in t part. The mesh is m a d e of four -node plane stress elements with a total of 364 elements and 418 nodes.

In this study, the ceramic and resin boards were assumed to be linearly elastic. The solder alloy was elastic-viscoplas- tic with c reep and plastic de fo rmat ion

considered together. Its stress-strain relation is given by

• :.:e..14.1:pl.t.i~cr g i j = . q -~q -~q (1)

where the total strain rate tensor ~j is the sum of the elastic strain rate tensor &t] ~, the plastic strain rate tensor [P~, and the creep

strain rate tensor ~r . The definition of elastic and plastic strain rate is the same as usually used in nonlinear F E M calculation. The creep strain rate is defined as (Ref. 14)

~cr = BID(_~)3 +B D[°e ~7 ' [ 7 ) (2)

where E is elastic module, B l = 1.7 x 10 ~2, B 2 = 8.9 x 1024, D = exp(-5413/T), and o e is Mises equivalent stress, which can be defined as

a,, = ~ SqS o

with the devitoric stress tensor

(3)

1 s, j - o , j - 7 a , j o * * (4)

where o e is the stress tensor and 6ij is the Kronecker delta. Equa t ion 2 was combined with the M A R C program by using a user self-defined subroutine. The material propert ies used in F E M calculation were obtained from Ref. 15 and listed in Table 1. The load profile from temperature cycling is shown in Fig. 4.

l'[,"~.'! JUNE 2002

A 50,

40 I i

I

t~ 301 n ~s

=o- 2o l

t3

l o l

ol

first cycle

I L 0 30

~ le I i I i I

60 90 120 150 180

T i m e ( m i n )

B 0.30

0.25 i-

t-- 0.20 F

"~ 0.15 F

U

0.10 I.-

_c o.os ~-

0.00 I-

L-_. i /--

I / I i I i I 0 30 60 90 120 150 180

Time (rain)

Fig. 5 - - Mechanical response history in the solder joint under temperature cycling. A - - Mises equivalent stress; B - - inelastic strain.

Simulation Results and Discussions

Since the greatest local mismatch of coefficients of thermal expansion is between the ceramic board and Sn60-Pb40 solder, the stress-strain response is obtained from the node, which is at the inner corner of the solder joint and near the ceramic/solder interface. The location is just like point A shown in Fig. 3. Figure 5 shows the equivalent stress and inelastic strain history under temperature cycling. Figure 6 is the shear stress-strain curve for five cycles. The basic feature of the stress-strain field is temperature cycling, which led to stress cycling, and this led to ratchetting behavior, e.g., the accumulation of inelastic strain. Furthermore, Fig. 5 shows the equivalent stress kept invariant during the low-temperature hold time, but relaxation occurred during high-temperature hold time. Corresponding to the times of A, B, and C during one temperature cycle in Fig. 4, the equivalent stress and shear stress distribu- tions in the solder joint are shown in Figs. 7 and 8, which analyze the stress field under temperature cycling. The whole geometry of the stress contour shown in Figs. 7 and 8 is the same as the solder region shown in Fig. 3; therefore, its real dimension is 1 x 0.2 ram.

In Figs. 7 and 8, the stress distribution in the solder joint during the entire temperature cycle was temperature/time dependent for both the maximum stress level and the tensile or compression stress. This indicated the stress distribution in the solder joint was related to the temperature history. Although the maximum stress value occurred at the low-temperature stage, it should be noted the mechanical property of the solder alloy was also temperature dependent. Therefore, the temperature effect should be taken into account instead of the stress value alone.

Relative Damage Stress and Failure of the Solder Joint

Failure mechanism of the solder joint is interface void damage (Refs. 8-10), and such phenomenon is dependent on stress triaxiality, not equivalent stress (Refs. 11-13). The concept of equivalent damage stress was developed by Lemait re through thermody- namics and mesome- chanics analysis in order to evaluate the damage process (Ref. 16)

15 10 ~N~NN~~ firM/de -5

~ -10

- , S_o o~ .o'o, -o 'o 2 o'oo Shear strain

0.02

Fig. 6 - - Shear stress-strain response in the solder joint showing ratchetting behavior.

1/2 oD = a~oR~ (5)

temperature. The new concept of relative damage stress o* is defined as

° * =crD / ~ Y ( T ) (7)

where oo is the equivalent damage stress, Oe~ is the Mises equivalent stress, R v is a

H . . . . function of stress trmxlahty as

2

~ . ~ O,,q ) (6)

where v is the Poisson's ratio and o H is the hydrostatic stress. The physics meaning of the above equation is well known: plasticity is mainly due to slips, which do not depend upon the hydrostatic stress. Cavita- tion damage is influenced by the hydrostatic stress or triaxiality ratio and also by Poisson's ratio, which governs the elastic volume change (Refs. 11-13, 16, 17). In order to reflect the temperature effect, Equation 5 is normalized by the material yield stress, which is the function of

It must be noted such a concept is a dominant mechanical factor that reflects the interface failure feature and ductile damage mechanism of the solder joint, not the failure criterion. That is to say, it is difficult to determine the occurrence of cavitation by defining a critical value of relative damage stress, but we can evaluate the possibility of cavitation initiation at a different temperature stage. Figure 9 is the relative damage stress response at the ceramic/solder alloy interface of the solder joint during the fifth temperature cycle. It was concluded that it is easiest for void damage to occur at the high-temperature hold time during temperature cycling.

Figures 10 and 11 show the experimental data for the thermal fatigue life of solder joints from Ref. 18. In Fig. 10, tern-

WELDING JOURNAL |'4rJB,..1

W E L D I N G + R E S B A R C H i i

A

B

~=__.Z_~ -~ _

A

B

c c

Fig. 7 - - Mises equivalent stress distribution in the solder joint at different stages during a temperature cycle (MPa): (A) at the beginning of temperature-up stage, (B) at the beginning of high-temperature hold time, and (C) at the end of high-temperature hold time.

Fig. 8 - - Shear stress distribution in the solder joint at different stages during a temperature cycle (MPa ): (A) at the beginning of temperature-up stage, (B) at the beginning of high-temperature hold time, and (C) at the end of high-temperature hoM time.

high temp. [-"'--o" . ]

,' ", __tow_temp-

240 250 260 270 280 290 300

Time, min

Fig. 9 - - Relative damage stress response at the ceramic~solder alloy interface of the solder joint during the fifth temperature cycle.

perature cycling profiles A and B have the same high-temperature hold time but different low-temperature hold times. In this case, the thermal fatigue life of the solder joints was the same. In Fig. 11, profiles A and B have the same low-temperature hold time but different high-temperature hold times. In this case, the thermal fatigue life of the solder joints was different. This indicated that during temperature cycling, the high-temperature hold time has a significant effect on the reliability of

the solder joints. Such phenomenon cannot be explained by a traditional mechanical concept, such as equivalent stress or strain, because their value or accumulation is very low in the high-temperature hold time (Refs. 15, 19). Some scholars had proposed dwell time was not important for the solder joint's reliability and had little meaning in the design of an accelerated thermal fatigue test (Ref. 19). But such a conclusion, based on

traditional mechanical concepts, is not in agreement with the above experimental results. On the other hand, the concept of relative damage stress provides a good explanation because it has maximum value during high-temperature hold time of temperature cycling.

Summary

Finite element numerical simulation

results showed stress distribution in the solder joint was dependent on temperature cycling history. Furthermore, considering the mechanical property of the solder alloy was also temperature dependent, a new concept of "relative damage stress" was put forward. It included stress triaxiality, which promotes void damage; Mises equivalent stress, which determines plasticity; and the material yield stress, which is a function of temperature. Such a concept attempts to reflect the failure mechanism of the solder joint under temperature cycling load and is useful for evaluation of stress status in the solder joint during temperature cycling.

Acknowledgment

The Association of International Ed- ucation and Ministry of Educat ion of Japan is acknowledged for its scholarship support so that X. Ma could do this work at Hiroshima University.

References

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2. Akay, H. U. 1997. Fatigue life prediction

I:!:~[,,1 JUNE 2002

400

380

360 -'1

E i~. 320

30o

~ ProEle A: 25/125°C, 24cycles/day cycles to failure: 338

i i 2o ,~ ~ .o 1oo

Time, min

400

38O

360

E R=°/ 32o

3O0

ProEle B: 25/125°C, 15cycles/day cycles to failure: 338

/ Time, min

Fig. 10 - - Effect of low-temperature hold time on the thermal.fatigue life of the solder joint (Ref 18).

340

33O

32o 3 ~ . 310

E 4) I-- 300

~ Profile A: 25/B5°C, 60¢yderdday cycles to failure: 2512

=

Time, min

340

33O

32O

~z. 310 E 4) I-- 3o0

29O 0

./ Profile B: 25/65°C, 60¢ycles/day ]

cycles to failure: 2155 ]

; 1'0 15 20 25

Time, min

Fig. 11 - - Effect of high-temperature hold time on the thermal fatigue life of the solder joint ( Ref 18).

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15. Hong, B. Z.; and Burrel, L G. 1997. Modeling thermally induced viscoplastie de- formation and low cycle fatigue of CBGA solder joints in a surface mount package. IEEE Trans. CPMT Part A 20(3): 280-285

16. Lemaitre, J. 1996.A Course on Damage Mechanics. p. 45. New York, N.Y: Spring- Verleg.

17. Ashby, M. F., Blunt, E J., and Bannis- ter, M. 1989. Flow characteristics of highly constrained metal wires. Acta Metall. 37(7): 1847-1857.

18. Pan, T. Y. 1994. Critical accumulated strain energy (case) failure criterion for thermal cycling fatigue of solder joints. ASME Journal of Electronic Packaging 116(3): 163-170.

19. Yu, Q., and Shiratori, M. 1997. Fatigue- strength prediction of microelectronics solder joints under thermal cyclic loading. IEEE Trans. CPMT Part A 20(3): 266-273.

WELDING JOURNAL I:~X'-"]

WELDIN ESEARCH

A Study of Weld Pore Sensitivity of Self-Shielded, Flux Cored Electrodes

An investigation revealed both nitrogen and oxygen content can affect the formation of porosity in welds made using FCA W-S electrodes

BY Q. WEI, Q. HU, F. GUO, and D. J. XIONG

ABSTRACT. Porosity in weld metal refers to the cavity-type discontinuities formed by gas entrapment during solidification. It is one of the most common defects of the self-shielded, flux cored arc welding (FCAW-S) process. In the present study, the causes and influence factors of pore formation in welds made by a self-shielded, flux cored electrode were investigated. The results of this study revealed nitrogen content is not the only main influence factor in the formation of porosity in welds made by an FCAW-S electrode; oxygen can also rapidly increase the number of pores in such welds. It was found aluminum and rare earths (RE) effectively reduce the pore sensitivity of welds. Of the two materials, aluminum has a stronger ability of reducing nitrogen than RE. Both aluminum and RE significantly reduce oxygen content in the weld.

Introduction

Self-shielded flux cored arc (FCAW-S) welding has become popular for many applications because it does not require equipment for gas shielding, re- suiting in simplicity of operation. Also, the electrode holder is simpler than the one used with auxiliary shielding gas. De- velopment of all varieties of the self- shielded, flux cored electrodes (FCAW-S electrodes) has been, as a result, an area of great manufacturing and research interest (Refs. 1-4).

Q. WEI, Q. HU, and D. J. XIONG are, respectively, Associate Professor, Doctoral Student, and Professor at Beijing Poly- technic University, School of Materials Science and Engineering, Beijing, P.R.C. E GUO (guofu@pilot .msu.edu) is a Doctoral Student at Michigan State Uni- versity, Department of Materials Science and Mechanics, East Lansing, Mich.

Porosity in weld metal is one of the most difficult problems to be solved when developing an FCAW-S electrode. Since there is neither an outside protective atmosphere nor welding flux provided in the welding area, liquid weld metal can be easily contaminated by air. Pore sensitivity of a weld thus increases and is difficult to control. In production practice, porosity frequently appears in welds made by a FCAW-S electrode, which seriously impairs the quality of weld metal and influences the overusage of FCAW-S electrodes (Refs. 5, 6). Much research has been done to investigate the causes and prevention of pore formation in the weld metal of FCAW-S electrodes. The effects of metallurgical reaction (Refs. 5-11), as well as welding parameters (Refs. 7, 12-15) on the formation of weld porosity, have been two major areas of research. Various models and mathematical/ther- modynamical evaluations of pore susceptibility were also presented in an effort to clarify the mechanism for pore formation (Refs. 8 ,11 , 16). Typically, nitrogen is re- garded as the determinative factor for formation of pores in welds made with FCAW-S electrodes (Refs. 5, 6, 8-11), but other research findings have concluded porosity was not well controlled by reducing nitrogen content only in the weld metal (Refs. 17, 18). Therefore, it is imperative the mechanisms and influence factors of porosity formation in a FCAW-S weld be thoroughly studied. The present study thus focuses on other factors influ-

KEY WORDS

Pore Sensitivity Self-Shielded, Flux

Cored Electrode FCAW-S Porosity

encing pore formation in the weld in addition to nitrogen content. The effects of simulative gaseous flow, oxygen content in the weld, as well as aluminum and RE alloy addition in the flux core, on pore sensitivity are presented.

Experimental Method

The FCAW-S electrodes used in the experiment were CaFa-A1-Mg type FCAW-S electrodes that meet AWS A5.20 E 70 T-G requirements. The electrodes consisted of a thin, low-carbon steel sheath surrounding a core of fluxing and alloying materials. The cross section of the electrode was 2.0 mm in diameter and O-shaped, as illustrated in Fig. 1.

In order to test pore sensitivity, the experiment conditions were varied as follows.

1) Added to shield the arc area was a simulative gaseous flow with different compositions (pure argon, pure oxygen, COa, air, and mixed gases with varying proportions of oxygen and argon, nitrogen and argon, oxygen and nitrogen), as shown in Table 1.

2) Two series of FCAW-S electrodes were designed by separately changing the amount of RE alloys and AI in the flux core. Changes in the added RE alloys are shown in Table 2.

Two kinds of steel sheaths (H08A and H05A1) with different AI contents were used. The composit ion of the steel sheaths is listed in Table 3. The varied percentages of added A1 powder in the flux core were 7, 9, 11, 13, and 15% when using the H08A steel sheath and 2, 4, 6, 8, 10, and 12% when using a H05AI steel sheath containing aluminum.

The weld metal specimens were prepared by welding two no-groove, low- carbon steel plates (150, 100, and 10 mm) with single-pass butt joint welding. Weld- ing parameters are listed in Table 4. The amount of surface and inner pores in a

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N2 N 2+0 2= 100% °2

Fig. 1 - - Illustration o f experimental setup. Fig. 2 - - Effect o f oxygen and nitrogen content on weld metal porosity.

T a b l e 1 - - T h e C o m p o s i t i o n o f S i m u l a t i v e G a s e o u s F l o w (%)

Gas Type Ar N2 O: COz Air Simulative Gas #

1 0 0 0 100 0 2 0 0 0 0 100 3 100 0 0 0 0 4 75 25 0 0 0 5 50 50 0 0 0 6 22 78 0 0 0 7 0 100 0 0 0 8 0 0 100 0 0 9 20 0 80 0 0 10 50 0 50 0 0 11 60 0 40 0 0 12 70 0 30 0 0 13 78 0 22 0 0 14 0 90 10 0 0 15 0 78 22 0 0 16 0 70 30 0 0 17 0 50 50 0 0 18 0 40 60 0 0 19 0 20 80 0 0

T a b l e 2 - - E f f e c t s o f R E o n O - C o n t e n t , N - C o n t e n t , a n d P o r o s i t y in W e l d M e t a l

Amount of RE Effective RE Alloy Addition Amount in the Content of Content of Number of

Type of Re in the Flux Flux Core* Oxygen Nitrogen Pores in Additivcs Core (%) (%) (%) (%) Weld Metal

Ca-Mg-Ba-RE Alloy

Ni-RE Alloy RE Metal Mixture

1 0.041 0.0157 0.032 15 3 0.123 0.0148 0.032 5 5 0.205 0.0126 0.033 5 7 0.287 0.0130 0.046 8 9 0.369 0.0125 0.039 6 3 1.050 0.0057 0.041 0 1 1.000 0.0035 0.044 0

*The pcrccntage of RE in Ca-Mg-Ba-RE alloy is 4.1%. Thus, the effective amount of RE added to the flux core of the wire are c c (1.041 q~, 0.123c/G 0.205~, 11.287 ~, and 0.369 5, corresponding to the percentage of Ca-Mg-Ba-RE alloy addition of 1%, 3%, 5%,

7'7f. and 9%.

100-mm length of cooled weld was visu- ally examined and X-ray inspected. The m i n i m u m size of counted pores was '/,, in. (0.4 m m ) according to AWS A5.20. The exper imenta l se tup and basic d imens ions of the base meta ls are also i l lustrated in Fig. 1.

Resu l ts and D i s c u s s i o n

Effect of Different Shielding Gases on Weld Porosity

Exper imenta l results show no pores in weld m e t a l we lded in a p u r e a r g o n or pure C O e a tmosphere . A small a m o u n t of pores was found in meta l welded in pure oxygen, pure ni t rogen, mixed gas of oxygen and argon, mixed gas of n i t rogen and argon, and air a tmospheres . These results indicate the flux in the core of the exper- imenta l FCAW-S e lec t rode can provide a gas and slag shield for hot metal tha t will p reven t a different arc a tmosphe re f rom c o n t a m i n a t i o n and s o m e w h a t r e d u c e weld pore sensitivity, as previously men- t i o n e d (Refs. 17, 18). T h e a m o u n t of pores increases rapidly unde r a mixed gas of oxygen and n i t rogen and reaches an ex- t r eme value with a con ten t of 80% oxygen - 20% ni t rogen, as shown in Fig. 2. To be more specific, the n u m b e r of pores increases with an increase in oxygen content up to 80% and n i t rogen con ten t up to 20%. The actual welding a tmosphe re of the FCAW-S e l e c t r o d e is air. T h e mixed p ropor t ion of oxygen and n i t rogen in the air falls in the left side of the ex- t r e m e value , w h e r e weld poros i ty increases with the increase of oxygen con- t en t in the arc area . In o t h e r words , oxygen enhances the possibility of pores be ing produced in the weld meta l of an FCAW-S electrode. Therefore , it is impor t an t to prevent n i t rogen f rom coming

WELDING JOURNAL [4liE,.1

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into the arc area and to reduce the oxygen content in weld metal to obtain an acceptable porosity level in welds made using an FCAW-S electrode.

Some weld pores of FCAW-S electrodes were observed to be similar to very small pinholes of nitrogen, while others were similar in appearance to wormholes of CO (Ref. 19, 20). Some pores with a different morphology, such as round pores, were also noted in the weld metal. So, it can be inferred the weld pores of the FCAW-S electrode are not simply N 2 or CO pores but a mixture of both N 2 and CO pores, and even more complicated combination pores of CO and N 2 according to pore morphology and weld metal oxygen and nitrogen content.

Effect of Deposited Oxygen and Nitrogen Content on Weld Metal Porosity

As stated previously, oxygen and nitrogen content in weld metal affect the formation of weld pores. In order to determine the relationship between pore sensitivity and oxygen and nitrogen content in weld metal, a large number of data points with specific oxygen and nitrogen contents were collected and plotted in Fig. 3. The figure illustrates pore occurrence at certain oxygen and nitrogen levels and shows pores were formed only when the oxygen and nitrogen content in the weld metal were above the diagonal line. No porosity was evident in weld metal with oxygen and nitrogen content below the diagonal line. Therefore, the higher the oxygen and nitrogen content in the weld metal, the greater the pore sensitivity. In addition, an analysis of the experimental results from Fig. 3 found the average nitrogen content of weld metal produced with FCAW-S electrodes in the no-porosity condition can reach 400-500 ppm, a much higher level than that of

T a b l e 3 - - T h e C o m p o s i t i o n o f S t e e l S h e a t h e s

Type of C Si Mn S P AI Steel Sheath

H08A 0.06 0.029 0.26 0.009 0.015 0.035 H05AI 0.05 0.062 0.54 0.013 0.016 0.7

T a b l e 4 - - W e l d i n g P a r a m e t e r s

Current Voltage Travel Speed Polarity (A) (V) (mm/s)

240-260 25-28 10-15 DCEP

weld metal produced with SMAW electrodes. However, the average oxygen content of weld metal produced with FCAW-S electrodes can reach as low as 16 ppm under the same condition, which is much lower than that of weld metal produced with SMAW electrodes. As a comparison, in the no-porosity condition, the nitrogen content is -150 ppm in deposited weld metal produced with a titania-type SMAW electrode and is - 100 ppm in deposited weld metal produced with a low hydrogen-type SMAW electrode. The oxygen content in deposited weld metal of the titania-type SMAW electrode was -650 ppm, and -200-300 ppm in deposited weld metal produced with a low hydrogen-type SMAW electrode (Ref. 19). Therefore, it is evident the weld metal produced with an FCAW-S electrode is significantly affected by nitrogen in the air, which causes a dramatic increase in nitrogen content. The high nitrogen content in weld metal produced with an FCAW-S electrode is difficult to control to a lower extent (Refs. 17, 18). Consequently, to prevent the formation of pores in weld

metal produced with an FCAW-S electrode, the oxygen content should be much less than that of weld metal produced with an SMAW electrode to compensate for the high nitrogen content. An example that is less than 100 ppm is shown in Fig. 3. This conclusion provided more experimental evidence that oxygen can enhance the possibility of pore formation.

A possible mechanism of nitrogen and oxygen deposition in weld metal can be explained by

1 N 2 .4- 1 0 2 = N O 2 2

using the interaction between nitrogen and oxygen in the welding atmosphere.

The product of the reaction, NO, can be adsorbed on the surface of liquid weld metal, then decomposed into N and O under the action of its surface tension (Ref. 19). Meanwhile, the N and O atoms dissolve in liquid weld metal. Therefore, the formation of NO in the arc atmosphere ultimately increases both oxygen and nitrogen content in weld metal.

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Fig. 5 - - Effect o f ahtminum addition in the flux core on the formation of pores h7 weM metal with different metal sheaths.

Effect of Aluminum on Weld Metal Porosity

Aluminum is an effective element to reduce porosity in weld metal (Ref. 19). The changes of oxygen and nitrogen content in weld metal with the percentage change of aluminum powder in the flux core of the electrode are shown in Fig. 4. The decrease in both the oxygen and nitrogen content is obvious when aluminum powder in the flux core is increased, which proves aluminum has a powerful capability of deoxidizing and reducing nitrogen content.

However, only limited amounts of aluminum powder can be added to the flux core of the electrode because of its low density. Excessive additions of aluminum powder in the flux core will cause fabrication difficulties and lead to bad processing properties of the electrode. In order to reduce the aluminum powder in the flux core and to simultaneously make the weld metal porefree, a new type of metal sheath containing aluminum (H05AI) was used instead of the ordinary metal sheath (H08A). This new type of metal sheath (H05AI) overcame the problems related to the presence of large amounts of aluminum powder in the flux core. The change in the amount of pores in weld metal with the amount of aluminum powder in the flux core is illustrated in Fig. 5 for both H08A and H05A1 metal sheaths. It shows the amount of pores was reduced with the increase of the percentage of aluminum powder in the flux core of the electrode for both metal sheaths. It was also found the amount of weld pores was reduced to zero only if the percentage of aluminum powder in the flux core reached 13% with H08A metal sheath. The content of residual aluminum in weld metal is 1.22 wt % in this condition. In

contrast, when the electrode was fabricated with H05A1 metal sheath, no pores appeared when the percentage of aluminum powder in the flux core reached 8%. In this case, the residual aluminum content in weld metal was only 0.84 wt %. The above comparison shows the electrode made with a metal sheath containing aluminum can increase the protective effect, and thereby decrease the pore sensitivity. The substitution of an

H08A metal sheath with an H05A1 metal sheath effectively reduces the residual aluminum content in weld metal and, consequently, improves its toughness. In addition, the fabrication process of the electrode becomes more convenient due to the reduced amount of aluminum powder in the flux core.

The experimental results and analyses discussed above suggest the mechanism for aluminum to reduce pore sensitivity can be based on the following:

1) Aluminum is a better deoxidant than titanium, carbon, magnesium, or zirconium (Ref. 20). Aluminum can reduce oxygen potential in the welding atmosphere. The reaction formulas of deoxi- dization are the following:

2 A l + 3 C 0 2 = 3 C 0 + A I 2 0 3 4A1+302 = 2AI203

2) Aluminum can reduce the nitrogen concentration in weld metal by reducing O potential and the NO partial pressure in the welding atmosphere.

3) Aluminum and nitrogen have a great affinity for reacting with each other to form a stable aluminum nitride, which does not dissolve in molten steel but instead in slag. Therefore, it can be seen the higher the aluminum content in the flux core, the less the oxygen and nitrogen content in the weld metal, resulting in a lesser number of weld pores that will occur in the weld metal.

Effect of RE Alloy Addition on Weld Metal Porosity

The effects of three kinds of RE additives on oxygen content, nitrogen content, and porosity in weld metal were investigated in this study.

Table 2 shows the oxygen content and the porosity level decrease with the increase of Ca-Mg-Ba-RE alloy addition in the flux core. Note the nitrogen content was not affected by the change of alloy addition. Table 2 also indicates porosity was not completely eliminated and the oxygen content in weld metal was still high even with a 9% addition of the Ca-Mg-Ba-RE alloy in the flux core. Incomplete deoxi- dization due to the low content of RE in Ca-Mg-Ba-RE alloy (only 4.1%) may account for the high residual oxygen content in the weld metal. RE metal mixture was shown to have a strong ability to deoxidize. A small amount of RE metal mixture added in the flux core (only 1%) could significantly reduce the oxygen content and the pore sensitivity in the weld metal. However, because the RE metal mixture can be oxidized at room temperature and is extremely difficult to crush into powder form, it cannot be applied in industrial practice. Compared with the two types of RE additives mentioned earlier, Ni-RE alloy was also shown to have a strong ability to deoxidize and reduce pore sensitivity. The main advantage of this alloy is it can easily be added in the flux core of the electrode during fabrication. Therefore, Ni-RE alloy is suggested as the best RE additive among the three. RE elements reduce pore sensitivity by reducing oxygen content in weld metal due to their strong affinity with oxygen. The reaction product will eventually enter into slag in the form of RE oxide (RE203). As a result, oxygen content and CO pore sensitivity decrease dramatically with an increase in RE content in the flux core. The results in Table 2 also show there is no meaningful change in nitrogen content with the change of RE alloy addition in the flux core, which indicates the capability of RE additives to reduce nitrogen content in weld metal is weaker than aluminum.

C o n c l u s i o n s

1) Weld porosity of FCAW-S electrode is related to both oxygen and nitrogen content in weld metal. Oxygen can enhance the possibility of pore production in weld metal. Reducing oxygen and nitrogen potential in the welding atmosphere, as well as the oxygen and nitrogen content in weld metal, is the main measure of pore sensitivity reduction.

2) Aluminum and RE can effectively reduce pore sensitivity of the weld because both aluminum and RE have a strong ability to reduce oxygen content in weld metal. In this investigation, aluminum had a strong ability to reduce nitrogen content in weld metal and RE alloys had no meaningful affect on nitrogen content reduction in weld metal.

WELDING JOURNAL I[zI*~,."l

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Acknowledgment

The au thors acknowledge the support of the 8th Five-Year Key Technological D e v e l o p m e n t Pro jec t Funds , admin i s - t e r ed through the Beij ing E d u c a t i o n a l Commit tee , for help with this project.

References

1. ASM Committee on Flux Cored Arc Welding. 1983. Metals Handbook, Vol. 6, 9th ed., p. 96. Metals Park, Ohio: American Soci- ety for Metals.

2. Gustafsson, B., and Widgery, D. 1989. Cored wires. A review. International Journal for the Joining of Materials 1(3): 6-13.

3. Anon. 1991. What's new in welding consumables? Welding and Metal Fabrication 59(3): 138, 140-142.

4. Hesbrook, W. G. 1993. Adopting self shielded wire for shipbuilding. Welding and Metal Fabrication 61(5): 223-224.

5. Wegrzyn, J. 1992. Porosity and toughness of self shielded flux cored wire weld metal. Welding International 6(9): 677-682.

6. Wegrzyn, J. 1993. Toxicity, porosity and impact strength; problems in welding with self

shielding cored wires. Welding International 7(9): 677-682.

7. BuKi, A. A. 1984. Self-shielding properties of welding wires. Welding Production 31(10): 13-16.

8. Zhang, Z., Chen, B., Zhang, W., and Feng, L. 1997. Investigation on mechanism of fixing nitrogen in self shielded flux cored arc welding. China Welding 6(1): 25-30.

9. Yeo, R. 1997. It's quicker by tube - - welding with self-shielded cored wires. Welding and Metal Fabrication 65(3): 13-14.

10. Gruszka, W. 1989. Surfacing and welding using cored wire electrodes. Welding Inter- national 3(6): 492--496.

11. Gonzalez, J. C. 1987. Simple method to estimate nitride and nitrogen contents in self- shielded FCAW (flux cored arc welding) weld metal. Journal of Materials Science Letter 6( 1): 111-112.

12. Ramirez, J. E., Han, B., and Liu, S. 1994. Effect of welding variables and solidification substructure on weld metal porosity. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science 25(10): 2285-2294.

13. Yeo, R. B. G. 1993. Electrode extension often neglected when using self-shielded cored wires. Welding Journal 72(1): 51-53.

14. Stenbacka, N., and Svensson, O. 1987. Some observations on pore formation in gas metal arc welding. Scand. J. Metall. 16(4): 151-153.

15. Stenbacka, N., and Runnerstam, O. 1990. Aspect of pore formation on GMAW (gas metal arc welding). Welding and Metal Fabrication 58 (10): 553-554.

16. Redchits, V. V., and Froloc, V. A. 1996. Calculation and analytical evaluation of the gas pore formation susceptibility of metals and alloys in fusion welding. Welding International 10(1): 76-79.

17. Wei, Q., and Xiong, D. J. 1998. The influence of oxygen, nitrogen and hydrogen on porosity in the weld of SSFCW.AcademicJour- nal of Beijing Polytechnic University 24(3): 89-92.

18. Wei, Q., and Xiong, D. J. 1997. Study on pore sensitivity of self-shielded flux-cored wire with high BaF2 slag system. Proc. 8th National Welding Symposium, eds. S. Wang, and L. Wang, Vol. 2, pp. 95-97. Beijing: China Ma- chine Press.

19. Zhou, Z., and Zhang, W. 1988. Welding Metallurgy and Weldability of Metals, pp. 53, 66. Beijing, China Machine Press.

20. Chert, B. 1982. Base of Metal Weldabil- ity, p. 43. Beijing: Tsinghua University Press.

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• Why was the work done? • What was done? • What was found? • What is the significance of your results? • What are your most important conclusions? With those questions in mind, most authors can

logically organize their material along the following lines, using suitable headings and subheadings to divide the paper.

1) Abstract. A concise summary of the major elements of the presentation, not exceeding 200 words, to help the reader decide if the information is for him or her.

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3) Experimental Procedure, Materials, Equipment.

4) Results, Discussion. The facts or data obtained and their evaluation.

5) Conclusion. An evaluation and interpretation of your results. Most often, this is what the readers remember.

6) Acknowledgment, References and Appendix.

Keep in mind that proper use of terms, abbreviations and symbols are important considerations in processing a manuscript for publication. For welding terminology, the Welding Journal adheres to ANSI/AWS A3.0-94, Standard Welding Terms and Definitions.

Papers submitted for consideration in the Welding Research Supplement are required to undergo Peer Review before acceptance for publication. Submit an original and one copy (double-spaced, with 1 -in. margins on 8 ~ x 11-in. or A4 paper) of the manuscript. Submit the abstract only on a computer disk. The preferred format is from any Macintosh® word processor on a 3.5- in. double- or high-density disk. Other acceptable formats include ASCII text, Windows TM or DOS. A manuscript submission form should accompany the manuscript.

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[ ~ . 1 JUNE 2002

Fume Model for Gas Metal Arc Welding

Metal evaporation and condensation calculations predict fume formation rate for DC-positive operation in globular and spray modes

BY C. J. R E D D I N G

ABSTRACT. This paper describes changes to a previous model for calculating fume formation rate in mild steel gas metal arc welding (GMAW). The changes attempt to produce a more theoretically based model. They include calculation of droplet falling time in place of empirical values, mass transfer rate from droplet to plasma in place of the Lang- muir equation for evaporation into a vacuum, and fraction metal vapor condensing to base metal, which varies with parameters in place of a fixed 90% condensation value. The model is for DC electrode positive (DCEP) operation in the globular and spray modes. It has been applied to an experimental data set, used in the previous model, for a 1.2-mm- diameter (0.047-in.) mild steel welding wire. The new model is shown to be a poorer predictor than the previous model. The new model also predicts Fe to Mn ratio in the fume from which concentrations can be estimated. Fe concentration is underestimated and Mn concentration is overest imated with greater divergence from experimental results at the higher currents.

In t roduct ion

Welding Fume and Health Risks

Worldwide, industry lays down an estimated one million tons of weld metal annually. Based on an average fume production of 0.5% of weld metal, an estimated five thousand tons of fume are produced annually. Some of this fume is breathed in by the welder and can affect health. Effects on the welder include irritation of the lining of the lungs and metal fume fever. Stud- ies have indicated a slightly increased prevalence of lung cancer (Refs. 1, 2) and asthma (Ref. 3) as a result of welding work. A way of predicting fume formation rate (FFR) and fume composition in a given situation may aid occupational hygienists in assessing fume exposure risk, although the

C. J. REDDING is" with the Metal Fume Re- search Unit, Department of Environmental Sci- ence, University of BradJbrd, BradJbrd, UK.

link between emission and exposure is not clear. Prediction of FFR as a function of welding parameters may also aid industries in selecting lower fume operating conditions. An understanding of how fume is formed may aid welding consumable manufacturers in developing lower fume products and processes.

Fume Formation Rate Models

Prediction models can be empirically or theoretically based or an intermediate between the two (semiempirical). This paper describes an intermediate model. Fume is micron and submicron solid particles that are largely metal oxides. In globular and spray modes, it forms mainly by evaporat ion of metal from droplets at a tempera ture of approximately 2500 K. There is some evaporation from the weld pool. Fume can also be formed through bursting of gas bub- bles in droplets and from droplets thrown out of the arc region that rapidly oxidize in air (spatter). Most of the metal vapor is thought to condense without forming fume but some leaves the arc region and reacts with oxygen to form metal oxide fume. Only fume formed by evaporation from droplets forming on the welding wire tip and falling through the arc was considered here.

Model Development

The model described draws on two semiempirical models for FFR: the first, referred to here as the Deam Model (Ref.

KEY WORDS

DCEP Deam Model Dennis Model Fume Formation Rate Gas Metal Arc Welding Welding Fume

4), and the second, referred to here as the Dennis Model (Ref. 5). Both models rely on results of theoretical work by Haidar (Ref. 6). The models predict droplet temperature, calculate metal evaporat ion from the droplets and subsequent condensation to the base metal, and result in prediction of metal vapor to fume rate. The aim of the New Model was to produce a procedure that improved model- ling of the system and required fewer difficult-to-measure inputs. To be generally useful, a model should be able to predict FFR using commonly measured welding parameters combined with information on the welding wire supplied by the manufacturer. The Dennis Model, in addition to physical property data inputs, required welding current, welding wire feed rate, droplet rate, electrode extension, and arc length. Experiments to test the Dennis Model used an argon-based shielding gas containing 5% CO, and 2% 02. Standoff distance was 35 mm (1.378 in.) and arc length was 5 mm (0.197 in.), giving an electrode extension of 30 mm (1.181 in.). Arc length is not a commonly or easily measured quantity in many welding situations, and the New Model does not require it to be measured.

Note: In the text, linear dimensions for Tables 3 and 4 are given in millimeters and inches. The model equations use SI units, so for calculation purposes, dimensions must be in meters, as specified in Table 1.

M e t h o d

A description of the Dennis Model is given, followed by comments on changes made in the New Model. Details on the equations are then given. The New Model has been applied to the Dennis Model experimental data set (Ref. 5) and the resulting droplet temperatures and FFRs compared with the Dennis Model results.

The Dennis Model

Droplet Temperature

Droplet temperature was calculated using an energy balance on the welding

WELDING JOURNAL 114]~"~'11

Table 1 - - Definitions of Symbols and Conversion Factors

Adp droplet projected area Ads droplet surface area A w welding wire cross-sectional area Cp welding wire and droplet

specific heat capacity Cpp plasma specific heat capacity d d droplet diameter d w welding wire diameter DAB mass diffusivity element

A through element B e charge on an electron E i mass evaporated for element i f friction coefficient F d force on droplet g acceleration due to gravity h convective heat transfer coefficient Hfusion welding wire latent heat of fusion Hr, welding wire tip volumetric heat content HvF e latent heat of vaporization Fe HvMn latent heat of vaporization Mn i element Fe or Mn I current Jw welding wire current density = I/A w k Boltzman's constant kci mass transfer coefficient element i kTp plasma thermal conductivity lmi x metal vapor into shielding gas

mixing length = dw/2 L electrode extension L a arc length m d droplet mass MFF R metal vapor to fume rate M i atomic mass element i MVG R metal vapor generation rate P-f plasma viscosity at film temperature N u Nusselt number = hdd/kTp Pi pure vapor pressure element i Pr Prandtl number = larCpp/kTp Qcon convection energy transfer QEvap evaporative energy loss Qrad radiation energy transfer Qres resistive heating in droplet R Universal gas constant R e Reynolds number = pUpdd/~tf Pd droplet density pf plasma density at film temperature Pvi vapor density element i Pw welding wire density S c Schmidt number = ~tf/(rfDnB ) S h Sherwood number = kcda/DAB o d droplet resistivity t time period trail droplet falling time T a ambient temperature T d droplet mean temperature Tds droplet surface temperature Tf film temperature = (To- Tds)/2 T m welding wire melting temperature Tp plasma (arc) temperaure Uw welding wire velocity U o shielding gas velocity at nozzle outlet Up plasma velocity = 3809u w V a anode potential Vwf droplet material work function potential to droplet transfer frequency x i mass fraction element i in droplet X i mole fraction element i in droplet

[m 2] (1550 in. 2) [m 2] (1550 in. 2) [m 2] (1550 in. 2) [J,kg-l.K-I](0.239 x 10 -3 Btu.lb -I °F-l)

[J.kg-I.K ]](0.239 x 10- 3 Btu.lb q °F-I) [m](39.37 in.) [m](39.37 in.) [m 2.s-11(1550 in.2,s -1)

[c] [kg](2.205 lb) [] [N](0.225 Ibf) [m.s 2](0.03937 in..s -21 [W.m-2.K-q(0.176 Btu.h-t.ft-2.,°F-]) [J.kg-q(0.430 x l(J -6 Btu.lb -I) [J.m-3](0.268 x 11) ~) Btu.ft ~) [J.kg -t ] (0,430 x 1 ()-~ Btu.lb-t ) [J.kg -t ](0.430 x 10 -~' Btu.lb-1 )

[1 ]nl [A.m 2](0.645 x 10 -3 A.in. 2) [J.K-t](0.527 x 11/-3 Btu.°F -I) [m.s-J](39.37 in..s I) [W.m-t.K-t](0.578 Btu.h-t.ft-t.°F-t) [m](39.37 in.)

[m](39.37 in.) [m](39.37 in.) [kg](2.205 Ib) [kg.s-I](2.205 lb.s I) [kg.mol I](2.205 lb.mo1-1) [kg.s-I](2.2051b.s -1) [N.s.m-2](0.6672 Ib.ft I.s I) [] [N.m-2](0.145 x 10 -3 Ibf.in. -2)

[1 [J](0.948 x 10 -3 Btu) [J](0.948 x 10 -3 Btu) [J](0.948 x l0 -3 Btu) [J](0.948 x 10 -3 Btu)) [J.mol-LK-t](0.527 x 10- 3 Btu.mol-t.°F -1) H [kg.m-3](62.4 x 10 -3 Ib.ft -3) [kg.m-3](62.4 x 10 -3 lb.ft -3) [kg.m-3](62.4 x l0 -3 Ib.ft -3) [kg.m-3](62.4 x 1(~ 3 Ib.ft -3)

I1 [1 [f2.m](39.37 ~.in.) [sl [sl [K] [K1 IK] [K] [KI [K] [m.s-l](39.37 in_s -I ) [m.s-l](39.37 in_s -] ) [m.s-I](39.37 in_s -] ) [v] [vl Is-l] [l [1

wire extension and droplet forming at its tip. Current flowing in the welding wire extension heats it up. Electrons transferring from the arc provide further energy

and this results in melting of the welding wire and an increase in its temperature above the melting point. The molten welding wire forms a droplet at the weld-

ing wire tip. A mild steel welding wire was studied and Fe and Mn evaporation considered separately. From the initial energy balance the initial droplet temperature was found.

Evaporat ion from Forming Droplet

From the droplet temperature, the initial evaporation rate was calculated using the Langmuir equation for evaporation into a vacuum. At the welding wire tip the droplet grows, receiving mass from the welding wire and losing it by evaporation. Mass balances over small time intervals were integrated to give the total mass loss over droplet formation time. Incremen- tal energy balances accounting for resistance heating in the droplet and evaporative energy loss were also performed and the droplet temperature change calculated. Radiation and convection energy transfers were estimated, found to be small compared to other energy transfers, and were ignored.

Evaporat ion from Falling Droplet

Eventually the droplet detaches and no longer receives mass from the welding wire being fed in. The energy exchange situation also changes. Separate calculations were made for the falling droplet. Droplet falling time was estimated using arc length measurement together with experimental data for droplet velocity (Ref. 7). The data was applicable to a 5-mm (0.047-in.) arc and, although mild steel welding wire size was not explicitly given, it can be implied to have been 1.6 mm (0.063 in.) rather than the 1.2 mm (0.047 in.) used in the Dennis Model experiments. Current and welding wire velocity combinations were also different, so using the data was not ideal.

Suitability of Langmuir Equat ion

T h e D e n n i s M o d e l a s s u m e d o x i d a t i o n o f m e t a l v a p o r c lo se to t h e d r o p l e t s u r - f ace r e s u l t e d in e v a p o r a t i o n ( o x i d a t i o n - e n h a n c e d e v a p o r a t i o n ) c lo se to t h a t p r e - d i c t e d by t h e L a n g m u i r e q u a t i o n . T h i s h a s b e e n s h o w n to b e t h e c a s e f o r F e e v a p o r a t i n g i n t o a n o x i d i z i n g a t m o s - p h e r e (Re f . 8), b u t t h e e x p e r i m e n t s w e r e p e r f o r m e d at m u c h l o w e r t e m p e r a t u r e s t h a n t h o s e e n c o u n t e r e d in t h e arc. I n t h e c a s e o f M n , t h e o x i d a t i o n - e n h a n c e d r a t e s w e r e less t h a n 1 0 % o f t h e L a n g m u i r r a t e .

D o u b t w a s e x p r e s s e d (Re f . 5) t h a t F e O c o u l d exist a t t h e t e m p e r a t u r e s e n c o u n -

t e r e d n e a r t h e d r o p l e t s u r f a c e . F e ini t ial ly f o r m s F e O , w h i c h bo i l s a t 2700 K a n d de - c o m p o s e s at 3400 K. T h e d r o p l e t s u r f a c e w o u l d b e b e t w e e n a b o u t 2000 a n d 3000

K, w i t h t h e a r c p l a s m a b e t w e e n 6000 a n d

114I,-"~1 JUNE 2002

20,000 K or higher. The Dennis Model used mean drople t t empera tu re in the calculat ions, a l though drople t surface t empe ra tu r e would be expec ted to be higher than this.

The New Model

The New Model replaces the Langmuir equat ion with calculation of convective mass transfer coefficients for Fe and Mn and, thence, evaporation rates. Radiation and convective energy transfers were estimated and incorporated into the energy balances. In calculations, droplet surface temperature was used in place of mean temperature. Droplet falling time was estimated by calculating arc length from standoff, welding wire feed velocity, and current using an equation for electrode extension derived from Ha lmw' s paper (Ref. 9). This was combined with a calculation of droplet accelerat ion resulting from gravity and drag force due to the high-velocity plasma flowing around the droplet. The plasma velocity was estimated from an equation used in the Deam Model. It applies to a 1.2-mm- diameter (0.047-in.) welding wire. Con- densation to the base metal was estimated using the method described in the Deam Model. The method is based on potential flow and incorporates shielding gas velocity and metal vapor density at the droplet surface. Details of equat ions are given below. Definitions of symbols used, with units and conversion factors, are given in Table 1. Values of physical properties, constants, and parameters are given in Table 2.

Droplet Temperature

The initial mean droplet temperature as a new drop starts to form after the previous one has detached from the welding wire tip was calculated using the Dennis Model initial energy balance equat ion, which follows:

uwA,.pw{Cp(Td - T, )+ H li,.,i,m }t = HLUwAwt

/7)t.

The term on the left-hand side represents the energy absorbed in raising the temperature of the welding wire fed into the arc f rom ambient t empe ra tu r e to the mean droplet temperature and includes the heat of fusion. The energy was provided by resistance heating in the welding wire extension (first term on right-hand side) plus electron condensation heating comprising work function potential plus anode potential plus kinetic energy loss per coulomb multiplied by the coulombs of charge as electrons condensing (It).

Table 2 - - Values of Physical Propert ies , Constants , and Parameters

A~ 1.13 x 104, [m-'] Mu,, C~ 753 [J.kg ,.K-,] gf C,o 593 [J.kg ,.K,] P, d~ 1.20x 10' [m] R D ...... 2.89 x 10-~ [m:.s ,] p, D ...... 2.90 x 103 [m-'.s-,] p, e 0.160 x 10-,~ [C] o,, g 9.81 [m.s :] T,, H ........ 247 x 10~ [J.kg-,] T, H,,~ 6.54 x 1% [J.kg ,] T,, H,.. 4.31 x 10,, [J.kg '1 T, k 13.8 x 10 -~ [J.mol ,.K ,] U., k,,, 0.164 [W.m ,.K-,] V• I .... 0.600 x 10~ [m] V~, M~ 55.9 x 103 [kg.mol ,]

54.9 x 10s [kg.mol ,] 0.172 x 103 [N.s.m ~'] 0.622 [1 8.314 [J.mol,.K,] 78.1 x 10 ~ [kg.m ~] 7.70 x 10, [kg.mq 1.32 x 10~, Q.m] 293 [K] 6.25 x 10s [K] 1.81 x 10~ [K] 10.0 x 103 [K] 3.90 [m.s ,] 1.00 [V] 4.18 [V]

C

t ~ t ~

1.0E-05

8.0E-06

6.0E-06

4.0E-06

2.0E-06

0.0E+00

160

° • ,O • , ° 0 " • • i " ~ ' • • • 0 o e

• o " | L • 0 . ° ,

200 240 280 320 Current (A)

---A----New • experimental . additional - - O - - Dennis ]

Fig. 1 - - FFR against current: experimental values and the Dennis Model predictions from Ref 5 with

the New Model predictions added.

~o

r ~

1.0E-05

8.0E-06

6.0E-06

4.0E-06

2.0E-06

0.0E+00

160

°

• ,o o ; , .o

"-,

200 240 280 320 Current (A)

[ - - - ~ New (L constant) • experimental • additional . - O - - Dennis ]

Fig. 2 - - FFR against current: experimental values from Ref 5 with New Model predictions assuming eonstant electrode extension and are" length.

W E L D I N G J O U R N A L I[e)L$."!

W E L D I N G R E S E A R C H : i

3600

3400

3200 ?

, 3000

2800

2600

2400

• . . . A . . . . . . .A . . . . . . . . • . . . . • - - -A . . . . . . . •

2200 , , , ~ . . . . . . . . . . . .

160 200 240 280 320 C u r r e n t (A)

+ New initial ---O---Dennis initial -- 4 , - N e w d e t a c h m e n t I

/ - - - O - Dennis detachment.. ~r - -New final . . ~ . . . Dennis final

Fig. 3 -- Droplet temperatures predicted by the Dennis and New Models.

tion that assumed a constant resistance, molten metal cylinder of the same diameter as the droplet at detachment, ignor- ing evaporation mass loss, and of a length equal to the diameter of the droplet at any given time. Current density was assumed constant with position at a given time. This is a very simple approximation for what is a complex situation. In reality, the resistivity, conductor cross section, and current density in a droplet varies with position and is dependent both on the area covered by the arc and droplet shape. The resulting equation for resistance heating integrated over the time period t~ to t., was

( ~ I/3 QRes=adl2( 3-.~-]] 41rpd I

\ 2~2 \ uwAwP w I tO213(t4/3 ,4/3~ _,,, [,]

Radiation Energy Transfer

Radiation energy loss from the droplet over a given time increment was estimated using the equation

The analysis only applies to electrode positive operat ion, which is the most common form of GMAW. Resistance heating in the welding wire was calculated using a method described by Halm0y (Ref. 9). The energy content per unit volume at the end of the electrode extension as a result of resistance heating in the welding wire, HL, was given by a second order polynomial curve fit to Halm0y's data for Union K56 Si-Mn steel solid welding wire (Ref. 5).

H L = 1.69 x 107

. [ Li 2 +2.232 x lO-" I ~----~-~ l

kUw)

+5.98 x lO-23( Lj212 kUw)

J.m-3 ] (2)

The droplet surface temperature was given by

Tds = 2[Td - Tm }+ Tm [K] (3) T h i s was d e r i v e d f r o m the a s s u m p t i o n the mean droplet temperature was midway between droplet melting point and droplet surface temperature as in the Deam Model. The incremental time period chosen for the forming droplet was ¼,,,th of the formation time where the formation time was given by the inverse of

the droplet rate (I/to). Over this incremental time period, the volume of welding wire that flowed into the droplet, expressed as volume at droplet temperature, was

Incremental volume

From this volume, a droplet surface area was calculated assuming a spherical droplet. Droplet densitywas evaluated as a function of droplet temperature using an equation fitted to density data. The density data was for a 1.4% Mn in Fe alloy calculated using an estimation method supplied by the U.K. National Physical Laboratory. The Dennis Model used an equation derived from density data for liquid 304 stainless steel (Ref. 10). There was not a lot of difference between the densities calculated using the two different equations, and model results are fairly insensitive to small changes in density.

pd = 8363.2-(Td )

+6.559xlO-5(T2! Ike.m - ' ' ] (5) \ d :

Droplet Resistance Heating

Resistance heating in the droplet was calculated using a Dennis Model equa-

QRad = 5.67 x 10 -a Ads

[,] (7)

where 5.67 x 10-~ [W/m 2/K-4] is the Ste- fan-Boltzman constant and 0.29 is the emissivity of the molten metal surface. The equation assumes no radiation received from the arc by the droplet, i.e., arc emissivity is zero. The estimation of arc emissivity is complex. One estimate for an argon plasma arc was 0.012 (Ref. 11), but Welty, Wicks, and Wilson (Ref. 12) state inert gases and diatomic gases of sym- metrical composition, such as 02, can be considered transparent to thermal radiation. They also state polyatomic gases such as CO2 absorb and emit radiation. Shielding gases often contain CO2, so radiation loss from the droplet should decrease as CO2 shielding gas content increases due to the droplet receiving more radiation from the arc; this, in turn, should increase metal evaporation rate.

Convection Energy Transfer

Convective energy transfer from the arc to the droplet was calculated from the equation

Qcon = hAds(Tp - Tds )

(1/lOOto) [J ] (8)

h is the convective heat transfer coeffi-

I~1:~1 J U N E 2 0 0 2 1

Table 3 - - Exper imenta l Data Set from Ref. 2

Typical welding wire composition C Mn (mass %) 0.1 1.4

Welding wire diameter :1.2 mm (0.047 in.) Standoff :35 mm (1.378 in.) Arc length :5 mm (0.197 in.) Welding polarity :DC electrode positive Shielding gas composition :93%Ar, 5%CO2, 2%O~ Shielding gas flow rate :7.8 x 10-4m~.s i (1.66 ft3.min, i)

Si Fe 0.9 97.6

Experimental test 1 2 3 4

Droplet rate (to) [s-,] 33.4 80.9 130.7 122.4 Wire velocity (u,d [m.s -1] 0.091 0.108 0.129 0.148 Current (I) [A] 175 188 212 240 FFR [kg.s-q 4.67 x 104, 3.45 x 104

5 6 7

158.7 182.8 172.4 0.175 0.185 0.2(17 256 269 294

4.68 x 10 ~ 8.15 x I(F ~

cient obtained from a relationship between the Nusselt number, No = hdJkp; the Reynolds number, R~ = pfUpdd/ [LI , f; and the Prandtl number, Pr = pjCpp/p~. These were evaluated for arc plasma flowing over the droplet using plasma properties evaluated at a film temperature given by the following:

,9,

For simplicity, the heat transfer coefficient was evaluated at one film temperature, Tf = 6250 K, and for the droplet diameter at detachment assuming no mass loss due to evaporation and a density evaluated at the initial droplet temperature. The film temperature of 6250 K was the mean of an assumed droplet temperature of 2500 K (approximately midway between alloy melting and boiling points) and an assumed plasma temperature of 10,000 K. Arc plasma temperature varies with position and current. Lancaster (Ref. 13) gives values of 6000 K for an iron vapor arc and 10-15,000 K for a 200-A argon arc. Ten thousand K is an approximation. Using properties evaluated for a film temperature of 8000 K resulted in a fall in predicted FFR of between 12 and 20%. This gives an indication of the sensitivity of the model to a change in film temperature. Plasma velocity was given by the following (Ref. 4):

U p = 3 8 0 9 U w [ m . s -1 ] (10)

This applied to a 1.2-mm (0.047-in.) mild steel welding wire. The equation used to relate N., R~, and P~ was (Ref. 12)

N u =0.37R°'6P! 1/3) (11)

This equation applies to forced convection for a gas flowing over a sphere. It is valid for 20<R~< 150,000.

Evaporation

Evaporation from the droplet was calculated from the convective mass transfer coefficient for each metal, k~, using the following equation:

Ei =(kcixiPiMi)

Ads(1/ lOOw)/(RTds ) [kg] (12)

This equation approximates the situation by assuming metal vapor concentration in the plasma is small compared to vapor concentration at the droplet surface and, so, can be taken as zero. As in the Dennis Model, only Fe and Mn evaporation were considered. Evaporation of Si and trace elements found in mild steel were ignored, x~P~ represents the vapor pressure of element i and is the product of mass fraction i in the droplet and pure vapor pressure i at temperature Td~. Strictly speaking, the mole fraction for the element, rather than the mass fraction, should have been used, but since the atomic masses of Fe and Mn are similar and these two elements make up the majority of the welding wire, then mass and mole fractions were very similar. It was assumed in calculating the change in composition of the welding wire that the other elements found in small amounts in the welding wire remained at the same mass fraction values. Representing the vapor pressure using xiP~ assumes an activity coefficient equal to one. The Lang- muir equation for comparison is

E i = XiPiAds 0.5

(1 ,oo 4 (13)

Pure vapor pressures were calculated using the Dennis Model equations, which

represent curve fits to National Physical Laboratory data.

Log PFe = 10.41682 - 15724 / Ta. ,. -3930000/T2 [N.m -2 ] (14)

Log PMn = 9.50342 - 9246 / Tas -2940000/T 2 [N.m -2 ] (15)

To obtain k~ values, it was necessary to

calculate the Sherwood number, Sh = k~da/DM~. In this case, the Fr6essling equation (Ref. 12), which follows was used.

,,, = 2.o+ o.,,2R! 16)

The equation is valid for 2<R~<800 and 0.6<S¢<2.7, where the Schmidt number, St = gf/(pfDAlO. DAR is the mass diffusivity of A through B and was evaluated for Fe and for Mn diffusing through the shielding gas mixture given in Table 3. For simplicity, kcw and kcM, were evaluated for plasma properties at a film temperature of 6250 K and for the droplet diameter at detachment assuming no mass loss due to evaporation and a density evaluated at the initial droplet temperature.

Evaporation Energy Transfer

Once the evaporation mass loss over a given time increment was determined, the energy loss due to the latent heat of vaporization could be calculated as follows.

QE,.ap = EFeHvFe + EvM,,HvM,, [J] (17)

Forming Droplet

Due to the droplet increasing in size as it grows, heat transfers by radiation, con-

WELDING JOURNAL 1[4tzl~.-]l

Table 4 - - Selected Calculated Quant i t ies Using the New Model

Experiment Predicted Arc Fe Length Evaporation

Rate Test [mm(in.)] [kg.s,]

1 6.1 (0.240) 2.63E-05 2 3.4 (0.134) 2.27E-05 3 4.4 (0.173) 2.38E-05 4 7.4 (0.291) 2.80E-05 5 5.0 (0.197) 2.40E-05 6 6.2 (0.244) 2.58E-05 7 7.8 (0.307) 2.81E-05

Mn Fraction Evaporation Metal Vapor

Rate to Fume [kg.s-,] Fe Mn

4.87E-06 0.052 0.051 4.62E-06 0.066 0.064 5.07E-06 0.066 0.064 6.04E-06 0.056 0.053 5.81E-06 0.056 0.054 6.22E-06 0.054 0.052 6.91E-06 0.048 0.046

Reynolds Fe Mass Mn Mass Number Transfer Transfer

Coefficient Coefficient R, k,~[m.s-,] k,M . [m.s ~]

306 16.1 16.1 285 19.9 19.9 308 22.7 22.8 378 23.1 23.2 432 25.3 25.3 444 26.3 26.4 525 26.7 26.7

Table 5 - - Fume Composi t ion

Experiment Experiment Predicted Predicted Current Fe Mn Current Fe Mn [A] [mass %] [mass %] [A] [mass %] [mass %]

180 59 7.9 175 55.1 9.9 205 56 9.4 188 54.3 10.7 220 57 8.9 212 53.9 11.1 240 57 7.0 240 53.8 11.2 260 58 6.4 256 52.8 12.2 268 59 6.6 269 52.8 12.2 300 61 6.4 294 52.6 12.4

vection, droplet resistance heating, and evaporation change. Temperature of the droplet also changes. Over each time increment, energy and mass transfers were calculated and used to adjust the droplet temperature and composition at the beginning of the next time period. This process was repeated until the droplet detached from the welding wire at time l/t0.

Falling Droplet

Once the droplet detached from the welding wire tip, it fell across the arc, accelerated by the plasma jet drag force and gravity. During the falling stage, the droplet was no longer receiving mass from the welding wire. Electron condensation and resistance heating ceased since zero current flow through the detached droplet was assumed. Only radiation, convection, and evaporation were considered. Mass and energy balances were conducted over small time incre- ments to obtain droplet temperature, mass, and composition changes with time. Droplet falling time was estimated by calculating the drag force on the detached droplet as follows:

where Up = 3809u, as used previously and f is a dimensionless friction factor, which can be expressed as the following function

of Re, valid for 0.2<Re<800 (Ref. 14):

f =12(l+O.15RO'687)/Re (19)

Droplet acceleration is drag force divided by mass plus acceleration due to gravity. The falling time was calculated, as follows, assuming constant acceleration.

tfall=(2Lamd/(F a +mdg)) °5 [s] (20)

Plasma properties were evaluated for a film temperature of 6250 K and used to calculate f and F d. Mass and diameter of the falling droplet were calculated assuming no loss by evaporation and a temperature of Td (initial). A time increment of t J 1 0 0 was used for the falling time calculations. The arc length was derived from electrode extension, which was estimated using an equation from Halm0y (Ref. 9) for wire velocity valid for HL>4 x 109 J.m -3 and for Union K56 Si-M steel solid welding wire. The equation was rearranged as given below:

L =uw(15.1x 109- 3.5jw)/

(1.2xlO-6j 2) [m] (21)

Arc length was obtained by subtracting electrode extension from standoff (assumes base of arc level with base metal surface).

Metal Vapor Generation Rate and Fraction Condensed on Base Metal

The results of the above calculations, performed using a computer spreadsheet program, included Td~, xve, and XM, as functions of time. Mass Fe and Mn evaporated can be evaluated from droplet composition, welding wire feed rate, and welding wire composition. Multiplying total mass of metal evaporated from one droplet by the droplet rate gave the metal vapor generation rate (MvGR). Not all of this is thought to form fume. Haidar (Ref. 6) calculated 85 to 95% of the evaporated metal comes into contact with the base metal; most would be expected to condense. Parameters used were 1.6-mm- diameter (0.063-in.) mild steel welding wire at 300 A, pure argon shield, 8-mm (0.315-in.) initial arc length, 24-mm (0.945-in.) welding wire extension, and 1.67 x 10-2m3.s-I gas flow rate. The Dennis Model used an average value of 90% condensed in the calculations for FFR. The New Model used the Deam Model method. In this method, vapor condensation on the base metal was estimated assuming potential flow. The resulting equation relating rate of metal vapor entering fume (MFFR) to MVGR was

MFF R = MVG R (I+MvGR/2a) -1 [kg.s -1 ] (22)

ot = Uosr lmi x Pv kg "s-1 (23)

The equation was evaluated separately for Fe and Mn. The metal vapor density for element i, assuming ideal gas behavior, was given by the following:

Pvi = MixiPi /(RTds) [kg.m -3] (24)

Using this method, the fractions of metal condensed for Fe and Mn vapors were calculated separately and applied to the

liIOl~'~ JUNE 2002

metal evaporation results to give values for the total MFF R. GMAW fume contains oxidized metal and is typically 65% metal with the remainder mainly oxygen. M~FR values were multiplied by 100/65 to give predicted FFRs.

Results and Discussion

Calculations were performed on the experimental data set given in Table 3, which covers the globular to spray transi- tion region and full spray region. Table 4 gives a selection of calculated quantities using the New Model.

FFR Predictions

Explanation of Figure 1

Figure 1 shows FFR against current taken from Ref. 5 with the New Model FFR predictions added.

In the legend, "experimental" points are those obtained by A. D. Workman (Ref. 5) for which arc length was controlled to 5 mm (0.197 in.) and droplet rate was measured. '~ddi t ional" points w e r e FFR measurements done by other workers under conditions close to those used by Workman, but without arc length controlled to 5 mm (0.197 in.). The "additional" points give a better idea of the shape of the FFR current curve and the variation in measured FFR at a particular current. In preparing this paper, it was discovered the typical wire composition given in Ref. 5 was incorrect according to analysis by the wire manufacturer. Mn was given as 1.2% whereas 1.4% is a more correct figure. The Dennis Model predictions in Fig. 1 were calculated using the value of 1.2% Mn and the same liquid metal density equation as used in the New Model. Using a value of 1.4% Mn would give a maximum increase in Dennis Model predicted FFRs of less than 8%.

Predictions

The New Model predicts approximately constant FFR with values less than experimental measurements in the low and high current regions. The Dennis Model is a better predictor except for the prediction at 240 A. Since neither model includes contributions to fume from processes other than evaporation from droplets, the predicted FFRs would be expected to be less than experimental rates.

Tapering in Spray Region

The divergence between the New Model predictions and experimental values at the higher currents may be partly due to the effects of electrode tip taper-

70

.=_ A

A A

50

A A A A

160 240 320

Current (A)

IA New Model • experimental ]

Fig. 4 - - Fe concentration in fume estimated using the New Model compared with experimental values obtained under similar conditions.

15

t~

.E

A

A

A A A

160 240

Current(A)

320

ANew Model • experimental I

Fig. 5 - - Mn concentration in fimTe estimated using the New Model compared with experimental values obtained under similar conditions.

ing, which occurs in the spray transfer region. As a result, the area of molten metal is greater than that predicted assuming a simple spherical droplet shape. Photo- graphic evidence (Ref. 15 and Ref. 7 [for aluminum]) indicates in spray transfer, the arc envelope extends up the taper, whereas in globular transfer, it is largely confined to the droplet and region extending to the base metal. The taper gives greater area for radiation and convection energy transfer from the arc and greater area for evaporation than predicted by the simple spherical droplet model used here. Surprisingly, the Dennis Model results, also obtained using a spherical

droplet model, give reasonable agreement with experimental results in the spray region. Droplet shape and area and the effect of electrode tapering could be better modeled. Detailed data from experimental observations and measurements would aid in that. For an analysis of liquid flow and heat transfer at the wire tip in spray transfer, see Waszink and Van Den Heuvel (Ref. 16)

Effect of Using Halm~y Equation

One major difference between the two models was the New Model used arc lengths (Table 4) est imated using the

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Halmcy equation for wire velocity (Ref. 9) rearranged to give electrode extension as a function of wire velocity (Equation 21). The New Model results were reeval- uated using a constant arc length value of 5 mm (0.197 in.), as used in the Dennis Model. Figure 2 shows the resulting FFRs, which demonstrate improved prediction. It appears the use of the Halm0y equation was a major source of the difference between our predict ions and those from the Dennis Model. The equation for wire velocity was applicable to Union K56 Si-Mn steel. A more valid calculation would need further experiments to determine the constants in the equation for the specific wire used in the Den- nis Model experiments. In deriving the equation, Halmcy took the heat content per unit volume of the droplet at detachment as being the sum of the resistance heating in the wire and the effective anode heating. Halmcy compared his equation with an approximation of an equation from Lesnewich (Ref. 17) and concluded the heat content at detachment was constant. Detaching droplets having a constant specific heat content is inconsistent with the change in detachment temperature with current predicted here. Halm0y did not take into account evaporation, convection, or radiation. Further study is necessary to find out the reasons for the inconsistency.

Temperature Predictions

Figure 3, based on Ref. 5, shows temperature predictions for droplets as they start to form (initial), when they detach from the wire tip (detachment), and when they enter the weld pool (final). Dennis Model predictions were calculated using corrected wire composition and a liquid metal density equation as used in the New Model. The New Model predictions gave much higher temperatures because surface temperature values were used as opposed to mean temperature values. New Model initial temperatures were in excess of alloy boiling point and fell with increasing current. Interestingly, New Model detachment temperatures were roughly constant at around the alloy boiling point (approximately 3100 K). This may be connected with using the Halm0y equations. Final temperatures were approximately 200 K lower. Villeminot (Ref. 18) measured surface temperatures of droplets and found values ranging from 2600 to 3100 K, which are comparable with New Model predictions for droplets at the detachment and final stages.

Fume Composition

Fume composition in terms of Fe and

Mn concentrations can be est imated from the ratio of MVFR values for Fe and Mn. The calculations use the assumption of a constant F e + M n content for the fume of 65% (GMAW fume is typically 65% metal). Table 5 compares predicted compositions with experimental compositions obtained under conditions that were similar but not identical. Figures 4 and 5 show these results in graphical form. Fe concentration is underestimated and Mn concentration overest imated with divergence between experimental, and predicted values increasing at the higher currents. Droplet surface temperature largely determines the predicted ratio of Fe to Mn in fume. As the temperature of an alloy of Fe and Mn increases, the ratio of the equilibrium vapor pressure of Fe to Mn increases, hence vapor composition becomes richer in Fe and leaner in Mn. Complete evaporation of microdroplets resulting from gas bub- ble burst and other mechanisms would result in a fume richer in Fe. If mixing in the droplet was insufficient to supply Mn to the surface as fast as it was evaporating, then Mn depletion at the surface would occur, which could also result in a fume richer in Fe. In one study involving pulse welding, depletion was not found except at high oxygen concentrat ions (20%) (Ref. 19). In the Method section of this paper, mention was made of oxidation- enhanced evaporation and how it was less for Mn than for Fe. If oxidation-enhanced evaporation was taking place, it might account for differences between experimental and predicted compositions. Formation of FeO and MnO on the droplet surface would have an effect on evaporation rates. Further study of oxidation and evaporation processes occur- ring at the droplet surface would help to establish the validity of a simple metal evaporation model.

Shielding Gas Effects

Shielding gases used in mild steel GMAW normally contain oxygen and/or carbon dioxide. Carbon dioxide can be a source of oxygen at high temperatures. The presence of oxygen may result in oxidat ion-enhanced evaporat ion from droplets. This was assumed in the Dennis Model, but no account was taken of varying oxygen concentration effects. Studies have found an increase in oxygen concentration in shielding gas can lead to increased FFR (Refs. 20, 21). Shielding gas composition can also affect droplet rate. Oxygen in low concentrations enhances spray transfer by lowering surface tension of the droplets. Droplet rate is one of the inputs to the model, which is not a normally measured quantity in continu-

ous current commercial welding situations. A method to predict droplet rate from normally measured parameters is one requirement for an improved model. Shielding gas flow rate influences predicted FFR in the New Model due to its effect on the proportion of metal vapor condensed to the base metal. Experi- ments at different shielding gas flow rates would enable a comparison of the predicted effect with the experimental effect. A comprehensive F F R model would have to incorporate shielding gas composit ion and flow rate effects on FFR. The New Model used gas physical property data estimated for the shielding gas composition used in the experimental work. The New Model was also run using physical property data estimated for CO2 and the predicted F F R was found to increase by 16 to 22%.

Conclusions

• The New Model has addressed certain points raised in Ref. 5 concerning the Dennis Model. It has replaced the Langmuir evaporat ion assumption with a mass transfer correlation. It has included the effects of radiation and convection energy transfers. It has calculated droplet falling time in place of using an equation derived from indirectly applicable experimental data. It has calculated condensation based on system conditions in place of using a constant approximate value. It has replaced measurement of arc length with a method to calculate arc length. The result has been a more theoretically based model that is not as good as the Dennis Model in predicting FFR and that predicts initial surface temperatures in excess of the boiling point.

• Improvement of the model to account for the effects of tapering of the welding wire tip in the spray region may improve predictions, although the Den- nis Model gave reasonable predictions for the spray region despite using a simple spherical droplet model.

• The use of the Halm0y equation for wire velocity to estimate arc length was one major source of difference between the models. Fur ther study would be necessary to improve this part of the model.

• The New Model allows estimation of fume composition (as did the Dennis Model). It underestimates Fe concentration and overestimates Mn concentration. Divergence between experimental and predicted values increases at the higher currents.

• The New Model incorporates calculation of fraction metal vapor condensed

l[oY~ JUNE 2002

to the base meta l . The f r ac t ion de- pends on sh ie ld ing gas veloci ty and may be a par t ia l exp lana t ion of observed effects of shielding gas flow rate on FFR.

Acknowledgments

Much of the con ten t of this paper relies on work by D e a m , S impson , and Haidar (Ref. 4) and by Dennis , Hewitt , Redding, and Workman (Ref. 5). Figures 1-3 and Table 3 are taken, with changes, f rom Ref. 5 with the permiss ion of the British Occupat ional Hygiene Society.

Refi, rences

1. International Agency for Research on Cancer (IARC). 1990. Evaluation of carcino- genic risk to humans. Chromium, nickel and welding. IARC 49. Lyons, France.

2. Milatou-Smith, R., Gustavsson, A., and and Sj6gren, B. 1997. Mortality among welders exposed to high and to low levels of hexavalent chromium and followed for more than 20 years, hzt. J. Occup. Environ. Health 3(2): 128-131.

3. Beach, J. R., Dennis, J. H., Avery, A. J., Bromley, C. L., Ward, R. J., Waiters, E. H., Stenton, S. C., and Hendrick, D. J. 1996. An epidemiological investigation of asthma in welders. Am. J. Resp. Critical Care. Med. 154(5): 1394-1400.

4. Deam, R. T., Simpson S. W., and Haidar, J. 2000. A semi-empirical model of the fume formation from gas metal arc welding. J. Phys.

D: AppL Phys. 33: 1393-1402. 5. Dennis, J. H., Hewitt, P. J., Redding, C.

A. J., and Workman, A. D. 2001. A model for prediction of fume formation rate in gas metal arc welding (GMAW), globular and spray modes, DC electrode positive. Ann. Occup. Hyg: 45(2): 105-113.

6. Haidar, J. 1999. An analysis of heat transfer and fume production in gas metal arc welding. IlL J. AppL Phys. 85(7): 3448-3459.

7. Needham, J. C., Cooksey, C. J., and Mil- her, D. R. 1960. Metal transfer in inert gas shielded arc welding. British Welding Journal (2): 101-114.

8. Turkdogan, E. T., Grieveson, P., and Darken, L. S. 1963. Enhancement of diffusion- limited rates of vaporisation of metals. J. Phys- ical Chemistry 67(8): 1647-1654.

9. Halmoy, E. 1979. Wire melting rate, droplet temperature and effective anode melting potential. Conference on Arc Physics and Weld Pool Behaviour, pp. 49-57. United King- dom: The Welding Institute.

10. Zacharia, T., David, S. A., and Vitek, J. M. 1991. Effect of evaporation on weld pool development. Metallurgical Transactions B 22B (April): 233-241.

11. Metcalfe, J. C., and Quigley M. B. C. 1977. Arc and pool instability in GTA welding. Welding Journal 55(5): 133-s to 139-s.

12. Welty, J. R., Wilson, R. E., and Wicks, C. E. 1979. Fundamentals of Momentum Heat and Mass Transfer, 2nd ed. New York, N.Y.: Wiley.

13 Lancaster, J. E 1987. Metallurgy of Weld- ing, 4th ed. London, United Kingdom: Allen and Unwin.

14. Coulson, J. M., and Richardson, J. E 1968. Chemical Engineering Vol. 2, 2nd ed., p. 140. New York, N.Y.: Pergamon Press.

15. Lesnewich, A. 1958. Control of melting rate and metal transfer in gas shielded metal arc welding: Part II: control of metal transfer. Welding Journal 37(9): 418-s to 425-s.

16. Waszink, J. H., and Van Den Heuvel, G. J. P. M. 1982 Heat generation and heat flow in the filler metal in GMA welding. Welding Jour- nal 61(8): 269-s to 282-s

17. Lesnewich, A. 1958. Control of melting rate and metal transfer in gas-shielded metal- arc welding, Part 1: control of electrode melting rate. Welding Journal 37(8): 343-s to 353-s.

18. Villeminot, E 1966. Pyrometrie pho- tographique appliquee au soudage. Document 212-83-66, International Institute of Welding.

19. Corderoy, D. J. H., Wills, B., and Wall- work, G. R. 1980. Gas/weld metal reactions in MIG arc plasma. Conference on Weldpool Chemistry and Metallurgy, pp. 147-153. United Kingdom: The Welding Institute.

20. Gray, C. N., Hewitt, E J., and Hicks, R. 1980. The effect of oxygen on the rate of fume formation in metal inert gas welding arcs. Con- ference on Weldpool Chemistry and Metallurgy, pp. 167-176. United Kingdom: The Welding Institute.

21. Heile, R. E, and Hill, D. C. 1975. Partic- ulate fume generation in arc welding processes. Welding Journal 54(7): 201-s to 210-s.

WELDING JOURNAL liD~.-q

Primary Circuit Dynamic Resistance Monitoring and its Application to Quality

Estimation during Resistance Spot Welding Weld strength and nugget diameter were estimated by using primary circuit

process parameter as a real-time in-process monitoring system

BY Y. CHO and S. RHEE

ABSTRACT. Resistance spot welding is one of the most widely used processes in sheet metal fabrication. Improvements in quality assurance are important to increase welding productivity. Until now, quality estimation was performed using dynamic resistance at the secondary circuit, which is easily measured. However, this method has many problems when applied to in-process real-time systems. In this study, weld quality was ensured through the use of a new dynamic resistance monitoring method. This method used instantaneous current and voltage values measured at the primary circuit. A weld quality estimation system is suggested using these variables. For quality estimation, ten factors relating to quality were extracted from the primary circuit dynamic resistance, measured in the timer. The relationship between these factors and weld quality was determined through a regression analysis. Four regression models were developed using the results of the analysis in order to estimate weld strength and nugget diameter. Neural network models were also suggested using these factors. The results of the neural network were compared with those of the regression models. This was designed so weld quality estimation could be obtained upon completion of welding. Moreover, the proposed method using the primary circuit dynamic resistance has an advantage over the conventional one, such as obtaining information on quality without the use of extra devices.

Y CHO is a Research Associate, Department of Mechanical Engineering, The University o f Michigan, Ann Arbor, Mich. S. RHEE is an As- sociate Professor, Dept. of Mechanical Engi- neering, Hanyang University, Seoul, Korea.

This paper was presented at the A WS 81st An- nual Convention, April 25-27, 2000, Chicago, Ill.

Introduction

For several decades, resistance spot welding has been an important process in sheet metal fabrication. The automotive industry, for example, prefers spot welding for its simple and cheap operation. Recently, however, attempts are being made to reduce the number of spot welds to increase productivity. In order to min- imize the number of spot welds and sat- isfy essential factors such as strength, weld quality must be obtained. Tradition- ally, to check weld quality, destructive and nondestructive tests were used on randomly sampled workpieces at the production site. These processes, however, can only be examined off-line, making it impossible to receive pertinent information regarding the weld quality during the process. Weld quality estimation must be done in real time to monitor and repair weld defects as they occur.

As resistance spot welding has electro- mechanical elements, various weld quality control techniques have been proposed based upon the following process parameters: dynamic resistance, welding current, voltage, and electrode displacement (Refs. 1, 2). In general, electricity- based systems, which maintain the volt-

KEY WORDS

Resistance Spot Welding Inductive Noise Primary Circuit Dynamic Resistance Regression Analysis Correlation Neural Network Quality Estimation

age or the current at a constant preset level (Refs. 3, 4), have been used to control those parameters automatically. Al- though the general voltage supply is reliable, severe voltage fluctuations may occur in some areas and, in such situations, automatic voltage regulators have been employed. The idea to maintain constant power or current for a set period of time has also been employed in cases where the impedance changes during welding. In addition, a combined current and voltage regulator, which adjusts the phase-shift control automatically, was introduced. Investigations based upon the thermal expansion have been undertaken in attempts to control the quality as well.

A resistance spot welding machine has moving parts such as electrodes or arms. Moreover, a direct relationship between the rate of electrode separation and the properties of the weld exists. Johnson, et al. (Ref. 2), developed a spot-weld correction system based on sensing the weld thermal expansion in which correction was achieved by automatic adjustment of weld load. A real-time adaptive spot welding control system based upon a measurement of electrode displacement was also operational on the factory floor throughout the recent study (Ref. 5). Re- sistance correction technique forms another basis for an automatic quality control system in spot welding (Ref. 6). In the early 1970s, commercial units of these quality control systems were developed and attached to welding machines in the auto body industry (Ref. 4).

Measurement of dynamic resistance has been one of the most effective techniques of quality monitoring and estimation during the past several decades. Some of the earliest and simplest techniques were to monitor the voltage and current at the secondary circuit. The electric parameters, however, vary frequently during welding cycles due to resistance change.

|[o~$.',! JUNE 2002

Primary Power Cable

Is

Secondary Circuit Monitoring System

Robot ~ [ ] ~ Controller

T rner

Primary Circuit Monitoring System

Fig. 1 - - Schematic diagram o f resistance spot welding monitoring system.

Current monitoring unit r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

io SCR I L ~ o co~eae,

AC G2 R X,

r --[ j ,~ . ,~ - - ] TR Elect ode i ~ T R m i

, v o i i i ~ c~ve~er

I I -~ -~- i voltage monitoring unit

Therefore, the monitored power input may not be appropriate, and the true energy state of welding is not represented. Dynamic resistance, on the other hand, has relatively accurate information on energy generation during nugget formation (Ref. 7). In earlier studies (Ref. 8), the potential of dynamic resistance as a parameter indicative of weld quality was explored. The values of dynamic resistance as a nominal condition of test welding were sampled and stored in an electronic memory. These values were compared with values sampled at the production welds. The values in agreement with those for the test weld, within an acceptance band, might then be considered as good as the initial test weld. Another quality evaluation technique was proposed with microprocessor- based resistance monitoring system as an in-process scheme (Ref. 9). The dynamic resistance characteristic of an accepted weld was computed as a reference in the monitoring system. The next procedure was very similar in comparison to the first example except not only the absolute values were compared to the reference but also the slopes of the dynamic resistance characteristics.

In order to acquire the resistance signal, the dynamic resistance was calculated from the welding current, and the voltage was measured at the secondary circuit using an oscilloscope in the early stages (Refs. 10-12). The physical meaning of resistance variation, however, could not be clearly explained in these studies. Dynamic resistance was calculated more efficiently by applying the root mean square (rms) value of the measured signal to the analog circuit using the Hall- effect sensor and voltage-measuring devices (Ref. 13). In this study, the effect of the dynamic resistance on the nugget formation and ensuing dynamic resistance pattern were considered. The study was useful in explaining the variations of the dynamic resistance according to the nugget formation, such as the collapse of

the contact resistance, the increasing temperature

Fig. 2 - - Simplified welding machine circuitry including primary circuit monitoring units.

of the faying surface, and the melting and plastic defor- mation of the nugget. Kaiser, et al. (Ref. 14), and Thornton, et al. (Ref. 15), at- tempted to examine the nugget formation according to changes in contact resistance. Kaiser, et al., explained the effect of the dynamic resistance and initial contact resistance on the lobe curve, while Thornton, et al., looked into the contact resistance of the aluminum alloy and the ensuing dynamic resistance variance.

Research based on dynamic factors continues to be carried out regarding weld quality estimation (Refs. 16-20). In a weld quality estimation system using multiple linear regression analysis (Ref. 16), weld quality was examined by defining the relationship between factors, such as electrode displacement, dynamic resistance, and weld quality. Livshits (Ref. 18) suggested a system that could more commonly be used. In his research, the dynamic resistance based on the current density of the faying surface was used to assure weld quality. Research was also performed on weld quality estimation using an intelligent algorithm such as the neural network on resistance spot welding. Brown, et al. (Ref. 19), used the normalized dynamic resistance, welding current, and electrode diameter to predict the nugget diameter, which was closely related to weld strength. Dilthey, et al. (Ref. 20), however, examined the shear strength using welding current and voltage through a similar method.

Although such studies based on results obtained from the secondary circuit can be applied to real-time weld quality estimation, in-process usage has several limitations. These limitations include the installation location of the voltage measuring device and increased costs due to additional measuring devices. Therefore, in this study, the primary circuit dynamic

resistance was used, which proved efficient for in-process application. By comparing the rms dynamic resistance acquired from the traditional method of the secondary circuit monitoring system with the proposed dynamic resistance based on the primary circuit monitoring system, it became evident there was a direct relationship between the primary and secondary circuit dynamic resistance. Fur- thermore, the primary circuit dynamic resistance was used to estimate the weld quality. Tensile shear strength and nugget diameter were estimated through the regression analysis and neural network. Throughout the research, a system was proposed in which the weld quality could be estimated in real-time upon completion of the weld.

Process Parameter Monitoring

Inductive Noise and Dynamic Resistance Monitoring

As the resistance spot welding is processed, the electrical resistance variation of the welds, due to the Joule heat generated by the weld current, becomes one of the most important factors in nugget formation. Unlike the initial contact resistance of the faying surface, the dynamic resistance includes information on nugget formation as welding occurs (Refs. 13, 15, 21, 22). Generally, the resistance can be obtained by the voltage divided by the current. In resistance spot welding circuitry, however, many problems occur in the measurement of resistance due to the inductive reactance elements of the electrical circuit. A simple means to acquire dynamic resistance, un- influenced by inductive noise, is to use the rms value. When the rms voltage detected across the electrode, which does

WELDING JOURNAL lil~~..']l

5C

Dynamic resistance

X~. Rls I --

X8: mean(R) XS: max(R) X9: stdr (R)

l XIO: stdr(dR)

- ~ / . . i / / ' 7~--~ i X" max(R) - rain(R)

V/X~R- ising speei x 4 : ~ X = R . . . .

Welding cycles XI: beta peak location

Fig. 3 - - Primary circuit dynamic resistance pattern and quality estimation f a c t o r s .

Strength or

Nugget Diameter

X2

X4 •

X5

Input layer 1~ hidden layer 2~ h n:lden layer Output layer

Fig. 5 - - The neural network architecture.

E 842 £ '~4C

~a5

i=I 't 15""" 15

not include much inductance (Ref. 12), is divided by the rms current of the secondary circuit, resistance can be obtained with no consideration to the phase shift due to the inductive noise. Another way of effectively eliminating the inductive noise from the dynamic resistance is to use the voltage and current when the welding current is at the peak value of each cycle. This method is based on the principle that only the pure resistance element, not the inductive reactance element, influences the impedance of the alternating current circuit when the rate of change of current equals zero (Refs. 1, 9, 15, 23). The greatest advantage of this method is that the pure resistance variation at the secondary circuit can be monitored at the primary circuit.

Figure 1 is a schematic diagram of the resistance spot welding system generally used in auto body manufacturing. The welding current that is controlled in the timer of the welding machine is passed through the transformer TR to the welding gun by the primary power cable. As the secondary circuit dynamic resistance monitoring system of this study, welding

o I = 6.5kA ,,,~...." o I = 8.0kA . ,~ .~ -

I = 11,0kA z ~ o ~ " ~ ~ j j ~ ~tU

x x~ °~ ×

= i i i

20 25 30 35 40 45 Secondary circuit resistance [micro Ohm]

50

Fig. 4 - - Linear relationship plot between primary and secondary dynamic resistance.

voltage and current are measured in terms of rms values. By attach- ing the clips to each electrode tip, the instantaneous welding voltage drop was measured. The Hall-effect sensor located on the lower arm of the welding machine

monitored the current flowing in the secondary circuit. By using an analog-to-digital converter (ADC), the analog voltage and the current were monitored simultaneously. In the ear l ier study (Ref. I), when a 60-Hz alternating current was used, a sampling rate of more than 1 kHz should be used. However, in order to effectively reflect the sharp voltage waveform produced by the electrical triggering of the silicon control led rectifier (SCR) to the resistance value, a sampling rate of 6 kHz was used in this study. This allowed the calculation of the dynamic resistance with the 50 numbers of data per half cycle. By using the digitized voltage and current, each rms value of a half cycle was calculated. As another approach, this research introduced a process to detect the dynamic resistance from the timer as a primary circuit monitoring system, using a microprocessor. In the primary circuit, the welding voltage and current could be detected without extra measuring devices; thus, this method could be used effectively as an in-process system. This method will be addressed in the following sections.

Analysis of Welding Machine Circuit

The resistance spot welding machine consists of a relatively simple electric circuit that includes a transformer. The simplified equivalent circuit is shown in Fig. 2. In the figure, the primary circuit elements are shown as subscript p and the secondary circuit elements as s. In the primary circuit, R_ stands for the total resistance value o ( t h e primary circuit. Xp stands for the primary leakage reactance. In the secondary circuit, R s stands for the total resistance value of the secondary circuit, which includes the welding gun and the electrode. X s stands for the secondary leakage reactance. R L stands for the resistance change across the electrodes. When the secondary circuit elements are shifted to the primary circuit, the resistance of the circuit, including shifted secondary circuit elements, which are shown as the reflected impedance described with the transformer ratio a, can be written as an equivalent resistance R and an equivalent inductive reactance X in Equations 1 and 2, which corresponds with the primary circuit current.

R=Rp+a2(Rs+RL) (1)

X = X p + a 2 X s (2)

By using the inductive el imination method, as stated in the preceding section, the inductive reactance X can be removed to calculate the dynamic resistance from the measured current and voltage of the primary circuit. Also, if assumed the transformer will operate ide-

lI[=[,"~1 JUNE 2002

ally and the resistance change due to the temperature change of the entire welding machine circuit can be ignored, the relationship between the resistance across the electrodes R L and the measured dynamic resistance Rmeas from the voltage Vp. and the current L in the primary circuit can be shown in ~quation 3 below.

Vp R +a2(Rs+RL) Rmeas I P P (3)

Where Ip is the peak current value of the instantaneous current from the primary circuit and Vp is the voltage at that moment.

Primary Circuit Dynamic Resistance Monitoring and Quality Estimation Factors

The primary current made by the phase control was measured using the current transformer (CT) from the inside of the timer. This primary current waveform was appropriately amplified using the gain se- lector. The signal at this stage includes high-frequency noise from the SCR current control unit and amplifier. By using the integrator, which has a suitably selected condenser, the high-frequency noise signal can be converted into a noise- free welding current waveform. The welding voltage was detected at the primary circuit and was attenuated using the measuring transformer. The monitoring trigger pulse was created when the rate of change of current reached zero, triggering the sample and holding circuit, which were connected by the detected welding current and the attenuated primary voltage. The instantaneous welding current and voltage were converted into digital values by the analog-to-digital converter. These values were used to calculate the dynamic resistance by dividing the current from the voltage of half cycle. The measured dynamic resistance Rmcas includes the resistance of the primary circuit resistance Rp and secondary circuit resistance R~ and R L. Therefore, to measure the resistance of the weld, the R_ and R s must be removed

1o . ,

effectively from the calculated resistance value. Fortunately, in the general resistance spot welding machine, the square of the transformation ratio a 2, shown in Equation 3, has an order of hundreds or thousands, so the R.p included in the calculated dynamic resistance Rmeas is a relatively small value. In other words, the Rp can be ignored. With the proper measurement, the resistance of the secondary circuit R s also can be obtained. This method converts the primary circuit dynamic resistance into the dynamic resistance change across the electrodes.

Table 1 - - Correlation Coefficients, Root Mean Square Errors, and Maximum Errors between Primary and Secondary Dynamic Resistance

6.5 kA 8 kA 9.5 kA 11 kA R E,m, E ..... R E .... E ...... R E .... E ..... R E . . . . E ......

0.9207 2.0223 7.6392 0.9519 1.5340 4.1564 0.9625 1.5967 4.4573 0.9682 2.1217 6.(X)91

Table 2 - - Correlation Coefficients between Independent Variables Extracted from the Primary Circuit Dynamic Resistance and Dependent Variables of Weld Strength YS and Nugget Diameter YD

YS YD Xl X2 X3 X4 X5 X6 X7 X8 X9 Xl0

X1 -0.957 -0.978 1.000 X2 0.864 0.895 -0.892 1.000 X3 0.894 0.910 -0.891 0.972 1.000 X4 0.589 0.626 -0.636 0.884 0.817 1.000 X5 0.524 0.488 -0.458 0.639 0.689 0.535 1.000 X6 0.374 0.347 -0.326 0.359 0.401 0.229 0.363 1.000 X7 -0.906 -0.937 0.924 -0.950 -0.947 -0.799 -0.509 -0.357 1.000 X8 -0.551 -0.592 0.609 -0.816 -0.740 -0.942 -0.353 -0.152 0.771 1.000 X9 0.255 0.274 -0.219 0.526 0.536 0.636 0.624 0.114 -0.428 -0.577 1.000 X10 0.576 0.616 -0.616 0.850 0.790 0.961 0.534 0.211 -0.780 -0.898 0.654 1.000

The primary circuit dynamic resistance is generally in a formation, as shown in Fig. 3. After monitoring, ten factors were extracted and used in the weld quality estimation based on the dynamic resistance pattern. First, the location of the beta peak X1, which is related to the initial nugget formation, and the rising speed of the dynamic resistance after the alpha peak X2, which is related to the heating rate of the faying surface, were selected as the geometric extraction factors. Based upon similar dynamic resistance analysis (Refs. 13, 14), beta peak is a balance point between a resistance increase, resulting from increasing temperature, and a resistance drop due to molten nugget growth and mechanical collapse. Therefore, the beta peak tends to be reached earlier in high heating rate (i.e., current level) and later in low heating rate. To make the estimation factor reflect the variations in resistance value, the difference between the maximum and minimum values of the dynamic resistance X3 and the maximum value of the dynamic resistance variation in each cycle X4 were selected. At low currents, the heating rate is relatively slow, resulting in small changes in resistance. At expulsion level currents, however, large variations of resistance can be observed, such as from a sharp drop due to the reduction in material thickness and an increase in effective contact area. Also, the absolute values of the monitored dynamic resistance, such as the maximum value of the dynamic resistance X5, the initial resistance X6, the final dynamic resistance X7, and the average value of the total dynamic resistance X8 were selected as estimation factors. The standard deviation

of the dynamic resistance X9 and the standard deviation of the dynamic resistance variation per cycle XIO were used to comprehend the effect of the trends in resistance variation.

Experiment

Welding was performed on a 0.7-mm- thick sheet of uncoated low-carbon steel. A resistance spot welding machine using single-phase, 60-Hz alternating current with an attached pneumatic cylinder was used. A 16-mm-diameter, dome-type electrode with a 6-mm-diameter, flat tip end made with copper alloy of RWMA class II was used. Welding was performed on a specimen prepared according to an AWS standard (Ref. 24) while varying the current under ten cycles of welding time and 2.45kN of electrode force. The welding current was increased at 1.5-kA intervals starting from 6.5 kA up to 11 kA. Welds were tested in tensile-shear to determine the ultimate strength and measured nugget diameter. These readings were used as the criterion for weld quality.

Results and Discussion

Relationship between Primary and Secondary Circuit Dynamic Resistance

In order to investigate the relationship between the dynamic resistance of the primary and secondary circuits, the experimental results were analyzed statisti- cally. First, the welding was carried out by selecting four levels of current. The experiment used the one-way factorial design with nine replicates under each condition. The selection order of the

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Fig. 6 - - Strength estimation results o f the models. A - - Linear model," B - -

nonlinear model; C - - neural network model.

in Fig. 4. Figure 4 shows the relationship between the two dynamic resistances, according to the changes in current. This figure shows a small change in the resistance value of about 23--40 pQ in the low current. On the other hand, 18-46 taf~ can be observed in the high current. The distribution of the resistance values at 8 kA was gathered around the central line without any ab- normal protru-

experimental schedule was done randomly to reduce, as much as possible, the error generated by noise such as electrode wear or measurement settings. To quantitatively check the relationship between the secondary and primary circuit dynamic resistance, a correlation analysis was carried out. The results, shown in Table 1, are the correlation coefficient of the two dynamic resistance values and the corresponding rms error Erm s and maximum error Ema x. Although the correlation coefficient somewhat increased as the current increased, the rms error showed a minimum value at the current set point of 8 kA. This is not because the two data coincide better as the current increased but because the sudden decrease in resistance in the expulsion of the high current caused a gap in the resistance value, which is relatively larger than that of the other conditions. This can be seen

sions, showing the lowest rms error. The distribution also coincided relatively well with the central line under most conditions, excluding a few anomalies. Through the result described herein, it can be seen the suggested primary circuit dynamic resistance can be used in the same way as the secondary circuit dynamic resistance.

Quality Estimation by Regression Analysis

To estimate weld quality for resistance spot welding, regression models were formulated through multiple linear and nonlinear regression analyses. The tensile shear strength and the nugget diameter were selected as dependent variables, and ten estimation factors were used to determine the regression equation. Be- fore performing the linear regression

analysis, the correlation between dependent variables, such as weld strength YS and nugget diameter YD, and the estimation factors X1 to XI0, the independent variables, were observed. The results are shown in Table 2.

Compared to the relationship between the dependent variables and welding condition ( i .e . , current set point), which has the correlation coefficients of 0.884 for weld strength and 0.909 for nugget diameter, it can be seen the location of the beta peak X1, the difference between the maximum and minimum value of the dynamic resistance X3, and the final dynamic resistance X7 were in relative good linearity with strength YS and nugget diameter YD. However, the correlation coefficient between X2 and X3 exceeded 0.97, showing the two variables were very closely related in terms of linearity. Therefore, when these variables are used simultaneously in the regression model, a multicolinearity effect can be observed. Thus, there was a possibility the error rate of the regression models, which included all these variables, would increase. In order to overcome such problems, the independent variables were in- putted in order from those having the highest explainability regarding weld quality, and a regression analysis using the stepwise method to determine the regression model was performed. The variables were applied to the regression model in stages, based on the partial correlation and significance probability values of the regression coefficient, until the significance level exceeds 0.10, at which point they were eliminated. Tables 3 and 4 show the variables entered at each stage, the significance probability values of the coefficients, and the coefficients of determination R 2 according to the model in each stage.

An observation of Model I, which is a

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l inear regression model for s t rength esti- mat ion, shows X1, X5, X4, and X3 are entered into the regression equa t ion in tha t order . In the case of X5 in Model I-4, the var iable is excluded in Model I-5 as it is no t stat ist ically s ignif icant . T h o u g h X5 has been e l iminated , the de t e rmina t ion coefficient main ta ins a value of 0.941. In M o d e l II, which is a l inea r mode l for nugget d iamete r es t imat ion, X1, X7, X3, X4, and X2 are selected into the est ima- t ion model at each stage, and then X3 is excluded as s ta ted above. The final l inear r eg ress ion e q u a t i o n s of M o d e l I and Model II, based on the above results, are shown in Equa t ions 4 and 5.

Y S = 3 . 4 5 3 - 0 . 0 9 7 3 • X l - O . O 1 0 8 " X 4

+ 0.0218. X3 (4)

Y D = 7 . 5 9 6 ~ 0 . 2 7 7 " X 1 - 0 . 0 8 0 2 • X 7

+ 0 .0641 " X 4 + 0 . 0 9 0 1 " X 2 (5)

The regress ion coefficients, which have been s tandard ized to observe the effect of each factor on the s t rength and diameter , are shown in Table 5. According to this table, the location of be ta peak X1 has the greates t effect on bo th s t rength and di- a m e t e r es t imat ion, followed by the difference be tween the max imum and minimum value of the dynamic resis tance X3 in s t r e n g t h e s t i m a t i o n and the r is ing speed of the dynamic resis tance X2 in diame te r es t imat ion.

N o n l i n e a r r eg res s ion mode l s us ing the above variables are shown in Equa- t ions 6 and 7. The non l inea r regression models are fo rmula ted by analyzing the factors used in the l inear model , with log- a r i thm, and t hen i n v e r s e - t r a n s f o r m e d . The factors, which de te rmine the regression model , are selected with the same m e t h o d used in the l inea r r eg res s ion analysis. The results are shown in Tables 6 and 7. In Mode l III, which is a model for the es t imat ion of s t rength, X2, X4, X7, and X5, are en te red into the non l inear regression model in tha t order . X2, X4, X3, and X5 are used in Model IV, which esti- mates nugget d iameter . As in the l inear regression model , the de t e rmina t ion coefficient increases as the factors are entered. The effects of each factor on the non l inea r model are shown in Table 8.

YS = 2.6143 • X 2 °.1t9 • X4q).0461 •

X741.166. X5l). 160 (6)

YD = 30.9384" X2 °.347 • X44J.°s88 • X31,1~l. X5 ~).778 (7)

Quality Estimation by Neural Network

Following the regression analysis, the multi layer artificial neural network, which was learned through the error back-prop-

Table 3 - - Significance Probability Values of Regression Coefficients for the Stepwise Regression Analysis and Its Results for Model I

Significance probability values of entered variables Constant X1 X5 X4 X3 R-"

Model I-1 4.9E-102 9.79E-44 - - - - - - 0.916 Model I-2 2.5E-20 8.48E-40 2.52E-03 - - - - 0.926 Model I-3 5.02E-19 7.83E-37 3.83E-04 4.18E-02 - - 0.930 Model I-4 1.63E-21 3.15E-13 7.25E-01 4.26E-05 1.95E-04 0.941 Model I-5 9E-58 5.65E-16 - - 1.32E-05 2.55E-07 0.941

Table 4 - - Significance Probability Values of Regression Coefficients for the Stepwise Regression Analysis and Its Results for Model H

Significance probability values of entered variables Constant X1 X7 X3 X4 X2 R 2

Model II- 1 2.79E-86 5.96E-55 - - - - 0.957 Model II-2 2.94E-45 3.63E-22 1.42E-04 - - 0.964 Model II-3 3.00E-19 9.96E-22 8.60E-02 9.70E-02 0.964 Model II-4 6.04E-25 8.28E-17 3.92E-05 9.61E-05 1.21E-07 0.976 Model II-5 1.96E-23 1.12E-10 1.44E-05 2.11E-01 4.44E-07 1.92E-02 0.978 Model II-6 6.92E-25 1.7E-10 9.62E-07 - - 6.48E-09 1.19E-05 0.977 J

Table 5 - - Standardized Regression Coefficients of the Final Linear Models

X 1 X2 X3 X4 X5 X6 X7 X8 X9 X 10

Model I-5 -0.672 - - 0.491 -0.239 . . . . . . Model II-6 -0.478 0.439 - - -0.354 - - - - -0.361 - - - - - -

Table 6 - - Significance Probability Values of Regression Coefficients for the Stepwise Regression Analysis and Its Results for Model I11

Significance probability values of entered variables Constant In X2 In X4 In X7 In X5 R 2

Model III-1 5.54E-86 1.33E-42 - - - - - - 0.910 Model III-2 1.02E-89 3.55E-40 1.22E-08 - - - - 0.941 Model III-3 2.51E-10 4.38E-21 3.10E-09 1.19E-02 - - 0.946 Model III-4 1.18E-03 2.62E-19 5.57E-10 2.31E-03 3.17E-02 0.949

aga t ion m e t h o d , was used to e s t ima te weld quality. The format ion of the neura l network was de te rmined through the previously men t ioned regression analysis re- suits. The X1, X2, X3, X4, X5, and X7 factors app l ied to l inear and n o n l i n e a r models were selected as input variables for the neural ne twork quality es t imat ion models such as Model V for s t rength esti- mat ion and Model VI for nugget diameter est imation. Two h idden layers with six nodes were used to de te rmine the output values of weld s t rength and nugget diameter, respectively. This neural network ar- chi tecture is shown in Fig. 5.

Performances and Evaluation of the Models

Two m e t hods were used to evalua te the pe r fo rmance of each model , and each es t imat ion result was r ep resen ted using the coefficient of cor re la t ion R and root

m e a n square error. In the first method, the original data used in formulat ing each r eg res s ion m o d e l and n e u r a l n e t w o r k were used in a model to es t imate the per- fo rmance of the suggested model . In the second method, mult iple regression with a val idat ion test (Ref. 16) was introduced. First , a single da ta po in t was r e m o v e d f rom the data set of N data points, and the remain ing set of N- 1 data points was used to m a k e an e s t ima t ion model . T h e removed single data point was then appl ied to this model to obta in a val idat ion result. This p rocedure was repea ted N-t imes for each piece of N data in the data set, obta ining N val idat ion results. Tables 9 and 10 show the results of s t rength and diam- e t e r e s t ima t ion t h r o u g h such methods . As expected , the resul ts f rom the da ta used in formula t ing the model provided more accurate results, but the results of the val idat ion test also showed good esti- mat ion pe r fo rmance with only a small dif-

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and predicted values are presented in Table 10, showing values higher than 0.98. It can also be seen in the nugget d iameter estimation model that the neural network demonstrated the best performance.

Conclusions

In order to develop a real-t ime quality estimation system for in- process resistance spot welding, the welding variables were monitored at the primary circuit of the welding ma-

ference from the previous results. In strength estimation, the neural net-

work model showed the best performance followed by the nonlinear regression model and the l inear regression model. These results can be seen in Fig. 6. The estimation performance was especially good in the neural network model. Evaluating the nugget diameter estimation, the linear model showed similar, but slightly better, results than the nonlinear model. Figures 7A and B shows the results for nugget diameter estimation for linear and nonlinear regression models. Although the distribution range of the estimated result near a nugget diameter of 4-5 mm is up to 1.3 mm, overall estimation results show good correspondence with measured nugget diameter. The correlation coefficients between measured

chine and the dynamic resistance obtained was used to es- t imate weld strength. In order to effectively eliminate the unwanted inductive noise, the primary current and voltage were measured when the rate of change of current was zero. These were used to calculate the primary circuit dynamic resistance using the microprocessor of the welding machine timer. The welding machine circuit with a transformer was also analyzed, and the primary circuit dynamic resistance was converted into a dynamic resistance of the welds. To consider the relat ionship between dynamic resistance and secondary circuit dynamic resistance, a correlation analysis was carried out. It was shown the correlation coefficient was more than 0.92 and maximum error was only 7.6392 IxQ. Therefore, the dynamic resistance pat-

tern, which contains information about the nugget formation mechanism of the welds, could also be effectively obtained in the welding machine timer. We have also observed the effect of dynamic resistance on weld quality through the regression analysis of the factors extracted from the dynamic resistance pattern. In the linear regression model, weld quality estimation was influenced by beta peak location X1, the rising speed of dynamic resistance X2, difference between the minimum and maximum values of dynamic resistance X3, the maximum value of dynamic resistance variation per cycle X4, and the final dynamic resistance X7 while it was influenced by the rising speed of dynamic resistance X2, difference between the minimum and maximum values of dynamic resistance X3, the maximum value of dynamic resistance variation per cycle X4, the maximum value of dynamic resistance X5, and the final dynamic resistance X7 in the nonlinear model.

As another method of evaluating weld quality, a neural network with two hidden layers was used. The factors determined in the regression analysis were used as the input while the strength and nugget diameters were selected as the output. Ac- cording to the performance results of quality estimation through such models, the weld strength estimation showed a maximum error of 0.2061 kN, a correlation coefficient exceeding 0.96, and an rms error under 0.0836 kN. The neural network showed the most accurate re- suits in nugget diameter estimation as well as in the strength estimation. The performance of the nugget diameter estimation showed a maximum error of 0.66093 mm, correlation coefficient over 0.98, and an rms error under 0.2317 mm. According to the results described in this paper, not only can weld quality estimation be performed without the attach-

l i l i lo~-] l JUNE 2002

ment of additional moni tor ing devices in the secondary circuit of the welding machine but also real- t ime quality estimation is made possible.

Acknowledgment

This work was suppor ted by a grant from the Brain Korea 21 Project and Crit- ical Technology 21 Project of the Ministry of Science and Technology, Korea.

Reference

1. Gedeon, S. A., Sorensen, C. D., Ulrich, K. T., and Eagar, T. W. 1987. Measurement of dynamic electrical and mechanical properties of resistance spot welds. Welding Journal 66(12): 378-s to 385-s.

2. Johnson, K. I., and Needham, J. C. 1972. New design of resistance spot welding machine for quality control. Welding Journal 51 (3): 122- s to 131-s.

3. Wood, R. T., Bauer, L. W., Bedard, J. E, Bernstein, B. M., Czechowski, J., D'andrea, M. M., and Hogle, R. A. 1985. A closed-loop control systems for three-phase resistance spot welding. Welding Journal 64(12): 26 to 30.

4. Johnson, K. I. 1973. Quality control resistance welding quality-control techiniques. Metal Construction and British Welding Journal 5(5): 176-181.

5. Haefner, K., Carey, B., Bernstein, B., Overton, K., and D'andrea, M. 1991. Real- time adaptive spot welding control. Transac- tions of the A SME, Journal of Dynamic Systems, Measurement, and Control 113(3): 104-112.

6. Towey, M., and Andrews, S. R. 1968. In- stantaneous resistance during spot weld formation as a parameter for an automatic control system. Welding and Metal Fabrication 36(10): 383-392.

7. Tsai, C. L., Dai, W. L., Dickinson, D. W., and Papritan, J. C. 1991. Analysis and development of a real-time control methodology in resistance spot welding. Welding Journal 70(12): 339-s to 351-s.

8. Andrews, D. R., and Bhattacharya, S. 1973. Quality control resistance-weld monitoring for production. Metal Construction and British Welding Journal 5(5): 172-175.

9. Patange, S. R., Anjaneyulu, T., and Reddy, G. R 1985. Microprocessor-based resistance welding monitor. Welding Journal 64(12): 33-38.

10. Studer, E J. 1939. Contact resistance in spot welding. Welding Journal 18(10): 374-s to 380-s.

11. Tylecote, R. E 1941. Spot welding part II: contact resistance. Welding Journal 20(12): 591-s to 602-s.

12. Roberts, W. L. 1951. Resistance variations during spot welding. Welding Journal 30(11): 1004-s to 1019-s.

13. Dickinson, D. W., Franklin, J. E., and Stanya, A. 1980. Characterization of spot welding behavior by dynamic electrical parameter

Table 7 - - Significance Probability Values of Regression Coefficients for the Stepwise Regression Analysis and Its Results for Model IV

Significance probability values of entered variables Constant In X2 In X4 In X3 In X5 R2

Model IV-1 3.98E-42 6.92E-47 - - - - - - 0.930 Model IV-2 1.71E-48 5.44E-49 2.41E-13 - - - - 0.965 Model IV-3 8.36E-40 1.41E-17 2.77E-15 4.52E-04 - - 0.971 Model IV-4 3.08E-08 6.49E-19 3.15E-13 1.57E-06 2.37E-06 0.978

Table 8 - - Standardized Regression Coefficients of the Final Nonl inear Models

InX1 InX2 InX3 InX4 InX5 InX6 InX7 InX8 InX9 InX10

Model III-4 - - 0.962 - - -0.443 0.076 - - -0.320 - - - - - - Model IV-4 - - 0 . 8 6 7 0.380 -0.264 -0.115 . . . . .

Table 9 - - Strength Estimation Results as Correlation Coefficients, Root Mean Square Errors, and Maximum Errors for the Original and Validation Data Set

Linear Nonlinear Neural R E,m, Em,x R E~, E~°x R E=, Em°~

Original dataset 0.9702 0.0751 0.1719 0.9726 0.0721 0.1838 0.9959 0.0284 0.1002 Validation dataset 0.9652 0.0836 0.1967 0.9684 0.0774 0.2061 0.9943 0.0290 0.1053

Table 10 - - Nugget Diameter Estimation Results as Correlation Coefficients, Root Mean Square Errors, and Maximum Errors for the Original and Validation Data Set

Linear Nonlinear Neural R Erm~ Em,x R E,m~ E .... R E,m, E .....

Original dataset 0.9889 0.1871 0.6013 0.9877 0.1949 0.5790 0.9989 0.0571 0.1767 Validation dataset 0.9853 0.2040 0.6609 0.9816 0.2317 0.6378 0.9975 0.0583 0.1790

monitoring. Welding Journal 59(6): 170-s to 176-s.

14. Kaiser, J. G., Dunn, G. J., and Eager, T. W. 1982. The effect of electrical resistance on nugget formation during spot welding. Welding Journal 61(6): 167-s to 174-s.

15. Thornton, E H., Krause, A. R., and Davies, R. G. 1996. Contact resistances in spot welding. Welding Journal 75(12): 402-s to 412-s.

16. Hao, M., Osman, K. A., Boomer, D. R., and Newton, C. J. 1996. Developments in characterization of resistance spot welding of aluminum. Welding Journal 75(1): ls-s to 8-s.

17. Chakalev, A. A., and Vishnyakov, I. V. 1994. Controlling the properties of welds in resistance spot welding. Welding International 8(10): 810-813.

18. Livshits, A. G. 1997. Universal quality assurance method for resistance spot welding based on dynamic resistance. Welding Journal 76(9): 383s-s to 390-s.

19. Brown, J. D., Rodd, M. G., and Williams, N. T. 1998. Application of artificial intelligence techniques to resistance spot welding, lronmaking and Steelmaking 25(3): 19%204.

20. Dilthey, U., and Dickersbach, J. 1999. Application of neural networks for quality

evaluation for resistance spot welds. ISIJlnter- national 39(10): 1061-1066.

21. Cho, Y., Rhee, S., Shin, H. I., and Bae, K. M. 1999. Characterization of primary dynamic resistance in resistance spot welding. Journal of the Korean Welding Society 17(2): 159-165.

22. Cho, Y. 2000. A study of dynamic resistance monitoring and intelligent quality estimation for the manufacturing process automation during resistance spot welding, Ph .D. dissertation. Seoul, Korea, Hanyang University.

23. Savage, W. E, Nippes, E. E, and Was- sell, E A. 1978. Dynamic contact resistance of series spot welds. Welding Journal 57(2): 43-s to 50-s.

24. American Welding Society. 2000. Rec- ommended Practice for Resistance Welding. CI.IM/CI.1.

25. Kimchi, M. 1984. Spot weld properties when welding with expulsion - - comparative study. Welding Journal 63(2): 58-s to 63-s.

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